process manufacturing ensuring food safety, white paper, english, us

Infor

Process Manufacturing Ensuring Food Safety Through Active HACCP Management

Process Manufacturing > Whitepaper

Table of contents


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Infor is in no way committing to the development or delivery of any specified enhancement, upgrade, product or functionality. See “disclaimer” paragraph contained herein.

Executive summary .................................................................................................................................................... 3The food safety issue ................................................................................................................................................. 4Seven principles of HACCP ........................................................................................................................................ 5Gaining visibility with Infor PLM Optiva .................................................................................................................. 7Managing production equipment with Infor EAM ................................................................................................ 8Acting instantly with Infor Event Management ................................................................................................... 9Conclusion ...................................................................................................................................................................10

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Process Manufacturing > WhitepaperInfor is in no way committing to the development or delivery of any specified enhancement,upgrade, product or functionality. See “disclaimer” paragraph contained herein.

Food contamination and product recalls continue to be big news. The results of food contamination can be grim indeed: numerous illnesses and deaths, not to mention the loss of profits and reputation for the process manufacturers involved.

In 2008, the root causes of various recalls covered a wide range of issues that included material tampering, allergen labeling, inadequate end-user food handling or preparation instructions, potential cross-contamination of ingredients, plant health and safety conditions, unsubstantiated (or even willfully inaccurate) marketing label claims, and shelf-life issues

In the most recent high-profile case, the Peanut Corporation of America—the main company responsible for a nationwide salmonella outbreak that killed nine people and sickened more than 600 others in 44 states—closed its doors for good, filing for Chapter 7 bankruptcy liquidation in February 2009.

In another example, Topps Meat closed its doors in 2007 after recalling 21.7 million pounds of frozen meat (one year’s production) contaminated with E. coli. Also in 2007, ConAgra was forced to recall all Peter Pan and Great Value peanut butter manufactured at its Sylvester, Ga., plant since October 2004 after the product was linked to hundreds of cases of salmonella across the United States.

As a result of these incidents, and others, food safety regulations have come under increasing scrutiny. Process manufacturers may soon find themselves facing much stricter rules—including having to report possible contamination within 24 hours.

These manufacturers can proactively prevent food contamination by leveraging existing technology to automate and ensure the effectiveness of the food safety program known as Hazard Analysis and Critical Control Point (HACCP).

HACCP is a systematic approach to food safety that addresses physical, chemical, and biological hazards as a means of prevention rather than finished product inspection. Using HACCP, manufacturers can identify potential food safety hazards and then take key actions at critical control points to reduce or eliminate the risk of those hazards. For successful implementation of a HACCP plan, management must be strongly committed to the HACCP concept—and have the technology to successfully carry it out.

Infor™ has the product lifecycle management (PLM), event management, and enterprise asset management (EAM) tools you need to ensure compliance with HACCP principles and prevent a food recall—in the process saving your company’s profits and reputation.

Executive summary


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The issue of food safety is nothing new, but it has become more and more complex and more difficult to control. This is true for two main reasons:

Time pressure—Process manufacturers are increasingly being pressured to report possible food contamination earlier. At the same time, supply chains and products are getting more complex. This makes reliance on manual processes and human intervention increasingly risky. With compliance and safety constraints integrated into planning and scheduling processes, your company can simulate the impact of a potential problem, and stop the chance of a product safety breach. For example, with proactive planning you can ensure that organic lots are not stored in the same bin as non-organic lots.

Product proliferation—As you create more and fresher products, you also increase outsourcing, consolidate supplies, and extend supply chains to meet consumers’ demands for wider variety. This intensifies the chance that product safety issues will arise from cross-contamination or a safety breach. In addition, the risk of more complex product claims increases. By integrating HACCP across your supply chain and implementing constraint-based optimization, you can help ensure product compliance, safely reduce risks, and improve profitability.

The food safety issue

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HACCP’s systematic approach to the identification, evaluation, and control of food safety hazards is based on seven principles:

1) Conduct a hazard analysis. Hazards (biological, chemical, and physical) are conditions that may pose an unacceptable health risk to consumers. To conduct a hazard analysis, you must identify the significant hazards associated with each step of your manufacturing process, as well as the measures (for example, temperature, pH, and moisture level) that can prevent them.

2) Determine the critical control points. Critical control points (CCPs) are steps at which you can apply control to prevent, eliminate, or reduce a food safety hazard to acceptable levels. Examples are cooking, acidification, and drying steps in a food process.

3) Establish critical limits. All CCPs must have measurable preventive measures. Critical limits are the operational boundaries of CCPs that control food safety hazards. If you don’t meet pre-established critical limit criteria, you are not preventing, eliminating, or reducing food safety hazards to acceptable levels.

4) Establish monitoring procedures. Monitoring is a planned sequence of measurements or observations to ensure critical limits are being met. It allows you to assess trends before a loss of control occurs, and to make adjustments while continuing the process. The monitoring interval must be adequate to ensure reliable control of the process.

5) Establish corrective actions. Should loss of control occur, you must have written plans in place for disposition of the product and correction of the process. If, for instance, a cooking step must result in a product center temperature between 165 and 175 degrees Fahrenheit, and the temperature is only 163 degrees, the corrective action could require a second pass through the cooking step with an increase in temperature of the cooker.

6) Establish record-keeping and documentation procedures. The HACCP system requires the preparation and maintenance of a written HACCP plan together with other documentation. This must include all records generated during the monitoring of each CCP and notations of corrective actions taken. Usually, the simplest record-keeping system—yet one that still ensures effectiveness—is the most desirable.

Seven principles of HACCP


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7) Establish verification procedures. Verification has several steps. You need to document the scientific or technical validity of the hazard analysis and the adequacy of the CCPs. Verification of the effectiveness of the HACCP plan is also necessary. The system should be subject to periodic revalidation using independent audits or other verification procedures.

Within this whitepaper, you will find out how Infor solutions automatically address and manage all seven of the HACCP principles.

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Key to any HAACP program is visibility into the capabilities and risks of materials, formulas, packaging, processes, storage and handling, and application recipes. As your company outsources more frequently, sources more widely, broadens product lines, and strives to minimize time to market, your over-reliance on manual processes and documents is regularly tested.

Infor PLM Optiva is invaluable to process manufacturers, as it supports five of the seven HACCP principles: hazard analysis, identification of CCPs, establishing critical limits, record-keeping, and verification.

In reinforcing those principles, Infor PLM Optiva:

Provides design and simulation from sub-raw materials to finished goods. Supports definition and verification; manages the definition and setup of HACCP in downstream

data and processes. Expands supplier capabilities. Performs supplier audits and captures results.

With HACCP integrated into all levels of modeling, Infor PLM Optiva’s modeling tools roll up values and immediately alert you on any HACCP or claim substantiation risks. This means you can immediately mitigate issues and ensure that proper HACCP controls are developed and integrated into all appropriate downstream processes and systems. Through an integrated, closed-loop development and introduction process, you can facilitate downstream processes, ensure compliance and safety, and minimize time and costs.

Infor PLM Optiva’s integrated projects, dashboards, workflows, and modeling applications help improve information transparency throughout your organization, from developers to all stakeholders. With the ability to manage more than just formulas, your company can more effectively meet HACCP challenges, ensure product safety, and protect brand equity.

Gaining visibility with Infor PLM Optiva


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Process industries are asset-intensive; Infor EAM solutions can help ensure effective preventive maintenance of your assets. By giving you the ability to manage production equipment, warehouse, and mobile equipment, Infor EAM provides a one-stop solution for process manufacturers. It also provides you with the tools to effectively follow the HACCP principles of hazard analysis and record-keeping.

Preventive maintenance capabilities within Infor EAM solutions not only reduce safety risks and improve product quality, but also increase asset availability and extend asset lifecycles. Effective preventive maintenance puts an end to “out of tolerance” conditions, which proactively improves product safety, supports audits, minimizes write-offs, and improves customer service.

In light of recent high-profile recalls that began with leaky pipes, leaky roofs, inadequate sanitation procedures, and improperly maintained filling equipment, it makes even more sense to have the tools you need to integrate HACCP practices into preventive maintenance programs. Not only will you protect brand equity of your products, you’ll reduce record-keeping costs.

Managing production equipment with Infor EAM

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Infor Event Management provides proactive, real-time exception management technology that allows you to detect conditional change anywhere in your supply chain and communicate it instantly to those who need to take action—both inside and outside your organization.

By actively monitoring your CCPs and providing immediate alerts, Infor Event Management allows you to take action instantly—a critical feature, as every hour lost increases the percent of contaminated product, and new food safety regulations may require 24-hour notification.

Not only does Infor Event Management monitor CCPs, it establishes corrective action that automates across departments, plants, and into the executive level. Plus, the solution supports HACCP’s record-keeping and verification principles by tracking execution, performing audits, and capturing results.

Acting instantly with Infor Event Management


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Food contamination is a hot-button issue—just one product recall can ruin your company’s hard-built reputation.

Tarnished reputations have not only impacted process manufacturers’ short-term revenue and profits, they also have forced many companies into bankruptcies and hostile acquisitions. An effective recall process can reduce costs and disruption, but doesn’t slow the pace of recalls, and can only slightly reduce the impact on your company or brand.

With the recent spate of food recalls and imminent stronger regulation, now is the time to install the technology that will allow you to move from traditional reactive strategies to more holistic, proactive product safety strategies.

Proactively developing and certifying products and materials, preventing equipment safety risks, scheduling, and planning with compliance constraints, can help you improve decisions and mitigate risks. Together these strategies help you improve product safety and reduce non value-added costs, as well as increase consumer confidence, create more competitive products, and expand profitability.

By integrating Infor PLM Optiva, Infor EAM and Infor Event Management into your existing enterprise resource planning (ERP) system, you can form a holistic and proactive food safety strategy that will identify contamination at its earliest stages and keep it from getting out the door.

About InforInfor acquires and develops functionally rich software backed by thousands of domain experts and then makes it better through continuous innovation, faster implementation options, global enablement, and flexible buying options. In a few short years, Infor has become the third largest provider of business software. For additional information, visit www.Infor.com.

Conclusion

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DisclaimerThis document reflects the direction Infor may take with regard to the specific product(s) described in this document, all of which is subject to change by Infor in its sole discretion, with or without notice to you. This document is not a commitment to you in any way and you should not rely on this document or any of its content in making any decision. Infor is not committing to develop or deliver any specified enhancement, upgrade, product or functionality, even if such is described in this document.

process manufacturing ensuring food safety, white paper, english, us

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