Food safety management procedures

Abstract

Food safety and standards are key drivers in the food industry. To safeguard consumer health and brand integrity retailers have been important in creation of standards for production of safe foods. Back in 2004 Regulation was introduce in the European Union that requires food businesses to implement procedures based on Codex HACCP principles(Regulation EC 852/2004, Regulation EC 853/2004). Pre-requisites procedures general principles of hygiene need to be in place and operational before HACCP system can be implemented. A good food safety management system is a set of written procedures and policies that demonstrate how businesses ensure that food is safe to eat by means of monitoring processes and corrective actions that would need to be applied. Business operators are regularly audited by third party audits to ensure that HACCP and quality systems are being followed.

Regulation on hygiene of food

Good food hygiene is essential for businesses to be able to operate and sell food that is safe to consume. Food hygiene is about the control of harmful bacteria which can cause serious illness. General hygiene procedures or pre-requisites (premises design, personnel hygiene, pest control, storage, traceability, supplier specifications etc.) are set out on Regulation (EC) No. 852/2004 and No. 853/2004. Food manufactures must implement these regulations in order to ensure food safety and protect the final consumer. Different types of food production need different guidelines. These regulations separate two distinctive food business activities. In one hand the primary production and handling of products of plant or animal origin that does not substantially alter their nature (regulation 852/2004), and further processed/ transformed food of animal origin (regulation 853/2004) where the control of

harmful bacteria requires separate guidelines (temperature control, sterilisation of equipment). The agri-food industry is required to establish, under HACCP based principles, procedures to manage food safety hazards. Businesses are required to look at their product processes, decide where hazards (biological, chemical, allergenic or physical) may occur and put in place adequate controls and continuously monitor them. HACCP is based on seven principles and they are: analysis of hazards assessment; identification of process Critical Control Points (CCPs); establish critical limits for preventative measures associated with each CCP, establish procedures for monitoring the CCPs; establish corrective actions to be taken when monitoring indicates deviation from an establish critical limit; establish effective record procedures that document the HACCP system and establish procedures for verification that HACCP system is working correctly. These procedures include up to date documents and records, they should be written down and reviewed regularly. Training is also an important tool to ensure good hygienic practices and should be appropriate for the work carried out. These food safety regulations in the food industry are monitored by Environmental Health Officers (EHO) who are responsible for the enforcement of food safety laws to protect the public(Food Standards Agency 2014). Taking the example of food animal product chain the EHO will assess differently at every stage of the production, rearing or slaughter. The inspector will verify the effectiveness cleaning and sorting procedures in place at primary production of animals going to slaughter (Annex 1, part A, Point II.4(c) of Regulation (EC) No 852/2004). Slaughterhouse businesses must ensure training and procedures are being followed by operators to ensure that animals are clean (Annex III, Section I, Chapter IV, point 4 of Regulation (EC) No 853/2004). In order for the EHO to enforce food hygiene laws they will inspect records, photographic evidence or samples may be taken or serve a notice (Hygiene or food labelling improvement notice, hygiene emergency prohibition notice or remedial action notice). Inspectors can also recommend a prosecution, in serious cases. If successful, the food business may be forbidden from using certain processes, premises or equipment, closed the premises or it could also lead to a fine or imprisonment. Inspections might be on a routine basis or generated due to a complaint in food hygiene/ safety.

QA Procedures

As part of the HACCP principles Quality Assurance procedures are used in food manufacturing to ensure the safety of food stuff and be able to provide evidence of due diligence in preventing physical, chemical or biological cross contamination. Good manufacturing practices (GMP) cleaning procedure. Another good example is the temperature control procedures of foods, both important in meat processing plants.

Good manufacturing practices (GMP) cleaning procedure

GMP is the responsibility everyone in a food business (Food Standards Agency 2014). As food handlers, everyone has a responsibility to maintain high hygiene standards and food safety. In a cleaning procedure it is vital the use of the right tools. Whether the food manufacturer uses a manual or clean-in place system, developing an effective cleaning and sanitizing program requires the right equipment. These tools include potable water (hot or cold), appropriate chemicals for every step pf the cleaning process. Employees should be trained on the procedure requirements to effectively conducted cleaning and sanitisation of equipment. The GMP procedure requires to keep facility and equipment, utensils and food contact surfaces clean and sanitised. A cleaning schedule should be in place with focus on equipment vital for the manufacturing processes. This procedure is extremely important for food manufacturers to demonstrate due diligence in case of a complaint of food poisoning. Issues may arise due to the lack of training or complacency of employees as to how to conduct a cleaning regime. The cleaning procedure should therefore be periodically verified, by swabbing, for control of allergens and/or harmful bacteria, as well as verification that the cleaning regime is sufficient and followed correctly. If it is found that the cleaning and disinfection regime is not preventing food contamination

more frequent swabbing and inspection of cleaning process should take place. Employees may need more adequate training and time to carry out the equipment hygiene. The schedule may need revising to more frequently clean a specific machinery that is falling the swabbing or the procedure for that machine and/ or chemicals used need to change.

Temperature control procedures of foods

Meat microbiological quality is sensitive to temperature and storage conditions throughout the production process (Food Standards Agency 2014). The first step is to identify the process (storage, cooking, etc), product (cooked, raw) and the required method of storage (chilled, frozen). Each step in the process is to be considered to determine where the conditions that affect quality can be out of control. A temperature target should be agreed and a range of limits in place. Monitoring should take place at every step of production with temperature probes (calibrated as per appropriate procedures) and records taken at regular intervals by trained employees. For products of animal origin there are a set of sandards that shoul be followed. Storage units should also be monitored regurlarly to ensure appropriate storage conditions. When production involves cooking large pieces of meat should be probed at the thikest part. When receiving deleveries or preparing a load for despatch, appropriate controls and records are also used to ensure that transportation was or will be carried out at the recommended temperature for the product. If the temperature control procedure is not being followed according to the business HACCP plan, records should be made of the problem identified and the corrective action taken. If it is a reocurrent issue it may be necessary to review and ammend the controls and the process in the HACCP plan. This will enable the business to identify where and how can the temperature of the product stay inside of the limits throughout the process.

Product recall

With ever increasing consumer focused market, product recall procedures still is a complex process involving many stakeholders in the supply chain. Food manufacturers have a duty to recall products as soon as they become aware that a product pose a risk to consumers or face liability. Legislation also requires to separately notify government agencies, health departments and the public (Wynn, Ouyang et al. 2011). It is a very expensive operation not only monetarily but also to the business reputation. Globalization has meant that the supply chain has become longer and complex. To recall a product successfully coordination is essential. Systematic recordings in the supply chain is critical for the traceability and risk control. Product recalls still take far too long, a good example is the horse meat scandal in Europe. Food businesses are required to use unique identifiers and documentation to assist on how ingredients and food join or split in the supply chain (Storøy, Thakur et al. 2013). But with so many links in the chain and the use of a varied range of identification systems it is a huge operation to trace every single ingredient used back to its source. To facilitate and accelerate traceability it will be necessary to overcome the variety of unique number systems and create a global non-proprietary standard. There is also a need for better techniques when understanding the role played by the supply chain and operations management in product safety (Marucheck, Greis et al. 2011). Regulation and standards, supplier management, product lifecycle management, traceability and recalls could benefit from existing methods of operations to safeguard consumers.

Third Party Audit Standards

The proliferation of a new food manufacturing industry, focused in producing solely under supermarkets own label has driven higher standards of quality and food safety. Retailer standards have become the main governance in supply chains. Third party audit standards facilitate competitive strategies.

Tesco Food Manufacturing Standards (TFMS) (Tesco Stores ČR a.s 2014) is an example of nonregulatory standards that food manufacturers have to comply with in order to be a Tesco supplier. Prior to an audit, carried out by an proved Tesco auditor from the Product Integrity Unit (PIU), information will be facilitated in the form of site and HACCP plans as well as active product specifications that should be made available on the Tesco Technical Library. The objectives of the audit mill be agreed in the initial meeting. PIU auditor will inspect site facilities such as storage, production areas, laboratories and staff facilities. Full traceability assessment of records for one or more products will be carried out to demonstrate that product complies with Tesco specification and is safe for consumers. General policies and procedures related to production will audited. Non-conformances raised during the audit will be discussed and can be classed as critical, major or minor. A colour coding classification (from better to worst: Blue, Green, Amber and Red) result of the audit is dependent on the number and classification of the issue raised. If an audit is Red means that no further Tesco production will take place until corrective action is completed and the food business will need re-approval audit. Amber audits will require food manufacturers to resolve any non-conformances raised in an agreed time table. Another form of third party audits is certification of compliance such as “Red Tractor” for primary production. Red tractor logo is now present in food packaging in all food retail outlets. It indicates compliance with specific food assurance schemes that are registered with Assured Food Standards (Red Tractor Assurance 2014). This logo indicates that food can be traced back to farms. Businesses will only gain certification if standards are meet. Regular independent audits of production process, including animal movement, housing, feed, animal health and welfare, hygiene and food safety are assessed. Access to relevant parts of the holding, key members of staff and relevant documentation is necessary for the audit. If auditor will point out non-conformances with the scheme standards as the audit progresses and note corrective action you propose to take. A notice of remedy is then given or sent to the business operator with details of non-conformances with respective corrective actions and timescales to resolve them.

Conclusion

Public health should be the primary concern the agri-food industry from farming, processing storing or retailing. Food should be protected from cross contamination when being produced. In 2004 the European Comission regulated and issued guidance to food businesses becoming mandatory the use of the HACCP principles plan to safeguard consumers. Retailers on the other hand in a ever increasing competitive market developed standards and specification for own label products to protect their brand integrity. Food manufacturers under these regulations and standards must be able to prove due diligence and appropriate corrective actions in producing food that is safe. Product recalls are the last step of possible actions that a business could take, for these to be effective traceability of products is of high importance.

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