FreshTech Learning Center: “Food Safety Guidelines for the Fresh-Cut Industry” Sponsored by:
Food Safety Guidelines for the Fresh-Cut Produce Industry; 5th Edition Brian Zomorodi Sr. VP Technology & Quality Food Safety & Technology Council May 2013
Food Safety Food SafetyGuidelines Guidelines For the For the Fresh-cut Sanitary Fresh-cut Produce Guidelines For the Produce Industry Industry Fresh-cut 3rd Edition nd Produce 2 Edition Industry 1st Edition
Vision To create a credible guidelines for the Fresh-Cut Produce Industry, as a reference document for all stakeholders of the produce supply chain. Goals • A “Go-To” document for Fresh-Cut Food Safety • Incorporate the latest science and industry best practices • Include latest information from the FDA Food Safety Modernization Act • Reflect global perspectives • Re-write, based on “Supply Chain Food Safety” • Guidelines to be inclusive and applicable to all size operations
A United Fresh document: Written for the Industry, by the Industry
5th Edition, a Changed Approach • On-Line Publication o o o o o
4th Edition was a single document; “A Book” 5th Edition is a compendium; “Electronic Edition” Instantaneous Access to latest information Suitable for today’s communication platforms Will be posted on United Fresh website (Fee-based access)
• A “Living Document” o Ongoing updating o Acceptance of different styles of writing o “Comment Blog” at the end of each chapter for immediate feedback o Searchable
5th Edition • Preface / Table of Contents • Acknowledgement Page o Chapter Authors Also Acknowledged at the End of Chapter o Chapter Reviewers Acknowledged
• Each Chapter is Independent o Own Style, Independent Numbering
• 15 Chapters o 13 Completed o 2 “Under Construction”
• 3 Supplemental Documents • Gatekeeper; United Fresh and Current “Editor-in-Chief”
Authors & Contributors More than 40 Participants with 20 Lead Authors Editor-In-Chief, 5th Edition Brian Zomorodi, Ready Pac Foods, Inc.
Technical Reviewers:
5th Edition Chapter Authors:
Chapter Highlights Chapter 1: Raw Produce Food Safety Trevor Suslow
“Under Construction”
Chapter Highlights Chapter 2: Microbiology of Fresh-Cut Produce Lead Authors: Courtney Parker / Trevor Suslow (Jim Gorny) • Microbiological Overview of Fresh-cut Produce o Diversity of type and source of produce impacting spoilage and potential of contamination by pathogens o Importance of microbiological safety of raw produce o Importance of preventing contamination during processing
o Importance of cold chain o Importance of prerequisite and preventive programs o Relation between spoilage microorganisms and pathogens during shelf life
Chapter Highlights – Chapter 2 • Review of Microorganisms on Produce o Spoilage microorganisms; types and relation to spoilage o Pathogens of concerns o Listeria, Salmonella, E.coli… o Viruses; Hepatitis A, Norovirus o Parasites: Giardia, Cyclospora
o Outbreaks linked to produce o Sources of human pathogens on produce o Attachment and internalization of pathogens on produce o “Once it is attached, difficult to remove” o Conditions leading to internalization
Chapter Highlights – Chapter 2 • Microbiology in a Processing Facility o Application of microbiology o Validation & Verification o Environmental monitoring using indicator microorganisms
Conclusion: Produce and Fresh-cut products microbiological environment and building multiple barriers against their potential risks.
Chapter Highlights Chapter 3: Food Safety Prerequisite Programs Joan Rosen / Michael Jantschke
• Comprehensive Review of Prerequisite Programs o o o o
Concept and background (historical use) Regulatory requirement FDA, USDA (sanitation and sanitary practices) FSMA and prerequisite programs (FSMA does not directly address, but requires similar type programs)
• Commonly Used Programs o Prerequisite as the core of facilities GMP compliance o Supplier management & approval program (Provides a sample program)
o Receiving & Storage
Chapter Highlights – Chapter 3 • Complete Outline of Employee GMPs o Procedures & Guidelines on key elements
• Sanitation; Key recommendations for sanitary operations & flow management o Master Sanitation Schedule (sample model)
• Equipment Sanitation o o o o
Basic sanitation model (Table) SSOP model (Key procedures, tools, conveyors…) Sanitation, verification and corrective actions Sanitation chemicals
• Environmental Monitoring Program (EMPs) o Visual & microbiological
Chapter Highlights – Chapter 3 o o o o
Microbiological verification techniques (Table) Sanitary design Pest control, chemical control Control of physical contaminants o Sources and prevention of foreign materials
o Control of add-ins, re-work and WIP
• • • •
Complaint Management Program Key Elements of Writing an SOP Documentation & Recordkeeping Monitoring, Verification & Validation Very comprehensive and detailed Chapter on what is necessary and what is required.
Chapter Highlights Chapter 4: Hazard Analysis & Preventive Controls William Hurst / Michael Jantschke / Tony Banegas
• Historical Background of HACCP & Fresh-cut Produce • Developing/Implementing the HACCP Plan o Definitions & principles o Prerequisite programs o How to put the program together
• Complete Hazard Analysis in Fresh-cut Processing Facility • Complete Program to Address All Identified Hazards and Their Control Points • Monitoring & Corrective Actions
Chapter Highlights – Chapter 4 • HACCP Plan Model for Shredded Lettuce • Developing a Food Safety HARPC Plan o HACCP vs. HARPC o HARPC uses & preventive controls
• Elements of Required Food Safety Plan (Excellent guide for developing a HACCP Plan)
A Chapter with a long history and very well updated. Future fine-tuning for FSMA impact
Chapter Highlights Chapter 5: Sanitary Plant and Equipment Design Gurmail Mudahar
• Facility & Equipment Design (Based on the assumption that raw produce may contain pathogens)
• Importance of Sanitary Design in Relation to Proposed Food Safety Rules • Fresh-Cut Produce Processing Facility Design (Food Safety & Processing) o Building design guidelines o Processing areas and support facilities o Supply areas
Chapter Highlights – Chapter 5 • Equipment Design (Focus on Quality and Food Safety ) o Key elements of general requirements o Refrigeration and cooling equipment o Processing line; unit by unit o Examples of processing units and wash systems Focus overall on processing steps to produce safe and quality Fresh-cut produce.
This topic is republished from 4th Edition due to valuable checklists
Chapter Highlights Chapter 6: Plant Cleaning and Sanitation: Materials and Systems Justin Kerr / Ross McKenney
• Overview of Sanitation o Safety of workers o Complete analysis of factors affecting cleaning (Interactions between water quality, soil and chemicals)
o Functions and selecting of cleaning compounds based on; products, surfaces and purpose
• Recommended Cleaners for Fresh-cut (complete model) • Cleaning Systems and Equipment (Table) • Sanitizers Selection; Types, Applications, Equipment and Benefits (Excellent application Tables)
Chapter Highlights Chapter 7: Process Water Quality Management and Verification Karan Kurana / Trevor Suslow / Yaguang Luo / (Devon Zagory)
The Latest Concepts in Wash Water Decontamination by Experts and Scientists • Water as Vehicle of Cross Contamination • Preventing Cross Contamination as a Main Goal • Clearing Misconceptions about Washing Produce • Principles in Designing Wash Water Systems • Wash Water Disinfectants May Be Regulated by FDA and EPA
Chapter Highlights – Chapter 7 • Water Application in Fresh Produce o Post-Harvest applications o Circulating and single pass applications
• Factors Affecting Decontamination Performance (Sanitizers, water quality, pH…)
• Wash Water Sanitizers and Their Effectiveness o Chemistry of sanitizers (Chlorine) in wash water o Advantages and disadvantages of sanitizers
• Effective Management & Measurement of Performance of Sanitizers (Manual, Continuous) • ORP and Free Chlorine • Conclusion: “Bringing it all together”
Chapter Highlights Chapter 8: Fresh-Cut Produce Packaging and Food Safety Jeff Brandenburg / Randy Beaudry
• Basic Functions and Technologies of Packaging for Fresh-cut Produce • Behavior of Microorganisms and Control of Pathogens in Fresh-cut Packaging • Packaging Formats & Applications o Flexible & Rigid o Regulations for food contact packaging
Chapter Highlights Chapter 9: Storage and Distribution Tom Mack / Saul Morales
• Handling and Sanitary Practices During Storage o Warehouse sanitation & EMPs o Cold chain & FIFO
• Truck Sanitation and Product Handling During Distribution o Temperature management o Prevention of product cross contamination o Truck washing guidelines
• Temperature & Food Safety
Chapter Highlights Chapter 10: Supply Chain Traceability Dan Vache / Micah Fuson
•Produce Traceability Initiative (PTI) o Supply Chain Traceability o External & Internal Traceability o Standardization based on GS1
•Traceability & Regulations (Bioterrorism Preparedness and Response Act of 2002) o 1-Step Up / 1-Step Down o Source of all ingredients in the finished lot (FSMA 2011) o New authorities to access records o Improve FDA systems to track / trace foods
Chapter Highlights – Chapter 10 • Action Plan; Best Practices o Pallet and Case level best practices based on GS1 (examples) o Item level (use of UPC)
• Traceability Process o Receiving (1-Step Down) o Shipping (1-Step Up) New Technologies are Revolutionizing Traceability; Updates to Include Packaging, Processing Practices and All Ingredients, in Addition to Capability of External Tracking
Chapter Highlights Chapter 11: Product Recall Drew McDonald / Gale Prince (Gurgit Shergill) “Recall Under Fire” A comprehensive and first-hand look at the recall
• General Recall Information • Classifications • Different Scenarios Leading to a Recall (Examples) • Key Behavioral Considerations
Chapter Highlights – Chapter 11 • Recall Program Detail and Goals o Press Release and FDA Communications (Model Press Release)
• Complete Guidelines for Recall Plan o o o o
Teams & Responsibilities Flow Diagrams Retrieval / Disposals Mock Recall
• Key Elements of Traceback Program
Chapter Highlights Chapter 12: Regulations Affecting the FreshCut Industry David Gombas / David Durkin
• FDA, GMPs, Regulations (2013 Proposed Rule: To replace “Current good manufacturing practices and Hazard Analysis and Riskedbased Preventive Controls for Human Food”) o Food Safety Plan o HACCP o Preventive Controls for Hazards o Monitoring / Corrective Actions / Verifications o Recall Plan
Chapter Highlights – Chapter 12 • • • • • •
Facility Registration Recall Authority Reportable Food Registry (RFR) Food Labeling (complete review) USDA Regulations Canadian Regulations Affecting Fresh-cut Produce
This Chapter will be updated as the rules become final.
Chapter Highlights Chapter 13: Food Safety Verification Programs and Self Audits Eileen Chase / Donna Lynn Johnson Are You Walking the Talk?
• Verification for Processing Plants o What, How, Who?
• Documentation • Most Common Activities o Prerequisite Programs & HACCP
Chapter Highlights – Chapter 13 • Internal Inspections and Audits (Roles, criteria, training)
• Performing Audits (Guidelines, standards, communication, documentation and corrective actions)
• 3rd Party Verification Audits (Domestic & Foreign Suppliers)
Update for Audits and Auditors Based on FSMA
Chapter Highlights Chapter 14: Developing a Food Safety Plan Roger Becker
• Basic Outline and Recommendations for Beginners • The Importance of a Food Safety Plan • Component of Food Safety Plan (GMPs, HACCP, Hygiene…) o Recall o Traceability o Training
Chapter Highlights Chapter 15: Food Defense Walter Ram
“Under Construction”
Supplemental Documents Best Practices for Garment Use in Fresh-cut Produce Plants Kari Valdes and the Contributors of Original Document
Excellent Document for Garments Used in Freshcut Processing Facility for Materials and Best Practices
Supplemental Documents Sanitary Equipment Design Buying Guide & Checklist
Supplemental Documents Guidance on Environmental Monitoring and Control of Listeria for Fresh Produce Industry David Gombas and Working Group
• Importance of the Publication • Scope Covers: o o o o
Comprehensive Work In Progress
Fresh and Fresh-cut Produce Packing houses & processing plants Transportation & Distribution Retail & Foodservice
• Background; o Sources in Supply Chain o Listeriosis linked to produce
• Regulatory Response to Listeria
Supplemental Documents • Listeria Control Measures Relevant to Fresh Produce • Usefulness of Testing for Listeria o Field Testing of Produce o Finished Product Testing o Environmental Monitoring
• Minimizing Contamination in the Field • Designing an Environmental Control Plan for Facilities (Based on Risks and Controls) • Prerequisite Programs Affecting Listeria Controls • Designing an Environmental Monitoring Plan • Response to Listeria Protection • Training
5th Edition, A Personal Journey
FreshTech Learning Center: “Food Safety Guidelines for the Fresh-Cut Industry” Sponsored by:
