Leading Food Safety Hazards in Food Processing: Lecture 2

Leading Food Safety Hazards in Food Processing Lecturer: Michael King Learning Outcomes for Module The Learning Outcomes for this modules are LO 1: State the principles of HACCP as part of GMP in the food industry. LO 2: Identify the relevant elements of a HACCP programme. LO 3: Identi...

Leading Food Safety Hazards in Food Processing Lecturer: Michael King Learning Outcomes for Module The Learning Outcomes for this modules are LO 1: State the principles of HACCP as part of GMP in the food industry. LO 2: Identify the relevant elements of a HACCP programme. LO 3: Identify the regulatory agencies and requirements for a HACCP programme. LO 4: Evaluate and audit a HACCP system 2 Learning Outcomes for Module The Learning Outcomes for this modules are 4: Design protocols and procedures for food hygiene and contamination controls in a food production facility and the levels of control required in low risk, high risk and high care production facilities. 5: Design and recommend a documented HACCP system using appropriate control measures at identified critical control points. 6: Identify and prescribe corrective actions for failures at identified critical control points. 3 Learning Outcomes – Lecture 2 After Tonight's Lecture 1. Classify the leading food safety hazards 2. Understand the control measures used by the food industry to control identified hazards 3. Understand the importance of production description and product intended use in the design of a HACCP system 4 Learning Outcomes – Lecture 2 4: Design protocols and procedures for food hygiene and contamination controls in a food production facility and the levels of control required in low risk, high risk and high care production facilities. 5: Design and recommend a documented HACCP system using appropriate control measures at identified critical control points. 6: Identify and prescribe corrective actions for failures at identified critical control points 5 Assessment of this module Continuous Assessment = 40% of overall marks will take place online on 08/03/2024 Final Exam in May 2024 will be worth the remaining 60% Remember that a minimum of 30% must be achieved in both the final exam and in the Cas overall. The pass grade is 40% overall 6 Categories of Leading Food Safety Hazards 1) Biological Food Safety Hazards (B) - micro- organisms 2) Physical Food Safety Hazards (P) 3) Chemical Food Safety Hazards (C) 4) Allergens – usually addressed in the Pre- requisite programme and through a sperate risk assessment. 5) Radiological – mainly associated with certain dried ingredients and is addressed separately rather than through the standard hazard analysis 7 Biological Food Safety Hazards Micro-organisms of most importance to the food industry are; Salmonella spp, E.coli and E.coli 0157:H7 Campylobacter spp Cl. Botulism Cl. Perfringens B. cereus and other Bacillus spp Staph. aureus Listeria monocytogens The risk posed by these bacteria and suitable control measures are covered in the Food Microbiology module 8 Physical Food Safety Hazards - Introduction About 80% of foreign body ingestions occur in the paediatric age group, or children below the age of three. It is estimated through a variety of reports and case studies that anywhere from 1% to 5% of foreign bodies ingested will result in some injury. A classic and very sad example of foreign materials and children occurred within the past few years. A gel-based candy was taken off the market after causing choking deaths in young children. This candy was supposed to melt in the mouth. Instead, it lodged in the throat and stayed there. 9 Physical Food Safety Hazards - Introduction Link to additional information; http://www.foodqualitynews.com/Regulation-and- safety/Plum-Organics-Little-Cremes-recall-halts-p roduction/?utm_source=newsletter_daily&utm_m edium=email&utm_campaign=15-Sep-2014&c=Y adv%2FEEBMk4ljQvmSLw4geI4VGTWnf6B 10 Physical Food Safety Hazards - Introduction Link to additional information; - Another example from June 2020 https://www.fsai.ie/news_centre/food_alerts/ABC_j elly_products.html 11 Physical Food Safety Hazards - Introduction Product: ABC Jelly Products: Girl Jelly Fruity Bites; Boy Jelly Fruity Bites; Fruitery Jelly Assorted Jar; Fruitery Jelly Assorted Bag; Pentagon Cup Jelly Snacks Bag; Pentagon Cup Taro Bag; Pentagon Cup Taro Jar; Assorted Jelly Snacks. 12 Physical Food Safety Hazards - Introduction Message: The above ABC jelly fruit cup sweets are subject to recall, as they may cause a choking risk, due to the presence of gel-forming food additive ingredients. Point-of-sale recall notices will be displayed in stores supplied with the implicated sweets. 13 Classification of Physical Food Safety Hazards Broadly speaking physical food safety hazards can be broken down into two categories; Intrinsic Foreign Materials – these are materials or objects that are an integral part of a component part of a product eg. Gristle in a beef burger Extrinsic Foreign Materials – these are material that are a foreign component of a product – eg glass in a hash brown 14 Physical Food Safety Hazards - Introduction The leading physical hazards in food processing are;  Glass  Perspex  Wood  Metal  Aluminium foil slivers  Hard plastic  Plastic Film  Cardboard  Paper  Hair  Fibre  Bone  Gristle  EVM (Extraneous Vegetative Material)  Miscellaneous foreign material 15 Physical Food Safety Hazards – Two Categories Intrinsic Physical Safety Hazards. These are recognised physical hazards that are part of the raw material that we do not want to find in a finished product. Examples include; - gristle (connective tissue) in a beef burger - Onion skins in diced onion - Pepper Seeds in diced peppers. 16 Physical Food Safety Hazards – Two Categories Extrinsic Physical Food Safety Hazards: These are recognised physical hazards that are foreign to all the raw materials and should not be in the finished product. Examples include; Glass, metal, wood Beef gristle in a vegetarian product 17 Physical Food Safety Hazards – Glass – Practical Controls Replacement – Wherever possible glass and brittle plastics should be replaced with sustainable alternatives. – Eg Replace Perspex rulers with metal rulers. – Replace glass window with Perspex in internal office windows Where this is not possible the glass items must be suitable protected – – Example 1. a protective sheet can be affixed to glass windows so that in the event of glass shattering all fragments will be held in place. Eg Solarguard 18 Physical Food Safety Hazards – Glass – Practical Controls – Example 2 – A perspex covers can be placed over all fluorescent light tubes. – Example 3 – Shatterproof light tubes on Electrical Fly Killing (EFKs) Units. 19 Physical Food Safety Hazards – Glass – Practical Controls Where there is no alternative to glass packaging the following controls must be put in place. 1. Incoming inspection checks 2. General standard operating procedures (SOPs) for the handling of glass packaging materials. 3. Glass breakage procedures – including for example disposal of all materials within 10m of a breakage in a glass filling line. 20 Physical Food Safety Hazards – Glass – Practical Controls Best practice dictates that glass hard plastic and brittle plastics be treated with the same caution. Wherever possible that glass/prespex/brittle plastic should be of a colour that is different to the food material. A register of all glass, prespex and brittle plastic must be maintained for the entire production facility (including amenity areas and offices). Scheduled routine audits based on risk assessment must be carried on all items on the register. 21 Physical Food Safety Hazards – Glass – Risk Assessment The frequency of assessment is based on risk assessment. Daily assessment of documented items that a directly over open product or packing lines or are likely to fall onto these lines if broken. Monthly assessment of documented items that are not directly over open product or packing lines or are likely to fall onto these lines if broken. Three monthly assessment of offices, amenity areas and other low risk areas 22 Physical Food Safety Hazards – Glass – Risk Assessment The audit must record the condition of the item e.g. intact, broken, damaged but intact, undamaged but not working. Any issues raised must be investigated to establish if the glass breakage procedure has been followed and if not, whether product has been put at risk. A risk assessment must be completed to determine how quickly repairs must be made. 23 Physical Food Safety Hazards – Glass Breakage Control Measures A detailed procedure must be in place for the management of glass, brittle plastic and hard plastic breakages. This must include: Stopping of production Restriction of movement through the affected area Quarantine of affected materials Report to management Clean up of breakage and disposal / cleaning of cleaning equipment Safe removal of glass from area Repair or replacement of damaged item 24 Physical Food Safety Hazards – Glass Breakage Control Measures The checking of PPE (including footwear) and changing if necessary Completion of an incident log and sign off that production can restart, by a responsible/senior person. A sample of broken glass must be retained in a safe manner Corrective Action to prevent reoccurrence TRAINING All employees must be briefed on the glass breakage procedure at induction. All production / hygiene managers and engineers must be trained to understand and apply the glass breakage procedure. 25 Physical Food Safety Hazards – Glass – Example of Product Recall https://www.fsai.ie/news-and-alerts/food-alerts/recall-of -a-batch-of-karma-kefruit-citron-figue Message: The above batch of Karma Kefruit Citron Figue (Lemon Fig) drink is being recalled due to the possible presence of glass fragments. Recall notices will be displayed at point-of-sale. Action Required: Manufacturers, wholesalers, distributors, caterers & retailers: Retailers are requested to remove the implicated batch from sale and display a recall notice at point-of-sale. Consumers: Consumers are advised not to drink the implicated batch. 26 Physical Food Safety Hazards – Glass – Example of Product Recall https://www.fsai.ie/news-and-alerts/food-alerts/recall-of-a-batch-of- nora-salmon-roe Message: The above batch of Nora Salmon Roe is being recalled due to the possible presence of pieces of glass. Recall notices will be displayed at point-of-sale. Action Required: Inspectors: Distribution details will be provided to relevant official agencies. Please notify the FSAI of any concerns. Manufacturers, wholesalers, distributors, caterers & retailers: Retailers are requested to remove the implicated batch from sale and display recall notices at point-of-sale. Consumers: Consumers are advised not to eat the implicated batch. 27 Physical Food Safety Hazards – Glass – Example of Product Recall https://www.fsai.ie/details.aspx?id=17720 Message: True Natural Goodness Organic Alfalfa seeds in 3 pack sizes are being recalled due to the presence of glass fragments. Nature Of Danger: The packs may contain glass fragments which renders the implicated batches unsafe for consumption. 28 Physical Food Safety Hazards – Metal All modern food processing equipment is made of metal mainly stainless steel. This equipment can wear and fail. Also engineers used metal tools and small metal items to carry out necessary maintenance. Many other product also have metal in their packaging - bag clips, cans, aluminium foils on pies and other packaging materials) 29 Physical Food Safety Hazards – Metal Knives are commonly used in production preparation Controls may include: Reconciliation of numbers Inspection of condition before and after production runs. Knife, blade, scissors and needle control must be in place and include Only company issue, captive, identified and registered knives, blades and scissors must be used 30 Physical Food Safety Hazards – Metal No snap blade knives must be used Knives, blades and scissors must only be used for the task for which they were designed Equipment must be accounted for and the condition checked and recorded (minimum start and end of production). In the event of breakage or loss, all parts must be accounted for and the incident logged. Corrective action must be taken to prevent re- occurrence. 31 Physical Food Safety Hazards – Metal Knife and blade sharpening must take place away from production areas and equipment must be returned in a clean condition A procedure for disposing of used knives Knives and blades must not be stored in personal lockers, knife blocks or plastic scabbards. These may only be used for temporary storage. -Shadow boards, magnetic holder, secured clean storage are normally used for this purpose 32 Physical Food Safety Hazards – Metal – Best Practice Best practice also includes; All knives / scissors issued will be individually numbered to ensure they can be accounted for. Knife sharpening with steels is acceptable, provided they are not used over product. Where sharpening devices are fixed within butchery areas, the location and use do not pose a risk of contamination 33 Physical Food Safety Hazards – Metal – Engineering Activities Engineering Activities Engineering activities must be controlled to avoid compromising product safety or quality. In open product areas; Start up checks of equipment must identify damaged or missing parts. These are usually carried out with the glass and hard perspex checks. In the event of damage or loss, all parts must be accounted for and the incident logged. Corrective action must be taken to prevent re-occurrence. 34 Physical Food Safety Hazards – Metal – Engineering Activities Engineering Activities (cont.) Potential transfer of metal contamination from engineering areas must be suitably controlled (e.g swarf mats). When purchasing small items, where possible they must be metal detectable at level of detection on site Wire brushes and scourers must be in good condition and stored away from the production process or below product height when not in use 35 Physical Food Safety Hazards – Metal – Engineering Activities Engineering Activities (cont.) Mobile engineering work stations must not be used in open food areas After use the area where the wire brushes or scourers were used must be inspected. There must be a planned preventative maintenance (PPM) program that covers all equipment critical to safety, legality and quality, which is fully implemented 36 Physical Food Safety Hazards – Metal – Engineering Activities Engineering Activities (cont.) A system must be in place to record all maintenance work requested and PPM work completed. Work must be completed in the agreed timescales. Procedures must be in place to manage work not completed within agreed timescales. Engineering work areas (including stores) must have good standards of fabrication, hygiene and housekeeping. 37 Physical Food Safety Hazards – Metal – Engineering Activities Engineering Activities (cont.) The areas must be within the scope of the site Pest Control Programme. Production or food containers must not be used as general storage containers in these areas. Wherever possible, engineering work must take place away from production areas. Engineering and maintenance areas that access directly into production areas must have restricted access. 38 Physical Food Safety Hazards – Metal – Engineering Activities Engineering Activities (cont.) Welding, drilling, riveting and soldering etc. must not take place on equipment being used for production or on any equipment immediately adjacent, unless suitable hygienic screening is in place. Tools must be captive to site or adequately cleaned prior to transferring into open food areas. Tools must be captive to high risk / high care areas or disinfected into the area. 39 Physical Food Safety Hazards – Metal – Engineering Activities Engineering Activities (cont.) In the event of electrical items being required they must be clean and wrapped so that the item is waterproof, and then disinfected into the area. Engineers completing repairs in production areas must be provided with lockable metal or plastic tool box. All tools and parts must be controlled. A system must highlight and initiate an investigation if a tool or part is missing. Tool boxes must contain an inventory of items they contain 40 Physical Food Safety Hazards – Metal – Engineering Activities Engineering Activities (cont.) Engineers and Contractors must comply with necessary Health and Safety requirements and operational GMP of the site, including wearing of protective clothing. A list of approved contractors who have been briefed on site controls must be in place. A permit to work system must be in operation if the maintenance work required poses a potential risk to product (e.g. welding, cutting etc.) or individuals e.g. in confined spaces 41 Physical Food Safety Hazards – Metal – Engineering Activities Engineering Activities (cont.) After engineering work (including temporary repairs) has been completed, a system must be in place to assess cleaning requirements prior to use in production. Where cleaning is required following maintenance, this must be undertaken before production commences and must be recorded. Equipment must be checked and signed back to production by the engineer and production / QA (depending on sites procedures) following work and any necessary cleaning. 42 Physical Food Safety Hazards – Metal – BRC V8,Clause 4.9.2.2 - Interpretation Staples, paper clips and similar metallic items Staples are often used in packaging. However, their use needs to be considered, since they are a potential source of contamination and the purchase of ingredients or packaging materials containing them must be avoided. Where ingredients with potential foreign bodies cannot be avoided, there need to be controls to manage these hazards. Staples, paper clips and drawing pins (i.e. thumb tacks or pin tacks) must not be used in open product areas. One common yet simple example is to use plastic sleeves to store production records 43 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment The risk of product contamination shall be reduced or eliminated by the effective use of equipment to remove or detect foreign bodies. Interpretation The risk of foreign-body contamination must be minimised using food industry best practice, such as X-ray inspection, metal detection, sieves, magnets or scanner technology. 44 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment A documented assessment in association with the HACCP study shall be carried out on each production process to identify the potential use of equipment to detect or remove foreign-body contamination. Typical equipment to be considered may include: filters sieves metal detection 45 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment magnets optical sorting equipment X-ray detection equipment other physical separation equipment (e.g. gravity separation, fluid bed technology). 46 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment Documented assessment The HACCP analysis should be the starting point for implementing an effective foreign-body control programme. Potential hazards and their sources must be identified so that appropriate control procedures can be put in place to minimise the likelihood of product contamination 47 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment The type, location and sensitivity of the detection and/or removal method shall be specified as part of the site’s documented system. Industry best practice shall be applied with regard to the nature of the ingredient, material, product and/or the packed product. The location of the equipment or any other factors influencing the sensitivity of the equipment shall be validated and justified. 48 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment Operation of a metal detector https://youtu.be/vAsYLI_sHr4 49 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment Testing of a metal detector https://youtu.be/9xcJyODF4dc 50 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment Clause 4.10.1.2 Type, location and sensitivity The choice of location for foreign-body detection equipment is vital for its effective use. Equipment should be placed as close to the end of the production process as is practical, so that the whole process (including packing lines) is protected. When selecting equipment and determining the best location for it, the potential environmental effects (e.g. temperature, moisture or speed of line) should be considered and discussed with the equipment supplier. 51 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment The sensitivity of detectors must be specified and best practice applied, taking into account the nature of the food, contamination characteristics, and the location and aperture size of the detector. For example, it is likely that metal detectors will be sensitive to ferrous, non-ferrous and stainless steel test pieces, using test sizes according to industry best practice for the particular product type or customer requirements. Good practice is for foreign-body detectors to have adequate security settings so that only authorised personnel can alter them 52 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment BRCGS Standards expect the detector and its location to be validated at set-up; for example, by adjusting the machine’s sensitivity using a range of typical products to establish the most sensitive practical setting which gives rise to consistent rejection without false rejects. The established settings must be recorded and verified through regular checks of the equipment; these checks are generally undertaken using test pieces of a size just above the limit of detection. 53 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment The site shall ensure that the frequency of the testing of the foreign-body detection and/or removal equipment is defined and takes into consideration: specific customer requirements the site’s ability to identify, hold and prevent the release of any affected materials, should the equipment fail. 54 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment The site shall establish and implement corrective action and reporting procedures in the event of a failure of the foreign-body detector and/or removal equipment. Action shall include a combination of isolation, quarantining and re-inspection of all products produced since the last successful test or inspection. 55 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment System monitoring and corrective action The frequency of testing the monitoring equipment must be defined in procedures. The frequency of routine tests should consider: the need for additional checks at start-up and finish of shifts product changeovers the need for regular checks throughout production (hourly testing is expected for many detection systems) 56 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment changes in machine settings or following downtime any specific customer requirements the site’s ability to recover and retest product in the event of a failure. In the event that equipment is discovered not to be working, all of the product that has passed through the detector since it was last verified to be working should be rechecked. 57 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment Where foreign material is detected or removed by the equipment, the source of any unexpected material shall be investigated. Information on rejected materials shall be used to identify trends and, where possible, instigate preventive action to reduce the occurrence of contamination by the foreign material. 58 Physical Food Safety Hazards – Metal – Foreign Body Detection and Removal Equipment The data on rejected and retained product must also be used as the basis for analysing trends. This trend analysis may be used to establish preventive actions to reduce future contamination. Information about false rejects should also be recorded, because this may suggest an error with the detector or indicate that the settings are too sensitive for a particular product and require adjustment. 59 Physical Food Safety Hazards – Metal – Other good practices All metal detectors must have the capability of detecting ferrous, non-ferrous and stainless steel (with the exception of foil packed products or similar metalized films). All foreign body detectors must be located as close as possible to the finished packaging point. All foreign body detectors must have adequate security devices, so only authorised personnel have access to alter settings. 60 Physical Food Safety Hazards – Metal – Other good practices A conveyor type detection system must have: An effective automatic rejection system A locked box to receive rejected product A fully enclosed area around the search head and rejection box A visual or audible alarm system in the event of detection. Belt stop systems may only be used for bulk or sensitive items. Where belt stop systems are in use these must have a visual or audible alarm. 61 Physical Food Safety Hazards – Metal – Other good practices The best foreign body detector systems include: A data capture system to show pack numbers checked – The number of rejects, number and type of tests – Foreign body detector system highlights when tests are due – Visual or audible alarm system in the event of line fault and fail safe activation 62 Physical Food Safety Hazards – Metal – Other good practices The foreign body detector must be fully operational at the start of production. An effective testing method must be in place and all checks must be documented. Detectors must be checked at the beginning and end of production and minimum hourly. Conveyor Metal Detector Systems Detectors must be checked using clearly identified test packs at the same temperature as standard product passing down the line and test pieces of a defined size (based on risk assessment) 63 Physical Food Safety Hazards – Metal – Other good practices The test pieces must be passed through the detector as close to the centre of the aperture as can be achieved with the test pack. Test packs must be passed successfully through the metal detector prior to being used for the check. Test packs must be allowed to be rejected fully into the bin. Consecutive leading and trailing checks must be completed in long packs to ensure the reject mechanism can successfully reject, unless the metal detector has a photo electric cell that measures the product prior to passing through the search head. 64 Physical Food Safety Hazards – Metal – Other good practices The test must be representative of how products would normally travel through the detector during normal production. Inline Systems An effective testing method must be in place for the equipment. Refer to advice from the equipment manufacturer. X-Ray Detection Systems The test pieces must be placed in the worst case scenario area. Refer to advice from the equipment manufacturer. 65 Physical Food Safety Hazards – Metal – Other good practices Detector fail safe systems where fitted, must be challenged at regular intervals (minimum start and end of day) to make sure they are effective. Reject confirmation Bin full Air pressure low Search head failure Back-up sensor Photo electric cell pre search head Each batch of metal detectable plasters must be checked to ensure they are detected by the lowest sensitivity metal 66 Physical Food Safety Hazards – Metal – Other good practices All staff involved with foreign body detection must be trained not only in the technical and operational aspects but also the principles of metal and foreign body detection to ensure full understanding of the purpose. Risk assessments must be completed to determine whether a particular material requires sieving/filtering (including liquids). Where sieves and filters are used these must be metal detectable or of a contrasting colour to the food. 67 Physical Food Safety Hazards – Metal – Other good practices Sieving/Filtering equipment must be inspected for integrity at pre-defined intervals as identified in the risk assessment and recorded. Equipment must be accessible to enable inspection. Mobile equipment must be uniquely identified to ensure that the integrity of each sieve is being managed. Sieves and filters must be included on the preventative maintenance plan. Training of personnel operating or inspecting the sieving/filtering equipment must take place. 68 Physical Food Safety Hazards – Metal – Other good practices Records must be in place to demonstrate when ingredients have been sieved/ filtered (traceable to batch level). Stored sieved ingredients must be protected to prevent post sieving contamination A sieve matrix must be in place detailing the type of material, sieve size, frequency of inspection and sieve location. Sieve tailings must be checked and recorded at regular intervals as defined in the risk assessment. 69 Physical Food Safety Hazards – Metal – Other good practices Procedures must be in place for actions when foreign bodies are found. A full investigation must take place to ensure the source of contamination is identified and corrective action plan implemented (and product is dealt with in appropriate manner). Details of the investigation must be recorded 70 Physical Food Safety Hazards – Metal – Example of Product Recall Tesco Free from Digestive Biscuits – April 2022 https://www.fsai.ie/news-and-alerts/food-alerts/recall-of-a-b atch-of-tesco-free-from-digestive-biscuits Brakes Bread Sticks – June 2020 https://www.fsai.ie/news_centre/food_alerts/breadsticks_re call.html Unilever/HB Ice Lolly Pops – June 2020 https://www.fsai.ie/news_centre/food_alerts/Calippo_Recall. html 71 Physical Food Safety Hazards – Metal – Example of Product Recall Decathlon Chocolate Flavour Whey Protein due to the presence of metallic pieces – November 2024 https://www.fsai.ie/news-and-alerts/food-alerts/recall-of-a-batch-of-de cathlon-single-whey-chocola Recall of specific batches of Magnum Almond Ice Cream 3 pack due to the possible presence of plastic and metal pieces – April 2024 https://www.fsai.ie/news-and-alerts/food-alerts/recall-of-specific-batc hes-of-magnum-almond-ice-cr Recall of Johnston Mooney & O'Brien baked products due to the possible presence of metal pieces – July 2024 https://www.fsai.ie/news-and-alerts/food-alerts/recall-of-johnston-mo oney-o-brien-baked-products-d 72 Physical Food Safety Hazards – Wood Wood should not be used in open product areas except where this is a process requirement (e.g. maturation of products in wood). Where the use of wood cannot be avoided, its condition must be montoring on a risk based frequency to ensure it is in good condition and free from damage or splinters which could contaminate products Wood used for food contact purposes must be fit for purpose – free from damage or splinters, free from taint and wood treatment agents or where agents have to be used these agents are in accordance with relevant legislation and approved for food use. 73 Physical Food Safety Hazards – Wood – BRC V8 – Clause 4.9.5 –Interpretation Wood in open product areas The use of wood is not permitted in production areas except where it is a requirement of the process (e.g. wooden casks used for some alcoholic beverages, or wooden crates for incoming raw materials in fresh produce packhouses). Therefore items such as wooden pallets should not be present in open product areas. Where wood cannot be avoided, a procedure must be in place to: ensure the use of wood is covered by the HACCP risk assessment identify damaged items minimise the potential for contamination ensure that the wood is continually monitored (e.g. by regular checks to ensure it is in good condition and clean). 74 Physical Food Safety Hazards – Wood – other good practices The use of wood within the site production and storage areas where possible must be eliminated (e.g. hand tools, pencils, clip boards, furniture, brooms etc). Industry is moving towards the use of plastic pallets in many circumstances but this practice can pose health and safety risks Where wood cannot be eliminated in production and storage areas it must be minimised and suitably controlled 75 Physical Food Safety Hazards – Wood – other good practices Controls may include: Layer separation between pallets and product Coverage of materials stored under wooden pallets on racking systems Broken pallets removed from the system Wooden boxes where used in good condition or system of repair (e.g. potato storage boxes) Demarcation of where wooden pallets are or are not permitted within the site. In general wooden pallets are prohibited in open product areas. 76 Physical Food Safety Hazards – Wood – other good practices Where wood is used in the process or integral to the product it must be controlled (e.g. skewers, cheese ripening shelves, salami poles, barrels, wood smoke chips). Controls for wood used in processing must be based on risk assessment. They must include: Intake Checks Inspection for splinters/damage Procedures for handling of breakage 77 Physical Food Safety Hazards – Wood – Example of Product Recall Super Valu Long Grain Rice https://www.fsai.ie/news-and-alerts/food-alerts/recall-of-all-batches-o f-supervalu-long-grain-rice ChockBlok ice-cream https://www.fsai.ie/news_centre/food_alerts/ChokaBlok_icecreamreca ll.html 78 Physical Food Safety Hazards – Plastics and other FM Procedures shall be in place to prevent physical contamination of raw materials by raw material packaging (e.g. during debagging and deboxing procedures to remove the packaging). 79 Physical Food Safety Hazards – Plastics and other FM - Interpretation Raw material packaging Prior to packaged raw materials being taken into open product or processing areas, the packaging should be visually checked for any potential sources of contamination, and cleaned if necessary. Where packaging is removed from raw materials prior to use, documented procedures should be in place so that the person carrying out the activity knows how to do so without creating a contamination hazard to the raw material. 80 Physical Food Safety Hazards – Plastics and other FM Portable handheld equipment, e.g. stationery items (pens, pencils etc.), mobile phones, tablets and similar portable items used in open product areas, shall be controlled by the site to minimise the risk of physical contamination. The site may consider, for example: excluding non-approved items restricting the use to site-issued equipment ensuring stationery items such as pens are designed without small external parts and are detectable by foreign- body detection equipment, or are used in designated areas where contamination is prevented. 81 Physical Food Safety Hazards – Plastics and other FM Control of pens The type of control applied to pens will depend on the nature of the process, the site and the potential for contamination should those pens be lost or damaged in the production or storage area. In some cases, the purchase of metal-detectable pens is sufficient, whereas in others, the purchase of pens is restricted to those with no small parts so that any breakage does not result in small pieces of undetectable plastic in product. 82 Physical Food Safety Hazards – Plastics and other FM Examples of good pens for food production areas 83 Physical Food Safety Hazards – Plastics and other FM As discussed brittle plastics are treated in the same manner as glass and prespex in the food industry. Plastic bags are commonly used in the industry to wrap food and thereby protect it from environmental contamination. These same plastic wrapping pose significant physical contamination risk to the food processor. 84 Physical Food Safety Hazards – Plastics and other FM To minimise the risk of contamination from clear plastic liners and bags a contrasting colour must be used where possible – eg blue liners on red meat Bags and film gauges must be specified and be appropriate to avoid potential entrapment or tearing All unnecessary packaging must be removed prior to transfer of materials into production areas. (Traceability must be maintained – this is usually achieved by electronic means or by the use of labels) All wrapping must be removed from materials before cutting (e.g. butter, cheese). 85 Physical Food Safety Hazards – Plastics and other FM Inspection procedures must ensure that all entrapped packaging materials are removed during decanting of materials e.g. frozen. If entrapped packaging is identified, corrective action must be taken to remove the packaging prior to the material being used in production or the material must be rejected. Inspection procedures must ensure that all entrapped packaging materials are removed during decanting of materials e.g. frozen. 86 Physical Food Safety Hazards – Plastics and other FM – other good practice If entrapped packaging is identified, corrective action must be taken to remove the packaging prior to the material being used in production or the material must be rejected. Procedures include: Rejection at intake Controlled tempering An alternative supplier may be sourced Opening and re-sealing methods of containers and packaging must minimise the risk of potential contamination E.g. The use of scissors or sharp knives, not torn. - A Bag opening procedure 87 Physical Food Safety Hazards – Plastics and other FM – other good practice The correct type, grade, colour and quality of material must be selected for each application e.g. factory containers and PPE. Considerations may be given to the following: Freezing Blast chilling Washing technique Exposure to acid/alkali materials Abrasion or impact damage Contrasting colour to product 88 Physical Food Safety Hazards – Plastics and other FM – other good practice All damaged food / ingredient containers and trays (including bulk palletainers) must be removed from the system and corrective action implemented to prevent reoccurrence. The use of food containers (e.g. plastic trays, cans, foil trays etc) to store other materials e.g. nuts, bolts etc. must not be permitted All pens used within production, storage and packing areas must be site issued, one piece and of a contrasting colour. Staples, hole punches, drawing pins etc must not be permitted in production, packing or storage areas. Use plastic sleeves as an alternative. 89 Physical Food Safety Hazards – Plastics and other FM – other good practice One piece (i.e. no lid) factory issue pens with no clear plastic parts in production and storage. Metal detectable pens, in sites where metal detectors are used. (These may be of the impregnated plastic type or of metal construction) Alternatives to staples and drawing pins are used wherever possible. Metal detectable items in use. PPE to be supplied without unnecessary foreign objects (e.g. rubbers band on sleeves or aprons, no card inserts in aprons). Utensils in open food areas, wherever possible are metal detectable. 90 Physical Food Safety Hazards – Plastics – Product Recalls Recall of specific batches of Cape Herb and Spice products due to the possible presence of plastic pieces – Jan 2025 https://www.fsai.ie/news-and-alerts/food-alerts/recall-of-specific-ba tches-of-cape-herb-and-spice 2021 Recall of various batches of Ambrosia My Mini Rice, My Mini Custard and My Mini 30% Less Sugar Custard due to possible presence of plastic pieces – Feb 2024 https://www.fsai.ie/news-and-alerts/food-alerts/recall-of-various-a mbrosia-my-mini-rice-my-mini-cu Recall of a batch of Lidl Fin Carré White Chocolate due to the possible presence of plastic pieces – Nov 2023 https://www.fsai.ie/news-and-alerts/food-alerts/recall-of-a-batch-of -fin-carre-white-chocolate 91 Physical Food Safety Hazards – Paper and Cardboard – good practices While plastics technology has improved to allow many product to be wrapped case-less (pallets of frozen beef) it is still necessary to pack significant amounts of products in cardboard boxes and/or paper sacks. Additionally, all product must carry identification and traceability information. In many circumstances this information is carried on adhesive paper labels. Consequently, paper and cardboard pose a significant food safety risk and need to carefully controlled. 92 Physical Food Safety Hazards – Paper and Cardboard – Good Practices The type, condition and location of any labels used must not pose a risk of contamination. Paper labels in open food areas are kept to a minimum and stored in a designated area All signage must be secure and effectively sealed against the wall e.g. to minimise the risk of debris collecting between sign and wall. All signage must be washable and magnetic signage used wherever possible 93 Physical Food Safety Hazards – Paper and Cardboard – Good Practices The use of cardboard in production areas must be managed / controlled. Cardboard boxes are opened correctly to prevent ripping using a documented procedure Storage and packing areas are regularly swept to remove card shards from packing boxes A risk assessment must be conducted prior to the use of cardboard in production areas. Ideally, cardboard should not be used in open product areas. A procedure must be in place for the de-boxing and debagging of raw materials and packaging, which aims to minimise the risk of contamination. 94 Chemical Food Safety Hazards There are five leading categories of chemical food safety hazards 1) Contamination from cleaning chemicals 2) Pesticide and other environmental residues 3) Residues of veterinary medicines in foods of animal origin 4) Migration of chemicals from product packaging 5) Contamination from non food grade oils or lubricants 95 Chemical Food Safety Hazards –BRC V9 Processes shall be in place to manage the use, storage and handling of non-food chemicals to prevent chemical contamination. These shall include, at a minimum: an approved list of chemicals for purchase availability of material safety data sheets and specifications confirmation of suitability for use in a food-processing environment avoidance of strongly scented products 96 Chemical Food Safety Hazards –BRC V9 the labelling and/or identification of containers of chemicals at all times a designated storage area (separate from chemicals used as raw materials in products) with access restricted to authorised personnel Processes shall be in place to manage the use,storage and handling of non-food chemicals to prevent chemical contamination. These shall include, at a minimum: use by trained personnel only procedures to manage any spills 97 Chemical Food Safety Hazards –BRC V9 – Interpretation Storage and handling of non-food chemicals Non-food chemicals present a potential product contamination or taint risk if they are not stored and handled correctly. The site needs to demonstrate controls on non- food chemicals, including the following: an approved list of chemicals for purchase – this is to prevent inappropriate chemicals from being purchased. This applies to all cleaning chemicals, pesticides and other chemicals which may be used in the production environment 98 Chemical Food Safety Hazards –BRC V9 – Interpretation material safety data sheets and specifications provided by the supplier. These should be up-to-date and accurate confirmation that the chemicals are suitable for use in a food-processing area (i.e. they are non-tainting and not highly toxic). For example, cleaning chemicals must be selected to avoid the risk of product tainting (chemicals such as phenolics and those that are strongly scented are not suitable) avoidance of strong-scented products identification of chemicals (e.g. labelling of all containers) at all times, to minimise the potential for inadvertent use 99 Chemical Food Safety Hazards –BRC V9 – Interpretation designated storage with restricted access limited to authorised personnel. Potentially harmful chemicals (e.g. sodium hypochlorite) must be suitably stored to prevent inadvertent product contamination. Good practice is to provide bunded areas around appropriate chemical and oil tanks and to ensure that safe-use/storage instructions from the manufacturer are implemented (e.g. store acid and alkaline materials away from each other and store powders above liquids in case of spillage and subsequent reaction). Good practice also includes supplying cleaning chemicals to production areas ready diluted (for use with verified auto-dosing systems) and to ensure that stocks of cleaning chemicals not required for the current production or cleaning activity are stored away from the 100 Chemical Food Safety Hazards –BRC V9 – Interpretation Chemicals that are likely to come into direct contact with foods when used as intended (e.g. materials such as oils or lubricants used on machinery), as well as terminal sanitisers that are designed to be used without rinsing with water, should be confirmed as suitable for food use. (This would not include general detergents and cleaning materials, as these should not come into direct contact with food.) 101 Chemical Food Safety Hazards –BRC V9 – Interpretation Consideration may need to be given to the legislative requirements of specific countries, states or territories. For example, legislation may require that materials do not contain toxic or prohibited substances, that lubricants are suitable for food use or that terminal sanitisers meet applicable standards (e.g. the Biocidal Products Regulation (EU) No. 528/2012). 102 Chemical Food Safety Hazards –BRC V9 Where strongly scented or taint-forming materials have to be used, for instance for building work, procedures shall be in place to prevent the risk of taint contamination of products. 103 Chemical Food Safety Hazards –BRC V8 – Interpretation Strong scents and taints Wherever possible, strongly scented or taint-forming materials must not be used. However, where these are necessary (e.g. for some building work), procedures must be in place to avoid the risk of taint contamination of products. For example, relevant information must be requested from contractors, detailing the chemicals to be used and the controls (such as the extraction of fumes) that will need to be in place. A risk assessment of the information should be completed prior to commencement of the work. 104 Chemical Food Safety Hazards – other controls Pesticides and Environmental Residues Buy raw materials from approved suppliers ideally accredited to the BRC Global Food Safety Standard Issue No. 9 Buy raw materials against signed raw material specifications – Ensure that the section in the specification on chemical hazards specially required compliance to all EU standards for residues Request results of annual monitoring where necessary 105 Chemical Food Safety Hazards – other controls Veterinary Residues Buy raw materials from approved suppliers ideally accredited to the BRC Global Food Safety Standard Issue No. 9 Buy raw materials against signed raw material specifications – Ensure that the section in the specification on veterinary chemical hazards specially required compliance to all EU standards for residues. Request results of annual monitoring where necessary 106 Chemical Food Safety Hazards – other controls Migration of Chemical from Product Packaging Ensure all food contact packaging is certified as food grade – this includes cardboard, ink and glazing/finishing Buy packaging from approved suppliers and buy the packaging against agreed product specifications Confirmation that the materials are suitable for direct food contact(EC Regulation No. 1935/2004) from suppliers 107 Chemical Food Safety Hazards – other controls Oils and Lubricants Ensure that food grade oils and lubricants are used wherever possible. Keep appropriate certificates on file Where non food grade lubricant have to be used these need to be clearly marked, used by trained staff and used in dedicated utensils (grease guns etc) Appropriate guarding used be in place to protect the product from possible contamination as appropriate. 108