Lecture 7 - Quality Management System in the Food Industry 2024 PDF

Quality Management Systems in the Food Industry Lecturer: Michael King Module Learning Outcomes The Learning Outcomes for this modules are 1: Describe the quality management systems for ingredients and components. 2: Identify the relevant EU regulatory, industrial and retailer standards...

Quality Management Systems in the Food Industry Lecturer: Michael King Module Learning Outcomes The Learning Outcomes for this modules are 1: Describe the quality management systems for ingredients and components. 2: Identify the relevant EU regulatory, industrial and retailer standards in the food industry. 3: Define the legal implications of non- conformance 4: Describe the QC testing pathway in food manufacturing industry. 5: Comply with Food Hygiene standards Level 1 and Level 2 ©2020, Innopharma Labs Ltd and King Quality Solutions 2 Learning Outcomes – Lecture 7 After Tonight's Lecture 1: Describe the quality management systems for ingredients and components. 2: Identify the relevant EU regulatory, industrial and retailer standards in the food industry. 3: Define the legal implications of non- conformance 4: Describe the QC testing pathway in food manufacturing industry. ©2020, Innopharma Labs Ltd and King Quality Solutions 3 Structure of a typical Technical/Quality Assurance Dept Technical/Quality Manager Quality Customer Process Control Assurance Service Process Customer Technologist Service QA Supervisors Representatives Packaging and Food Technologist Technologists Test Kitchen Ops ©2020, Innopharma Labs Ltd and King Quality Solutions 4 Technical Dept – Roles and Responsibilities Technical Manager/Quality Manager The Quality Assurance Manager is responsible for the Total Quality Assurance Programme, for auditing finished product quality and reporting regularly on the product quality and food safety to the General Manager and the Factory Management Team. (S)he has day to day responsibility for the food safety/quality function. The Quality Assurance Manager is the nominated Management Representative who oversees the overall implementation of activities that ensure food safety, legality and quality. He maintains the food safety and quality system and ensures that both the requirement of the global standard for food safety legality are met in each area. ©2020, Innopharma Labs Ltd and King Quality Solutions 5 Technical Dept – Roles and Responsibilities  The Quality Assurance Manager (cont.)  (S)he is responsible for organising internal quality auditing, takes over the responsibility for the control and detection of foreign bodies, document control, pest control, the approval of the disposal of non-conforming product, handling customer complaints and product recall. He ensures the promotion of awareness of customer requirements throughout the organisation and liaises with external bodies on matters relating to food safety, legality and quality management systems. ©2020, Innopharma Labs Ltd and King Quality Solutions 6 Technical Dept – Roles and Responsibilities The Quality Assurance Supervisors (S)he report directly to the Quality Assurance Manager and are responsible for the efficient management of the QA function within their department. The supervisors work with the Department Managers and develop corrective action programmes along with identifying opportunities for improvement within each department. The Quality Supervisors are also responsible on a day-to-day basis for the prevention and detection of foreign bodies including glass. Also manages traceability systems and the maintenance of high standards of hygiene and housekeeping ©2020, Innopharma Labs Ltd and King Quality Solutions 7 Technical Dept – Roles and Responsibilities Test Kitchen The people working in the test kitchen cook samples being produced in production against the cooking instructions on product packaging and test against standard product to check consistency They also monitor the consistency of key quality attributes such as meat content through “washouts” They also “benchmark” the company’s products against competitors products ©2020, Innopharma Labs Ltd and King Quality Solutions 8 Technical Dept – Roles and Responsibilities Process Technologist  The Process Technologist are product or process experts and are responsible for the continuous improvement programmes on the products and processes  Process Engineers  Food Technologist  Bakery Technologist  Meat Technologist  Flavour Technologist  Packaging Technologist ©2020, Innopharma Labs Ltd and King Quality Solutions 9 Technical Dept – Roles and Responsibilities Customer Services Manager  The effective management of customer services function. Acting as the customer’s representative on site, ensuring all customers’ requirements are fully understood and implemented.  Ensure that all finished product specifications are signed off by customers and that a copy is held on site.  Attends customer consistency panels and all benchmarking panels  Days to days contact with customer’s technical departments and leads the resolutions of day to day issues ©2020, Innopharma Labs Ltd and King Quality Solutions 10 Technical Dept – Roles and Responsibilities Customer Services Representatives  Ensure that the company has signed specifications for all raw materials on site and that these documents are signed by both the supplier and company management  Ensure that all finished product specifications are signed off by customers and that a copy is held on site.  Resolution of minor day to day issues with counterparts in Technical Departments of various customers  Assistant NPD in the approval of new product where necessary ©2020, Innopharma Labs Ltd and King Quality Solutions 11 Raw Material Specifications Key points in a Raw Material Specification include Supplier details including key contacts and emergency contact details Recipe details Allergen/Food intolerance information Packaging details Nutritional information Bacteriological standards GMO details Must be signed by both parties to make the document legal (May be 12 to 15 pages in length) ©2020, Innopharma Labs Ltd and King Quality Solutions 12 Finished Product Specifications Key points in a Finished Specification include Company contact details including key contacts and emergency contact details Recipe details Detail information on raw materials used, including component breakdown, country of origin and spices and other information requested by customers HACCP Food Safety Plan Allergen/Food intolerance information Packaging details ©2020, Innopharma Labs Ltd and King Quality Solutions 13 Finished Product Specifications (cont.) Nutritional information Quality Attribute Sheets – (QAS) details on Organoleptic Standards) Bacteriological standards GMO details Must be signed by both parties to make the document legal (May be 25 to 30 pages in length) ©2020, Innopharma Labs Ltd and King Quality Solutions 14 Systems for Monitoring of Suppliers Purchasing from Approved Suppliers. This approach ensures that you know and trust the suppliers of your raw materials. If you have BRCGS accreditation then you would most likely require your suppliers to be BRCGS accredited also. Agreed and Signed Specifications By having agreed specifications both side clearly understand that raw material standards are and then a consistent standard can be delivery every time. By signing these specifications both parties have an agreed reference document should any disagreements occur. Certificates of Analysis (for key parameters) Ensures that key parameters are routinely tested and reported and confirmed to the signed specification. Certificates of Analysis for migration in food contact packaging. Ensures that there is no migration from the packaging into the finished product and that is packaging is suitable for direct food contact. Certificates of Conformance Ensures that the suppliers are reviewing their own test results and that they are confirming that the product that they are supplying is in conformance/in agreement with the signed and agreed raw material specification. Visual Inspection of deliveries – see following slides ©2024, Innopharma Labs Ltd and King Quality Solutions 15 Testing Parameters for Incoming Raw Materials Temperature Hygiene of delivery vehicle Batch codes Expiry dates Evidence of pests Quantity delivered Identity of materials delivered against purchase order ©2020, Innopharma Labs Ltd and King Quality Solutions 16 Testing Parameters for Incoming Packaging Deliveries Quantity delivered Identity of materials delivered against purchase order Evidence of pests Batch codes Evidence of moisture or other damage ©2020, Innopharma Labs Ltd and King Quality Solutions 17 Testing Parameters for Finished Product Taste, Texture Appearance Condition of packaging Weight control Microbiological testing Typical Tests to determine shelf life are microbiological testing and organoleptic testing ©2020, Innopharma Labs Ltd and King Quality Solutions 18 Traceability Systems Recording of information at Goods Inwards Supplier Supplier Quantity Batch Expiry Accepted Signed/ Raw Material Suppliers Code AllocatedReceived Code Date Y/N Date ©2020, Innopharma Labs Ltd and King Quality Solutions 19 Traceability Systems – option 1 for Raw Materials Allocating a product traceability code – The breakdown of the Batch code is as follows: A batch number will be placed on product where necessary using the following E.g. Batch No. 02/001 02/001 02=The code allocated to the particular material (Lemon Juice) 02/001 01= The sequential number for the delivery of that material in the calendar year 02/001 The first batch of lemon juice delivered in the calendar year 02/010 The tenth batch of lemon juice delivered in the calendar year ©2020, Innopharma Labs Ltd and King Quality Solutions 20 Traceability Systems – option 2 for Raw Materials Allocating a product traceability code – The breakdown of the Batch code is as follows: A batch number will be placed on product where necessary using the following E.g. Batch No. 2450/01 2450/01 24= 2024 2450/01 50 = Week No 50 2450/01 01 = First Delivery in Week 50 of 2024 2450/15 15 = Fifteenth Delivery in Week 50 of 2024 ©2020, Innopharma Labs Ltd and King Quality Solutions 21 Traceability Systems (cont.) Production Records To link the finished product traceability code to the allocated raw material codes it is necessary to record all this information on the production records for each raw material and for each batch. See example below ©2020, Innopharma Labs Ltd and King Quality Solutions 22 Traceability Systems (cont.) Packing Records The packing records capture The batch code of packaging used to pack each batch of finished product. The quantity of each batch code of product that is used to make up each pallet of finished product. Other relevant information including metal detection and checkweigher data ©2020, Innopharma Labs Ltd and King Quality Solutions 23 Traceability Systems (cont.) Dispatch Records These records capture The pallets numbers and quantity on each pallet sent to each customer The temperature of the product at dispatch The vehicle used to transport the dispatched product (number/cleanliness and temperature setting details) The number of the trailer seal used ©2020, Innopharma Labs Ltd and King Quality Solutions 24 Traceability Systems (cont.) Allocation of Expiry date onto product packaging Shelf life – product day + shelf life “Use By” + 10 days Today = 26/11/2024 Code = Use by 06/12/2024 “Best Before End + 12 months BBE Nov 2025 ©2020, Innopharma Labs Ltd and King Quality Solutions 25 Traceability Systems (cont.) Allocation of Finished Product Batch Code Product Code – Production Date 26/11/2024 – 330th day of the year Pack time 14:00 hrs Code consists of 1 digit for year = 4 for 2024 3 digits for sequential day number of the year = 330 Pack Time = 14:00 Product code = 4330 14:00 ©2020, Innopharma Labs Ltd and King Quality Solutions 26 Traceability Systems (cont.) Different QA Status – Given to Raw Materials – In-Process and Finished Products Work in progress Materials that have changed from raw material but have not yet being full converted into finished product eg prepared vegetables, prepared sauces Hold stock Product that has not been released by the quality department for quality or food safety reasons Non-Conforming Product Products that do not meet the company or customer food safety or quality standards Released stock Product that has passed on the quality checks and has been released to the customer Mass Balance Traceability In these studies must be able to account for all the quantity of a given batch number of a raw material and trace it to all the finished product that were made used that batch of raw material. For finished product, In a product withdrawal/recall situation if you can compete a full reconciliation of all of a finished product code within your supply then you can justify doing a product withdrawal. ©2020, Innopharma Labs Ltd and King Quality Solutions 27 Dealing with Unsafe and Non-Conforming Products Overall responsibility The Technical/Quality Manager has overall responsibility for dealing with non-conforming products. (S)he has the following options available Dump - Unsafe product that cannot be reprocessed must be dumped as these are illegal products Reprocess – Unsafe product can be repossessed to make it safe eg additional cooking Downgrade – Sell the product off at a discount or donate to charity (product must be legal) eg damaged biscuits, over-labelled products. Rework – Reuse suitable products at 5% to 10% in other production runs. E.g. overbaked bread, made into breadcrumbs and then used in subsequent batches. Sell under concession – Sell product at normal price even if the product does fully meet quality standards e.g. tomato sauce that is slightly orange in colour. This is never an option for unsafe foods. ©2020, Innopharma Labs Ltd and King Quality Solutions 28 Product Sampling Sample plan The level of sampling that a company plans to carry out on a material or process Sample size The actual numbers of samples a company take when carry out the sample plan Sample procedure The details of the steps to be followed when taking samples ©2020, Innopharma Labs Ltd and King Quality Solutions 29 Open Plant Cleaning Four Step Cleaning plan Step 1 – Gross Clean. – Physically remove the heavy debris using a power hose of manually remove. Step 2 – Apply Detergent – Apply forming detergent to breakdown the fats and oils Step 3 – Rinse – Rinse off the detergent and the remaining fats and oils to leave the surface visually clean Step 4 – Sanitise – Apply a sanitiser to leave all surface microbiologically clean ©2020, Innopharma Labs Ltd and King Quality Solutions 30 Verification of Cleaning Standards Three Options 1 – Visual. – Visually assess the cleanliness of the equipment – – Disadvantage – will not tell you that the equipment is microbiologically clean 2 – Microbiological Swabbing – Following visual inspection take some microbial swabs. This will inform you that the equipment was microbiologically clean. – Disadvantage – slow process takes up to two days. Tells you on Thursday about your plant conditions on Tuesday. 3 – ATP Swabbing – Rapid testing that tells you the microbial status of the plant within 20 seconds of swabbing. – Disadvantage – Significantly more expensive ©2020, Innopharma Labs Ltd and King Quality Solutions 31 International Best Practice Standard Brand Recognition through Compliance (BRC) Global Standard for Food Safety Issue No. 9 ©2020, Innopharma Labs Ltd and King Quality Solutions 32 BRC Standard – Background Information Background The leading UK retailers decided not to use food safety as a competitive advantage. The technical leaders of each retailer along with leading suppliers agreed to meet and they eventually agreed common standards for food safety and food legality. The first standard was published in 1999 ©2020, Innopharma Labs Ltd and King Quality Solutions 33 BRC Standard – Contents Section 1 – Senior Management Commitment Section 2 – Food Safety - HACCP Section 3 – Food Safety and Quality Management Systems Section 4- Site Standards Section 5 – Product Control Section 6 – Process Control Section 7 – Personnel Section 8 – High Risk, High Care, Ambient High Care Production Risk Zones Section 9 – Requirements for Traded Products ©2020, Innopharma Labs Ltd and King Quality Solutions 34 BRC Standard – Fundamental Clauses Within the Standard certain requirements have been designated as ‘fundamental’ requirements. These are marked with the word ‘FUNDAMENTAL’ and denoted a special symbol. These requirements relate to systems that are crucial to the establishment and operation of an effective food quality and safety operation. The requirements deemed fundamental are: ©2020, Innopharma Labs Ltd and King Quality Solutions 35 BRC Standard – Fundamental Clauses Senior management commitment and continual improvement (1.1) The food safety plan – HACCP (2) Internal audits (3.4) Management of suppliers of raw materials and packaging (3.5.1) Corrective and preventive actions (3.7) Traceability (3.9) Layout, product flow and segregation (4.3) ©2020, Innopharma Labs Ltd and King Quality Solutions 36 BRC Standard – Fundamental Clauses Housekeeping and hygiene (4.11) Management of allergens (5.3) Control of operations (6.1) Labelling and pack control (6.2) Training: raw material handling, preparation, processing, packing and storage areas (7.1). ©2020, Innopharma Labs Ltd and King Quality Solutions 37 Food Allergens Peanuts Tree Nuts Milk and Milk Derivatives Gluten Egg and Egg Derivatives Soya and soya Derivatives Lupin and lupin Derivatives Fish and fish derivatives Molluscs and mollusc derivatives Crustaceans and crustacean derivatives Sesame Seed and sesame seed derivatives Celery and celery derivatives SO2 Mustard and mustard derivatives ©2020, Innopharma Labs Ltd and King Quality Solutions 38 EU Regulatory Affairs for the Food Industry: Focus on Sustainability The European Union has been at the forefront of implementing legislation aimed at enhancing the sustainability of food packaging. Recent, current, and upcoming regulations highlight the EU’s commitment to reducing environmental impact through innovative approaches to packaging waste management. We will cover key legislative measures, including the Packaging and Packaging Waste Regulation (PPWR), Deposit Return Scheme (DRS), tethered caps on bottles, and Single Use Plastics (SUP) Directive. ©2020, Innopharma Labs Ltd and King Quality Solutions 39 Packaging and Packaging Waste Regulation (PPWR) Adopted by the European Parliament on November 22, 2023, the PPWR sets ambitious targets for reducing packaging waste across the EU. Key provisions include: Reduction Targets: An overall reduction of packaging waste by 5% by 2030, 10% by 2035, and 15% by 2040. Specific targets for plastic packaging are even stricter, aiming for reductions of 10% by 2030, 15% by 2035, and 20% by 2040. Bans on Harmful Substances: The regulation bans the use of "forever chemicals" such as PFAS and Bisphenol A (BPA) in food- contact packaging. Recyclability Requirement: By 2029, the regulation mandates that 90% of packaging materials must be collected separately for recycling​(Packaging Law)​​(European Commission)​. ©2024, Innopharma Education and King Quality Solutions 40 Single Use Plastics (SUP) Directive The SUP Directive, effective since July 3, 2021, aims to reduce the impact of single-use plastic products on the environment, particularly the marine ecosystem. Key aspects include: Prohibitions: Bans on specific single-use plastic items such as straws, cutlery, plates, and balloon sticks. Consumption Reduction: Measures to reduce the consumption of plastic food containers and beverage cups. Design Requirements: Obligations for product design, such as the requirement for beverage containers to have attached caps by 2024, ensuring these components are recycled together​ (beveragedaily.com) ©2024, Innopharma Education and King Quality Solutions 41 Deposit Return Scheme (DRS) Ireland launched its Deposit Return Scheme on February 1, 2024. The DRS incentivises consumers to return plastic bottles and aluminium cans by charging a refundable deposit at the point of purchase. Details of the scheme include: Deposit Rates: 15 cents for containers between 150ml and 500ml, and 25 cents for containers between 500ml and 3 liters. Return Mechanism: Consumers can return their empty containers to participating retail outlets or through reverse vending machines, receiving a refund of their deposit​(Citizens Information)​​ (beveragedaily.com)​​. Impact: This initiative aims to boost recycling rates and reduce litter, aligning with the EU’s goal of recycling 90% of drinks containers by 2029. ©2024, Innopharma Education and King Quality Solutions 42 Tethered Caps As part of the Single Use Plastics Directive, from July 2024, all plastic beverage bottles in the EU must have tethered caps. This regulation ensures caps remain attached to bottles, reducing litter and facilitating recycling. The tethered cap requirement is designed to prevent caps from being discarded separately, thus decreasing plastic pollution significantly​(Citizens Information)​. ©2024, Innopharma Education and King Quality Solutions 43 Examples and Industry Impact Reusable Packaging: Initiatives encouraging consumers to bring their own containers for takeaway food and drinks. Innovation in Packaging: Companies are innovating to comply with the new regulations, such as developing biodegradable materials and improving recyclability of packaging. These legislative efforts are part of the EU’s broader strategy to transition towards a circular economy, significantly reducing the environmental impact of packaging. By implementing these measures, the EU not only aims to achieve higher recycling rates but also to foster a culture of sustainability within the food industry and beyond. ©2024, Innopharma Education and King Quality Solutions 44