Quality Control for the Food Industry PDF

Quality Control for the Food Industry  Historical view Quality control of the food parallels with history of food production Food manufacturer, handler and consumer attempted to evaluate and control the quality of the food used. The decisions made on the basis o...

Quality Control for the Food Industry  Historical view Quality control of the food parallels with history of food production Food manufacturer, handler and consumer attempted to evaluate and control the quality of the food used. The decisions made on the basis of sensory evaluation of the quality attributes. 1  Quality Control for the Food Industry  This field become as distinct discipline, due to the development of instrumental methods of measuring food quality and statistics for results interpretation. 2  Definitions  For normal consumer: Quantity + Price + Physical attributes (Appearance, Texture, Aroma, Taste  For food specialists: Safety and stability (Microbial, Chemical, physical and Nutritional aspects)  For legislating authorities: follow their standards and specifications. 3  General Definition for Quality  Quality: Characteristics that differentiate individual units of a product, and have significance in determining the degree of acceptability of that unit by the buyer.  Overall quality of good product must be analyzed for its component attributes.  Must be measured and controlled independently by satisfactory instrumental method  It may result in additional work and cost 4  Degree of Excellence of a Product Set of specifications which should be met within given limits (average quality required in market) It could be excellent, good or poor. 5  Given Limits  Quality must be controlled and applied to the complete manufacturing process and marketing (raw materials, machines, management, and transportation….etc) as efficient as possible. 6  Control  The measurements of attribute by a method (procedure and instrument)  Standardization and calibration  Applying international and local standards (ISO, GMPs, HACCP…..)  ISO: Degree to which set of characteristics fulfils requirements. 7  Quality Control Definition: Effective measures that should be taken by all departments in a company to improve, enhance, develop, modify or maintain special characteristic of a product to meet buyer satisfaction at low cost. 8  C O N T I N U A L I M PR O V E M E N T O F Q U A L I T Y M A N AG E M E N T SY ST E M I I n M a n a g e m en t n t S t e r e s p o n s ib ility a e r t r i e R s e s e M ea s u r e m e n t, f s q R e sou rc e t a n a lys is, a t u m a n age m e n t c e i e d r im p r o v e m e n t t d i e o P m n P e a a n r t r t In put Pro du c t Ou tp ut t s Product i r e a liz a tio n i e e s s F ig. 1 M o de l of th e pr o c e s s a p pr o a c h. 9 Quality Control Cycle 10 Predicting Quality of Finished Products  Accurate measurement may change the quality of the final product to desirable level  The quality of finished product may be predicted by measurements obtained at critical points during the entire manufacturing process. 11  Measurements  Subjective (Human sense):  Limitations: comparative rather than absolute.  Objective (instrumental such as physical, chemical or microbial examinations):  Accurate, but not rapid and add extra cost to the product.  Sensory panelists under controlled conditions.  Degree of correlation between panel scores and instrumental method. 12  Measurements  Accuracy of measurements: degree of correlation (correlation coefficient) between panel scores and instrumental method.  If a correlation coefficient≥0.90 then instrumental method is sufficiently accurate measure for quality attribute (good agreement)  If a correlation coefficient ≤ 0.80 do not show good agreement between panel and instrumental method panelists is enough. 13  Precision  Precision: coefficient of variability between duplicates (product or instrument duplicates) on a percent basis.  Results by instrumental method for quality level of a product must be identical for identical samples.  Any instrument proposed for quality evaluation must be calibrated by generally accepted methods. 14 Accuracy vs Precision 15 Quality Control Department 16  Functions of QC Department (1) Establishment of specifications (2) Development of test procedures (3) Development of sampling procedures (4) Recording and reporting (5) Troubleshooting (6) Special problems (7) Training of personnel 17  Quality Control Department Responsibilities 1. Establishment of specifications (Raw materials, suppliers, containers, shelf life …finished product  Usually established with the help of the sales and production departments 2. Development of test procedures: measuring quality attributes and production variables (raw material final product).  Established with the help of research and development, local standards, trade associations and government agencies. 18  Quality Control Department Responsibilities 3. Development of sampling schedules  Establishing efficient procedures for handling samples, number of units and frequency of sampling. 4. Recording and reporting  Preparing forms for results recording, tables and charts. 5. Trouble shooting  Problems correction  Work with the research and development to find solution  Correction vs Corrective action 19  Relation of Quality Control Department to Management  All reports of QCD must reported to the top management.  Reports include production operation control, decision making, pricing, budget policies, sales, personnel performance.  Quality control program must be supported by the top management and QCD reports and indications must be fully approved without hesitation.  QC department is the management's tool for delegating authorities and responsibility for product quality. 20  Relation of Quality Control Department to Sales and Purchasing  Sales is buyer's representative for product specifications.  Product marketed successfully if it meets customer requirements as reported by the sales dept.  QCD specifications for raw materials and supplies to purchasing department  Special interests in sampling and testing are directed by QCD.  QCD is the channel of communication between sales or purchasing, and production. 21  Relation of Quality Control Department to Sales and Purchasing Relation to Sales and Purchasing Since the sales department is the primary contact between the processor and customer, it is the salesman who should be in the position to appreciate exactly what the buyer is looking for in the product. Sales, therefore, may be considered as the buyer’s representative, in developing specifications. a product can be marketed successfully only if it meets the customer’s requirements, not the manufacturer’s opinion of what these requirements should be. (example: PepsiCo) 22  Relation of Quality Control Department to Research and Development  The two departments are closely related and can be considered as one department in small companies.  QCD continuous assessment of current operation but R&D department is responsible for researching new or innovated ideas/products  R&D needed if products are out of control or for creating new methods for measuring quality attributes. 23 R&D Relation Example Example: the routine examination of canned cut green beans reveals a sudden increase in the incidence of bright green color on the cut surfaces. This reduces the quality grade of the product from A to C. The quality control inspector quickly reports this to the production foreman, who would like to correct the situation. However, production personnel is unable to solve the problem immediately. The problem is then referred to management. Instructions are subsequently issued to suspend additional purchases of raw beans and instruct that the smaller sizes are to be used as whole beans, and the larger size raw beans are to be put into cold storage. In the meantime, quality control and research personnel are asked to investigate the problem and to come up with a solution as rapidly as possible. Within 24 hours, it was discovered that a change in the water softening process had resulted in a somewhat higher calcium and magnesium content in the water. This condition tended to preserve the chlorophyll and, thus, allowed the cut surface to retain a green “halo.” The water-softening process was then corrected. 24  Relation of Quality Control Department to Production Department  QCD directly report to top management and it is independent from production department.  Production department responsible to produce maximum quantity while QCD insure from product quality with maximum profit.  QC inspector usually located at the process line  If there is out of control, report to production employee to take immediate action or discontinue the operation or alert management.  All line inspectors must take instructions and training from QCD.  Quality and quantity of production line should be considered to avoid large numbers of defective units 25 26 Classification of Quality Attributes 27  Classification of Quality Attributes  Sensory quality attributes  Appearance  Flavor  Texture  Kinesthetic (Viscosity, consistency)  Quantitative attributes  Greater interest to the trade than the consumer (yield of process)  Consumer can obtain the product of same quality by low price or obtain larger quantity by the same price.  Quantity of fruits in Jam  Net and gross weight of canned food 28  Classification of Quality Attributes  Hidden attributes Attributes that may affect food stability and health (hazards) and cannot be evaluated by human senses. Food must be free from toxic or harmful ingredients. Nutritive value under hidden attributes, product claims regarding nutritive must be true at its minimum level. 29  Quality Standards To ensure quality many types of quality standards have come into existence:  Research standards: Internal standards set up by the company to ensure product excellence and highly competitive in market.  Trade Standards: set by members of industry to assure at least minimum acceptable quality and prevent lowering standards of quality.  Government standards: Developed to protect health and preventing consumer cheating.  International standards: sets to facilitate trade in globe and help producer, dealer, wholesaler and consumer in marketing products. 30 Why Food Quality Standards? 31  International Standards  General Agreement on Tariffs and Trade (GATT)  Established in 1948 until Jan 1st 1995 when the World Trade Organization (WTO) was established after an agreement by 123 nations in Marrakesh on April 15, 1994.  It was governing international rules for trade between states.  It focused on tariffs for imported goods. 32  International Standards  World Trade Organization (WTO)  Its objectives are to help trade flow (for producers of goods or services, importers, exporters) as freely as possible for goods, services and agricultural products.  More than 60 agreements are now existed. 33  International Standards  ISO  Established to facilitate food trading with health issues in considerations through quality management systems  9000, 9001-9004, 22000, 14000 34  International Standards  Codex Alimentarius Commission (CAC)  Setting and developing food standards, guidelines and codes of practices to protect the health of consumers and to ensure fair practices in the food trade.  Its primary objectives are to  Protect consumer’s health  Ensure fair practices in food trade through the elaboration, harmonization and publication of food standards and other related texts. 35  International Standards  SPS: Sanitary and Phytosanitary Measures (One of WTO agreements)  Ensure that countries apply measures to protect human and animal health and plant health measures based on risk assessment.  Guidelines and rules that will develop, and enforce harmonized sanitary and phytosanitary measures and minimize their negative effects on trade. 36  International Standards  SPS:  Emphasize on food safety (protect human from risks associated with (Additives, contaminants, toxins, plant and animal carried disease, disease causing organisms).  It covers (regulations, laws, tests, inspection, procedures, processing, packaging and safety of food). 37  International Standards  TBT: Technical Barriers to Trade.  It covers all technical requirements and standards (applied to all commodities), such as packaging, marking and labeling, testing and procedures certification that are not covered under the SPS Agreement.  TBT Agreement does not recommend the use of a specific international standard-setting body. 38  International Standards  TBT:  TBT Agreement encourages member states to use international standards where appropriate, but does not require states to change their levels of protection as a result.  Regulations on food quality must not be more restrictive on imported products than the products produced locally. 39 Types of standards 40  International Standards  Horizontal: Measures applied for all food in general.  Vertical: For specific food. Mandatory or Obligatory: Food complies with the standard under certain marketed names (restriction on similar foods) Guidelines: procedure Nutritional labeling. 41  International Standards Optional, Voluntary or Advisory: Follow certain recommendation, or guides for good practices. Not requiring formal acceptance by government. Facilitate marketing product for countries interested in good practices (hygiene, buildings, machines..). 42  Successful Quality Control System Reduces waste by preventing errors before they occur. Optimizing sales of product. Increase process efficiency. Reduces consumer complaints. Control cost of raw materials and processing operations. Ensure product safety. Provide good management compliance with legislation affecting product quality. 43  Principles of Quality Control For raw materials Raw materials selected with high attention and details to specifications, good storage and transportation. Testing selected materials in relation to its contribution to product quality (chemical, physical, Microbial). Released materials after recording test results. Relate processing results to the raw materials test. 44  Principles of Quality Control For process control Control steps in process carefully. Determination critical points in the process. Providing new ideas to avoid difficulties and immediate steps for correction any variation in production. 45  Principles of Quality Control Finished product inspection To confirm that other controls are operated properly and show any weakness which may exist in previous controls. Effective sampling. Accelerated storage for safety. Statistical considerations. 46