Ensuring Food Quality & Safety Through Multifaceted

ProgramsPrograms

Bhadriraju Subramanyam (Subi), PhDProfessorProfessorDepartment of Grain Science and IndustryKansas State UniversityM h KS 66506Manhattan, KS 66506E-mail: sbhadrir@ksu.eduhttp: www.oznet.ksu.edu/grsc_subip g _

What is Food?What is Food?

• Articles consumed by humans and animalsanimals

• Includes chewing gum and drinking water

What is Wholesome Food?What is Wholesome Food?

• Nutritionally balanced• Food without defects

What is Safe Food?What is Safe Food?

• Food that does not causeFood that does not cause injury or harm when consumed by humans or

gh

animals

wH

ig

• Trust is placed in food manufacturer to produce

Losafe food

• Consumers are unaware of dangers with food!

Adulterated FoodAdulterated Food

• Food containing poisonous or deleteriousFood containing poisonous or deleterious substances

Basis for HACCP– Basis for HACCP• Food containing added poisonous or

d l t i b tdeleterious substances• Food containing filth from animal or vegetable

matter• Food prepared under unsanitary conditions

– Basis for Good Manufacturing Practices

Before You Do Anything:Identify Th H dThe Hazards

• Hazards:a Physical peeling paint rust glass metala. Physical- peeling paint, rust, glass, metal,

wood or plasticb Ch i l l b i t ti idb. Chemical- grease, lubricants, pesticides,

allergens, condensationc. Biological- insects, microorganisms,

rodents, birds, and their by-products

H dHazards

• Likelihood of occurrence – High, Medium, Low

• Severity of occurrence– High, Medium, Lowg , ,

Severity of occurrence

H M L

e

H HH HM HL

curr

ence

M MH MM ML

od o

f occ

L LH LM LL

Like

lihoo

L

How Does a Food Manufacturer C b H d ?Combat Hazards?

• Multifaceted programs taking a holistic view of a food plant from the outside inview of a food plant from the outside in

St l k d li t !• Stop, look and listen!

• Seek root cause analysis on eliminating “cause” and not reacting to symptomsg y p

Remember We Have Laws To F ll !Follow!

• Food laws help ensure unadulterated product during food manufacturingproduct during food manufacturing

• Complying with the laws is good businessTh i ti f t i• Theory: prescriptive=> manufacturing flexibility=>innovation in plant equipment

d d iand design

B F d LBasic Food Laws

• Good Manufacturing Practices (GMPs) • Hazard Analysis and Critical Control Points• Hazard Analysis and Critical Control Points

(HACCP) Program P ti f d f t– Preventive food safety program

– Critical point vs Critical control point

UNDERSTANDING AND INTERPRETING FOOD SAFETY STANDARDS(GMP Example)

What is the language? How will the company comply

How will the company assure compliance

110.10 Personnel(a) Disease control. Any person who, by medical examination or supervisory

110.10 Personnel(a) Disease control. Employees who are sick or have open wounds, sores,

110.10 Personnel(a) Disease control.

observation, is shown to have, or appears to have, an illness, open lesion, including boils, sores, or infected wounds, or any other abnormal source of microbial contamination by which there

boils, or bandages on such wounds, shall report such conditions to their supervisor, and must not work with food, food-contact surfaces, or food packaging materials

A form showing which employee was excluded in performing operations, the date, and time, and employee’s reassigned duties if not absent.

microbial contamination by which there is a reasonable possibility of food, food-contact surfaces, or food packaging materials becoming contaminated, shall be excluded from any operations which

packaging materials.

Number of employees excluded by month from a particular operation.

may be expected to result in such contamination until the condition is corrected. Personnel shall be instructed to report such health conditions to their supervisors.supervisors.

What is the language? How will the company comply

How will the company assure compliancep y p

110.20 Plants and grounds.( ) G d Th d b f d

110.20 Plants and grounds( ) G d Th d di

110.10 Plants and grounds.( ) G d(a) Grounds. The grounds about a food

plant…….limited to:(a) Grounds. The grounds surrounding the food plant will be made of concrete and maintained in such a fashion so as to eliminate food contaminants.

(a) Grounds.

Daily inspection of the food plant exterior (a form is needed for this)

(1) Properly storing equipment, removing litter and waste, and cutting weeds or grass within the immediate vicinity of the plant buildings or

(1) Equipment cannot be stored on grounds. All equipment must be stored in the equipment storage shed on grated shelves. The perimeter of the f d l ill h 2 f i

A separate form showing when roads were repaired, shrubs, and bushes were trimmed.

vicinity of the plant buildings or structures that may constitute an attractant, breeding place, or harborage for pests.

food plant will have a 2-ft vegetation-free barrier zone. Shrubs and trees will be trimmed at established schedules and inspected for rodent and insect activity.

(2) Maintaining roads, yards, and parking lots so that they do not

y

(2) All roads shall be paved kept in good repair.

constitute a source of contamination in areas where food is exposed

Table I: Number and percent of recall actions by industry (N=1146)1999-2003

Industry No. recall actions PercentBakery products 217 18.94%Fishery/seafood products 135 11 78%Fishery/seafood products 135 11.78%Bean/vegetable products 88 7.68%Multiple food dinner products 85 7.42%Non-chocolate candy products 75 6.54%Fruit products 66 5.76%Ice cream products 62 5.41%pChocolate products 50 4.36%Snack food products 48 4.19%Beverage/beverage base products 38 3 32%Beverage/beverage base products 38 3.32%Cheese products 29 2.53%All other products 253 22.07%Total 1146 100%

Recall actions by specific processor-level problems (N=1146)

Proactive Versus Reactive Food Industry Programs

• Proactive, you’re a hero! Reactive, you’re a scapegoat!scapegoat!– Knowledge, intent, and foreseeability

• Prevent ALL “pest” harborages by sanitary• Prevent ALL pest harborages by sanitary design and program designK l d h i hb !• Know your plant and thy neighbors!

• Must have personal accountability– Attitude to do the right thing

P V RProactive Versus Reactive

• People, people, people- food plant is a p p pcommunity

• People make mistakes!• Are people adequately

trained to do the job?– Education– Training

B ll E A h O dBulls Eye Approach-Outside

• Outside- farthest away and work toward plant

a. Perimeter secured/fenced?

b Neighbors good andb. Neighbors- good and bad

c. Wind patterns, sun exposure on building

d. Landscaping

B ll E A h O dBulls Eye Approach-Outside

e. Pest interceptors such as rodent bait stations/traps or insect pheromone trapsstations/traps or insect pheromone traps

f. Paved lots; eliminate standing water R f th l d t kg. Roof areas- smooth, clean, ductwork, gutters

Rats and MiceRats and Mice• Family Muridae has 500 species• Rats and mice of SE Asia include:Rats and mice of SE Asia include:

– Rice field rat, Rattus argentiventer– The black rat, Rattus rattus diardii– The wood rat, Rattus tiomanicusThe wood rat, Rattus tiomanicus– The Norway rat, Rattus norvegicus– Little Malay rat, Rattus exulans– Greater bandicoot rat Bandicota indica

R. argentiventer (GR Singleton)

Greater bandicoot rat, Bandicota indica– House mouse, Mus musculus (several

subspecies)• Pelage: Vibrissae (long stiff hairs). Guard hairs

i i /i / d /i dg ( g )

– Protect from cold; tactile feedback; wetness; defense

www.irri.org/irrc/rodents/index.asp

M. musculus

Features• Nocturnal in habit• Excellent swimmers• Good climbers• Good sense of smell and hearing• Can gnaw through materials like leadCan gnaw through materials like lead

sheathing, aluminum, wood, wiring, etc

• Can enter through very smallCan enter through very small openings

• Tail– Variable length furry scaly or– Variable length, furry, scaly, or

bare– Cools the animal

Prehensile– Prehensile– Provides balance

Rodent Control Fights Hunger!Rodent Control Fights Hunger!Continent Production Gained No. extra Percentage of

(Million tons)

production (Million tons)

people nourished (Millions)

Undernourished benefiting

A i 1086 46 54 32 217 3 39Asia 1086.46 54.32 217.3 39Latin America 156.70 7.74 31.3 60

Africa 113.66 5.68 22.7 11Europe 37.70 1.89 7.5 26

Total (world) 1394.52 69.73 278.8 34

Includes all cereals in 113 countries where undernourishment exists.Includes all cereals in 113 countries where undernourishment exists.

Source: Meerburg, BG, GR Singleton, and H Leirs. 2009. The year of the rat ends–time to fight hunger! Pest Manag. Sci. 65: 351-352.

Unsanitary conditions outdoors

Building Exterior

Have an 2 ft vegetation free barrier zone

Shrubs too close to buildingg

Bait StationsBait StationsBait StationsBait Stations

BBBaitsBaits

TrapsTraps

Bi dBi dBirdsBirdsPigeon

E li h H SPigeon

E li h H SEnglish or House SparrowEuropean Starling

English or House SparrowEuropean StarlingEuropean StarlingEuropean Starling

Bi d M tBi d M tBird ManagementBird Management• Exclusion• RepellentsRepellents

Non-chemicalCh i lChemical

• Trapping

E l iE l iExclusionExclusion

Exclusion tactics

E l iE l iExclusionExclusion

Repellents

B ll E A h O dBulls Eye Approach-Outside

h. Lighting- mercury vapor highly attractive versus metal halide; illuminate back ontoversus metal halide; illuminate back onto building; never above doors or air intakes

i Dock/rail/personnel doors/windowsi. Dock/rail/personnel doors/windowsj. Storage areas- protected, up off ground,

ll tno palletsk. Building seams

Pest entry pointsPest entry points

B ll E A h I dBulls Eye Approach-Inside

• Start at receiving a Dock/waste areasa. Dock/waste areasb. Light traps, pheromone traps, rodent

t l i t i f ilcontrol, air curtain failuresc. Any need to separate/segregate employees

for microbial control?d. Shoe/Uniform programp g

A good pest exclusion practice

Improper stocking or storage practices

Give 12 inches of space betweenGive 12 inches of space betweenthe wall and palletsPallets, 6 inches off the floor

B ll E A h I dBulls Eye Approach-Inside

e. Restroom/locker rooms- slanted top of lockers no personal food storage periodiclockers, no personal food storage, periodic locker cleanouts/pest control

f Product flow raw materials in one end andf. Product flow- raw materials in one end and finished product out the otherP iti ti ig. Positive versus negative air pressure

Poor Sanitation

Spillage

Prevent unsanitary conditions

Sanitary Design AspectsSanitary Design Aspects

Sanitary Design AspectsSanitary Design Aspects

Building Interior: Unsanitary Conditions

Flat surfaces

Storage of unused equipment

Clean or avoid flat surfacesDi d d iDiscard unused equipment

Rate Rate Facility Facility Infestation By Infestation By L i f S i iL i f S i iLocation for SanitationLocation for Sanitation

P b bilit f i f st ti d t l ssP b bilit f i f st ti d t l ssSevereSevere HighHigh ModerateModerate LowLow

Probability of infestation or product lossProbability of infestation or product loss

DailyDaily ProductionProductionAreas; receivingAreas; receiving

FloorsFloors

WeeklyWeeklyuenc

yue

ncy

yy

MonthlyMonthly Spouts; Spouts; conditionerconditioner

BathroomsBathrooms

ing

freq

uin

g fr

equ

YearlyYearly Building Building exteriorexteriorCl

ean

Clea

n

EEquipment

• What type of product is produced?- dry, wet caustic acidic or perishablewet, caustic, acidic, or perishable

• Risks- meat, seafood, juices are regulatedW t d l d l COP CIP• Wet or dry cleaned, manual, COP, CIP, vacuum, air

EEquipment

• Is there a cross-functional member equipment review/approval program?q p pp p g

• No unprotected glass• Ceilings/overheads- no ledges false ceilingCeilings/overheads no ledges, false ceiling

trap• Food contact surfaces-corrosion resistant,Food contact surfaces corrosion resistant,

non-porous, non-absorbent, and non-puddlingp g

EEquipment

• Easy, quick disassembly and accessible• Micro/allergen cleanable and verifiable• Micro/allergen cleanable and verifiable• No hollow areas• Design aspects: continuous welds versus

stitch

IInspections

• Not a waste of time; must know plant inside and outand out

• Multidisciplinary in membership team, cross train rotate document deficienciescross-train, rotate, document deficiencies observe for proper follow upCl th l t j t “li t” t• Close the loop; not just a “list” creator; understand reasons for problems

IInspections

• Develop checklists

• Take corrective action/develop a preventive solutionsolution

• No third party inspector should inspect your• No third party inspector should inspect your plant and find an un-inspected area by the teamteam

Master Sanitation/Cleaning S h d lSchedules

• Daily versus non-daily; weekly, monthly, quarterly, semi-annual and annualq y,

• Only way you can answer question: “when was the last time this was cleaned?”

• Leave no space blank• Keep it simpleKeep it simple• Floor drains• Evaluate and determine economic benefits• Evaluate and determine economic benefits

Preventive Maintenance and W k O dWork Orders

• Simple and document

• Filters, sifters, strainers, lubricants, magnets d t l d t tand metal detectors

P l E d TPeople, Equipment and Training

• Proper people doing the proper job with the proper equipment and documented trainingproper equipment and documented training

• Money driven but be careful how you phrase message to employees (motivation)phrase message to employees (motivation)

Management Systems for Product Safety

• Organization• Vendor Specifications

• Employee Training• Preventive Cleaningp

• QC Programs/Lab Access/Sampling

• IPM programs• Management Self-Inspection

• Receiving Programs• Preventive

Program• Consumer Complaint/Recall

Maintenance/Equipment Specifications

Program• HACCP

Organization

• Clearly defined charts

Cl li f• Clear lines of responsibilities/Accountability

• Trained Staff

O C i ti• Open Communication

• Team Effort

“If you want 100% safety you have to stopIf you want 100% safety, you have to stop eating….”

Dr. Marion NestleDr. Marion NestleProfessor of NutritionNew York University

A Food Manufacturer ShouldA Food Manufacturer Should….

M it i di t lit• Monitor ingredient quality• Keep an inventory of ingredients/additives

C l i h l d d• Comply with regulatory standards • Coordinate delivery fleets• Institute preventive maintenance programs• Be computer literate• Manage and motivate people• Keep abreast of technology and the changing

consumer• It is not an easy task!

Subi’s Proactive Approaches for Food SafetyFood Safety

A h 1Approach 1

• Government-based inspection systems will not assure food safetyy– FDA in US inspects only 1% of the total food – A good-self inspection program is necessary– Focus on effective inspections rather than on more

inspections Use your four senses during inspection– Use your four senses during inspection

• Sight• Touch• Hearing• Smell

A h 2Approach 2

• Examine current trends in food consumptionconsumption– The frequency of any type of food safety issue

is based on food trends and eating habitsis based on food trends and eating habits

A h 3Approach 3

• Your basic programs should be fundamentally strongfundamentally strong– GMPs and HACCP

Not only at the processing facility but also– Not only at the processing facility but also along the farm to table continuum

A h 4Approach 4

• Analyze food safety risks with your product and allocate resources and systems toand allocate resources and systems to manage the risks (prioritize risks)– Apply risk-based criteria to regulatory andApply risk-based criteria to regulatory and

inspection efforts

A h 5Approach 5

• Design and implement better food safety systemssystems– ISO 22000:2005 international standard

Evolution beyond HACCP (5 + 7 steps)– Evolution beyond HACCP (5 + 7 steps)– All standards followed should be auditable!

Auditing vs inspection– Auditing vs inspection– Work on the process not the product (conduct

gap analysis)gap analysis)

A h 6Approach 6

• Educate all who handle and consume your productproduct– Food safety does not stop at your company

Food safety is a farm to table concept– Food safety is a farm to table concept

A h 7Approach 7

• Expand partnerships– Government alone cannot guarantee food safety– Government alone cannot guarantee food safety– Establish public-private-government

partnershipspartnerships

A h 8Approach 8

• Follow international food safety standards– Prevents duplication of effort– Prevents duplication of effort– Enhances sharing of information

Reduces multiple audits and inspections– Reduces multiple audits and inspections

A h 9Approach 9

• Enhance economic incentives to embrace food safetyfood safety– Cost of recalls is expensive

A h 10Approach 10

• Insist on supplier quality performance– Melamine in pet food– Melamine in pet food– Melamine in milk

Melamine in Rabbit candy– Melamine in Rabbit candy– Peanut Corporation of America (Salmonella)

S l ll i i t hi– Salmonella in pistachios

Thank You