Food Safety /Quality in the New Millennia
April 02, 2010 Golden Pacific Foods, Inc. Issues Allergy Alert for Undeclared Milk and Soy in Marco Polo Brand Shrimp Snacks NY Gourmet Salads Inc. Recalls Chick Pea Salad Because of Possible Health Risk (Listeria t i monocytogenes) ) Glutino Food Group Issues Allergy Alert on Undeclared Egg Product in Raisin Bread Zatarain's Recalls Original Dirty Rice Mix Package Due to Unlabeled Wheat and Barley Ingredients Binell Bros. Cutlery Voluntarily Recalls Black Pepper (Salmonella) Watkins Incorporated Recalls Crab Snack & Dip Seasoning Because of Possible Health Risk from Ingredient Supplied by Kerry Ingredients (Salmonella)
Salmonella Tennessee in HVP < Feb 12, 2010 Company analysis revealed Salmonella Tennessee in HVP Feb 12, 2010 FDA inspects and cites: Lack of microbial controls over product Lack of hygiene monitoring Lack of sanitation Building issues (Plumbing and Drains) Feb 26, 2010 Basic Flavors LV, NV recalls product Back to Sept 2009 (last FDA inspection) FDA finds S. Tennessee in plant
HVP Recall Over 178 products have been recalled containing HVP Do you have a recall plan? What product(s) is it in? What lot codes are effected? What if I have a dry mix with HVP in it that must be rehydrated and cooked by the consumer? 5-7 log lethality validation Label instructions Does recalled HVP have to be discarded?
HVP Recall Lessons Once again Salmonella has been found in a dry product at low numbers. Over 178 products have been recalled containing HVP plus the original HVP ingredient back to Sept 2009. Hundreds of companies will incur costs of recalls. Do you have a recall plan? Are you prepared?
HVP Recall Lessons FDA cited lack of hygiene monitoring. Do you monitor the sanitation of your plant? FDA cited plumbing and waste issues. Do you have building maintenance issues of your own? Companies that could validate a cooking or lethality step in their process did d not have to recall product provided the lethality was validated. Are your lethality steps validated? Companies that provided consumer cooking instructions were also exempt from recall. Do your product(s) contain cooking instructions?
Salmonella & Pet Food PA Pet Food Contaminated with Salmonella 70 human cases infection 19 states in 2006-7 Still had cases from plant after clean-up 2008 Recalled over 23,000 tons dog food Made multiple brands: Pedigree, Country Acres, Members Mark, Ol' Roy, Paws & Claws, Pet Pride, PMI Nutrition, Red Flannel, Retriever, and Wegeman's This is every e retailers e fear Plant is now closed
Brand identity in a small world and many employees have cell phones with video cameras. Just think of the possibilities
Changing Consumer Consumers are: Redefining value (lowering bar) Less premium, more value E.g., organic food sales flat Buying more private label (Store brands gain market share) Higher coupon redemption rates Foodservice getting g tighter te Buying more comfort foods Data from Dairy Management Inst Data from Dairy Management Inst. Strategic Analysis 2010
Today s environment has changed the way that food is produced, processed, transported and consumed. It presents all stakeholders with new challenges to food safety and quality.
Food regulation More Legislation FDA, USDA, & international Labeling, Claims, Benefits Supply Chain Transparency Animal Health Food Safety in the headlines More recalls likelyl Traceability Testing for adulterants (melamine, etc.) Ingredient identity (mislabeled fish) Bioterrorism a constant concern
Consumers Demand Balanced value (price vs quality) Confidence and transparency Consistency and predictability Regulatory compliance Adequate control over product security, recall and traceability (protect us) Above all else the food is safe to eat!
Retailers Demand Balanced value (price vs quality) Confidence and transparency Consistency and predictability Regulatory compliance Adequate control over product security, recall and traceability (protect us) Above all else the food is safe to eat! Brand Protection
Control Compliance with regulatory requirements? The safety of your food? Pre-process (ingredients and packaging) Process (GMP and HACCP) Post-process (retail and consumer handling) Your brand identity and reputation? The market for your product category?
Control food safety / quality sanitation regulatory internal audits crisis management external audits haccp and gmps food security risk management standards
GFSI: A global solution Launched at CIES Annual Congress (May 2000). Established as a non-profit Foundation (June 2005) Holistic and integrated approach by industry to establish uniform guidelines for food safety and quality. Managed by CIES The Food Business Forum
GFSI GOALS Converge FSQ standards globally Reduce audits to 1 Protect the brand Remove competitive element from product safety Seek continual improvement Cover farm to fork
Get Started 1. Understand d GFSI standards d Identifies non-conformities Optional training course Major Minor 2. Self assessment Gap analysis Correct non-conformities 3. Certification scheme Get specific standards Select audit company Certification decision 4. On-site Audit Continuous improvement
1. Get Standards a) CIES GFSI version 5 benchmark http://www.ciesnet.com/pfiles/programmes/foodsafety/gfsi_guidance_document_5th%20 Edition%20_September%202007.pdf b) SQF (Safe Quality Foods) Schemes a) SQF 2000 http://www.sqfi.com/sqf_2000_code_edition6.pdf b) Implementing SQF http://www.sqfi.com/sqf_2000_guide.pdf /SQF id df c) BRC (British Retail Consortium) http://www.brcbookshop.com/ ($$) d) FSSC (Food( Safety System Certification) http://www.fssc22000.com/downloads/1.pdf Presentation (with links) will be posted Presentation (with links) will be posted on foodsafety.usu.edu
What are standards a) Senior management and continual improvement commitments b) Foundation food safety y( (GMP/HACCP) c) Food safety management d) Food quality management e) Site standards f) Product control g) Process control h) Personnel control
2. Gap Analysis Document Control Control of Quality Records Management Responsibility Communication Emergency Preparedness Competence, Awareness and Training Infrastructure Work Environment Control of Nonconformity Verification Planning Traceability Validation of Control Measures Control of Monitoring and Measuring Devices Food Safety Management System Verification Internal Audits
Document Control 2. Gap Analysis Control of Quality Records Management Responsibility Communication Emergency Preparedness Competence, Awareness and Training Infrastructure Work Environment HVP recall lessons learned Control of Nonconformity Verification Planning Traceability Validation of Control Measures Control of Monitoring and Measuring Devices Food Safety Management System Verification Internal Audits
3a. Choose Program* a) SQF (Safe Quality Foods) a) Level 1 HACCP and GMPs b) Level 2 Expanded Food Safety c) Level 3 Expanded Food Quality (GFSI approved) b) BRC (British Retail Consortium) c) IFS (International Food Standards) d) Dutch HACCP e) FSSC 22000 (ISO 22000 + PAS 220) new f) SQF 1000 & NZGAP for Farm related safety
3b. Choose Cert. Body a) Must be certified to GFSI scheme b) Consider largest customers in choosing vendor and scheme c) SQF has 3 levels to gradually obtain full GFSI compliance d) SQF requires trained practitioner on-site (take relevant course then exam online) e) If previously ISO 22000 certified consider FSSC 22000 program f) Negotiate all costs
4. On-site Audits Usually 2 days 75% document verification 25% physical inspection 1 day of report writing N f iti ll h dl d i Non-conformities usually handled via correspondence (especially documents)
Annual Certification Cost Desk Audit >$9-12 K per year 1-2 Days Pre-Assessment Audit 1-2 Days Certification Audit 1-3 Days Typical Total 3-5 Days Annual Certification Fee $650 Auditing Body Fee $1200 per day Travel Expenses Variable Employee Time/Effort?
Risk Management Identify risks (food safety and quality) Analyze risks (matrix) Identify risk mitigation factors Implement risk mitigation factors Assess Mitigation