Process & Quality Controls

Safety Quality & Legality Controls must be in place for Controls must be in place for Raw Materials Raw Materials Work In Progress Work In Progress Packaging Packaging Finished Product Finished Product Monitored Monitored Records Records Including claims on labelling Including claims on labelling Computerised records aspired to Computerised records aspired to

Process Deviations What happens when a product or process deviates from the agreed specification? What happens when a product or process deviates from the agreed specification? Quarantine Quarantine Action Action Corrective Action Corrective Action Trend analysis of deviations Trend analysis of deviations What should a Quarantine Procedure include? What should a Quarantine Procedure include?

Unsafe or Illegal Product must be notified immediately of any illegal and or unsafe products which have been produced and despatched must be notified immediately of any illegal and or unsafe products which have been produced and despatched

New Product Development

NPD Control of Product and Process begins at New Product Development Control of Product and Process begins at New Product Development NPD must be familiar with NPD must be familiar with Manufacturing Standard Manufacturing Standard Specification Specification Codes of Practice Codes of Practice HACCP HACCP

Process Concept Samples (Kitchen) Concept Samples (Kitchen) Development Samples (Kitchen) Development Samples (Kitchen) Samples Accepted Samples Accepted Factory Trials Factory Trials Sampling (Organoleptic, Chemical, Micro, Shelf Life) Sampling (Organoleptic, Chemical, Micro, Shelf Life) First Production Run First Production Run Launch Launch

Product & Process Trials Testing to verify they are capable of repeatedly producing safe and legal products Testing to verify they are capable of repeatedly producing safe and legal products product formulation product formulation manufacturing processes manufacturing processes F0 values, F0 values, cook/chill, cook/chill, microbiological testing, microbiological testing, label claims label claims

Nutritional Analysis Completed and checked against spec & label BEFORE launch Completed and checked against spec & label BEFORE launch Challenge nutritional claims and verify using worst case Challenge nutritional claims and verify using worst case <2% fat, <2% fat, High in omega 3 High in omega 3 Meat & Fish Quantitative Ingredient Declarations (QUIDs) Meat & Fish Quantitative Ingredient Declarations (QUIDs)

Finished Product Trials Shelf life trials Shelf life trials meet requirements meet requirements trial results documented and retained trial results documented and retained Transit trials must be completed, where appropriate Transit trials must be completed, where appropriate Changes in formulation and process Changes in formulation and process must be adequately assessed must be adequately assessed communicated communicated documented documented

NPD Department Label all development materials Label all development materials Equipment must be clean and well maintained Equipment must be clean and well maintained Records of the development process should be retained Records of the development process should be retained

Product Controls

Start Up Checks Start of each shift and intermediate checks between product runs. Start of each shift and intermediate checks between product runs. Hygiene Hygiene Foreign Body Checks Foreign Body Checks Safety & Guard Checks Safety & Guard Checks Clear Line Check (clear of all product) Clear Line Check (clear of all product)

Product Control Sampling plan in place and followed Sampling plan in place and followed Specific on-line product analysis: Specific on-line product analysis: Recipe & Quality - pH/Brix/fat/moisture/texture Recipe & Quality - pH/Brix/fat/moisture/texture Organoleptic Organoleptic Temperature Temperature Can seam assessment Can seam assessment Vacuum/gas analysis Vacuum/gas analysis

Quality Additional recipe checks should be made at particular stages of work in progress Additional recipe checks should be made at particular stages of work in progress Brix (Fruit Juices) Brix (Fruit Juices) Moisture (Crisps) Moisture (Crisps) Fat (Mince) Fat (Mince) Texture (Mayonnaise, cakes) Texture (Mayonnaise, cakes) Viscosity (Oil Dressings, Sauces) Viscosity (Oil Dressings, Sauces) Chemicals (Nitrite) Chemicals (Nitrite) Visual Visual

Temperature Checks Regular checking against risk assessment Regular checking against risk assessment Critical limits or tolerances set Critical limits or tolerances set Action to be taken on deviation outlined Action to be taken on deviation outlined Temperatures must be taken with calibrated probes Temperatures must be taken with calibrated probes

Temperature Checks Product Checks Product Checks Chilled <8°C (target <5°C), Chilled <8°C (target <5°C), Frozen <-18°C Frozen <-18°C Process Temperature Checks Process Temperature Checks Critical Critical Non-Critical Non-Critical

Critical Controls

CCPs Check documents at location Check documents at location Accurate & comply with summary Accurate & comply with summary Most recent version Most recent version Records are complete & readable Records are complete & readable Historical records – trace exercise + 3 months ago Historical records – trace exercise + 3 months ago Check operation Check operation Operatives complete check correctly Operatives complete check correctly Operatives have been trained Operatives have been trained

Examples of CCPs Can Seam Assessment Can Seam Assessment Documented seam analysis measurements for each can size and seamer used. Documented seam analysis measurements for each can size and seamer used. Modified Atmosphere and Vacuum Packaging Modified Atmosphere and Vacuum Packaging Seal checks - no leaks Seal checks - no leaks Thermal processes Thermal processes Manual Manual Automatic Automatic Real-time Real-time pH pH Buffered on use & buffers controlled Buffered on use & buffers controlled

Critical Temperature Controls Equipment vs Core Equipment vs Core How do you establish core temperature How do you establish core temperature Cook/Cool profiles Cook/Cool profiles Equipment Equipment Frequency Frequency Cold spots Cold spots Enclosed systems Enclosed systems

Cooking & Cooling Validation Micro Micro 3 Lots/Batches 3 Lots/Batches Frequency Frequency Back up plan for maintenance and breakdown of critical equipment Back up plan for maintenance and breakdown of critical equipment

Finished Products Standards

Finished Product Testing Finished product testing comply with Finished product testing comply with Product Specifications Product Specifications microbiological, microbiological, chemical, chemical, physical, physical, organoleptic organoleptic other specific requirements other specific requirements Free From and Nutritional Claims Free From and Nutritional Claims

Micro Testing Finished Product Finished Product Microbiological Standards Microbiological Standards Raw materials and work in progress Raw materials and work in progress assessed in accordance with legislation (micro criteria) assessed in accordance with legislation (micro criteria) industry guidelines/standard practice industry guidelines/standard practice

Micro Testing Micro standards Micro standards Target Target Report level Report level Reject level Reject level Given to the testing laboratory Given to the testing laboratory Site can be contacted if out of specification Site can be contacted if out of specification

Chemical Testing Relevant to the product Relevant to the product Claims made on the label Claims made on the label Low Fat/Reduced Salt/High Fibre Low Fat/Reduced Salt/High Fibre Compositional standards Compositional standards Chocolate Regs Chocolate Regs Legal requirements Legal requirements Meat content Meat content Additive levels Additive levels Pesticides Pesticides Quality criteria Quality criteria Acidity levels/pH Acidity levels/pH Moisture levels Moisture levels

Physical Testing Quantitative measurable on-line checks Quantitative measurable on-line checks Counts Counts Weights Weights Diameters Diameters Thickness Thickness Wash-outs Wash-outs

Organoleptic Obvious faults for Raw Materials, WIP & Finished Product Obvious faults for Raw Materials, WIP & Finished Product Taste Taste Texture Texture Odour Odour Appearance Appearance Assess product in detail Assess product in detail Compare similar products Compare similar products

Organoleptic Panelist training Panelist training Start of Life Start of Life End Of Life End Of Life Trend Analysis Trend Analysis

Product Analysis Laboratories Testing must be conducted in accredited laboratories Testing must be conducted in accredited laboratories Accreditation must be by an internationally recognised country body. Accreditation must be by an internationally recognised country body. Scope of accreditation must cover all tests undertaken Scope of accreditation must cover all tests undertaken Laboratories must participate in proficiency/correlation testing (ring tests) Laboratories must participate in proficiency/correlation testing (ring tests)

Product Analysis Laboratories Procedures detailing Procedures detailing samples, sampling methods, type of tests to be conducted, durability information samples, sampling methods, type of tests to be conducted, durability information Pathogen labs - separate building Pathogen labs - separate building Routine QC checks which are completed in a laboratory environment e.g. measuring dimensions of the product or quality sampling DO NOT need laboratory accreditation Routine QC checks which are completed in a laboratory environment e.g. measuring dimensions of the product or quality sampling DO NOT need laboratory accreditation

Laboratory Results How are results reported How are results reported Out of Spec Out of Spec Verbal & written? Verbal & written? Evidence of investigation and action for failures Evidence of investigation and action for failures Trend Analysis Trend Analysis

Records All test results must be recorded All test results must be recorded CCP records must show the target, tolerances and critical limits CCP records must show the target, tolerances and critical limits Document controlled to ensure they are up to date Document controlled to ensure they are up to date Records must be in ink, readable, dated and signed Records must be in ink, readable, dated and signed