[PPT]Kraft Foods · Web viewShelf-Life of Pre-packaged Food Products An Industry Perspective...

Shelf-Life of Pre-packaged Food Products

An Industry Perspective

Dr. Ahmet Anbarci

Scientific & Regulatory AffairsKraft Foods CEEMA Region

Dubai International Food Safety Conference24-26 February, 2009

DIFSC, Dubai, 24 – 26 February, 2009 / Dr Ahmet Anbarci - 2

Agenda

• Kraft Foods in short• Shelf-life – Definition, Dimensions• Shelf-life Kraft Foods RD&Q functions • Establishing and Managing Shelf-life• Testing, Principles, Parameters• Selected Aspects, Examples• Discussion


Kraft Foods Overview, 2008


Worldwide headquarters in Northfield, Illinois, U.S.

Sales in more than 155 Countries

Operations in 70 Countries

With approximately 100,000 employees, more than 180 manufacturing and processing facilities

11 global or geographic Research and Development Centers around the world

Kraft Foods Overview, 2008


9 Brands over $1 billion annual revenue50+ Brands over $100 million40+ Brands over 100 years old

One of Best Brand Portfolios in Food & Beverage Industry


Eastern Europe, Middle East & Africa Region

Fast FactsFast FactsRegion headquarters: Vienna, Austria Region headquarters: Vienna, Austria

Key markets in the region: Key markets in the region:

Bulgaria, Egypt, Romania, Russia, South Africa, Bulgaria, Egypt, Romania, Russia, South Africa, Turkey, Ukraine and the Gulf Cooperation Council, as Turkey, Ukraine and the Gulf Cooperation Council, as

well as other Middle East & Africa Marketswell as other Middle East & Africa Markets

Some key region brands:Some key region brands:Kraft cheeses; Tang powdered beverages; Alpen Kraft cheeses; Tang powdered beverages; Alpen

GoldGold, , KarunaKaruna, , KoronaKorona and and MilkaMilka chocolates; chocolates; EstrellaEstrella and and CipsoCipso salted snacks; salted snacks; RascoRasco biscuits; biscuits; Carte NoireCarte Noire, , JacobsJacobs, , MaxwellMaxwell HouseHouse and and Nova BrasiliaNova Brasilia coffees. coffees.


Kingdom of Saudi Arabia:- Production Facility – Biscuits - Employees: 138 (23% Saudi)- Brands: Oreo, Ritz and Belvita Kingdom of Bahrain:

- Production Facility - (Tang and Cheese)- Employees: 287 (17% Bahraini)- Brands: Tang, Kraft Cheese

Kraft Foods in GCC

United Arab Emirates:- MEA Regional Office- Employees: 130- Lead Brands Marketed in GCC:


Shelf-life, definition, dimensions

Shelf-Life is the time between manufacture and possible latest consumption, wherein the characteristics of a food product are considered to remain acceptable with following dimensions and aspects:

products must be safe- self-speaking, un-debated, un-compromised; HACCP

------------------------------------------------------------------------------------------ quality must remain acceptable

- consumer accepted quality; vital to gain consumers and maintain their loyalty

nutritional value needs to be maintained- prime aspect for food; maintain claims on products

commercial stability to be assured- package integrity, look; key for customers and at point of

sale


Packaged food over shelf-life


Shelf-life Food Research, Development & Quality (Kraft Foods RD&Q)

Category Category ExpertiseExpertise

GeographicGeographicProximityProximity

FunctionalFunctionalExcellenceExcellence+ +

• CoffeeCoffee• Refreshment BeveragesRefreshment Beverages• GroceryGrocery• Biscuits and CakesBiscuits and Cakes• ConfectioneryConfectionery• Savory SnacksSavory Snacks• Cheese/DairyCheese/Dairy• Convenient MealsConvenient Meals

• Banbury, UKBanbury, UK• Tarrytown, NYTarrytown, NY• East Hanover, NJEast Hanover, NJ• Munich, GermanyMunich, Germany• Glenview, ILGlenview, IL• Madison, WIMadison, WI• Battle Creek, MIBattle Creek, MI• Melbourne, AustraliaMelbourne, Australia• Curitiba, BrazilCuritiba, Brazil

• Quality and Safety Quality and Safety • Scientific AffairsScientific Affairs• RegulatoryRegulatory• NutritionNutrition• ResearchResearch• ChemistryChemistry• MicrobiologyMicrobiology• Sensory / Consumer InsightSensory / Consumer Insight• PackagingPackaging• Intellectual Property/ PatentsIntellectual Property/ Patents

Kraft Foods RD&Q is the owner of shelf-life and has the responsibility, expertise and the infrastructure for establishing products’ shelf-life.


Our RD&Q centre in Munich has the geographic responsibility for West, Central, East Europe, Middle East and Africa

Functions in MunichFunctions in Munich Product DevProduct Dev Process DevProcess Dev PackagingPackaging MicrobiologyMicrobiology &

Food SafetyFood Safety QualityQuality ChemistryChemistry SensorySensory RegulatoryRegulatory Scientific AffairsScientific Affairs NutritionNutrition

Munich – Geographic ScopeMunich – Geographic ScopeWest, Central, East Europe, Middle East and AfricaWest, Central, East Europe, Middle East and Africa

Munich – Product RoleMunich – Product RoleCheese/Dairy, Convenient Meals, Refreshment Cheese/Dairy, Convenient Meals, Refreshment Beverages, Grocery, Chocolate Confectionery, Savory Beverages, Grocery, Chocolate Confectionery, Savory Snacks, (Quality & Safety for Coffee)Snacks, (Quality & Safety for Coffee)

GlobalGlobal Glenview, ILGlenview, IL East Hanover, NJEast Hanover, NJ Tarrytown, NYTarrytown, NY Banbury, UKBanbury, UK Munich, GermanyMunich, Germany

Geographic / LocalGeographic / LocalMadison, Battle Creek, Madison, Battle Creek, Melbourne, Curitiba and 50 Melbourne, Curitiba and 50 other smaller centersother smaller centers


Same principles around the Globe

• Product Safety/Public Health is our uncompromised priority.• Food Safety is pre competitive.• Food Safety is based on sound science and correct risk assessment.• HACCP and our ISO based QCMS (Quality Chain Management

System) are central to our business process.• Kraft applies common Food Safety & Quality Standards globally.

In addition we believe in:• a systems and process driven approach• a strong upstream focus with major supplier collaboration• covering each and every component in the business Value Chain.

Kraft Product Safety & Quality Assurance Guiding Principles


Quality Chain Management System

• Kraft Foods worldwide approach to the systematic management of product Safety and Quality is called the Quality Chain Management System (QCMS).

• QCMS is a complete embodiment of the ISO 9001 quality system model enhanced to include the product Safety and Quality requirements of Kraft Foods worldwide food businesses.

• QCMS defines the requirements throughout the process of design, procurement, manufacture, distribution and customer/consumer product usage and relations.

Shelf-life evaluation and management is an essential part of successful food quality management. Ideally, shelf-life is an integral part of an overall Quality Management System through the entire value chain.

Kraft Foods’ procedure on “shelf-life evaluation” is a fundamental part of QCMS and has to be applied by all relevant employees around the world.

Objective: “All Kraft Food businesses shall have a process in place for establishing and managing the shelf-life of all products.”Scope: “Shelf-life evaluation applies globally to all KF businesses and categories. Key elements are parameters, procedures, storage conditions, shelf-life management and modification of shelf-life.”


Food Value Chain


Shelf-life, definition, dimensions

Shelf-Life is the time between manufacture and possible latest consumption, wherein the characteristics of a food product are considered to remain acceptable with following dimensions and aspects:

products must be safe- self-speaking, un-debated, un-compromised; HACCP

------------------------------------------------------------------------------------- quality must remain acceptable

- consumer defined quality; vital to gain consumers and

maintain their loyalty nutritional value needs to be maintained

- prime aspect for food; maintain claims on products commercial stability to be assured

- package integrity, look; key for customers and at point of sale


RD&Q functions involved

products must be safe

- Quality /Safety- Chemistry- Microbiology- Toxicology- Packaging

nutritional value to be maintained

- Scientific Affairs- Regulatory- Nutrition- Chemistry- Packaging

quality must remain acceptable

- Quality /Safety- Regulatory- Chemistry- Microbiology- Sensory / Consumer Insight- Packaging

commercial stability to be assured

- Quality /Safety- Regulatory- Packaging

RD&Q is responsible for the “design” and establishing shelf-life; Category Product Development Groups lead, relevant RD&Q functions as listed below support the process. Other parties along value chain consulted as required, e.g. Manufacturing.


Testing

Close to reality conditions pursued

- Full shelf-life testing and beyond- Representative samples- Representative storage conditions- Consumer relevant sensory testing- Consumer research, if required

Testing protocols

- Sampling- Testing conditions- Testing period- Schedule, intervals- Attributes, parameters- Methods- Record keeping

Shelf-life testing is a vital part of new product development. Existing products are re-evaluated, if an extension of shelf-life is targeted or any changes are considered. Re-evaluation may also be triggered by consumer complaints or quality issues.


Testing – parameters, questions to be considered

Product Safety and Robustness are uncompromised and checked and verified for the intended use and foreseeable misuse of products.

risk of pathogens ? risk of toxins ? allergens ?

Shelf-Life beyond safety: Many parameters and a high number of possible combinations for industrially packaged food lead to a wide range of possible shelf-life’s.

product category, type, nature ? micro-stability, risk of spoilage ? chemical reactions ? physical changes ? organoleptic, sensory, consumer ? packaging integrity and protection ? transport and storage conditions ? consumer behaviour, usage ?


Shelf-life – Regulated limits?

Considering the complexity inherent to shelf-life, i.e. many parameters, their interaction, possible combinations (vs. the time we have in this forum), only some selected aspects/examples will follow.


Aspects/Examples: Basics for micro risks

LAGLOG

STATIONARY

DEATH

Time of LAG phase determines maximum shelf life possible.LAG phase can vary depending on other parameters and can be extended by improved sanitation, processing, storage conditions, preservatives, modified atmosphere or some emerging technology.

Microbiological Growth


Aspects/Examples: Consumer Relevant Shelf-life Testing

1. Representative Sampling- Final testing with plant products only (pilot products only for pre-assessment)- Freezing samples (= freezing the time)- If products cannot be frozen, multiple lots testing (assess impact of lots’ variability)

2. Representative Storage Conditions- All along the Value Chain (transport, warehouses, consumer households)- Close to reality simulation (consider varying conditions, best / worst case scenarios)

3. Test plan/methods relevant to product, market, potential consumers alienation- Internal sensory testing (people without project involvement, descriptive)- Quantitative descriptive analysis (trained panel)- Consumer acceptance testing (consumer liking, judgemental)

Key elements:


Shelf-life of food products

Internal Sensory Testing

• At least three of the same participants at each tasting, involving people without project background.

• Focus should be descriptive, not judgement. After documenting the descriptive differences, judgement about the expected seriosity of deviations may be necessary.

• Representative control product needs to be used as a reference.

• Project leaders organize the taste sessions, sample storage and ensure right participants at each session. Consumer Sensory group provides the test procedure and analysis forms.

• Project leaders own next steps as agreed by team



Quantitative Descriptive Analysis (QDA)

• A tool to test in an objective manner, whether sensory changes are perceivable.

• Generally recommended, when significant changes are expected / predicted over shelf-life.

• In case of changes that are not necessarily negative: Perceivability and relevance of changes need to be tested with consumers, to determine effects on consumer acceptability.

• Key acceptance drivers are known from earlier consumer tests can be used to judge the differences observed in QDA and the shelf life.


Shelf-life, Consumer testing

Consumer Acceptance Testing

• For key products, and for critical cases, consumer acceptance testing is recommended.

• Multiproduct Central Location Test of samples at different stages in shelf life, before, at, and after end of shelf life at stake.

• Absolute safety of samples to be ensured via thorough micro testing.

• Test should be run with target consumers in the target countries. Participants need to be unaware of the test background.


Aspects/Examples: Cheese and many parametersSame category, different types, processing, storage conditions, packaging, …… => Shelf-life’s in a range of few to 18 months.

18 months18 months

12 months12 months


Aspects/Examples: Packaging materials

Substrate OTR(cc/m2/24hrs)

WVTR(g/m2/24hrs)

Light Barrier Strength

Foil 0 0 100% Low

Aluminum laminate <1 <1 100% Medium

Polyester (PET) 90 40 <5% Medium

Metallised PET (met-PET) 0.5 <1 >95% Medium

PVdC coated PET 6 14 <5% Medium

Biaxially Oriented Polyprop. 1900 6 <5% Medium

PVdC Coated BOPP 10 5 <5% Medium

Metallised BOPP (met-BOPP) 100 1.5 >95% Medium

Biaxially Oriented Nylon (OPA) 45 260 <5% Medium

PVdC Coated OPA 6 7 <5% Medium

Glass Jar 0 0 <5% High

PP Rigid <1-200 <1-100 <5% High

Tetrapak/Combibloc 0 0 100% Medium

3 Piece Metal Can 0 0 100% High


Aspects/Examples: Packaging with the right protection

Metal can

Glass Jar

Composite can

PET container

Aluminium laminate

Metalised laminate

Plastic container

C o s t s

Processed Cheese in a glass jar with a proven shelf-life of 12 months.

High protection and other factors help to achieve a long shelf-life:


Shelf-life: Regulated limits?

Considering the complexity of shelf-life, limits set for shelf-life of packaged foods would either be overcomplicated (wide array, needs regular updating) or a weak compromise, most likely at category minimum. Risks and disadvantages for all appear to outweigh any advantages.

Consumers and all stakeholders along the value chain benefit from safe and high-quality products with tested and proven shelf-life. While the added safety, quality and value through regulated shelf-life limits is open to discussion, some risks and disadvantages are certain for industrial, packaged food:

- Avoidable costs, economic penalty, if the limits set are too conservative, , i.e. at the category minimum (lowest common denominator)- Risk of low quality products to consumers, if the limits set are too broad- Risk of missing new aspects, development or scientific progress- Low incentive, low motivation for industry to innovate or apply the “new”


Shelf-life: Regulated limits?

Conclusions:The food industry should perform due-diligence to judge, test and establish the shelf-life for each single product they manufacture, regardless how strict or wide the limits set by regulations may be.

Food companies in general have to have their products’ data and expertise and to know about the nature, details and limits of their products.

Shelf-life limits set for packaged food are open to abuse and do not appear to add value, safety or quality of especially packaged food.

Shelf-life limits may be an unnecessary hurdle, especially for long tested products with a good record in country of origin or in other markets.



Thank you!

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