Process & Process & Quality ControlsQuality Controls

Safety Quality & LegalitySafety Quality & Legality

Controls must be in place for Controls must be in place for Raw MaterialsRaw Materials Work In ProgressWork In Progress PackagingPackaging Finished ProductFinished Product

MonitoredMonitored RecordsRecords

Including claims on labellingIncluding claims on labelling Computerised records aspired toComputerised records aspired to

Process DeviationsProcess Deviations

What happens when a product or What happens when a product or process deviates from the agreed process deviates from the agreed specification?specification? QuarantineQuarantine ActionAction Corrective ActionCorrective Action Trend analysis of deviationsTrend analysis of deviations

What should a Quarantine Procedure What should a Quarantine Procedure include?include?

Unsafe or Illegal ProductUnsafe or Illegal Product

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

New Product New Product DevelopmentDevelopment

NPDNPD

Control of Product and Process Control of Product and Process begins at New Product Developmentbegins at New Product Development

NPD must be familiar withNPD must be familiar with Manufacturing StandardManufacturing Standard SpecificationSpecification Codes of Practice Codes of Practice HACCPHACCP

ProcessProcess

Concept Samples (Kitchen)Concept Samples (Kitchen) Development Samples (Kitchen)Development Samples (Kitchen) Samples AcceptedSamples Accepted Factory TrialsFactory Trials Sampling (Organoleptic, Chemical, Sampling (Organoleptic, Chemical,

Micro, Shelf Life)Micro, Shelf Life) First Production RunFirst Production Run LaunchLaunch

Product & Process TrialsProduct & Process Trials Testing to verify they are capable of Testing to verify they are capable of

repeatedly producing safe and legal repeatedly producing safe and legal products products product formulation product formulation manufacturing processes manufacturing processes

F0 values, F0 values, cook/chill, cook/chill, microbiological testing, microbiological testing, label claimslabel claims

Nutritional AnalysisNutritional Analysis

Completed and checked against spec Completed and checked against spec & label BEFORE launch& label BEFORE launch

Challenge nutritional claims and Challenge nutritional claims and verify using worst caseverify using worst case <2% fat, <2% fat, High in omega 3High in omega 3 Meat & Fish Quantitative Ingredient Meat & Fish Quantitative Ingredient

Declarations (QUIDs)Declarations (QUIDs)

Finished Product TrialsFinished Product Trials

Shelf life trials Shelf life trials meet requirements meet requirements trial results documented and retainedtrial results documented and retained

Transit trials must be completed, Transit trials must be completed, where appropriatewhere appropriate

Changes in formulation and process Changes in formulation and process must be adequately assessed must be adequately assessed communicated communicated documenteddocumented

NPD DepartmentNPD Department

Label all development materialsLabel all development materials Equipment must be clean and well Equipment must be clean and well

maintainedmaintained Records of the development process Records of the development process

should be retainedshould be retained

Product ControlsProduct Controls

Start Up ChecksStart Up Checks

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

Product ControlProduct Control

Sampling plan in place and followedSampling plan in place and followed Specific on-line product analysis:Specific on-line product analysis:

Recipe & Quality - Recipe & Quality - pH/Brix/fat/moisture/texturepH/Brix/fat/moisture/texture

Organoleptic Organoleptic TemperatureTemperature Can seam assessmentCan seam assessment Vacuum/gas analysisVacuum/gas analysis

QualityQuality

Additional recipe checks should be Additional recipe checks should be made at particular stages of work in made at particular stages of work in progressprogress 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) VisualVisual

Temperature ChecksTemperature Checks

Regular checking against risk Regular checking against risk assessment assessment

Critical limits or tolerances setCritical limits or tolerances set Action to be taken on deviation Action to be taken on deviation

outlinedoutlined Temperatures must be taken with Temperatures must be taken with

calibrated probescalibrated probes

Temperature ChecksTemperature Checks

Product Checks Product Checks Chilled <8°C (target <5°C),Chilled <8°C (target <5°C), Frozen <-18°CFrozen <-18°C

Process Temperature ChecksProcess Temperature Checks CriticalCritical Non-CriticalNon-Critical

Critical ControlsCritical Controls

CCPsCCPs

Check documents at locationCheck documents at location Accurate & comply with summaryAccurate & comply with summary Most recent versionMost recent version Records are complete & readableRecords are complete & readable Historical records – trace exercise + 3 Historical records – trace exercise + 3

months agomonths ago Check operationCheck operation

Operatives complete check correctlyOperatives complete check correctly Operatives have been trainedOperatives have been trained

Examples of CCPsExamples of CCPs Can Seam Assessment Can Seam Assessment

Documented seam analysis measurements for Documented seam analysis measurements for each can size and seamer used. each can size and seamer used.

Modified Atmosphere and Vacuum Modified Atmosphere and Vacuum PackagingPackaging Seal checks - no leaksSeal checks - no leaks

Thermal processesThermal processes ManualManual AutomaticAutomatic Real-timeReal-time

pHpH Buffered on use & buffers controlledBuffered on use & buffers controlled

Critical Temperature Critical Temperature ControlsControls

Equipment vs CoreEquipment vs Core How do you establish core How do you establish core

temperaturetemperature Cook/Cool profilesCook/Cool profiles

EquipmentEquipment FrequencyFrequency Cold spotsCold spots

Enclosed systemsEnclosed systems

Cooking & Cooling Cooking & Cooling ValidationValidation

MicroMicro 3 Lots/Batches3 Lots/Batches FrequencyFrequency Back up plan for maintenance and Back up plan for maintenance and

breakdown of critical equipment breakdown of critical equipment

Finished Finished Products Products StandardsStandards

Finished Product TestingFinished Product Testing

Finished product testing comply Finished product testing comply with with

Product Specifications Product Specifications microbiological, microbiological, chemical, chemical, physical, physical, organoleptic organoleptic other specific requirements other specific requirements

Free From and Nutritional ClaimsFree From and Nutritional Claims

Micro TestingMicro Testing

Finished ProductFinished Product MicroMicrobiologicalbiological Standards Standards

Raw materials and work in progressRaw materials and work in progress assessed in accordance with legislation assessed in accordance with legislation

(micro criteria) (micro criteria) industry guidelines/standard practiceindustry guidelines/standard practice

Micro TestingMicro Testing

Micro standards Micro standards TargetTarget Report levelReport level Reject levelReject level

Given to the testing laboratoryGiven to the testing laboratory Site can be contacted if out of Site can be contacted if out of

specificationspecification

Chemical TestingChemical Testing Relevant to the product Relevant to the product Claims made on the label Claims made on the label

Low Fat/Reduced Salt/High FibreLow Fat/Reduced Salt/High Fibre Compositional standards Compositional standards

Chocolate RegsChocolate Regs Legal requirements Legal requirements

Meat contentMeat content Additive levelsAdditive levels PesticidesPesticides

Quality criteria Quality criteria Acidity levels/pHAcidity levels/pH Moisture levelsMoisture levels

Physical TestingPhysical Testing

QuantitativeQuantitative measurable on-line measurable on-line checkschecks CountsCounts WeightsWeights DiametersDiameters ThicknessThickness Wash-outsWash-outs

OrganolepticOrganoleptic

Obvious faults for Raw Materials, Obvious faults for Raw Materials, WIP & Finished ProductWIP & Finished Product TasteTaste TextureTexture Odour Odour AppearanceAppearance

Assess product in detail Assess product in detail Compare similar productsCompare similar products

OrganolepticOrganoleptic Panelist trainingPanelist training Start of LifeStart of Life End Of LifeEnd Of Life Trend AnalysisTrend Analysis

Product Analysis Product Analysis LaboratoriesLaboratories

Testing must be conducted in Testing must be conducted in accredited laboratories accredited laboratories Accreditation must be by an Accreditation must be by an

internationally recognised country body.internationally recognised country body. ScopeScope of accreditation must cover of accreditation must cover

all tests undertakenall tests undertaken Laboratories must participate in Laboratories must participate in

proficiency/correlation testing (ring proficiency/correlation testing (ring tests)tests)

Product Analysis Product Analysis LaboratoriesLaboratories

Procedures detailing Procedures detailing samples, sampling methods, type of tests samples, sampling methods, type of tests

to be conducted, durability informationto be conducted, durability information Pathogen labs - separate buildingPathogen labs - separate building Routine QC checks which are Routine QC checks which are

completed in a laboratory environment completed in a laboratory environment e.g. measuring dimensions of the e.g. measuring dimensions of the product or quality sampling product or quality sampling DO NOTDO NOT need laboratory accreditationneed laboratory accreditation

Laboratory ResultsLaboratory Results

How are results reportedHow are results reported Out of SpecOut of Spec

Verbal & written?Verbal & written?

Evidence of investigation and action Evidence of investigation and action for failuresfor failures

Trend AnalysisTrend Analysis

RecordsRecords

All test results must be recordedAll test results must be recorded CCP records must show the target, CCP records must show the target,

tolerances and critical limits tolerances and critical limits Document controlled to ensure they Document controlled to ensure they

are up to dateare up to date Records must be in ink, readable, Records must be in ink, readable,

dated and signeddated and signed