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Foreign Material Contamination HACCP and Prerequisite Programs. Troie Burch Director of Quality Assurance Quik-to-Fix Foods Southwest Meat Association. Food Safety Hazard. PR/HACCP Final Rule definition:

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foreign material contamination haccp and prerequisite programs
Foreign Material ContaminationHACCP and Prerequisite Programs

Troie Burch

Director of Quality Assurance

Quik-to-Fix Foods

Southwest Meat Association

FSIS Technical Conference; Omaha, Nebraska

food safety hazard
Food Safety Hazard
  • PR/HACCP Final Rule definition:
    • Any biological, chemical, physical property that may cause a food to be unsafe for human consumption
    • Does not take into account “significance” in risk to human health

FSIS Technical Conference; Omaha, Nebraska

food safety hazard3
Food Safety Hazard
  • NACMCF definition:
    • a biological, chemical, physical agent that is reasonably likely to cause illness or injury in the absence of its control.
    • Takes into account “significance”

FSIS Technical Conference; Omaha, Nebraska

haccp hazard analysis
HACCP - Hazard Analysis
  • Product History - ingredients, processes
  • Customer Complaints
  • Is it a food safety hazard or a contaminate?

FSIS Technical Conference; Omaha, Nebraska

extraneous matter
Extraneous Matter
  • Any object/material which may become a part of the product being produced, which is not designed to be a part of such product
  • Not usually a significant risk, but depends on size, shape, and type

FSIS Technical Conference; Omaha, Nebraska

adulteration or contamination
Adulteration or Contamination
  • Adulteration - the bearing of any deleterious substance which may render the food injurious to health
  • Contamination must be addressed in SSOP, not in HACCP

FSIS Technical Conference; Omaha, Nebraska

haccp hazard analysis7
HACCP - Hazard Analysis
  • Evaluate information on hazards to decide which are significant and reasonably likely to occur and must be addressed in the HACCP plan
  • If not significant and reasonably like to occur - not covered by HACCP, but in Prerequisite Programs

FSIS Technical Conference; Omaha, Nebraska

haccp hazard analysis8
HACCP - Hazard Analysis
  • Low risk, low frequency- not HACCP
  • Low risk, high frequency-depends
  • High risk, low frequency-depends
  • High risk, high frequency-HACCP

FSIS Technical Conference; Omaha, Nebraska

prerequisite programs
Prerequisite Programs
  • Multiple Points of Evaluation
    • Supplier Certification
    • Incoming Inspection
    • Sanitation/Preventive Maintenance
    • Processing Steps
    • Employee Practices
    • Finished Product Inspection
  • Employee Training

FSIS Technical Conference; Omaha, Nebraska

supplier certification
Supplier Certification
  • Meats
    • Metal Detection - 10.5 mm ferrous
  • Dry Ingredients
    • Letters of Guarantee
    • Sifters and Magnets
  • Packaging
    • Letters of Guarantee

FSIS Technical Conference; Omaha, Nebraska

incoming inspection
Incoming Inspection
  • Product packaging condition
  • Food Code 3-202.15 Package Integrity
    • “Food packages shall be in good condition and protect the integrity of the contents so that the food is not exposed to adulteration or potential contaminants.”

FSIS Technical Conference; Omaha, Nebraska

sanitation preventive maintenance
Sanitation/Preventive Maintenance
  • Proper assembly of equipment
  • No extraneous material
  • No missing or damaged parts

FSIS Technical Conference; Omaha, Nebraska

grinding
Grinding
  • Checks after every batch
    • Large object metal detection before pre-grind
    • Grind plate and knife blade check
    • Bone meat check
    • Knives and plates sharpened and inspected at end of each day
    • Metal detection before final grind

FSIS Technical Conference; Omaha, Nebraska

sifters and magnets
Sifters and Magnets
  • Dry ingredients
  • Magnets remove enrichment

FSIS Technical Conference; Omaha, Nebraska

employee practices
Employee Practices
  • Colored vs clear plastic gloves
  • Proper placement of gloves when not in use
  • Small Tool Policy

FSIS Technical Conference; Omaha, Nebraska

finished product
Finished Product
  • Visual at Packing
  • Finished Product Metal Detection
    • 1.5 - 2.0 mm ferrous
    • 2.5 mm non-ferrous
    • 3.0 mm stainless steel 316

FSIS Technical Conference; Omaha, Nebraska

foreign material
Foreign Material
  • In meat and non-meat items
  • Wood
  • Plastic
  • Cardboard
  • Metal - biggest concern
  • UFO - unidentified foreign object

FSIS Technical Conference; Omaha, Nebraska

slide18
Wood
  • Likely source
    • pallets
  • Pallet inspection program
  • Pallet rebuild program
  • Transfer to plastic pallets
  • Slip sheets
  • Wrap combo and wood pallet

FSIS Technical Conference; Omaha, Nebraska

plastic
Plastic
  • Likely source
    • Processing or measuring tools
    • Packaging
    • Liners frozen in meat
    • Chub ends frozen in meat
    • Gloves
  • Small tool program

FSIS Technical Conference; Omaha, Nebraska

cardboard
Cardboard
  • Likely source
    • faulty incoming packaging - frozen boxed meat and poultry products
    • sticks to the meat
    • frozen in the meat

FSIS Technical Conference; Omaha, Nebraska

metal
Metal
  • Lead shot
    • finished product metal detection
  • Injection Needles
    • Inspect equipment during production
  • Meat Hooks
  • Boning knives
    • Incoming 10.5 mm metal detection

FSIS Technical Conference; Omaha, Nebraska

metal continued
Metal continued
  • Metal to metal rubbing
  • Equipment - missing bolts, etc
  • Metal detectors expensive for small processors
    • Cost of equipment
    • Trained employees

FSIS Technical Conference; Omaha, Nebraska

slide23
Bone
  • Not necessarily a contaminant - inherent
  • Prevention/reduction methods
    • Visual inspection
    • Incoming Specifications
    • Grinding Specifications
    • Bone elimination equipment
    • Lack of re-use of bone meat

FSIS Technical Conference; Omaha, Nebraska

suspected contamination
Suspected Contamination
  • Metal
    • If no finished product metal detection
      • Use another resource that has equipment to inspect
      • X-ray < 0.8mm or lowest detectable level
      • Double pass at 90 degrees

FSIS Technical Conference; Omaha, Nebraska

suspected contamination25
Suspected Contamination
  • With use of metal detection
    • Re-inspect product at higher sensitivity
      • < 0.8 mm ferrous or lowest detectable level
      • Double pass at 90 degrees

FSIS Technical Conference; Omaha, Nebraska

suspected contamination26
Suspected Contamination
  • Plastic - depends on density and material characteristics
    • X-ray < 0.8mm or lowest detectable level

FSIS Technical Conference; Omaha, Nebraska

challenges for small plants
Challenges for Small Plants
  • Lack of resources
  • Small number of employees
  • Large number of products

FSIS Technical Conference; Omaha, Nebraska

challenges for small plants28
Challenges for Small Plants
  • Need flexibility for implementation
    • Non capital alternatives
    • Best means available
    • Based on strengths of company

FSIS Technical Conference; Omaha, Nebraska

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