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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 ContaminationHACCP and Prerequisite Programs

Troie Burch

Director of Quality Assurance

Quik-to-Fix Foods

Southwest Meat Association

FSIS Technical Conference; Omaha, Nebraska


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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


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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


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HACCP - Hazard Analysis

  • Product History - ingredients, processes

  • Customer Complaints

  • Is it a food safety hazard or a contaminate?

FSIS Technical Conference; Omaha, Nebraska


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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


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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


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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


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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


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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


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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


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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


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Sanitation/Preventive Maintenance

  • Proper assembly of equipment

  • No extraneous material

  • No missing or damaged parts

FSIS Technical Conference; Omaha, Nebraska


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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


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Sifters and Magnets

  • Dry ingredients

  • Magnets remove enrichment

FSIS Technical Conference; Omaha, Nebraska


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Employee Practices

  • Colored vs clear plastic gloves

  • Proper placement of gloves when not in use

  • Small Tool Policy

FSIS Technical Conference; Omaha, Nebraska


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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


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Foreign Material

  • In meat and non-meat items

  • Wood

  • Plastic

  • Cardboard

  • Metal - biggest concern

  • UFO - unidentified foreign object

FSIS Technical Conference; Omaha, Nebraska


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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


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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


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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


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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


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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


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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


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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


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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


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Suspected Contamination

  • Plastic - depends on density and material characteristics

    • X-ray < 0.8mm or lowest detectable level

FSIS Technical Conference; Omaha, Nebraska


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Challenges for Small Plants

  • Lack of resources

  • Small number of employees

  • Large number of products

FSIS Technical Conference; Omaha, Nebraska


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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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