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Food safety must be taken seriously  The consequences of food being unsafe to eat are rather more far-reaching than a consumer being disappointed about.

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Presentation on theme: "Food safety must be taken seriously  The consequences of food being unsafe to eat are rather more far-reaching than a consumer being disappointed about."— Presentation transcript:

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2 Food safety must be taken seriously  The consequences of food being unsafe to eat are rather more far-reaching than a consumer being disappointed about its quality.  If foods do not meet the required safety standards the outcome is potentially fatal.  Manufacturers are required to adhere to food laws.  The Food Safety Act ensures that all food products:  meet all food safety regulations  have not been contaminated, making them harmful to health  are fit for human consumption  have been accurately described and presented to the consumer

3 About HACCP  space age technology designed to keep foods safe in outer space.  in the 1970's, a food safety programme was developed for astronauts.  focused on preventing hazards that could cause food-borne illnesses by applying science based controls to the manufacturing process, from raw material to finished products.

4 Why HACCP?  Throughout the manufacturing process, food products are subject to strict quality checks to ensure that the products meet the agreed quality standards.  These have to be right first time, every time.  This quality assurance is different to quality control, which involves inspection and testing at the end of the manufacturing process.

5 WHY?  HAACP (Hazard Analysis and Critical Control Point) is one particular quality assurance process used by the food industry.  It takes a systems approach to identifying hazards and risks and defining the means for their control.  Developing HACCP assists companies to comply with legislation and fulfils customer requirements for a food safety management system.

6 HACCP involves seven principles:  Analyse hazards. Potential hazards associated with a food and measures to control those hazards are identified. The hazard could be biological, eg. a microbe; chemical, eg. a toxin; or physical, eg. metal fragments.  Identify critical control points. These are the points during a food's production - from its raw state through processing and distribution to consumption by the consumer - at which the potential hazard can be controlled or eliminated. Examples are cooking, cooling, packaging and metal detection.  Establish preventative measures with critical limits for each control point. For a cooked food for example, this might include setting a minimum cooking temperature and time required to ensure the elimination of any harmful microbes.  Establish procedures to monitor the critical control points. Such procedures might include determining how and by whom cooking time and temperature should be monitored.  Establish corrective actions to be taken. This would be when monitoring shows that a critical control limit has not been met, for example, disposing of food if a metal has been detected.  Establish effective record keeping. Documenting the HACCP system provides detailed records that may be needed for traceability and accountability.

7 About the product  Customers expect same quality every time.  possible to maintain consistency of quality, taste and appearance by using systems and computer technology.  particularly with a popular product like Hamburgers!!!  If customers disappointed they will take their custom elsewhere.  The burgers featured in this case study are a single commodity product, ie. they contain 100% beef with no fillers or binders added.

8 About HACCP during burger production  As part of HACCP in a food factory, the operating manual for each product provides instructions for all stages of manufacture.  is for quality assurance and for training staff in exact procedures and processes.  this helps identify and list all the potential hazards.  hazards identified then preventative control measures based on knowledge of the hazards & contamination points can be drawn up.

9 How HACCP is approached for burger production.. See where on the factory floor the critical control points CCP’s are managed!

10 Unit operations and critical control points:  Flow chart shows unit operations in burger manufacture.  made in a purpose built factory.  3.8 million patties (regular hamburgers) and 1.52 million quarter pounders produced every day for distribution.

11 Critical control point 1: Delivery of meat Inspect all deliveries to check that food is not contaminated *observe delivery vehicle to see if it is clean. Reject food if it is unacceptable *seek out new supplier meat must be from approved supplier all vehicles must be sealed on delivery vehicles must be clean, without off- odours, fit for purpose and free from other materials

12 Critical control point 1: Delivery of meat Inspect meat for damage or contamination *ensure properly packaged, correct temperature, no signs of contamination. Reject products in damaged packaging, incorrect temperature or appear to be contaminated fresh meat temperature: target <+4degrees C frozen meat temperature: target

13 Critical control point 2: Chiller storage of ingredients Monitor and record chiller storage is operating between 0 and +5 degrees Adjust settings or contact a refrigerator technician. computer tracks chiller storage progress

14 Critical control point 3: Frozen storage of ingredients Monitor and record freezer storage is operating between minus 15 and minus 25 degrees Adjust settings or contact a freezer technician. computer tracks chiller and frozen storage progress

15 Critical control point 4: Meat preparation- personal hygiene Personal hygiene procedure before handling ingredients, equipment and utensils. Check fellow workers, use a fresh hairnet each shift, Hairnet- two if required. Wash Hands in warm soapy water Sanitize hands Put jacket on Wash hands again

16 Critical control point 4: Meat preparation- blending and mincing Ensure fat content meets the nutritional and quality specifications Modify formulation to meet specifications. computers used to track the progress of each batch of meat stage by stage. fat content is important as it affects the taste, texture and cooking properties. Too little fat may cause under-cooking problems and too much may result in shrinkage on cooking.

17 Critical control point 5: Meat preparation- blending and mincing Ensure physical defects are eliminated Grind and screen mince to remove any grissel and bone fragments Physical defects may pose a risk to the consumer if eaten (bone) They may also cause the product to have poorer quality. Defects could mean the product is recalled and therefore cannot be sold, being a monetary loss to the company.

18 Critical control point 6: Pattie production- shaping and forming Ensure patties are visibly the correct shape, size and weight Make adjustments to machinery if necessary A forming machine is used to shape patties under pressure in mould plates which determines the patty shape, size and weight.

19 Critical control point 7: Pattie production- freezing Ensure correct freezer temperatures are maintained to inhibit bacterial growth and prevent dehydration of the final patties. Sensors read and record and monitor temperature of the freezer areas in the factory. Freeze quickly to prevent dehydration.  Once formed they move into a freezer tunnel.

20 Critical control point 8: Pattie production- Metal detection Ensure there are no machinery fragments in the hamburgers which may pose as a risk to consumers. Pass product through two metal detectors to screen patties. Stop process if metal detected and audit machinery.  Once formed they move into a freezer tunnel. In-line metal detectors fitted with automatic rejection systems at freezing tunnel exits

21 CCP5: Metal detection  Packaging The beef patties are manually packed into boxes.  sealed and coded with the date, time and production line used. This information will allow traceability.

22 Boxes are sealed and coded!  Boxes are sealed and coded with the date, time and production line used. They are passed through a metal detector. All data is stored on computer and provides an important record in the line of traceability.

23 CCP6: Product storage  the product is kept at minus 18 degrees C  Inspection-  Patties checked by a quality assurance team.  checked against the specifications and all data is recorded on computer.  Cleaning-  Each night all machinery in the plant is thoroughly cleaned

24 Patties are checked & Electronic scales are used to indicate when a packed box is complete.

25 Data is recorded on hand held data loggers before being transferred to the main frame computer.

26 CCP7: Factory hygiene  daily clean of all manufacturing equipment  foam detergent followed by sanitiser  daily visual inspection  microbiological swabbing to check for contamination!

27 Samples of the patties are taken from the production line and cooked as they would be in food outlets.  Samples of the patties are taken from the production line and cooked as they would be in food outlets. Regular patties should cook in 42 seconds (42-46 seconds is the tolerance) and quarter pounders in 120 seconds ( seconds is the tolerance). Regular taste tests are carried out.

28 Where the burgers are cooked and sold to consumers, regular checks are carried out to ensure that they are prepared to the required standards, eg. cooked burgers must reach a minimum internal temperature of 70 degrees  Where the burgers are cooked and sold to consumers, regular checks are carried out to ensure that they are prepared to the required standards, eg. cooked burgers must reach a minimum internal temperature of 70 degrees C.


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