| Ever overdraw on your checking account or max out a credit card? It’s not hard to do if you’re not keeping track of things. How can we manage household expenses without some sort of record keeping?
Away from home, in the business sector, record keeping becomes even more important. In fact, it’s the very thing covered by HACCP Design Principle No. 7. Principle 7: Establish record keeping procedures. – This HACCP principle requires that all food manufacturing plants maintain records to show they implemented a HACCP plan, are following all principles, and the plan is working effectively. Let’s look at an example. In keeping with the directive of HACCP Design Principle 7, the engineering department of a food manufacturing plant must keep records for each design project. The design record for a new cookie forming machine would contain things like engineering calculations to determine strength requirements of machine parts and supports, as well as power requirements for the electric motor that drives the machine. This design record would also contain documentation concerning materials selected to construct the machine, as well as dimensioned mechanical drawings of the machine and its parts. These dimensioned drawings will show all physical dimensions of the machine and its constituent parts. The record would also contain test results and analysis of the results. Lastly, the design record must include a risk analysis of potential hazards that could result. Other activities include identification of CCPs, establishment of critical limits, and other factors in accordance with HACCP Design Principles 1 through 5. In other words, the record must be complete, bearing witness to an effective adherence to HACCP Design Principles 1 through 5. Principle 7 also encompasses guidelines set in place through Design Principle 6, which calls for the establishment of procedures to govern Principles 1 through 5. A complete record would contain the procedures themselves, along with any revisions. It would also contain documentation that the procedures were reviewed and approved by management along the way. Finally, of what use would records be if they were incomplete, disorganized, and outdated? A document control system not only establishes procedures, but assigns responsibilities to personnel within the department for filing design records to make sure that everything is up to snuff. This system would encompass everything, from the creation of engineering documents, to their timely entry into the record keeping system. We have now exhausted our discussion on HACCP Design Principles. We’ll switch to a new topic next time, examining some basic concepts behind the control of industrial equipment and machinery. ____________________________________________
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Posts Tagged ‘food production line’
Food Manufacturing Challenges – HACCP Design Principle No. 6
Sunday, November 20th, 2011| My daughter’s boy friend stayed for dinner recently and was impressed with our after-dinner cleanup. He watched as each of us carried out our individual assigned tasks, my wife putting away leftovers and condiments, my daughter rinsing and stacking plates into the dishwasher, and me at the sink hand washing. To him we seemed a model of efficiency. It didn’t take long to return the kitchen to its usual state of pristine evening cleanliness. “Our kitchen is always a mess,” he complained, “probably because we’re so disorganized.”
You can imagine what would happen if a food manufacturing plant operated like a disorganized household kitchen. Although employees may know they are responsible for delivering safe products to consumers, without the right procedures in place an unsafe chaotic mess may result. To get everyone moving in the right direction we look to guidelines established in HACCP Design Principle No. 6. Principle 6: Establish procedures for ensuring the HACCP system is working as intended. – In large part this Principle acts as a report card. It follows up on the guidelines established in Principles l through 5, organizing activities into written procedures. For example, design engineers must routinely analyze important identified stages within a design project, then write procedures, that is, a step-by-step instruction guide, which encompasses them. In this way personnel involved in the design process make best use of the safeguards put in place by HACCP Design Principles 1 through 5. These steps include things like preparing design proposals, analyzing risks and hazards, creating preliminary designs, conducting design reviews, building prototype equipment and tooling, running tests, collecting test data, and analyzing test results. For each step, responsibilities of key individuals involved must be clearly defined and sequentially ordered. But writing department procedures is only part of Principle 6. Procedures are no good if they’re just thrown into a file cabinet and no one ever looks at them. What good are guidelines without a full understanding of how to use them? Training may be necessary, and management must decide what form that educational process takes to be most effective. Engineering management must verify that established procedures are adequate to the task. This typically involves taking a hard look at finished design projects and checking critical factors. Was an adequate risk analysis performed? Were sufficient critical control points established and critical limits monitored for effectiveness? Next time we’ll wrap up our discussion on HACCP Design Principles by examining No. 7. It’s the last of the Principles and it’s concerned with establishing record keeping procedures. ____________________________________________
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Food Manufacturing Challenges – HACCP Design Principle No. 5
Saturday, November 12th, 2011| Picture yourself on a highway, it’s dark out, the wind is blowing fiercely, and you’re unable to see that the pavement is accumulating icy patches. You hit one, and your car veers out of control. Luckily you drive one of the new generation of “smart” vehicles. Wheel sensors detect your predicament and immediately initiate a sequence of events to correct the situation and bring your vehicle back into control.
Corrective measures need to be taken in many situations when things go awry, whether they be computer-generated or human-generated corrections, and food manufacturing facilities are not exempt from the process. Let’s look at how this applies within HACCP Design Principle No. 5. Principle 5: Establish corrective actions. – Simply put, when an established critical limit at a designated critical control point (CCP) has been found not to be functioning as intended, thereby exposing consumers to potential food safety issues, design engineers must enact corrective measures to resolve the issue as soon as possible. Let’s return to the example set out in our last article, where we discussed HACCP Design Principle 4. An engineering manager has discovered a problem with the lower critical limits established by her design engineer’s software logic as it concerns a CCP established with regard to cooker temperature. The time and temperature in the logic create a hazardous situation by not taking into account that larger cuts of meat require more cooking time, resulting in them being undercooked. Fortunately, the engineering manager’s diligent and ongoing day-to-day monitoring has alerted her to the error. She immediately provides feedback about it to the design engineer, who makes corrections to the software logic. Problem solved, and all is working well within the food manufacturing plant, right? Yes, but we’re not finished. We have to make sure that a mechanism is set in place to ensure that HACCP Principles 1 through 5 are being followed and that they are actually working to protect consumers from potential food contamination hazards. Next time we’ll take a look at the last of the HACCP Design Principles, No. 6, which concerns itself with maintenance and housekeeping issues. ____________________________________________ |
Food Manufacturing Challenges – HACCP Design Principle No. 4
Sunday, November 6th, 2011| Imagine going on a diet and not having a scale to check your progress, or going to the doctor and not having your temperature taken. Feedback is important in our daily lives, and industry benefits by it, too.
Generally speaking, feedback, or monitoring, is a tool that provides relevant information on a timely basis as to whether things are working as they were intended to. It’s an indispensable tool within the food manufacturing industry. Without it, entire plants could be erected exposing workers to injury and consumers to bacteria-laden products. It’s just plain common sense to monitor activities all along the way, starting with the design process. Now let’s see how monitoring is applied in HACCP Design Principle No. 4. Principle 4: Establish critical control point monitoring requirements. – Monitoring activities are necessary to ensure that the critical limits established at each critical control point (CCP) established under Principle 3 discussed last week are working as intended. In other words, if the engineer identifies significant risks in the design of a piece of food processing equipment and establishes critical limits at CCPs to eliminate the risk, then the CCPs must be monitored to see if the risk has actually been eliminated. Monitoring can and should be performed in food manufacturing plants by a variety of personnel, including design engineers, the manager of the engineering department, production line workers, maintenance workers, and quality control inspectors. For example, engineering department procedures in a food manufacturing plant should require the engineering manager to monitor CCPs established by the staff during the design of food processing equipment and production lines. Monitoring would include reviewing the design engineer’s plans, checking things like assumptions made concerning processes, calculations, material selections, and proposed physical dimensions. In short, monitoring should be a part of nearly every process, starting with the review of design documents, mechanical and electrical drawings, validation test data for machine prototypes, and technical specifications for mechanical and electrical components. This monitoring would be conducted by the engineering manager during all phases of the design process and before the finished equipment is turned over to the production department to start production. To illustrate, suppose the engineering manager is reviewing the logic in a programmable controller for a cooker on a production line. She discovers a problem with the lower critical limits established by her engineer at a CCP in the design of a cooker temperature control loop. You see, the time and temperature in the logic is sufficient to thoroughly cook smaller cuts of meat in most of the products that will be made on the line, however the larger cuts will be undercooked. The time and temperature settings within the logic are insufficient to account for the difference. This situation illustrates the fact that monitoring does no good unless feedback is provided with immediacy. In our example, the design engineer who first established the CCP and the critical limits was not informed in a timely manner of the difference in cooking times that different size meats would require, resulting in the writing of erroneous software logic. Fortunately, continued monitoring by the engineering manager caught the error, leading her to provide feedback about it to the design engineer, who can then make the necessary corrections to the software. Next week we’ll see what design engineers do with the feedback they’ve received, as seen through the eyes of HACCP Principle 5, covering the establishment of corrective actions.
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Food Manufacturing Challenges – HACCP Design Principle No. 1
Sunday, October 16th, 2011| Imagine a doctor not washing his hands in between baby deliveries. Unbelievable but true, this was a widespread practice up until last century when infections, followed by death of newborns, was an all-too common occurrence in hospitals across the United States. It took an observant nurse to put two and two together after watching many physicians go from delivery room to delivery room, mother to mother, without washing their hands. Once hand washing in between deliveries was made mandatory, the incidence of infection and death in newborns plummeted.
Why wasn’t this simple and common sense solution instituted earlier? Was it ignorance, negligence, laziness, or a combination thereof that kept doctors from washing up? Whatever the root cause of this ridiculous oversight, it remains a fact of history. Common sense was finally employed, and babies’ lives saved. The same common sense is at play in the development of the FDA’s Hazard Analysis Critical Control Point (HACCP) policy, which was developed to ensure the safe production of commercial food products. Like the observant nurse who played watchdog to doctors’ poor hygiene practices and became the catalyst for improved hospital procedures set in place and remaining until today, HACCP policy results in a proactive strategy where hazards are identified, assessed, and then control measures developed to prevent, reduce, and eliminate potential hazards. In this article, we’ll begin to explore how engineers design food processing equipment and production lines in accordance with the seven HACCP principles. You will note that here, once again, the execution of common sense can solve many problems. Principle 1: Conduct a hazard analysis. – Those involved in designing food processing equipment and production lines must proactively analyze designs to identify potential food safety hazards. If the hazard analysis reveals contaminants are likely to find their way into food products, then preventive measures are put in place in the form of design revisions. For example, suppose a food processing machine is designed and hazard analysis reveals that food can accumulate in areas where cleaning is difficult or impossible. This accumulation will rot with time, and the bacteria-laden glop can fall onto uncontaminated food passing through production lines. As another example, a piece of metal tooling may have been designed with the intent to form food products into a certain shape, but hazard analysis reveals that the tooling is too fragile and cannot withstand the repeated forces imposed on it by the mass production process. There is a strong likelihood that small metal parts can break off and enter the food on the line. Next time we’ll move on to HACCP Principle 2 and see how design engineers control problems identified during the hazard analysis performed pursuant to Principle 1. ____________________________________________
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Food Manufacturing Challenges – Avoiding Contamination
Sunday, October 9th, 2011| Perhaps you’ve heard of the non-reciprocal wine and sewage principle. I’m not sure where it originated, but it states that if you add a cup of wine to a barrel of sewage, you still get a barrel of sewage. No brainer, right? Well, consider the flip side. If you add a cup of sewage to a barrel of wine, you also get nothing more than a barrel of sewage. In other words, a small amount of contamination goes a long way.
The premise of this principle also applies within the food manufacturing industry. If you were to add uncontaminated food to garbage, you would just get more garbage, and if you add garbage to food… well, you get it. The term garbage can encompass an endless variety of contaminants, such as broken glass, metal shavings, nuts, bolts, plastic fibers, grease, broken machine parts, errant human body parts, and on and on. Although the FDA does allow for certain levels of natural contaminants, like insect parts and rodent hairs, consumers are never pleased when undesirable elements enter their food supply. It could even be dangerous. When design engineers create food processing machinery and production lines, they must be on the lookout for potential risks of contamination hazards. They must also provide a quick means of mitigation, before contaminants can enter into commercial production. A systematic approach provides the best means of addressing these needs, allowing for a pre-emptive method to ensure food safety. Checklists and procedural policy set in place for these reasons will enable design engineers to identify, assess, and control risks before they turn into hazards. This is where Hazard Analysis Critical Control Point (HACCP) planning comes in. To address these needs, the FDA has set up the HACCP (pronounced, “hass-up”) system, defined as “…a management system in which food safety is addressed through the analysis and control of biological, chemical, and physical hazards from raw material production, procurement and handling, to manufacturing, distribution and consumption of the finished product.” HACCP is the outgrowth of FDA current Good Manufacturing Practices (cGMP), which are set out in the Code of Federal Regulations pertaining to commercial food processors and manufacturers, Title 21, Part 110, entitled, “current Good Manufacturing Practice in Manufacturing, Packing or Holding Human Food.” Every commercial food processor, regardless of size, must implement a cGMP/HACCP quality assurance program to comply with these regulations. HACCP is a proactive strategy where hazards are identified, assessed, and then control measures developed to prevent, reduce, or eliminate potential hazards. A key element of HACCP involves prevention of food contamination during all phases of manufacturing, and way before the finished food product undergoes quality inspection. This strategy extends into the food manufacturing equipment and production line design process as well. Next time we’ll continue our look at HACCP and how its seven principles are used by design engineers to prevent food product contamination.
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Food Manufacturing Challenges – Cleanliness
Monday, October 3rd, 2011| My wife and I have an agreement concerning the kitchen. She cooks, I clean. Plates and utensils are easy enough to deal with, especially when you have a dishwasher. Pots and pans are a little more challenging. But what I hate the most are the food processors, mixers, blenders, slicers and dicers. They’re designed to make food preparation easier and less time consuming, but they sure don’t make the clean up any easier! Quite frankly, I suspect the time involved to clean them exceeds the time saved in food preparation.
Food processors on a larger scale are also used to manufacture many food products in manufacturing facilities, and being larger and more complicated overall, they’re even more difficult to clean. For example, I once designed a production line incorporating a dough mixer for one of the largest wholesale bakery product suppliers in the United States. A small elevator was required to lift vast amounts of ingredients into a mixing bowl the size of a compact car. Its mixing arms were so heavy, two people were required to lift them into position. It was also my task to ensure that the equipment as designed was capable of being thoroughly cleaned in a timely and cost effective manner. Food processing machinery must be designed so that all areas coming into contact with ingredients can be readily accessed for cleaning. And since most of the equipment you are dealing with in this setting is far too cumbersome to be portable, the majority of the cleaning must be cleaned in place, known in the industry as CIP. To facilitate CIP, commercial machinery is designed with hatches and special covers that allow workers to get inside with their cleaning equipment. Small, portable parts of the machine, such as pipes, cutting blades, forming mechanisms, and extrusion dies, are often made to be removable so that they can be carried over to an industrial sized sink for cleaning out of place, or COP. These potable machine components are typically removable for COP without the use of any tools and are fitted with flip latches, spring clips, and thumb screws to facilitate the process. Everything in a food manufacturing facility, from production machinery to conveyor belts, is typically cleaned with hot, pressurized water. The water is ejected from the nozzle end of a hose hooked up to a specially designed valve that mixes steam and cold water. The result is scalding hot pressurized water that easily dislodges food residues. Bacteria doesn’t stand a chance against this barrage. The water, which is maintained at about 180°F, quickly sterilizes everything it makes contact with. It also provides a chemical-free clean that won’t leave behind residues. Once dislodged, debris is flushed out through strategically placed openings in the machine which then empty into nearby floor drains. As a consequence of the frequent cleanings commercial food preparation machinery requires, their parts must be able to withstand frequent exposure to high pressure water streams. Parts are typically constructed of ultra high molecular weight (UHMW) food-grade plastics and metal alloys such as stainless steels, capable of withstanding the corrosive effects of water. And since water and electricity make a dangerous combination, gaskets and seals on the equipment must be tight enough to protect against water making its way into motors and other electrical parts. Next time we’ll look at how design engineers of food manufacturing equipment use a systematic approach to minimize the possibility of food safety hazards, such as product contamination. ____________________________________________
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