Giáo trình quản lý chất lượng nhà máy thực phẩm và hoá học Chương 4

FOOD SAFETY AND QUALITY LEGISLATION GMP’s - Good Manufacturing Practice The minimum legal demand of safety for aseptic food processing  HACCP - Hazard Analysis and Critical Control Poi

QUALITY ASSURANCE IN A

FOOD MANUFACTURING PLANT

BY: DUY NGUYEN LONG, MSC, MBA, 18/OCT/2021 – CHAPTER 4

NỘI DUNG MÔN HỌC

CHƯƠNG 1

• Giới thiệu QLCL trongnhà máy hóa thực phẩm

• Thông tin cơ bản về hóa thực phẩm

• Vai trò của chất lượng trong nhà máy hóa thực phẩm

• Các mô hình QLCL hiện nay

• Xu hướng phát triển và định hướng nghề nghiệp

CHƯƠNG 2

• Khái niệm về an toàn thực phẩm

• Nhận diện các mối nguy trong ngành thực phẩm và

• Khái niệm chất lượng

• Các phương thức kiểm soát chất lượng

• Khái niệm quản lý chất lượng

• Các phương thức quản lý chất lượng trong nhà máy

• Các phương pháp, kỹ thuật và công cụ QLCL(Fish bone diagram, 5 Why, Is and Is Not, Thống kê, Brain storming, PDCA, 5S, FMEA, )

• Vai trò quản lý của nhà nước đối với hoạt động QLCL

• 30% thảo luận nhóm và trình bày

• 60% thi cuối khóa (trắc nghiệm và tự luận)

CHƯƠNG 4

Tìm hiểu về các HT QLCL theo ISO 9001:2008, GMP, SSOP, HACCP, ISO 22000, FSSC 22000, SQF, IFS, QHP, QACP, QMS, TQM, BRC, Kosher, HALAL,…

Các phương pháp, kỹ thuật và công cụ QLCL

(Fish bone diagram, 5 Why, Is and Is Not, Thống kê, Brain storming, PDCA, 5S, FMEA, )

FOOD SAFETY AND QUALITY

GMP HACCP QACP ISO 9000 ISO 22000 FSSC 22000

https://www.researchgate.net/

FOOD SAFETY AND QUALITY LEGISLATION

 GMP’s - Good Manufacturing Practice

The minimum legal demand of safety for aseptic food processing

 HACCP - Hazard Analysis and Critical Control Points

A tool for assessment of HEALTH hazards, risks and identification of subsequent

critical control points

 QACP - Quality Assurance Control Points

A tool for assessment of SPOILAGE hazards, risks and identification of

subsequent critical control points

 ISO 9000 - International Organization for Standardization

Quality level is re-assured and documented

 ISO 22000

All above could be integrated in this Food Safety Management System

► FSSC 22000- Food Safety System Certification

Is used to control food safety risks

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GMPsHACCP

QACPISO 9000ISO 22000FSSC 22000

1/ Trình bày hiểu biết của bạn về Hệ thống IFS và SQF Cho ví dụ vài trường hợp áp dụng cụ thể.

2/ Trình bày hiểu biết của bạn về Hệ thống TQM Cho ví dụ vài trường hợp áp dụng cụ thể.

BÀI TẬP TÌNH HUỐNG

Giả sử nhà máy ABC (thành lập vào tháng 6/2019, có trụ sở tại KCN Vĩnh Lộc, Q.Bình Tân, Tp.HCM, chuyên sản xuất các nguyên liệu bột trà, bột kem không béo, hạt trân châu dạng viên bột, cung cấp cho các chuỗi kinh doanh trà sữa) đã xây dựng thành công hệ thống chất lượng ISO 9001:2015 vào tháng 12/2019, hệ thống GMP và SSOP vào tháng 03/2020 và hệ thống HACCP vào tháng 8/2020 Vào tháng 10/2021, Ban giám

10/2022

Một ban dự án gồm các trưởng bộ phận QA, QC, Sản xuất, R&D, Kho, Thu Mua, S.H.E., Kỹ Thuật, Hành chính nhân sự, Tài chính,… phụ trách tham gia và hoàn thành mục tiêu này Đóng vai trò của họ, các bạn cần chuẩn

bị và thực hiện những việc gì để đạt mục tiêu trên?

CÂU HỎI THẢO LUẬN NHÓM & BÀI TẬP TÌNH HUỐNG

Mỗi nhóm chọn ra 4 công cụ (tùy thích) trong số 18 công cụ được kể tên ở trang sau để làm bài thuyết trình ppt và file word

Các nhóm chỉ được trùng nhau 1-2 công cụ

Mỗi nhóm có 25 phút thuyết trình, với nhiều thành viên cùng trình bày.

Trình bày hiểu biết của các bạn về các công cụ, kỹ thuật trong quản lý chất lượng sau:

Gơi ý:

Cho ví dụ về 1 vài trường hợp cụ thể

BÀI TẬP NHÓM

Các công cụ, kỹ thuật trong quản lý chất lượng thường gặp:

iii Phương pháp “Is và Is Not”

iv Bảy loại công cụ thống kê về chất lượng

vi Chu trình PDCA

vii Phương pháp 5S

viii Phương pháp FMEA (Xử lý sai lỗi)

ix Phương pháp vẽ sơ đồ tư duy với MindMap và Sketchnoting

xi Phương pháp KAIZEN

xii Phương pháp sản xuất tinh gọn (LEAN MANUFACTURING)

xiii Phương pháp DMAIC và Six sigma

xiv Kỹ thuật phỏng vấn tại hiện trường bằng câu hỏi mở và câu hỏi đóng

xv Kỹ thuật tổ chức 1 cuộc họp hiệu quả

xvi Kỹ thuật tạo mục tiêu, lên kế hoạch, phân công công việc và giám sát mục tiêu, đánh giá kết quả xvii Phương pháp truy xuất nguồn gốc sản phẩm - ngược và xuôi (traceability)

xviii Quy trình tiếp nhận và xử lý khiếu nại khách hàng

BÀI TẬP NHÓM

Main drivers of food safety

► Consumer awareness boosting

food safety demands

► Food safety legislation and standards (FDA, EU,

Codex, ISO etc and local regulations) *

► Retailer’s Global Food Safety Initiative, GFSI and

*Link to Legislation Training Material for more information

Consumer quality

is more transparent Retailer quality requirements increasing

Difficult to contain/eradicate issues

Struggle to control production process

Quality control cost and competence

Regulatory pressure increasing

…and the implications for food quality and safety

OVERALL CHALLENGES OF LIQUID FOOD MANUFACTURING

Quality of incoming raw material difficult

to control

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TRACEABILITY

 Traceability is the process that enables you to see the movement of product, at the

smallest saleable units level, across the value chain

You can Track Forwards to see the intended route of the product towards to the point of care And you can Trace Backwards to identify the history of the transfers and locations of the products

WHAT IS TRACEABILITY?

All food producers need a traceability system to track:

 Origin of all ingredients

 Processing history of all products

 Distribution of all products

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TRACEABILITY IS BECOMING MORE IMPORTANT BY THE DAY

Distribution Warehouse/

raw material Processing line Packaging line

MES Suite

ERP

CLOUD

Foundation for traceability from gate to gate

Secure food safety and high, consistent product quality

Support fulfilment of regulatory and industry

Easily access data in interactive reports for fast, effective root cause

analysis and to demonstrate traceability in audits

Enable communication of credence attributes

to consumers

TRACK PRODUCTS AND ALL RELEVANT PROCESSING DATA

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FOOD SAFETY

AND QUALITY MANAGEMENT

LEGISLATION AND REGULATIONS

WHAT IS THE DIFFERENCE BETWEEN FOOD QUALITY AND FOOD

SAFETY?

/ 17

SmellFresh

Formulation

Nutritional Value

Ensuring consumers get high quality products they enjoy

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FOOD SAFETY

- The process of preventing food from risks and hazards, which can adversely affect the consumer

IMPORTANT NOTE

Food Safety (HACCP) is not the same as Food Spoilage (QACP)

Food can be spoiled and have NO health risk to the consumer

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Food safetyis - product produced safe for human consumption

Food quality is that the product produced

meet the required specifications and design

HOW DOES FOOD SAFETY HAPPEN?

LOCAL LEGISLATION

LOCAL LEGISLATION

 National and state/provincial authorities

 Define the Food Standards

 Provide the legally enforceable rules

E.g Food Act

 Defines requirements for food manufacturers

 Food companies must comply with the Food Standards

 Food companies must implement a food safety programme

 Enforcement of the rules

 Other authorities

 National testing authority, Import/export, fair trade legislation, etc.

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EXAMPLE OF LOCAL LEGISLATION (AUSTRALIA)

 Food Standards Australia and New Zealand (FSANZ)

 Develop the Food Standards Code

 Some parts shared between Australia and New Zealand

 No ability to enforce

 States and Territories

 Each has its own Food Act

 Food companies must comply with FSANZ Food Standard Code

 Food companies must implement a food safety programme

 Only sell safe and suitable food

 Food Authority

 Most states have a single authority covering paddock to plate

 Responsible for enforcement of food safety

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INTERNATIONAL FOOD SAFETY STANDARDS

HOW DOES FOOD SAFETY HAPPEN?

INTERNATIONAL FOOD SAFETY STANDARDS (EXAMPLES)

FSSC 22000 Standard

Global Red Meat Standard BRC Global Standard for Food Safety Safe Quality Food (SQF)

International Featured Standard (IFS) Food Standard

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Food Safety and QualityFood Safety

COMMON COMPONENTS OF INTERNATIONAL FOOD SAFETY STANDARDS

FSSC 22000, BRC, SQF, IFS,

etc.

Components

• Internal auditing programme

• HACCP based risk assessment for food safety hazards

• Pre-requisite programmes

• Suitable premises and equipment

• Records are maintained

• Statement to follow relevant local food legislation

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GLOBAL FOOD SAFETY INITIATIVE

 Benchmarking of International Food Safety

Standards

 Achieved by comparison of each standard against a

GFSI guidance document

 Objectives are to

 Encourage equivalence and convergence between the

standards

 Eliminate redundancy and improve operational efficiencies

 Develop competency and capacity building in food safety

 Create consistent and effective food safe systems

/ 27 Food Protection Support May20

MATERIAL IN FOOD CONTACT, A LEGAL DEMAND AROUND THE WORLD

TELLS YOU WHAT AND WHY, BUT NOT HOW…

FDAFood and Drug

Administration

EFSAEuropean FoodSafety Authority

MoHChina Ministry

of Health

Consequences if not fulfilling the legislation;

Withdrawal, sales stop Fines

Imprisonment Execution

XFDALocal Food & Drug Administration

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MATERIAL AND PARTS IN FOOD CONTACT

Intended use, is key – The selected article, material and component must

withstand impact of the food to be produced, including additives as well as

detergents and sanitizers to be used.

- Always secure the selected article, material and component are hygienically designed (if used for food processing and have safe approved material when used in food contact or indirect food

ALLERGEN LABELLING LEGISLATION

FOOD SAFETY PROGRAMMES

FOOD SAFETY PROGRAMMES

Local Legislation and

Food Safety Standards

Require food manufacturers

to have a Food Safety Programme

Define what a Food Safety Programme must address

Food Safety Programme

Food safety plans, procedures, specifications, methods and work instructions

Defines what an organisation will do

Records Records, reports, test results Evidence that procedures

were followed

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FOOD SAFETY PROGRAMME

Internal auditing programme HACCP based risk assessment for food safety hazards Pre-requisite programmes

Suitable premises and equipment Records are maintained

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PRE-REQUISITE PROGRAMMES

Calibration Cleaning Good Hygienic Practice Pest Control Approved Supplier programme

Maintenance Document Control Training Labelling Product Identification and Traceability Incoming material requirements Allergen management

Specific pre-requisite programme requirements are detailed within individual International Food Safety Standards

WHAT ABOUT CODEX ALIMENTARIUS?

CODEX ALIMENTARIUS

Promote uniformity in manufacture and supply of safe and wholesome food

Enable harmonisation of definitions and requirements for foods

Ensure fair practices in the food trade

Facilitate international trade

Reference material for development of national standards

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Provides a collection of standards, guidelines and codes of practice to:

CODEX ALIMENTARIUS

/ 37

General Principles of Food Hygiene (CAC/RCP 1-1969 (Rev 4 - 2003))

Provides foundation for ensuring food hygiene

Refers to “food safety”

and “suitability for consumption”

(= Food safety and food quality)

Recommends application of a HACCP-based approach as a means

to enhance food safety

There is no similar CODEX recommendation for enhancing food quality

FOOD SAFETY AND QUALITY MANAGEMENT

FOOD SAFETY AND QUALITY MANAGEMENT

Quality Management System

• Incorporates food safety and food quality

Food Safety

• Codex Alimentarius, Local legislation and International Food Safety Standards

What about Food Quality?

• There are no internationally accepted standards or guidelines that specifically address food quality

• There is no equivalent process to the HACCP concept for food quality

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SAFETY QUALITY FOOD (SQF) CODE

WHAT ABOUT FOOD QUALITY?

ISO 9000 series for

Many indicate a requirement to address food quality, but with limited detail

SQF Code

Food safety codes for primary production, manufacturing, storage and distribution, food packaging, retail and food service

Food quality code, comprehensive and based on HACCP

QACP

Approach for food quality

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FOOD SAFETY AND

QUALITY ASSURANCE MANAGEMENT

/ 44

Food Safety and Quality Management

2 Quality ingredients

Raw material

3 CIP and Cleaning

Food Allergen preventive Controls

4, Process Preventive Controls

CP and CCP

Food Safety Charts

5 Quality system in production

1 HAZARD ANALYSIS PREVENTIVE CONTROLS

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Principles of HACCP and QACP

/ 47

HAZARD ANALYSIS AND PREVENTIVE CONTROLS DETERMINATION

If a point is not a Food Safety CCP, But will spoil the product

It is a CP for your QACP programme

Intentional Contamination

HACCP

Food Defense

Product ControlProcess ControlInfrastructure Control

SAFE LEGAL QUALITY

Process failures and

controlsAdulteration

Risks EvaluationFood Fraud

Biological

Chemical

QACP

RISK ANALYSIS FOR FOOD SAFETY AND QUALITY

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Source

Causal Factors

Event (Risk)

CRITERIAProbability analysis

RISK ANALYSIS CONSIDERATIONS

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Supply Chain (in the provider)

•For raw materials or supplies that require control from the supplier

Prerequisite programmes

•The programmes aim to reduce the appearance of dangers and sources of risks, which affect the quality or safety of products.

Critical Control Points (Process)

•Process or stage with factors and variables to monitor, corrective actions, monitoring mechanisms, to prevent significant hazards from appearing above levels not required

Control Points (Process)

•Actions that focus on controlling the appearance of dangers and risks that are relevant

Could be extended to supplier and customer as control measures Critical limits and forms of monitoring must be defined.

In food management there are 4 approaches to reduce or eliminate a hazard that creates a risk

Exposure, coverage, resilience, etc.

RISK ANALYSIS

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Safety Legality Quality

Brand name Finance Business Consequence in:

HAZARD ANALYSIS AND PREVENTIVE CONTROLS

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Contamination, Chemical and Foreign bodies

Correct and certified material in food contact

Contamination, Chemical and Foreign bodies

/ 54

Understanding the risks associated with each can dramatically reduce:

Biological Chemical Physical Allergenic

Foodborne illness

Food quality deviations.

HAZARDS AND CONTAMINATION

/ 55

Define the difference between

a food quality contamination and

a food safety risk

Example:

Paper – QACP Glass - HACCP

MICROBIOLOGICAL QUALITY AND SAFETY

MICROBIOLOGICAL QUALITY AND SAFETY

Bacteria, health risk and food spoilage;

 The most common organisms that spoil low-acid food A few of these are foodborne pathogens

 A main part of microbiological problems in the food industry is related to food quality

 Some spoil high-acid food, although none of these are food

pathogens

 Some can form spores and some produce toxins and toxins is not affected by the kill step

GROWTH FACTOR: ACIDITY – KNOW YOUR MICROBIOLOGY!

Bacteria, special characteristics, gram negative;

 The Gram negative, which have a very thin cell wall and occur only as vegetative cells This group contains the great majority which are also able to multiply at refrigeration temperatures

 Very low resistance to desiccation, chemicals and heat

 Heat sensitive ~72C

 Usually spread by water

Food Safety Examples:

Salmonella

E coliShigella

Food Quality Examples:

Bacteria, special characteristics, gram positive;

 The Gram positive group, which has a thick, rigid cell wall By far the majority occur only as vegetative cells

 A small number of gram positive microorganisms can sometimes occur as spores

 Often withstands desiccation

 Low resistance to heat and chemicals However spores are very resistant to heat

 Usually spread by air, but also by water

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Food Safety, Examples:

Bacillus cereus (104)Strep faecalis

Staph aureus

Food Quality Examples:

Micrococcus

Lactobacillus

Bacillus, Strep, Staph, sp

MICROBIOLOGICAL QUALITY AND SAFETY