Different Food Safety and Quality Management Tools to Accomplish Food Safety

Devastotra Poddar

Department of Nutrition

Different Food Safety and Quality Management Tools to Accomplish Food Safety

• Food safety always talks about the safe food that should be free from unintentionally added components like contaminants (physical, chemical, and biological contaminants) or intentionally added components like adulterants.
• Both adulterants and contaminants can make the food unsafe for human consumption and can cause health hazards .
• Foodborne threats like microbial and chemical contaminants can continuously associate with public health risks and can lead to a decrease in food trade with significant financial losses and social costs.
• Controlling of entry of contaminants into the food chain is a difficult task. It may enter at any point from the harvesting stage to the consumption stage.
• Several issues are responsible for contaminant/hazard entry into a food production process flow, which include poor sanitary practices, poor handling practices, poor manufacturing practices, poor transportation and storage practices, and usage of contaminated primary commodities like raw materials, the absence of proper control and preventive measures at each and every stage of the food chain, etc.

Different Food Safety and Quality Management Tools to Accomplish Food Safety

• Supplying/exporting of poor quality and contaminated food to foreign countries may lead to the cancellation of consignments and it creates a big barrier to trade, reflecting decreases in foreign exchange.
• In order to facilitate the global trade of Indian products and making their availability in major leading retailer chains, food safety industry standards play a key role in producing the product safely in a consistent manner.
• In 2006, Food Safety and Standard Authority of India (FSSAI)—a regulatory body under the Ministry of Human Health and Welfare—came into force to implement the science-based standards to provide safe food throughout the food supply chain for customer consumption. Initially India is supported by different sector-based acts.

The Emerging Scenario of Contaminants and Residues Related to Food Safety

• These days food safety has already become a global concern. Chemical residues and biological contaminants are constantly pushed to cause food safety risks and are also continuously disrupting economic growth and international trade.
• Food safety regulators all over the globe have shown an increased concern toward antibiotic residues, pesticides, and biological contaminants because of rampant of incidents happened during food exporting.

The Emerging Scenario of Contaminants and Residues Related to Food Safety

• For instance, a recent issue happened to be the ban on import of Indian Alphonso mango in the European Union (EU) temporarily because of pest infestation which resulted in the development of trade barriers for exporters (EU bans Indian Alphonso mangoes, 4 vegetables from May 1, 2014).
• Another case of ban happened is with the exporting of Indian honey to the EU because of high doses of antibiotic application for the purpose of beekeeping which resulted in high levels of antibiotic residues in honey compared to the set standards.
• Upon shipment to EU and followed by inspection with those food safety investigators it has been found that the presence of cross-contaminated antibiotics in honey is at higher levels compared to those EU norms. In addition, they also found lead contamination in that respective shipment. Hence, it leads to the cancellation of consignment and now EU is showing no more interest in accepting Indian honeys (Schneider, 2011).

The Emerging Scenario of Contaminants and Residues Related to Food Safety

• Similarly, after the ban of Indian Alphonso mango temporarily by the EU another product under examination for banning by the importers is Indian green chilies by Saudi Arabia.
• They recently expressed their concern about the quality products they are importing from India to Agricultural and Processed Food Products Export Development Authority (APEDA) stating that as Indian green chilies are contaminated with unacceptable levels of pesticide residues, which is not complying with their norms.

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The Emerging Scenario of Contaminants and Residues Related to Food Safety

• The global presence of pesticide and antibiotic residues are always under stringent regulation. In India, FSSAI is the technical standard setting body and it establishes values of maximum residue levels (MRLs) with the help of the Medical Toxicology Unit of Central Insecticides Board & the Registration Committee (CIB&RC). Once the values of MRLs are established, they will be incorporated into the Food Safety and Standard Regulation.
• Before exporting the products to countries like the EU, Australia, United States, and other developed countries several quality evaluations have to be undertaken at the direction of their specified quality limits.

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Hazard Characterisation

What is the safe dose/intake of a chemical?

• Need to identify the critical effect in the safety data
• Effect should be relevant for man

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• No Observed Adverse Effects Level (NOAEL)

- Dose that produced no adverse effects in the study.

- Identifying the critical effect in the most sensitive species

NOAEL: Highest data point at which there was not an observed adverse effect.

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LOAEL: Lowest data point at which there was an observed toxic or adverse effect.

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Dose in mg/kg body weight per day

Frequency of response

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Threshold Effects

Exposure Assessment

median lethal dose, LD₅₀ of a toxin, radiation, or pathogen is the dose required to kill half the members of a tested population after a specified test duration

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Salt LD-50 – 180 gm/day

Salt ADI – 6 gm/day

Humans can get exposed to various chemical substances via oral route (i.e, eating food, drinking groundwater, hand to mouth transfer). It is necessary to determine the maximum amount of a chemical that can be ingested on a daily basis to protect human health. That is why we need to calculate the Acceptable Daily Intake (ADI). For pesticide residues and food contaminants, ADI may also be called Tolerable Daily Intake (TDI). ADI is  defined as the maximum amount of a chemical that can be ingested daily over a lifetime with no appreciable health risk.

The ADI is normally derived from the lowest  no observed adverse effect level (NOAEL) determined from long-term animal (in vivo) studies. The ADI is calculated by applying a safety or uncertainty factor, which is commonly 100, to the NOAEL obtained from the most sensitive test species. The 100-fold safety factor is based on the need to take into account both the differences in species and differences in toxicokinetics and toxicodynamics.

• ADI = Long-term NOAEL (lowest value)/100

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The Emerging Scenario of Contaminants and Residues Related to Food Safety

• The World Health Organization’s (WHO) recently released data show that contaminated food is associated with deaths of nearly 2 million people annually (WHO campaigns, 2015).
• Salmonella is a pathogen which causes vomiting, nausea, and diarrhea in humans and its contamination is frequently associated with fresh produces (Lawley, 2013).
• A case of under scan of the ban is linked with Indian betel leaves because of consistent reports of salmonella contamination since 2011 by the EU Rapid Alert System for Food and Feed (RASFF).

The Emerging Scenario of Contaminants and Residues Related to Food Safety

• Before shipping the produce to exporting countries it should be ensured that strong microbiological compliance is required in accordance with the demands of the exporting country.
• Hence, it is recommended that before forwarding a shipment to foreign countries it is important to understand the quality norms set by the exporters, their country regulatory requirements, product hygiene, quality and choosing the right scientific testing service to know the analytical status of the commodity and microbial compliance, then only it allows the food industry to supply a food product with high-quality standards that constantly meet their demands.

Different Food Safety Certification Schemes, Quality Systems, and Other Popular Standards

• Globalization of a food supply chain requires an organization to be certified by different international standards.
• Crafting the following basic food safety requirements and standards will help us in building the technical proficiency in food safety risk management and improves the quality.
• The following are the generic controls and standards considered moderately to build quality into the product in order to improve food safety and increase consumer confidence toward the brand:
• 1. Prerequisite programs (PRPs). 2. Hazard analysis and critical control point (HACCP). 3. Quality management systems (QMS): ISO 9001. 4. Food safety management systems (FSMS): ISO 22000. 5. Laboratory management system: ISO 17025. 6. Retailer standards. 7. Technical barrier for exporting.

Prerequisite Programs (PRP)

• These are the basic requirements for a food-related sector.
• Their scope and concept is wide and they cover and integrate a set of activities such as good manufacturing practices (GMP), good hygienic practices (GHP), standard operating procedures (SOP), (sanitation standard operating procedures (SSOPs), and good handling practices (GHP) to ensure the safety of food.
• All these sets of practices and activities are a part of the quality assurance system.
• Before implementing a HACCP system in a food industry, they have to strengthen their PRPs effectively at a place. Following these practices and activities will ensure them in producing the product consistently in a controlled manner.

What is HACCP

• HACCP is a acronym used to describe the hazard analysis and critical control point system.
• HACCP concept is a systematic approach to food safety management based on recognized principles, that aim at identifying the hazards that are likely to occur at any stage of the food supply chain and put into place the controls that will prevent them from happening.
• HACCP is a very logical and covers all stages of food production from growing stage to the consumer, including all the intermediate processing and distribution activities.

Where did it come from?

• HACCP concept originated in the early 1960’s by the Pillsbury company working along with the national Aeronautic and Space Admintration (NASA) and the US army laboratories.
• It was based on the engineering concept of failure, mode effect analysis (FMEA), which looks at what could potentially go wrong at each stage in an operation and puts effective control mechanism in place.
• This was adapted into a microbiological system in the early days of the US manned space programme to ensure the safety of food for astronauts, to minimize the risk of a food poisoning outbreak in space.

Holding Tube- Pasteurization temperature- CCP

A CCP is a step at which ‘control can be applied and is essential to prevent or eliminate a food safety hazard or reduce it to an acceptable level’ (Codex 2009b). CCPs relate to control of significant food safety hazards only.

Hazards

Preparation and planning

Principle 1 Conduct Hazard Analysis

Principle 2 Determine the CCP

Principle 3 Establish the Critical Limit

Principle 4 Establish System to monitor Control of the CCP

Principle 5 Establish corrective actions to be taken when the monitoring system indicates that a particular CCP is not under control

Principle 6 Establish procedures for verification to confirm that HACCP system will control the hazards of concern.

Principle 7 Establish Documentation concerning all procedures and records appropriate to these principles and their application

HACCP Records

Monitoring Records

Audit

CCP Records Reviews

Training

HACCP Plan

Process Flow Diagram

HACCP Control Chart

HACCP Team List

Product Description

Hazard Analysis Chart

HACCP SYSTEM OVERVIEW

HACCP System Overview

An effective HACCP System needs to be planned, studied, implemented verified and maintained in a logical systematic way.

HACCP in the context of other management systems.

Business management practices are the day-to-day “business” skills that when thinking HACCP as a project, will be invaluable in making sure that the work involved is carried out efficiently and effectively, example. Leadership,

Management commitment, project management, process mapping, data analysis, problem solving, auditing, team skills, record keeping and documentation.

Prerequisite programs (PRP’s) are the GMP, GHP’s that reputed food business operator would be adhering to ensure that safe, wholesome food is provided to the consumer.

Quality management System(QMS)- acts as a framework withing which any process activity can be managed including HACCP. All of this needs to operate within a strong business food safety culture.

Quality Management Systems (QMS): ISO 9001

• This system was designed to meet the customer need, satisfaction, and requirements in terms of quality.
• In order to improve the performance of an organization, continual improvement is considered as a key quality parameter which will bring you out when the organization is implemented with QMS.
• If an organization is supported with ISO 9001 it means that it is committed to deliver quality service to the customer.
• Generally, ISO 9001:2008 sets out quality requirements according to the customer expectation and requirements.
• Recently, ISO 9001:2008 underwent revision and launched ISO 9001:2015 with the latest upgradations in order to maintain consistency and make the organization more competent.

WHY ISO 9001?�

• ISO 9001 sets out the criteria for a quality management system.
• It can be used by any organization, large or small, regardless of its field of activity.
• This standard is based on a number of quality management principles including a strong customer focus, the motivation and implication of top management, the process approach and continual improvement. 
• Using ISO 9001 helps ensure that customers get consistent, good-quality products and services, which in turn brings many business benefits.

Quality management principles

• “Quality management principles” are a set of fundamental beliefs, norms, rules and values that are accepted as true and can be used as a basis for quality management.
• The QMPs can be used as a foundation to guide an organization’s performance improvement.
• The seven quality management principles are: QMP 1 – Customer focus; QMP 2 – Leadership; QMP 3 – Engagement of people; QMP 4 – Process approach; QMP 5 – Improvement; QMP 6 – Evidence-based decision making; QMP 7 – Relationship management.
• These principles are not listed in priority order. The relative importance of each principle will vary from organization to organization and can be expected to change over time.

Food Safety Management Systems (FSMS): ISO 22000

• ISO standards help organizations by promoting the quality and safety of food and also by increasing the efficiency of the food supply chain from farm to table by managing or eliminating food safety risks.
• Globalization of food chains leads to increased demands in the safety and quality of the supplied food from farm to consumer.
• Consequences of exporting unsafe foods are more severe and are concerned with brand reputation and financial loss due to food recalls.
• World-wide recognized requirements and international standards are required these days in order to guarantee product safety along the food chain.

Food Safety Management Systems (FSMS): ISO 22000

• Food safety management standards help in identifying and controlling the potential hazards in the food chain.
• In order to ensure food safety, ISO 22000 merged with HACCP and with other preventive procedures. ISO 22000 standards undergo reconsideration and revision at least once in every 5years.
• The ISO working group collects the information about the existing gaps by considering experts, modifications, latest updates, and requirements which will be incorporated in the next revision.

Overview of ISO 22000-associated documents

1. Specific requirements for an organization to implement food safety management systems.

2. Organizations commitment toward controlling food safety hazards in order to produce safe food for human consumption.

3. Establishing effective traceability system along the feed and food chain

4. Implement, design, and maintain prerequisite programmes (PRPs) for food Manufacturers, catering, farming , food packaging industries

5. Helps in managing food safety risks along food supply chain.

6. Procedures about how to conduct audit and gain certification from bodies by fulfilling ISO 22000 requirements.

Laboratory Management System: ISO/IEC 17025:2005

• Food safety parameters and analytical challenges involved in the ascertaining food safety risks.
• Performing and documenting analytical studies is one of the major requirements to ensure food safety by continuously meeting the country’s own regulatory requirements and the exporting country’s regulatory demands, crossing obstacle trade barriers like SPS (Sanitary and Phytosanitary Measures Agreement), and by giving food safety assurance to the consumer

ISO/ IEC 17025:2005 accreditations

• Meeting these demands need state-of-the-art laboratory infrastructure. In the quality control division, testing of a product and calibration and validation of the equipment and parameters are the two key important aspects for successful quality assurance.
• To increase the confidence toward their product testing, most of the suppliers, retailers, and even food manufacturers supported by the quality lab always choose testing and calibration results from laboratories which have ISO/ IEC 17025:2005 accreditations.

ISO/ IEC 17025:2005 accreditations

• ISO/IEC 17025 is a general requirement for a testing and calibration laboratory to show their technical capability and competency toward their analyses .
• Data or results generated by ISO 17025-accredited laboratories are more readily accepted because of the accuracy in their results.
• For a laboratory to undergo formal recognition with ISO17025:2005, it has to maintain the documented quality management system, technical management in order to show their competency and administrative operations.

ISO/ IEC 17025:2005 accreditations

• In India, the National Accreditation of Board of Laboratories (NABL) is the third-party accreditation body.
• If any laboratory wants to be accredited by NABL, it has to prove compliance with the entire clause of ISO 17025:2005.
• Moreover, international trade always demands laboratory-based data for their exporting product and also at the same time the laboratory has to be recognized by the importing country to meet their technical compliances.
• This concern leads to the implementation of the Mutual Recognition Arrangements (MRAs) between the accreditation bodies of other countries.
• Hence, MRAs will act as a channel for international trades and also increase the cross-border stakeholder confidence and the acceptance of recognized compliance assessment bodies

Retail Standards

• In a food supply chain generally the food product moves from manufacturers to distributors, distributors to wholesalers and from wholesalers to retailers and finally from a retailer the product will directly reach to the consumer.
• During the journey, the product may lack its safety, quality, and hygiene due to extreme storage conditions and improper handling results in the entry of various kinds of contaminants which in turn influences the retailer’s brand value.
• By keeping this point in view, the retailers started demanding their food product manufacturers/suppliers to follow certain food safety and quality standards in order to bring out safe and quality food and they also started auditing toward their respective manufacturers/suppliers, so that they believe in their abilities to meet their needs and requirements.

Retail Standards

• These days compared with the suppliers, the retailers are becoming more powerful and thus these kinds of reasons lead to the retailers to create their own brand standard to guarantee food safety across the supply chain and to preserve their own brand forever in the market.
• To meet their requirements, the Global Food Safety Initiative (GFSI), a nonprofit organization, was established in 2000 by a group of food safety experts from different disciplines to increase the safety of food and enhance customer trust.
• The GFSI recognized standards are the British Retail consortium (BRC), the Safe Quality Food (SQF) code, the International Featured Standard (IFS), FSSC 22000, Global GAP, and many more.

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