an exploratory study of manufacturing strategy of packaging product-manufacturing companies in
FSMS -Food Packaging Manufacturing
Transcript of FSMS -Food Packaging Manufacturing
FOOD SAFETY MANAGEMENT SYSTEMS FOR FOOD PACKAGING
MANUFACTURINGVive la Différence
Tom DunnFlexpacknology LLC
How do These Relate to Each Other ?
Food Safety Management System
Say what
you do
Do as planned
Record as done
Actual vs.
Expected
Act on varianc
es
Food Packaging Manufacturing
•Bottles•Cans•Bags•Boxes•Trays•Liners
Food safety and packagingChoking hazard: film wrapper
Nauseating odor: box liner
Illegal chemical: brick box
glass shards: metal-capped jar
Carcinogen: film lamination
AgendaPoints to cover
• FSMS for manufacturing food packaging• Good manufacturing practices
• Rules of management systems• Cost of food safety
• Enforcement of management systems
• Expectations of management systems
@ 40,000 feet
Public Health
Supply chain
integrity
Societal Optimu
m
I. FSMS for manufacturing food packaging• Safe Materials
• Compositionally fit for:• Food type• Use Conditions
• Safely made• Good manufacturing
practice (gmp)
• Suitable purity• RM supplier FSMS• Internal
storage/handling
Safe materials (relative to food & use)
Safely made (with a bias toward safety)
•Good manufacturing practice
1. Establishment2. Control of Operations3. Maintenance & cleaning4. Hygiene5. Transportation6. Product Info & awareness7. Training
•GMPs
• All have same basic structure
• Details depend!• What is being manufactured?
• Hazard assessment• Risk analysis• “Prerequisite programs (PRPs)
Good manufacturing practices
• Basic structure: stays the same
• Details: relative to product manufactured
• Compare to ‘speed limit”
Good manufacturing practices
• Basic structure: stays the same
• Details: relative to product• Safety hazards to Product?• Practice(s) mitigate risk?• Reduce frequency of risk
occurring• Reduce severity of actual
event
Manufacturing facility
GMP mitigatio
n
Hazards to
product
Mitigated
product hazards
HACCP•HA
• Hazard Analysis• Biological hazards• Chemical hazards• Physical hazards
• Do GMPs satisfactorily mitigate hazard?
•CCP• Remaining hazard = unacceptable
risk?• Critical Control Point
Control limitsMonitoring procedureCorrective actionVerificationRecordkeeping
Manufacturing facility
GMP mitigatio
n
Hazards to
product
Mitigated
product hazards
Incoming resin hazards SAFETY HAZARD CATEGORYBiological?Chemical?Physical?
GMP INDICATED? Pathogens killed at extrusion temperatures. *Regulatory composition Contaminates filtered out at screen pack* Good hygiene practices still needed post-
extrusion
Suitable purity (supply chain integrity)
Substance
Raw material
Article
FoodSupplyChain
II. Management systems rulesCommand & control model Contract law model
Rules of management systemsCommand & control model Contract law model
Rules of management systemsFirstly, do no harm Comply with all relevant
laws
Command & control vs. Contract models
Global Food Safety Initiative•Reduce food safety risks with equivalence and convergence among effective FMSs.
•Manage global food system cost: eliminate redundancy and improve operational efficiency
•Provide international stakeholder platform for collaboration, knowledge exchange & networking
Hippocratic Oath• Firstly, do no harm• What is the positive this
does? …Avoids food borne illness
and related disease
Global Food Safety Initiative•A program of The Consumer Goods Forum (Paris)
•GOVERNANCE: major global retailers, manufacturers and food service operators
•VISION: “Safe food for consumers everywhere”.•MISSION: to provide continuous improvement in food safety management systems to ensure confidence in the delivery of safe food to consumers worldwide
•METHOD: Technical working groups develop and maintain “Guidelines” in order to determine equivalency between FSMSs (“Benchmarking”
Contract law model for societal optimum
Public health
Supply chain integrity
Econ
omic
System to deliver diverse/low cost goods to public
Envi
ronm
en tal
Material & energy efficient Delivery system
Socia
l
Reliably safe & nutritious food
Sustainable Business Model
Retailers: “biggest skin in the game”
Supplier Processor Retailer Consume
rs
Value Added
Elements of food safety costs • Failure
• Falls short of specification• Internal: before delivery• External: after delivery
• Appraisal• Product testing• Quality control
• Prevention• Compliance capability• Investment
Examples of safety costs
• Failure• Internal
• Down-grade• Re-work• Re-inspect
• External• Handle complaints• Manage recalls• Lose goodwill
• Appraisal • Inspect
• Raw material• Work in process
• Measure• Equipment capital• calibration
• Prevention• Train• Maintain
preventatively • Houseclean• Operate capable
process in control
Packaging: liability multiplier
70 x Value AddedMulti-layer film:$100 k
Filled packages:$4 million
Retail packages:$7 million
III. Management systems enforcement
Securities and Exchange Commission
Certified Public Accountants
Management systems enforcement
Securities and Exchange Commission
Certified Public Accountants
• Roles• protect investors• maintain fair, orderly, & efficient
markets• facilitate capital formation.
• Roles• accounting• auditing• financial reporting• internal controls • legal compliance.
Safefood
Supply chain
integrity
Public well being ($ , )
Complimentary food safety roles
FDA FSMS Auditor
IV. Management systems expectations1. Scheme owners “benchmark” their system to the GFSI guidelines
1. BRC2. SQF3. IFS4. FSMS 22000
2. “Certifying Bodies” (CB) obtain license to audit to the system1. Auditors have specific training to the scheme and for auditing activities2. Auditors have relevant industry experience and/or training
3. Manufactures hire a CB to audit their system1. “Evidence”: ongoing management of food safety system practices,
elements, commitment2. Much more than housekeeping inspection
Management systems expectations•One world. One standard, One annual audit
•Employee awareness of role in food supply chain•Lower failure and appraisal safety costs•Higher probability of distributing low/no risk product to market
•Fewer market recalls
ConclusionFood packaging can pose risks to foodCommand & control model has limits$takes can be highContract model complements command & control Contract model targets continuous improvement3rd party certification compares to financial auditAlign organization toward food safety
Public Health
Supply chain
integrity
Societal Optimu
m
Thank you!
Questions?