SMR Quality Control in F. Industry

8/14/2019 SMR Quality Control in F. Industry

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Quality Control inQuality Control in

Food IndustryFood Industry

Prof. S. M. ReddyProf. S. M. Reddy


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Food safety issues

Additives, colors and Antibiotics and other food additives

Fertilizers and other growing aids Irradiation Microbiological contamination Naturally occurring food toxicants Nutrition

Pesticides Pollutants Processing, packaging and labeling Tampering

Specific food safety concerns differ markedly and include:


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Types of adulterants

Type substances added

International adulterants Sand, marble chips, stones,

mud, other filth, chalk powder

water, mineral oil, harmfulcolors

Incidental adulterants Pesticide residues, tin from

can, droppings of rodents

larvae in food

Metallic contamination Arsenic, lead and

mercury from pesticides, water,

effluents from chemical

industries, tins and cans


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Incidental adulteration

Regular market surveys to warn people of dangerousbuildup of toxins in food

Stepping up the integrated pest management programmeto educate farmers about the judicious use of pesticides.No spraying should be done a week before harvest.

Promoting the control of pest using their naturalpredators.

Preventing industries from dumping poisonous effluents

Considering health costs while deciding pesticide policy. Use of safer pesticides like synthetic pyrethroides or

malathion.

Through washing of foods to get rid of much of toxins.

The incidental poisoning can be prevented by the following


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The poison chain: Sequence of

incidental adulterants in foods

Contamination begins when farmers use pesticides to protect crops.

The health department also sprays them to control malaria-causing

mosquitoes.

Residues remain for a long period after spraying

Cattle fodder and chicken feeds are affected.

Meat, fish, milk and egg get contaminated

More spraying is undertaken to prevent fungus and rodents from attacking

Stored grains. This further boosts the residue levels in foodstuffs.


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Sellers dip vegetables in pesticides to make them look fresh as well as

to preserve them. Oils and sweets are adulterated

with prohibited substances

Washing vegitables and other foodstuffs helps but cooking rarely

destroys toxic residues. When ingested, pesticides are absorbed by

the small intestine.

The fatty tissue distrubed throughout the body store these pesticides.

These can damage vital organs like heart, brain, kidney and liver


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Adulterated food Is or contains a poisonous or deleterious substances that may render

it injuries to health. (If the substances is present in the food naturally

and the quantity contained is not injurious, It is not consideredadulterated.

Is or contains any food of color additive deemed unsafe.

Is or contains any filthy, putrid or decomposed substance.

Is or contains any residue in excess of the established tolerances.

Is or contains any substance that increase bulk or weight.

Is prepared or packed under unsanitary conditions.

Is taken from any part of a diseased animal

Is packed in material that contains poisonous or injuries material.

Is prepared with a valuable constituent omitted.


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THE CODEX GENERAL

PRINCIPLES OF FOOD HYGIENE

Identify the essential principles of food hygieneapplicable throughout the food chain (includingprimary production through to the final consumer),to achieve the goal of ensuring that food is safe andsuitable for human consumption;

recommended a hazard analysis and critical point(HACCP)-based approach as a means to enhancefood safety;

Indicate how to implement those principles; and

Provide a guidance for specific codes which may beneeded for sectors of the food chain; processes;or commodities; to amplify the hygiene requirements

specific to those areas.


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Seven principles of HACCP

Analyze hazards: Potential hazards associated with a foodand measutes to control those hazards are identified. Thehazard could be biological, such as a microbe; chemical,such as a toxin; or physical, such as ground glass or metalfragaments.

Identify critical control points: These are points in a foodsproduction; from its raw state through processing andshipping to consumption by the consumer at which thepotential hazard can be controlled or eliminated.

Examples are cooking, cooling, packaging, and metaldetection.

Establish preventive measures with critical limits for eachcontrol point: For a cooked food, for example, this mightinclude setting the minimum cooking temperature and timerequired to ensure the elimination of any harmful microbes

Cont.,


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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 when monitoringshows that a critical limit has not been met-Forexample, reprocessing or disposing off food it the minimumcooking temperature is not met.

5. Establish procedures to verify that system is working properly-

for example, testing time and temperature recording devices toverify that a cooking unit is working properly

7. Establish effective record keeping to document the HACCPsystem. This would include records of hazards and theircontrol methods, the monitoring of safety requirements andaction taken to correct potential problems. Each of theseprinciples must be backed by sound scientific knowledge: forexample, published microbiological studies on time andtemperature factors for controlling food borne pathogens.


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Advantages: HACCP offers a number of advantages

over the current system. Most importantly

Focuses on identifying and preventing hazards fromcontaminated food

Is based on sound science

Permits more efficient and effective monitoring atgovernment level, primarily because the recordkeeping allows investigators to see how well a firmis complying with food safety laws over a periodrather than how well it is doing on any given day

Places responsibility for ensuring food safetyappropriately on the food manufacturer of distributor

Helps food companies compete more effectively inthe world market

Reduces barriers to international trade


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Importance of ISO

Because it makes good business sense (Especially from amarketing, product quality and financial point of view)

Because it is fast becoming a condition for doing business(Increasingly so and for many firms, non compliance to ISO

standards often means lost sales).

Because firms who are ISO registered often use it to gaincertain advantages over competitors who arent

Because evidence of compliance is becoming increasingly

visible. (It can be noticed that more and more companies aredisplaying the fact that they are ISO registered on theirbuilding and on their business letterhead)

Because customers generally perceive ISO registered firmsas being successful, competent and industry leaders


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Common benefits of ISO quality system

Error reduction resulting from better systematic inspection andtesting.

Error reduction resulting from increased employeeparticipation, involvement, awareness and systematicemployee training

Better products resulting from better design control. Improved productivity resulting from planning and teamwork.

Reduction in cost associated with failures Resolution of nonconformance and adoption of corrective and

preventive action in a systematic way Improved communications both internally an externally which

usually improves quality, efficiency, on time delivery andcustomer/supplier relations

Recognition of compliance by an unbiased organization! (Oneassessment by an accredited register usually satisfies thequality system requirements of many customers)


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ISO Standards are available

The standard Council of Canada (SCC) Tel:

(613) 238-3222 1-800-267-8220 Fax: (613) 995-

4564

The American National Standards Institute

(ANSI) Tel: (212) 642-4900 Fax: (212) 398-0023

From companies that are accrediated to do ISO

registrations or sometimes from industry specific

associations or public libraries.


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As per PFA, the food deemed to

be adulterated

1. The article sold by the vendor is not of the nature, substanceor quality demanded by the purchaser and is to his prejudice,or is not of the nature, substance of quality which purports ofis represented to be.

2. The article contains any substance which effects or if thearticle is so processed as to affect injuriously the nature,substance or quality there of.

5. Any inferior or cheaper substance has been substitutedwholly or the quality there of.

4. Any constituent of the article has been wholly of in partabstracted so as to affect injuriously the nature, substanceor quality there of.

Cont.,


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The article had been prepared, packed or kept underunsanitary conditions whereby it has become contaminated orinjurious to health.

The article consists wholly or in part of any filthy, putrid,disgusting, rotten, decomposed or diseased animal orvegetable substance or is insect infested of otherwise unfit forhuman consumption

The article is obtained from a diseased animal

The article contains any poisonous or other ingredient whichrenders its contents injuries to health.

The container of the article is composed, whether wholly or inpart of any poisonous or deleterious substances whichrenders its contents injurious to health

Cont.,


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1. Any coloring matter other than that prescribed in respectthere of and in amounts not within the prescribed limits ofvariability is present in the article.

3. The article contains any prohibited preservatives or

permitted preservatives in excess of the prescribed limits

12. The quality or purity of the article falls below the prescribedstandards or its constituents are present in quantities whichare in excess of prescribed limits of variability.


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Why IS/ISO 9000 family standards

certification of FA

It is identical to internationally accepted ISO family ofstandards for Quality Systems.

It helps in gaining a competitive edge in domestic as well asglobal market

For saving money-quality systems ensures efficient and soundprocedures;

For ensuring optimum utilization of plant and reducing scrap

and time consuming rework and repairs;

It is a tool to ensure consistent quality improvement apart fromachieving quality control/quality assurance;

Cont.


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It brings confidence to the customer

It makes the system transparent through quality records;

It increased consumer satisfaction through: Quality of

product, Timely delivery, Better services, and Speedycomplaint redressed.

It ensures higher productivity

Ir increases employee motivation and participation.


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BIS Licensing Agricultural produce processing and milling machinery

Agricultural tractors and power tillers Apiary industry

Bakery, confectionery and nutritious supplementsindustry

Crop protection equipment Dairy products and equipment

Drinks and carbonated beverages

Farm implements and machinery

Fish and fisheries products Food additives

Food analysis and nutrition Food hygiene

Cont.,


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Food Microbiology

Food grains, food grain industries and starches

Irrigation and farm drainage equipment and systems

Livestock feeds

Livestock husbandry equipment and systems

Oil and oilseeds

Pesticides

Pesticides residues analysis

Processed fruits and vegetables products

Slaughter house and meat industry

Soil quality and improvement

Spices and condiments

Stimulant foods

Sugar industry

Tobacco and tobacco products


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Prerequisites for grant of license

Filing the application in the prescribed Applicationform (FORM) by the manufacturer desirous ofobtaining the license. A license is granted forvariety of products covered under a given IndianStandard.

The forms along with application fee of Rs. 1000/-is required to be submitted to the Branch Officerunder whose jurisdiction the manufacturing unit islocated.

Overseas applicant may approach the Director,Central Marks Department at BIS Head Quarters,New Delhi

Cont.,


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The following additional documents are required

to be submitted with the application

Location map of factory and factory layout Documentation authentication the premises of

manufacture List of manufacturing equipment and testing facilities

available

Scheme or testing and inspection in use, or anyproposed to be used, together with an undertaking tofollow the Scheme approved by BIS after grant oflicense

An undertaking to pay the prescribed marking fee from

the date of grant of license An undertaking to follow all terms and condition ofgrant of license and to suspend marking withimmediate effect in the event of suspension orcancellation of license

A flow chart describing the sequence of production andinspection stages.


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Scheme of testing and inspection

Marking to be applied on the product and the method ofapplying the Standard Mark

Definition of control unit

The levels of control unit wise

Frequency of sampling and tests on raw material, in processmaterials and finished products

Directions to licensees in event of quality related problems

Clause requiring free replacement of goods in case a complaintestablished bonafide.

The STI contains, inter alias the following provisions


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Textile and textile products

Chemicals, chemical products and fibers

Rubber and plastic products Non-metallic mineral products

Concrete, cement, lime, plaster, etc

Basic metals and fabricated metal products

Machinery and equipment

Electrical and optical equipment

Other transport equipment

Contd.,

The following 18 major economic activities by

Raad voor Accreditatie (RvA), the Dutch Council

for Accreditation.


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Wholesale and retail trade

Food Products, beverages and Tobacco

Leather and Leather Products

Wood and wood Products Pulp, paper and Paper Products

Printing Companies

Manufacturing and not elsewhere Classified Transport, Storage and Communication

Other Services


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Benefits to Customers

Provide assurance and satisfaction that their needsfor quality will be met

Saves time and money by reducing the need forassessment of their suppliers

Reduces incoming inspection costs

Work with reduced inventory levels, effectingsignificant cost reductions

Simplifies purchase decisions

Creates confidence in their suppliers because of theapproval by an independent third party

Better services, better and quick complaint redressal


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SOME NON-GOVERNEMT FOOD

TESTING LABOTARATORIES IN INDIA

Shriram Institute for Industrial Research(SRI), New Delhi.

Food Research and Analysis Centre(FRAC), New Delhi.


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Shriram Institute for Industrial

Research

Dairy products Spices and condiments Processed fruits and vegetables

Cereals and pulses Sugar and confectionary Food additives Vegetable oils and fats

Alcoholic and Non-alcoholic beverages Food packaging Meat and meat products


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Food Research and Analysis

Centre

Food grains and processed cereal products

Milk and Milk products

Edible oils and fats

Spices and condiments

Drink and carbonated beverages

Processed fruit and vegetable products

Meat and meat products Fish and fish products

Nuts and nut products

Cont.,


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SMR Quality Control in F. Industry

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