What is control? What is the relationship between control and food safety? Do you know what is the standard procedure that must be meet up to ensure that all those particular food products are always in a safe condition? How do you know that all of the procedures are good enough to protect the food from being contaminated? What action would you take in order to minimize the risk of food contamination cases?
According to the online Oxford Dictionary, ‘control’ means a person or thing used as a standard of comparison for checking the results of a survey or experiment. In alliance to the food safety area, controls are an important procedure that must take seriously by the operator of foodservice industry to ensure that the processed food items are safe and in an edible condition.
Quality control is the totality of all those controllable aspects that give effect positively or negatively to the quality of the finished product such as selection of raw materials, processing methods, packaging, methods of storage distribution and others.
1.1 Raw Materials Control
What is a raw material? Raw materials are the components that are used in the making of a product. It is the basic material that is used in the manufacture of a final product (Ask.com, 2014).
In terms of food quality control, raw materials should be control from the very beginning of the production processes which start from the choosing and purchasing the raw materials itself till the end processes.
There are seven (7) rules that must be check during selection of raw materials (Amankwa P.A, 1999). These procedures are made up to ensure the foods products are in a good condition so that it will be compatible with the particular market area:
1. The dominant raw material (s) are selected for priority of attention.
2. The selected raw materials are tested in relation to their contribution to product quality.
3. The raw materials tested are released from the stores only after the test results have been properly recorded.
4. Process control must relate the processing results to the raw materials test.
5. Define the critical points in the process and concentrate on these.
6. Finished product inspection should be reduced to the minimum level compatible with the confidence justified by the raw materials and process control.
7. Quality control is effective in proportion to its degree of integration into the overall
organisation of the factory.
1.2 Process Control
What is process? Why is it so important in foodservice organization? According to online Oxford Dictionary, ‘process’ means a series of actions or steps taken in order to achieve a particular end.
Process control is important in food quality control organisation. The common technique which foodservice operator always practice in their food processing centre is Good Manufacturing Practices (GMPs). This regulation had been enforced by the US Food and Drug Administration (FDA). The capabilities of the food processing centre which are in good situation, tools which are appropriately maintained and adjusted, personnel who are qualified and fully skilled, and procedures which are consistent and reproducible, are a few examples of GMPs regulation.
Others than that, foodservice operator also would usually apply HACCP in their establishment. HACCP which stands for Hazard Analysis Critical Control Point does take a major action in order to prevent any risk factors which could infect the food product. There are seven (7) elements in HACCP system which must be practice especially in foodservice organisation:
1. Conduct a hazard analysis:
Determine the food safety hazards and recognize the precautionary measures the plan can apply to control these hazards. A food safety hazard might be any biological, chemical, or physical materials which may be the reason a food cannot be eat for human consumption.
2. Identify critical control points:
A critical control point (CCP) is a point, in a food manufacturing process at which control can be practice and, as an outcome, a food safety hazard can be prevented, or reduced the risk to an tolerable level.
3. Establish critical limits for each critical control point:
A critical limit is the maximum or minimum value to which a physical, biological, or chemical hazard must be controlled at a critical control point to prevent or reduce the risk to an acceptable level.
4. Establish critical control point monitoring requirements:
Observing activities are needed to certify that the process is under control at each critical control point.
5. Establish corrective actions:
These are actions which need to be taken when observing indicates nonconformity from an established critical limit. Corrective actions are projected to ensure that no product is injurious to health, or else adulterated.
6. Establish procedures for ensuring the HACCP system is working as intended:
Validation ensures that the plants do what they were designed to do. Plants will be required to validate their own HACCP plans.
7. Establish record keeping procedures:
The HACCP guideline needs all plants to preserve certain documents, plus its hazard analysis and written HACCP plan, and records documenting the observing of critical control points, critical limits, verification activities, and the handling of processing deviations.
1.3 Finished Product Control
The quality of a finished product is very important for the consumer. All the finished product need to fulfil all the requirements on quality. They must have the appropriate nutritive value, typical sensory characteristics and fulfil all requirements from a safety point of view. The quality control of finished product is the crucial point of the whole quality control chain.
An observation must be obtain on how finished products need to be effectively monitored bearing in mind that all the control systems in a factory should be designed at preventing variation and contamination. As a result of spot check the level of some problems can be predictable with a view to tightening up controls earlier in the process. There is several checking procedure of the products:
– Pack weights and examination of process control pack weight records
– Pack appearance, correctness of coding or overprinting
– Storage tests to checks pack performance and product shelf life
– Recording the incidences of broken products within packs
– Organoleptic checks(tasting tests) on product texture and flavor
– Metal detection facilities review of product from the automatic machines
– Warehouse conditions example stacking and rotation of stocks
– Procedure for loading trucks and damage during distribution
– Storage conditions a stock rotation at depots.
The finished product need to obtain the specification and control test to make sure the product that produce by the particular company is safe and can be distributed to the users. There is several specifications that is important to the manufacturer to follow in producing the good quality of product.
1.3.1 Finished Product Specification
The finished product specifications are a set of tests and limits that are applied to the product in order to ensure that every batch is of satisfactory and consistent quality throughout its shelf life. The specifications must monitor all limitation where variation would be likely to affect the safety or efficiency of the product; and must ensure fulfilment with any applicable default standard.
Usually, tighter limits are applied at batch produce to critical parameters to allow for analytical mistake during batch release testing and to allocate for potential changes to the product during storage. Where variety tests and limits are applied at batch release and expiry, this must be clearly designate in the application.
1.3.2 Labelling
Labelling of food is the important part for the finished product. Its purpose is to provide the consumer with some of information which is necessary for making an informed choice in marketplace. The label should always bear the statement of identify, declaration of net contents, name and address of the manufacturer, packer or distributor and a list of ingredients.
In labelling, the most important information needs to be required are date of production and final date of sale especially in perishable foods. National regulations usually require further data such as content of nutrients of the products such as amount of vitamins, protein, fats and carbohydrates, energy content, and information about the food additives. Labelling of food is legislatively regulated on national or international levels.
1.3.3 Chemical Composition
Chemical composition of the finished product is very important to the consumer. Composition consist on the labels has to be in agreement with the given product. Water contents play an important role according to the stability of the perishable product during storage. The product with higher water content can expose in microbiological spoilage.
Special intention is given to the control of additives, because only some of the additives can be used in some food products, usually in a concentration given by law.
1.4 Storage Control
Food poisoning is usually cause by bacteria from foods that have been poorly stored, prepared, handled or cooked. Food contaminated with food poisoning bacteria may look, smell and taste normal. If food is not stored properly, the bacteria in it can easily multiply to dangerous levels. Incorrect storage of food can cause spoilage and food poisoning.
Proper storage extends the shelf life of food, which expends on the types of food, the packaging of the food and storage conditions, particularly temperature and humidity. Food quality must not decrease significantly during storage if the retailer or consumers follow the recommended conditions and storage times.
When the products are arrived, check the freshness dates on packaged food either the packaging is in the good condition. Make sure the refrigerated foods are cold and frozen foods are solid. Select the cold item and store them properly according to the proper temperature.
Practice the first-in, first-out method which can reduce the risk of spoilage of the food. When stocking the food storage area, place recently purchased item behind existing food. This will help ensure food is consumed before spoilage occurs, and before the expiration date passes. Food rotation is important to preserve freshness. When food is rotated, the food that has been in storage the longest is used first. As food is used, new food is added to the pantry to replace it; the essential rationale is to use the oldest food as soon as possible so that nothing is in storage too long and becomes unsafe to eat. Labelling food with paper labels on the storage container, marking the date that the container is placed in storage can make this practice simpler. The best way to rotate food storage is to prepare meals with stored food on a daily basis.
The cleanliness of the environment can affected the food during storage. Since the bacteria frequently get into food through careless food handling, it is important that everything is clean.
Next is predicting storage times. The exact length of time that foods can be stored depends on a number of factors. The storage life of food is affected by its freshness when it reached the market, the length of time and the temperature at which food was held before purchase, storage temperature and humidity in the some places, storage container or packaging. Generally food will maintain quality longer at cooler storage temperature.
For safety, it is important to verify the temperature of the refrigerator. Refrigerators should be set to maintain a temperature of 40 ??F or below. Some refrigerators have built-in thermometers to measure their internal temperature. For those refrigerators without this feature, keep an appliance thermometer in the refrigerator to monitor the temperature. This can be critical in the event of a power outage. When the power goes back on, if the refrigerator is still 40 ??F, the food is safe. Foods held at temperatures above 40 ??F for more than 2 hours should not be consumed. Appliance thermometers are specifically designed to provide accuracy at cold temperatures. Be sure refrigerator/freezer doors are closed tightly at all times. Don’t open refrigerator/freezer doors more often than necessary and close them as soon as possible. This is the guidelines of storing in refrigerator.
-All refrigeration units must have an accurate indicating thermometer to monitor the temperature which is suitable with the temperature of products.
-Temperatures must be maintained at 4??C (40??F) or less because in this temperature the bacteria cannot multiple easily.
– Store all raw foods below cooked or ready to eat foods to prevent cross contamination.
– Avoid packing refrigerator full, air needs to circulate to maintain proper temperature.
1.5 Distribution Control
Food distribution involves transporting food from suppliers to consumers. Environmental conditions in certain areas are more encouraging to producing certain types of crops, and farmers based in these areas produce large numbers of crops that have to be dispersed to other locations. Different types of livestock are more suited to certain climates, and this means that livestock farming tends to be concentrated in particular areas. Governments and businesses are in authority for developing effective food distribution networks to ensure that supply does not exceed demand.
Protecting the product is one of the most important aspects of the food distribution process. When food is in transit, distribution companies have to guarantee that the food is kept at a temperature that prevents it from spoiling. Planes and distribution trucks that been use for distribution are fitted with refrigeration systems and freezers. Measures also have to be taken protect foodstuffs and beverages that are stored in fragile containers, such as glass jars or bottles.
In foodservice industry, the most products that must be prioritized are the ice products and raw material products. Iced products usually include items such as broccoli, celery, green onions and others while raw material product can be define as meat, poultry and egg product. Usually this will give a sort challenges to distributors in order for them to distribute and transporting the product.
Ice products are normally packed in waxed grooved cartons and top with iced to keep them cool during transport and storage. Transport and storage temperatures are typically controlled at approximately 1?? C – 3?? C or 33?? F until 36?? F. At this temperature, this allows the ice to melt and the water from melted ice will run down through the product and on to the pallet on which products are packed, then finally onto the floor of the conveyance or cooler in which they are carried or stored. As the melt water gets on to the floor of a trailer, it has the ability to cross contaminate other products. For example, when the trailer hit the bump or going downhill and uphill, the water can be splashed upwards onto other pallets or goods inside. By that condition, it will carry the contamination with it. There are some of the solutions that can be implemented in order to prevent the melt water from contaminating the product. In a storage or distribution facility iced products should never be placed above any other food product. If storage space is only available vertically, then other effective controls must be implemented. Drip guards to protect the products underneath and implement sanitation procedures such as used the method of cleaning and sanitizing.
In the other side, we will discuss about food quality control in transporting and distribution of meat, poultry and egg product. Meat, poultry, and egg products are product that suspected have high risk of contamination from a wide variety of physical, microbial, chemical, and radiological agents. These products are particularly exposed to microbiological hazards because their moisture, pH levels, and high protein content promote ideal environments for bacteria to growth and manipulate. Meat, poultry, and egg products must be refrigerated or frozen after processing and before delivery to prevent spoilage and growth of pathogens.
In order to practice the good food quality control in distribution part, the distributor should be aware start from the vehicle or truck that will be deliver the product until the unloading of the product. This might require a lot of process, but since meat, poultry and egg product seems have a good criterion in promoting bacteria; all of these procedure must be aware.
i. Vehicles Used To Transport Meat, Poultry, and Egg Products
‘ Design and construct vehicles to protect product.
– Vehicles should be designed and built to make locking and sealing easy, protect the cargo against extremes of heat and cold, and prevent infestation by pests.
– Vehicle design should permit effective inspection, cleaning, disinfection, and temperature control.
– Interior surfaces should be made of materials that are suitable for direct food contact. For example, the surfaces may be made with stainless steel or be coated with food-grade epoxy resins
‘ Sanitize and properly maintain vehicles.
– Different cleaning procedures may be necessary for the different types of meat, poultry, or egg products that are to be transported. The type of product transported and the cleaning procedure used should be recorded. Generally, wash water should be at least 180
??F (82 ??C) and an approved sanitizer may be used to reduce the number of microorganisms and dissolve any fat particles adhering to interior surfaces.
– Equipment used in transferring meat, poultry, and egg products, such as hand trucks, conveyors, and forklifts, should be well maintained and kept in a sanitary condition.
‘ Use dedicated transport vehicles.
– Transport vehicles, containers, and conveyances should be designated and marked ‘for food use only,’ and be used only for transporting foods. This reduces the risk of cross contamination from previous cargo.
ii. Pre-loading
– Facilities should have an effective, systematic program for preventing environmental contamination and infestation by insects, vermin.
– Trailers and trucks should be pre-cooled for at least 1 hour before loading to remove residual heat from the insulation and inner lining of the trailer as well as from the air of the trailer. For pre-cooling, the doors should be closed and the temperature setting of the unit should be no higher than 26 ??F. However, that poultry products labeled ‘fresh’ must be shipped at temperatures higher than 26 ??F, usually between 26 ??F and 32 ??F.
– Examine trailer doors and seals to ensure that they can be secured and that there will be no air leaks.
– Dock foremen should document that all freight is 40 ??F or lower before loading. Freight should not be allowed to remain on the loading dock in warm weather in order to prevent the product temperature from rising above 40 ??F.
iii. Loading
– Use spacers on sidewalls and at the ends of trailers as well as pallets on the floor so that proper air circulation can be maintained.
– Keep loading time as short as possible to prevent temperature changes that could threaten the safety or quality of food products.
– Close doors immediately after the truck has pulled away from dock.
iv. Unloading
– Product should be inspected and sorted before being accepted at any point during transportation.
– Establish policy and procedures for rejection of packages and products that are not acceptable, can’t be verified against the delivery roster, or contain unacceptable changes to shipping documents.
– Move product from the loading dock into cold storage immediately to minimize product exposure to heat and contaminants.
Conclusion
As a conclusion, there are several factors that should be aware in order to achieve a good food quality control in foodservice industry. Starting from raw material selection and product quality which have seven role included selected the raw material, tested raw material in relation to their contribution to product quality, the process, the critical control point and finished product inspection, how the process being control, the finished product control, storage control until the last step which is distribution control that consist of factor that should be aware such as vehicle that has been used for transportation, pre loading, loading and unloading.
Besides that, in order to maintain the food quality control, several systems such as HCCAP, GMP, and FIFO can be practice by the foodservice organization. Every factor involve quality control have their own role and responsibilities.