Global Food SafetyFood Safety /Quality in the New Millennia

Br ian A. Nummer, PhDApr i l 2010

April 02, 2010 Golden Pacific Foods, Inc. Issues Allergy Alert for Undeclared Milk

and Soy in Marco Polo Brand Shrimp Snacks NY Gourmet Salads Inc. Recalls Chick Pea Salad Because of

Possible Health Risk (Listeria monocytogenes) Glutino Food Group Issues Allergy Alert on Undeclared Egg Product

in Raisin Bread Zatarain's Recalls Original Dirty Rice Mix Package Due to Unlabeled

Wheat and Barley Ingredients Binell Bros. Cutlery Voluntarily Recalls Black Pepper (Salmonella) Watkins Incorporated Recalls Crab Snack & Dip Seasoning Because

of Possible Health Risk from Ingredient Supplied by Kerry Ingredients (Salmonella)

Salmonella Tennessee in HVP< Feb 12, 2010 – Company analysis revealed

Salmonella Tennessee in HVPFeb 12, 2010 FDA inspects and cites:

Lack of microbial controls over productLack of hygiene monitoringLack of sanitationBuilding issues (Plumbing and Drains)

Feb 26, 2010 Basic Flavors LV, NV recalls productBack to Sept 2009 (last FDA inspection)

FDA finds S. Tennessee in plant

HVP RecallOver 178 products have been recalled containing

HVPDo you have a recall plan?What product(s) is it in?What lot codes are effected?What if I have a dry mix with HVP in it that must

be rehydrated and cooked by the consumer?5-7 log lethality validationLabel instructions

Does recalled HVP have to be discarded?

HVP Recall LessonsOnce again Salmonella has been found in a dry

product at low numbers.Over 178 products have been recalled containing

HVP plus the original HVP ingredient back to Sept 2009.

Hundreds of companies will incur costs of recalls.Do you have a recall plan? Are you prepared?

HVP Recall LessonsFDA cited lack of hygiene monitoring. Do you

monitor the sanitation of your plant?FDA cited plumbing and waste issues. Do you have

building maintenance issues of your own?Companies that could validate a cooking or lethality

step in their process did not have to recall product provided the lethality was validated. Are your lethality steps validated?

Companies that provided consumer cooking instructions were also exempt from recall. Do your product(s) contain cooking instructions?

Salmonella & Pet FoodPA Pet Food Contaminated with Salmonella70 human cases infection 19 states in 2006-7Still had cases from plant after clean-up 2008Recalled over 23,000 tons dog foodMade multiple brands: Pedigree, Country

Acres, Members Mark, Ol' Roy, Paws & Claws, Pet Pride, PMI Nutrition, Red Flannel, Retriever, and Wegeman's

This is every retailers fearPlant is now closed

Brand identityin a small world

…and many employees have cell phones with video cameras. Just think of the possibilities…

Changing ConsumerConsumers are:

Redefining value (lowering bar) Less premium, more value

E.g., organic food sales flat

Buying more private label(Store brands gain market share)

Higher coupon redemption ratesFoodservice getting tighterBuying more “comfort foods”

Data from Dairy Management Inst. Strategic Analysis 2010

Today’s environment

has changed the way that food is produced,

processed, transported and consumed. It presents

all stakeholders with new challenges to food safety

and quality.

Food regulation ↑More Legislation

FDA, USDA, & international

Labeling, Claims, BenefitsSupply Chain Transparency

Animal HealthFood Safety in the headlines

More recalls likely Traceability Testing for adulterants (melamine,

etc.) Ingredient identity (mislabeled fish)

Bioterrorism a constant concern

Consumers DemandBalanced value (price vs quality)Confidence and transparencyConsistency and predictabilityRegulatory complianceAdequate control over product –

security, recall and traceability (protect us)Above all else the food is safe to eat!

Retailers DemandBalanced value (price vs quality)Confidence and transparencyConsistency and predictabilityRegulatory complianceAdequate control over product –

security, recall and traceability (protect us)Above all else the food is safe to eat!

Brand Protection

ControlCompliance with regulatory requirements?The safety of your food?

Pre-process (ingredients and packaging)Process (GMP and HACCP)Post-process (retail and consumer handling)

Your brand identity and reputation?The market for your product category?

Control food safety / quality

standards

external audits

regulatory

haccp and gmps

internal audits

sanitation

risk management

food security

crisis management

GFSI: A global solution Launched at CIES Annual Congress (May

2000). Established as a non-profit Foundation (June 2005)

Holistic and integrated approach by industry to establish uniform guidelines for food safety and quality.

Managed by CIES – The Food Business Forum

GFSI GOALSConverge FSQ standards globallyReduce audits to 1Protect the brandRemove competitive element from

product safetySeek continual improvementCover farm to fork

4. On-site Audit

3. Certification schemeGet specific standards

Select audit company

2. Self assessmentGap analysis

1. Understand GFSI standardsOptional training course

Continuous improvement

Certification decision

Correct non-conformities

Identifies non-conformitiesMajor Minor

Get Started

1. Get Standardsa) CIES GFSI –version 5 benchmark

http://www.ciesnet.com/pfiles/programmes/foodsafety/GFSI_Guidance_Document_5th%20Edition%20_September%202007.pdf

b) SQF (Safe Quality Foods) Schemesa) SQF 2000 http://www.sqfi.com/SQF_2000_Code_Edition6.pdf

b) Implementing SQF http://www.sqfi.com/SQF_2000_Guide.pdf

c) BRC (British Retail Consortium) http://www.brcbookshop.com/ ($$)

d) FSSC (Food Safety System Certification) http://www.fssc22000.com/downloads/1.pdf

Presentation (with links) will be posted on foodsafety.usu.edu

What are standardsa) Senior management and continual

improvement commitmentsb) Foundation food safety (GMP/HACCP)c) Food safety managementd) Food quality managemente) Site standardsf) Product controlg) Process controlh) Personnel control

2. Gap AnalysisDocument Control Control of Quality Records Management Responsibility Communication Emergency Preparedness Competence, Awareness

and Training Infrastructure Work Environment

Control of Nonconformity Verification Planning Traceability Validation of Control

Measures Control of Monitoring and

Measuring Devices Food Safety Management

System Verification Internal Audits

2. Gap AnalysisHVP recall lessons learned

Document Control Control of Quality Records Management Responsibility Communication Emergency Preparedness Competence, Awareness

and Training Infrastructure Work Environment

Control of Nonconformity Verification Planning Traceability Validation of Control

Measures Control of Monitoring and

Measuring Devices Food Safety Management

System Verification Internal Audits

3a. Choose Program*a) SQF (Safe Quality Foods)

a) Level 1 – HACCP and GMPsb) Level 2 – Expanded Food Safetyc) Level 3 – Expanded Food Quality (GFSI approved)

b) BRC (British Retail Consortium)

c) IFS – (International Food Standards)

d) Dutch HACCPe) FSSC 22000 (ISO 22000 + PAS 220)

f) SQF 1000 & NZGAP for Farm related safety

new

*Keep in mind convergence

3b. Choose Cert. Bodya) Must be certified to GFSI schemeb) Consider largest customers in choosing

vendor and schemec) SQF has 3 levels to gradually obtain full

GFSI complianced) SQF requires trained practitioner on-site

(take relevant course then exam online)

e) If previously ISO 22000 certified consider FSSC 22000 program

f) Negotiate all costs

*Keep in mind convergence

4. On-site AuditsUsually 2 days

75% document verification25% physical inspection

1 day of report writingNon-conformities usually handled via

correspondence (especially documents)

Annual Certification Cost

Desk Audit 1-2 DaysPre-Assessment Audit 1-2 DaysCertification Audit 1-3 DaysTypical Total 3-5 DaysAnnual Certification Fee $650Auditing Body Fee $1200 per day Travel Expenses VariableEmployee Time/Effort ?

>$9 -12 K per year

GFSI Documentation

Risk ManagementIdentify risks (food safety and quality)Analyze risks

(matrix)

Identify risk mitigation factorsImplement risk mitigation factors Assess Mitigation