End-to-End Food Safety: From Farm to Fork with HACCP and Food Defence

www.pmg.engineering Vol .02-Issue .07-February2023 TECH-KNOWLEDGE The Official PMG Engineering Newsletter FOOD & BEVERAGE INDUSTRY ENGINEERING & DESIGN SCIENCE & TECHNOLOGY A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .07-February 2023 CONTENTS YOUR PARAGRAPH TEXT 1. WHITE PAPER A. Food Defense B. HACCP and its Principle 2. INDUSTRY BUZZ Latest Food Industry News Updates 3. WEEKS HIGHLIGHT A Look Into The Main Events Of The Week 4. DID YOU KNOW? Fascinating Food Facts To Expand Knowledge 2-5 6-7 8 9-10 PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .07-February 2023 FOOD DEFENSE Introduction Contamination in food can occur due to various factors including any human error, environmental factor, low hygienic condition or can be intentional in nature to sabotage the products. Food defense is a set plan made to protect the final food product from any form of intentional adulteration and contamination. Intentional adulteration can be of biological, chemical, physical, or radiological form. It and provides operational security. personnel physical, also It is quite common to misunderstand food defense with food safety, needless to say both terms are different from each other. Food prepared in large batches are a higher risk as large batches offer more servings and hence more possibility to reach out to large mass. Short shelf life increases risk as rapid consumption of the product makes it harder to identify a problem and warn consumers. There should be restricted access during the production and distribution to keep check on any intentional contamination. Threat can be either internal or external. Internal threats could be disgruntled employees, vendors or contractors. i.e., people that have ready access to the facility while external threats must gain access to the facility, through forced entry or a weakness in the facilities access control program and they could be criminals, protesters, terrorists, people coming in to the food facility may be as visitors etc. Prevention Plan To prevent any unwanted case of sabotage, it is important to come up with a plan so that no such situation is faced. There should be present plant that should be made by the facility in accordance to their requirement and from also from where intentional contamination can be caused. to keep food safe There should be written policies and programs in place from unintentional contamination with properly managed recall and traceability Program in case of any such situation occur. Sufficient self-inspection program should be facility along with chemical control there program. There should be visitor and contractor entry policy so that before entering in plant personal can be identified. in Entry gates should have proper lighting and have installed security cameras. ingredients or Incoming raw material or packaging material should have proper checking at entry point. trucks with PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION READ MORE.... Vol .02-Issue .07-February 2023 PLATE HEAT EXCHANGER All outgoing shipments should have proper seal on them so that any tampering can show evidence to sabotage chances and can be rejected. All entry and exit doors should be locked when not in use and should be under surveillance. Inside processing facility along with employees, visitors/contractors should also wear hairnets and should follow all dress code. It should be mandated to sign in and out for visitors/contractors entering the plant. Background checks and personality tests for employees before hiring them. Restrictions on what employees can bring into the facility. Employees should be provided with Security training. Employees are the FIRST line of Food Defense: Follow procedures company food defense plan and Inspect your work area and surrounding areas Recognize anything out of the ordinary Secure all product ingredients, supplies and finished Tell supervision if you notice anything suspicious Protection Strategies Step 1: Identify the hazards- Real or potential conditions that could introduce a harmful agent into the food chain that could cause property damage, illness, death or jeopardize employee. safety should be timely identified so that further planning can be done to keep check at situation. Step 2: Asses the risks- it is always necessary to ask ne self-questions like what would happen if someone entered the unsecured door? Could they contaminate product? Could they harm employees? What can be the overall impact of this hazard? These type of question can help in the assessment of risk. Step 3: Analyze risk control measures- Once possible risk has been assessed and identified there need to be proper planning and designing for minimum include incorporation of safety devices, providing warning devices, and developing procedures to fight such risk by proper training to employees. Never the less it is never possible to completely eliminate the risk. Planning risk. can Step 4: Risk control decision- It always benefits outweigh risks or cost. It involves personnel impact that can be caused by risk control actions so it is recommended to evaluate impact on the facility of the risk control action. The goal should not be to lower the level of risk, it should be to bring the risk level down to best level or risk for overall food safety and security. Step 5: Implement risk controls- If not put risk control actions in place it can be futile to have food defense plan hence risk checks should be implemented for all process and equipments. Step 6: Supervise and Review- Reviewing and maintaining a food defense plan is important to ensure it remains functional. It is recommended to ensure risk controls are effective and annual auditing can be helpful. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .07-February 2023 HACCP AND ITS PRINCIPLE Introduction HACCP (Hazard Analysis Critical Control Point) is a food safety program developed nearly 30 years ago and is applicable to the food processing industry for controlling hazards that are likely to occur in the food processing chain.It focuses on preventing hazards that could cause food-borne illnesses by applying science-based controls, from raw material to finished products. Safety of the food supply is key to consumer confidence. a is to approach systematic the HACCP identification, evaluation, and control of food safety hazards. System is based on assessing the natural hazards or risks in a particular product or process and designing a system to control them. identification of Step wise process hazards and installation of preventative measures to eliminate or reduce hazards in foods. It is proactive form of defense management rather than reactive. HACCP does not rely on end product the from testing and should be monitored beginning of receiving of ingredients, packaging and then through process steps and to final product and shipping. the process includes i.e., The end objective of HACCP is to make the product as safe as possible and to be able to prove that the product was processed as safe as possible. that The assurance of safety comes from the process of identifying the hazards, establishing controls for the identified hazards, monitoring the controls and periodically verifying the system works. Hazard can be physical, chemical, biological or allergen in nature. Not only the plant operator but people producer/grower, manufacturer. distributor, transporter, retailer is also responsible for preventing any type of hazard to product. Three points that’s that required to be ponder upon are what hazards can enter the product? Where do these hazards occur? How can we control or eliminate these hazards? like Critical Element Foundation to a HACCP program includes Good Manufacturing Practices, addresses food safety at all stages from receiving to shipping, includes indirect hazards. Hazard can arise from any point of material handling stage. 1. Premises: Under premises falls outside property and building, design, construction & maintenance, lighting, ventilation, waste disposal, inedible areas, employee & sanitary facilities, water/steam/ice etc. All hazard that can arise from above mentioned area’s need to be properly checked. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION READ MORE.... Vol .02-Issue .06-February 2023 2.Transportation and Storage: Considerable food carriers, temperature points controls, incoming and ingredients and packaging, non-food chemicals and finished product storage. in this are receiving storage, 3.Equipment: Design, installation, maintenance and calibration of equipment can lead to different type of hazard. 4.Personnel: It is important to determine if the person appointed for job is trained well and have understanding for food safety. 5.Sanitation & Pest Control: Process equipment & utensils, lunchrooms, washrooms rooms, floors, locker Identification of Allergens, 6.Allergen Control: their control like special handling, segregation, special sanitization procedures, rework and proper labelling 7.Supplier Quality Assurance: Vendor approval process, product specification and inspection of incoming materials. HACCAP Principle The seven HACCP principles are included in the international standard ISO 22000 FSMS 2011. This standard is a complete food safety and quality management system, incorporating the elements of prerequisite programmes like GMP & SSOP. HACCP is based on seven principles: 1.Conduct Hazard Analysis: Firstly, one should evaluate the processes, and then determine and identify various entry points for hazard. Hazard may be in any form making the food unsafe for consumption. 2. Identify Critical Control Point: In an on-going process or steps, critical points should be determined. Critical control points are points in the manufacturing process at which control can be applied. Limit: During Critical Establish 3. a manufacturing process, various parameters are involved that decides the quality of product, and in these parameter can adversely any change affect the product. Hence important to it determine and establish maximum and minimum level for such parameters. is 4. Establish Monitoring Procedures: After setting the critical control limit it is required to have them monitored at every specific interval of time, for which a systematic procedure is required to check if the critical limits are being followed. 5. Take Corrective action: Actions need to be planned in case the critical limits are not being followed during the process or the parameters show wide variation from the set points. Action plan can control any unwanted situation like product quality loss and others. Once small variations are noted on the values, corrective actions should be immediately implemented. 6. Verify Procedures: It is necessary to get all the HACCP plan validated, which help to check if they the monitoring verify are effective. To procedures are efficient, end product can be tested. Along with verification, there should be evidence for accuracy as well, i.e., results must be validated to prove the efficiency of HACCP plan. if Establish record-keeping 7. Procedures: According to HACCP regulation, it is required to maintain documents and records showing written HACCP plan, set critical limit points, verification and validate data. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter FOOD INDUSTRY INDUSTRY BUZZ Tetra Pak begins groundbreaking research on fiber-based packaging The Fête du Chocolat- A grand chocolate festival launched by Fabelle In partnership with Max IV, the world's most laboratory, advanced synchrotron radiation Tetra Pak has started groundbreaking research food to advance packaging. With to optimise the composition of materials used for paper straws, the research intends to unearth novel insights into the nanostructure of fibre materials. sustainable initial application fiber-based the At ForMax, a recently established research facility at the Max IV Laboratory in Lund, Sweden, devoted to the study of materials from the forest, this is the first industrial research and development experiment. The Indian luxury chocolate market has reached new and higher heights as a result of the homegrown luxury chocolate brand Fabelle Exquisite Chocolates from ITC Ltd., which is recognised for producing unmatched chocolate experiences. the brand's In keeping with mission to offer Indian consumers one-of-a-kind chocolate experiences and build trends with distinctive has introduced Fabelle Fête du Chocolat, an exquisite chocolate carnival. creations, chocolate it Additionally, the festival honours the season of love. The chocolate festival is taking place in shops across to the nation Valentine's Day, including those in Mumbai, Delhi, Bengaluru, Hyderabad, Kolkata, Chennai, and Ahmedabad. leading up PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Consumers can connect with farmers through Superplum's traceable supply chain. An innovative feature that enables customers to scan a QR code and pay a bonus to the farmer who grew the food they are eating was just released by Noida-based agritech business Superplum. For Superplum fruit, customers may already check the results of pesticide tests and visit the real farm where the fruit was cultivated. All of this is made possible by the business's fully digitalized and traceable supply chain, which keeps track of each pack a customer receives. The company's end-to-end digital platform enables in- depth quality analysis and control of every product. Lactobites and Nail the Nausea new flavors from Nutri-Zoe 2022 REVENUE GROWTH FOR CARGILL OF 23% TO $165 BILLION The women's health company Nutrizoe has added additional flavours to its Lactobites bar and oral strips that prevent nausea. Eliminate the nausea. In addition to a new combo pack with the flavours fennel and berries and chocolate vanilla, of Lactobites are now offered in chocolate vanilla first flavour. Experts created Lactobites, lactation-helping a breastfeeding mother's recommended dietary into account. The bars are allowance produced in BRC facilities and have undergone safety testing in a NABL lab. the taking India, (RDA) bar in Workshop organized on Agriculture Infrastructure Fund to encourage women to participate in agriculture Infrastructure Fund A one-day workshop on the Madhya Pradesh Farm Gate App and Agriculture (AIF) was organised at Noronha Administrative Academy in Bhopal on the occasion of India's G-20 presidency under the theme "One Earth, One Family, One Future" in order to promote a sense of global unity and increase the participation of women in agriculture. The major goal of this programme was to boost the involvement of women in the M.P. Farm Gate and Agriculture Infrastructure Fund (AIF). In her speech, G.V. Rashmi, managing director of the Mandi Board, discussed the Madhya Pradesh Agriculture Infrastructure Fund and emphasised some of the benefits of the MP Farm Gate App that the Mandi Board built. Kamal Patel, the agriculture minister for Madhya Pradesh, complimented you and encouraged you to use the MP Farm Gate App and AIF scheme widely in his video message. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION N O N - T E C H N I C A L C O N T E N T WEEKS HIGHLIGHT 13 FEBRUARY WORLD RADIO DAY World Radio day is observed on February 13 every year. Radio informs, transforms and unites us. It brings together people and communities from all backgrounds to foster positive dialogue for change. 13 FEBRUARY BIRTH ANNIVERSIRY Sarojini Naidu was one of the first women to participate in India’s struggle for independence from the British. Throughout her career, Sarojini Naidu worked for the dignity of the common man and the education and emancipation of women by actively encouraging the setting up of orphanages and schools for girls. 15 FEBRUARY CHILDHOOD CANCER DAY International Childhood Cancer Day is celebrated on February 15 every year in a collaborative campaign to raise awareness about childhood cancer and to express support for children and adolescents with cancer, the survivors and their families. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Y R A U R B E F PMG DID YOU KNOW? 1/4 2/4 T E C H N I C A L C O N T E N T Y R A U R B E F 3/4 4/4 Fact 1 To improve the nutritional content of staple foods such as rice, wheat, oil, milk, and salt, key vitamins and minerals such as iron, iodine, zinc, and vitamins A and D are added, process called as Fortification. These nutrients may have been present in the food prior to processing or may have been lost during processing. It supplements other methods of improving nutrition, such as dietary diversification and food supplementation. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter T E C H N I C A L C O N T E N T 1/2 2/2 Fact 3 Champagne is a sparkling wine made from grapes grown in France's Champagne region. It goes through secondary fermentation in the bottle to create carbonation. There are approximately 49 million bubbles in a 750ml bottle of Champagne. Fact 3 There are four main types of sweeteners to remember: 1. Sugars. 2. Sugar Alcohols. 3. Artificial Sweeteners 4. Naturally-derived low-calorie sweeteners, like Stevia & Monk Fruit. 1/5 Y R A U R B E F PMG DESIGN+BUILD FOOD FACTORIES. 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