Quality and Specification of Raw Materials and Finished Products

Objectives

To learn about the

Quality of raw materials

Quality of Finished products

Introduction

The concept of food safety covers all the steps involved in food chain starting from cultivation to
consumption or “farm to fork.” Good hygienic practices are therefore important to be followed from the
procurement of the raw resources, transport of raw food, storage of raw food materials more so for
commercial establishment

In earlier times when the food safety concept was not so critically emphasized.There was dichotomy in
research and development activities with each team working in isolation. But now convergence of all
teams put in their expertise due to increase access to unique and complex materials, global sourcing
handling methods, customer locations, and regulations. The unified team assess, if the material has
limitations or may be too costly to handle, and determines if additional measures are necessary to
prevent potential safety issues for the employees and product.

Components of food processing

Raw materials, including ingredients, processing aids, and packaging, are the foundation of finished food
products. As such, they must meet not only acceptable and standard specifications, but also regulatory
requirements such as safety, legal requirements. The specifications must be such that they contribute to
the functionality and quality of the chosen process and the product.

Raw Material Selection

Appropriate raw materials must be selected based on functionality. Functionality encompass multiple
requirements based on identified characteristics of the finished product (binders, thickeners, type of
resin for plastic packaging, etc.), organoleptic characteristics (flavor, color, aroma, texture), product
safety characteristics (to lower the pH or water activity), and preservatives (extension of shelf life, color,
or flavor retention, etc.).

No raw material or ingredient should be accepted by an establishment if it is known to contain parasites,

undesirable microorganisms, pesticides, veterinary drugs or toxic, decomposed or extraneous
substances which would not be reduced to an acceptable level by normal sorting and/or processing.
Where appropriate, specifications for raw materials should be identified and applied.
Raw materials or ingredients should, where appropriate, be inspected and sorted before processing.
Where necessary, laboratory tests should be made to establish fitness for use. Only sound, suitable raw
materials or ingredients should be used.

Raw Material Specifications

The key characteristics for the raw ingredients must be documented with all the relevant
specifications.This may be the dated Technical Data Sheet from the supplier. A purchase order should
list the supplier’s specific name and item number for the material. It is good to keep scope to revise this
data sheet as per periodic need. The manufacturer should obtain a certificate of analysis for each lot
(code). Each incoming lot should be sampled according to a predetermined sampling plan and analysed
for adherence to specifications.

Flexibility in sourcing and cost

Is the material a commodity-type item that can be purchased from multiple sources? If so, compare
existing specifications from multiple suppliers; allow comparison bidding/purchasing.

Can the tolerances for characteristics be expanded to be able to purchase from more than one source or
a wider range of possible, existing materials (such as granulation size for materials that are going to be
dissolved or melted)?

Can purchasing find a similar functionality material that costs less or has fewer concerns?

Considerations in Selection

If there is a raw material already in use with similar characteristics it can be retained. Depending on
whether it is agricultural item, commodity item or one with standard identity general specification that
can be used between multiple suppliers can be developed and maintained. The raw materials must fall
under Generally Recognized as Safe (GRAS) listing as approved by the food regulatory body of the
country. Ban on the use of as genetically modified materials depends on the legal status on use of these
items. Maximum levels for use, both in the country of manufacture and the country of sale/use again
depends on the food laws of both the countries. The raw material must also comply with the existing
company or customer standards namely for e.g., kosher, halal, organic, gluten-free and so on.
Specification requirements can be documented and recorded.

Raw Material Storage – Refrigerated and Non-Refrigerated

a) All raw materials should be –

• free from insect and rodent infestation

• free of contamination from other sources, e.g. birds, moisture, mold etc

If bulk floor handling and storage is in use then,

• Hose couplings, inside and outside plant, should be adequately protected from rodents, clean and in
good repair

• Dust collectors or ventilation bags at top of the bulk tank should be clean and insect free

• If system contains inspection ports, they should be free from contamination

b) The microbial load of all the food items like raw fruits and vegetables, liquid milk, meat, eggs, flour,
cereal grains etc. should be within the acceptable limits at receiving as well as during their storage in the
raw material store.

c) Depending on the nature of the food adequate facilities shall be available for storing refrigerated or
frozen foods, monitoring food temperatures, and controlling ambient temperatures and humidity to
ensure the microbiological safety and suitability of food.

d) In case of grain storage, fumigation should be done at regular intervals to ensure the absence of any
microbiological and pest activity.

High risk raw foods sourcing and storage

Milk and milk based products, meat, fish, vegetables and fruits perish fast. These items must be free
from contamination at source and must be later stored at proper temperature, humidity and other
conditions necessary to keep them safe. Precaution must be taken to follow the hygienic principles
while processing and preparing foods using these commodities.

Inventory management

Stocks of raw materials and ingredients should be subject to effective stock rotation. Prevention of
health hazards begins with control of incoming materials. Inadequate incoming ingredient controls could
result in product contamination and/or under processing. The degree of control exercised over incoming
ingredients is appropriate to the risk. The principle of first in first out should be followed.

The manufacturer should control incoming ingredients through the following programs. The first three
options apply to ingredients that may be critical factors where further processing is not likely to
eliminate a hazard. The fourth option applies to ingredients that are not likely to have an impact on the
safety of the food.

A .Periodic evaluation of incoming ingredients B .the manufacturer should have written specifications
for ingredients C. purchasing specifications should include a provision for compliance with the food law.
D. The manufacturer should maintain a documented history of adherence to specifications for each
supplier, e.g. analytical results.

Certificate of analysis

The manufacturer should obtain a certificate of analysis for each lot (code). A statistically representative
sample should be taken to verify the accuracy of the certificates of analysis at a scheduled frequency. A
new history of adherence to specifications should be established when a firm changes suppliers,
purchases ingredients from a new supplier or purchases a new ingredient from an existing supplier or
when spot checks do not agree with the certificate of analysis.

Vendor certification

When the manufacturer relies on vendor certification the following minimum requirements should be in
place:

· The manufacturer should have written specifications for ingredients.

· The manufacturer should have documentation to demonstrate adequate knowledge of the vendor's
process, e.g. process flow charts, on-site evaluations, identification of critical control points,
specifications, control limits, monitoring programs and frequencies, corrective action and verification
procedures.

· The manufacturer should have data to demonstrate the capability of the vendor's process to
manufacture consistently within specifications.

· Prior to implementation of a periodic monitoring program the firm should analyse an appropriate
number of consecutive lots to establish a historical database and confirm adherence to specifications.

· The manufacturer should conduct periodic monitoring to verify adherence to specifications.

· The manufacturer should conduct vendor audits to validate the status of the vendor certification
program.

Occupational Safety and Health Administration (OSHA)

OSHA Considerations

The safety of materials such as toxic, inflammable or irritants need handling safely and the facility for
the same must be available. The food handlers must know of the safe handling procedures.

Product Safety Considerations

Historical information about the raw materials can be obtained from the literature. The company can
conduct HACCP to assess the potential biological, chemical, and physical hazards affiliated with the raw
material (HACCP/HARPC review) as well as affiliated prerequisite programs and downstream
prevention/elimination/reduction steps for identified hazards (physical, chemical, and biological). If
there is a need for a new procedure (e.g., an allergen program and/or validation) over the existing
procedure, it can be included or revised.

Facility and Equipment Capabilities

 The plant must be technologically appropriate to handle the material. The machinery used should not
change the characteristics of the ingredient, should be capable of handling the raw material of specific
particle size, design wise suitable and not introduce process contaminants.

Water

As an ingredient

Only potable water should be used for food preparation. Water should meet the requirements of the
regulations. Water should be analysed by the manufacturer or municipality at a frequency adequate to
confirm its potability. Water from sources other than municipal supplies must be treated as necessary
and tested for potability.

Ice and steam

Ice used as an ingredient or in direct contact with food should be made from potable water and
protected from contamination. Similarly steam coming in contact with food should be made from
potable water.

For other purposes like water for use in fire control, washing and other purposes not connected with
food directly, other sources of clean water may be used.

Water recirculated for reuse should be treated and maintained in such a condition that no risk to the
safety and suitability of food results from its use. The treatment process should be effectively
monitored. Recirculated water which has received no further treatment and water recovered from
processing of food by evaporation or drying may be used, provided its use does not constitute a risk to
the safety and suitability of food.

There should be no cross-connections between potable and non-potable water supplies. All hoses, taps
and other similar possible sources of contamination should be designed to prevent back-flow or back-
siphonage.

Storage of water

If it is necessary to store water, storage facilities should be designed, constructed and maintained to
prevent contamination. The volume, temperature and pressure of the potable water should be
adequate for all operational and clean-up demands. Water if treated with chemicals, should not result in
unacceptable chemical residues in the water. Chemical treatment should be monitored and controlled
to deliver the desired concentration and to prevent contamination. Recirculated water should have a
separate distribution system which is clearly identified.

Packaging

For packaging materials, the specific composition of the packaging material would be specified, such as
glass, polyethylene (PET), polypropylene (PPE), and so forth. Packaging design and materials should
provide adequate protection for products to minimize contamination, prevent damage, and
accommodate proper labelling. Packaging materials or gases where used must be non-toxic and not
pose a threat to the safety and suitability of food under the specified conditions of storage and use.
Where appropriate, reusable packaging should be suitably durable, easy to clean and, where necessary;
disinfect. Where appropriate, the manufacturer should control incoming packaging materials from the
supplier using an approach similar to the options suggested for incoming ingredients.

Size and type of packaging

The size and type of packaging depends upon the nature of the food to be packed, quantity,
transportation, time on shelf, single or multiple use and consumer preferences. The package should
have adequate space for the required labeling as per the regulations.

Following are the information required on packaged food

The ingredient/material composition is listed in decreasing order of presence or as outlined in labeling

regulations.

 The name of the product and general name

 The supplier’s item number
 Components or composition of the materials
 Information on the presence of regulated or customer-recognized food allergens.
 Organoleptic information (appearance, flavor, and aroma).
 Relevant physical, chemical, and microbiological information
 Shipping and storage information
 Shelf life
 Handling information
 Allergens if they are likely to be present
 Instructions for use
 Best before date

Management and supervision

The type of control and supervision needed will depend on the size of the business, the nature of its
activities and the types of food involved. Managers and supervisors should have enough knowledge of
food hygiene principles and practices to be able to judge potential risks, take appropriate preventive and
corrective action, and ensure that effective monitoring and supervision takes place.

Documentation and records

Where necessary, appropriate records of processing, production and distribution should be kept and
retained for a period that exceeds the shelf-life of the product. Documentation can enhance the
credibility and effectiveness of the food safety control system.

Critical records, e.g. records related to the adequacy of the thermal process and the achievement of a
hermetic seal, should be signed and dated by a qualified individual designated by management prior to
distribution of the product. All other records should be reviewed at an appropriate frequency to provide
an early indication of potentially serious deficiencies.

Records should be retained for one year after the expiry date on the label or container or, if there is no
expiry date, for two years after the date of sale.

Records should be maintained at the manufacturing plant and should be available.

Recall procedures

Managers should ensure effective procedures are in place to deal with any food safety hazard and to
enable the complete, rapid recall of any implicated lot of the finished food from the market. Where a
product has been withdrawn because of an immediate health hazard, other products which are
produced under similar conditions, and which may present a similar hazard to public; health, should be
evaluated for safety and may need to be withdrawn. The need for public warnings should be considered

· Each pre-packaged food should have permanent, legible code marks or lot numbers and where
required expiry or "best before" dates on the package.

Recall capability

The manufacturer should be capable of producing accurate information on a timely basis to verify that
all affected product can be rapidly identified and removed from the marketplace. This can be
demonstrated by the manufacturer as follows:

· Records of customer names, addresses and telephone numbers available for the lot tested

· Records of production, inventory and distribution by lot available for the lot tested

Product inspection

Verifying the product quality and consistency

Before a batch of product leaves the factory it must pass a ‘positive release’ test to confirm it is safe to
consume. Quality tests have to be performed to verify product compliance with internal and external
standards, including for harmful compounds or microorganisms in the materials used, the environment
of operation and in products. Tests for allergens may have to be conducted if applicable.

Analytical Information

Food safety parameters or tolerances could include biological, chemical, or physical characteristics.

Biological – Microbiological limits for pathogens, such as Salmonella and Listeria monocytogenes.

Chemical – Fortification levels, sulfite levels, heavy metal content, etc.

Physical – Size and foreign material (rocks, glass, metal, bones, etc.)
Functionality or quality parameters would include characteristics that can impact the functionality of
the material or adversely impact your product.

Biological – Microbiological limits for spoilage organisms or indicators of poor sanitation, including total
plate count, yeast, mold, and coliform.

Chemical – Characteristics such as concentration levels or purity.

Physical – Characteristics such as viscosity, color, granulation size, insect parts, crush strength, physical
measurements, etc.

Transportation

For chilled or frozen products, this also means ensuring they are stored and transported at the correct
temperature. The transportation mode and capacity to be used depends again on product
specifications. The following measures must be followed to ensure food safety during transportation:

 Food must be protected from potential source of contamination

 Protect food from damage that may render it unfit for consumption
 Provide an environment which effectively controls the growth of pathogenic or spoilage
microorganisms and the production of toxins in food

If these aspects are not taken care during food transit it may get contaminated, or may not reach its
destination in a suitable condition for consumption, even if hygiene control measures have been taken
earlier in the food chain.

Container requirements

Conveyances and bulk containers should be designed and constructed so that they:

- do not contaminate foods or packaging

- can be effectively cleaned and disinfected

- permit effective separation of different foods or foods from non-food items during transport

- provide effective protection from contamination, including dust and fumes

- can effectively maintain any temperature, humidity, atmosphere and other conditions necessary to
protect food from harmful or undesirable microbial growth and deterioration likely to render it
unsuitable for consumption

- allow any necessary temperature, humidity and other conditions to be checked.

· Ingredients requiring refrigeration should be transported at 4°C or less and should be appropriately
monitored. Frozen ingredients should be transported at temperatures that do not permit thawing.
Use and maintenance of containers

Conveyances and containers for transporting food should be kept in an appropriate state of cleanliness,
repair and condition. Where the same conveyance or container is used for transporting different foods,
or non-foods, effective cleaning and disinfection should take place between loads.

Where appropriate, particularly in bulk transport, containers and conveyances should be designated and
marked for food use only and be used only for that purpose. Carriers should be inspected by the
manufacturer on receipt and prior to loading to ensure they are free from contamination and suitable
for the transportation of food. The manufacturer should have a program in place to demonstrate the
adequacy of cleaning and sanitizing. For example, for bulk carriers a written cleaning and sanitizing
procedure should be available.

· Carriers should be loaded, arranged and unloaded in a manner that prevents damage and
contamination of the food.

HACCP plans developed by the food industry must consider the control of temperatures and
contamination during the transport of foods. A food business operator may require an HACCP plan as a
condition of doing business with a particular transportation firm.

Summary

Food manufactures, handlers, transporters should be alerted on all aspects of maintaining the food
ingredients, products safe by education programs. The management must ensure that their products are
safe in all respect to the consumers.