Quality Assurance for the Food Industry: A Practical Approach

by Vasconcellos; J. Andres

• ISBN13: 9780849319129
• ISBN10: 0849319129
• eBook ISBN(s): 9781135495268
• Edition: 1st
• Format: Hardcover
• Copyright: 2003-12-29
• Publisher: CRC Press

Summary

Food companies, regardless of their size and scope, understand that it is impossible to establish a single division devoted to "quality", as quality is the responsibility and purpose of every company employee. Applying this theory demands the cooperation of each employee and an understanding of the methodology necessary to establish, implement, and evaluate a Quality Assurance program.Quality Assurance for the Food Industry: A Practical Approach provides in-depth coverage of all aspects of quality assurance. It identifies the basic concepts and principles behind Total Quality Management and presents examples of Quality Assurance programs that can be applied to the food industry using simple, proven formats. The author discusses the role of Quality Assurance in product manufacturing, emphasizing the need for interactions among an organization's Quality Assurance, Quality Control, Product Development, Marketing, Sales, and Consumer Affairs departments. He analyzes the characteristics of a quality audit and the purpose of a proper audit, then focuses on specific examples including product manufacturing audits, food plant sanitation audits, and product quality audits. A comprehensive examination of HAACP and its applications concludes the coverage.This practical, industry-oriented reference explains the fundamental role of Quality Assurance and provides the knowledge required for establishing a Total Quality Management system in your own company. The concepts and procedures discussed are the key components for attaining and maintaining the highest standards of quality in the food industry.

Table of Contents

Chapter 1 Introduction: Concepts	1	(18)
The Doctrine of "Strict" Liability	2	(1)
The Doctrine of "Total Accountability"	2	(1)
Management and Product Quality	2	(8)
Organizational Plan	3	(1)
Total Quality Program	4	(1)
The Working Environment	4	(6)
Workers	4	(2)
Managers and Supervisors	6	(2)
Building Teams of Empowered Employees	8	(1)
Employee Training	8	(1)
Work Teams and Empowerment	8	(1)
Quality at the Source	9	(1)
Steering Committees or QC Circles	9	(1)
What Is Quality?	10	(5)
Dimensions of Quality	11	(1)
Standards of Quality	12	(1)
Methods for Determining Quality	13	(2)
Subjective Methods	14	(1)
Objective Methods	14	(1)
Adulteration and Contamination	14	(1)
Differentiation Between Cell Types, Tissue Types, and Microorganisms of Various Stored Foods	15	(1)
Official Methods of Analysis in the Food Industry	15	(2)
The Association of Analytical Communities International (AOAC International)	15	(4)
The American Association of Cereal Chemists	16	(1)
The American Oil Chemists' Society	16	(1)
The American Public Health Association	16	(1)
The American Spice Trade Association	17	(1)
The Food Chemicals Codex	17	(1)
References	17	(2)
Chapter 2 Total Quality Management	19	(60)
Theories and Application	19	(3)
The Concept of Total Quality Management	21	(1)
The Basis for Superior Quality Performance	21	(1)
TQM and ISO 9000	22	(1)
The Structure of TQM	22	(1)
The Principles of TQM	23	(1)
The 10 Steps to TQM	23	(1)
Total Quality Management Tools	23	(20)
Statistical Analysis Tools	24	(11)
Data Sheet	24	(1)
Cause-and-Effect Diagram	24	(1)
Scatter Diagram	25	(1)
Flowchart	25	(2)
Pareto Chart	27	(1)
Histogram	28	(1)
Control Chart	28	(2)
X-Bar and R Charts	30	(2)
Attribute Charts	32	(1)
p-Charts	32	(1)
np-Charts	32	(1)
c- or u-Charts	33	(1)
Other Types of Charts	33	(2)
Management and Planning Tools	35	(7)
Afrmity Diagrams	35	(1)
Interrelationship Digraphs	36	(1)
Tree Diagram	37	(1)
Matrix Diagram	38	(1)
Prioritization Matrices	39	(1)
Process Decision Program Chart	39	(1)
Activity Network Diagram	40	(1)
Gantt Chart	40	(1)
Entity-Relationship Diagram	41	(1)
Key to Quality	42	(1)
TQM Vision and Mission	43	(1)
Integrated Business Plan	43	(1)
Some History of Total Quality Management	44	(24)
The Pioneers of Scientific Quality Management	46	(13)
Frederick Taylor	46	(2)
Walter A. Shewhart	48	(1)
W. Edwards Deming	49	(3)
Joseph M. Juran	52	(2)
Armand V. Feigenbaum	54	(2)
Philip B. Crosby	56	(3)
The Japanese Contribution	59	(9)
Kaoru Ishikawa	59	(3)
Genichi Taguchi	62	(4)
Quality Circles	66	(2)
Present Utilization of TQM Programs	68	(3)
Quality and Business Performance	69	(1)
Service Quality vs. Product Quality	70	(1)
The Malcolm Baldrige National Quality Award :	71	(4)
The Malcolm Baldrige Award Criteria	73	(2)
References	75	(4)
Chapter 3 Quality Assurance	79	(40)
Theories and Applications	79	(3)
Functions of a Quality Assurance Program	82	(5)
Quality Control	84	(1)
Quality Evaluation	84	(1)
Quality Audits	84	(2)
Education and Training	86	(1)
Process Improvement	86	(1)
Standards	86	(1)
Special Projects	86	(1)
Consulting	87	(1)
Auditing the Quality Program	87	(1)
Careers in Quality Assurance	87	(3)
QA Responsibilities and Operational Interactions	90	(1)
The Need for and Roles of QA	91	(1)
Organization of a QA Program	92	(1)
QA Personnel	92	(2)
The Vice President of QA	93	(1)
QA Professionals	94	(1)
QA Audits	94	(9)
Conducting an Audit	96	(1)
Purposes	96	(1)
Procedures	96	(2)
In-Process Monitoring	96	(1)
Statistical Procedures	97	(1)
The Audit Report	97	(1)
Types of Audits	98	(5)
Product Manufacturing Audits	98	(1)
Control of Nonconforming Products	99	(1)
Corrective Action	99	(1)
Plant Sanitation/GMP Audits	99	(2)
Plant Facilities	100	(1)
Employee Hygiene	100	(1)
In-Process Control	100	(1)
Contamination and Adulteration	100	(1)
Pest Control	100	(1)
Product Quality Audits	101	(1)
HACCP Audits	102	(1)
Special Audits	102	(3)
Document Control Audits	102	(1)
Supplier Audits	102	(1)
QC/Instrument Calibration and Maintenance Audits	103	(1)
Product Batch Preparation/Formulation Audits	103	(1)
Quality Program Review	103	(1)
QA Documentation System	103	(12)
Quality Manual	104	(1)
SOP (Manufacturing and Quality) Documents	105	(6)
PSM Documents	105	(2)
GMO Documents	107	(1)
QCA Methods Documents	108	(3)
SSOP Documents	111	(9)
GMP Documents	112	(2)
Equipment-Specific Sanitation Documents	114	(1)
Pre-Operation Sanitation Documents	114	(1)
Work Instructions	115	(1)
Records	115	(2)
HACCP Program Documents	117	(1)
References	118	(1)
Chapter 4 Ingredient Specifications and Supplier Certification Program	119	(22)
Raw Material/ingredient Certification Programs	120	(2)
Degree of Variability	121	(1)
Flavor Considerations	121	(1)
The Supplier Quality Program (SQP)	122	(14)
Supplier Qualification	123	(2)
Approved Vendors List	125	(6)
Supplier HACCP Qualification Standards	128	(1)
Supplier HACCP/QA Qualification List by Ingredients Purchased	129	(2)
Ingredient Specification/Certification	131	(3)
Supplier Auditing	134	(1)
Certificate of Analysis	135	(1)
Third-Party Inspections	135	(1)
Buying from Agents and Brokers	136	(1)
Identity-Preserved Products: A New Food Production Scenario	136	(3)
Defining IP Products	136	(18)
Consumer Desire	138	(1)
Processing Improvements	138	(1)
Product Attributes	138	(1)
Required Resources	138	(1)
References	139	(2)
Chapter 5 Statistical Methods of Quality Control in the Food
Industry	141	(1)
Introduction	141	(1)
Statistical Tools and Strategies for Process Control Improvement	141	(1)
Design and Analysis of Analytic Studies	142	(1)
Definitions of Terms and Concepts	142	(1)
Single Factor Experiments	143	(2)
The ANOVA Method	145	(4)
The Randomized Complete Block Design: Two-Way ANOVA	149	(5)
Quality Control Techniques	154	(20)
Variable Control Charts	155	(9)
X and R Control Chart	157	(5)
X and S Control Chart	162	(2)
How to Use Control Charts	164	(3)
Attribute Control Charts	167	(11)
p-Charts	167	(1)
np-Charts	168	(3)
c-Charts	171	(3)
References	174	(1)
Chapter 6 Manufacturing Audits: Control of Processing
Operations	175	(1)
Objectives of Process Control	176	(1)
Elements of Process Control	176	(1)
Education and Training	176	(1)
Process Control Documentation	177	(1)
Unit Operations in the Food Industry	178	(4)
Materials Handling	179	(1)
Cleaning	179	(1)
Separation	180	(1)
Disintegration	180	(1)
Pumping	180	(1)
Mixing	180	(1)
Heating	180	(1)
Cooling	180	(1)
Evaporating	181	(1)
Drying	181	(1)
Packaging	181	(1)
Controlling	181	(1)
Overlapping Unit Operations	181	(1)
Product Manufacturing Audits	182	(14)
Planning the Audit	182	(3)
Documentation	185	(2)
Product-Specific Manufacturing (PSM) Procedures	185	(1)
General Manufacturing Procedures	185	(2)
Standard Sanitary Operation Procedures	187	(1)
Analytical Control Procedures	187	(1)
Definitions	187	(6)
Quality Management Areas (Unit Operations)	187	(2)
Product-Dependent Operations	189	(2)
Product-Independent Operations	191	(2)
Process Control Points	193	(2)
Batching	194	(1)
Manufacturing Procedure Deviations	195	(1)
Risk Deviations	195	(1)
Nonrisk Deviations	195	(1)
Nonrisk Deviations to Risk Requirements	195	(1)
Audit Deviations: Example	196	(3)
Deviations from the Manufacturing Program	196	(2)
Batching and Formulation Practices	196	(1)
Traditional Chocolate Manufacturing Line	196	(1)
De Luxe Chocolate Manufacturing Line	197	(1)
Strawberry Topping Manufacturing Line	197	(1)
Ingredient Qualification and Storage Program	197	(1)
Ingredient Analysis Program	197	(1)
Analytical Test Methods	197	(1)
Consistency Brabender	197	(1)
HACCP Analysis	198	(4)
Batching and Formulation Program	198	(5)
Granular Sugar - Weighing Scale	198	(1)
Strawberry Topping Batching	198	(1)
Maple Walnut Topping	199	(1)
References	199	(2)
Chapter 7 Food Plant Sanitation: Good Manufacturing Practice Audits	201	(64)
Food Plant Sanitary Practices	202	(4)
Food Contamination	203	(3)
Humans	204	(1)
Equipment	204	(1)
Air and Water	205	(1)
Sewage	205	(1)
Insects, Rodents, and Birds	205	(1)
The Value of a Planned Sanitation Program	206	(1)
Storage Facilities	206	(1)
Litter and Garbage Disposal	206	(1)
Toxic Substances Control	206	(1)
Quality Assurance and Sanitation	206	(4)
Packaging Technology	208	(1)
Product Distribution	208	(1)
Personnel Sanitation and Health Considerations	208	(2)
Food Plant Sanitation Management	210	(22)
Sanitation as an Applied Science	210	(1)
The Food Plant Sanitarian	211	(1)
Personnel Training Programs	212	(1)
Plant Facilities Construction and Maintenance	212	(12)
Exterior of the Building	212	(1)
Grounds/Yard Areas/Landscaping	212	(1)
Interior of the Building	213	(3)
Doors/Windows/Other Openings	213	(1)
Air Curtains	214	(1)
Plant Walls/Ceilings/Floors	214	(1)
Heating, Ventilation, and Air Conditioning (HVAC)	214	(1)
Drainage and Sewage Systems	215	(1)
Waste Facilities	215	(1)
Catwalks/Stairs	215	(1)
Lights in Processing Areas/Exposed Food Ingredient Areas	215	(1)
Mirrors in Processing Areas	215	(1)
Equipment	216	(8)
Metal Surfaces/Support Structures	216	(1)
Can Conveyors and Can Tunnels	216	(1)
Conveyors/Sorting Belts/Shakers/Size Graders/Fillers/Flumes, etc	216	(1)
Flume Make Up Water	217	(1)
Mold Buildup	217	(1)
Belt Sprays	217	(1)
Equipment above Product	217	(1)
Moving Equipment or Parts that Rub Together	217	(1)
Motors/Gear Boxes/Pulleys/Other Drive Mechanisms	218	(1)
Water Sprays	218	(1)
Can/Bottle Lines	218	(1)
Line Covers	218	(1)
Fillers	219	(1)
Shears and End Plates	219	(1)
Tanks and Batching Kettles	219	(1)
Cooking Kettles	220	(1)
Utensils	220	(1)
Ingredient Containers	220	(1)
Ingredient Bags	220	(1)
Plastics and Rubber in Contact with Product or Ingredients	220	(1)
Exhaust Fans and Vents	220	(1)
Outside Surfaces of Equipment	221	(1)
General Construction of Equipment	221	(1)
Chemicals	221	(1)
Lubrication Practices	221	(1)
Cleanup Practices	222	(1)
Storage of Surplus Equipment/Supplies/Ingredients/Product/etc	222	(1)
Raw Fruits and Vegetables	222	(1)
Food Residuals	222	(1)
Condensate and Heavy Steam	222	(1)
Pest Control	223	(1)
Bait Stations/Rodent Traps	223	(1)
Insectocutors	223	(1)
Employee Practices	223	(1)
Incoming/Outgoing Material Control	224	(1)
Raw Material Receiving	225	(1)
Storage	225	(1)
Temperature and Humidity Controls	225	(1)
Returned Foods	225	(1)
Outgoing Products	225	(1)
Process Control: Sanitary Operations	225	(1)
Employee Hygiene and Sanitary Handling of Food	226	(1)
Sanitation and Housekeeping	227	(2)
Inner Perimeter Area of Buildings	228	(1)
Housekeeping Practices	228	(1)
Pest Control in Food Processing Plants	229	(3)
Insects	231	(1)
Rodents	231	(1)
Birds	231	(1)
Use of Pesticides	232	(1)
Finished Products	232	(1)
Lab Practices	232	(1)
Sanitation Laws and Regulations	232	(5)
FDA Regulations	233	(1)
USDA Regulations	233	(1)
EPA Regulations	234	(1)
The Federal Water Pollution Control Act	234	(1)
The Clean Air Act	235	(1)
FIFRA	235	(1)
The Resource Conservation and Recovery Act	235	(1)
Hazard Analysis and Critical Control Points Program	236	(1)
The Sanitation/GMP Audit	237	(25)
Objectives	239	(1)
Audit Checklist	240	(1)
General Description Sheet	240	(1)
Definition of GMP Observations	240	(26)
By Class	240	(2)
By Program/Control Area and Type of Observation	242	(3)
By Type	245	(8)
The Audit Worksheet (Observations Listing Form)	250	(3)
The Sanitation Audit Report	253	(27)
Report Format	253	(1)
Example of a Plant Sanitation Audit Report	254	(8)
References	262	(3)
Chapter 8 Product Quality Audits at the Retail Level	265	(24)
Definition	265	(1)
Objectives	266	(1)
Procedure	266	(1)
Planning	266	(5)
Preliminary Review Meeting	266	(1)
Protocol	266	(1)
Departments Involved	267	(1)
Product Sampling	267	(1)
Product Pick-Up	267	(4)
Testing	271	(8)
Packaging Quality	271	(7)
Sensory Evaluation	278	(1)
Analytical Testing	278	(1)
Example of a Product Quality Audit	279	(8)
Objectives	279	(1)
Protocol	280	(1)
Comparison between Eureka and Classic Beef Stew Products	280	(16)
Age	280	(1)
Drained Weight	280	(1)
Bostwick Value	281	(1)
pH	282	(1)
°Brix	282	(1)
Salt	283	(1)
Color Agtron	283	(1)
Sensory Evaluation	284	(2)
Eureka Beef Stew	284	(1)
Classic Beef Stew	285	(1)
Cans: Vacuum and Headspace	286	(1)
Can Packaging Quality	286	(1)
Reference	287	(2)
Chapter 9 Hazard Analysis and Critical Control Points	289	(100)
Introduction	289	(1)
The HACCP Concept	290	(5)
The Importance of HACCP	295	(1)
Advantages	295	(1)
The HACCP Program	296	(3)
Guidelines for Application of the HACCP Principles	296	(1)
HACCP Program Prerequisites	296	(2)
Education and Training	298	(1)
Development of an HACCP Program	299	(3)
The Preliminary Tasks of an HACCP Program	299	(3)
Choosing the HACCP Team	299	(1)
Description of the Food Product and Its Distribution	300	(1)
Description of the Intended Use and Consumers of the Product	300	(1)
Development of a Flow Diagram Describing a Food Product Manufacturing Process	300	(1)
Verification of the Flow Diagram	301	(1)
The Seven HACCP Principles	302	(26)
Principle 1: Conduct a Hazard Analysis	302	(26)
Categories of Hazards	304	(8)
Biological Hazards	305	(3)
Chemical Hazards	308	(2)
Physical Hazards	310	(2)
Preventive Measures	312	(2)
Questions to Consider when Conducting a Hazard Analysis	314	(6)
Ingredients	314	(1)
Intrinsic Factors	314	(4)
Procedures Used for Processing	318	(1)
Microbial Content of the Food	318	(1)
Facility Design	318	(1)
Equipment Design and Use	318	(1)
Packaging	319	(1)
Sanitation	319	(1)
Employee Health, Hygiene, and Education	319	(1)
Conditions of Storage between Packaging and the End User	320	(1)
Intended Use	320	(1)
Intended Consumer	320	(1)
Hazard Identification	320	(6)
The Raw Materials	320	(1)
The Manufacturing Process	321	(1)
Control Measures	321	(1)
Risk Categories	321	(4)
Documentation	325	(1)
Special Considerations when Conducting a Hazard Analysis	325	(1)
Deciding which Potential Hazards Must be Addressed in the HACCP Program	326	(2)
Principle 2: CCP Identification	328	(4)
Preventive Critical Control Measures (Microbiological)	330	(2)
CCP Decision Tree	332	(1)
Principle 3: Establish Critical Limits for Each CCP	332	(7)
Principle 4: Establish CCP Monitoring Procedures	339	(5)
Visual Observations	342	(1)
Sensory Evaluations	343	(1)
Physicochemical Evaluations	343	(1)
Microbiological Analysis	343	(1)
Principle 5: Establish Corrective Actions Procedures	344	(3)
Identifying Causes of Deviations	345	(1)
Determining Product Disposition	345	(1)
Recording the Corrective Action	345	(1)
Reevaluating The HACCP Plan	346	(1)
Principle 6: Establish Procedures for HACCP Verification and Validation	347	(5)
Verification	347	(4)
Events that May Require Verification Inspection of the HACCP Plan	349	(1)
HACCP Verification Protocol and Activities - Information in Verification Reports	349	(1)
Verification Schedules	350	(1)
Validation	351	(1)
Principle 7: Document the HACCP Program. Establishment of Record-Keeping Procedures	352	(10)
Format for HACCP Information	360	(1)
Examples of Records Required during Operation of the HACCP Program	361	(1)
Implementation and Maintenance of an HACCP Program	362	(22)
Practical Example: HACCP Plan Model for Refrigerated Stick and Sliced Celery	362	(22)
The Scope of HACCP	384	(1)
Regulatory Aspects of HACCP	384	(1)
Sanitation and the HACCP Concept	385	(1)
Conclusions	385	(1)
References	386	(3)
Glossary of Terms	389	(22)
Index	411