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Good Manufacturing Practices (GMP) in food plants are a comprehensive system of guidelines designed to protect food from potential contamination, which are outlined by the USDA and FDA. The following are some elements to include in a food company/facility GMP program: Personal Hygiene – team members must follow strict handwashing, use of protective clothing such as smocks, hairnets/beardnets, gloves, prohibitive use of jewelry, and prevention of eating/drinking or other pers

Biosecurity is defined as the procedures intended to protect humans against disease or harmful biological agents. The FDA & USDA provide guidance to all human food facilities in the important area of Biosecurity. Below is an overview of some key elements that should be included in a robust Biosecurity plan: Management and Policy - establish a Food Security Team (can be the Food Safety Team), conduct a Risk Assessment to evaluate vulnerabilities, establish Crisis Management

Undeclared allergens result in the highest amount of food recalls in the US annually. Although the number of recalls for this category has decreased year over year, it is still important to develop a program that manages this food safety threat. 90% of food allergic reactions are covered under what the US Government calls the “Big 9”: 1) Crustacean shellfish (e.g., crab, lobster, shrimp), 2) Eggs, 3) Fish, 4) Peanuts, 5) Milk, 6) Tree nuts (e.g., almonds, pecans, walnuts),

FM is defined as non-food substances that could cause injury to a consumer, and per USDA FSIS Directive 7310.5 examples of FM are foreign material such as metal, plastic, rubber, glass, wood, steel, or lead shot, and should be considered in the hazard analysis of the HACCP plan. Some sources of FM are Incoming Materials, Processing Equipment/Environment, Team Members, Product Packaging, Pests, Intentional adulteration, to name a few. FM Control Strategies: Incoming materials

USDA's Sanitation Standard Operating Procedures (SSOP) are essential for the structure and documentation of food safety related to the sanitation/sanitary design aspects of the food processing environment as outlined in 9 CFR Part 416. Key Requirements: Implementation and Monitoring – designated individuals in the establishment responsible for the implementation and monitoring of the SSOP plan must be identified. Typically, the QA department verifies the SSOP plan elements,

The USDA's HACCP (Hazard Analysis Critical Control Point) system is designed to ensure food safety by identifying and controlling potential food safety hazards. Initial/Preliminary steps: Food Safety Team – establishment of this group as the core team that creates and signs off on the HACCP plan, which is comprised of leaders of the facility such as Operations, Quality and Maintenance departments, at a minimum, and should be HACCP certified. Pre-requisite Programs - developme

Preventative maintenance is critical in food safety because it minimizes the risk of equipment failure that could lead to contamination, ensures compliance with food safety regulations/auditing standards, and maintains consistent product quality. Preventative Maintenance (PM) supports high standards in food production by not only preventing physical contamination of product through the degradation of equipment, but damaged surfaces can also harbor bacteria compromising food

Sanitation of a food processing environment is critical not only to assure that the product meets food safety and quality excellence, but also to establish a clean break in the processing regimen between production dates. The 7 Steps of Sanitation follow a sequence designed to remove soils, eliminate pathogens, and ensure regulatory compliance under the SSOP (Sanitation Standard Operating Procedure) plan. The completion and verification of the sanitation process should be do

External support plays a vital role in helping businesses navigate complex regulations, adopt best practices, and maintain consumer trust, through continuous monitoring and improvement, for long-term success. External support can assist with complex and evolving food safety regulations, provide expertise on specific hazards or testing methods and provide access to updated scientific research and technology. External support can also assist with: Third-Party Certification (BRC

To implement an effective QA program, food businesses should focus on several key components: Customer Specifications - Understanding your customer requirements through their specifications is a critical element for full alignment with them. Conducting Pre- and Post-Production meetings with the plant team/customer can expedite the alignment process as well. Customer Feedback - Listening to customers is crucial for continuous improvement. Feedback (through paths such as Surv

Food Safety is a primary concern for any food business. Contaminated food can lead to serious health issues, including foodborne illnesses, and recalls, which can destroy a food business. Implementing food safety practices helps prevent these issues. For example, regular inspections and testing can identify potential hazards before they become a problem. Additionally, having a robust food safety system can help businesses comply with local and international food safety regula

Often manufacturers understand their base, core component well but forget that what they add to it to create niche food products in the marketplace is equally important. Substandard suppliers pose a significant risk to food processors. Having reliable, high-quality/food safety driven suppliers is critical to a food company’s product consistency and success. It also assures compliance with Regulatory/GFSI standards and can prevent recalls due to undeclared sub-components an

When developing a Company Vision for Food Safety/Quality, it is best if it is a top-down approach that is communicated to all levels of your organization regarding the need to produce safe, high-quality food products. Meeting throughput and people safety metrics are important, but products that are unsafe or poor in quality will destroy a company. Some ways to do this are: · Create company FSQA leadership materials from executive leadership such as videos, breakroo

Food Safety and Quality (FSQ) culture is the shared values, attitudes and behaviors within a business that prioritizes safe, high quality food production at every level. Robust FSQ policies and procedures are the framework, and the Culture is the foundation on which they are built. It starts with the top leadership and flows, uninhibited, to the team member level, to ensure that food safety and quality standards are constantly met thereby contributing to the overall success

To maximize safety and quality, businesses must implement an effective and robust training regimen. By focusing on continual, routine training, businesses can maintain their relevance in the marketplace and reduce the risk of failure that can destroy relationships with their customers. Providing training ensures that everyone understands the importance of what they do and how they can contribute to the overall success of the business. Regular training sessions can cover top

Although I am not aware of the root cause, seeing a recent recall regarding contamination of a product sub-ingredient stresses the importance of partnering with great suppliers. Please see the post about the "Importance of Reliable Suppliers": https://www.faithfulfoodsolutions.com/post/the-importance-of-reliable-suppliers

Environmental food plant sanitation is more than just cleaning following the 7 Steps (see BLOGs on the 7 Steps of Sanitation for Industrial Food Facilities: https://www.faithfulfoodsolutions.com/post/7-steps-of-sanitation-for-industrial-food-facilities and SSOP Basics: https://www.faithfulfoodsolutions.com/post/ssop-basics). It is a system that is also heavily dependent on facility design and team member practices, to include robust monitoring. Elements should include: Pers

The USDA's HACCP (Hazard Analysis Critical Control Point) system identifies a layered review of critical control points (Monitor, Direct Observation and Pre-Shipment Review) that can be applied to any crucial quality or food safety element. The fact is that no matter how confident you are in sustaining a successful process, there is vulnerability for any human/process through error. People/Processes are not perfect resulting in mistakes that can be costly if not caught/corr

Building Customer Trust is paramount to the success of any business. With the pressures of team member safety, profit-loss metrics and regulatory compliance this focus can sometimes be lost during the fast-paced day-to-day operations. However, as with base quality and food safety SOPs/programs, a company should consider how it can place continual emphasis on the customer. All customers are important, but some carry a heavier weight if they represent a significant percenta

Investing in quality assurance can lead to significant cost savings in the long run. While it may seem like an added expense, the benefits often outweigh the costs through: Reduced Waste : By ensuring products meet quality standards, businesses can minimize waste from spoiled or defective items. Avoiding Recalls : A strong FSQA system can help identify issues before they escalate, reducing the risk of costly product recalls. Increasing Efficiency : Streamlined processes can l