Foreign Material Control

Successful foreign material (FM) control in food plants is a multi-hurdled system approach designed to prevent and detect physical contamination throughout the food chain process (from incoming materials through final packaging).  FM control ensures consumer safety, maintains regulatory compliance and protects brand reputation.

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:

·        Incoming materials – ingredients/core food items can contain FM

·        Processing equipment – metal or plastic fragments and machine bolts/parts

·        Team members – jewelry, gloves, ear plugs, hair, pens

·        Processing environment – overhead supports, walls, air handling units, floor jacks, pallets (wood or nails)

·        Product packaging – ingredient and final packaging can be a source of FM

·        Intentional adulteration of product through sabotage

·        Pests – insects, rodents/droppings

FM Control Strategies:

·       Incoming materials

• Suppliers should have effective FM control programs and have GFSI certification

• Installation of in-line filters/magnets, or use of manual inspection of incoming products for the possible existence and removal of FM

·        Processing equipment/environment

• Preventative maintenance programs, conducting a hazard analysis/Failure Mode Effects Analysis (FMEA) and removing unnecessary parts identified from the environment and from the equipment if not needed

• Metal/X-ray detection machines before final packaging

• Daily inspection of equipment and the environment

• Use of food grade lubricants and parts that are metal or x-ray detectable

• Glass should not be used (or if unavoidable shielded behind shatter-proof materials)

·         Pest Control Program

·         Team member training – making team members aware of how their role could lead to the potential contamination of product and creating an environment to recognize team members who report missing personal equipment or if they see something missing from the machinery/find a piece of foreign material is critical.  By involving all team members and by creating an environment where they feel empowered to report something missing can greatly assist with the prevention of foreign material from reaching the final consumer.

In conclusion, effective foreign material control protects your consumers and your company brand, as well as prevents expensive recalls/product withdrawals.