The Importance of Biosecurity for Food Plants

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 key elements that should be included in a robust Biosecurity plan for the receipt and storage of food ingredients, processing and shipment of food products and the prevention of intentional contamination of food products.

Management and Policy

• Food Security Team: Identify the key personnel responsible for biosecurity.  This can be the Food Safety Team (Operations, FSQA, Maintenance, Supply Chain/Warehousing)

• Risk Assessment: Evaluate vulnerabilities in plant operations, raw material supply, packaging, storage, and distribution.

• Crisis Management: Procedures for food tampering, product recall, and emergency evacuation.

• Coordination with Authorities: Maintain updated local, State, and federal law enforcement, and public health contacts.

Personnel Controls

• Background checks (including temporary, contract, and seasonal workers)

• Positive identification systems (ID badges, color-coded uniforms for access)

• Restricted area access based on job function and supervision levels

• Staff training in food security procedures, including tampering detection and response

• Monitoring unusual behavior and enforcing access restrictions on personal items

Note: Management should instill trust and confidence within their team so that they will not only closely monitor the food in the area but also report any suspicious activity they observe.  Without team member trust, the best food security program can be vulnerable if team members do not feel free to report things they see. All reporting, regardless of outcome, should be celebrated to continually strengthen this relationship.

Facility and Physical Security

• Secure perimeter with fencing, lighting, cameras, and self-locking emergency exits.  Roof access and storage facilities should be included.

• Control entry for visitors, contractors, and delivery personnel

• Controlled access to HVAC, water systems, electricity, chemical storage, ice machines, bulk ingredients (such as oil, flour, corn, CO2).  Padlock/other controls of offloading ports is an example of this type of control.

• Surveillance of incoming and outgoing vehicles and inspection of shipments.  Verification of serialized seals to incoming paperwork is one way of doing this.

• Laboratory biosecurity when handling hazardous biological agents, chemicals, or pathogens

Operations and Process Security

• Monitor equipment and production lines (e.g., blenders, chill tanks)

• Verify integrity of packaging and restricted ingredients

• Maintain traceability (lot numbers, Cool Labels) for all raw materials and finished products

• Control of returned goods and validation of their use in rework

• Regular inventory checks including hazardous chemicals

• Implement tamper-evident seals on outgoing shipments

Monitoring, Verification, and Preparedness

• Regular, confidential food security assessments and drills

• Mock recalls and perimeter security tests

• Evaluate effectiveness of contractors or third-party security

• Periodically revise food defense plans to address new risks or vulnerabilities

Water, Ice, and Mail Handling

• Protect water supply and in-plant ice machines from unauthorized access

• Inspect and restrict mail-handling in proximity to food areas

• Train staff to identify and manage suspicious mail

Computer and Data Security

• Firewalls, password-protection, activity monitoring

• Regular backups for critical operational data that could affect food safety

As with all Food Safety programs, an annual assessment of food defense plans is recommended.  Training during the Onboarding/Orientation of new team members and annually thereafter is critical.  The goal is to prevent, detect, and respond to intentional contamination while maintaining compliance with federal regulations.