Good Hygiene Practices Incoming Material Requirements Section 2 - Sub-Module 5.2

Good Hygiene Practices

Incoming Material Requirements

Section 2 - Sub-Module 5.2

Slide 2 Module 5.2 - Incoming Material Requirements

1. Understanding the importance of incoming material control

2. Using Raw Material Specifications

3. Standardizing procedures to manage incoming materials

4. Demanding compliance with specifications

5. Choosing suppliers

Incoming Material Requirements: Presentation Outline


Raw materials influence the safety and suitability of foods

Processing cannot remove all hazards


The 3 key aspects of incoming material control

Develop

1. Raw material specifications

2. Standardized procedures of operation

3. Strong trading relationship with suppliers









Why have raw material specifications?

Purpose:

Clear communication with suppliers

Proof to authorities that existing standards are being followed

Uniform internal system of supply management


Raw Material Purchasing Specifications should focus on certain key elements

SAFETY

Hazards Chemical Microbiological Physical

QUALITY

Criteria related to Appearance Packaging Size

Sensory characteristics Colour, taste and smell are

important factors that influence the recipe

Composition, critical ingredients

Protein, fat, water, etc. Additives


Base specifications on required and/or internationally recognized standards

Consult sources such as

Codex standards, national

legislation, ISO standards, food industry

norms.


Additives must be food grade

colorants antioxidant

s flavour

enhancers

Beware of carry-over !

Only use food-grade and permitted substances!









Upon arrival all materials must be checked

Check all incoming materials upon receipt and react

immediately if something is wrong.

Conform and safe?


Develop precise instructions on how to receive materials in a standardized

manner

Develop a standard operating procedure

(SOP) for receiving raw materials.


Records prove that incoming materials have been checked

Upon each receipt of materials one Standard Entry Form needs to

be completed.

Safety aspects


Tag or mark all materials that have been checked

Standard Entry Form


Not all incoming materials will be 100% conform

Materials of lower quality can still be used under certain conditions

Non-conforming materials must be rejected.


Grade incoming materials into a number of manageable categories

Categories:

• Accept

• Accept under condition that extra treatment necessary

• Reject

Do incomingmaterials meetspecifications?

No

Yes

Can it be treatedto reduce risk orused in adifferent process?

Store according toinstructions

Reject or store separately with clearinstructions that material is bannedfrom use (e.g. ground meat that isdelivered at room temperature).

Product Manager to take decision onfurther use (e.g. adapt processing oruse for lower-grade/different product).Store with clear tagging regardingspecial use.Yes

No


Lower grade materials must be identifiable

Standard Entry Form

Clearly identifiable low-grade tag


An example of a colour-coded form


Keep documents personnel must consult to a minimum

Divide instructions between a basic SOP and Incoming Material Specifications specific for each material so document

is easy to consult, and useful for instruction

purposes.

SOP

INCOMING MATERIAL

SPECIFICATIONINCOMING MATERIAL SPECIFICATION

Grades

INCOMING MATERIAL SPECIFICATION

Grades

INCOMING MATERIAL


Grades


Grades

INCOMING MATERIAL


Grades


Grades

INCOMING MATERIAL


Grades


Grades

INCOMING MATERIAL


Grades


Grades

INCOMING MATERIAL


Grades


Grades


Choose 2-3 people who will be responsible for checking incoming materials

Train personnel to check incoming material.

Give them the power and confidence to not accept material.

Material must be checked immediately upon arrival.


Overview of documentation of incoming materials

SOP

Standard Entry Document


Grades


Grades

The grading of all stored material must be visibly indicated.

INCOMING MATERIAL


Grades


Grades

INCOMING MATERIAL


Grades


Grades

INCOMING MATERIAL


Grades


Grades

INCOMING MATERIAL


Grades


Grades

INCOMING MATERIAL


Grades


Grades

INCOMING MATERIAL


Grades


Grades

Store only labelled materials!


Safe supplies require a steady level of communication

Production department should inform quickly about low stocks; inform personnel if supplier has not met specifications communicate actively with QS;

Buying department should foreseen potential lower quality of produce causes and

communicate to inspecting personnel;

QS-department should maintain good working relationships.









The aim of testing is to assess whether a product conforms to specifications

Rapid

Simple

Accurate

Cost effective

Tests should be:


Key indicators that can be measured without the use of complex equipment

Measuring indicators

Temperature

Moisture content

pH

Sensory assessments

Taste/flavour/odour

Texture

Odour

(grain) sizeMeasuring devices Measuring devices must be regularly must be regularly controlled for accuracy controlled for accuracy and precision! and precision!


The value of visual inspections is often underestimated

Trained personnel can

spot the difference!


Use visual inspections to check for physical contamination

Carefully sift through materials by hand or use

a special sieve.


Record results of all performed checks

Develop forms that are easy to complete


Certain tests require complex equipment

Testing for chemical contamination is not always

practical.


Complex test results often arrive after product has been sold

Results of microbial tests are often only available

after a certain number of days.


Demanding additional guarantees from suppliers

Demand written proof if criteria from supplier if:

lack of equipment or expertise; no adequate laboratories available; regular analysis too costly; results only available after product has been consumed; no tests available for attributes such as “biological”, “halal”;


Certificates of Analysis and Conformance

Certificate of Analysis (CoA)

Certifies the conformity of abatch of products to aspecified test results.

Certificate of Conformance (CoC)

Confirms supplies conformto specific attributes i.e.free of additives.


A Certificate of Analysis could look like this ..

COMPANY NAME

CERTIFICATE OF ANALYSIS

Product: “Best Cocoa“ cocoa powder Product Code: xxxxxLot: 310676Covering 300 bags of 25 kgBest Before date: 19/08/2010

Analysis Result SpecificationsColour up to standard up to standardFlavour up to standard up to standardfat content (%) 12% 10-12% (extraction with petroleum ether)pH 8.0 7.8 – 8.2fineness 99.7 99.5 min (wet through 200 mesh sieve)moisture content 4.5% 5% maxStandard plate count 400 5000 maxmoulds per g < 5 50 maxyeasts per g < 5 50 maxenterbacteriaceae negative negativeE. coli in 1 g negative negativeSalmonella negative negative (as per US FDA sampling method)

We guarantee that our products are not sterilised by means of gas treatment or radiation.

Signature: ........................................ Date: .............................(Laboratory Manager)


.. or like this (includes testing methods)

“Best Sugar” Company LTDCERTIFICATE OF ANALYSIS

CASTER SUGARAppearance White Granulated CrystalFlavour Aroma TypicalAllergens AbsentShelf Life Greater than 2 yearsGM Status Contains no GM ingredients, processing aids or additives during

production

PARAMETER Results of Analysis LIMIT TEST METHOD

Cane sugar 99.93 % Min- 99.9% DifferenceReducing Sugar 0.004 Max -0.04 % ICUMSA GS2/3-5Ash 0.01 0.02 % ICUMSA GS2/3-17Water 0.04 0.04 % HMAColour 22 50 Cl SpectroTurbidity 0 5 Cl SpectroInsoluble Matter 0.03 5 ppm filtrationScreen Analysis 2.7% 4.0% ICUMSA GS2/3-7 (T 600 micron) Thermophilic Spore Count 18 150 ICUMSA GS2/3-49Yeasts 1 10 ICUMSA GS2/3-47Moulds <1 1 0 ICUMSA GS2/3-47

This information was obtained by laboratory analysis from source

Batch ref #: 3098267


Be aware of fraudulent CoAs and CoCs

Always control authenticity of certificates









There are only limited possibilities of correction for non-conforming materials

Sorting and processing cannot correct safety deficiencies of

materials.


Food businesses need trustworthy suppliers

Identify and select supplies

communicate specifications

conduct on-site visits of supplies

provide training

enter long term trading relationship


Supplier assessment

Systems of supplier assessment (IT or manual) are useful tools to evaluate suppliers

Trading safety for a better price is not an option!

Inform suppliers once a year of how they have performed


Incoming Material Requirements: Conclusions

No raw materials/ingredients should be accepted by a food business if they represent a threat for food safety.

Improve management of incoming materials by standardising controls using written SOPs, forms and by recording data.

Personnel should be trained to check and grade incoming materials.

Food business operators need trustworthy suppliers.


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of Section 2 Applying GMPs after reviewing any supporting documents and links you desire, please proceed

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Good Hygiene Practices Incoming Material Requirements Section 2 - Sub-Module 5.2