There has been a great deal of scrutiny focused on the food and beverage industry recently, and with good reason. Despite the fact that the industry is peppered (pardon the pun) with risks and challenges, they must be checked and monitored on a regular basis. Managing quality checks consistently across your organization can be challenging, especially if you have a large number of products and suppliers to manage. If you are experiencing any of the difficulties listed below, we have a solution for you.
What issues can be resolved through the use of QADEX in the field of food analysis and quality control?
When manual paperwork is used for quality checks, the ability to pick up and resolve issues quickly is compromised because critical data is frequently left in a filing cabinet somewhere gathering dust while manual paperwork is used. Potential problems with the quality of food are not identified until they have escalated to the point where there are consumer complaints.
Quality checks on finished products and raw materials are not being managed consistently across your food safety and quality control processes, which is a problem. Patterns that could have been detected using statistical process control are not picked up by the system. It is possible that inappropriate analysis methods are being used, resulting in a waste of money and time on both sides.
Supplier performance issues are not being identified and addressed as quickly as they should be. Increasing pressure is being placed on food manufacturers to deliver continuous improvement. Unless you have a well-functioning food analysis and quality control process that includes a feedback loop for supplier non-conformances and supplier improvement, this will be more difficult to achieve.
Supplier quality issues can have a significant impact on the level of service provided or the quality of the product produced. The failure to detect out of specification raw materials due to the lack of robust analysis methods has negative consequences for process control, as well as a reduction in the overall quality of the food products sold.
The sharing of information about "problem" suppliers is done on an as-needed basis. Problem suppliers frequently go undetected until a major issue arises, at which point a detailed quality control analysis reveals that there were signs of problems but that the bigger picture was missed because teams at different locations, working alone, delivering their version of the food quality control and assurance process.
In what ways does Food Quality Control and Assurance differ from other types of quality assurance?
All raw materials used and finished products produced must comply with food safety, quality, and legal requirements, which is achieved through a system of processes and procedures called quality control and assurance in food production.
Each and every food safety and quality control system should be built with the commitment of senior management at its core. A lack of senior management commitment will almost certainly result in all systems being superficial, overruled or gamed by other departments, which will almost certainly be preoccupied with higher-priority tasks such as maintaining customer service levels, reducing labor costs, and increasing production yields.
It is necessary to have a hazard and risk management system in place. This will frequently be based on the principles of HACCP. In order to be effective, a hazard and risk management team that is both appropriately qualified and multi-disciplined must be assembled. Team members should have received the appropriate training prior to working together. Each member of the team should be well-versed in the company's operations and kept up to date on any changes in customer requirements. A documented hazard and risk analysis (HARA) must be in place, and it must be included in the quality management system. The scope of the project should be defined and should be applicable to all of the products that are produced. An overview of the entire manufacturing process, from raw material intake to finished product despatch, should be included in the process flow chart as well. It is necessary to complete a review of potential hazards arising from chemical, physical, microbiological, quality, integrity, and malicious intervention sources. Identifying hazards and assessing their risk should be done in a systematic manner, with each hazard being assigned a numerical scale to determine the severity and likelihood of it occurring. Other quality risks should be addressed through the implementation of pre-requisite programs, such as supplier and vendor assurance programs.
It is necessary to have a product safety and quality management system in place. As a result, a product safety and quality manual outlining working methods and procedures for all parts of the food processing process will frequently be substituted for this. For example, as part of the food safety and quality control process, many food businesses employ software systems such as the QADEX knowledge and document management module. This should be kept up to date, and relevant procedures should be displayed in prominent locations throughout the plant. The manual should be made available to all members of the relevant team. It is necessary to have effective document control in place, which includes the use of reference numbers and issue numbers. All amendments should be accompanied by comprehensive records and audit trails. Product safety, legality, and quality characteristics should be effectively controlled, and proper record keeping should demonstrate this. Records should be kept for a period of time that is consistent with the shelf life of the product, taking into consideration the fact that many fresh products are frozen at the consumer's residence. All quality assurance checks performed during production are documented and archived.
It is necessary to maintain comprehensive raw material and finished product specifications in place. All raw materials should be purchased in accordance with supplier specifications that have been agreed upon, and a supplier list that has been approved and includes all of the suppliers' contact information should be maintained. Supplier risk assessments should be carried out in order to determine the appropriate supplier approval process to be used, which may range from certification review to self-assessment questionnaires to on-site audits of suppliers and everything in between. Supplier performance should be monitored on an ongoing basis.
Internal audits should be conducted on a risk-based basis, with the scope of audits covering quality, safety, and legality. Regular audits should be conducted to ensure that the requirements of the food quality control and assurance system are being met, and that the system is functioning properly. Non-conformances discovered during audits should be signed off on, and corrective actions should be reviewed on a regular basis at management meetings.
quality control is necessary to have a traceability procedure in place that is effective and has been tested. It is necessary to record the batch codes of each raw material used on production records, and all intermediate products should be packaged and labeled during transit so that the product description, time/shift/date and code information are clearly visible. This is used to track finished products all the way back to their manufacturing or raw material source. Challenge tests are conducted on a regular basis to ensure that the traceability system is operational, and trace records should be available in a timely manner.
All complaints should be logged and reviewed according to the type of complaint, and a procedure for complaint handling should ensure that this is done. This is something that an increasing number of businesses are doing with the QADEX customer complaints module. Executive level management should be presented with and reviewed on a regular basis with regard to customer complaints and non-conformance reports.
External standards, building fabric and interiors, utilities, security, layout and product flow, equipment, maintenance, housekeeping and cleaning, product contamination control, chemical and biological control, waste and waste disposal, and pest control are all part of the site standards.
Product and process controls will include product development, artwork management, process control, calibration, product inspection, testing, and measuring, control of non-conforming product, incoming goods, storage, and despatch, among other activities.
Human resource control measures will include training and competence, personal hygiene, employee facilities, medical screening, and protective clothing.
A detailed program of work and hygiene training should be in place to ensure that employees are properly trained and competent. New employees, including temporary workers, should receive induction training, as well as aptitude tests, to ensure that they understand the job. It is recommended that training be based on work skills for each process, which should include hygiene and quality. Staff members should sign off on training records to confirm that the hygiene training has been provided and that the information has been understood.
As part of personal hygiene, it is recommended that a documented jewelry policy be in place, which should be distributed to all new employees during their induction and displayed prominently on notice boards. A handwashing station has been established, eating is only permitted in designated dining areas, smoking is only permitted in designated external areas, and drinking water is readily available.
How many different types of equipment can be used in the analysis of food and beverages?
The types of equipment that can be used to analyze food and drink are numerous, and the equipment that is used will vary depending on what is being analysed, why it is being analysed, and how often it is being analysed. Invariably, the goal of the analysis will be to ensure that the specifications for safety, legality, and quality are met. The majority of testing in the food industry will be based on the risk of contamination. Consider the following scenario: if meats are being sourced and the presence of veterinary drugs is a concern, a suitable test could be performed using the liquid chromatography-mass spectrometry technique. To receive more detailed advice on analyzing your food and drink, please contact us. If we are unable to assist you directly, we will refer you to one of our friendly experts who we are confident will have all of the answers to any food analysis questions you may have at some point in the near future.
