For class use only ACHARYA N. G. RANGA AGRICULTURAL UNIVERSITY B. Tech (Food Technology) FDST 318 Course No.: Credit Hours: 3 (2+1) THEORY STUDY MATERIAL FOOD QUALITY AND CERTIFICATION Prepared by Dr. Jessie Suneetha W Mrs. Syamala B College of Food Science and Technology, Pulivendula Mrs. Preeti Sagar R College of Food Science and Technology, Bapatla 1 DEPARTMENT OF FOOD SCIENCE AND TECHNOLOGY INDEX S. No Title of the Lecture Page No 1 Food Quality – its need and its role in Food Industry 3 2 Food Quality and Quality Attributes-Classification of Quality Attributes and their role in food Quality 14 3 Objectives, Importance and Functions of Quality Control 4 Methods of quality concepts of Dough Rheology 22 5 Quality Assessment of Food materials – Fruits and Vegetables 24 6 Quality Assessment of Food materials –Cereals and legumes 29 7 Quality Assessment of Food materials –dairy Products, 32 8 Quality Assessment of Food materials –Meat, Poultry, Egg and 41 Processed food Products 9 Statistical Quality Control of Foods 43 10 Sensory Evaluation of Food Quality – Introduction -Panel Screening- 53 Selection of Panel members 11 Requirements for conducting Sensory Evaluation and serving 56 procedures 12 Methods of Sensory Evaluation and Evaluation cards – Difference/discrimination procedures 59 13 Methods of Sensory Evaluation and Evaluation cards- Ranking and Rating procedures 14 Different methods of Quantitative descriptive analysis 15 Determination of Sensory thresholds and taste Interactions 67 16 Objective/Instrumental analysis of Quality Control 71 17 Food laws and Standards (BIS) 80 18 Consumer Studies – Types of Consumer studies- Preference Studies 82 and Acceptance Studies 19 Consumer Studies – Types of Consumer studies- Preference Studies 86 Objectives of Consumer Preference Studies-factors affecting consumer acceptance 20 Information obtained from Consumer Study -Factors Influencing results 88 from Consumer surveys 21 Methods of Approach-Development of the questionnaire- Types of 93 Questionnaire and other methods of data collection 22 Comparison of Laboratory Panels with Consumer panels. Limitations of 96 Consumer Survey 23 Fundamentals of Food regulations-pertaining to Additives and Contaminants 24 Food regulations pertaining to aspects of Hygiene - Novel Foods & 98 aspects of Labelling 25 Different existing Food legislations-norms in implementation 26 Food grade and standards 106 27 International food regulations and certifications 114 28 Indian food regulations and Certifications 119 29 Concept of Codex Alimentarius 128 30 The concept and process of implementation of HACCP in an industry 129 31 USFDA - the cause of its existence - its role in safe guarding food quality 136 - Significance 32 Food Adulteration and Food Safety 138 2 Lecture-1 • Food Quality – its need and its role in Food Industry Principles of Food Quality Assurance Food manufacturers usually have two stated levels of quality for products marketed. One deals with a product's quality established as company policy to meet consumer needs and the other deals with product quality in terms of meeting governmental regulations and laws. Branded products marketed by a company are matters requiring the most careful attention by company management. It is a general rule that company policy relating to branded product quality is more rigid than that required to meet governmental regulations. Company policy statements generally include a statement demanding that all products marketed meet the laws and regulations of all federal, state and local governments. The Need: The epidemiology of food-borne hazards has been summarized by the U.S. Centre for Disease Control Their analysis of where foods are mishandled is given in the table below. While the percentage of cases traced to food processing plants is low (6%), one factory can create widespread difficulty compared to a home or a restaurant. The outbreaks traced to foods from food processing plants are because of inadequate refrigeration as well as preparing foods in advance resulting in re-infection after the final heat processing, inadequate heat processing and holding foods at temperatures that favor bacterial growth. Places where foods were mishandled in such a way that Food - borne diseases outbreaks resulted Place Number Percentage Food service establishment 589 37 Homes 230 14 Food processing plants 104 6 Unknown or unspecified 692 43 Total 1615 100 Food - borne outbreaks in which processed foods were incriminated and the relationship between reported diseases and processes by various food industries Processed foods that received no heat treatment were often made up of contaminated raw ingredients. The source of contamination with salmonellae was raw ingredients. In the few cases of contamination with trichinellae (increasingly rare in the United States), the incoming pork was infested. Heat process failures were common. Processes such as smoking, often failed to kill salmonellae or trichinellae that were on or in the product. Clostridium botulinum cells multiplied and produced neurotoxins in canned or vacuum-packed foods after their spores survived improper heat processing. 3 Post-processing contamination with salmonellae or trichinellae by cross- contamination from raw products to heat processed food by equipment or workers during subsequent handling was another significant source. The frequency with which certain food processing plants have produced foods that have been incriminated in food-borne disease outbreaks and the factors that led to contamination, survival or multiplication of pathogens . Incoming raw materials (usually foods of animal origin) are revealed as hazards in the processing of meat, poultry, eggs, baked goods containing eggs, milk, fish salads and confections. Role of Government: Responsibility for the safety, wholesomeness and nutritional quality of food rests with the food industry, not with the Food and Drug Administration. The task of the FDA is to monitor the industry to determine whether it is meeting its responsibilities. The FDA has the role of motivating compliance, but does not act as a company’s quality assurance division. The FDA takes appropriate corrective actions when industry fails to meet its responsibilities. A number of techniques are used by the FDA in determining the manner in which industry accepts its responsibilities. These include: (1) Establishment of inspection - which may vary in comprehensiveness and intensity from that of the Hazard Analysis and Critical Control Point (HACCP) inspection to that of a less-comprehensive key indicator inspection. (2) Sample Collection and Analysis of a product during processing and of finished product in distribution channels. (3) Surveillance intended to identify new problems as well as to quantify the extent and significance of known problems that may be associated with processing, the environment, and other factors. Though these techniques are useful, the best hope for safety and quality in food lies in the development and maintenance of adequate in-plant quality assurance programs. Promoting quality assurance at the plant level is thus a primary goal in FDA regulation. Good Manufacturing Practices (GMP): The FDA has recently embarked upon a course of public rule making as a means of obtaining industry-wide compliance with the responsibilities of industry. Public rule-making developed with the input of all interested and affected parties. It provided the means by which to inform all persons of what is considered appropriate. The initial Good Manufacturing Practice Regulations for foods was published in 1969, and is often referred to as the Umbrella GMP. It made use of such words as "adequate," "proper," and "sufficient." Despite the fact that many provisions in the GMP were written as mandates, compliance was often difficult because of the vagueness of the subjective terms. In spite of these shortcomings, the most important objective of the Umbrella GMP was to provide guidance relative to long range improvement programs and 4 directed to plant facilities and practices. This general regulation served to encourage the adoption of quality assurance systems and to indicate the need for such systems where they were absent. The FDA has now embarked on a program of expanding the GMPs to include regulations that will ultimately apply specifically to all the major segments of the food industry. Detailed and specific GMP regulations which have been publically developed are now in effect for many areas of concern. A typical GMP outline has similarities to a quality assurance system. A preamble introduces the subject, discussing the background of the industry and why a GMP is considered necessary, and reports on information gathered in plant inspections. It also stresses reasons why certain features or requirements are needed. Each regulation has a definition section. Each definition states that the word "shall" mean that the requirement is mandatory and that the word "should" refers to an item that is desirable but not absolutely essential for the carrying-out of an operation. The next section refers to the Umbrella GMP regulation and is followed by specific sections pertaining to the industry. If there is concern for contamination from outside the factory or the possibility of cross-contamination between different operations, note is made. The next section deals with equipment and utensils and stresses general overall design criteria for equipment that is unique for that industry, or that requires special controls for safety and sanitation. A section on personnel sanitation facilities is frequently included. Sections on the cleaning and sanitizing of equipment follow. The FDA believes the most important part of the GMP involves processes and controls that are vital for the particular type of food manufacturing operation. A section usually is devoted to records and record-keeping that covers at least the average life of the product in distribution. FDA believes that the Good Manufacturing Practice regulations materially reduce the probability of release of food products that are not in compliance (i.e., distribution of an unsafe product, exactly the aim of any effective quality assurance system). An example of a GMP that delineates specific quality assurance requirements is the low-acid canned food GMP-"Thermally Processed Low-Acid Foods Packaged in Hermetically Sealed Containers." This GMP details the operations that must be conducted to assure the production of a safe low-acid canned food, according to the FDA. It contains the same elements found in quality assurance systems throughout industry. Quality assurance systems in industry dovetail the low-acid canned food GMP into their operations. Microbiological Standards: Another FDA regulatory area having an impact upon quality assurance systems is the establishment of microbiological quality standards. Acceptable microbiological levels for food products at the retail or consumer level, taking into account post-production abuses, are established. This is done by conducting a nationwide· statistical survey of the food under evaluation. The data are reviewed, and proposed standards are developed that considers both the producer's and consumer's risks in realistic terms. Once a 5 proposed standard is developed it is published in the Federal Register as a proposal with provision for comment. Each comment received is reviewed and is responded to through subsequent publication in the Federal Register, and changes indicated by comments are made. When the proposed standard is finalized, it is a mandatory standard that must be met under the provisions of Section 401 of the Food, Drug and Cosmetic Act. The projected impact of microbiological quality standards upon the food processing industry's quality assurance system greatly affects the distribution and retail outlet industries. The establishment of certain microbiological quality standards requires a re-evaluation of some quality assurance systems and causes the introduction of such systems in areas that now operate without such controls. Good manufacturing practices and microbiological quality standards are examples of FDA regulatory initiatives that affect quality assurance systems. The FDA indicates it supports efforts to require all food processors to establish and use quality assurance systems in their production operations, with emphasis upon monitoring and disclosure of hazards associated with the product and the means employed to control the hazards, in the public interest. Role for Industry: There are some ten elements of production safety if strict compliance with FDA safety standards is maintained. The minimum a food manufacturer must do is to assure the quality and ensure the safety of marketed products. (1) Product Safety Analysis: Food safety analyses must be conducted on all products to assess their microbiological, physical and chemical safety. All aspects of a product's makeup are evaluated (e.g., product formulation, processing, distribution and final use) to ensure safety in use. New products should not be manufactured, distributed or sold until a rigorous review of all aspects of a product's composition has been completed. The purpose of such a review is to assure that the proper formulation, processing and distribution of every product results in the offering for sale of unadulterated foods for consumption that meet or exceed federal regulations and requirements. (2) Product Specifications: Each product must have certain specifications for manufacture. These specifications must cover all safety, quality and regulatory requirements. They must specify the uses of processes, ingredients, and acceptance tests, packaging materials and labels, and include descriptions of utilized processes and finished products. Such specifications serve as the vehicle through which a company can communicate federal standards and regulations to factory production. Depending on the size of the manufacturing operation within a given company, the amount of documentation required for each product, packaging material, ingredient specification and testing procedure is compatible with simple specification files. However, 6 as the size of company’s operations expands, the magnitude of the files is such that an alternative means of recording specifications may be necessary. It is not difficult to computerize this process, once the specification files reach a certain size. Computerization creates an effective and efficient storage and retrieval system of documentations of product specifications. (3)Physical Systems Hazard Control: Industry is required to make and maintain inventories of food processing systems and their environments and the possible hazards that may occur within the context of each system. A hazard control system is usually generated by the particular facility in which food processing or production takes place. It is the responsibility of the manufacturer to prepare and maintain these documents so that clear identification of all physical systems hazards are known, and a complete and lucid understanding of each step in the processing and packaging of manufactured products is available. Flow diagrams are particularly suited for this purpose, because they can show where possible hazards may occur in a particular process or part thereof. A schematic representation of the manufacturing procedures and processes allows for their exposure on a level where hazards may otherwise pass unnoticed. The following procedure is useful in trouble-shooting for physical systems hazards: (a) Develop and maintain flow diagrams to cover all food processing and physical systems and environments (b) Identify all physical systems hazards to the safety and integrity of products. (c) Establish and document systems of control for all hazards, whether actual or possible. (d) Maintain records of control procedures for all physical systems hazards that are critical to product safety. Whenever possible, correctible hazards must be eliminated. Physical plant and systems hazards must be reviewed before a food product is manufactured in a facility. (4)Purchasing Requirements: Purchase of raw materials should be limited to approved suppliers who can offer an acceptable continuous guarantee of a material's quality. Further, it is in the company's interest to require the supplier to submit proof of ability to supply the appropriate quantities of materials of certain predetermined quality and safety standards. Raw materials must pass a plant inspection. Routine inspections assure that raw material quality is kept at the appropriate level. A supplier who frequently delivers products below the stated requirement levels should be covered by contracts describing specifications and safety analyses. The facilities used should be submitted to regular inspections by those who must approve any and all such products. 7 (5) GMP Compliance: High sanitation standards must be maintained, documented and rigorously observed in all production, storage and distribution facilities. Sanitation procedures instruct personnel on how to comply with sanitation standards. They must know the essential technical aspects of these procedures and why they must be followed. The knowledge behind these practices is given to personnel during their in-plant training. (6) Product Recall System: A tracing system is needed so that all products sold can be accounted for and located if it is necessary to recall products in retail distribution. Either manual or computerized systems suit these purposes, depending upon the size of the overall operation. Tests can be conducted periodically to ensure the workability of the system. Results should be recorded and documented for future reference or for possible improvements in the system employed. Some tests that can be conducted to measure the capabilities of a recall system are: (a) What is the least traceable unit of distribution, i.e., date, shift, batch, low, etc.? (b) How effective is the method used in determining the amount of product to be traced? (c) How long does it take to make a complete trace of a product? (7)Customer Service: Means of recording and responding to consumer and customer complaints are needed. This is not for public relations but is a means of detecting safety and/or deficiencies in products. Prompt attention is essential. (8) Inspections and Safety Incident: Means of recording and responding to all safety or regulatory incidents are needed. A regulatory incident is a visit by federal, state or local inspectors or any regulatory agency to any facility. A company facility is any of the following: plant, mill, warehouse, restaurant, research and development canter, factory, etc. Some of the regulatory agencies that might make such a visit are: FDA, USDA, EPA, OSHA, FEA, military veterinary corps, or state and local health inspectors. A means of instant communication on all regulatory incidents is needed so that those involved may be able to intelligently respond if a letter or notice is received from an inspection agency. Safety incidents should also be communicated, such as: products presenting a threat to the consumer; personnel safety incidents where serious infectious disease, injury or death have occurred; environmental incidents where hazardous material(s) is released into the environment, etc. Keep a comprehensive written record of all such incidents, containing the date, time, location, description of incident, and action taken to correct the condition if possible. (9)Auditing: All processing plants, warehouses, and other storage facilities should be routinely and periodically audited by company personnel to gauge the level of compliance with company standards regarding specifications, product safety and regulatory requirements. Regular audits for the purpose of evaluating the adequacy of safety, 8 documentation and the degree of compliance with established company procedures and standards are needed. (10) Product Integrity: To maintain a high standard of product excellence, a company must have an organized and centralized means of surveying and controlling the contributing processes and procedures. A company must be on guard against violations. Therefore, it is imperative that a company have an effective and efficient program to protect itself and the public it serves. Design of Company QA Program: Quality assurance (QA) is a major management function, usually organized at the senior level, reporting directly to the president of a company. For illustrative purposes, assume a company composed of divisions, each operating factories, each factory having a Quality Control (QC) Laboratory. The company has a central Purchasing Department. The approach is to conceive of a program in the form of two cycles. In the Quality control cycle, customer specifications for each quality factor are established, and then means of measuring them are developed. In the production cycle control is maintained over incoming raw materials and finished product. They believe such an approach prevents products which do not meet customer specifications from entering the channels of trade. Objectives • To establish, issue and maintain standards and specifications for all raw materials used and for all finished products sold by the company. • To assure that all ingredients and all finished products adhere to the company's quality standards and to recommend corrective action as required. This includes microbiological purity and nutritional integrity of all products and conformance to state and federal regulations. 9 To be of service to the company in all areas related to product quality. These areas include: trouble-shooting when quality problems exist; visiting production facilities for review and updating of QC Programs; designing laboratory installations and. expansions and training QC personnel in routine and new testing procedures. Further service is rendered by answering consumer nutritional inquiries and in reviewing consumer complaints concerning product quality. RAW MATERIAL QUALITY ASSURANCE: Specifications: All approved raw materials are covered by tentative or permanent specifications. As new raw materials are required for new products, tentative specifications are developed to cover their purchase. All specifications are constantly being updated and, as conditions permit, the limits of acceptance are made stricter. Bacteriological conditions are constantly stressed and limits are reviewed to be kept at least as strict as governmental regulations. New and/or revised specifications are generally prepared each month for raw materials. Survey Program: All company units sample and inspect raw materials as received. Most of the tests are simple and/or organoleptic in nature. More thorough and sophisticated tests are performed at the Company Central Analytical Laboratory. Raw material surveys are conducted periodically. Greatest attention is given to so called "critical" raw materials. Physical, chemical and bacteriological examinations are made not only to be sure that all public health regulations are met, but also to establish conformance with established company specifications. The average number of raw material samples handled monthly might be: Current raw materials 100 Alternate sources of supply 50 New raw materials 10 Service: In the area of raw materials, QA is in daily communication with production units, the Purchasing Department, and current or potential suppliers. With the number of ingredients used and the multitude of suppliers and production units involved, it is normal for many minor, yet important, problems to develop. These problems must be handled quickly and effectively. A considerable portion of the effort by QA for the company is related to these "little" day to day jobs which usually require numerous telephone calls, confirming letters, sample reviews, and discussions to arrive at the proper recommendations for resolving these problems. Vendor's Appraisal: An important aspect of raw material procurement is reliability of the supplier. In order to implement the program of Certified Analyses (which is particularly important for critical ingredients) visits are made by QA personnel to vendors' production 10