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Effectiveness of the
machines maintenance
and processes
Monography
Editing and scientific elaboration
Stanislaw Borkowski
Jacek Selejdak
Chapter 9
Katarzyna Szoltysee, Szymon Dziubcl
ISO 22000: INTERNATIONAL STANDARD IN FOOD
SAFETY MANAGEMENT IN THE PRODUCTION OF
BREAD WITH ADDITIVES
Abstract: Th proposed research shows the nee s ity of applying the rule of HAC P to
baking pr duction on th example of mixed bread ' ith add iti es (vital gluten vitamin C).
T this end a 12- tage procedure in accordance v ith the e en rul
of Code
Alimentarius (and also of the HACCP sy tern) was conducted. The re ult was meeting
with the legal r quirement (hygienic packet) with special emphasis placed on the
anal is of potential hazards. Four critical control points were determined ( CP ) along
with the methods of their v rification and its frequency. What follow d was defining th
necessary corrective actions and th methods of th syst m s udit (Codex Alim ntarius
2003) (PN- N ISO 9004:2001).
v ing to the er r cent introduction of norm ISO 22000, the propo ed research has
a ignificantl inno ative character and are demonstrati e in nature for rno t baking plant
in Poland.
Key words: PN- E
ISO 22000:2006 Food production syst m HACCP
9.1. Introduction
1 0 22000 is a norm i sued by the International Organization for tandardization in
eptember 2005 and it is applied to the food indu try. ince 2006 th re e i t al o the
Polish orm P - N-1 0 22000:2006 compliance with which is upposed to ensu re high
quality and, more importantly yet, afety at consuming various foods (PN - EN ISO
22000:2006).
ISO 22000:2005 is a system directed at producers of food and additives, as
well as of packages wholesalers and retailers in the food indu try logistics and
transportation companies.
The norm constitutes International Standard (IS) referring to food safety
1
Prof. dr hab. ini:. University of Economics in Wroclaw, Quality Analysis
Department, e-mail: [email protected]
2
Mgr inZ. University of Economics in Wroclaw, Quality Analysis Department
e-mail: [email protected]
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and created for all participants in the given ' food chain ranging from the basic
producer to the final consumer.
A such the norm directly concerns the following links with in the chain:
Producers of food and fodder.
Tran port and storage of food and fodder.
Distribution companies (warehouses, wholesalers).
Producers of food additives.
Producers of eq uipment machines and devices.
Packages for the contact with food.
Hygienic measu res (GHP, HACCP).
Servicers (hygienic services, DDD)
Basic (farm) producers.
It can be asserted that the international norm P -EN ISO 22000:2005 blends
in itself norms ISO of the 9000:2000 series and the HACCP system. The relation
to norm ISO 900 I :2000 terns from the fact that the most effective system in the
field of food afety are tho e which work within the framework of a con tructed
management system and are included in the organizations activities related to
management. This ensures maximum advantage for the organizations and the
involved sides (P - EN I 0 22000:2006) (PN - EN ISO 9000:200 I).
Target Group: all types of enterprises in the Food Supply Chain- advanced, less
adjusted, and companies without CCP
IS022000
}
Requirements
based on
Fig. 9.1. Requirements in the food supply chain.
Source: (Kowalska J 2006)
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Norm ISO 22000, similarly to norms from the ISO 9000 family introduces
the notion of the process approach and proces management, however, ISO 9001
and 1 0 22000 have disparate applications:
ISO 900 l: ensures the organization s ABILITY to achieve the professed
goals
ISO 22000: ensures FOOD SAFETY.
9.2. General characteristic of norm ISO 22000
Norm P - EN ISO 22000:2005 was prepared in accordance with the plan
of norm ISO 9001 with the aim of improving the compatibility of the two
norm . ISO 22000:2005 integrates the rules of HACCP system. With the aid of
controllable requirements this norm blends the HACCP plan with the
Preliminary Rules Programs (PR.Ps). Hazard analysis is the key to effective
system of food safety management, since conducting a hazard analysis helps in
ordering knowledge essential to introducing an efficient combination of
supervisory measures.
Norm 1 0 22000:2005 requires that all hazards which can be expected to
occur in the food chain be identified and estimated.
The purpose of preparing the norm ISO 22000 is global harmonization of
requirements in the area of FOOD SAFETY MA AGEMENT in all links of
'food chain.
orm ISO 22000:2005 meets the requirements of: 7 rules of Codex
Alimentarius 12 stages of the HACCP system the norm legal regulations
(hygienic packet - Fig. 9.2).
General Food Law- Regulation No. 178/2002
Food of animal origin
Regulation
Enterprises
H2
(853/2004)
Sanitary
and Veterinary
lnsp ctlon
Regulation
(882/2004)
Fig. 9.2. Requirements in the Food Supply Chain.
ource: (www.europa. eu)
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Regulation
H3
(883/2004)
The content of norm ISO 22000:
1. Range.
2. Reference documents.
3. Terms and definitions.
4.
ystem of food safety management.
5. Management responsibility.
6. Resource management.
7. Planning and realization of safe products.
8. Verification, validation and perfecting of the SZBZ.
Attachment A: Common elements oflSO 22000:2005 and ISO 9001:2000
Attachment B: Common elements of ISO 22000:2005 and HACCP
Attachment C: Requirements of Food Codex with regard to particular sectors
(PN - EN ISO 22000:2006).
9.3. The application of the norm I 0 22000 in the production of rye
bread with additives
As has already been mentioned in Part I the stages and rules of the HACCP
system constitute the basis of norm ISO 22000, therefore, they need to be
meticu lously described during the process of their implementation.
After having established HACCP team, this team describes the product its
future application, prepares a technological schema and analyses CCPs.
Further on technoloogical schema of the researched product was presented
below: Rye bread with adclitives (Fig. 9.3).
Then in compliance with the prepared procedure, taking account of the
requ irement of the so-called ottermans Tree analysis of CCPs likely to occur
during the process of receiving the researched product according to the workedout scale was conducted.
After having performed the following actions, documentation needs to be
prepared (Fig. 9.4).
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Fig. 9.3. Technological schema of rye bread with additives.
ource: authors' own study
Fig. 9.4. Technological schema of rye bread with additives with Control and
Critical Control Points.
Source: authors ' own study
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Table 9.1. Hazard Analysis for Raw Materials and Packages
Potential hazard
Raw material,
pnckn e
1.Receiving th raw
materinl:
1.1. flour
1.2. yeasts
1.3. potato tarcb
1.4.salt
1.5. fruit nnd
etabl~
B- insects and their
r~mnant. s . M - b cu~ria
(Bncillu ubtilis,
magatcrium). musts
{ s pergi llu •
P~nicilium), F- and,
glass. rocks. root or
other plant
Risk
level
3
CP,
p
CP-1
Pre enti e
ction
hoice of suppli r,
current PZB quality
atte t
2. Water
3. Packing foil
F-du t
Choice of suppli r,
current PZH quality
atte t
ource: authors' own study
Table 9.2. Hazard Analysis in tlte Production Process
Raw Material/Package I
Activities
1. Kneading of dough
Potential Hazard
B- insects, rodents,
birds, leftovers, M bacteria (Bacillus
Subtilis Megaterium
type), putrid bacteria,
coli group bacteria,
musts (Aspergillus,
Penicilum), Torulla type
yeasts
Hazard
Level
CCP, CP
P-1
P•eventive
Ac~
Choice of supplier, quality
attest, process control,
water quality examination,
Hygienic -Sanitary Control
of machines and devices,
Health and Hygiene Control
of the Crew
F - possibility of
penetration by foreign
bodies, dust;
parameters of the
Kneading process,
tempera. tu re
-
2. Division into Bites
B • insects, rodents,
birds, leftovers, M bacteria (Bacillus
Subtilis Megaterium
type), putrid bacteria,
coli group bacteria,
musts (Aspergillus,
Penicilum), Torulla type
yeasts
F- possibility of
penetration by foreign
bodies, dust; the weight
of a single bite
ource: authors ' own stud
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Process control, water
quality examination,
Hygienic- Sanitary Control
of machines and devices,
Health and Hygiene Control
ofth Crew
J
Table 9.3. Hazard Analysis in the Production Proce s
L:
w
Materiai /Pac~
Potential Hazard
Activities
5.GAROWAN IE-the growth
of the dough
8-lnsec~
Hazard
Level
CCP, CP
-.:::::..::;:;=:==::r:;::::==
M- bacteria (Bacillus
Subtdl Megatenum type) ,
musts (Aspergillus.
PeniCll um), Torulla type
yeasts
F- possililrty of penetrallOO
by foreign bodies, dust.
perametera of the proee ..
- mo sture
CCP-2
&.Baking
b k•ng of bread
7. Removal of moulds
from the ba ed bites
8. Ftnel Baking
p.J
L_. --..·-··--..··-·· . . ._Jl . J:~.~~.;~~J..:ye•:s
Source: authors own study
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machines and deVICes, Heallh
and Hygiene Control of the Crew,
preven~on from miCroorganisms
Constant 1 mperature control,
maintaining appropriate
parameters, process control,
water quality examination,
Hygienic - Sanllery Control or
machines and d lAces, Heallh
and Hygiene Control of the
Crew. prelol!ntlon from
microorganisms
8 ·Insects. rodents, birds,
leftCMJrs. M - bacteria
(Bacillus Subtills
Mogoterium type), musts
(Aspergillus. Penlcllum),
Torutle type yeas ts
F - possibility of
penetration by foreign
bodies, dust p8rameta rs
ofthe proce~
tamperatura, time
Control or conditions of storing
and cooling, Hygienic Sanitary Control of rooms
designated for cold stores
8 ·Insects, rodents, birds,
leftCMJrs
M -bacteria (Escherichia
coli. Salmonella, Shigella,
lhomnldlum auranuecum
-colour1ul spots)
10. Cutting. Packlng
~~~~lten~~~=;ol of
Hygienic -Sanitary Control or
machines and devices, Health
end Hygiene Control or the Crow,
prevenbon from miCroorganisms
M - bacteria (Bacillus
SUbblls Megaterlum type),
musts (Aspergilus,
Penicllum), Torulla type
yeasts: F- possbilrty of
penetrabOn by foreign
bod•es, dust
B-lnsocts, ro dents,
birds, leftovers, Mbactarl• (Escherichia
coli, Salmonella ,
Shigella, Thamnldlum
aurantlacum - col o urllJI
Constanl temperature control.
maintaining appropriate
parameters, process control,
water quality examination,
Hyg.enic- Sanll8ry Control of
machines and deVICes, Health
and Hygiene Control of the Crew
Constant temperature control ,
mamtalnlng appropnate
parameters, process control.
8 · Insects, rodents, birds,
leflOVers, M- bacteria
(Baeilus SUbtihs Megatera~m
type), musts (Asperg Ius,
Penldlum). Torulle type
ye sts
F- possibility of penetration
by foreign bodiBS, dust;
parameters of the process:
temperature, time
Preventive Actions
CP-3
Choice of the packages'
supplier. quatlty attest,
hygienic - sanitary control of
rooms designated for storage,
control ol packing machines
and deiAces
Table 9.4. Table of all Control Poi11ts (CPs)
CPiocation
Monitoring
1. Receiving the raw
material, flour,
yeast, potato starch,
salt, vegetable and
fruit
Controlling the raw
material according to the
norm, laboratory
analysis
2. Rounding and
forming of bites
3. Cutting, packing
Frequency
Control of the devices'
efficiency,
hygienic - sanitary
control
Control over complying
with the hygienicsanitary rules,
control of protections
aga nst penetration by
foreign bodies.
control of rooms
Each supply
Once In
a quarter
Corrective actions
Evaluation of the
supplier,
Replacement of
supplier
Repairs,
trainings
Constant
Constant
Eliminating
disparities,
Enhancement of
protections' efficiency
Once a week
Source: author ' own study
Table 9.5. Table of all Criticlll Cotltrol Pi11ts CCPs
Location
and number
ofCCP
Kneading of
the dough
CCP1
Supervision method
Frequency
Laboratory control ,
organoleptic control
once in a
quarter,
constant
Warming
CCP -2
Time control,
Temperature Control,
Constant
Moisture Control
Baklng,
baking of
bread
CCP -3
Final Baking
CCP-4
Ttme control,
Temperature control
Constant
Time control,
Temperature control
Constant
Toleration
border
according
to the
norm and
good
practice of
production
time: 20-35
mlns,
temperatur
e45
degreesC,
moisture
80%
time: 20-25
m ins,
T220
degreesC
tlme: 20 25mlns
T=210220"C
Source: authors own study
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Critical value
Borderline norm's
values ,
bad texture of the
dough
Borderlln values
Borderline values
Borderline values
Corrective measures
Corrective
procedures
admissible In the
production process,
rejection of further
production
Parameters
reg ulation
Parameters
regulation
Parameters
regulation
Table 9.6. Verification of all Critical Control Points (CCPs)
----·- ...-----CCPnumber
CCP-1
CCP-2
CCP-3
Verification Method
Evaluation of production
conditions, technical inspection
of the device
Verification
Frequency
Constant
Control of the technological
card during production,
Technical inspection of the
device
Constant
Technical Inspection
of the device
Constant
Technical inspection
of the device
I
Corrective actions
Replacement of devices,
Regulation ,
Trainings
Introducing modifications on the
parameters,
Replacement of devices
-·---· -·l
Once a week
~. CCP-4
-·-·---------·--·]
Constant
Once a week
Cleaning,
· Regulating,
Replacement of devices
Cleaning,
Regulating ,
Replacement of devices
I
I
__j
Source: authors own study
9.4. Summary
The goals of ISO 22000 implementation
The requirements of the norm are supposed to help the organization in the
following spheres:
providing frnal products which do not pose any threat to the consumers'
health
assessing and estimating the consumers expectations
demonstrating how to successfully communicate with clients
demonstrating how to adjust to and meet legal requirements with regard to
food
ensuring adherence to the self-detetmined policy of food safety.
Benefits of implementing 11orm ISO 22000
systematization of actions related to the production of safe foods,
introducing an efficient communjcation between all elements of the food
chain
improving food safety and decreasing the risk of transmitting diseases
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increasing the clients contractors , and suppliers trust
efficiency at conducting a systematical analysis with the aim of hazard
elimination,
compliance with the EU General Food Law
international certificate acknowledged in Poland Europe and other
countries.
Bibliography
I.
2.
3.
4.
5.
6.
7.
8.
9.
Codex Alimentarius comm1 10n. Food Hygiene Basic Texts, Recommended
International ode of Practice. General Principles of Food Hygiene. 2003. Annex.
llazard Anal i and Critical ontrol Point (HACCP) ystem and Guidelines for it
Application CAC/R P- 1969 revi ed 4- 2003 FAOIWHO.
Ko1oZ)'n - Krajew ka D. 2007. Higiena produkcji :iywnosci. Wydawn ictwo G W.
War zawa.
KO\ at ka J. Majew ka . bi dzinski M., Zadernow ki M. 2006. Nowe prawo
tywnosciowe Unii Europejskiej a ystemy GMP, GHP, HACCP. Wydawnictwo
DDK. Gdansk.
PN - N I
22000:2006 ystemy Zarzqdzania Bezpieczenstwem Zywnosci Wymagania dla katdej organizacji naletqcej do lancucha :iywnosciowego.
P - E 1 90 0:2001 ystemy Zarzqdzania Jakosciq - Podstawy i terminologia
P - E 1 0 90 1:200 I ystem Zarzqdzania Jakosciq - Wymagania.
PN I 0 9004:2001 ystemy Zarzqdzania Jakosciq - Wytyczne doskonalenia
funkcjonowania.
R zporZ(!dZ nie (W ) nr 852/2004 Parlamentu uropcjskiego i Rady z dnia 29
kwi tnia 2004 r. w prawi higien srodk6w pozywczych L 13911 Dziennik
UrzydowyUnii ... uropej kiej 30.4.2004
www.europaeu.int/eur-lex/lex.
Thi cientiflc work wa financed from finan ce sources on the science in 200920 I 0 years a a re earch project.
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