FUNDAMENTALS OF QUALITY CONTROL FOR THE FOOD INDUSTRY
CONTENTS CHAPTER INTRODUCTION: CONCEPTS THE DOCTRINE OF “STRICT” LIABILITY THE DOCTRINE OF “TOTAL ACCOUNTABILITY” MANAGEMENT AND PRODUCT QUALITY ORGANIZATIONAL PLAN TOTAL QUALITY PROGRAM THE WORKING ENVIRONMENT WORKERS MANAGERS AND SUPERVISORS BUILDING TEAMS OF EMPOWERED EMPLOYEES EMPLOYEE TRAINING WORK TEAMS AND EMPOWERMENT QUALITY AT THE SOURCE STEERING COMMITTEES OR QC CIRCLES WHAT IS QUALITY? DIMENSIONS OF QUALITY STANDARDS OF QUALITY METHODS FOR DETERMINING QUALITY SUBJECTIVE METHODS OBJECTIVE METHODS ADULTERATION AND CONTAMINATION DIFFERENTIATION BETWEEN CELL TYPES, TISSUE TYPES, AND MICROORGANISMS OF VARIOUS STORED FOODS OFFICIAL METHODS OF ANALYSIS IN THE FOOD INDUSTRY THE ASSOCIATION OF ANALYTICAL COMMUNITIES INTERNATIONAL (AOAC INTERNATIONAL) THE AMERICAN ASSOCIATION OF CEREAL CHEMISTS THE AMERICAN OIL CHEMISTS’ SOCIETY THE AMERICAN PUBLIC HEALTH ASSOCIATION THE AMERICAN SPICE TRADE ASSOCIATION THE FOOD CHEMICALS CODEX REFERENCES CHAPTER TOTAL QUALITY MANAGEMENT THEORIES AND APPLICATION THE CONCEPT OF TOTAL QUALITY MANAGEMENT THE BASIS FOR SUPERIOR QUALITY PERFORMANCE TQM AND ISO 9000 THE STRUCTURE OF TQM THE PRINCIPLES OF TQM THE 10 STEPS TO TQM TOTAL QUALITY MANAGEMENT TOOLS STATISTICAL ANALYSIS TOOLS DATA SHEET CAUSE-AND-EFFECT DIAGRAM SCATTER DIAGRAM FLOWCHART PARETO CHART HISTOGRAM CONTROL CHART X-BAR AND R CHARTS ATTRIBUTE CHARTS P-CHARTS NP-CHARTS C- OR U-CHARTS OTHER TYPES OF CHARTS MANAGEMENT AND PLANNING TOOLS AFFINITY DIAGRAMS INTERRELATIONSHIP DIGRAPHS TREE DIAGRAM MATRIX DIAGRAM PRIORITIZATION MATRICES PROCESS DECISION PROGRAM CHART ACTIVITY NETWORK DIAGRAM GANTT CHART ENTITY-RELATIONSHIP DIAGRAM KEY TO QUALITY TQM VISION AND MISSION INTEGRATED BUSINESS PLAN SOME HISTORY OF TOTAL QUALITY MANAGEMENT THE PIONEERS OF SCIENTIFIC QUALITY MANAGEMENT FREDERICK TAYLOR WALTER A SHEWHART W EDWARDS DEMING JOSEPH M JURAN ARMAND V FEIGENBAUM PHILIP B CROSBY THE JAPANESE CONTRIBUTION KAORU ISHIKAWA GENICHI TAGUCHI QUALITY CIRCLES PRESENT UTILIZATION OF TQM PROGRAMS QUALITY AND BUSINESS PERFORMANCE SERVICE QUALITY VS PRODUCT QUALITY THE MALCOLM BALDRIGE NATIONAL QUALITY AWARD THE MALCOLM BALDRIGE AWARD CRITERIA QUALITY ASSURANCE THEORIES AND APPLICATIONS FUNCTIONS OF A QUALITY ASSURANCE PROGRAM QUALITY CONTROL QUALITY EVALUATION QUALITY AUDITS EDUCATION AND TRAINING PROCESS IMPROVEMENT STANDARDS SPECIAL PROJECTS CONSULTING AUDITING THE QUALITY PROGRAM CAREERS IN QUALITY ASSURANCE QA RESPONSIBILITIES AND OPERATIONAL INTERACTIONS THE NEED FOR AND ROLES OF QA ORGANIZATION OF A QA PROGRAM QA PERSONNEL THE VICE PRESIDENT OF QA QA PROFESSIONALS QA AUDITS CONDUCTING AN AUDIT PURPOSES PROCEDURES IN-PROCESS MONITORING STATISTICAL PROCEDURES THE AUDIT REPORT TYPES OF AUDITS PRODUCT MANUFACTURING AUDITS CONTROL OF NONCONFORMING PRODUCTS CORRECTIVE ACTION PLANT SANITATION/GMP AUDITS PLANT FACILITIES EMPLOYEE HYGIENE IN-PROCESS CONTROL CONTAMINATION AND ADULTERATION PEST CONTROL PRODUCT QUALITY AUDITS HACCP AUDITS SPECIAL AUDITS DOCUMENT CONTROL AUDITS SUPPLIER AUDITS QC/INSTRUMENT CALIBRATION AND MAINTENANCE AUDITS PRODUCT BATCH PREPARATION/FORMULATION AUDITS QUALITY PROGRAM REVIEW QA DOCUMENTATION SYSTEM QUALITY MANUAL SOP (MANUFACTURING AND QUALITY) DOCUMENTS PSM DOCUMENTS GMO DOCUMENTS QCA METHODS DOCUMENTS SSOP DOCUMENTS GMP DOCUMENTS EQUIPMENT-SPECIFIC SANITATION DOCUMENTS PRE-OPERATION SANITATION DOCUMENTS WORK INSTRUCTIONS RECORDS HACCP PROGRAM DOCUMENTS INGREDIENT SPECIFICATIONS AND SUPPLIER CERTIFICATION PROGRAM RAW MATERIAL/INGREDIENT CERTIFICATION PROGRAMS DEGREE OF VARIABILITY FLAVOR CONSIDERATIONS THE SUPPLIER QUALITY PROGRAM (SQP) SUPPLIER QUALIFICATION APPROVED VENDORS LIST SUPPLIER HACCP QUALIFICATION STANDARDS SUPPLIER HACCP/QA QUALIFICATION LIST BY INGREDIENTS PURCHASED INGREDIENT SPECIFICATION/CERTIFICATION SUPPLIER AUDITING CERTIFICATE OF ANALYSIS THIRD-PARTY INSPECTIONS BUYING FROM AGENTS AND BROKERS IDENTITY-PRESERVED PRODUCTS: A NEW FOOD PRODUCTION SCENARIO DEFINING IP PRODUCTS CONSUMER DESIRE PROCESSING IMPROVEMENTS PRODUCT ATTRIBUTES REQUIRED RESOURCES STATISTICAL METHODS OF QUALITY CONTROL IN THE FOOD INDUSTRY INTRODUCTION STATISTICAL TOOLS AND STRATEGIES FOR PROCESS CONTROL IMPROVEMENT DESIGN AND ANALYSIS OF ANALYTIC STUDIES DEFINITIONS OF TERMS AND CONCEPTS SINGLE FACTOR EXPERIMENTS THE ANOVA METHOD THE RANDOMIZED COMPLETE BLOCK DESIGN: TWO-WAY ANOVA QUALITY CONTROL TECHNIQUES VARIABLE CONTROL CHARTS X– AND R CONTROL CHART X– AND S CONTROL CHART HOW TO USE CONTROL CHARTS ATTRIBUTE CONTROL CHARTS C-CHARTS MANUFACTURING AUDITS: CONTROL OF PROCESSING OPERATIONS OBJECTIVES OF PROCESS CONTROL ELEMENTS OF PROCESS CONTROL PROCESS CONTROL DOCUMENTATION UNIT OPERATIONS IN THE FOOD INDUSTRY MATERIALS HANDLING CLEANING SEPARATION DISINTEGRATION PUMPING MIXING HEATING COOLING EVAPORATING DRYING PACKAGING CONTROLLING OVERLAPPING UNIT OPERATIONS PLANNING THE AUDIT DOCUMENTATION PRODUCT-SPECIFIC MANUFACTURING (PSM) PROCEDURES GENERAL MANUFACTURING PROCEDURES STANDARD SANITARY OPERATION PROCEDURES ANALYTICAL CONTROL PROCEDURES DEFINITIONS QUALITY MANAGEMENT AREAS (UNIT OPERATIONS) PRODUCT-DEPENDENT OPERATIONS PRODUCT-INDEPENDENT OPERATIONS PROCESS CONTROL POINTS BATCHING MANUFACTURING PROCEDURE DEVIATIONS RISK DEVIATIONS NONRISK DEVIATIONS NONRISK DEVIATIONS TO RISK REQUIREMENTS AUDIT DEVIATIONS: EXAMPLE DEVIATIONS FROM THE MANUFACTURING PROGRAM BATCHING AND FORMULATION PRACTICES TRADITIONAL CHOCOLATE MANUFACTURING LINE DE LUXE CHOCOLATE MANUFACTURING LINE STRAWBERRY TOPPING MANUFACTURING LINE INGREDIENT QUALIFICATION AND STORAGE PROGRAM INGREDIENT ANALYSIS PROGRAM ANALYTICAL TEST METHODS CONSISTENCY BRABENDER HACCP ANALYSIS BATCHING AND FORMULATION PROGRAM GRANULAR SUGAR — WEIGHING SCALE STRAWBERRY TOPPING BATCHING MAPLE WALNUT TOPPING FOOD PLANT SANITATION: GOOD MANUFACTURING PRACTICE AUDITS FOOD PLANT SANITARY PRACTICES FOOD CONTAMINATION HUMANS EQUIPMENT AIR AND WATER SEWAGE INSECTS, RODENTS, AND BIRDS THE VALUE OF A PLANNED SANITATION PROGRAM STORAGE FACILITIES LITTER AND GARBAGE DISPOSAL TOXIC SUBSTANCES CONTROL QUALITY ASSURANCE AND SANITATION PACKAGING TECHNOLOGY PRODUCT DISTRIBUTION PERSONNEL SANITATION AND HEALTH CONSIDERATIONS FOOD PLANT SANITATION MANAGEMENT SANITATION AS AN APPLIED SCIENCE THE FOOD PLANT SANITARIAN PERSONNEL TRAINING PROGRAMS PLANT FACILITIES CONSTRUCTION AND MAINTENANCE EXTERIOR OF THE BUILDING GROUNDS/YARD AREAS/LANDSCAPING INTERIOR OF THE BUILDING DOORS/WINDOWS/OTHER OPENINGS AIR CURTAINS PLANT WALLS/CEILINGS/FLOORS HEATING, VENTILATION, AND AIR CONDITIONING (HVAC) DRAINAGE AND SEWAGE SYSTEMS WASTE FACILITIES CATWALKS/STAIRS LIGHTS IN PROCESSING AREAS/EXPOSED FOOD INGREDIENT AREAS MIRRORS IN PROCESSING AREAS METAL SURFACES/SUPPORT STRUCTURES CAN CONVEYORS AND CAN TUNNELS CONVEYORS/SORTING BELTS/SHAKERS/SIZE GRADERS/FILLERS/FLUMES, ETC FLUME MAKE UP WATER MOLD BUILDUP BELT SPRAYS EQUIPMENT ABOVE PRODUCT MOVING EQUIPMENT OR PARTS THAT RUB TOGETHER MOTORS/GEAR BOXES/PULLEYS/OTHER DRIVE MECHANISMS WATER SPRAYS CAN/BOTTLE LINES LINE COVERS FILLERS SHEARS AND END PLATES TANKS AND BATCHING KETTLES COOKING KETTLES UTENSILS INGREDIENT CONTAINERS INGREDIENT BAGS PLASTICS AND RUBBER IN CONTACT WITH PRODUCT OR INGREDIENTS EXHAUST FANS AND VENTS OUTSIDE SURFACES OF EQUIPMENT GENERAL CONSTRUCTION OF EQUIPMENT CHEMICALS LUBRICATION PRACTICES CLEANUP PRACTICES STORAGE OF SURPLUS EQUIPMENT/SUPPLIES/INGREDIENTS/PRODUCT/ETC RAW FRUITS AND VEGETABLES FOOD RESIDUALS CONDENSATE AND HEAVY STEAM BAIT STATIONS/RODENT TRAPS INSECTOCUTORS EMPLOYEE PRACTICES INCOMING/OUTGOING MATERIAL CONTROL RAW MATERIAL RECEIVING STORAGE TEMPERATURE AND HUMIDITY CONTROLS RETURNED FOODS OUTGOING PRODUCTS PROCESS CONTROL: SANITARY OPERATIONS EMPLOYEE HYGIENE AND SANITARY HANDLING OF FOOD SANITATION AND HOUSEKEEPING INNER PERIMETER AREA OF BUILDINGS HOUSEKEEPING PRACTICES PEST CONTROL IN FOOD PROCESSING PLANTS INSECTS RODENTS BIRDS USE OF PESTICIDES FINISHED PRODUCTS LAB PRACTICES SANITATION LAWS AND REGULATIONS FDA REGULATIONS USDA REGULATIONS EPA REGULATIONS THE FEDERAL WATER POLLUTION CONTROL ACT THE CLEAN AIR ACT FIFRA THE RESOURCE CONSERVATION AND RECOVERY ACT HAZARD ANALYSIS AND CRITICAL CONTROL POINTS PROGRAM THE SANITATION/GMP AUDIT OBJECTIVES AUDIT CHECKLIST GENERAL DESCRIPTION SHEET DEFINITION OF GMP OBSERVATIONS BY CLASS BY PROGRAM/CONTROL AREA AND TYPE OF OBSERVATION BY TYPE THE AUDIT WORKSHEET (OBSERVATIONS LISTING FORM) THE SANITATION AUDIT REPORT REPORT FORMAT EXAMPLE OF A PLANT SANITATION AUDIT REPORT PRODUCT QUALITY AUDITS AT THE RETAIL LEVEL DEFINITION PROCEDURE PLANNING PRELIMINARY REVIEW MEETING PROTOCOL DEPARTMENTS INVOLVED PRODUCT SAMPLING PRODUCT PICK-UP TESTING PACKAGING QUALITY SENSORY EVALUATION ANALYTICAL TESTING EXAMPLE OF A PRODUCT QUALITY AUDIT COMPARISON BETWEEN EUREKA AND CLASSIC BEEF STEW PRODUCTS AGE DRAINED WEIGHT BOSTWICK VALUE °BRIX SALT COLOR AGTRON EUREKA BEEF STEW CLASSIC BEEF STEW CANS: VACUUM AND HEADSPACE CAN PACKAGING QUALITY REFERENCE HAZARD ANALYSIS AND CRITICAL CONTROL POINTS THE HACCP CONCEPT THE IMPORTANCE OF HACCP ADVANTAGES THE HACCP PROGRAM GUIDELINES FOR APPLICATION OF THE HACCP PRINCIPLES HACCP PROGRAM PREREQUISITES DEVELOPMENT OF AN HACCP PROGRAM THE PRELIMINARY TASKS OF AN HACCP PROGRAM CHOOSING THE HACCP TEAM DESCRIPTION OF THE FOOD PRODUCT AND ITS DISTRIBUTION DESCRIPTION OF THE INTENDED USE AND CONSUMERS OF THE PRODUCT DEVELOPMENT OF A FLOW DIAGRAM DESCRIBING A FOOD PRODUCT MANUFACTURING PROCESS VERIFICATION OF THE FLOW DIAGRAM THE SEVEN HACCP PRINCIPLES PRINCIPLE 1: CONDUCT A HAZARD ANALYSIS CATEGORIES OF HAZARDS BIOLOGICAL HAZARDS CHEMICAL HAZARDS PHYSICAL HAZARDS PREVENTIVE MEASURES QUESTIONS TO CONSIDER WHEN CONDUCTING A HAZARD ANALYSIS INGREDIENTS INTRINSIC FACTORS PROCEDURES USED FOR PROCESSING MICROBIAL CONTENT OF THE FOOD FACILITY DESIGN EQUIPMENT DESIGN AND USE SANITATION EMPLOYEE HEALTH, HYGIENE, AND EDUCATION CONDITIONS OF STORAGE BETWEEN PACKAGING AND THE END USER INTENDED USE INTENDED CONSUMER HAZARD IDENTIFICATION THE RAW MATERIALS THE MANUFACTURING PROCESS CONTROL MEASURES RISK CATEGORIES SPECIAL CONSIDERATIONS WHEN CONDUCTING A HAZARD ANALYSIS DECIDING WHICH POTENTIAL HAZARDS MUST BE ADDRESSED IN THE HACCP PROGRAM PRINCIPLE 2: CCP IDENTIFICATION PREVENTIVE CRITICAL CONTROL MEASURES (MICROBIOLOGICAL) CCP DECISION TREE PRINCIPLE 3: ESTABLISH CRITICAL LIMITS FOR EACH CCP PRINCIPLE 4: ESTABLISH CCP MONITORING PROCEDURES VISUAL OBSERVATIONS SENSORY EVALUATIONS PHYSICOCHEMICAL EVALUATIONS MICROBIOLOGICAL ANALYSIS PRINCIPLE 5: ESTABLISH CORRECTIVE ACTIONS PROCEDURES IDENTIFYING CAUSES OF DEVIATIONS DETERMINING PRODUCT DISPOSITION RECORDING THE CORRECTIVE ACTION REEVALUATING THE HACCP PLAN PRINCIPLE 6: ESTABLISH PROCEDURES FOR HACCP VERIFICATION AND VALIDATION VERIFICATION EVENTS THAT MAY REQUIRE VERIFICATION INSPECTION OF THE HACCP PLAN HACCP VERIFICATION PROTOCOL AND ACTIVITIES — INFORMATION IN VERIFICATION REPORTS VERIFICATION SCHEDULES VALIDATION PRINCIPLE 7: DOCUMENT THE HACCP PROGRAM ESTABLISHMENT OF RECORD-KEEPING PROCEDURES FORMAT FOR HACCP INFORMATION EXAMPLES OF RECORDS REQUIRED DURING OPERATION OF THE HACCP PROGRAM IMPLEMENTATION AND MAINTENANCE OF AN HACCP PROGRAM PRACTICAL EXAMPLE: HACCP PLAN MODEL FOR REFRIGERATED STICK AND SLICED CELERY THE SCOPE OF HACCP REGULATORY ASPECTS OF HACCP SANITATION AND THE HACCP CONCEPT CONCLUSIONS