Upon receipt of the Coo, revision needs to be performed to (1) ensure batch code present in the Coo reconciles with the batch information on on actual product, (2) ensure information and results of analysis stated on Coo reconciles with the factory requirements and limits. In case the material/Coo received is not compliant for either lack of analysis agreed or results outside specification, material is not released for production but instead could be returned to supplier. Step 3- Quality control point 3.
Step 3 is only relevant for materials that require storage and transportation under controlled temperature. In the case of this exercise, only butter is subject to this quality control. As storage requires temperature below 4 degrees Celsius, a dedicated storage is required. To ensure that temperature is always below limit, a log needs to be kept and for quality reasons, all records must indicate compliance. (Note that a defined frequency needs to also be agreed). If records indicate measurement is above the maximum limit, adjustment needs to take place to guarantee temperature is returned to optimum level.
Note that in this exercise, storage is not capable to reach freezing temperatures. If it was the case, lower limit would also be required to be added in the HACK document in order to guarantee that freezing temperatures are not reached. Step 4- Quality control point 4. Flour is sieved to ensure that any physical hazards bigger that mm are removed and discarded Physical hazards in flour could be traces of strings, plastic, stones, whole grains, hair, among others. This process is also used to ensure that any lumps are dissolved. The maintenance of the sieving equipment is also important since any abject can obstruct the sieving equipment.
Monitoring procedures also need to be in place to check that the sieving equipment is not damaged, torn or loose. The sieving equipment needs to be checked regularly to verify compliance to initial standard and requirements of 180 microns. Step 5- Quality control point 5. Sugar passes through the grinder as a quality control point to ensure that there are not lumps of sugar going into the mixture, interfering in the shortbread biscuit observation of material needs to be performed to ensure effectiveness of the process. Step 6- Quality control point 6.
The salt needs to go through the grinder as a quality control point to ensure that there are not lumps of salt going into the mixture, interfering in the shortbread biscuit quality, in the final product. Correct functioning of the grinder and visual observation of material needs to be done to ensure the effectiveness of the process. Step 7- When mixing dry ingredients, one of the controls must be that all the material are properly mixed. A second control is personal hygiene when personnel are mixing ingredients and emptying the materials sacs into the mixing cylinders.
Employees must ensure adequate level of personal hygiene and wear adequate uniform to prevent foreign bodies into production. Employees must ensure hands are always washed prior to entering the factory. In addition, if uniform is not used adequately, contamination with hair, buttons and pieces of Jewelry and articles that may fall from their pockets. The most important requirement is that all those in the factory handling food should observe basic rules of personal hygiene such as correct uniform and hair nets, factory shoes and in some cases beard net. This is part of the
Good Manufacturing Practices (IGMP) and if not applied As per Duncan Manley, microbiological contamination of Staphylococcus ruses can occurred if basic hygiene rules are not followed. (Duncan Manley, Elsevier, 28 Seep 2011) step 8- Add butter and mix to dry ingredients. This is a simple step where the control that needs to take place is to verify that the dough is thoroughly mixed and that it is not over mixed so that the shortbread may not lose its characteristics in the baking Step 9- Quality control point 7. The dough needs to be shaped into the desired form, controlling that all biscuits are heaped equally.
There is a visual inspection that takes place to verify that the desired form is given and that there are no errors with the machinery. If some parts of the dough are not shaped correctly, they may be reworked. Note that pieces of equipment (e. G. Pipes, cylinders and belts) need to be correctly cleaned and therefore employees must be trained for this process. The cleaning of the equipments is fundamental for food safety. It is best to organize a full-time hygiene officer to oversee and organize all cleaning operations. Operators of the production rear should clean their machinery regularly and at the end of every production.
Tests need to be done regularly after cleaning, testing the water that comes out from the pipes, cylinders or belts, verifying that there are not any micro-biological traces or excessive chemical products that could leave residues and lead to a chemical contamination of food. Other observations should be that all equipment must be cleaned. Floors walls and ceilings should be maintained to minimize the risk of food contamination. Regular maintenance to prevent product contamination by foreign bodies arising from equipment failure. Cleaning of ventilation systems including filters and tubes.
These are some of the procedures needed to prevent food contamination and a good IGMP. Step 10- Critical control point 1. This is the step after the shortbread biscuits are shaped and are about to be baked. There is a critical control point in this step, because if the product is not baked correctly there could be a microbiological contamination of Listener monocotyledon (usually a risk from Dairy products) and/or Bacillus cereus (usually a risk from flour). The critical limit is to have the core of the shortbread biscuits reaching 71 co for 2 minutes.
A thermometer reading is used to verify that the core temperature needed for food safety has been reached and there needs to be monitoring checks in place. If the critical limit (71 co for 2 min. ) is not met for a specific period of time during the production process, the semi-finished material needs to be discarded. To avoid reoccurring incident, engineers must re-calibrate equipments to ensure limits are met and measurements are reliable. Note that in this stage the verification of creamily formation in cooked food is also tested as overheated biscuit could generate creamily.
Biscuits are in the class of foods in which the baking can promote creamily formation. Studies have shown that creamily is potentially a carcinogen to humans, therefore analytical methods to check creamily levels in baked goods are tested. “The creamily recovery ranged from 90. 5 В± 0. 3% to 99. 1 В± 1. 8%. The results showed that the ammonium bicarbonate concentration in shortbread, and the high temperature, influenced the creamily formation during the processing highlighting that the final creamily concentration is influenced by the processing parameters” (O.
Marion, E. Brave, G. Preterit, R. Martini, L. Montana and P. Fantasizing First published online 05 Cot 2010) Step 11- Quality control point 8. A quality control is made to verify that the shortbread biscuits have cooled down properly to the correct temperature and in the correct time limit. Cooling belts need to be regularly checked and cleaned to avoid contamination. After complete cooling, the shortbread biscuits continue through the belt where a quality assurance specialist verifies uniformity in the product.
Quality assurance could involve sampling biscuits every 20 minutes (for instance) to test for color, moisture and texture infirming that the product conforms to quality standards. Step 12- Quality control point 9. A quality control is made to check that the moisture in the shortbread biscuits is at 0. 3 moisture level for this specific product. Online measurements can assess moisture inside the product after baking. Moisture in biscuits ensure food safety control, as products with a high moisture content can have higher risk of microbiological multiplication.
The moisture content is also tested to verify the also receive a primary package which could be a thin plastic package. After receiving his plastic film, the pack biscuits are weighed. There are two systems: (1) check weight, a belt that also weighs the packs. This piece of equipment is connected to a system that records the weight of all packs of biscuits and uses statistical calculation to ensure legislation requirements are met. (2) Sample check to ensure statistics of the sample taken met legislation requirements.
Step 13- Critical control point 2. This is a critical control point where the shortbread biscuits pass through an x-ray to check for any physical hazards in the final product. This step is essential in the recess as it can detect metal, foreign bodies, plastic, wood stone, glass, basically anything that is outside of the regulated density the machine is programmed to detect (density of the shortbread). New technology has allowed the industry to utilize x-rays to measure even more details of products that were not possible to be measured before.
For example, a final quality control check can be made to ensure that the right amounts of biscuits are in the primary package and if the correct number is not present, the belt can automatically send the product to be reevaluated. Coo Whither, 12th February 2014) Step 14- Quality control point 10. Control that the correct package has been used and that the correct labeling is in place. There are cases of misplacement of packages, where the wrong package is used in one item. Other cases could be of wrong labeling. All packages of products need to be checked as to correct package and correct labeling.
Labeling a product incorrectly could incur in many problems, leading even to food poisoning and eventual recall, either when the expiry date is incorrect of the batch code applied on the packaging material is incorrect. Visual inspection is used in this quality control mint and the validation of the batch needs to be put in place. Considering that more than 90% of contamination of baked goods is during the cooling and packaging operations, the factory needs to once again control the good manufacturing practices in place. Helen Valued, 2009) step 15- The final step to the production is the process to store and dispatch. There needs to be a control that the correct procedures to ensure product safety during storage, loading and transportation procedures apply. The cleanliness of storage areas and vehicles, the rule to not leave products outside and the maintenance of vehicles are el important procedures to ensure food safety and quality. The way the pallets are stored is important to also ensure there will be no further contamination to the finalized product.