Food Safety, from Farm to Fork

We welcome our latest contributor to Food Focus. Rika has extensive experience in the food industry and is an FSSC 22000 auditor and consultant. In this article she addresses the issue of food safety during the journey from farm to fork. Look out for her regular contributions.

What is food safety

The term ‘food safety’ defines the concept that food will not cause harm to the consumer when it is prepared and/or eaten according to its intended use as per the ISO22000:2005 international standard for food safety management systems. Food safety is related to the occurrence of food safety hazards and does not include other human health aspects related to, such as malnutrition.

Food safety is relevant at different stages of supply, preparation/processing, distribution and serving. The food chain starts on the farm and ends on the fork. During every stage great care must be taken to ensure that the end product will be safe for human consumption. This article presents an overview of the areas in which hygiene plays a crucial role in food safety.

On the farm

Live animals and birds must be handled and cared for humanely and professionally by trained professionals and with proper supervision by qualified vets. Processes such as the administration of growth hormones, antibiotics and the like, should be done bearing in mind the possibility of residues thereof ending up in the product that lands on the consumers’ plate. A withdrawal period must be implemented. The Meat Safety Act prescribes the provision of health certificates with each lot destined for slaughter, in order to prevent the consumption of residues by the end consumer. Other hidden risks should also be taken into consideration e.g. the transfer of Salmonella from chicken to egg before the egg is laid.

Crops must be planted, irrigated, grown, harvested in such a way that all physical, chemical and microbiological risks are known to the farmer and thus managed by him/her. The possibilities of faecal contamination (e.g. through manure during organic farming) and pesticides residues present in the end product, should be taken into consideration when the farming operation is planned and managed. The possibilities of faecal contamination by birds can also compromise food safety; a guideline is not to plant underneath overheads.

An E. coli outbreak at the beginning of 2011 due to contaminated bean sprouts, caused many fatalities in Germany. Recalls due to Salmonella spp not italic contamination were also reported in the USA in January 2012, when certain mock salts were recalled due to concerns that an ingredient (celery seeds) may be contaminated with Salmonella.

Transport and food safety

Transportation of live animals and harvested crops must be done in such a way, that food safety is not compromised. Ethical codes and guidelines obtained from the State Veterinarian can also be used to manage food safety. With regard to animals, it is important to note that stress levels should be kept to a minimum during loading, transportation and off-loading. Stressed or hurt animals can compromise their own health and consequently food safety.

Harvested crops transported in the open might also be contaminated by birds and insects. It is therefore advisable that great care be taken to cover crops, if possible, and where relevant, the cold chain is strictly adhered to. Once these products reach the processing plants, strict hygiene controls must be in place to ensure that contamination which may have taken place along the road, is addressed.

At the factory

Hazards which occur during the processing and packing operations in facilities, can also compromise the safety of the end product. These operations include abattoirs, pack houses, silos, processing operations (e.g. milling, emulsification, baking, cooking), packing stations and related storage areas. All these sites should be authorised by the appropriate regulatory bodies, depending on the discipline and the applicable regulation. Abattoirs will be inspected and approved by the state veterinarian, whereas bakeries will be inspected by the environmental heath practioner.

An effectively implemented food safety management system is the only way in which the processor can manage food safety. The processor should implement minimum pre-requisite programmes (covering good manufacturing practices, among others). Pre-requisite programmes can be defined as basic conditions and activities that are necessary to maintain a hygienic environment throughout the food chain, suitable for the production, handling and provision of safe end products and safe food for human consumption.

Examples of these programmes are pest control, foreign object management to prevent end product contamination, premises and structures, services e.g. water, cleaning and disinfection of the plant and equipment, and hygiene of personnel. This means that strict cleaning protocols, dress codes, and food-handling practices should be in place. Hand-washing facilities, secure lockers, wash areas and the use of hairnets, safety shoes, overalls and gloves are all part of these programmes.

Temperature control is of the utmost importance to prevent spoilage and to maintain food safety and hygiene. Storage temperatures of raw material, work in progress or final products should be in line with regulation R962.

Food production processes all require validation of critical limits as well as documented verification of the measures taken to ensure food safety and hygiene. Here are some of the recalls that took place due to non-adherence to food safety and hygiene practices:

• During January 2012 vanilla cakes from a major manufacturer was recalled due the possible presence of plastic fragments. This is a clear indication that the prevention of foreign object contamination such as sieving was probably not effectively implemented.
• Undeclared allergens (eggs) in Rugelach (a rolled type of cookie) led to a national recall during January 2012 in the USA. The same applies to BBQ sauce where anchovies were not declared as an allergen. Here labelling and tracing practices come into play. Proper controls are required for preventing cross contamination.

Distribution issues

Food distribution of work in progress or final products should be managed in such a way that food safety and hygiene is not compromised. Applicable regulations (national and provincial), especially those that cover temperature regimes such as the table above, have to be used for the implementation of control measures.

Food storage before/during/after transportation forms part of the distribution process and thus part of the food chain; food safety should also be managed in this area. The same temperature control measurements required by R962 above must apply.

On the plate

Preparation and serving of food in food service institutions is a crucial link in the food value chain. Food safety and hygiene should be especially strictly managed during this stage. Provision should always be made for separate work stations for unsanitised vegetables, raw meat, dairy confectioneries and salads. These foods cannot be prepared in the same stations and with the same use utensils such as cutting boards.

Staff hygiene and cleanliness is of utmost importance and correct protective wear must be supplied. In addition, temperature control should be very well managed. The prevention of cross contamination should be taken into consideration when control measurements are implemented.

By managing food safety during all these stages of the food chain by implementing effective control measures one can limit the risk of contracting food borne illness considerably.

This article was originally published in FoodLink

Author

Rika Le Roux Kemp