Raw materials (ingredients, processing aids, and packaging materials) are the foundation of finished food products. As such, they must meet regulatory requirements (safe and legal for your intended use) and your specifications (contribute to the functionality and quality of your process and product).
Historically, research and development worked alone when selecting a new raw material. But now a broad team of expertise is needed, due to increased access to unique and complex materials, global sourcing, handling methods, customer locations, and regulations. The team assesses if the material has limitations or may be too costly to handle, and determines if additional measures are necessary to prevent potential safety issues for the employees and product.
Traditional Roles
A description of team responsibilities helps in the understanding of the diverse expertise needed to identify key raw material characteristics.
Each area’s expertise is necessary to determine the desired specifications for each raw material.
Raw Material Selection
R&D selects the appropriate raw materials based on functionality. Functionality can encompass multiple areas, such as providing identified characteristics of the finished product (binders, thickeners, type of resin for plastic packaging, etc.), organoleptic characteristics (flavor, color, aroma, texture), product safety characteristics (to lower the pH or water activity), and preservatives (extension of shelf life, color, or flavor retention, etc.).
Considerations in Selection
Is there a raw material already in use that has the same or similar characteristics?
If so: Don’t add unnecessary complexity.
Resource: List of existing approved materials and their specifications.
Is this a raw agricultural item, commodity item, or one that has a standard of identity?
If so: Develop a general specification that can be used between multiple potential suppliers.
Resources: Supplier technical information, the standard of identity, food action defect level from regulations, comparison of different suppliers’ specifications from the Internet.
What are the limitations on the use of the raw material?
Resources: Supplier technical information, regulations for the country of sale, e.g., U.S. Code of Federal Regulations (CFR), Canadian Food Inspection Agency, European Commission, etc.
Are there legal, maximum levels for use, both in the country of manufacture and the country of sale/use?
Resources: Same as previous.
Does the raw material meet existing company or customer standards (e.g., kosher, halal, organic, gluten-free)?
Resources: Company standards, customer requirements, supplier technical information, supplier-provided certificates.
Plant Discussions and Trials
Trials require close collaboration between R&D and the manufacturing team. These examples of questions to be answered and the method for initiating discussions before, during, and after the trials will help facilitate the trial process.
OSHA Considerations
Food Defense Considerations
Product Safety Considerations
Facility and Equipment Capabilities
Material and Production Costs
Post-Trial Discussions
Flexibility in sourcing and cost
Size and type of packaging based on forecast use
Typically, the larger the container purchased, the cheaper the cost-per-pound. However, if the forecast is for use of 100 pounds in a year, what is the appropriate-sized container to purchase? It would not make sense to purchase in 50 pound bags (multiple handlings of the package with resulting potential of damage or contamination) or in a Super-Sak (with destruction of, or potential use of, expired materials).
In part 2 we look at Raw Materials, the Certificate of Acceptability and Validation and Verification.
About the Author
Robin Amsbury is a HACCP Coordinator, AIB.
This article was first published in Quality and Assurance Magazine, and is reproduced with permission.
http://www.qualityassurancemag.com/article/aib0613-raw-materials-requirements/