Mass production of processed foodDone by: KerineContents:What is mass productionCertifications and guide to follow for production What is QA and QCWhat are the tests that are done to ensure that the food is of good qualityReference What is mass productionMass production are manufacturing products in a huge quantity. Because the quantity of products that are produced in mass production are huge, the products are often sold at a lower cost. The two types of methods that are used for mass production are human labours and machineries.1 Human laboursHuman labours are also known as manual labour, this method making use of human for production instead of using machines. This method has been in used before machines were being produced and used in the modern world. Some works still require manual labour for works like construction. AutomationTechnology are improving everyday in these days.
Everything now are using machines and electronic stuffs for work, communication and casual. Machines are getting more popular these days because it helps to reduce the amount of human errors and can be more precise compared to humans. 1.1 Comparison between human labour and automation in productionHuman LabourAutomation Cheap ExpensiveHigher chance of getting errorsLower chance of getting errorsHigher chance of getting injuriesLower chance of getting injuriesProduction is slowerProduction is fasterRequires resting time Does not require resting time 2. Certifications to follow for production of processed foodProcessed food require ISO 22000.
This standard is for food safety management and processed food are meant for consumption, thus if a company wants to produce food products, they are required to get the certificate for ISO 22000. For mass production, it is usually produced in a factory which will require HACCP 2.1 ISO 22000ISO 22000 is a standard for food safety management system. 2 This standard is required in food industries as they are dealing with products that are for consumption. This standards helps to ensure that the food products that are produced by the company is safe and clean for consumption for customer. The food products are to remain clean and safe until it reaches the customer hands.
2 The main purpose for requiring ISO 22000 is because it aims to lower the risk of causing infection by the food due to contamination. During production, before a food is finally made into a finished product, it will go through lots of procedure and hands in order to make the product. Going through all the process will cause the chance of contamination to be higher as the food is being transferred from one place to another place. This will increase the risk of bacterial contamination, this can cause danger to a person health.
2.1.2 Example Checklist for ISO 22000Source from: https://www.foodsafetymagazine.com/magazine-archive1/december-2005january-2006/a-global-standard-puzzle-solved-how-the-iso-22000-food-safety-management-system-integrates-haccp-and-more/ Point 4 to 4.
2 The points in number 4 is focus mostly on the documentations that are used in the company. Some documents are written daily, while documents are written occasionally and must be signed and verified by respective supervisor or managers. These documents must be ensured that the informations and the details are up to date. Point 5 to 5.7The points here are focusing on the management within the company. The company will have to come up with a food safety team for food safety and plan a food safety policy where everyone in the company will have to follow. This food safety team will need to have a team leader and also know the responsibility of each other roles. This food safety team will have to ensure that all communication within or outside the company is clear so that there will be no miscommunication within each other during production or when talking to external people.
Point 6 to 6.4For point 6, it focus on the resources that the company currently have. From human resources eg; management, production and the raw materials that is needed for production. For human resources, there should be some trainings that are needed for certain type of job like operation of machines or forklifts. Another focus will be the building structure of the company or factory. The auditors will check if the infrastructure of the building is safe for production and is working environment safe for the workers to work here. Point 7 to 7.
10This area are focusing on the used of the HACCP. The food safety team that was mentioned before are to identify the hazards that could potentially present in the company which could affect the safety of the food products and the workers who are working there. This process is called Risk Assessment process.Source from: RP Laboratory Management learning package one; Lecture notesAfter identifying the hazards in the company, they would need to evaluate the risk of that particular hazard will cause. Consequence would be how serious will the outcome if the hazard cause any injury while likelihood would be how frequent the hazard will cause injury.
1 is the lowest, 5 is the highestSource from: RP Laboratory Management learning package one; Lecture notesA high consequence could mean that the hazard can cause death or serious injury like paralysed waist down. A low consequence could mean that the hazard might cause minor cuts or bruise A high likelihood would mean that the frequency of the hazard causing injury is very common. A low likelihood would mean that the frequency of the hazard causing injury is not very common.
Point 8 to 8.5This part of the audit would focus on the internal of the company. How often they conduct a internal audit and if the control measures that the company get from the risk assessment is valid and useful. The auditors will also check if the previous rectification is being applied in the company.
2.2 HACCPHACCP is also known as Hazard Analysis Critical Control Point. It is a system that is under the FAO (Food and Agriculture Organization). This system is created to help to control hazards from causing injuries to people, be it chemical or physical hazards during production. 3This system is usually used during raw material production, and during the process of production to make the raw materials into finished goods. In a production company, a HACCP plan is needed for the workers so that they will know what steps to do and the flow of the process that are needed to do for mass production. The main purpose for HACCP plan is to identify what are the hazards or what are the possible hazards during production which might cause spoilage to the food or harm the consumers. Here are the possible types of hazard that can be found in production.
4Types of HazardsExamples Physical Wet floors, uneven floors, loose objects on the floor, protruding objects Ergonomic Lifting heavy objects, standing position, Psychological Sounds, bright lights, heightBiological Bacterias, virus3. What is QA and QCQA is Quality Assurance while QC is Quality Control. These two are often worked together, within a company to ensure that the products are produced are the same and are of good quality. 3.1 What is the job scope of a QARight before a product is being manufactured into a finished product, a QA manager is supposed to plan out what are the possible problems or quality issues will occur during the production of the finished product. His job will be to plan out and set some guidelines 5 that are required for the product to be produced in a good quality form. For example; calibration of meters. The QA manager will have to plan out the procedure on how to calibrate the meters, the time and steps.
Thus, whoever is doing the calibration, will have to follow these steps that are planned by the QA manager. In another words, a role of a QA manager is to prevent defects or error from occurring during production. The QA manager will have to plan what are the documents that are needed for which steps, for example; during production, what is the sample size that are supposed to be taken for taste and what are the test that are supposed to be done for the sample. When the sample is being taken, where is it supposed to be documented in. 6 Another example, is when there is raw materials received. What is the sample size that is supposed to be taken for that amount of raw materials that are received.
Eg; if 350,000 caps are received, a sample size of 50 is to be taken out for inspection. These caps that are taken out, needs to document in which file and submit to who is also planned by the QA manager. 3.2 What is the job scope of a QCA main job of the QC is to check and ensure that all raw materials are of good quality when the company receive the materials. The main job of the QC is to check the raw materials base on the guidelines that the QA manager planned and what are the sample size that is needed to check. When a product is being manufactured out into a finished product, the job of the QC is to check the finished product before delivering it out to the customer. 5 The QC will follow the guidelines that are planned out by the QA manager and check the finished product. The main job of the QC is to ensure that the finished product is of good quality after going through all the process.
3.3 Difference between QA and QCSource from: RP Good Manufacturing Practice Problem 1; 6th presentationFor QA, they focus more on how the product are being developed through the process. They will have to think of ways to prevent defects or bad quality finished product from the production. For QC, they will check and identify what are the defects that are found in the finished products before it reaches the customers’ hands. To put it simply would be QA are in charge of ensuring the products’ quality before it is manufactured out and developed while QC are to check the products that are being produced out from the machines and ensure that the finished product are of the good quality that the company have promises the customer’s requirements.