AusDrinks 25 th March, 2014

Transcription

1 AusDrinks 25 th March, 2014 Inside and Outside the Supermarket Standards Presented by: Gary Kennedy

2 Agenda Introduction What do the supermarket standards cover? Business management systems Food Safety and Quality Good Manufacturing Practices Social Accountability Where is ABWI harder?

3 Introduction This presentation will discuss shelf stable drinks. Bottled water; soft drinks; energy drinks; shelf stable juices and cordials It will not cover: Chilled fruit juice and similar beverages Unpastuerised chilled fruit juices These have to meet additional requirements not covered by this presentation, including the exceptionally hard high care requirements for some products.

4 Overview: What do they cover? 1. Legislation Sites supplying Australian and New Zealand supermarkets must meet all pertinent regulation. Includes all local, state and federal laws, so bodies like the ACCC; AQIS / DAFF; customers; Weights and Measures have to be considered. 2. Business management systems ISO 9000 / systems, pretty much in full 3. Food Safety Codex HA Prerequisite / Support programs In-house and supermarket specifications

5 Overview: What do they cover? 4. Food Quality Weight; Colour; Aroma; Turbidity, etc Some colours not allowed [Coles; Aldi] In-house and supermarket specifications 5. Good Manufacturing Practices Cleaning; Maintenance; Pest Control; etc And, potentially 6. Social accountability systems WH&S; Environmental; Fair Wages; Child Labour; Working from home; etc [usually only applied to overseas sites that are in developing countries.

6 Background: Standards that apply SQF 2000 [level 3] Originally a 1990 s West Australian agricultural standard, now owned by the US FMI Food Marketing Institute and the standard for US supermarkets. Recognised as a GFSI standard [Global Food Safety Initiative]. Recognised by: Costco; Metcash as is Aldi; Coles plus their additional checklist

7 Background: Standards that apply BRC The UK standard for the British Supermarkets [BRC = British Retail Consortium] Recognised as a GFSI standard [Global Food Safety Initiative]. Recognised by: Costco; Metcash as is Aldi; Coles plus their additional checklist

8 Background: Standards that apply What products need to be certified? Aldi: All Products Coles: All Coles Branded Products Costco: All Products Metcash: All Metcash Branded products [Black & Gold; Signature] IGA not required [currently]

9 Background: Standards that apply Woolworths WQAV8 applies to all Woolworths Branded products Non-Woolworths branded drinks do not have to comply. Woolworths recognise no other standard.

10 How often? WQA Six monthly BRC & SQF Six monthly; then annually depending on result

11 Business Management Systems a. Management Commitment A much greater focus on senior management, including potentially as head office. Senior management are auditable In the BRC standard, if the senior managers are not present for the audit, including the opening and closing meeting, then the audit is an automatic fail.

12 Business Management Systems a. Management Commitment Must provide evidence of genuine commitment to food safety and food quality. A quality policy not only signed but understood by all levels of staff from the CEO to casuals

13 Business Management Systems b. Management Systems How the organisation runs it s business; Organisation charts; job descriptions, etc Must describe the interrelationship with head office if that exists. Must be a back up for all job roles.

14 Business Management Systems c. Management Review A meeting between senior managers including: CEO/COO; Production; Quality Assurance Should not only consider what has happened since the last meeting, but also consider what s planned to happen As much a business planning meeting as a food safety meeting if done properly Some standards require trend analysis of complaints and corrective actions

15 Business Management Systems d. Business Continuity A policy that no matter what goes wrong, the supermarkets will never run out of your product. Depending on the standard, may have to cover: Fire; Flood; Power failure; Computer virus; Sabotage; Bioterrorism; Adulteration; Lack of ingredient supply; Staff illness;

16 Business Management Systems e. Product Development Full procedures with records kept at every step of development From the initial idea through concept sample; trial batch; scale up; full run Includes shelf life trials; challenge testing; legality of artwork; microbial / nutrition panel / chemical testing Potentially additional WH&S updates

17 Business Management Systems f. Other Business Management Systems: Document control Record control Recall / withdrawal Compliant with FSANZ Recall Protocol Complaint management Site Security / Food Defence Including during the period travelling between your facility and the supermarket

18 Food Safety & Quality Codex HA systems mandatory Covering hazards and controls for food safety, food quality and food regulatory Specifications for Raw materials Ingredients; packaging; food additives; processing aids Work-in-progress Final product

19 Food Safety & Quality Policies required for stock control such as: Product rework What s done with partial batches; leftovers; products to be repacked; staff sales; donations for charity Product release A formal policy on how products are approved for release for sale. Non-conforming products policy

20 Food Safety & Quality Some supermarket verification activities Mock recall Mock business continuity Mock traceability Annual retest of nutrition information Challenge testing for transport and elevated temperatures Internal audit Covering construction; work practices; documented systems and records

21 Food Safety & Quality Purchasing / Approved Supplier Program Covers ingredients; packaging; food additives and processing aids Covers all service providers: Labs; trainers; warehouses; transport; garbage; security; maintenance; calibration; etc Anyone who you rely on to undertake work for you, but not employed by you. Must have signed contracts in place with all service providers

22 Food Safety & Quality Product Identification and Traceability: covering Raw materials Full traceability during production Each ingredient; packaging and processing aid to be traced during processing Work in progress Allergen control even those in the lunchroom and offices Identify preserved foods [e.g. sugar free ]

23 Food Safety & Quality Product Identification and Traceability: covering Final product Legality of labelling and artwork Formal annual review of all labels; Comparing to nutrition panel test results and formal review of recipes / formulations. Non-conforming product

24 Good Manufacturing Practices Training Must follow the Food Standards Code Induction; Training in specific duties for both those undertaking and supervising tasks Review of training Additional Requirements Can include HA; Cleaning; Internal Auditor; Allergen Controls Must be done in a language understood by staff Some standards require refresher training

25 Good Manufacturing Practices Construction Evidence of Council / Government approval Food Standard / AS4674 Construction & Fitout of Food Premises Surface and food contact material evidence Floors, walls, ceilings, stairs, platforms; lighting; drains, roof cavity; washbays Equipment, storage rooms; interior of vehicles Amenities, bathroom facilities, smoko area Garbage, chemical store, maintenance shed External grounds

26 Good Manufacturing Practices Personal Hygiene Handwashing Illness & Injury Clothing, Change Rooms and Laundry Services Jewellery and Personnel Effects Visitors and Contractors Staff Amenities

27 Good Manufacturing Practices Pest Control Cleaning and Sanitation Maintenance Calibration ALL measuring equipment Other: Water and Ice supply [operations water] Air quality

28 Potentially social accountability may apply

29 Social Accountability Policies to be covered include: Bribery & Corruption Labour Rights Freedom of Association Workplace Health & Safety Child Labour Living Wages Working Hours Discrimination Regularity of Employment

30 Social Accountability Policies to be covered include: Harsh or Inhumane Treatment Entitlement to Work / Immigration Subcontracting / Working from Home Environmental

31 So where are is the ABWI Model Code harder?

32 Where is the ABWI Model Code harder? The ABWI Model Code is more prescriptive in a few areas. Some of the areas in which the supermarkets standards are equally or more prescriptive apply for high risk products such as smallgoods, salads, sliced cheese and other ready-to-eat potentially hazardous foods These are not applied to low risk products such as bottled water, soft drinks and shelf-stable fruit juices and cordials.

33 Where is the ABWI Model Code harder? 1. Construction. The supermarket standards may also apply to farms [especially SQF], so many specific aspects required for ABWI are not: Size of conveyor openings; Materials approved for use for conveyors Self-closing doors in lunchrooms & no packaging Positive pressure; Enclosed rooms

34 Where is the ABWI Model Code harder? 2. Cleaning and Sanitation : The ABWI Model Code covers; Specific equipment cleaning programs are detailed as to frequency [e.g. washer, tanker] Frequency of cleaning [other standards don t often specify a frequency] Swabbing Testing of the strength of cleaning and sanitising solutions [in WQAV8]

35 Where is the ABWI Model Code harder? 3. Product Testing Many of the Supermarket standards do not require raw material [e.g. source / tanker] testing, just final product testing. Testing frequency is often annual or six monthly and the list of what to test is shorter and simpler. ABWI can be per batch for some testing requirements. The supermarkets either detail in their specifications what they require for testing, or require the product to be legally compliant.

36 Where is the ABWI Model Code harder? 3. Product Testing Supermarket requirements: a. Hydrologist s report Generally not required b. Microbiological annual / six monthly testing, usually just for E. Coli / coliform. Some specifications will cover other pathogens. Heterotrophs not commonly mentioned. c. Radiological Not required [but must not have any radiological issues]

37 Where is the ABWI Model Code harder? 3. Product Testing Physical testing Annual compliance to specification [e.g. turbidity; dissolved solids, colour]; and to any claims on the label [e.g. specific mineral content] here the supermarkets are harder.

38 Where is the ABWI Model Code harder? 3. Product Testing Chemical The list of chemical tests required by ABWI is longer than specified by the supermarkets, who basically expect compliance with legislation. Much testing is just for broad screen organochlorides and organophosphates. Testing is therefore less for Organics; volatile organics; inorganics; unless These are detailed in the specification.

39 Where is the ABWI Model Code harder? 4. Production requirements ABWI specifies: 1 micro filtration; HEPA filtration of air Positive pressure; Mineral water to be 250mg/litre In some cases, what must be on the record [e.g. tanker deliveries]

40 Summary Having a program in place that meets a supermarket standard will not necessarily pass an ABWI audit and vice versa. The supermarket standards tend to be more broadly focussed on the business as a unit, not just the production and source; they require aspects to be covered that are not in the ABWI Model Code; and some sections in the ABWI Code are more detailed in the supermarket standards.

41 Summary Whereas, the ABWI Model Code has very specific requirements on bottled water production in addition to these supermarket standards

42 Conclusion Questions?