Quality and Food Safety through the Control Systems Francisco José Alferez Canales Automation Business Driver PS&E, TS&S, Packaging Coordination Tetra Pak Iberia / 1
Quality and Food Safety through the Control Systems Agenda Introduction Quality and Food Safety concept How a Control System contributes to the safety and quality of food production. Quality Control and Quality Assurance through control system Contribution of Batch Systems in the Safety and Quality of food processes. S88 compliance Conclusions / 2
Introduction Food & Beverage Market The food and beverage sector is becoming more dynamic and competitive. The rapid introduction of new products in the market and the number of references produced necessitate the use of increasingly efficient and secure automation and / or software systems. On the other hand the society requires standards of quality and food safety only comparable to those demanded in traditionally more demanding sectors, such as the pharmaceutical sector. The tendency is to converge towards standard regulations in both sectors in a common aspect such as health. / 3
Introduction What are the main challenges for producers? Safety and food quality Operational Performance and Cost Efficiency Instability in product quality High number of claims Limited traceability Manually scattered and manipulated data quality Low reliability and flexibility in production High level of shrinkage No root cause analysis, or continuous improvement Limited Performance Tracking Manual and low quality data reports Environmental Performance and Improvement The high consumption of services and level of waste No environmental performance monitoring Manually dispersed and manually scattered environmental data / 4
Introduction What does the market demand? Producers Dealers Consumers Society Protect the brand image Limit claims Supply Chain Control Supply Chain Control Protect the brand Limit claims The guarantees on: Contents Origin Production Food safety legislation / 5
Quality and Food Safety What are they? Food quality The quality of food is the set of qualities that make food acceptable to consumers. It includes both qualitative aspects (taste, smell, color, etc.) and quantitative (ph, FAT, Brix, etc.) Quality Control and Quality Assurance Food safety Food safety includes a number of routines that must be performed when handling food in order to prevent potential harm to health. Through manual and / or automatic procedures Avoid source contamination Health and Allergies / 6
Quality Control Management The highest standards of product quality Food safety management System Retailers Consumers Management commitment 3 rd -party audit Authorities Customer quality laboratory Implementation of standards e.g. GMP Customer quality manager Raw material Processing line Packaging line Distribution Process parameters PP PP PP PP PP Critical control points CCP CCP CCP CCP CCP CCP Cleaning in place CIP CIP CIP CIP Interlocks / 7
Control of process parameters Full control of all process parameters Real time view of process parameters Raw material Processing line Packaging line Distribution Process parameters PP PP PP PP PP Critical control points CCP CCP CCP CCP CCP CCP Cleaning Line in place controller: Monitors cooling temperature in milk reception Ensures that milk is sufficiently cold CIP CIP Stops pump CIP if milk is not sufficiently cold CIP Controls and monitors conveyor speed Interlocks Controls speed of conveyors to avoid damaging packages / 8
Control of process parameters Benefits Consistent end-product quality Lower defect rate Provides operator assistance Efficient troubleshooting Values Reduce off spec production Higher yield Reduce waste / 9
Control of critical control points Simplified food safety management Fast response Support production of safe food Raw material Processing line Packaging line Distribution Process parameters PP PP PP PP PP Real-time monitoring and control Checks packaging material being loaded Critical control points CCP CCP CCP CCP of pasteurization CCP temperature: CCP into filling machine: Ensures that product is pasteurized Cleaning in place Matches material to product to be filled CIP CIP CIP Pasteurizer goes CIP into circulation until it is safe to continue production, if temperature Avoids wrong combinations that can be dangerous falls below set limits Interlocks to allergic consumers / 10
Major improvements in food safety Benefits Values Full control of critical control points Prevents mixing of product and detergents Alarm logging and visualization Fast response Helps protect brand equity Meets regulatory demands Easier to provide CCP documentation when inspected / 11
Control of cleaning in place (CIP) Secure proper CIP procedure is followed Reduce waiting time when performing CIP Optimised CIP Raw material Processing line Packaging line Distribution Tank CIP status parameters Process parameters PP Monitors cleaning status PP PP PP Ensures that product is only stored under safe conditions PP Critical control points CCP CCP CCP Prevents CCP product from entering a CCP tank that is dirty, or that has not CCP been cleaned recently enough Cleaning and sterilization of filling machine: Cleaning in place Secures proper cleaning is performed CIP CIP CIP CIP Interlocks Secures sterilization parameters / 12
Optimized CIP Benefits Effective CIP Improved hygiene CIP recipe handling enables optimization of CIP programs Reliable, consistent CIP Values Reduced time losses when running CIP Reduce the energy needed for CIP Reduce consumption of detergent / 13
Interlocks prevent off-spec production Avoid costly operational errors Supports QA/QC procedures are adhered to Raw material Processing line Packaging line Distribution Prevents sub-standard product from proceeding in production: Process parameters PP PP PP PP PP Before emptying of a tank can start, quality staff checks the product Checks that right cardboard is used: and enters the results Production stops if the wrong material is entered Critical control points CCP CCP CCP CCP CCP CCP Product will only be allowed to proceed if it passes the quality check Prevents production of sub-standard products Cleaning in place CIP CIP CIP CIP Interlocks / 14
Interlocks Benefits Secures that right equipment conditions are met Avoids unintentional mixing of products/materials Enables fast troubleshooting when condition is not fulfilled Values Less product and material waste Increased availability / 15
Quality Control and Quality Assurance Differences Quality Control Quality Control refers to the quality activities associated with the creation of the final products. Verify and measure that the product has acceptable quality Compare with standards and act on the difference Composed of tools, know-how or techniques Quality assurance Quality Assurance Refers to processes that are used to provide adequate confidence that a final product will meet the required quality requirements Emphasizes end products Avoiding defective products Avoid repetition of errors (continuous improvement) Quality assurance is born as a natural evolution of quality control / 16
Total control over product quality QA / QC management and reporting system Management system for raw material results and laboratory tests Quick and easy access to complete quality control information for all stakeholders Raw material Processing line Packaging line Distribution Process parameters PP PP PP PP PP PP Quality lab QC QC QC QC QC QC Reports / 17
Example : performing Quality Control of mixing tank Quality lab module Take and label sample Lab performs QC test Activate quality control Label printed for laboratory sample container Register QC result Perform QC test according to spec. enter QC result Product approved for further transfer Sticker applied to sample ready for QC lab Approve/reject sample and write any comments Save result and QC is approved / Not approved Scan sample container / 18
Ensures the right end product quality every time Supports work to manage and improve product quality performance Results in fewer claims, increased sales and reduced costs Ensures satisfied consumers Logs, stores and integrates all QA and QC data for the complete view Simplifies management of quality control system facilitating compliance with HACCP and GMP Enables easy configurability of quality specifications Secures high, consistent end product quality / 19
Example: ERP Order download and feedback Food & Beverage Market ERP generates production order that is downloaded to batch Control The order is split-up into batches matching recipe and equipment set-up Automatically populates the batch list Feedback of actual production and material usage back to ERP system / 20
Batch Systems Benefits Cost savings The Batch system is not only conceived as an operating system, but also as a powerful analysis tool that helps us to save costs: Control of Ingredients and materials used in the recipe. Optimization of resources and traceability Quality Control Quick problem identification tool Productivity Management and optimization of operating times Efficient mixing solutions Fewer claims involve higher sales and lower costs / 21
Batch Systems Benefits Batch Report & Golden Batch Additional General information and operations Quality Information Detailed Control of Ingredients Used in the Recipe Golden Batch / 22
Batch Systems Benefits Food safety Batch Control Systems or Batch Systems incorporate elements of Food Safety Process Interlocking Material included in the recipe Avoid mixing incompatible products Avoid product and packaging incompatibilities Validation of samples from integrated laboratory in control system Registration of all ingredients and materials It can incorporate functions of Hazard Analysis and Critical Control Points and (HACCP) 1 Compliance with all legal requirements 1 HACCP: Hazard Analysis and Critical Control Point / 23
Batch Systems Benefits Food quality Batch Control Systems or Batch Systems incorporate elements of Food Quality Consistency and quality of products. Consumer and Customer Trust Human operator errors are avoided: Add adequate amount of ingredients At the right time Ingredient checks and controls Graphical and complete real-time information of what is happening and what will happen in production Quality Control and Quality Assurance / 24
Batch Systems Benefits Integrated System - MES It will allow you to manage lots and / or recipes according to the production orders generated through an ERP system (or manually) Integration in the Plant MES system Track your story through reports Traceability Recipe Management Quick and flexible Efficient Cost Solution Process Recipes Packaging Parametrization According to ISA S88/S95. Interoperability Connection between Batch Systems / 25
Batch Management System Simplified operation based on batch managed production Benefits Control materials and ingredients used in the recipe Resource optimization and traceability Reduces the risk of operator errors Quality Control Quick identification tool problem sources Secures food safety and consistent product quality Productivity Management and optimization of operating times Efficient solutions mixing Easy coordination of operations following a predefined recipe Legal & Standards ISA S88 and support identification of critical control points (HACCP) Values Higher yield - reduce waste Improved performance through minimised time losses Reduce off spec production Reduced number of claims Cost reduction and increased sales / 26
Quality and Food Safety through the Control Systems Conclusions The programming of control systems can and should integrate functions that ensure food quality and safety. The integration of MES / ERP / Quality systems provide powerful tools for quality control and food safety. Control systems must adapt to the new demands of the future. / 27
Many Thanks!!! Francisco José Alférez Canales SE&MA Automation Business Driver PS&E, TS&S, Packaging Coordination Tetra Pak Iberia Processing Solutions/Automation francisco.alferez@tetrapak.com www.tetrapak.com Francisco José Alferez Canales President francisco.alferez@tetrapak.com www.isa-spain.org / 28