FOod tech study AT2

Production and processing of food-Q uality and quantity control in the selection of raw materials for food processing Raw Materials: any item that is used to manufacture a food product, doesn’t just include naturally occurring ingredients but synthetic ones too like additives. Raw materials include: ---- Ingredients; fruits, vegetables, milk, flour, meat Processing materials; steam and water Food additives; emulsifiers, preservatives, colours and flavours Packaging materials; cans, bottles, plastic, glass Band 6 responses will refer to processing materials, packaging and food additives in a Q about raw materials opposed to just ingredients. Value added products are raw materials that have been processed in a way to make the product more valuable to the consumer increasing profits Quality control of raw materials: conducting tests to check the standards of raw materials or products before, during or after production Raw material specifications (what they criteria they are tested against:------ Physical characteristics: shape and size Sensory characteristics: how it looks, smells, tastes Chemical characteristics: moisture content or pH levels Biological characteristics: microbial limits Nutritional characteristics: nutritional content Contamination characteristics: limit of bacteria in raw material that make it unsuitable for consumption Inferior batch results in dissatisfied customers and damage to company image. There are 4 steps in the quality control testing process 1. Describing the characteristics of the raw material; what of the above characteristics are suitable for the product manufacture 2. Choosing the sample of the raw material to be tested; how many will they test 3. Testing for each characteristic; specific tests undergone to determine quality 4. Taking action on the result; decision on use of the raw material or rejection Creating the raw material specifications are established through consultation with FSANZ, the team responsible for establishing specifications are research & development, quality assurance and production. Info included in specifications consists of; name and description, food allergens, sensory, physical chemical and microbial info, storage and shipping, shelf life and handling directions.-De scribe processes that transform raw materials into manufactured food products Specific ones I may not remember definition of: Processing technique Description Canning Food products are packed into a can and heated to high temp to kill harmful microorganisms. Pasteurisation Heating and quick cooling of food products to kill microorganisms. Deep-freezing Freezing of a product that forms ice crystals in the food product’s tissue extending shelf life. Sterilisation Canned food products are steamed to kill harmful bacteria. Fermentation Sugar in food products is broken down by microorganisms in a low oxygen environment. Blanching Heating of product with steam or water prior to canning.-R ole of food additives in the manufacturing process Food additives: substances added to raw materials when making a product, used in small amounts for a range of functions, necessary for efficient manufacturing and distribution. Food labels typically display presence of additives. The functions of food additives are to:---- Improve the stability or keeping quality: sorbitol a humectant used in the preservation of dried fruit to reduce moisture level Adapt foods to provide for special dietary needs: artificial sweeteners such as aspartame used in sugar free substitutes like coke zero to market the product to people with diabetes Restore or improve sensory characteristics of processed foods specifically taste and appearance: Beeswax as a glazing agent to coat apples to improve appearance Extend shelf life: sulphur dioxide used as a preservative in sausage meat to limit microbial growth Commonly asked in the HSC. BE sure to know an example for each Additive Description Examples Antioxidant Prolong shelf life by preventing oxidation – fats or oils turning rancid Ascorbic acid in jams and cured meats Preservatives Prevents growth of mold or bacteria Sulphur dioxide in dried fruits, pickles, sausages and juice Colours Restore colour or enhance physical appearance Red 40 used in confectionary Flavouring Restores flavour and odour lost through processing Flavour concentrates added back to fruit juice or soup packets Flavour enhancers Improves existing flavours Monosodium glutamate MSG used in packet noodles Food acids Maintain acidity Citric acid in juice or lollies Artificial sweeteners Substitute for sugar in low KJ foods Aspartame in coke zero Emulsifiers Allows combination of oil and water without separation Lecithin in salad dressing Vitamins and minerals Added to fortify foods if lost in production Addition of vitamin D to margarine Humectant Absorbs moisture, prevents food from drying out. Sorbitol in dried fruits Regulation of food additives and consumer safety: carefully regulated by FSANZ, assesses each food additive, determines what levels at which it can be safely used and consumed. TNC’s with products with banned additives are required to alter recipe if they wish to sell within Australia. FSANZ also requires additives listed on labels. Code numbering has been used to list additives in labelling because it’s easier to spot, can specify things like type of colour etc. Disadvantages: adverse reactions occur in some of the population, food colour and additives negatively impact children, can cumulate and become toxic, can be used to deceive consumer. -C haracteristics of equipment used in different types of production and factors influencing their selection Domestic and industrial equipment often share the same if not similar processes the only difference is scale of operations. Food manufacturing equipment must be strong, hygienic, efficient and durable (SHED). Strong: needs to produce large amounts of food, sturdy to ensure safety for employees and operators. Hygienic: made of stainless steel, easy to clean to prevent cross contamination. Efficient: time delays can impact the amount of food produced, also produces consistent product. Durable: may have to operate 24/7, able to withstand high volumes of production and continuous operation. Factors that influence a company selecting equipment include cost, accessibility and intended use. -P roduction systems used in the manufacture of food, eg small, scale, large scale, manual, automated and computerised Production systems: systems used to manufacture food, systems vary between foods produced and size of the company making them. Automated: when machines handle and control the processing of food from receiving the raw materials to the finished product. Automated systems have pre-set and predetermined specifications for operation including cooking time, chilling time, weight of products, mixing times and speed, temperature control etc. Computerised: located in highly sophisticated manufacturing organisations (TNC’s), similar to automated but operated by computerised sensors that store complex data, batch numbers, dates, times, production conditions etc. HOWEVER, very costly, isn’t necessarily needed within Australia due to lower demand for food products with a smaller population.-De scribe the processing techniques, equipment, storage and distribution systems used in industry and compare with those used domestically-Q uality management considerations in industrial practises to achieve safe foods for public consumption, e.g., hazard analysis and critical control point ( health and safety and hygiene HACCP ); work Quality management systems: a set of policies, processes and procedures required to plan and execute a safe reliable food supply for consumers. Covers all aspects of product development, production, marketing and servicing. Quality assurance: use of management systems to ensure standards in quality are achieved and maintained. Procedures include: o Clear concise final product specification o Procedures for assessing and measuring quality o Clear specifications for all production areas o Sampling and testing of the completed product is undertaken Without proper procedures in place, there is the risk of food poisoning which can impact all sectors of the agri-food chain as well as all companies involved. Educating the importance of food safety to workers paired with accurate records of relevant information and quick responses to any problems reduce this risk and help the company maintain a safe high quality product. Quality control: characteristics are measured, compared to a standard and any differences that occur may be acted upon. HACCP – Hazard Analysis Critical Control Points is a quality assurance and food safety system that identifies potential food hazards and their control points throughout all stages. HACCP is compulsory in some food sectors and recommended in others. The system is used worldwide and viewed highly. Advantages of HACCP: more profit and less waste for businesses, edge over competition, preventative measure, consumer confidence in safety, job security is improved. Disadvantages of HACCP: costly, requires a lot of manpower, not often realistic for smaller companies and restaurants. HACCP principles 1. Assess the hazards – identify hazard and determine risk level, severity of each hazard is rated for its potential to cause harm to the consumer. Catering kitchen knowing raw chicken contains salmonella bacteria, so they prepare and store it separate from other foods. 2. Identify critical control points – determining where a safety issue arises, known as critical control points (CCP), includes all processes where failure of control can compromise food safety. Examples of CCP’s: storage and transport, cooling, chilling or freezing, heating for pasteurisation etc, cleaning and santising, packaging and sealing. 3. Set critical limits – set limits to ensure issues don’t arise. Limits of 0 to -4 degrees for the storage of a product. 4. Monitoring critical control points – implementing a monitoring system to ensure limits are adhered to, quantitative testing measuring aspects such as temperature, acidity, water activity and microbial load to predetermined standards (example of critical limits), qualitative testing by visual inspection of colour, texture. 5. Establish corrective actions – deciding actions to take if critical limits are not adhered to, involve adjusting the process to prevent future failure or wasting current batch. 6. Verification of HACCP procedures – reviewing process, making adjustments, when necessary, regular reviews of procedures, checking records, outside inspector ensures verification 7. Establish record keeping procedures – keep records of hazard identifications and CCP’s, limits and corrective actions, must be retained for 4 years and available for audit, documentation identifies each batch. Good manufacturing practice (GMP): system ensuring food products are consistently produced and controlled according to quality standards. International Organisation for Standardisation (ISO): specifies requirements for a food safety management system. Creates guidelines for food safety management, relevant and suitable for all organisations within the agri-food chain. Work health and Safety: ensures safety of workers, machinery can be dangerous, accidents in the workplace are often caused most by a worker being unskilled at their job, rushed or poorly maintained equipment, in businesses of more than 20 staff, a WHS committee must be formed. Work Health and Safety Act 2011 (NSW) is a legislation that requires safety for workers including safety guards, correct PPE and rotation of workers. SafeWork NSW enforces this legislation and investigates issues such as injury and death in order to make recommendations and implementations. Advisory Groups That Have A Role In Formulating And Implementing Policy And Legislation ● Policy - express outcomes or aims that the government wish to achieve, and strategies on how to achieve them to improve all aspects of living ○ Food nutrition policies are high on the government priority list due to ‘obesity epidemic’. ○ Main policies involve: National Health and nutrition Policy, Safety, Trade, Environment, Competition policy ● Legislation - refers to laws passed by the government to specify what can or cannot be done without prosecution. Legislation aims to achieve government policy. ○ examples of legislation include the Trade Practices Act and the Food Act ○ Food laws aim to unify all states, without national food laws there would be many complications in food production (i.e. some products may be more nutritious in NSW than QLD) ● Advisory Groups Governments are advised by independent organizations on the development of policies and legislation. Advisory groups can be in the form of: ● Business groups within a sector e.g. Australia Dairy Corporation. ● A group that advises on specific health issues e.g. National Heart Foundation. ● An independent body able to make/change laws relating to food e.g. FSANZ ● A group that protects local food supply against contamination. E.g. AQIS Advisory Group Role Example of Impact on AFI Australian Citrus Growers Incorporated (national level) Represent citrus growers around Aus. Assist in management of issues such as fruit fly infestation or drought. Working with gov. to help salvage drought-stricken farming businesses and ensure a stable supply of citrus for Aus. Consumers. NSW Food Authority (NFA) (state level) Monitoring food safety across all sectors of the food industry.- Ensures food safety across entire food chain Launched a campaign to educate public of the dangers of listeria bacteria during pregnancy, and how it can be avoided.- Commissioned report from primary production to retail. showing almost ½ of pregnant women ignore risks associated w/Listeria bacteria which can lead to miscarriage, infection or still birth and launched campaign about it as a result. CSIRO’s Crusader Meat Rabbit Advisory Group Represents farmers and processorsofCrusader rabbit meat used for human consumption. Undertake research and development on rabbits for safety and quality purposes, for exportation. Australian Beverages Council Limited Represents the interests of manufacturers, distributors and importers of non-alcoholic beverages. Works with the Australian Food and Grocery Council to standardises nutritional labelling on beverage products. Food Standards Australia New Zealand (FSANZ) Independent body that can make food laws in Australia. Coordinated product recall for frozen pomegranates contaminated with hep. A. Australian Quarantine and Inspection Service (AQIS) Protect agriculture against pests and diseases that may enter the country. Worked with gov. on preparations for avian flu entering Australia. National Heart Foundation Provide advice from their research to the gov. on reducing the burden of heart disease on healthcare, and its prevention. Establish campaigns, e.g. Jump Ropes for Heart, and advertisements to educate the public on ways to decrease the risk of heart disease/problems. FSANZ – Food standards Australia New Zealand ▪ independent legislative bodyset up by Act of Parliament in 1991 to standardize food laws ▪ liaises with council of health ministers from Australian State and Territory governments and inspectors from AQIS ▪ liaises closely with Australian Commonwealth government and New Zealand government ▪ in July 2002 changed name to FSANZ from ANZFA (Australia New Zealand Food Authority) ▪ FSANZ co-ordinates the following tasks:- enforcement and revision of the Australian Food Standards Code-- Participates in the development of international food standards and policies and risk assessment policies on imported foods into Australia provision of safety education in food and food manufacture, including development of food safety codes of practice for the food industry, i.e. codes for nutritional information- Coordinates surveillance of food available in Australia- Coordinates food product recalls to ensure safety- Provides the food management framework Australian Food Standards Code ▪ Consumers need to know the food is safe and the labels are accurate, informative and not misleading ▪ The AFSC is the tool used by FSANZ to publish approved food standards; it outlines a general list of standards to which food products must adhere. ▪ outlines general list of standards which producers must follow:- accurate labeling and advertising---- date of production/manufacture control of use of food additives residues in food, e.g. insecticides foreign objects in food or packaging ▪ Labelling and advertising: country of origin, ingredients list, e.g. level of cream present for a product to be called "ice-cream" ▪ Substances added to or present in food: additives, vitamins/minerals, processing aids ▪ Contaminants and residues: metals and toxicants, AgVet chemicals, prohibited and restricted plants and fungi, etc. ▪ Foods requiring premarket clearance: novel foods, GM foods, irradiation of food -- ▪ Microbiological limits and processing requirements Also includes food hygiene standards: food storage temp, use of transport vehicles HACCP is stated in the FSC as a requirement for all food premises to ensure safety of production and also specifies premises building requirements Examples of Impact FSC has on AFI---- Ingredients must be sourced from licensed suppliers and transported in vehicles only used for food transport HACCP implemented in daily procedures + HACCP plans written, applied, documented. Standards for primary production of food such as seafood, poultry, meat, dairy products and specific cheeses. Menu descriptions of products must comply with FSC, licenses and cleaning must meet requirements Codes of practice ▪ FSANZ involved in developing codes of practice in AFI, e.g. nutrient claims on labels and ads. Consumers need to be informed and protected by claims made by producers to make informed choices Product recall ▪ Recall is the removal from sale, distribution and consumption of foods that may pose a safety hazard to consumers (harmful micro-organisms, toxic chemicals, harmful foreign bodies) ▪ FSANZ must notify in question the manufacturer, producer, or importer of food before initiating product recall ▪ FSANZ has overall responsibility every business must have a product recall management plan in place ▪ Products may be recalled for two main reasons:- Quality defect that is not a public health risk- Quality defect potentially threatening consumer safety due to a production fault or tampering ● Food product may return to market once issue has been resolved ● Consumers who return recalled products should not consume then but return them to their store of purchase to receive a full refund. ● Recalled products are temporarily or permanently removed from the market and returned after the issue has been resolved. AQIS – Australian Quarantine Inspection Service ▪ Operates within the Agriculture and Fishery sector ▪ It is responsible for: o Protecting Australian primary producers and the community from exotic pests and disease o Inspects legally imported animals and plants and products o Checks the quarantine status of overseas travelers passing through airports and sea ports o Provides export certification for agricultural produce so they can compete in global marketplace ▪ part of Department of Agriculture, Fisheries and Forestry ▪ works with Australian Customs Service and Australia Post to protect Australian agriculture from contamination ▪ AQIS enforces these responsibilities through: inspection of all plant and animal material to be exported----- an airports program using x-ray detection and sniffer dogs to detect prohibited materials a sea ports program plant quarantine stations where exotic plants are kept for inspection (in NSW the plant is located at Eastern Creek) a ballast water program is enforced to keep a check of where visiting vessels have taken up ballast water, as contaminated water cannot be dumped an international mail program for inspection of foreign mail ▪ To fulfil the task of protecting Australia from exotic pests and disease, AQUIS runs:- Inspections of imported foods according to categories set by FSANZ.---- An airport program that uses X-ray detection + sniffer dogs to detect prohibited foodstuffs Seaports program that involves inspecting visiting water vessels + their cargo A ballast (bulk) water program which is enforced to keep a check of where visiting water vessels have taken up ballast water, as if it's contaminated it cannot be dumped. International mail program for the inspection of foreign mail. - Plant quarantine stations + imported animal quarantine stations ● Government Policies And Legislation (Local, State, Federal) That Impact On The Australian Food Industry Including Legislative Requirements For Labelling Health and nutrition policy ▪ Many large businesses have responded to national health and nutrition policies by developing their own company nutrition policy ▪ main aim is to educate people on wise food choices, so as to restrict the incidence of diet-related disease (obesity, diabetes, coronary heart disease, etc) and reduce the cost of health care ▪ Food Safety Campaign Group conducts public education on food safety. Established in 1997, the group consists of government, industry, consumer and professional associations. They aim to raise awareness amongst consumers and food handlers of the need for safe food handling practices ▪ Growing cost of health care system means government wants to prevent where possible o Australian guide to healthy eating aims to avoid overeating, prevent diet-related diseases and choose a healthier diet ▪ Aimed to educate Australians on food choices, physical activity and healthy weight to address lifestyle diseases and reduce their financial burden on the healthcare system. ▪ Examples: the Five Food Groups, the Recommended Dietary Intake Scheme (RDI), the National Public Health Partnerships Nutrition Strategy and Action Plan – Eat Well Australia, 2000-2010. ▪ The Strategic Inter-Governmental Nutrition Alliance (SIGNAL) was responsible for the development of the latter policy, striving for national public health nutrition by working with the government, industry groups, health professionals and NGOs. Trade policy ▪ Policy of fair trade o Government’s moves to eliminate trade barriers include reduced tariffs, raised quotas, eliminated subsidies, and Australia’s free trade agreements with several countries o instituted the removal of trade barriers affecting both import and export of food. o Exports– to promote exports the commonwealth government aims to remove barriers to export, encourage Australian industry to seek export markets, and promote benefits of Australian agri-food products around Asia-> increasing the global market share of profits that can come back to Australia. o Imports– Government trade policies have resulted in considerable increase in imported foods as a result of trade barriers being removed. Imported foods important in shortfall in our production as a result of poor growing season. They also reflect more demand for ethnic and specialty foods. However, the huge increase in imports has reduced Australian company profits and their market share; in response the companies are expanding overseas. ● Greater competition in the marketplace ● Advantages such as price competition and product variety for consumer ● Policies regarding imports have allowed a gradual reduction in tariffs (taxes) on imported foods. ● Establishing free-trade agreements has increased quantity of both exported and imported foods, esp. exported processed meats, dairy and processes fruit/veg, imported ethnic/speciality foods. ● Australian government promoting value-added and ‘Australian quality’ foods in Asia. Environmental policy ▪ Australia is known for its ‘clean-green’ image and companies within the AFI aim to reduce environmental impact of food production and generate a good company image Legislations Affecting the Food Industry- Details of food law (legislation) in Australia at the 3 levels of government. ▪ When new issues occur, the government must ensure that rules and laws emerge to protect Australians (i.e. GM foods). Food industry legislation is administered on 3 levels: ▪ Federal– includes HACCP, FSANZ, AQIS ▪ State–includes OH&S, NSW food act ▪ Local–includes food surveillance/health inspectors Federal Government Legislations: ▪ Trade practices Act 1974 o Strengthens competition at all levels of private enterprise covered by the legislation o Reduces the difference in power businesses hold over consumers / gives power to consumer o The consumer has power by deciding to buy a business’s product and giving them profit o Businesses compete to provide what they can at the most reasonable price, therefore even competition o The act addresses four areas: ▪ Restrictive trade practices– Misuse of market power (large company uses market power to eliminate competitors), Exclusive dealings (supplier cant force retail to purchase only from them), Resale price maintenance (supplier can’t decide retailer sale price), Price discrimination (cannot vary price according to customer), Prohibition of acquisitions that result in less competition (restrictions on companies who consider ‘buying up’ competitors) ▪ Unconscionable conduct– Restricting acts of unprincipled, unwritten law (immoral acts) ▪ Consumer Protection– False/misleading conduct, Gifts/Prizes with no intention, Bait advertising (advertising certain product but then replacing it with another), referral selling (persuading consumer to buy good given that they must benefit the company in some way, i.e. referring others assist in supply/service), safety standards and unsafe goods, company responsibility ▪ Liability of manufacturers/importers for defective goods– Consumer injury or loss – the company is liable for compensating ▪ Competition and Consumers Act (2010). Limits company competition techniques to protect consumers, addressing four areas: banning restrictive trade practice and unconscionable conduct, ensuring consumer protection and liability of manufacturers and importers. ▪ Export Controls Orders (1993) ▪ Gene Technology Act (2000). Ensures public and environmental health/safety for the potential risks of GM animals, fruit/veg and grains. ▪ Imported Food Control Act (1992). Ensuring imported foods meet Australian standards for labelling and packaging as well as additives and preservatives, working with AQIS. State Government Legislations: (eg NSW) ● Clean Air Act 1961 o Policed by the State Environment Protection Authority; it advises companies on ways to prevent/minimize plant pollution and monitors pollution levels o Food processing may produce odour, smoke and radioactive substances which are unpleasant for locals o Factories are required to use equipment to control the amount and type of impurities released o Equipment must be maintained and must operate efficiently ● Clean waters Act 1970 o Waste which may be discharged into waterways, pollutant being a gas, solid or liquid that will alter the waterway in any way. Failure to meet regulations is an offence ● Noise Pollution Act 1975 o Noise produced during food processing, sound and vibration o Equipment required to control noise and reduce pollution ● Trade Measurement Act 1989 o Measurement instruments must be fair and accurate o Measurements are performed where customer can observe weighing or measuring process o Misleading customer about measurement given, or incorrectly calculating weight is offence o Giving less than the quantity specified in a sale offer is also an offence ● Food Act 1989 o Trade Measurement Act (1989). Ensures measuring instruments for production and sales are accurate, so that consumers are not mislead. o Details food hygiene regulations and food standards ● Adulteration occurs when: A reduction of nutritive value occurs through mixing or diluting food with other substances, Substance prohibited by food standards is added to a food, Inappropriate or excessive ingredients, A food is concealed of damage, Taboos are used in the food i.e. dog ● False description of food occurs if: A food sold as a certain type of food does not meet the standard for that food. E.g. 85% of peanuts in peanut butter, The food/part of the food has been removed from its package and replaced by another food, Incorrect/misleading label information ● Unlawful practices occurs when: content and packaging requirements of food standards not met, false advertising of food ● State food inspectors may: Collect records that relate to food production, manufacturing and sale, Open and examine food packages, Demand, select, obtain samples of and food intended for sale, Make enquires and investigations to determine if an offence has been committed, May take possession of any materials showing an offence has occurred (adulteration, false description, etc.) The inspector gives notice to a food store to clean it up and this must be carried out within 24 hours. ● Food Act (2003) [NSW]. Ensures that food is safe/suitable for consumption, prevents misleading sales, provides application in NSW for national Food Standards Code. Conducts inspections of food industry businesses to ensure they meet standards. ● Workplace Health and Safety Act (2011). Protects safety and welfare of employees, and requires employers to follow standards for PPE, equipment training, workplace conditions etc. ● Fair Trading Act (1987). Establishes honest sales practices protecting consumers and companies. Enforcing sanctions against instances where these are breached. ● Protection of the Environment Act (1997). Maintaining/enhancing NSW environment quality, reducing risks to human health and environment degradation by pollution/harmful wastes. Occupational health and safety act 2000 Local Government Legislations (council) ▪ Implements federal and state legislation and policies. ▪ Regulates food safety of local businesses and community organisations and events. ▪ The local government develops and implements codes in relation to: ▪ Appointment of Environmental Health Officers (EHOs) o Local council may appoint an environmental health officer to be a food surveillance officer for the Food Act within the local area ● Codes for inspections of food and food premises o Each council is responsible for establishing its own code for inspection which shops to exclude, and what foods and equipment to be inspected o No notice is needed to be given for an inspection to be performed. They take place at least once a year o Covers how often they should be done and exemptions from inspection e.g. some councils choose not to inspect fruit & veg shops as they are low risk ● Codes for construction and alteration of food premises o Designed to achieve satisfactory hygiene standards, and allow easy cleaning and maintenance o Codes in each council include: material use for building, cleaning facilities, garbage storage, storage temperatures, exterior shop colours o Covers building materials and installation guidelines for fixtures, equipment, toilets and window displays. Labelling Requirements ● Manufacturers have obligation under a number of legislative requirements ● Food Standards Code sets labelling standards to ensure consumers are provided with correct information and safe food through proper packaging. Other acts influencing food labelling requirements include:- State Trade Measurement Act enforces correct labelling of weight of food.- Trade Practices Act ensures that imported foods have the correct country of origin on the label + prohibits misleading and deceptive conduct in respect to labelling and packaging. Food Labelling Food labelling is controlled by Australian Food Standards. It focuses on three areas:- Statements or words that must appear on a label- Statements or words that must not appear on a label- Statements or words that may appear on a label under certain circumstances.