ated to ensure it is still effective. This review should include
a determination of whether there is a need to revalidate the
control measures. Online monitoring and observations may
also identify weaknesses in the food safety system that will
change the food safety control processes and trigger a revalidation study.
• Changes in the distribution system or customer handling practices
can cause the need for validation. For example, a chicken
pot pie recall identified the need to improve the cooking instructions on the pot pie packages. Of course, providing
proper cooking instructions does not necessarily mean that
the consumer will follow them. Over 30 years ago, several
outbreaks of botulism that were traced to pot pies almost
led to regulation of this product.
• New scientific or regulatory information. Food processors need
to be aware of changes in food safety knowledge. For example, three years ago, peanut butter was considered a low-hazard food. Recent outbreaks in the peanut industry have
caused many food manufacturers to rethink food safety
control measures for low-moisture foods. As an example,
many peanut processors felt that a 2–3 log reduction in
Salmonella was adequate. In light of the outbreak and what has
happened with the U.S. almond industry, the minimum log
reduction will undoubtedly increase.
Validation is a critical part of the food safety management
system. Proper validation studies not only ensure that the
process parameters or prerequisite programs properly control a
hazard, but they also provide confidence to the food processor’s customers that the food safety system has been designed
to ensure that foods are safe. ;
PROCESS CONTROL (continued from page 21)
John G. Surak, Ph.D., is the principal of Surak and Associates
and provides consulting on food safety and quality management
systems, auditing management systems, validating manufacturing
processes, designing and implementing process control systems
and implementing Six Sigma and business analytics. His Web site
is www.stratecon-intl.com/jsurak.html. He can be reached at
jgsurak@yahoo.com.
Richard F. Stier is a consulting food scientist with international
experience in HACCP, food plant sanitation, quality systems,
process optimization, GMP compliance and food microbiology.
Stier has worked in Asia, Africa, Australia, Central and South
America and Europe. He has done projects in over 30 countries.
References:
1. ISO, 2005. ISO 22000: Food safety management systems—
Requirements for any organization in the food industry. (
International Organization for Standardization, Geneva, Switzerland).
2. BSI, 2008. PAS 220:2008: Prerequisite programmes on food
safety for food manufacturing. (British Standards, London, UK).
3. www.almondboard.com/Programs/content.cfm?ItemNumber
=890&snItemNumber=450.
4. Codex, 2008. CAC/GL 69: Guideline for the Validation of Food
Safety Control. (Codex Alimentarius Commission, Rome, Italy).
Read more about HACCP, ISO 22000 and food safety
management systems in our Signature Series articles on our
Web site at www.foodsafetymagazine.com/signature.asp
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