I want to be a good graduate Good

I want to be a good graduate Good is just a characteristic…like crunchy peanuts

Food technology program learning outcomes (PLO; the quality characteristics); what we think industry/nation want PLO 1 : Demonstrate adequate knowledge and understanding of different principles of food science and technology PLO 2 : Exhibit communication skills and leadership qualities PLO 3: Capable to perform as an entry level food technologist and be able to engage with multidisciplinary teams in all the Areas of food processing industry PLO 4: Establish high level of competency with higher order thinking skills in various disciplines of food science and technology PLO 5: Exhibit ethical values, social skills and responsible attitudes towards the society 2

Graduation requirements (the finished product specifications) Minimum residential of 8 semester, maximum residential Of 14 semesters Fulfill credit requirements for core, electives/minor, University/ Options (for food tech; ……? ) Obtained CGPA of 2. 00 or above for core components. Obtained CGPA of 2. 00 or above for the program. Achieve a minimum C grade or a grade point of 2. 00 for BM, English, TITAS, Ethnic relation and entrepreneurship 3

The business process Sem I and II Admission requirement In process NO Program review For improvement Exit meeting/ Mock interview/ Industry feedback Quality Characteristics Achieved? All Specifications Fulfilled? YES 4

Quality is like time… Quality is like electricity… You can’t “see” quality, but you can “measure” it. If you can measure then, you can manage it. 5

The quality objective shall be achieved by an integrated system including (i) Quality Assurance, (ii) Quality Control and (iii) Good Practice (basics). (i) Good practice for production; Basics. The basic requirements of Good Practice are that: a) all manufacturing processes should be clearly defined, and known to be capable of achieving the desired ends; b) all necessary resources and facilities are provided, including e. g. : - appropriately trained personnel; - adequate premises and space; - suitable equipment and services; - correct materials, containers and labels; - approved procedures (including cleaning procedures); - suitable storage and transport; c) operators are trained to carry out the procedures correctly 6

(ii) QC. To achieve effective control of quality (i. e. maintaining a good system) • Authority and responsibility should be clearly defined to avoid misunderstanding. Where possible QC management should be on a separate reporting structure from production, and be empowered to make independent decisions on quality. • Adequate facilities and staff, for sampling, inspecting and testing starting materials, packaging materials, intermediate /in-process products, bulk and finished products, and when appropriate determine environmental quality • samples should be taken by personnel and using methods approved by the person responsible for QC 7

• results of inspection and testing should be formally assessed against specification by the person responsible for QC before products are released for sale or supply • product assessment should include a review and evaluation of relevant manufacturing documentation • sufficient reference samples of starting materials and finished products should be retained to permit future examination if necessary 8

The basic tools of quality control could be: Ingredient Specifications √ Approved Supplier List √ Product Formulas √ Product Standards (Specifications) √ Manufacturing Procedures √ Critical Control Point Identification/Sampling Program In-Process Analysis, Records and Reporting Packaging Specifications Label Specifications Cleaning and Sanitizing Program Good Manufacturing Practices (GMP) Requirements Recall Program Warehousing, Shipping and Receiving Program Laboratory Analysis (too many to cover in this course!) 9

Ingredient Specifications a) The quality of the finished food product after manufacture depends on the quality of the raw materials and ingredients. The best starting point for developing ingredient specifications is the supplier (for students? Your STPM/Matric CGPA etc) b) Ask for a copy of the supplier's ingredient specifications. Review the information and modify the specifications to your needs. c) Discuss and settle specifications with the supplier. At times, specifications need to be negotiated with suppliers. d) Custom specifications from suppliers are possible. The ingredient specifications should be documented in a form consistent with the processor's needs. The prepared ingredient specifications become a tool for control. The information under each heading should be simple but informative. Read More on page 131 the QA book. 10

GROUND BLACK PEPPER CODE NUMBER: A-001 PRODUCT DESCRIPTION: Ground black pepper shall be prepared from the dried, immature berries of Piper nigrum. The color can vary from light-gray to a speckled blackgray. EFFECTIVE DATE: Today's date CRITICAL SPECIFICATIONS: Salmonella E. Coli MAJOR SPECIFICATIONS: Action Level none Action Level Reject Level Positive in 100 Positive Reject Level Granulation 4. 5% (retained on a U. S. #35 sieve) > 5% Volatile Oil 2. 5% <2% 11. 5% >12% Moisture Color light-gray to black-gray off-white to light gray Yeast/Mold <100 per gram >100 per gram MINOR SPECIFICATIONS: None INGREDIENT STATEMENT: Ground Black Pepper Typical Ingredient specification document (example) 11

Critical specifications • include two items associated with public safety. • also include factors influencing wholesomeness or legality. Action levels • as a reference point to identify a potential problem. If the ingredient consistently reaches action levels, notify your supplier. Reject level • the point of refusing delivery of the ingredient. The ingredient statement • a reference point to assure that the supplier has not changed the material. *The final key point for ingredient specifications is for the supplier to know and agree to the content of the document. It’s a contract. 12

G Un ra iv du e at rsit es y: In Product Standards • A key tool to assure quality in a finished processed food. • Recall: Define the food by physical, chemical and microbiological characteristics. (Appearance, aroma, flavor and texture can and should also be considered for product standard). Establish a reject level for each product standard along with acceptable methodology. Base minimum reject levels upon regulatory requirements and practical production experience (refer food acts, then try out the Production at least 2 weeks). 13

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15 ex ood Pr am st od pl an uc e da t rd G

ex ood Pr am st od pl an uc e da t rd G Question: How to control in order to meet the finished Product’s specification? 16

Approved Supplier List For each ingredient, an approved supplier list should exist and be available to individuals responsible for purchasing and quality control (Keep it confidential though!). In theory, more than one supplier per ingredient is desirable. A good target is three suppliers per ingredient. A supplier is an ingredient manufacturer, a broker or a distributor. When necessary, identify both the manufacturer and distributor on the approved supplier list. In Ac Un ad ive em rs ic ity: s ta ffs ? Approve all sources of supply only after careful evaluation and review of their performance in the product 17

Proprietary formulas/recipe For each food product, written documentation of the formula or recipe should exist and be available for use by selected individuals. The formulas should be used daily as a means to assure consistency between batches, lots and even days of production. Manufacturing personnel need to know the recipe to assure that the product is formulated correctly. In C Un ur iv ric e ul rsi um ty s? : For highly confidential formulas, the production worker does not need all the details. A simplified recipe can be provided to assure that the secret stays a secret. 18

Manufacturing Procedures For each product, document the method of processing procedures to ease duplication from lot to lot, shift to shift and day to day (SOP, WI). The rest? DIY… ng rn i In Te Un ac ive hi rs ng it & y: L ea Key steps in the process which can impact upon yield, quality or production efficiency should be highlighted. s? A simpleway to approach this is a clear and concise "cookbook“ approach. 19

(iii) Quality Assurance (i. e. improving the system, gives confidence). The objectives of QA are achieved when; • Processes have been defined, when followed; Will yield a product that complies with its specification and the quality expected, + when the finished product; (a) Contains correct ingredients in correct proportions (b) Correctly processed, according to defined procedures (c) of purity/strength/grade required (d) Enclosed in proper container, which (e) Bears correct label (or suitably marked or identified) (f) Is stored, distributed and recommendations given for Its subsequent handling in accordance with the recommended Storage conditions, so that its quality is maintained Throughout its designated or expected life Read page 82 and 85 -87 for details of QA function (QA book) 20

Quality • Part of quality management focused on fulfilling quality control (QC) requirements. • The operational techniques and activities that sustain a quality of product or service that will satisfy given needs; also the use of such techniques and activities. • The operational techniques and activities used to fulfill requirements for quality Quality assurance (QA) • Part of quality management focused on providing confidence that quality requirements will be fulfilled. • All those planned or systematic actions necessary to provide adequate confidence that a product or service will satisfy given needs. • All the planned and systematic activities implemented within a quality system that can be demonstrated to provide confidence a product or service will fulfill requirements for quality 21

QC QA QM? They are both part Of QM 22

In essence… QA : preventing and detecting quality problems QC : detecting errors in the product. Quality management activities? are those that ensure that a company’s products are exactly what they are supposed to be, that is, they meet all their specifications 23

We cannot obtain quality through leadership alone. There must be a system that everybody can refer to. A capable QA system is to maintain a daily quality improvement Basic QA; • Well designed and documented procedures for products and process control, inspection and testing, control of measuring and test equipment, corrective and preventive action, and statistical techniques. • ISO 9000 provides a basic framework (see ISO 9001: 2008 standard given but there is the latest one!). 24

Designing QAS Management responsibility for • defining, documenting, and supporting quality policy (that identifies key objectives) • identifying and providing resources (people, equipment, technology, software etc. ) • providing audit programs to determine compliance QAS involves all phases of a product’s life cycle (including specification and design control, process control, inspection, testing, controlling of nonconforming products, corrective actions, controlling inspection, measuring and test equipment, control of essential records and documentation) 25

QA covers (normally) • procedures are written in instructional form, in clear and unambiguous language, and are specifically applicable to the facilities provided • records are made during manufacture (including packaging), which demonstrate that all the steps required by the defined procedures were in fact taken, and that the quantity and quality produced were those expected • records of manufacture and distribution, which enable the complete history of a lot to be traced, are retained in a legible and accessible form • a system is available to withdraw or recall from sale or supply any lot or product, should that become necessary 26

• The QA procedures of suppliers of raw and packaging materials should be monitored, preferably with regular audits. • A supplier QA procedure should be developed to define the criteria for selection, approval, review, and ongoing approval to ensure that purchased products and services meet the organization’s requirements; 27

• there need to be rapid feedback of information in the form of summaries of quality performance data (accompanied where appropriate by advice) to manufacturing personnel, enabling prompt adjustment or corrective action to be taken when necessary; and to the purchasing function in respect of raw material lots; • customer complaint samples should be examined, the causes of defects investigated where possible, and appropriate measures advised for corrective action to prevent recurrence A continual review of QA system should be undertaken to ensure that they remain effective. 28

General principle of Quality management – Co-ordinated activities to direct and control an organisation with regard to quality, according to e. g ISO standards (or any other standards). There should be a comprehensive system so (a) designed, (b) documented, (c) implemented and (d) controlled, and (e) furnished with personnel, equipment and other resources as to provide assurance that products will be consistently fit for their intended use. 29

The attainment of this quality objective requires the involvement and commitment of all concerned, at all stages of manufacture, storage and distribution. This is the concept of ‘quality by design’ – i. e. the product should be designed and developed in a way that takes into account all the essential quality requirements. 30