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    IFS Foreign Body Management Guideline

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    10 views54 pages

    IFS Foreign Body Management Guideline

    Uploaded by

    Ana Cristina Ventura
    IFS Foreign Body Management Guideline

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 54
    slFS International Featured Standards IFS Foreign Body Management guideline Mee ne een management from the perspective of IFS ACKNOWLEDGEMENTS FS would the to thankallpatcpant nthe working group who assed ceting this quien {oc foreign body management FS would ao het thank the members of th Internationa Technical Comanitee who partipated Fa developing and improving ths document Ther contbutone and pinons were agrest help oS. Participants nthe IFS Foreign Body Management working group mens Anwander ‘Austian Chamber of Commerce Chasing Baggemann ators, Fyancarney METRO AG ‘Olver TOV rd cert Jurgen Behmann ulna arena Gmbh & C4 ‘rg Kinemann gust trek KS \Wotgong Leste DEXA Handesceselichaf Siwest mbH Anko Lorence ‘Austian Chamber of Commerce oi baden Zens Gb CONG Florin reut ‘Quart Qalttscherang Gmbh its Mle Ya 105 cFS Gna De Jorgen Sommer Freberger Leben GmbH &.Ca Anoaberth van der Steege METRO AG ‘Alezandia Weber tegut ‘anne Gone IFS Monagement mb Inmet Rather de Suster IFS Management be Im addition the IFS wants tothank the fllwing members ofthe IC for theirsupport odes Aton ‘CONAD, on beha of ANCD (Associo Nasonale Cooperative ta Detain aly Sébasien Bian Groupe Cas, France Finally IFS would aso like to thank the following people for their professional suppor Andes rie -MerneRTOLEDO Stéphanie erate Bureau eras Dirgen Hofmann Ingenieubie Hofmann ylene Russo Garefour ‘Gadine Tit Gorefour Mathew Fours Carefour Vincent Prodtonme Gnetour Romain Cuyrat Canfour Thomas Reinold Procema GmbH Michael Mayer AZO Soe Peter aggenrock Str nee CONTENTS + troduction 2 ISrequtement reacting Foreign Body Management 2. Risk analysis for Foreign Body Management ‘Question cateogue:Quertone that shold be akan every werkace and during every processten 4 Entry foreign bodies via awmaterials 5 Optons or detecting freon bodies 51, Visual consol by aff 52, Sevesand magnets 2 53, Met detecionsytems and Kay nspection systems 2 6 Handling foreign body contamination 26 7 Taining ca Appendix AY Special area: Glass pacaging “ 122 Vesifcaton and validation “6 |A3__Rskeminimising machine design and preventative maintenance [M__teSaquiements-hanling orsign body contamination and complaints so 1 Introduction Metal wires in Cookies ‘Consumer reports finger stall in sausage Is thetic material jin chocolate bars Dark chocolate shavings - foreign body in the product, bristles from a cleaning brush jign: Warning Product recal tin baby food of glass fragm Plastic parts in sausages Due to metal parts in food, recast manufacturer must {Seall its ready-made pr sold ata discount Supermarket, Introduction: Foreign Body Management Foreign bos in ood always lead to negative publity and healnes. They cause nt only tnvousness end outrage but may also be spotentl kt the consumer and lsd tof ampli he Incesaing perception of foregn Boees being fund in food not ust & Curent fad o¢ 9 short ved complain wed that wl lssn in mpertance in the ear ture IFanything tian neressingly important aspect for consumers and the medi Consurars parceve anything that det not belong tothe product as orig boy. Experts ftingueh between mo dant ype of foreign bodes endogencus foreign bodies that ould orgist om he produc (2g coresorbones or exogenous foreign bates tha donot belong to the product eg. plate part) The dference i ot revant forthe consume 3 they la nat sczept form bodies even they donot pose a det iskto heat such 35 sal ‘eras cf paper nthe product. The consumer expects t fecal the produc sit as buen tdesenbed anda t's dated ~no more and roles. “These suis shoul act ta bss forthe interested user in tems of how to handle ts ‘anstivetopi thin food incu The ebjecve so produce food 3 fey spose tnd o not desppoint consumers Ths guidlinecontalns leas regarding foreign body management are ako provides potential solitons, Isobjectve isnot to set mandatory standard techricalequlpmentor detectors Detectors focforelgn boss maybe ofinterest to companies andactasa valuable suppor. homevethe tdecsonregnding tet wse mustbe madelndvdaliyonthebasi#ofshazardand kaso mont. This gudline intended to hep plement an effective and stable foreign body ‘management forthe cernpany. The IFS viewpoint ociseson the prevention f foreign oss {nd tant orale avarenestof the possblesouces of eontaminato. neon ke shoud leaatosenstized employes who ate encourage to report ay contamination istsataneaty ‘age ssedon the nlmationrordeby this qucetne, companies shouldbe bleto beter ‘decide how somthing canbe safely used ad what mantring neces, ‘The guldlne does no: cm tobe Fly comprehensive, buts base on yeas of eperience from tore involved inet cartiication bodies and inst. P | IFS Food requirements regarding Foreign Body Management 2. IFS food requirements regarding Foreign Body Management hen It comes o food - row mot tan ever belore— lists reales and corsues trot the highest posible eats of fey and qual, For this purpors, i neceuay to Profersonally montarand conta he whole supply han incang delivery an production Drow meters and packaning services manufctrng processes, storage and varsprt). Far the food manufacture tis means tht inplemenation ofthe IS requirements fr forelgn booy managenent should not just focus on the requeents epected of the production process, Eut als tke requiements from other chapters into consideration, (Seedagrny ps7) Senior Management Fesponsibilty Corporate poly an re aes ak | smugness fn eee am) ahs ae Lean ie eae I ete machine seting fren monte? "Mat ong dettason Is the collection vessel fequemty empie? | ‘packaging from rior preduction fully removed? + Ssttenon pid to product remants/ulkups and ae they uly removed? | Maintenance/Repairlnstallation l + Mom isi ensuted thal os and atv aback nthe poster sion of saenteral sve provides fer wos complete? «re parts ising or are too many avalble? + Temporary reps roduc fey considered an shot I Ce 5a. Visual inspections by staff Where are visual inspections cara out? “Theisalnspecion or visual checks an optical test ofa product for defects. These can ether bein regards tothe produce. ncoming goods reduction a nainspecton or regards ‘What diferent Hinds of sua inspections exist? In gener vsualinspetons canbe eistingushed between: + itc vivalpecton without id fbserving the tt ares withthe ke ye) Dect sal spection with sop aie such t magni, mete + Indvect visual nspaction with eamra systems 08 bot Inspection Which influences must he taken nt acount? This chat foeies ony on veal checks aan act cared out by people Due to the fluctuations mayarse depending on the complet ofthe product and working conditions However, inspections only conducted via machines may ct aways be pore Fagerding checks cared ou: by people tsimportanto ensuetha seul and Fequert waning isgven fan that a sutabie work envionment provided The company shoul aways wy te esr hat the Work conden fora vil nspeton ae 35 good 35 posite inorder ta reduce the numberof undacovered defects, Anite test cn be crests to monitor the eicincy of detection and fo estabihing the {ptimum belt pied ot regular intervals In this cae, cfd and relevant frign bodies ‘optimum setting: 5.2.1, Sieves When ate sieverused? Within the context of pedut safety contr! sting ud be usd to ensure that foreign bodies do net et into the product. In ation, coare sifting may protect subsequent machinery and equipment fom being damaged due to large pieces Inter of process engineering sleving ls seen asa separation process that involves the mechanical breaidown of product Thi i frtner divided into casitation end sorting, Which product properties must be taken into account? In essence the flowing properties of Haus and dry product inlunce the sieving behav and thus the steering ate Viscosity, prtce size ctrbuton, cohesion forces Ginterpart ‘ular adbesivefoces) pate shape and electostatcchage 8 wo asthe meshes ofthe seve. The screening proces for ‘Stanulted Buk Froducts canbe estimated Amajorceteron for —[ | {hi the ati particle sze Oto rash opening (W inthe steve for. The open sving ars 40 sve fabri canbe etblihed in ine with 50478 Buk product with gain sz x < 100 jn eather uncutable for sieving due to aesve forces between partes (Van der Wess ora) The smal parties bond teach other and form sggomsater clamps) which maybock the mesh The clectetaticbeaviour fhe blk product has majorinfvene onthe emering a Product moisture aot the sreening at gresty inthe case of ul the voy ithe dace factor regula grin forms canal influence sieving bebavout Long particles prim clinical treed frn aad to sieve and on dependlng on the orentation, passthrough the Sieve even though the poricle lengths somewhat longer than the gaps in themes Spheticl partes and regu, compact farms are ease to ov. What influences the flow rate? ‘Ahesive forces between the tices nd azolatedchmping can have a tong eet on ine passage through re seve, For this reason tessto determine th respective screening rat tre recommended The quantity of matron the seve surfaces the determining fact for on optimum screening ate The gebte the quanty of materl onthe seve netting or seve Suvfce thelongerthesovng process Moreover therein ko breakage isthe mesh size appropriate forthe product? Depending on the aplication, mesh ss of 0.09 mm to 20 mm have proven effective fegerding protective nd canal iting of bulk product Mesh sizes up to 4 mm re used forpoteetieandcortol iting Wider math openings are wed for corse siting of larger foreign bosies Such conse ives shouldbe red rng the product n-eed of a mate Tals in ord to lowe the isk ofthe seve breaking de to foreign bodes in subsequent Siving macnines SU 4703 contains gudenes for seecing the combina mes ‘opening size and wie diameter, What rates te ued forthe saves? Depending on the aplication, valour mater can be used fr te slve neting Typical sieves vein indtlseing technology ae made ron, carbo, ane tails see and fre sed a8 fable or perforate plates. During the sk assessment process the usabty of Inca ives wth th wie should be evaluated and partiubfocu laced er How thn broken wre pce canbe detected What must be taken into account when monitoring the sleves? Sieve should bechockd Frequent or defectivemeshesandforegn body residues Fesuent sual checks shouldbe caredout aossthe enti seve nating andbe documented acon Ingy nding the mesh gps covering the ene see neting ate are checked for detect Gieve breakage) and unacceptable expansions, Defective seves must be replaced ted stely~furtheruseisnotpermted Upon replacement, the produc that wae being tested prior {othe replace ofthe sieve shouldbe checked agan here ae foreign bodies on he sieve nting they shoul be removed inmedlataly, Sve beshage can cca do material fague ofthe sive netting, sharedged or henvy objects orsign bose), but ao du to ‘ovetading the seving machine with bage quant of need mati The folowing types of damage may occur tosleve nating «Sieve breakage due to tearng ag holes appearing asa est of meth ening none or more places) + Espanson of mesh e.g. impemisibie expansion of indus mesh gaps) Expansion Geese se) seve account when ung sleves wth weaden frames. What must be taken inte account during deaning and maintenance? In order to cleanseving machines, the sieve materi generally removed without at) when the machine Isnetin operation, Seving machines ae dry oF wet cleaned depend Ingon hysiene requirements Foreign bodiesmoy be reested during the cleaning process hen removing the seve Fortis eason, cleaning work should ony be performed by {tained and supervised stl. Every cleaning procedure shouldbe documented. Brshes ‘with natural or pastcbristies and clearing wipes made ofnatural and synthetic ives are ‘recommended for dy cesning onthe outide nen using bruses for the inside parts there es that individual bristles may become detached and ssbsequemty enter the process 25 foreign bodies. Depending on the 5.22. degrees of contaminstion, leaning agents canbe usd that are pected by the manu factuer ofthe equipment The ive neting should be uly monitored for damage after ‘leaning and only berenstalled when ts re of defect. Necessary maintenance work svogested by the equlpment manufacturer should be followed accordingly. ‘Magnets When ae magnets used? Magnetic separators hve watious applications and ses: They an separate Impurities in 3 [anger spectrum of shoes nd sins than mata detector andray devices They a terefore especialy in combination nth other metal detection devices highly een for detecting {ong thin shop andmagnbsabl foreign bodes (29. wire pices). Whereare they used? Magnet re nthe production proce often located before metal detectors his potion ‘makes the most eerie an finan sense Adtonall, magnets can be used to monitor Incoming goods (e9. ous aan o sugar sack or big bag). Here, the detectors ar used to imonitor potently centaminated goods and to prevent lage magoaticforegn bodes such {5 ides rom entering the production rocess, where they may be shred fries and ‘Subsequent nay no bnge be detectable under certain conetion could end o damage own then, ow are the metal pats found inthe product? Magnet sepratorsytes attract metalic foregn objects when te mantored goodshave no Imopnet ably end theefore arena attracted tothe meget themselves Magnet separator Spates ere therefore not suitable for repaating nortenous metas steels and organic materi Staines ste! poricls which ate generat by fcton sheer ec have 2 modified mio Seucture defo the hysa ses (lphomartenst Thus they have developed magnetic properties which paitseparton lethe strength of the magnet appropriate forthe product? ogneve systems mua aapredo he product quant, aw wei especie process tepleators Ingenent the smal the suspected contaminants the higher the fx ens. ‘The same applies o hgh speedo al and lange product flows. Therefore whe using m3 hesIn the productonrocees the focus shoul be on high a densty and durbiity other tse the mage wl be the effecvenest ina shor ero tne, Monitoring the magnet ‘ome regula ase wt regard tos perfomance a equred mantenance mesure, 281 ‘ne sgnicant option of vetfying and checking magnet performance Ie uking magnet meter to messire the fx densty at regular oth intervals The cunt fu ders measured onthe magnet’ roduc facing surface using Hal probe. The magnet ea heck for defematon and suo damage, When product temperatures ae constant a ‘or above 40% a shorter interval between inspections Is ecommendd. The manufac ‘pecieatioe ae ecommendatonssheulbe ken io acount the strength of he magnet stil present and suitable? Revalidation tesng has tote place atleast onan anna bass wth 2 eile mesuring ‘device rom thenational menting authori) and tested reference magnet. nth cse, the magnetomear is compared onsite with the telerence magnet then the magnets are tested by messing the surface fox density. Ths method I lable a i fly tacesle “Tesing methods by ataching and removing metalic txt places are physics wrong and witout reference tothe intended purpose ~ namely to separate smal impure, Shortt ‘montoring interes should be chosen a higher produc nd deaning temperature 2g. (CP cleaning or szombse sera. 5.3.1 Metal detection systems What do find whenusing ameta detector? In prince, metal detectors detec al types of metals, However, magnetic metas fa. ron) tre mow really ecegnlsed compared to nommaghetc metals (ronderous metals and non-magnetic tales sel). How are the metal ys found nthe product? ith metal detector the product moves trough anelecromapne il Metal pats can be detected also within» product they cause changes to the eecomagneti fel The Cente ofthe deve’ opering ithe pont where the electromagnet ld a ts weakest Snel therefore wher the detection capably alo atts est Te coret ratio of product ‘imensons ta the tunel mension important and a tunnel thats oo large should be =| (im What effects do the shape, postion and type of metal have on the detection? ‘Thagetctabty ofmtal objects dependsonthelocation athe posionin which the et! parts ess through the the metal detector, Anon-sphreal metal part (2g 2 ple of wire Tigges smaler or lager sigals depencing onthe eitecton in which It passes through the detector, Detection becomes even mote effcult with meta shavings 8s the shavings Structures porus inhomogeneous and generates an even weaker inal than awe 201 In aon the oetectionacuacy varies depending onthe typeof metal and he locaton in ict posses though the mata detector (28g) Fes Non-maget on oneragnte ediontiermepat ano eefeout mid nonmgne Seiad snnea Tenataaye pond ‘Boer writen ‘poor Has the positionof the test ample been correctly chosen? Since detection sens atts oust inthe center ofthe cpening the test sample together wth the product shuld pass tough the metal detector in thi locaton, The felwing agra show a tent test procedure rows Metaldetcor Eq pode pcg In general est saps should be a smal as posible in onder to detec the widest posible spectrum of mete foreign bodes Furthermore, customer speciation have to be taken Into account shuld be ensued that the ts soipes re tact and donot pose ay ype “contamination ri therselvs there re doubts about the integrty ofthe tet specimen, Should be replaced te the sting of the mata! detector appropiate forthe product? there isa prodict change, the progam modified accordingly? “The conductivity of product = product fect depends on vaious factors sch a5 + Moisture and sain (sat content texture, nd composition = Temperature * Preduct quantity ae dimensions » Packaging materials etal detecing dvcescan minimise prod fe through ged ajstment fa prod te change scarred ot hen acoreqponding programme change shoul aloe pa atten ls the belt peed adaoted to the detection and rejection process? 1 vansgontion speets ae exceeded or oe too slow, then detection accuracy cannot be ‘uarnted plese obzerve monuactutrsspctatons) With flauatng transport speeds {ea star stop operations), there a isk fal under the real wanspertation seed which ould yest the lof detecon accuracy. oducts that ate within the detector une ‘his point in time shoud be inspected once again. is nacessary ens that the ection procter mantored song wth he selected belt speed gues {sthere reporting systom/alarm system ifthe rejection device fais andifthe ‘ejection bin al? ftherejction bull othe election device fle ti pore that contamina product snot propery rected wilcontinuein the process Therefore the entersecton process, Including the ection bin and the contra sncors shouldbe checked Fequenth ‘Are environmental actors taken into consideration? Environmental fictorcan havea negative ffecton metal detection. Theo Include vibra to, ar hums er ra, insulation, elcrc supa and interference fequencies A see seen ~~ ( &>~ Vw ave the manufbctrer’ specifications and instrctions been taken into account? ‘The manufacturers operating instructions and guidelines may conan addtional or other requirements are should be folowed accurately, Is there suitabledocumentation? Appropriate acuacy fo the detector shouldbe etblihed and monitored depending onthe roduc, Frequent montring must be documented and comectiveacone must be estab lished inthe event of malfunctioning. the fllowing points shouldbe logged nthe doc Product nd ne + spect * ate and ine, necessny) = Tesssample Measures in cae of crepancies «+ Signatar or dt cllection system 5.3.2. X-ray inspection systems What an find usingan Xray inspection sytem? Ferrous and non erus metas 35 welas tines steel can be eal ecogised th Xay inspection syst Te technology ia stable for recognising other foreign bodes such ‘aes stone ceramics, bones, dense plastics, or rubber compounds What additonal advantages does an Xray inspection system provide? Kay inspection sts can cy outa sees af adonal quality assurance tests on the producton line, hes incide counting components, recognition of missing or damaged products monitoring oduct forms or fil lve checking eas to ensure they are nac. ane the cognition of aged packaging How ae the foreign bodies found inthe product? “rayinsoectons re wie scan for foregn bodes that absorba geste quant ofrdtion omar to the redit within which they af ou. The quantity ofthe absorbed 3) fadation depends on product hicknes and dent Imputtes uchasqlssormetal become Ville during an Xryinspection due to the dering desis. Anas of the ay image ‘ried cut set on an vation ofthe shades faethe more homogeneous the product Is the Bette the detection sens. owns 2 Wat effects de the shape, postion and type of material have on detection? In general detecson of foreign boos sony posible if thy are denser than the product wth Inch they aelcate The folowing etealimis apply to most ods containing water Density inkgint epedrgen rit Donen hes ey ee ) Isthe elt speed coordinated with the detection and rejection process? “An uneven or inegular tans rom and othe transport conveyer af the Xray device can lead to product backups and problems with the X-ay mage preesing. Nevethles the ‘necessary minimum dlstance between individ! products s general determined by the ‘requirements for oflectve rejection aed nt those orceting images The correct functioning ofthe eecson process shouldbe established in conjunction withthe slated bet speed, 'sthere a reportng system/alarm system ifthe rejection device falls and ithe ‘ejection bin ial? Fhe eeton bins fl othe jection device or proces fl spose that a contai- rated product ot propel ejected an wl continue inthe process Therefore the ene rejection process including the rejection bin and the contol sensors should be checked regent \sthe sie and the materi ofthe test amples appropriate forthe product? General cet tales steel an ls pers are sed forthe ection tests thelr ‘erty canbe relsbly quntfed Problems moy ase Ia gas test pacman has 3 higher ‘deri than the loss mater that are used onthe production le. In sucha case, the cass tert pecan wil be recognised but nt the gas part ofthe vessel. With a glassin-lass polation fl recormended thatthe glass nprodcton used fr vtificaten purposes. ‘The ptmal verison method shouldbe established for every applation an est samples ‘ould be selected in acordance wth the product and the requlrements ofthe customer ‘peciestion If there ne doubts abou the Integy ofthe fest samp, hen should be replica lethe potion ofthetert specimen comect? ely thee should be cecrely attached to the bat ofthe pachaged product should be sare under ay cieumstanc, thatthe est spl an be found at ever location within the pactaging To dom the equpment should have stable settings and the eats sample sae ertslished sing test sees. Wa products changed. isthe program modified accordingly? with» product change, the maid varies of the pruct and packaging must be taken into accoun. the prod compost eg. homogeneity), product dens and thickness and the packaging mater as they can infuence absorption Behaviou With anew reduce forelgn bose: can emg tat que a medication fo the setings or the fage ans. For ths eason, inthe cae of product change - Ifthe properties vay spac atenton shouldbe pact the program change Have the manufactur speciiations an instructions been taken into account? “The operating instucons and guldelnes from the manufacturer may contain aditonl or ther equremants and ehoud be flowed eeu. Ie suitable documentation avalable? Aesroptemesierant accra forthe inspection stem should be established and Imontored fr the a Inpacon sytem depending on the prec. A requlrcheck must be documented Conctv actions mutbe established for cstrbances The following pont should belogged nine dacumenston 39, » Product nd ine » rspector * Date and tine. + Testsarple Teresa * petonmeasures incase of discrepancies * Signaturear dectroe data recoding 6 | Handling foreign body incidents and complaints \ 6. Handling foreign body incidents and complaints Ie. despte all preventive sctionsan interna contos, foreign bodies ar found in prod {cts by staf, eonsumes or authors, then isimportant that a comprehensive analysis is eared out In ti cate, the folowing poets should certainly be considered (see ‘Appendix At detledrequitements of the, 26,50): Management of complaints rom autos and customers Management of no-conformttes and nor

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