Foreign Material

Prevention &
Control
Eng. Eman Bukhari
FS/Q Consultant
 Goal

• To use all information needed to establish a risk-based

approach to foreign material elimination
• To detect and remove suspect foreign material risks.
 Session Start End

First Session

Break

Second Session
 Course Evaluation Criteria

Pass the assessment by 50 %:

1. Attendance 5 marks
2. Individual assessment including participation and presentations 5
marks
3. Group work during the class 10 marks
4. Submitting of a complete case study hand book 50 marks
5. Written exam 30 marks
 Identify Hazard

• A biological, chemical or physical agent in, or condition of,

food with the potential to cause an adverse health effect.
 Foreign Material

• Foreign material is defined as foreign bodies that may

cause illness or injury to the consumer, or are perceived by
the consumer to be alien to the food.
• While not all foreign material is harmful, it is a physical
hazard and its potential to cause injury or illness must be
considered
 Source Of The Foreign
Material
INTRINSIC EXTRINSIC

• materials not normally

• a component of the food found in food, such as
such as bones. stones, insects, plastic,
glass, or metal
 Why foreign material
prevention program
• Is the major single cause of customer complaints received by
many food manufacturers, retailers, and enforcement
authorities
• That because Physical hazards are easily identified by the
consumer. Physical hazards can often be seen in the food item
before consumption whereas biological and chemical hazards
are rarely identified by sight.
Foreign material program
(System)

• A foreign material program is a validation of each foreign

material control point for all process steps, areas and plants by
using risk based approach.
 Foreign material risk
management program
• Depend on:
• Prevention: its objective is to prevent foreign object
contaminations.

• Detection: its objective is to detect any foreign object

contamination occurring in the processing plant, before the
finished product is distributed.

• Investigation: once a foreign object contamination does

happen, the purpose of investigation is to find out exactly what
caused it and how it happened.
 Prevention risk
assessment
• what foreign objects are more likely to contaminate food,
and where are they likely to come from?
1. Suppliers
2. Transportation of Raw material
3. Storage and internal movements of goods
4. Processing and packaging
5. Processing environment and equipment
6. People
Prevention and detection
methods
• Sieving / Screens
• Magnets
• Washing and cleaning
• Optical sorting
• Metal detector
• X-ray detection
• Glass policy
• Etc.
 FMPP is established for:
• line pre-start-up,
• change-over,
• post-maintenance and
• shutdown checks

to ensure foreign object risk are mitigated.

How to develop FM
prevention plan?
12 steps
 The Twelve Steps
Step One: Assemble The HACCP Team
Step Two: Describe Product
Step Three: Identify Intended Use
Step Four: Construct A Flow Diagram
Step Five: On-site Confirmation Of Flow Diagram
Step Six: (Principle 1) Conduct A Hazard Analysis (F M )
Step Seven: (Principle 2) Determine Critical Control Points (F M )
Step Eight: (Principle 3) Establish Critical Limits
Step Nine: (Principle 4) Establish Monitoring Systems (F M )
Step Ten: (Principle 5) Establish Corrective Actions (FM)
Step Eleven: (Principle 6) Establish Verification ( F M )
Step Twelve: (Principle 7). Establish Documentation and Record
Keeping
 FMPP Team
• multi-disciplinary team is established to define and review the
foreign material plan. Team is represented by all key
functions, (i.e. operations, sanitation, engineering, quality
assurance, product development, maintenance, and
finance/purchasing, etc.)
 FM Analysis
• Raw Materials
• Raw material transportation
• RM storage
• Process Steps and packing
• FP storage and transportation
• Equipment
• Process environments
 Identify control points
and Monitoring System
 Prevention / detection
measures examples
• Assurance of zero wooden pallets in processing areas
• Wood pallets used in other areas shall be of good quality and
inspected.
• Pens in use can be detected by the foreign material control device
in use.
• Pens and thermometers shall not have removable clips
• mitigate risk of sharps (e.g. knifes, blades, needles) and other
materials/ equipment such as thermometers, pallets, gloves,
ingredient packaging
• Glass policy
• Foreign material detection device such metal detector X-ray
device ..etc.
 Corrective action /
Incident report
• The size and type of material found
• The quantity of product affected
• False rejections are tracked if we use rejection device
• Corrective action including preventative measures to avoid a
reoccurrence
• Final disposition of the product
 Verification and Review
• review of the system plan and its records;
• review of deviations and product dispositions;
• Review customer complaints
• confirmation that CPs are kept under control.

Where possible, validation activities should include actions to confirm the

efficacy of all elements of the system.
 Verification
of a system

Is the system being complied with in

practice?

How do I find out

what is happening
in practice?
Conduct an audit.
How often?
• Changes
• Incident
• Customer complaints
• Others …..

When is verification
necessary?
Last step and first step is
documentation
Questions and Feedback

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