The Quality Assurance Department plays a crucial role in ensuring the safe production and handling of prepared items within the facility. With this responsibility comes very specific guidelines that are enforced by the USDA that must be followed as well as internal measures taken above and beyond to guarantee that our products are not only safe for consumption but are of the best quality possible.
There is an extensive list of procedures performed daily by the QA department that are set in place by the USDA and our own facility that maintain food safety and quality. These procedures are part of the HACCP (Hazard Analysis Critical Control Point) plan devised for this facility.
This HACCP plan is put in place to ensure that all known potential biological, chemical, and environmental hazards are recognized so that they can be prevented, eliminated, or reduced to a safe level. The following items are taken into consideration within the HACCP plan.
Before the beginning of production each day, a pre-operative inspection is performed by QA of all departments. This includes, but is not limited to:
- A visual inspection of all equipment and food contact surfaces (any area food may actually come in contact with) and the cleanliness of the department as a whole.
- Although not required by the USDA, QA does environmental swabbing of all USDA regulated departments. The swabs detect any food debris or bacterial growth that is not detected in the visual inspection that can be sources of contamination of the product, and therefore, leading to possible food-borne illness or questionable quality. This is also a way to determine the effectiveness of our sanitation procedures performed by employees.
- Every finding that does not comply with either USDA regulations or QA and facility standards is documented and the appropriate person is notified of the issue.
- From this point, each issue is addressed before production may continue, and QA must approve all measures taken. If QA does not approve, the area or equipment may be “tagged”. If this occurs, no one is allowed to produce in that area with that equipment until QA removes the tag when standards are satisfied.
- If a USDA inspector is present, they must be escorted around the facility before production proceeds. From that point, any issues they may have are taken care of immediately.
Although not directly related to the pre-operative inspection, sanitized mats are placed at every entrance to the production floor for employees to step through. Sanitizer is also provided for their hands, and they are dressed in company provided attire. All of these measures are taken in attempts to eliminate any possible outside contamination as employees enter the facility at the beginning of the work day.
QA also monitors freezer and refrigerators on a daily basis by verifying that all temperatures are maintained within an acceptable range. These verifications are noted, and any deficiencies are addressed and corrected in a timely manner to ensure product integrity.
Proper labeling is also a critical concern of the QA department. There are specific USDA guidelines that must be followed concerning correct label information. All labels must provide any ingredient present, and ingredients of that ingredient, within the product and must be listed in proper descending order. For example, if an item contains cheese, you must state cheese as not only an ingredient of that product, but you must list all ingredients included in the cheese itself. Also any known allergens should be provided in the ingredient legend. All of this information must be verified and documented by the QA department before any label is to be attached to any product.
Allergens are a major production concern. All products produced must be done so that no other product is exposed or comes in contact with any residual allergens from previously produced product. The order of production follows a QA developed allergen matrix. This ensures the safety of the items produced. If the matrix cannot be followed in a manner that ensures no allergen cross-contamination, a complete, chemical wash down and sterilization must be performed and witnessed by a QA member.
Throughout production, QA monitors the quality and ensures the safety of the products. As products are produced, their pH, temperature, texture, aroma, and taste are noted. Any variances observed are investigated to find the deficiency. Any adulterated product is discarded or placed on QA hold pending further findings. Consistency of product is a top priority within the department. Products produced are also tested for microbial contamination. Such tests include yeast and mold, e. coli, and standard plate count. This information is an additional tool QA uses to ensure product integrity. Any items exceeding acceptable limits are then discarded and destroyed to prevent the possible release into commerce and further contamination of any other product it might come into contact with.
Critical temperatures must be achieved during the cooking process of all products. This is considered a critical control point within the HACCP program written by QA and approved by the USDA. This is to eliminate any possibility of food-borne pathogens. This information is documented and kept on record in the event of a possible product recall.
All of the above listed are QA measures to eliminate the possibility of adulterated product, leading to a product recall. Any product released into commerce has been exposed to all QA measures to ensure its safety. In the event that a recall situation arises, there are proper steps taken. All vendors are notified of product information and asked to locate and destroy any questionable product. |
