Good practices of food chain in Polish food

Good practices of food chain in Polish food industry facts and chalanges Małgorzata Korzeniowska Wrocław University of Environmental and Life Sciences

Life Cycle Assessment

Definition of food chain Ø A food supply chain, logistics network, or supply network is a coordinated system of entities, activities, information and resources involved in moving a product or service from supplier to customer. Ø The entities of a supply chain consist of primary producers, secondury production, manufacturers, service providers, distributors, and retail outlets. Food supply chain activities transform raw materials and components into a finished product. The primary objective of food supply chain management is to fulfill customer demands through the most efficient use of resources.

Sustainable food chain Environmental objectives: 1) air pollution control, 2) water pollution control, 3) soil pollution control, 4) noise pollution control, 5) protection against radiation. Nutritional objectives: 1) providing enough food for mankind, 2) providing nutritious food (macro- and microelements), 3) providing safe food, 4) providing stable food delivery, 5) providing food in time and place required by consumers. Economic objectives: 1) achievement of equality point between supply and demand, 2) ensuring moderate food prices, 3) maintenance of job posts, 4) maximization of added value, 5) maximization of return on investment. Social objectives: 1) ensuring a good standard of life for families of farmers, processors, traders and all involved in the food chain, 2) promotion of good interpersonal relations between people involved in the food chain, 3) promotion of good health of all food consumers, 4) promotion of prolonged lifespan of all food consumers.

Relationship betwen food quality , food health quality and food safety traits Food quality Safety (hazard-free) Nutritional values Sensory values Convenience Food Healthy Quality

Obligation of food safety and quality systems Quality & Safety Assurance and Management Systems Obligatory (required by law) Safety GMP/GHP, HACCP Voluntary (expected by consumers) Quality QACP, ISO 9000, ISO 14000

Diagram of the relationship between GMP, GHP, HACCP, QACP, QMS (ISO-9000, ISO-14000, etc. ) and TQM (Sikora & Strada)

Integration of good nutritional practice in quality system

Good Practice means activity of the quality assurance which ensures that food products and food related processes are consistent and controlled to assure quality procedures in food systems. If analyse good practices we can find three categories of good practices: Ø Directly connected with food (i. e. : GMP good manufacturing practice) Ø Indirectly connected with food issues (i. e. : GRP good research practice) Ø Needed be not existing in reality (i. e. : GKP good housekeeping practice)

Good practices directly conected to food issues ü good agricultural practice (GAP) ü good catering practice (GCP) ü good housekeeping practice (GKP) ü good hygiene practice (GHP) ü good laboratory practice (GLP) ü good manufacturing practice (GMP) ü good retail practice (GRP) ü good storage practice (GSP) ü good transport practice (GTP)

GAP Good Agricultural Practice is selection of the methods of land use which can best achieve the objectives of agronomic and environmental sustainability in primary food production. A GAP approach aims at applying available knowledge to addressing environmental, economic and social sustainability dimensions for on-farm production and postproduction processes, resulting in safe and quality food and non-food agricultural products. Based on generic sustainability principles, it aims at supporting locally developed optimal practices for a given production system based on a desired outcome, taking into account market demands and farmers constraints and incentives to apply practices.

World agriculture in the twenty-first century is faced with three main challenges: 1) to improve food security, rural livelihoods and income; 2) to satisfy the increasing and diversified demands for safe food and other products; 3) to conserve and protect natural resources. GAP principles: 1. Soil 2. Water 3. Crop and fodder production 4. Crop protection 5. Animal production 6. Animal health and welfare 7. Harvest and on-farm processing and storage 8. Energy and waste management 9. Human welfare, health and safety 10. Wildlife and landscape

GCP Good catering practice consist of practical advices and assistance to managers of catering (food service) outlets and suppliers to caterers. The Guidelines concentrate on the essential steps needed to ensure that the food served is always safe and Wholesome.

GHP Good Hygiene Practice refer to procedures that must be undertaken and hygiene conditions that have to be fulfilled and monitored at all stages of production or trade in order to guarantee food safety. Good Hygiene Practice consists of practical procedures and processes that return the processing environment to its original condition (disinfection or sanitation programmes); keep building and equipment in efficient operation (maintenance programme); control of cross-contamination during manufacture (usually related to people, surfaces, the air and the segregation of raw and processed product).

GLP Good Laboratory Practice consists of a qualitative system governing organisational processes and conditions of planning, implementing, controlling, recording and reporting. The principles which consist of GLP are intended to identify the GLP requirements for test facilities (laboratories) which perform studies for regulatory purposes.

GMP Good Manufacturing Practice denotes all the actions that must be undertaken and conditions to be fulfilled in order to ensure that production of food, wrapping materials and other materials expected for contact with food, is executed in proper way to guarantee safe end products and safe food for human consumption. Good Manufacturing Practice consists of practical procedures and processes that ensure quality system, provide consistent manufacture and control of products by qualitative criteria and conformity assessing criteria with intended purpose as required by the marketing authorisation and specification of the product. It is part of the quality assurance which ensures that food products are consistently produced and controlled to the quality standards appropriate to their intended use.

GMP principles: 1. Cleaning and disinfection 2. Pest control 3. Water and air quality 4. Temperature control 5. Personnel (facilities, hygienic way of working, health, education) 6. Structure and infrastructure (surrounding area, building, materials, equipment) 7. Technical maintenance 8. Waste management 9. Control of raw material 10. Work methodology

GRP Good Retail Practice consists of practical procedures and processes that ensure the right products are delivered to the right addressee within a satisfactory time period and at required conditions. A tracing system should enable any faulty product to be found and there should be an effective recall procedure.

GSP Good Storage Practice consists of practical procedures and processes that ensure appropriate handling of foods, regarding implementation and control of product storage in accordance with a defined regime prior to their use.

GTP Good Transport Practice consists of practical procedures and processes that ensure a qualitative system governing the organization, implementation and control of transport of food products from the producer to the final user.

Good Nutrition Practice interlinking relevantgood practices in food supply chain

Good Nutritional Practice as basis for launching Good Life Practice principles

The Prerequisite Programme (GHP/GMP) is the first step to implementation of food safety and quality systems along the entire food chain beginning with the initial production, feed production, animal rearing, processing, transport and ending with the retail trade. The area covered by the GHP and GMP requirements [Turlejska 2003] comprises: – the site, surroundings and infrastructure of the enterprise, – enterprise facilities and their functional layout, – machines and equipment, – washing and disinfecting processes, – water supplies, – waste control, – pest protection and appropriate control in this field, – personnel training, – personnel hygiene, – keeping documentation and records in the area of GHP.

New European Union Food Hygiene Regulations require that all food businesses (except primary producers) implement food safety management procedures based on HACCP principles from 2006. The principal objective of the new general and specific hygiene rules is to ensure a high level of consumer protection with regard to food safety (Regulation EC, 2004).

HACCP (hazard analysis and critical control point) is a quality management system for effectively and efficiently ensuring farm-to-table food safety by controlling microbial, chemical, and physical hazards associated with food production. A prevention-based system, it takes a proactive approach by identifying the principal hazards and the control points where contamination can be prevented, limited, or eliminated across the whole food production process rather than trying to identify and control contamination after it has occurred. HACCP principles are being applied to an increasing range of food products.

Critical control points (CCPs) are the result of hazard analysis and, in practical conditions, they can be treated as an operation or action that the manufacturer must pay special attention to because these points pose real hazards to the safety of food products in the case of deviations from the established parameters. At the same time CCPs are the point of control for the identified hazard but is not always the point where the hazard occurs i. e. enters the food chain. The control can be applied before the hazard occurs or after i. e. cooking.

CCP decision tree

The HACCP system is based on seven principles which, simultaneously, make up consecutive stages of its implementation: Ø hazard analysis, in other words, identification and assessment of threats and possible hazards of their occurrence and determination of control measures and methods of counteracting these threats, Ø determination of critical control points (CCP) in order to eliminate or minimise the occurrence of hazards, Ø establish critical limits for the critical control points identified, Ø determination and implementation of a system for the monitoring of critical control points, Ø establishment of corrective actions, if a critical control point does not fulfill the necessary requirements, Ø establishment of verification procedures in order to confirm if the system is effective and acts in accordance with the plan, Ø elaboration and maintenance of the documentation of the HACCP system concerning stages of its implementation and determination of the method of data registration and storage as well as archiving of the system documentation. The basis for the elaboration and implementation of the HACCP system is the Codex Alimentarius. Other standards are also known, among others, the Danish Standard or the new ISO 22000 Standard.

The application of HACCP Stage 1. effective preparation and planning Stage 2. the application of the 7 HACCP principles Stage 3. the implementation of the HACCP study output Stage 4. the ongoing of the HACCP system

HACCP awarness and understanding of HACCP concept Identification and training of the HACCP team Baseline audit and gap analysis (evaluate current control measures) Plan the HACCP study (inc. the HACCP system structure) Stage 1. Preparation and planning

Describe the product and identify the intended use Construct and validate process flow diagram Identifiy hazards and control measures Identify critical control points Establish critical limits Identify monitoring procedures Establish corrective action plan procedure Validate the HACCP plan Stage 2. HACCP studies and HACCP plan development

Determine method of implementation Agree actions and timetable Conduct awarness training Set up monitoring systems Set up facilities and equipment Confirm implementation actions complete Verify implementation through audit Stage 3. Implementing the HACCP plan Corrective actions

Defined standards and regular audit Ongoing maintenance Records review and data analysis (verification) Problem solving Corrective and preventative action HACCP plan re-validation Documentation controlled update Stage 4. Maintaining the HACCP plan

Standards from the ISO 9000 family include standards which implement in various organisations systems of quality management. They were elaborated in such a way as to allow their application in different enterprises irrespective of branches in which they operate. It is, therefore, unimportant if a given organisation manufactures a product or provides services. The ISO 9000 family comprises the following standards: – ISO 9000, which embraces the basis of the quality management systems and terminology [ISO 9000: 2000], – ISO 9001, which specifies requirements concerning the quality management system; it is precisely this standard that is implemented in enterprises [ISO 9001: 2000], – ISO 9004, which specifies guidelines for the improvement of the system already implemented in a company [ISO 9004: 2000], – ISO 19011, which contains recommendations concerning auditing [ISO 19011: 2002].

ISO 9000 standard in accordance with the eight principles: – customer-oriented, – leadership (leaders establish the unity of the aim and operation of the organisation), – involvement of the personnel, – process approach, – system approach to management, – continuous improvement, – decision taking on the basis of facts, – mutually beneficial cooperation with suppliers. It also simplifies purchase and supplier qualification procedures and, at the same time, reduces costs associated with these operations. The quality management system based on the ISO 9000 standard covers the following areas: management of the organisation, management of resources, process of product realisation as well as measurements, analyses and improvement.

The International Food Standard (IFS) and the British Retail Consortium (BRC) standard are based, among others, on the GHP/GMP principles, the HACCP system and the ISO 9001 standard. However, the above standards include requirements which are not found in any of the earlier discussed norms and comprise: – the obligation to include in the threat analysis of the hazards associated with allergies, – monitoring of work effectiveness, – the need to cover facial hair with appropriate hygiene masks, – checking of the hands’ hygiene of workers, – the requirement to carry out application tests of products, – documented system of management of stocks of raw materials and products, complying with the FIFO principle, – elaboration of a system which allows the company to obtain information about GMO, – elaboration of procedures in case of unusual situations, – the requirement to apply metal detectors, – elaboration of the list of places in the production-storage area where glass and other hazardous material occur, – development of a procedure for the qualification, approval and verification of suppliers, – total ban of smoking on the entire area of the company. Both the IFS and BRC standard do not allow any freedom and each, even the smallest requirement, is described precisely. The advantage of this approach is that there are no problems with the interpretation of requirements and later on with the overinterpretation of auditors.

The ISO 22000: 2005 standard is a completely new standard published in September 2005 with the aim to unify principles of the quality systems used in the food industry. It is an optional standard because it goes beyond the framework of the GHP/GMP and HACCP requirements. Its range encompasses [ISO 22000: 2005]: – The Prerequisite Programme (PRP), i. e. the GHP/GMP principles and GAP (Good Agricultural Practice), GVP (Good Veterinarian Practice), GPP (Good Production Practice), GDP (Good Distribution Practice ), GTP (Good Trading Practice), – the HACCP system, – the identification system (traceability system), – the quality management system ISO 9001: 2000. ISO 22000: 2005 integrates both the quality management system (ISO 9001: 2000) and HACCP system. There also cross references between ISO 22000, ISO 9004 and terms and definitions from ISO 9000. The most effective system of food quality and safety was designed, which implemented into existing structure of management can give profits both organisation and other interested party. Furthermore, it may be implemented independently of other management systems existing into enterprise.

The level of GHP, GMP and HACCP system implementation in Polish food industry after accession to the European Union

The level of GHP implementation in Polish food industry Source: Morkis G. , 2007, 2008

The level of GHP implementation in Polish food industry in 2005 Source: Morkis G. , 2007, 2008

The level of GMP implementation in Polish food industry Source: Morkis G. , 2007, 2008

The level of GMP implementation in Polish food industry in 2005 Source: Morkis G. , 2007, 2008

The level of HACCP system implementation in Polish food industry Source: Morkis G. , 2007, 2008

The level of HACCP system implementation in Polish food industry in 2005 and 2007 Source: Morkis G. , 2007, 2008

Dynamic [%] of GHP, GMP and HACCP implementation in Polish food industry between 2004 and 2007 industry GHP GMP HACCP Baking 440 521 1058 Pasta 221 209 227 Cereales 189 173 203 Fruit-vegetables 166 168 167 Mineral water and beverages 155 175 158 Dairy 18 15 93 Fish 1 6 86 Sugar 26 26 40 Teas and coffees 45 53 - - Oils and fats Source: Morkis G. , 2008 67

Benefits from the implementation of HACCP system in terms of improving food safety Trafiałek i Kołozyn-Krajewska, 2007

Intangible benefits from the implementation of HACCP system in terms of improving food safety Trafiałek i Kołozyn-Krajewska, 2007

Tangible and economical benefits from the implementation of HACCP system in terms of improving food safety Trafiałek i Kołozyn-Krajewska, 2007

Main barriers during HACCP implementation v training, v human resources, v planning, v knowledge and competence, v documentation, v resources, v management commitment

Barriers faced by firms in implementing HACCP Implementation of HACCP impeded by internal budgetary constraints Problems obtaining external funding Current food safety controls considered sufficient Lot of changes to our production processes needed before HACCP could be put in place The things needing to be done in order to implement HACCP overwhelmed us Other investments considered more important Lot of changes to our food safety controls needed before HACCP could be put in place Wide scale upgrading of the plant needed before HACCP could be put in place Scale of operation is too small to have HACCP Not sure whether the implementation of HACCP would meet future regulatory requirements Uncertain about the potential benefits of implementing HACCP difficult to implement because of internal organization of the company Concerned that HACCP would reduce our flexibility in production Thought it best to wait and see the experiences of other companies before implementing ourselves Did not really see HACCP as suitable for our plant Not sure whether the implementation of HACCP would meet our customers requirements Considered that costs of implementing HACCP likely to get cheaper over time Greater priority given to other issues than enhancing our food safety controls Food safety issues not considered sufficiently important to warrant the investment HACCP goes against all of the ways in which we have traditionally done things

Factor loadings of barriers to HACCP Implementation: Uncertainty about potential benefits from HACCP Perception that current food safety control are sufficient Tendency to learn from other's experience before acting Uncertainty about whether future regulatory requirements met by HACCP Perception that firm's scale of operation is too small for HACCP Perception that HACCP is not suitable for the firm Perception that HACCP would reduce the flexibility of operations Perception that HACCP goes against our traditional methods Uncertainty about meeting customer requirements with HACCP Scale and scope of changes prior to adopting HACCP Scale and scope of changes to food safety controls Wide scale facility upgrading required for HACCP implementation Overwhelmed by things to be done to adopt HACCP Greater priority given to other issues Food safety investment being a low priority Relative importance of other investments Internal budgetary constraints Difficulty in obtaining external funding

Economic difficulties during the implementation of the HACCP system before and after Poland’s accession to the EU Trafiałek i Kołozyn-Krajewska, 2007

Difficulties with personel composition and with essential facts concerning the problem during the implementation of the HACCP system before and after Poland’s accession to the EU Trafiałek i Kołozyn-Krajewska, 2007

What can be done more? ? ? No let-up on the basics In the food processing environment, constant reinforcement on the food safety basics is necessary. These basics include such procedures as personnel hygiene practices and training programs, cleaning, sanitation and maintenance procedures, effective product recall programs, provisions for safe water supply, and procedures for handling product throughout the entire manufacturing and distribution processes.

Continuing consumer education Once food leaves the processor, there is also a role for consumers and others to play in maintaining basic food safety precautions. Improper food handling in the home and at retail food establishments accounts for more reported cases of foodborne illness than does failure at the food processing level.

Greater use of risk-based criteria and greater flexibility in directing regulatory resources quickly and efficiently to high-risk areas Massive restructuring of the nation’s food regulatory agencies may not be politically or economically feasible, at least in the short term. However, attention can and should be focused on strengthening regulatory agency capabilities in areas where greatest risks lie. In today’s world of heightened terrorist awareness, where deliberate contamination of food supplies is a very real threat, additional attention and resources will be directed at this problem. But that effort can complement existing food safety approaches in many ways. Many of the systems and tools that will strengthen protections against accidental contamination will also help protect against deliberate contamination of the food supply.

Expanded partnerships. The public’s perception is that the government will protect them 100 percent when it comes to eating their food. The reality is that government has to work in partnership with industry and in partnership with consumers themselves in guaranteeing safer food.

More sharing of information and less duplication of effort The advent of international food safety management system standards is opening up new avenues for cooperation and sharing of data among food safety regulatory agencies, the food industry, and the network of privatesector organizations that are springing up to audit the food industry to these new standards. Multiple audits and inspections of individual facilities can be reduced. These opportunities need to be exploited.

Greater use of economic incentives Economic incentives are demonstrably more effective than regulatory pressure. An example is the USDA Agricultural Marketing Service’s use of economic incentives and performance standards linked to statistical process control and continuous improvement to ensure that ground beef purchased for school lunch programs is safe and meets purchasing requirements. In the four years that this program has been in effect there has been a continual improvement in the microbiological quality of the ground beef. If purveyors want to sell ground beef to the school lunch program, they must have systems that are shown to be in process control. If a supplier’s process deteriorates, that supplier will be removed from approved status and placed on conditional status. During this time the supplier must take appropriate corrective and preventive actions to bring the process back into compliance with specification. If the supplier fails to do so it will be placed on ineligible status.

Expanded diligence performance by food companies on supplier quality The recent sickening of pets from toxic ingredients blended into pet foods was more a failure of corporate supplier quality programs than a failure of the regulatory establishment

Globally applicable tools for a global food chain Sourcing of food and food ingredients is now a global business, so it makes sense to tackle food safety issues with internationally accepted and globally applicable tools such as the ISO 22000: 2005 standard.

More effective inspection—not more inspection State inspection resources are limited and workload is growing, so these resources need to be targeted where they are needed most. Food producers and processors— domestic or foreign—that do not show evidence of compliance with HACCP and/or ISO 22000: 2005 and those dealing in higher-risk foodstuff should be subject to closer surveillance.