Food Safety & Quality Management. 15 th November Emma White European Food Safety & Quality Business Partner

Transcription

1 Food Safety & Quality Management 15 th November 2012 Emma White European Food Safety & Quality Business Partner

2 What are we going to cover? Kelloggs history When it goes wrong Kevin s story Importance of Food Safety What Kelloggs is doing Understanding Reputational Damage

3 History of Kellogg Two brothers discovered a brand new breakfast cereal in the late 19th Century A multi-national company. A huge global industry, changing the eating habits of whole nations. 19 th February 1906 William Keith Kellogg filed the papers that officially incorporated the Battle Creek Toasted Corn Flakes Company. The popularity of his new Corn Flakes cereal encouraged William to set up the Kellogg company - the most successful cereal manufacturer in the world.

4 Why Food Safety? Food is strength, and food is peace and food is freedom, and food is a helping hand to people around the world whose goodwill and friendship we want. John F. Kennedy

5 The Sobering Statistics

6 Food Safety A Global Health Issue Diarrhoeal disease is a leading cause of child mortality and morbidity in the world, and mostly results from contaminated food and water sources Food borne illness is estimated to cost the United States $152 billion every year! Does not include long-term outcomes and other costs, such as public health expenditures, that are often overlooked

7 Food Safety More than just a Tummy Ache According to the Food and Drug Administration, an estimated 2 to 3 percent of food borne illness victims develop secondary long-term medical complications Factors Contributing to UK Outbreaks 50% inadequate cooking or re-heating 45% food stored inappropriately 39% cross contamination 12% infected food handler 97 % of food poisoning outbreaks involve food handler error

8 Recent Major Food Poisoning incidences

9 Recent Major Food Poisoning incidences 2006 Spinach Outbreak E.Coli 0157:H7 in bagged, prewashed spinach 276 illnesses in 26 states 141 hospilitisations 31 cases of HUS 3 deaths Cost spinach industry estimated $100 million Result of water contamination traced to upstream cattle 2002 ConAgra Outbreak E.coli 0157:H7 in ground beef 45 illnesses in 23 US states 8.6 million kilos recalled

10 Recent Major Food Poisoning incidences 2007 Melamine Outbreak One of the largest consumer product recalls in history 60 million containers of pet food 1,000 products 95 brand names 27 manufacturers 18,000 consumer complaints No written recall strategy $24 million settlement Resulted in criminal action 2009 Salmonella Outbreak Peanut Corporation of America 714 illnesses in 46 states and 9 deaths Creeping recall 3,600 products History of positives PCA files for bankruptcy $12 million victim settlement $1 billion in industry losses

11 Kevin s Story

12 Kevin Kowalcyk s Story Barbara Kowalcyk Director of Food Safety

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14 Food Safety Barriers to adopting Safe Food Practices Barriers to implementation: It s too much work to follow all of the safe food practices! Reality: Prevention is essential! Serious food borne illness may result in the loss of life or serious long-term health problems. Regulation By law food must be legal, safe & fit for consumption. Food shall not be placed on the market if it is unsafe. It is deemed unsafe if it is; Injurious to health Unfit for human consumption

15 What does Kelloggs do to mitigate risk?

16 Some programmes to mitigate the risks Management of Food Safety and HACCP Cleaning and Sanitation Environmental Monitoring Adverse Event Management Allergen management Adherence to Construction, Installation & Major Maintenance Requirements Hygienic & Sanitary Design High risk ingredient management

17 Management of Food Safety & HACCP (Hazard Analysis Critical Control Point)

18 HACCP What is HACCP? HACCP (Hazard Analysis Critical Control Point) - systematic preventative approach to food safety. Physical, chemical and biological hazards Significant benefits to organisations operating within the food supply chain Determination of key controls over processes What are Critical Control Points? CCP - point, step or procedure at which controls can be applied and a food safety hazard can be prevented, eliminated or reduced to acceptable (critical) levels. The most common CCP is cooking, where food safety managers designate critical limits.

19 Main Benefits of HACCP Based Procedures Improved Hygiene Standards Reduced Microbial Counts Higher Customer Satisfaction Formal basis for developing relationship Providing a basis for legal defence in court

20 Cleaning and Sanitation Environmental Monitoring Adverse Events

21 Kellogg Equipment Sanitation Verification & Validation Global guidelines for cleaning and sanitation Verification and validation - conducted on each cleaning cycles prior to start up; Verification Doing what we say we re doing - Visual Inspection, Testing. Validation Doing the right thing - Micro swab testing at defined frequency. Corrective actions are developed re-clean, re-test Investigation for pathogens Establishment of the level of hygienic operation Environmental swabs / sponges are taken

22 Adverse Events - When things go wrong! Incidents that could potentially cause contamination to the food stream Blocked or Backed up Drains Roof Leaks Condensate Leaks Plumbing Leaks Non Potable/Potable water Introduced How do we deal with it? Risk assessment Area Isolated, Cleaned and Sanitised SSOP, Documented. Environmental Swabbing Elevated Sampling Plan (Salmonella) Line Re-Started, Held product released

23 Allergens

24 Allergens Allergy occurs when the body s immune system reacts inappropriately to a food or substance that is harmless for most people. Causes include foods, certain drugs, insect stings and natural rubber Incurable - avoidance the only treatment Statistics Symptoms 22% of Adults in the UK believe they have a food allergy 3-4% of Children are diagnosed 1-3% of adults are diagnosed Peanut and tree nut allergy affects 1 in 50 children. Figures are comparable across the EU Variable from mild to severe Itching, Swelling, Gastro-intestinal upset, Difficulty Breathing, Hypotension, Anaphylatic shock, death.

25 Foods that give the most severe reactions Peanuts and tree nuts give more severe reactions than any other foods Egg can cause reactions at a lower dose than peanuts Milk, sesame and lupin can also cause very severe reactions

26 One close call Kelloggs had in 2006 Sesame in Coco Pops Straws Several (half a dozen) anaphylactic shock reactions in France and UK Children admitted to hospital All have recovered For one individual it was their first ever allergic reaction to food Changed pack labelling but is it enough?

27 Food Safety Policies - Allergens The key Allergen Food Safety Management points are: 1. Prevention of the contamination of non-allergen product with allergenic ingredients. 2. Ensure the ultimate consumers of the product are aware of the presence of allergens through correct labelling and safe management of promotions. 3. Preventing the introduction of new allergens under our brands. May Contain labelling is not a substitute for effective allergen control

28 Labelling May contain is frowned upon among those with allergies - can be seen as a cover all and gives the impression the company does not manage allergens correctly. Survey by Food Safety Authority Ireland found that in 94% of foods with may contain labels no allergen residues were found. Research has shown many individuals ignore may contain labels esp. males 18+ May contain is advisory only - not legally required

29 Construction, Installation & Major Maintenance Requirements Hygienic & Sanitary Design

30 Food Safety Requirements for Construction and Major Maintenance Activities What are we trying to do! Eliminate any risk by containment of the hazards. Identify any risks associated by any construction and maintenance. Focus is on potential contamination of finished food by exposure to micro organisms. Identify sources of contamination Doors, Floors, Drains Roofs, Pallets, Pests Ingredients Shoes Construction Visitors Hands Control strategies Routine Cleaning Focused Cleaning SSOP s SOP s Mechanical Barriers Chemical Barriers Procedural Barriers Waste. Process steps Shutdown

31 Hygienic Design & Zoning Sanitary design Reduces the risk of contamination. Reduces the time to clean equipment Improves access and visibility Evaluates the effect of chemicals Establishes the sanitation method Hygenic Zoning Some production areas have a higher risk of cross contamination than others. Separation of areas and the traffic in between is restricted and controlled. High risk areas - Raw areas. Low risk areas RTE (Ready to eat) More common focus in facilities processing foods traditionally considered as sensitive are meat, poultry, dairy But the principles of separation and transition control are now used in our industry!

32 High Risk Sensitive Ingredients

33 High Risk Sensitive Ingredients & auditing Critical Ingredients Inherent Micro Risk Sensitive Ingredient Critical Ingredient used post final validated thermal kill step Kellogg and Contracted Operations facilities approx. 120 Sensitive Ingredients across 60 suppliers All Sensitive Ingredient Suppliers to Kelloggs are audited Comprehensive Kellogg Food Safety audit Suppliers with a 3 rd party certification annually All sensitive ingredients tested for Salmonella and E-Coli

34 Food Safety Management If we put in good systems and we train our staff now we have done our job and if we find a food handler NOT doing what they should do we can blame (punish) that individual! WRONG!!!! More than 50% of food handler mistakes are due to management failures

35 The impact of catastrophes on shareholder value

36 Recoverers and non-recoverers

37 Reputation When we are wondering why we are doing all of the things that we re doing? let us always remember that we re not making T shirts or CDs, we are making food which people put into their bodies and which effects their wellbeing. We must constantly do everything in our power to ensure that our people, our culture and our processes always have this at the front of mind Andy Heyes Food Safety & Quality Director

38 A reputation is a very fragile thing

39 Summary Kelloggs history When it goes wrong Kevins story Importance of Food Safety What Kelloggs is doing Understanding Reputational Damage

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