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
 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.
 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:
 Directly connected with food (i.e.: GMP good manufacturing practice)
 Indirectly connected with food issues (i.e.: GRP good research practice)
 Needed be not existing in reality (i.e.: GKP good housekeeping practice)
Good practices directly conected to food issues
 good agricultural practice (GAP)
 good catering practice (GCP)
 good housekeeping practice (GKP)
 good hygiene practice (GHP)
 good laboratory practice (GLP)
 good manufacturing practice (GMP)
 good retail practice (GRP)
 good storage practice (GSP)
 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:
 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,
 determination of critical control points (CCP) in order to eliminate or minimise the
occurrence of hazards,
 establish critical limits for the critical control points identified,
 determination and implementation of a system for the monitoring of critical control
points,
 establishment of corrective actions, if a critical control point does not fulfill the
necessary requirements,
 establishment of verification procedures in order to confirm if the system is
effective and acts in accordance with the plan,
 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 are 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
 training,
 human resources,
 planning,
 knowledge and competence,
 documentation,
 resources,
 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
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.