Taking control of food safety

by Ron Wall

Alberta food processors and distributors have checks and balances in place to ensure food safety for everyone.

E. coli. Hamburger disease. Mad cow disease. Terms we didn’t know about just a few years ago, but today most everyone has at least heard of them or knows how deadly they can be. So how safe is the food we buy at the grocery store or eat in a restaurant? What measures are there to prevent an outbreak of disease from bacteria found in foods? Excellent questions. The answer lies with something called HACCP.

The plan, boss, the plan

Developed in the ‘60s for the NASA space program, Hazard Analysis Critical Control Points (HACCP) is a scientific approach to food safety that identifies and monitors critical control points in the production of a food product. Rather than wait for the end product to be tested, HACCP enables processors and producers to manage the hazards that can affect food production all along the line.

While production processes differ for the myriad of food products we have, the system gives a framework for everyone involved in production – a complete process to ensure the product is safe and ready to ship out whether it’s a drink of milk, a loaf of bread, a bag of chips, a gourmet sauce, a dozen eggs or a pound of ground beef. In a nutshell, each step in food production is monitored, checked and documented, leaving a paper trail to prove everything was done correctly, meets standards and is safe to eat.

Rod Worobo, a food systems specialist with the Alberta Food Processors Association, has been bringing Alberta food production companies up to speed on how to develop a HACCP system for their specific operations. HACCP systems, which are becoming the industry-wide standard, are mandatory for any company that wants to ship meat or poultry products to the United States, says Worobo.

So what is it exactly? “The HACCP system includes the management of the direct hazards associated with food production – Critical Control Points (CCP) – and these hazards include the management of chemical, physical and biological hazards,” says Worobo. “So if there is a CCP or direct hazard in the food production process, the critical control point will have to be monitored, recorded and documented. For example, the cooking step of ready-toeat food products is a CCP to ensure the food is properly cooked to eliminate biological hazards. The time and temperature are monitored and recorded.”

In addition to the direct hazards of food production, the HACCP system addresses the indirect hazards. “These indirect hazards are called prerequisite programs and include premises, transportation and storage, equipment, personnel training, sanitation and pest control and recall,” Worobo says. “Each of these programs has procedures that have to be monitored and documented as well.” The program has been accredited by the International HACCP Alliance at Texas A&M University as a leading training program in North America.

Safety, all in one basket

One industry player that has been a leader in making HACCP the basis of its on-farm food safety program is the Alberta Egg Producers. As part of their Start Clean, Stay Clean program, the 165 registered egg producers in Alberta have their facilities randomly inspected on a regular basis to ensure compliance with strict industry standards.

Brenda White, Alberta Egg Producer Board’s marketing and communications manager, says the random checks ensure that “not only are the hens’ health and well-being maintained but proper procedures on egg handling and refrigeration are also being carried out.”

White says the program started several years ago when salmonella was recognized as the main food safety issue with eggs. “We recognized a potential food safety risk and proactively took steps to do something to greatly reduce the chances of a problem.

“We are continually refining the process to ensure producers are documenting everything like the temperature of the coolers the eggs are stored in. Alberta’s registered egg producers work very hard to ensure their operations consistently meet and exceed the standards. They recognize how important it is for the consumer’s trust,” says White.

“Looking for the Canada Grade A symbol on egg cartons in retail stores is the consumer’s best bet when it comes to buying safe, quality eggs.”

Here’s the beef

Also maintaining high food safety standards is the Cargill Foods plant located near High River. In operation since 1989, the plant processes nearly 4,000 head of cattle each day and ships beef products across Canada, the United States and around the world. The plant is a fully integrated facility housing slaughter, fabrication, rendering and hide operations under one roof.

According to Dave Kasko, Cargill Foods technical service manager, the plant operates under the Food Safety Enhancement Program which is administered by the Canadian Food Inspection Agency (CFIA). The plant has a fully integrated HACCP program, which requires both accreditation and auditing by the Government of Canada.

“When we received our HACCP accreditation in 1997, we were one of the first plants in Canada to do so. We have used HACCP since we opened in 1989. It’s been part of culture since the beginning,” says Kasko.

A recent addition to the plant is a 4,000 square foot on-site Level 2 laboratory. Kasko says the laboratory will enable them to do more extensive research on pathogens or bacteria that cause disease. “We do significant testing on pathogens now, but this laboratory gives us the ability to do more research and focus on environmental areas in our own production processes.”

Other measures to ensure food safety take place when the animals are processed. Kasko says the plant uses equipment such as steam pasteurization, steam vacuums and, this fall, he added a pre-evisceration wash – all measures are designed to kill any bacteria that may be on a carcass.

Kasko adds the plant is also looking to incorporate more automation on the production floors. “With more automation, we are addressing the ability to control processes from a sanitation standpoint. The more automation that can be done, the less the product is being handled.”

According to Kasko, the plant regularly meets with packers, processors, food service and retail distributors to assess how the industry is handling the product through what is known as Cold Chain Management – a process where meat or dairy products are manufactured, shipped and stored at regulated temperatures.

“As an industry, we believe the cold chain is being managed very well in Canada,” says Kasko.

Front line food safety

Canada Safeway knows first-hand how important food safety is. With about 13,000 products on the shelf, the company can experience hundreds of food recalls and withdrawals each year, putting grocery stores like Safeway on the front lines of food safety.

According to Colin Rose, Canada Safeway’s director of food safety and environmental affairs, products are recalled when a specific health hazard has been identified. Product withdrawal from store shelves occurs if a manufacturer has a quality concern or labeling issue and they want the product off the shelf. Immediate attention is given to any product that has been identified as a health hazard and recalled by the Canadian Food Inspection Agency.

“We are seeing more recalls as a result of undeclared allergens in a product, like nuts or milk, that may cause an allergic reaction,” says Rose.

“When the stores are notified, personnel immediately pull the product off the shelf,” he explains. “Each store has a specific set of instructions on what to do and how to secure the product. Visible signs are attached for easy identification of the secured product once it is moved from the store.” To confirm that the recall procedure has been completed, each store reports back to a district office.

In addition to food recall procedures, each Safeway store has specific food safety programs in place to ensure the proper temperature of product is maintained, sanitation procedures are followed correctly and products are handled and stored properly.

As part of Safeway’s ongoing commitment to food safety, an internal inspection program has been initiated for the 213 Safeway stores located from Victoria, B.C. to Thunder Bay, Ont., as well as the company’s distribution centres.

“We have a crew of five specialists who do random, unannounced food safety inspections at all of our stores and distribution centres,” says Rose. “Our inspectors make sure all the programs we have in place are being followed. We have a structured audit process that allows for continuous education of our staff on food safety matters. If we find a concern, we work to educate our employees, implement corrective action and require follow-up.”

Rose sees Safeway’s initiatives as industry leading and being ahead of government food inspectors. “We are checking ourselves, making sure that we are doing all the things we are supposed to be doing,” he says.

The provincial government in British Columbia recently introduced new legislation requiring grocery stores and restaurants to have written food safety plans and HACCP-based plans in place. Rose sees this as reality for Alberta and Saskatchewan food retailers and restaurants as well. Rose points out that Safeway’s food safety programs already meet these criteria. “It’s quite rewarding to know that Safeway already has programs in place prior to the regulations coming into being.”

When it comes right down to it, food safety is everyone’s business. From the farm and the proper care of the animals to the consumer bringing food home and safely storing and handling it, food safety is in everyone’s hands.

Tips for safe food handling

Reduce the risk of food-borne illness by following these four simple steps.

Clean

• Wash hands, utensils and surfaces with hot soapy water before, during and after preparing foods.
• Sanitize countertops, cutting boards and utensils with mild bleach and water solution.
• Wash all produce thoroughly before eating or cooking.

Separate

• Keep raw meats and poultry away from other foods during storage.
• Keep separate cutting boards for raw meats and vegetables.
• Always keep foods covered.

Cook

• Cook food thoroughly – cooking times and temperatures vary for different meat and poultry.
• Prepare foods quickly and serve immediately so foods don’t linger at room temperature where bacteria can grow.

Chill

• Refrigerate or freeze perishables, prepared food or leftovers within two hours.
• Make sure the refrigerator is set at 4°C (40°F) and keep the freezer at -18°C (0°F).

Source: Canadian Partnership for Consumer Food Safety Education (www.canfightbac.org).

Food Safety Info Line: 1-800-892-8333