Energy Efficiency - Food Processing Sector

Energy Efficiency - Food Processing Sector

Energy savings in the food processing industry can be found in nearly every facet of operations. Key areas to look for energy savings are the processes used to manufacture, package, and process food. Fifteen of these key areas are highlighted below:

• Air Handling
• Boilers
• Blanchers
• Conveyors
• Evaporators
• Fork Trucks and Utility Vehicles
  
  
• Motors
• Packaging
• Process Controls & Sensors
• Process Heat
• Pumps
• Refrigeration and Freezing
• Steam
• Waste Reduction
• Water Usage

Food Safety

Food Safety

The food sector in India is governed by a multiplicity of laws under different ministries. A number of committees [2], including the Standing Committee of Parliament on Agriculture in its 12th Report submitted in April 2005 [3], have emphasized the need for a single regulatory body and an integrated food law.

The Food Safety and Standards Bill, 2005, aims to integrate the food safety laws in the country in order to systematically and scientifically develop the food processing industry and shift from a regulatory regime to self-compliance. As part of the process of consolidation, the Bill proposes to repeal eight existing laws related to food safety.

Key features

Regulatory authority
The Bill proposes to establish the Food Safety and Standards Authority of India (FSSA), which would lay down scientific standards of food safety and ensure safe and wholesome food. The FSSA would be assisted by a Central Advisory Committee, a Scientific Committee and a number of Scientific Panels in specifying standards. The standards would be enforced by the Commissioner of Food Safety of each state through Designated Officers and Food Safety Officers.

The FSSA would consist of a Chairperson and 18 members. The Chairperson would be either an eminent food scientist or a civil servant not below the rank of Secretary. Seven of the members would be ex-officio, not below the post of Joint Secretary, from various ministries. Five members would be appointed by rotation every three years from the states and Union Territories. The Authority would have two representatives each from the food industry and consumer organizations, one food technologist, and one member from a farmers' organization.

Standards for Food Articles 
The Bill prohibits the use of food additives, processing aid, contaminants, heavy metals, insecticides, pesticides, veterinary drugs residue, antibiotic residues, or solvent residues unless they are in accordance with specified regulations. Certain food items such as irradiated food, genetically modified food, organic food, health supplements and proprietary food cannot be manufactured, processed or sold without adhering to specific regulations.

The Bill makes it mandatory for the distributor of a food article to identify the manufacturer and the seller to identify either the manufacturer or the distributor of a food item. Every packaged food product has to be labelled as per regulations in the Bill. The packaging and labelling of a food product should not mislead consumers about its quality, quantity or usefulness.

Food Recall Procedures 
The Bill has special provisions for food recall procedures. If a food business operator (i.e., anyone owning or carrying out a business relating to food) considers that a food item is not in compliance with the specified standards, he has to initiate procedures to withdraw the food in question and inform the competent authorities.

Enforcement 
Every food business operator is required to have a licence in order to operate his food business. Petty manufacturers who make their own food, hawkers, vendors or temporary stall holders do not require a licence. Instead, they need to get their businesses registered with the local municipality or Panchayat.

The Bill empowers the FSSA and State Food Safety Authorities* to monitor and regulate the food business operators. The Commissioner of Food Safety of each state appoints a Designated Officer (DO), not below the level of Sub-Divisional Officer, for a specific district whose duties include issuing or cancelling licences, prohibiting sale of food articles that violate specified standards, receiving report and samples of food articles from Food Safety Officers and getting them analysed. The DO also has the power to serve an 'improvement notice' on any food operator and suspend his license in case of failure in compliance with such a notice. The DO also investigates any complaint made in writing against Food Safety Officers. Food Safety Officers are appointed for a specified local area and their duties include taking samples of food articles, seizing food articles that are of suspect quality or inspecting any place where food articles are stored or manufactured.

The State Commissioner, on the recommendation of the Designated Officer, decides whether a case of violation would be referred to a court of ordinary jurisdiction or to a Special Court. Cases relating to grievous injury or death for which a prison term of more than three years is prescribed are tried in Special Courts.

The Bill provides for a graded penalty structure where the punishment depends on the severity of the violation. Offences such as manufacturing, selling, storing or importing sub-standard or misbranded food could incur a fine. Offences such as manufacturing, distributing, selling or importing unsafe food, which result in injury could incur a prison sentence. The sentence could extend to life imprisonment in case the violation causes death. Petty manufacturers who make their own food, hawkers, vendors or temporary stall holders could be fined up to Rs 1 lakh if they violate the specified standards.

In order to judge cases related to breach of specified regulations, the state government has the power to appoint an Adjudicating Officer, not below the rank of Additional District Magistrate. Any person not satisfied by the decision of an Adjudicating Officer has the right to appeal to the Food Safety Appellate Tribunal (or to the State Commissioner until the Tribunal is constituted). The Tribunal enjoys the same powers as a civil court and decides the penalty in case of non-compliance with the provisions of the Act.

Certification and Quality

1. 

   HACCP
2. BRC
3. EUREPGAP
4. ISO 22000
5. Fami-QS
6. IFS
7. GMP+

Hazard Analysis Critical Control Point (HACCP)

HACCP is a state of the art system/concept to ensure food safety. It is a preventive quality assurance process designed to provide increased control and monitoring during critical stages of the food processing chain and is accepted worldwide. Buyers in different parts of the world often demand HACCP Certification or compliance.

  
HACCP is the acronym for Hazard Analysis Critical Control Point.  It is a food safety tool developed by the food industry for the food industry. HACCP examines every step in a food operation, identifying specific hazards as well as implementing effective control measures and verification procedures.  HACCP is not a zero risk system. It is designed to minimise risk and as such it is a risk management tool.

HACCP

• Can be applied throughout the food chain (“from farm to fork,” “from paddock to plate”, etc.)
• Increases confidence in food safety
• Requires full commitment and involvement of management and workforce
• Requires a multidisciplinary approach
• Is  compatible with the implementation of quality management systems
• Is the system of choice for Food Safety management

TÜV South Asia also provides expertise in the development and implementation of HACCP programs in different processed food industries including Seafood Processing. All Seafood exports to USA now come under "HACCP Regulation" as envisaged by the USFDA (U.S Food and Drug Administration).
B.R.C. Certification

Retailer branded products represent over 50% of all food sold in the U.K.  Under the terms of the Food Safety Act 1990, Retailers have an obligation to take all reasonable precautions and exercise all due diligence to avoid failure, whether in the development, manufacture, distribution, advertising or sale of food products to the consumer.

The obligation in the context of Retailer branded products includes the verification of technical performance at food production sites.  Until recently, each Retailer used to undertake this activity separately. They used to verify food production site performance against their individual, internally developed standards.  In some instances verification was undertaken by the Retailers’ in-house technologists and in other instances by third party inspection bodies. 

  
Technical inspection of supplying companies’ production premises forms only part of the Retailer’s due diligence system, and the acceptance for a company to supply, rests with the individual Retailer.

BRC Technical Standard: The Standard requires

• The adoption of HACCP
• A documented Quality Management System
• Control of Factory Environment Standards, Product, Process and Personnel

Benefits:
There are a number of benefits arising from the introduction of the BRC Technical Standard:

• A single standard and associated protocol allowing inspection to be carried out by Inspection Bodies, who are accredited against the European standard;
• Single verification commissioned by the supplier, in line with an agreed inspection frequency,  allows Suppliers to report the status to those customers who recognize the Standard;
• Comprehensive covering all areas of product safety and legality;
• Addresses part of the due diligence requirements of both the supplier and the retailer;
• Within the associated inspection protocol, there is a requirement of Ongoing Surveillance and Confirmation of follow up of corrective actions of non conformance;

There will be future recognition of Inspection Bodies in countries where product is sourced.

EUREPGAP Certification - Protocol for Fresh Fruit & Vegetables

What is it?  The EUREP GAP (Fresh Fruit & Vegetable) Protocol describes essential elements and develops best practice for global production of fresh produce and horticultural products. It demonstrates to customers a company's commitment and ability to produce safe and clean food, under an exhaustive system (HACCP) verified by an internationally recognized independent third party. 

  

Background:
EUREP (Euro Retailer Produce Working Group), represents leading European food retailers and uses GAP (Good Agricultural Practice) as a framework for verification. It is presently specifically designed for businesses in the fresh produce supply chain. It offers a means of incorporating Integrated Crop Management (ICM) and Integrated Pest Management (IPM) practices within the framework of commercial agricultural production.

Based on its success and involvement of a wide range of stakeholders EUREPGAP is now also working on a standard for Livestock, Flowers, Coffee and Combinable Crops.

Benefits:

• Ensures retailer and consumer confidence through responsible and sustainable production
• Complies to the minimum standard acceptable to leading retail groups in Europe
• Incorporates IPM and ICM in commercial agricultural production
• Supports the basic principles of HACCP ( BRC)
• Primary producers, retailers like Sainsbury, Mark & Spencers, grower-associations, traders and their organizations can be certified against EUREP GAP standards. The following sectors are covered: fruits, vegetables, potatoes, salads, cut flowers, nursery stock

ISO 22000
ISO 22000:2005 specifies requirements for a food safety management system where an organization in the food chain needs to demonstrate its ability to control food safety hazards in order to ensure that food is safe at the time of human consumption.

It is applicable to all organizations, regardless of size, which are involved in any aspect of the food chain and want to implement systems that consistently provide safe products. The means of meeting any requirements of ISO 22000:2005 can be accomplished through the use of internal and/or external resources.

ISO 22000:2005 specifies requirements to enable an organization:

• To plan, implement, operate, maintain and update a food safety management system aimed at providing products that, according to their intended use, are safe for the consumer,
• To demonstrate compliance with applicable statutory and regulatory food safety requirements,
• To evaluate and assess customer requirements and demonstrate conformity with those mutually agreed customer requirements that relate to food safety, in order to enhance customer satisfaction,
• To effectively communicate food safety issues to their suppliers, customers and relevant interested parties in the food chain,
• To ensure that the organization conforms to its stated food safety policy,
• To demonstrate such conformity to relevant interested parties, and
• To seek certification or registration of its food safety management system by an external organization, or make a self-assessment or self-declaration of conformity to ISO 22000:2005

Fami-QS Certification
Fami-QS is a derivation of European Feed Additives and Premixtures Quality System. The European Regulation on Feed Hygiene (183/2005) sets up hygiene and safety requirements for the whole feed chain - this includes feed additives and premixtures. This Regulation also promotes the establishment of codes of practice in the feed chain. Therefore the feed additive industry has decided to establish a code of practice covering feed additives and premixtures (as defined in Regulation 1831/2003/EC on additives for use in animal nutrition).

This code is the FAMI-QS Code of Practice for Feed Additive and Premixture Operators, a public document from which its content can be freely followed by any feed additive or premixture operator.

Running side by side, a parallel and independent certification system has been developed by FAMI-QS Asbl. Participation in the FAMI-QS auditable system is based on voluntary commitment.

The FAMI-QS Code is certified by independent certification bodies, and run by the FAMI-QS Asbl association. TÜV SÜD is one of the few certification bodies which is accredited to certify to the Fami-QS Code wordwide.

IFS Certification: 
Supplier audits have long been an inherent part of retail and industry. In the past, audits have been carried out by the retailers’ quality assurance departments. Now the situation has changed because of growing demands of consumers, the rising incidence of claims for damages. The globalisation of commodity flow have also put the development of a uniform standard on the agenda. A solution had to be found to reduce the costs associated with a multitutde of audits, for both retailers and suppliers. At an international level, the "The Global Food Safety Initiative" was created, seeting up a general framework with its \"Guidance Document\". In 2002, in order to create a common food safety standard, German food retailers from the HDE (Hauptverband des Deutschen Einzelhandels)  developed a common audit standard called International Food Standard or IFS. In 2003, French food retailers (and wholesalers) from the FCD (Fédération des entreprises du Commerce et de la Distribution)  joined the IFS Working Group and have contributed to development of IFS version 4. The aim of the IFS is to create a consistent evaluation system for all companies supplying retailer branded food products with uniform formulations, uniform audit procedures and mutual acceptance of audits, which will create a high level of transparency throughout the supply chain. The IFS defines requirements in content, procedure, evaluation of audits and a requirement profile for the certification bodies and auditors.

• Structure of the IFS (catalogue of requirements):
• Management of the Quality System
• Management Responsibility
• Resource Management
• Product Realisation
• Measurements, Analyses, Improvements

The auditor audits against the IFS standard which is divided into two levels. After clearing the higher level the organization can apply for a recommendation.

• Foundation level: These criteria are considered as minimum requirements for the international food industry.
• Higher level: These criteria are considered as a high standard in the food industry.
• Recommendations: This criteria is recommended for all auditees, who wish to demonstrate "best practice" in the sector.

GMP+ Certification
GMP+ provides the basic foundation for the development of a Food Safety and Quality Management System, i.e. Hazard Analysis Critical Control Point (HACCP). Good Manufacturing Practice (GMP) Good Agricultural Practice (GAP) are minimum sanitary and processing requirements which should apply to all food processing establishments. GMP generally relates to good housekeeping practices concerning food safety and quality issues.

Many food industry sectors have implemented Good Manufacturing Practices for food processing establishments as the foundation upon which they have developed and published more specific practices for food safety in their particular industry sector

Area of application:
GMP01:  general
GMP02:  mixed fodder
GMP03:  pre-mixtures
GMP05:  raw feeding stuff
GMP07:  transport
GMP09:  admixtures
GMP13:  QC-PDV

Hygiene audits and training programs:

Hygiene audits is a global initiative, which addresses the need of all players in the retail & hospitality industries with regard to safe food practices and the implementation and monitoring of good hygiene standards. It follows the international trend of outsourcing hygiene management to established experts, relieving you of the requirement for an in-house function.

Consumers are becoming more aware and more demanding of health and safety issues when it comes to food. Brand loyalty is encouraged through the demonstration that you are committed to upholding a safe and hygienically acceptable establishment.

Hygiene audits help the companies to:

• Protect & enhance reputation and brand loyalty.
• Promote consumer confidence.
• Conform to regulatory and market requirements. 

Voluntary Product Certification

TÜV SÜD South Asia can verify conformity with standards, procedures and technical / regulatory specifications as defined in the certification scope. It can be used to certify origin,   purity,   variety or other product characteristics

The Test procedures are:

• System/Process Audit
• Product Testing
• Specification Testing
• Material Qualification
• Product Machinery

A step-approach is followed

1. Planning - Analyze the product and production systems

• Draw up specifications
• Define test criteria and procedures
• Decide on the scope of testing
• Agree on costs 

1. Evaluation

• Implementation of test criteria and procedures
• Data collection for product criteria – VERTICAL
• Data collection for system criteria – HORIZONTAL
• Data management
• Beginning of product certification

1. Verification

• Regular testing and/or auditing
• Compare test effort to sales volumes
• Managing the mark
• Data capture and processing
• Analysis of market trends
• Customer and consumer information

Glossary for Names of Fruits, Vegetables & Spices

Glossary for Names of Fruits, Vegetables & Spices

Almonds	Badam
Alum	Phitkari, Turti
Amaranthus	Cholai
Amla	Avla
Aniseed	Saunf, Badishep
Apple	Seb, Safarchand
Apricot	Jardalu/Khumani
Asafoetida	Hing
Ash gourd	Petha
Banana	Kela
Basil	Tulsi
Bay Leaf	Tej Patta
Betel Nut	Supari
Bitter Gourd	Karela
Black Cardamom	Badi Eliachi
Black Cumin	Shahi Jeera
Black Dates	Khajur
Black Grapes	Angur / Kali Draksh
Black Onion Seeds	Kalonji
Black Pepper	Kali Mirch / Kali Miri
Black Salt	Kala Namak
Bottle Gourd	Dudhi/Lauki
Brinjal	Baigan / Vangi
Brown Vinegar	Sirka
Button Mushrooms	Gucchi
Cabbage	Patta Gobi
Capsicum	Shimla Mirch / Dhobali Mirchi
Caraway Seeds	Shahi Jeera
Cardamom	Elaichi / Veldode
Cardamoms (green)	Chhotti Elaichi
Carom Seeds	Ajwain /Aova
Carrots	Gajar
Cashew Nuts	Kaju
Cassia Buds	Nag Kesar
Cauliflower	Phool Gobi
Chick Peas	Kabuli Chana
Chilli (green)	Hari Mirch
Chilli (red)	Lal Mirch
Cinnamon	Dalchini
Cloves	Lavang
Cluster Beans	Gavar Phali
Coconut (dried)	Khopra
Coconut (fresh)	Nariyal
Colocassia	Arbi
Colocassia Leaves	Arbi Patta
Coriander	Hara Dhania
Coriander Seeds	Dhania / Kothimbir
Corn Cobs	Bhutta / Makka
Corn Kernels	Makkai
Cucumber	Kheera / Kakdi
Cumin Seeds	Jeera
Currants	Daakh/Draksh
Curry Leaves	Karipatta
Custard Apple	Sitaphal
Dates	Khajur
Dried Mango Powder	Amchur
Drum Sticks	Shajan phalli /Shevga
Fennel Seeds	Saunf
Fenugreek	Methi
Fenugreek Greens	Methi Sag
Fenugreek Leaves (dried)	Kasoori Methi
Fenugreek Seeds	Methi Dana
Fig	Anjeer
Garlic	Lasan/Lahsun
Ginger	Adrak
Ginger Powder (dried)	Saunth
Grapes	Angur
Green Almonds	Hara Badam
Green Berry	Ber
Green Chillies	Hari Mirch
Green Peas	Mattar
Groundnuts	Mungphali / Shengdane
Guavas	Amrud / Peru
Honey	Shahed /Madh
Horse Radish	Muli
Indian Gooseberry	Avla
Jackfruit	Kathal
Jaggery	Gud
Lady's Finger	Bhindi/Okra
Lemon	Nimbu/Neebu/Limbu
Lotus Stem	Kamal Kakdi/Bhein
Mace	Javitri
Mango	Aam
Mango Powder (Dried)	Aamchur
Margosa	Neem
Melon Seeds	Magaz
Mint	Pudina
Mushrooms	Khumb/Guchhi
Musk Melon	Kharbuza
Mustard Greens	Sarson
Mustard Oil	Sarson Tel
Mustard Seeds	Rai
Nigella Seeds	Kalonji
Nutmeg	Jaiphal
Okra	Bhindi/Lady's Fingers
Olives	Ziatun
Onions	Piaz / Kanda
Orange	Santra
Papaya	Papita
Peach	Aadu
Peanuts	Mungphali
Pear	Nashpati
Peas (Fresh)	Mattar
Peppercorns	Kali Mirch
Pine Nuts	Chilgoza
Pineapple	Ananas
Pistachios	Pista
Plums	Alubukhara
Pomegranate	Anar
Pomegranate Seeds	Anar Dana
Poppy Seeds	Khus Khus
Potatoes	Aloo/Batata
Pumpkin	Kaddu
Purple Yam	Kand
Radish	Muli
Raisins	Kishmish
Raw Banana	Kacha Kela
Raw Mango	Kairi
Red Cabbage	Lal Patta Gobi
Red Chillies	Lal Mirch
Red Mango	Kokum/Amsool
Ridge Gourd	Turai
Rock Salt	Kala Namak
Saffron	Kesar
Sesame Seeds	Til
Spinach	Palak
Sunflower Seeds	Chironji
Sweet Lime	Mosambi
Sweet Potato	Ratalu/Shakarkand
Thyme	Ajwain
Tomatoes	Tamatar
Turmeric	Haldi
Turmeric Powder	Haldi Powder
Vinegar	Sirka
Walnuts	Akhrot
Watermelon	Tarbuza