HOLY SPIRIT UNIVERSITY OF KASLIKS

202303821

Prof. Lara Hanna-Wakim

GAA 619 Quality Assurance and
Consumer Health
Lebanon is facing an ongoing economic crisis, with unstopping inflation,
currency losing value, and a massive debt. One of the ways to reduce the
economic crisis and increase employment is improving the system in industries.
For the success of the food industry, many aspects should be achieved one of
them is quality. For a business to fully succeed many steps should be followed:
The main rule of business is to set realistic expectations and never oversell.
Following the market trends consumers are seeking high quality food. They are
looking for safe, and high-quality items to achieve their nutritional goals. The
degree of quality goes beyond what is on the label it depends on several factors
such as manufacturer, supplier, and others in the production process. In addition
to achieve quality standards, food industries should follow good manufacturing
process
GMPs, known as the minimum hygiene standards, and serve as the baseline
requirements that manufacturers must fulfil to ensure the safety which includes
supervising raw materials, intermediate products, and finished goods to ensure
compliance with quality standards. On the other hand, food industries should
maintain clean and hygiene facilities, equipment, and personal hygiene of
employees to prevent contamination of food products.
No success can happen without the proper and adequate training in food safety
practices by professionals about hygiene protocols. GMP regulations require
thorough record-keeping to document different aspects, such as ingredient
sourcing, processing conditions, quality control assessments, and product
distribution. Maintaining precise records is crucial for traceability,
accountability, and meeting regulatory standards.
Good agricultural practices (GAP) aim to reduce potential hazards that are
divided into three biological, chemical, and physical. Manufacturers must
ensure that their products are free from incorrect ingredients, not contaminated
by substances like pesticides, heavy metals such as lead, or harmful bacteria.
Furthermore, products should be properly packaged and labelled to prevent any
misinterpretation or misinformation for consumers.
Adulteration is a way that manufactures use to increase profit and harm
consumers by the addition of contaminants, mislabelled products with allergens,
chemicals, or artificial sweeteners not FDA approved. A negative report from
any consumers can lead to the shutdown of the food industry. Providing high
quality products offers businesses an advantage in the market. Customers are
ready to invest more for exceptional quality, allowing companies to set
themselves apart from rivals and secure a larger group of the market. "food
quality" is a widely used term, defining it poses a challenge, because
perceptions of acceptability and value can vary greatly among consumers,
influenced by factors such as cultural differences and regional preferences.
Consequently, unless specific criteria or standards are referenced, the notion of
quality remains subjective. Quality managements system include HACCP
globally recognized as a proactive tool for risk management, empowering food
and feed manufacturers to pinpoint critical control points for various
contaminants like microbiological (e.g., salmonella), chemical (e.g., pesticides),
physical (e.g., glass), and allergenic (e.g., nuts) substances.
While European legislation mandates minimum standards concerning HACCP
and GMP, it does not prescribe the specific implementation methods within the
industry. As a result, numerous organizations have devised their own quality
assurance standards, while others depend on both Auditing involves evaluating
a food business's adherence to regulations and internal policies. This process
entails reviewing documentation and conducting checks and interviews to
ensure compliance with a specific standard. Audits are categorized as first,
second, or third-party audits.

1.2.
The Food Safety Modernization Act (FSMA) provides a major modification
in food safety regulations, highlighting the importance of prevention to
foodborne illnesses. FSMA was tailored to the US buts the principles and
practices it follows can suggest beneficial ideas for addressing food safety
challenges in Lebanon.
Preventive Method: FSMA points out the importance of preventive controls
from production to processing and distribution. Primary prevention measures in
Lebanon can stop the initiation of food safety problems before they happen,
instead of focusing on reactive measures after several food safety risks occur.
Lebanese food authorities can implement regulations related to FSMA and
adopt the Hazard Analysis and Critical Control Plans, pinpoint potential hazards
in the food production process and thereby include measures to prevent hazards.
Lebanon is full of corruptive leaders who are stealing or unqualified employees
that are not practicing their job ethically. A successful regulatory agency should
supervise food industry, by conducting surprise visits with consequences to
industries not following food industry regulations. Furthermore, after
implementing steps for preventive measures. It is crucial for Lebanese
authorities to develop training programs for food safety inspectors. To follow
precisely FSMA programs and ensure the best results Lebanese food authorities
can collaborate with international organizations such as World Health
Organization (WHO) and Agriculture Organization (FAO) to gain from their
technical expertise, training programs, and find ways to acquire funding
opportunities for innovative projects that can boost productivity and food safety
measures. The FSMA provides provisions for public education to consumers
and industry stakeholders' understanding of food safety practices. Similarly,
improving awareness about food safety hazards and expert practices in Lebanon
could help customers make more educated decisions and urge businesses to
prioritize food safety. Lebanese authorities, can collaborate with civil society
organizations and the media, may initiate public awareness campaigns about
food safety, sanitary standards, and the need of buying from trustworthy
vendors. Providing instructional materials and resources in several languages
and targeting vulnerable communities can maximize the reach and effect of
these activities. In the event of foodborne illness outbreaks or product recalls,
FSMA requires heightened traceability requirements as well as rapid response
processes. Establishing comprehensive traceability systems and response
procedures in Lebanon would aid in the rapid detection and containment of food
safety problems. Lebanese food authorities should collaborate with food
producers, distributors, and retailers to create traceability systems that allow
food products to be tracked and traced across the supply chain. Developing
standards for rapid communication and coordination during food safety
situations will ensure timely action and reduce public health risks.

2.
Step 1: Ingredients
Gather ingredients:
Tomato paste, onions, garlic, salt and pepper, pasta
sheets, meat sauce parmesan

Precooking :Meat Sauce, Part One

dice the garlic and mince onion,
cook the ground beef with olive oil

cook the tomato sauce seperately

from the ground beef
2.
 4. Assembling
Assemble the Lasagna - Begin by spreading a thin layer of
tomato sauce across the bottom
- Top the sauce with a layer of pasta heets.
- Top the noodles with a layer of beef sauce.
- Add some cheese and herbs on top.
cheese is on top.

5. preheat the oven

Preheat the oven to 375 degrees F / 200
degrees C.

6. place the assembled

lasagna at 375 F degreees for
40 minutes

7. Remove the lasagna from the oven and let it

cool

serving
Make sure the hot lasagna are in
appropriate containers that can
preserve heat, check that is
properly sealed to prevents leak

Transport the packaged

lasagna to resturants
serving site while
preserving the right
temperature
2
2.2 A critical control point: step that can be applied and is critical to remove a
food safety hazard or reduce it to an acceptable level that wont pose a risk to
consumers.
Step 1: cooking ground at the correct temperature to eliminate bacteria such as
E. coli, Salmonella, Campylobacter, or Listeria
The appropriate temperature to ensure safety, is to cook ground meat until it
reaches internal temperature of 160°F (71°C). This step is critical since
undercooked meat can offer serious health hazards. Food thermometer can be
used to check if ground meat reached the safe internal temperature.
Step 2: Cooling and storage:
Cooked lasagna must be cooled rapidly to prevent bacterial growth.
Lasagna should be cooled quickly, first from 140°F (60°C) to below 70°F
(21°C) in 2 hours, then from 70°F (21°C) to below 40°F (4°C) in another 4
hours.
Proper storage at temperatures below 40°F (4°C) is also required to prevent
bacterial growth until the lasagna is reheated for serve. Improper refrigeration
and storage can result in bacterial infection and foodborne disease.

2.3 Health hazards associated with undercooked meat and improper storage
are parasitic infections, cross contamination, foodborne illness, and antibiotic
resistance.
160°F (71°C) to make sure that all harmful bacteria are eliminated.
Bacteria can grow fast in the temperature range of 40°F to 140°F (4°C to
60°C), which is commonly referred to as the "danger zone" in food safety. This
temperature range promotes bacteria development, allowing them to reproduce
rapidly and potentially reach harmful levels in a short amount of time.

Foodborne diseases such as Salmonella, Escherichia coli (E. coli),

Campylobacter, and Listeria monocytogenes thrive at this temperature.
When food is left in the danger zone for an extended amount of time, the
number of bacteria might double every 20 minutes under ideal conditions.

3. 1 Here are some recommendations

1. Hazard Analysis and Critical Control Points: To maintain food safety, this
systematic program recognizes and eliminates biological, chemical, and
physical hazards through the production process. HACCP delivers a proactive
strategy to reduce food hazards rather on focusing on end products.
2. Good Manufacturing Process: Even if the organization already follow GMPs
guidelines, it is important to verify that these practices are regularly followed
and documented. GMPs address critical issues such as facility cleanliness,
equipment maintenance, worker hygiene, and recordkeeping. GMP compliance
is essential for creating safe and high-quality food items.
3. Food Safety Modernization Act (FSMA)
Companies that produce food for interstate commerce must follow FSMA
requirements. The FSMA operates by preventing foodborne illness rather than
responding to foodborne illness outbreaks. Preventive controls, supplier
verification, and record-keeping requirements are essential for the FSMA
program.
4. Supplier Quality Assurance Program: Implementing a strong supplier
quality assurance program guarantees that raw materials and ingredients
acquired from outside sources follow quality and safety recommendations.
This includes performing supplier audits, checking supplier certifications, and
employing procedures to evaluate supplier performance and ensure traceability.
5.Allergen Management Program: Salad Production implemented without
guidance, might lead to multiple allergy outbreaks. Salad production includes
multiple ingredients being prepared. To avoid allergen cross-contact,
implementing an allergen management program is crucial. This involves the
process of separating allergenic materials, applying efficient cleaning
techniques, offering allergen training to employees, and labelling products to
inform customers about allergen content.
6. Product Labelling and Compliance: To meet regulatory recommendations
it is crucial to provide accurate label for products, to help consumers choose
based on clear information. The label should include nutrition label, allergen
information, ingredient list, and expiration dates with FDA approval.
Quality Management System (QMS): A professional Quality Management
System can manage health hazard risk and works on improving product quality
and safety. The system includes documentation control, (CAPA), internal
audits, management reviews, and employee training programs.

3.2 What other systems you recommend them to implement and why?
Customer Feedback and Complaint Management System: Customer
satisfaction is key for business success, therefore responding to customer
feedback and complaints is critical for preserving customer happiness and
loyalty in interstate commerce. Customers satisfaction can increase loyal
customers and therefore lead to a boost of the 80 percent of revenues from 20
percent of loyal customers (Pareto rule). This technique allows industries to
understand client preferences, allergies, dislikes and identify areas for
improvement, and respond quickly to issues or complaints presented by
customer which will help business differentiate themselves in competitive
marketplaces.
Data Management and Security System:
With interstate reliability on digital data, it is critical to implement strong data
management and security systems. Data encryption, access controls, data
backup and recovery, and cybersecurity practices are actions to protect sensitive
information from cyber-attack, therefore protecting customers confidentiality
and consumer trust.

3.3 In order to expand to the northeast region systems that only focus on manual
labour and no scalability might not be beneficial:
.
Excessive Automation Systems: While automation can help to update
operations and increase productivity, implementing many automation systems
without careful consideration of workflow, scalability, and human oversight
might be inefficient rather than beneficial. Businesses engaged in interstate
trade may prefer balanced automation solutions that complement humans rather
than replace them.
Manual systems:
Serving grocery store in different locations throughout the northeast region will
require strong supply chain management capabilities. Manual methods may fail
to properly handle inventory, logistics, and distribution over a wider geographic
area.

Manual Quality and Control System:

Manual quality control techniques may result in human errors and
inconsistencies in product quality. Human inspectors may have different
standards, that increase inconsistencies of salads provided to grocery retailers.
Humans are prone to error they might miss defects or contamination issues. In
the event of a food safety concern or product recall, it would be difficult to
identify the source of the problem and implement corrective actions
immediately.
Manual systems are still beneficial, but they should be supported with
automated technology to improve efficiency and accuracy. This hybrid
approach would better rank the company to satisfy the grocery store chain's
quality criteria while increasing manufacturing efficiency.

4.1
Adopt International Quality Standards: Quality standards know as, ISO
22000 or the British Retail Consortium's (BRC) Global Standard for Food
Safety, when followed shows the company's dedication to delivering safe and
high-quality products, which is critical for entering foreign markets and
building customer trust.
Invest in Quality Control:
quality control methods at all stages of the manufacturing process
1. raw material sourcing
2. packaging
3. distribution.
4. frequent inspections, testing for pathogens and pollutants.
5. monitoring temperature and storage conditions,
6. shelf-life studies to ensure product freshness and safety.

Training Employees.
Arrange training to staff in the following departments.
 food handling
 processing
 quality control.
 Prepare presentations and educational sessions about the importance of
food safety and quality standards, and the consequences of mishandling
any step.
 Explain how every department in food safety is integrated with another
and a simple mistake as not checking the temperature can lead to
outbreaks and contamination. Regular training sessions will help
guarantee that quality assurance processes are followed.

Establish Traceability Systems: Set up a reliable traceability system that

allows the organization to track and trace each batch of frozen chicken carcasses
throughout the supply chain. In case of a food safety concern while following
accurate records and documentation of suppliers, production methods, and
distribution pathways, a quick corrective action can be implemented.

Continuous Improvement: There is always room for improvement, set up

weekly meetings to check the quality assurance program's efficacy using
internal audits.
 Check customer feedback and previous reports.
 Recognize areas for improvement and take corrective actions to boost
product quality, efficiency, and compliance with regulations.
4.2
To comply with both
Hazard and Critical Control Points (HACCP) is required mandatory in
the United States and the European Union to ensure food safety. The
company should manufacture and implement a HACCP plan that
specifies the risks associated with processing frozen chicken carcasse
such as:
 microbiological contamination
 chemical hazards
 physical hazards.

ISO 22000: international standard for food safety management systems that
specifies standards for enterprises along the food chain. (not mandatory)
ISO22000 certification sets the company apart from other companies in addition
it is globally recognized and shows dedication to legal standards and customers
expectations
Good Manufacturing Practice (GMP):

GMP standards set the minimal requirements for manufacturing, processing,

packing, and storing food products to assure their safety and quality, critical for
meeting regulatory obligations in both the United States and Europe.
Allergen Program: An allergen management program to prevent cross-
contamination and supervise clear and accurate labelling of allergenic
ingredients.
Third-party audits and certifications:

Certifications like SQF (Safe Quality Food), BRC (British Retail Consortium),
and IFS (overseas Featured Standards) are globally recognized and may be
required by clients, particularly in overseas markets.

4.4 Total quality management

TQM is a procedure that works on continuously boosting quality in all aspects
of the organization. The key point of TQM includes the following:
customer focus, process improvement, staff empowerment, and data-driven
decision-making.

Supplier Quality Management:

A supplier quality control program is significant to assure the quality and safety
of raw materials used in chicken carcass production.
The company should monitor its suppliers using standards such as quality
standards, regulatory compliance, and a track record of performance and not
accepting any product below the minimum requirements.
1. supplier audits,
2. quality agreements,
3. performance indicators i
identify and resolve potential supply chain issues.

Continuous process improvement (CPI):

Lean Six Sigma and other CPI approaches can discover and eliminate waste,
reduce variability, and increase manufacturing process efficiency.
Using CPI principles, the company can streamline operations, improve product
uniformity, and lower costs while maintaining or improving product quality.

The Environmental Management System (EMS)

Implementing an EMS, such as ISO 14001, can assist the company reduce its
environmental footprint and comply with environmental standards.
An EMS's key components include identifying environmental elements and
impacts, establishing improvement objectives and targets, and monitoring and
measuring performance.