AIB Q1 2018 Magalog

10 Key People to
Add to Your Food
Defense Team
The team leader
will be ultimately
responsible for
managing the
food defense
plan. If you are
required to comply
with regulatory
requirements this
person may require
special training.
Even if you are not
required to comply
with regulatory
requirements, it’s
still a best practice
to get additional
training for this
individual as
they will lead this
program.
Maintenance
Manager
No one knows the
equipment and maintenance
requirements better than the
maintenance manager. They
can help identify potential
vulnerabilities related to
equipment that might
otherwise be overlooked.
This person is responsible for
managing contractors that
work inside the facility, so
their input about contractor
policies and vulnerabilities is
important.
The facility manager is beneficial,
because their involvement
will display the importance of
this program to the rest of the
employees. They can provide
financial and operational support to
implement control measures, such
as adding or changing equipment
to reduce identified vulnerabilities.
Additionally the facility manager
can add processes or procedures to
reduce identified vulnerabilities.
Team
Leader
Food Defense Team, AIB International - 2
One of the most important decisions related to your food defense program is who
you’ll include on your Food Defense Team. Personnel representing different departments
should be included because the team will work together to review policies and complete
a vulnerability assessment to prevent intentional adulteration and protect employees,
assets, and brand. A team comprised of different departments within an operation
ensures that your assessment considers all areas and procedures inside the facility. Take
each of these key positions into account when building your team.
Facility
Manager
IT Manager
Technology is key to running an
efficient operation. Automation
software is used to reject finished
product that contains metal; servers
house production documents to
manage raw material traceability;
websites, emails, and databases
hold secure information. Protecting
these programs and equipment
is as important as preventing
intentional adulteration. The IT
manager is key in identifying
potential vulnerabilities related to
these systems and programs.
The human resource
department already conducts
one of the most important
functions related to the food
defense program – employee
background checks. The HR
manager will act as the primary
enforcer for all company policy
and procedure issues as well
as disciplinary actions. This
team member can help identify
potential disgruntled employees
and notify the team of potential
issues. They are also key
in reviewing policies and
coordinating new hire training.
Human
Resources
Manager
Food Defense
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Trusted senior frontline
employees can identify
employee habits that could lead
to potential vulnerabilities. For
example, if third shift employees
turn off the back door alarm
to make it easier to go to the
smoking area even though
the policy says all doors must
remain locked and alarmed
at all times, a trusted line staff
worker could help you identify
the vulnerability so it can be
mitigated.
The production manager
can also communicate
the importance of the
food defense program to
employees. Their input
is essential to identify
vulnerabilities and establish
reasonable controls. They
will help ensure the food
defense plan is followed by
all employees and educate all
production team members.
Production
Manager
Senior Line
Staff
Quality
Manager
Security
Manager
Since the security
manager is
responsible for
managing facility
protection. They can
help review policies
and procedures
related to parking,
entrances, and
weapons policies.
Additionally, they
can include the
team in trending
information on
security violations
and other issues.
The quality manager
is usually required
to conduct or
monitor all tests on
ingredients, finished
products, monitor
equipment, and
the environment.
Additionally, they
investigate customer
complaints. As a
team member, they
can ensure all test
results and customer
complaints that
reflect potential
intentional
adulteration
activities are
communicated and
explored by the food
defense team.
Legal
Advisor
Legal counsel will
advise if process
or procedural
changes are within
legal limitations.
For example, if
the food defense
team is considering
searching all bags
brought into the
facility the legal
adviser will let you
know if it’s a legal
policy.
Training is key. FDA-registered companies must comply
with the Food Safety Modernization Act requirement to
have a qualified individual responsible for developing or
overseeing the vulnerability assessment and any individual
that has a responsibility for the food defense plan must be
qualified to fulfill that role.
The mechanical steps that transform flour and other ingredients
into baked products, produce a dough that should go easily
through the different stages
of bread manufacturing.
However, every dough can only
take so much physical work
before quality declines.
Symptoms of over stressed
dough include:
• Rough or sandy crust
• Irregular shapes with poor
pan flow
• Wrinkled crown
• White spots
To solve these issues, first
review the water addition to
ensure full absorption, then review all steps where work is
applied to mix or shape the dough. Adjust the mixing time
after cleanup and make final adjustments to the divider,
rounder, and sheeting rollers to help improve finished dough
characteristics. If there is excess moisture in the proofer, you
may notice white spots along with wrinkles and a rubbery crust.
If these defects are plaguing your product, we recommend
reducing the relative humidity in the proofer.
When producing breads and rolls, many different ingredients
impact the finished product. Let’s look at some key players
namely: yeast, salt, and sugar.
Yeast: Yeast’s main function in breads and rolls is leavening,
which is the process of producing gas (carbon dioxide or
CO 2
). This gas, along with water vapor and entrapped air, then
expands during proofing and baking causing the dough to
increase in volume. The leavening of bread and rolls produces
a product that is lighter and more palatable to eat. It has a big
impact on the quality of the finished product. Leavening is also
responsible for the volume of the finished product.
Besides its leavening function, yeast enzyme activity is largely
responsible for the conditioning of the dough, which is
sometimes referred to as “mellowing” or “maturing” the dough
or sponge. Yeast converts sugars (starch) into alcohols and
acids during fermentation. The alcohols and acids have a
“mellowing” effect on the dough/sponge giving us biochemical
development or maturing of the dough/sponge. Acids lower
the pH and have a softening
effect on the dough, while
the alcohols also have a
maturing effect on the gluten
protein. These acids and
alcohols makes the gluten
more developed resulting in
thin, gas-retaining cell walls.
This biochemical development
develops the dough so it
retains its extensibility and
elasticity to expand without
rupturing during makeup
stress and proofing. This helps
with dough consistency and
results in better characteristics
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showing symptoms
of stress?
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that impact the symmetry and grain of the finished product.
The distinctive fermentation flavor and aroma that is unique
to yeast-leavened breads
and rolls is a secondary
product of the fermentation
process. Fermentation gives
us flavor from created organic
compounds produced like
acetic acid, lactic acid,
aldehydes, and other flavor
precursors.
Salt: One of the main
functions of salt in bread and
roll production is to bring
out the flavors of the other
ingredients. Salt is typically
used at levels of 1.50% to
2.25% (Baker’s Percent or flour basis). Breads made with salt
levels below 1.50% will taste bland while breads made with
more than 2.25% will taste salty. The flavor of salt is usually not
desirable, but salt has the property of enhancing other flavors.
It also has a toughening or tightening effect upon the gluten
during mixing and improves the gas retention and hence the
texture and grain of the finished product. In addition, salt helps
to regulate or control the action of yeast and thereby the rate
of fermentation. This is due to the osmotic pressure.
Sugar: In yeast-raised products like bread and rolls, sugar
provides food for the yeast and gives a sweet taste to the
finished product. In sponge and dough process, for example,
3-3.5% of fermentable solids are required for yeast activity.
These fermentable solids may be from the sugar, but can
also be derived from the conversion of the damaged starch
in the flour to sugar. Sugar is not an essential ingredient in
bread production. Sugars which remain after fermentation are
referred to as residual sugars and these residual sugars have
many secondary functions related to them. Residual sugars
will contribute a sweet flavor although breads typically are not
noted as being sweet baked products. These residual sugars
contribute to crust color due to their reactions during baking.
High levels of sugar will result in faster formation
of crust color and will give you a darker crust color. This
browning reaction will also contribute to the taste of the
finished bread. Sugar, being very hygroscopic (ability to attract
and retain moisture), will also improve the shelf-life of the
finished product.
Understanding ingredient
functionality of breads and
rolls is important for bakers.
Knowing how ingredients such
as yeast, salt, or sugar impact
the final product helps the
baker to troubleshoot problems
or develop breads and rolls to
desired product characteristics.
Is Your Dough Showing Signs of Stress, AIB International - 7