Quality Control Pratik
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- Pages: 36
• Product development is the lifeblood of the food industry. • Innovative products. • Improving existing products. • Keeps industry alive.
PARAMETERS • • • • • •
RAW MATERIALS PROCESS ADDITIVES FORTIFICATION TEXTURE PACKAGING
Food Product Innovation: Food Packaging innovations new packaging materials . new packaging design new packaging -product versatility. new packaging -ease of use .
Food Product innovations new ethnic concepts. Organic foods and health foods . Fortification . Prepared meals. new manufacturing techniques .
Food Product Innovation: Food Packaging innovations new packaging materials new packaging design new packaging -product versatility. new packaging -ease of use
Food Product innovations new ethnic concepts. Organic foods and health foods Fortification Prepared meals new manufacturing techniques
Yoghurt Product innovation
Principle 1:SEGMENTATION Principle 2:TAKEN OUT
Plain-cut versus Crinkle-Cut Potato Chips
Principle 17, ANOTHER DIMENSION
SOME INNOVATIVE PRINCIPLES • •
Principle 5: Merging Principle 6: Universality
• • • • • • • • •
Principle 10: Preliminary action Principle 9: Preliminary anti-action Principle 11: Beforehand Cushioning Principle 25: Self-service Principle 31: Porous materials Principle 32: Color changes Principle 35: Parameter changes Principle 36: Phase Transition Principle 39: Strong Oxidants
•
Principle 40: Composite Materials
DEFINITIONS
Quality control – controllable factor that have positive or negative effect on finished product
Quality
CONTROL – good raw material to good finished product.
AIM 1)to achieve as good & standard quality in product.
– attributes of food which make it agreeable to the person who eats it.
2)compatible with market & also for consumer.
PRINCIPLES 1)raw material control 2)process control 3)finished product inspection
STEPS IN QUALITY CONTROL 1)raw material selection 2)processing methods 3)packaging 4)methods of storage distribution
Positive factors 2) 3) 4) 5)
1) color flavour taste texture nutritive value
Negative factors free from microbes & undesirable substance
Major functions
Compliance with specifications Legal requirements, industry standards, internal company standards, shelf-life tests, customers' specifications
.
Test procedures Testing of raw materials, finished products, and in-process tests.
Sampling schedules Utilize a suitable sampling schedule to maximize the probability of detection while minimizing workload.
Records and reporting Maintain all QA records
so that customer complaints and legal problems can be dealt with.
Trouble shooting Solve various problems caused by poor quality raw materials, erratic supplies and malfunctioning process equipment; and investigate reasons for poor quality product to avoid repetition.
Special problems Customer complaints,
production problems, personnel training, short courses
Customer specification for each Quality factor
Action when needed
Testing methods
Reporting control charts
Control stations
QUALITY CONTROL CYCLE
Raw material control 1) formulate sampling & test for finished product 2)test must be fast, simple, reliable, authorized for raw materials 3)test can be chemical, physical, bacteriological or organoleptic 4)test should be done at frequent intervals 5) Vendor’s appeal 6) Specifications should be updated and made strict 7)Shipment of raw material in unsatisfactory conditions should be rejected
0
IN PROCESS CONTROL
High quality raw material – high quality finished product
Well balanced formula of mixing and process procedure
New product and new production technique
Monitor process conditions
Optimum process conditions
All reports should be reviewed
Customer specification
Shelf Life
Raw material
Storage Conditions
Blending, Sorting, Grading
Packaging
Processing
PRODUCTION CONTROL
FINISHED PRODUCT CONTROL
Organoleptic test by taste panel
Compositional analysis
Bacteriological test- sanitation and public health
Special test- off taste,lack of color development, high pH.
Methodology should be updated
HERBS AND SPICES PRODUCTS
QUALITY ASSURANCE AND CONTROL PROCEDURE
1)cultivation practices,harvesting & primary processing by growers 2)processing methods in production unit 3) packaging& storage after processing
QUALITY ASSURANCE IN FRESH MATERIAL
Appearance & presence of contaminants Odour & flavour Moisture content
PROCESS CONTROL washing
drying
(chlorinated water to remove soil and microbes) Solar drying Fan driven
storage
grinding
(remove dust and dirt)
Quick drying
to avoid moisture
Hammer mill, disc mill
Packaging& storage of finished product
Paper or air tight container
FINISHED PRODUCT CONTROL
“Good quality product cannot be obtained form poor raw material”
Kept under proper storage conditions
Proper quality control test
So maintain quality till product reaches consumer
To maintain quality
DEFINITION
Management philosophy.
Continuous improvement in performance of the process products and services.
Understanding role of customer involvement of the employees at all levels of an organization.
1- Customer focus. 2- Leadership. 3- Involvement of people. 4- Process approach. 5- System approach to management. 6- Continual improvement. 7- Factual approach to decision. 8- Mutually-beneficial supplier relationship
ISO 9000
Quality management guidance Identify quality system elements ISO 9000 Registration a documented quality system fully deployed and consistently followed
A company should Document what it does, review the process & improve it.
ASSURING QUALITY THROUGH TQM
Quality management frame work Quality laboratory processes Quality control Quality assessment Quality improvement & Quality planning
TQM PROCESS The components are
assembled in a loop or cycle continuous improvement of quality centered on quality goals or standards
TQM MODEL
One leg of the triangle is teamwork, The second is management commitment The third leg is quality techniques . The triangle emphasizes the importance of all phases since the legs are
TQM IN PRODUCT DESIGN The concept stage The formulation stage The scale-up stage
ERROR REDUCTION BY TQM Consistency of ingredients Consistency in formulation Consistency in manufacturing
CONCLUSION
Continuous improvement integrates scientific data teamwork communications with customer satisfaction. And customers, are where we will get our growth and our security for the future."
PARAMETERS • • • • • •
RAW MATERIALS PROCESS ADDITIVES FORTIFICATION TEXTURE PACKAGING
Food Product Innovation: Food Packaging innovations new packaging materials . new packaging design new packaging -product versatility. new packaging -ease of use .
Food Product innovations new ethnic concepts. Organic foods and health foods . Fortification . Prepared meals. new manufacturing techniques .
Food Product Innovation: Food Packaging innovations new packaging materials new packaging design new packaging -product versatility. new packaging -ease of use
Food Product innovations new ethnic concepts. Organic foods and health foods Fortification Prepared meals new manufacturing techniques
Yoghurt Product innovation
Principle 1:SEGMENTATION Principle 2:TAKEN OUT
Plain-cut versus Crinkle-Cut Potato Chips
Principle 17, ANOTHER DIMENSION
SOME INNOVATIVE PRINCIPLES • •
Principle 5: Merging Principle 6: Universality
• • • • • • • • •
Principle 10: Preliminary action Principle 9: Preliminary anti-action Principle 11: Beforehand Cushioning Principle 25: Self-service Principle 31: Porous materials Principle 32: Color changes Principle 35: Parameter changes Principle 36: Phase Transition Principle 39: Strong Oxidants
•
Principle 40: Composite Materials
DEFINITIONS
Quality control – controllable factor that have positive or negative effect on finished product
Quality
CONTROL – good raw material to good finished product.
AIM 1)to achieve as good & standard quality in product.
– attributes of food which make it agreeable to the person who eats it.
2)compatible with market & also for consumer.
PRINCIPLES 1)raw material control 2)process control 3)finished product inspection
STEPS IN QUALITY CONTROL 1)raw material selection 2)processing methods 3)packaging 4)methods of storage distribution
Positive factors 2) 3) 4) 5)
1) color flavour taste texture nutritive value
Negative factors free from microbes & undesirable substance
Major functions
Compliance with specifications Legal requirements, industry standards, internal company standards, shelf-life tests, customers' specifications
.
Test procedures Testing of raw materials, finished products, and in-process tests.
Sampling schedules Utilize a suitable sampling schedule to maximize the probability of detection while minimizing workload.
Records and reporting Maintain all QA records
so that customer complaints and legal problems can be dealt with.
Trouble shooting Solve various problems caused by poor quality raw materials, erratic supplies and malfunctioning process equipment; and investigate reasons for poor quality product to avoid repetition.
Special problems Customer complaints,
production problems, personnel training, short courses
Customer specification for each Quality factor
Action when needed
Testing methods
Reporting control charts
Control stations
QUALITY CONTROL CYCLE
Raw material control 1) formulate sampling & test for finished product 2)test must be fast, simple, reliable, authorized for raw materials 3)test can be chemical, physical, bacteriological or organoleptic 4)test should be done at frequent intervals 5) Vendor’s appeal 6) Specifications should be updated and made strict 7)Shipment of raw material in unsatisfactory conditions should be rejected
0
IN PROCESS CONTROL
High quality raw material – high quality finished product
Well balanced formula of mixing and process procedure
New product and new production technique
Monitor process conditions
Optimum process conditions
All reports should be reviewed
Customer specification
Shelf Life
Raw material
Storage Conditions
Blending, Sorting, Grading
Packaging
Processing
PRODUCTION CONTROL
FINISHED PRODUCT CONTROL
Organoleptic test by taste panel
Compositional analysis
Bacteriological test- sanitation and public health
Special test- off taste,lack of color development, high pH.
Methodology should be updated
HERBS AND SPICES PRODUCTS
QUALITY ASSURANCE AND CONTROL PROCEDURE
1)cultivation practices,harvesting & primary processing by growers 2)processing methods in production unit 3) packaging& storage after processing
QUALITY ASSURANCE IN FRESH MATERIAL
Appearance & presence of contaminants Odour & flavour Moisture content
PROCESS CONTROL washing
drying
(chlorinated water to remove soil and microbes) Solar drying Fan driven
storage
grinding
(remove dust and dirt)
Quick drying
to avoid moisture
Hammer mill, disc mill
Packaging& storage of finished product
Paper or air tight container
FINISHED PRODUCT CONTROL
“Good quality product cannot be obtained form poor raw material”
Kept under proper storage conditions
Proper quality control test
So maintain quality till product reaches consumer
To maintain quality
DEFINITION
Management philosophy.
Continuous improvement in performance of the process products and services.
Understanding role of customer involvement of the employees at all levels of an organization.
1- Customer focus. 2- Leadership. 3- Involvement of people. 4- Process approach. 5- System approach to management. 6- Continual improvement. 7- Factual approach to decision. 8- Mutually-beneficial supplier relationship
ISO 9000
Quality management guidance Identify quality system elements ISO 9000 Registration a documented quality system fully deployed and consistently followed
A company should Document what it does, review the process & improve it.
ASSURING QUALITY THROUGH TQM
Quality management frame work Quality laboratory processes Quality control Quality assessment Quality improvement & Quality planning
TQM PROCESS The components are
assembled in a loop or cycle continuous improvement of quality centered on quality goals or standards
TQM MODEL
One leg of the triangle is teamwork, The second is management commitment The third leg is quality techniques . The triangle emphasizes the importance of all phases since the legs are
TQM IN PRODUCT DESIGN The concept stage The formulation stage The scale-up stage
ERROR REDUCTION BY TQM Consistency of ingredients Consistency in formulation Consistency in manufacturing
CONCLUSION
Continuous improvement integrates scientific data teamwork communications with customer satisfaction. And customers, are where we will get our growth and our security for the future."
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