QUALITY CONTROL: FROZEN FOOD The ultimate method


of quality control? The British Frozen Food Federation’s (BFFF) Brian Young discusses the importance and implications of quality control in frozen food


Frozen food has been around since 3,000BC when the ancient Chinese started using ice cellars to preserve food through the cold winter months and beyond. The Romans also used to store provisions in compressed snow in insulated cellars. In principle therefore, frozen food has been with us for a long time.


20th century when Clarence Birdseye - fur trading in Labrador, Canada in 1917 - observed how local inhabitants preserved fresh fish and meat by letting it freeze rapidly in the cold Arctic temperatures. He also discovered fish left over from a previous expedition that had been preserved by the intense cold. The locals had discovered that freezing made it possible to preserve products at the very peak of quality, while at the same time locking in all their freshness and taste. Even before frozen food


T


manufacturing became mainstream, the benefits of using ice to preserve food had been observed, if not fully understood. We now know that bacteria does not multiply on frozen food - which makes it safer than any other form of food preservation.


SOLID TRACK RECORD Frozen food has a solid track record for product safety in the UK. Processors and manufacturers take the integrity of their products very seriously and along with stringent food safety practices in their factories, all frozen food


he modern frozen food industry, however, only dates back to the early


manufacturers must comply with the General Food Law regulation (EC) 178/2002 that requires traceability to be established at all stages of the food chain. This safeguards manufacturers from unwittingly buying low quality or contaminated food and ensures that should there be a safety issue with any one ingredient in the supply chain, it can be traced back to source. While freezing stops any


development, it does not kill bacteria which is why it is important for frozen food manufacturers to follow strict quality control practices as would any chilled, bottled or tinned food manufacturer.


UNDER SCRUTINY Good quality control practices start with intelligent sourcing. It is the manufacturer’s responsibility to select the safest and highest quality ingredients available and to ensure that their suppliers offer full traceability. Before they go into


production, raw materials should be scrutinised to make sure that they are of good, consistent quality with an appropriate shelf life. Most frozen food manufacturers will not accept deliveries of products if they are blemished, underweight or do not meet strict microbiological criteria. We have manufacturer members at the BFFF who have kitchen facilities in their delivery bays and they will often cook products before accepting the delivery to make sure that the ingredients will produce a quality end result. The storage of raw


ingredients is also important as it can lead to contamination or


deterioration. Temperature controlled areas in factories are used to ensure that all material is kept in peak condition until it is needed.


EMPLOYEE MATTERS The hygiene protocol for employees handling foodstuffs must also be stringent and the correct clothing and protective equipment along with changing and hand-washing facilites should be readily available. Standard attire includes freshly laundered overcoats, clean safety boots and well fitting hair and beard nets. Each piece of clothing must


only be worn inside the factory and must not be used in any other department – again to limit the chances of cross contamination or bacteria spreading.


SPLITTING RISK To further limit any chance of microbiological or bacterial contamination, factories are split into high risk and low risk areas. High risk areas contain foods that are particularly sensitive to microbiological contamination and readily


support microbial growth. These products should be stored at below 5ºC and cooked to above 70ºC to ensure they remain safe. Low risk areas in frozen food factories are where there is less risk to food safety due either to the storage temperature, subsequent processes carried out or the foods’ low susceptibility to microbial spoilage. There must be complete


physical separation of high and low risk areas in terms of products, processes and personnel. The incorporation of filtered air supplies, positive air pressure and appropriate personnel controls are required to maintain the integrity of high-risk areas as well as strict hygiene standards. Most manufacturers have


installed air control systems specifically for use in food factories that direct and filter the air so that even the tiniest particles cannot pass into the next section. Pairing this technology with the highest of hygiene standards for production areas and personnel goes a long way to protecting the integrity and safety of products.


The production of frozen ready meals, such as these cheeseburgers, has many safety issues, but the most important is often seen to be heating & cooling, as these, when done incorrectly, can cause bacteria growth


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