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Beyond vulnerability assessments

How to verify a food defense plan

The USA FSMA Intentional Adulteration Rule deadline is fast approaching, with implementation required by 26th July.  Food defense plans are our most requested service this month, and not just for companies in the United States.  Businesses that export to the US are also affected.

The Intentional Adulteration (IA) rule

The Intentional Adulteration (IA) rule requires food businesses to identify vulnerable parts of their food manufacturing processes, implement strategies to reduce the vulnerabilities and monitor and verify that those strategies are working.  As part of the verification processes, some experts are recommending that food businesses challenge their food defense system on a regular basis.  Food safety management system standards, including SQF Edition 8, also require that manufacturing facilities challenge their food defense system.  What exactly does it mean to ‘challenge’ a food defense system, and how is that different to monitoring and verification of the system?

Monitoring vs verification vs challenge testing

Monitoring, verification and challenge testing are different, but the terminology can be confusing when used with food defense plans.  Some commentators and trainers are using the three words almost interchangeably; however, the three words actually refer to different elements of a food defense plan.

Monitoring means, at its most basic level, to check that procedures are being followed and that processes are happening as they should.  The checking process must be documented.  So, the act of monitoring is documenting in real time the actions taken to follow a given procedure or the measured outputs of a specific process.

Within a food safety plan, an example of monitoring would be checking the internal temperature of three pies from each batch after a cooling step and recording the temperature on a form.  Within a food defense system, a mitigation strategy might be the implementation of a procedure to lock all external doors, or to leave all external doors locked.  For this procedure, the monitoring activity could be a once-per-shift process of checking and recording the lock/unlock status of each door.

Verification is the process of making sure that monitoring has been done properly.  When cooling pies, for example, verification could include a once-per-shift check by a supervisor or manager that the cooled pie temperatures are being recorded AND that appropriate action has been taken if the temperature has exceeded critical limits.  Verification also includes internal audits; the internal auditor checks that the managers have been signing off the monitoring records, that the records are complete and available for all shifts and that corrective actions have been properly recorded.

In our food defense example, verification could include a check of the door lock monitoring records by a manager or supervisor.  The manager would review the records to see that they were completed on time, at the correct frequency and that any deviations, such as a broken lock, have been identified and actioned correctly.  Verification of door lock status could also be included in a weekly plant walk-through by a manager.  Internal audits would check that all these activities were being done and recorded properly.

Challenge testing is real-world scenario testing of a system’s efficacy.  A challenge test aims to validate whether procedures are effective when implemented as expected, as well as highlighting any failures in implementation.  A challenge test is different to a verification process because it would usually test the implementation and effectiveness of many food defense mitigation strategies rather than focussing on one element such as door locks.

What is the weakest link in your food defense plan?

 

How to conduct a food defense challenge

  1. Decide on a challenge action. For example, a common food defense challenge test is a penetration test, in which an unauthorised person attempts to gain access to a sensitive area.
  2. Create a food defense challenge report. In the report document exactly what you plan to do in the challenge test.  Include what, when, how, who and next steps.

For example: A person unknown to staff (Ms Jane Doe, of Acme Services) will attempt to get from the main reception area into ingredient weighing area A.  She will be wearing a business suit covered by a lab coat.  Once there, she will remain for up to twenty minutes unless challenged by an employee.  She will then leave.

If the intruder is challenged, she will claim to be a new food safety consultant/pest control account manager/new human resources manager and attempt to remain in the area.

  1. Include written contingency plans in case of escalation, for example, what will be done if police are called.
  2. Get approval for the plan from senior management.
  3. In the report record the following:
    • Name of Senior manager who has signed off on this plan.
    • Names of people who have been informed of the challenge test
    • Names of people who will be working in the affected areas at the time of the challenge, have they been trained in food defense?
    • A description of what staff are supposed to do in this scenario; what procedures should be followed.
  4. Define and document the criteria for failure and success; what will happen if the food defense procedures are working 100% correctly; what will happen if the food defense procedures are working only partially; and finally, how might the scenario progress if there is a complete fail of procedures and systems?

For example, if the ‘intruder’ is able to remain in the ingredient weighing area for 20 minutes without being challenged by an employee this could be considered a complete fail of the food defense system.  If the intruder is challenged but can convince the employee to allow them to remain in the area unattended, this could be considered a partial fail; if the employee chooses to remain with the intruder to ‘keep an eye on them’ this could be considered a better outcome than leaving the intruder unattended.

  1. Run the challenge. Have a trusted staff member observe from a discreet distance.
  2. Describe in the report what happened.
  3. Convene a meeting of the food defense team and analyse the results of the challenge test.
  4. Perform root cause analyses and raise corrective action/s for any failures in the system.
  5. Close out corrective action/s
  6. Take action to prevent a scenario like this from reoccurring, based on the root cause analyses.

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Five things every food safety professional should know about food fraud

1. Food fraud is in the spotlight

Food fraud has been around for thousands of years but has recently become more prominent in the food safety and food certification industry, following the European horse meat scandal of 2013.  Although no food safety problems arose during that incident, it was realised that similar incidences could have serious impacts on food safety.  For that reason, food fraud and food authenticity have been introduced into most major food safety management system standards within the previous two years.

2. New terminology is being developed

Definitions related to food fraud and food integrity have been developed and refined and there is now consensus on the four key terms below, although the term food security still causes confusion at times.

food fraud,defense,safety,security

  • Food safety relates to issues of unintentional contamination, with the aim of reducing exposure to naturally occurring hazards, errors and failures in food systems.
  • Food fraud was defined by  Spink and Moyer (2011) as “a collective term used to encompass the deliberate and intentional substitution, addition, tampering, or misrepresentation of food, food ingredients, or food packaging; or false or misleading statements made about a product for economic gain.”  More recently that definition has been updated to capture all types of food crime: Food fraud is deception, using food, for economic gain (Food Fraud Initiative, Michigan State University).  Within food fraud there are types of fraud that involve tampering with the food by adulterating or diluting the food.  This type of fraud is sometimes called ‘economically motivated adulteration’ (EMA).  Other types of fraud that do not involve adulteration are also deemed to be ‘food fraud’.  These include black market and grey market sales, theft, illegal importing, avoidance of tax and counterfeiting.
  • Food defence is a term that has come to be defined as the effort to prevent acts of adulteration that are intended to cause harm to a food business or to consumers, such as acts of terrorism or attempted extortion.
  • Food security is unrelated to food fraud but is instead an issue of food supply and food access for populations who are under threat from food shortages.

Other terms to know:

  • Vulnerability assessments are assessments of vulnerability to food fraud, either at the raw material, product or facility level.  Within the USA the term vulnerability assessment often refers to a food facility’s vulnerability to malicious tampering of product on its site, either by its own employees or external forces.  Within Europe, and particularly as described in the most recent issue of the British Retail Consortium’s (BRC) food safety standard, a vulnerability assessment is an assessment of a food material’s susceptibility to food fraud.  Learn more about vulnerability assessments.
  • Horizon scanning is the act of looking for and analysing threats and opportunities that will emerge in the medium to long term.  Within the food industry, horizon scanning means the act of collecting information about current trends and predicted incidences that could increase the likelihood of food fraud for a particular food material.  For example, climate change is likely to reduce coffee production which could drive up prices and increase fraudulent activity in that sector.
Coffee,authentic,fraud,horizon scanning
Future coffee harvests are likely to be affected by climate change

 

3. Food safety standards have become more rigorous

Food fraud prevention and mitigation measures are being introduced into all major food safety management systems.  The Global Food Safety Initiative (GFSI), a group of food companies whose mission is to harmonize, strengthen, and improve food safety management systems around the globe, sets guidance for food safety standards.  Well known GFSI standards include BRC, FSSC 22000 and SQF.  Between 2015 and 2017, all GFSI food safety standards were updated to include requirements for food companies to perform a food fraud vulnerability assessment and have a food fraud mitigation plan in place.   Click here for the GFSI Food Fraud Position Paper.

The new requirements for vulnerability assessments and mitigation plans require more resources for most food businesses, particularly those with large numbers of raw materials and suppliers.

4. There are new regulatory requirements for food businesses

The Food Safety Modernization Act (FSMA) in the USA has been implemented for most food businesses in the previous few years.  Within the FSMA rules, food businesses are required to address hazards from adulterants introduced for the purposes of economic gain.  These must be included in food safety hazard analyses and if hazards are found, preventive controls must be implemented.  This means that economically motivated adulteration (EMA), a subset of food fraud, must be addressed under the new FSMA rules.

The Food Safety Modernization Act (FSMA) also includes specific requirements for ‘food defense’ which are aimed at preventing malicious adulteration and tampering as well as fraudulent adulteration.  This is known as the Intentional Adulteration (IA) rule.  The IA rule is being progressively implemented in the USA.  FSMA rules for IA will also be enforced internationally for all food facilities that manufacture food for export to America.  Click here for US FDA’s food defense guidance

food defense,vulnerability assessment,FSMA,
All American food companies will be required to have a food defense plan

 

5.  Detection of food fraud remains a challenge, despite new lab techniques

Our ability to detect food fraud has improved over the last few years, but challenges remain.  There are many technologies available, from traditional ‘wet’ chemical tests to spectroscopy and chromatography to modern forensic DNA methods.   Protein isoelectrofocusing (a type of electrophoresis) is a conventional test that provides information about the source of various milk proteins in a cheese and can be used to detect cows milk in “buffalo milk” mozzarella, for example.  PCR (polymerase chain reaction) techniques, in which a cow milk-specific gene is amplified and detected are being developed for cheese testing and they are claimed to be more specific.

Coffee variety testing has traditionally been done using Fourier transform infrared spectroscopy, a method that exploits the different amounts of chlorogenic acid and caffeine in robusta and arabica varieties.  However, a new method that exploits the different mitochondrial genetic markers in the two varieties will soon be able to achieve the same results quickly and easily in the field with ‘lab on a chip’ technology.

Researchers looking for fraudulent aloe vera can exploit its distinctive NMR (nuclear magnetic resonance) profile, due to the position of acetate groups within a key polysaccharide in the plant.  The NMR profile represents a ‘fingerprint’ for aloe vera.

Another type of ‘fingerprinting’ is based on the spectra created by different ratios of stable isotopes.  For example, it is possible to tell the difference between corn-fed and wheat-fed chicken, using stable isotope ratio mass spectrometry by comparison with databases of reference samples.  This method has also been used to check provenance claims for meat and wine products.

Authentic beef mince
What meat is that?

 

Despite the surge in technology surrounding food fraud detection, it remains difficult to detect fraudulent adulteration unless you know what you are looking for.  As an example, DNA testing can be used to determine if beef mince has been made from a cow but can’t tell me whether it has been adulterated with undeclared beef offal.  Olive oil that is suspected of having been adulterated with other edible oil can easily be tested for such adulteration in a lab test, but verifying its country of origin is more difficult.  Adulteration of ‘arabica’ coffee with the cheaper robusta variety can be detected with a simple test but that same test will not disclose whether ground coffee has been adulterated with cheaper fillers such as corn, soybean or wheat, a practice which is common in some markets.  There are new ‘fingerprinting’ techniques that are designed to ‘flag’ any sample that is not authentic, no matter what the adulterant, however they can only be used if there is already an extensive database of authentic samples with which to compare the suspect sample.  Australian honey brand owners who were caught with supposedly inauthentic honey in an NMR-based fingerprint test claimed that the database used in the testing, which was done in Germany, was not suitable for testing Australian honeys.  Read more about the Australian honey scandal.

We have a lot of tools in our arsenal to answer questions about fraudulent food but those tools are only useful if we ask the right questions.

Need to learn more?  Want practical advice from expert food scientists? Click here for a free introductory consultation.

 

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September food fraud update; trade wars, fruit scares and spuds

The ‘trade war’ between the USA and China is really hotting up, with China having imposed import tariffs of up to 25% on US lobsters and other food products in the previous 2 months.  The presence of tariffs greatly increases the risk of fraudulent cross-border activities; Food Fraud Advisors predicts that the new China tariffs will lead to significantly more food fraud within the Chinese-American trade sector as well as having a knock-on affect on food trade internationally.

There have already been allegations of fraud related to the tariff imposition in the North American lobster market.  Canadian lobsters can be imported to China without incurring the tariffs imposed on lobsters from the United States.  It has been alleged that lobsters grown in the USA are being shipped to Canada, re-labeled as Canadian lobsters then exported to China.  Canadian lobster growers fear damage to the ‘Canada’ brand from these activities.

The strawberry scandal in Australia has hit local consumers, retailers and growers hard.  It started with two consumers in the state of Queensland finding metal needles inside fresh strawberries.  The affected brand and its sister brand from the same grower were pulled from shelves.  Within days another needle-like object was found in strawberries from a different brand in a different state; the fruit source was completely different and the incident was labelled a ‘copycat crime’.  In Australia strawberries are typically sold to consumers in clear clam-shell containers with four air holes in the top surface.  The air holes are large enough to allow access to the fruit inside with a small sharp object like a needle while the strawberries are displayed on a supermarket (grocery store) shelf.  Public response has been confusion; why would anyone want to do such a thing?  Since then, other fruits, including apples and bananas have been similarly affected, again, in what appear to be completely independent occurrences.  The food safety sector in Australia is at a loss as to how to prevent this type of incident; fruit is by necessity displayed and accessible for consumers to touch prior to purchase, leaving it vulnerable to malicious adulteration.

Meanwhile, strawberry growers in Australia, who were already struggling to get good prices for their bumper harvest, have seen demand for their fruit plummet.  Media outlets have published reports about farmers who are dumping tonnes of unwanted fruit because the wholesale price has fallen below the cost of production.

Whole potatoes are generally thought to be at low risk of food fraud because of their relatively low value and because of their easily recognisable form.  However, like all fruit and vegetables, they are at risk of being misrepresented with respect to their geographic origin and their variety.  Growers groups have demanded that government authorities investigate allegations of potato fraud in Ireland, after a successful campaign to encourage consumption of locally-grown Queen potatoes.  It has been alleged that imported potatoes and potatoes of other varieties are being re-labelled as Irish Queen potatoes, providing an economic gain for the perpetrators of this fraud.