Regardless of the category, product safety and security are critical components of the consumer packaged goods industry. In food products, in particular, the proverbial clock ticks very loudly throughout the process, as manufacturers contend with production challenges and products with finite shelf lives, and brand owners relinquish some control as the products are produced and shipped.

So quality control throughout the production process must be closely monitored and process-oriented, according to Kristi Arend, quality assurance director, Golden County Foods Inc. (GCF), Plover, Wis. Arend kindly spent some time offering CM&P insight into the ever-growing expectations of quality control at manufacturing facilities and throughout the production cycle.

Q. How do you ensure quality control throughout the product life cycle, especially given that product control is out of your hands once delivered to a brand owner/another manufacturer?

A. We have a very in-depth quality program, and it starts at the very beginning of the process. Ordering ingredients from suppliers that adhere to the same quality programs that we follow, requesting Certificates of Analysis (COAs) on all incoming ingredients, weight control, taste. We do micro at each step in the manufacturing process to ensure that when the product leaves our dock that we have done everything to deliver a wholesome product to the end user.

Q. What specific QC issues are you looking for?

A. Quality is responsible for all incoming ingredients, monitoring our suppliers, pre-op inspections of the lines, weight control, monitoring the Critical Control Points (CCPs), testing finished product for both micro and product quality, as well as making sure all of our employees are following company Good Manufacturing Practices (GMPs).

Q. How has the increased incidence in food recalls affected how you handle production?

A. We have micro labs staffed with professionals at both facilities. Additionally, all product produced is placed on hold until all quality testing is completed. Perhaps more importantly, all GCF employees are engaged in an ongoing and thorough training program for food safety, food security, GMPs and HACCP review. Employee training is documented.

Q. Are brand owners demanding more from your company in QC given the heightened food safety concerns? How so?

A. Food safety and security are on every food manufacturer’s mind and should be — no company wants to be the headline of the nightly news for a recall of any kind. We have many programs in place to ensure all areas of our facilities and processing are monitored. In the past few years, we have added security cameras, locked down our facilities and added many programs to reduce the chance that a food safety issue would occur. GCF takes great pride in the fact that our quality programs would lead us to find and control such issues before the product ever leaves our facility.

Q. How can you ensure that the brand owner is handling your products appropriately up until the final delivery to its customer?

A. All of the items that GCF produces are frozen, which is a plus, as we have an extended shelf life. All of our packaging is designed to reflect this (Keep Frozen). Cooking instructions were developed to obtain the ideal finished product, along with a kill step if anything would occur out of our control. We have a USDA-approved HACCP Program that we follow daily. We pull product from each shift and each line to confirm this daily. Temperatures are taken on each out-going shipment; trailers are pre-cooled then sealed, and they are not opened until the final destination.       

Q. How do you monitor it with your customers?

A. Customer audits are done throughout the year. We have developed our own proprietary tracking and monitoring tools to assist us in making sure all areas of our quality programs are working and working well. Product formulation is strictly controlled to ensure every batch is the same day in and day out. Product is sampled for texture, flavor and appearance on an ongoing basis.   

Q. What is the most important QC issue when it comes to the contract manufacturing industry?

A. I would have to say that after 9/11 the quality assurance departments in all of food processing took on a bit of a different role in manufacturing. QA was always involved in areas of food safety, but now, as the resident experts, we are looked to for help in food security as well. It’s a big challenge to anyone in food manufacturing. The food supply must remain safe and secure for everyone.