Improvement of Food Safety and Quality by Statistical Process Control (SPC) in Food Processing Systems: A Case Study of Traditional Sucuk (Sausage) Processing

Increasing costumer demand for safe food has lead food industry to build up food safety and quality systems. The food safety and quality are affected by insufficiency on administration, supplier, production technologies, working environment, human resources and control activities. Hazard analyzes and critical control points (HACCP) is a system that identifies, evaluates and controls hazards which are significant for food safety. It is a structured, systematic approach for the control of food safety throughout the commodity system, from the farm to the plate. It requires a good understanding of the relationship between cause and effect in order to be more pro-active and it is a key element in Total Quality Management (TQM). The HACCP system has 7 elements called the HACCP principles and pre-requisite programs that must be in place for the system to operate effectively. HACCP is focused in two main steps, namely; (1) Hazard analysis and critical control points (CCPs) determination and (2) HACCP plan for the food processing. First step includes hazards identification, hazard assessment, preventive measure establishment, CCPs determination and their critical limits. The following step is to carry out HACCP plan preparation; monitoring system, corrective actions, verification system and related record system on each CCP. Statistical tools are an effective way for improving process quality and safety. A large number of managers have achieved the benefits from statistical process control (SPC) implementation. SPC includes flow charts, pareto analysis, histograms, cause-and-effect or Ishikawa diagrams, scatter diagrams, and control charts. Control charts enable the monitoring of key variables during production and they give warning when the process is out-of-control. The best-known charts are the X and s charts that show the temporal variability of the average and standard deviation of the sample subgroups. SPC tools are, particularly control charts, for trend analysis, monitoring and evaluating the critical control points (CCPs) statistically, obtaining advance warning on the status of a critical control point and not just a “Pass/Fail” classification and measuring process outputs and identifying if they vary within statistically defined upper and lower control limits. Use of

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