Quality Assurance in Seafood Processing: A Practical Guide

Quality Assurance in Seafood Processing: A Practical Guide

Quality Assurance in Seafood Processing: A Practical Guide A. D. Bonnell SPRINGER-SCIENCE+BUSINESS MEDIA, B.V.

1994 Springer Science+Business Media Dordrecht Originally published Chapman & Hall, Inc. in 1994 Softcover reprint of the hardcover 1 st edition 1994 All rights reserved. No part of this book may be reprinted or reproduced or utilized in any form or by any electronic, mechanical or other means, now known or hereafter invented, including photocopying and recording, or by an information storage or retrieval system, without permission in writing from the publishers. Library of Congress Cataloging-in-Publication Data Bonnell, A.D. Quality assurance in seafood processing: a practical guide / A.D. Bonnel!. p. cm. Includes bibliographical references and index. I S B N 9 7 8-1 - 4 6 1 3-6 1 3 4-3 I S B N 9 7 8-1 - 4 6 1 5-2 6 4 2-1 ( e B o o k ) D O I 1 0. 1 0 0 7 / 9 7 8-1 - 4 6 1 5-2 6 4 2-1 1. Fishery processing-quality control. 2. Quality assurance. I. Title SH335.5.035866 1993 664'.94'0687-dc20 92-26753 CIP

To Judy, Catherine, and Karen

Contents Preface xi Acknowledgements xiii Chapter 1 Chapter 2 Introduction 1 WHAT IS QUALITY? 2 QUALITY CONTROL VERSUS QUALITY ASSURANCE 5 THE PURPOSE OF QUALITY PROGRAMS IN SEAFOOD PROCESSING 6 MISCONCEPTIONS ABOUT QUALITY PROGRAMS 8 QUALITY AND COMPANY PROFITABILITY 10 Organizing for a Quality Program FUNCTIONAL RESPONSIBILITIES OF A QUALITYPROGRAM 17 PERSONNEL REQUIREMENTS 19 TRAINING OF QUALITY PERSONNEL 22 DAILY RESPONSIBILITIES OF A QUALITY ORGANIZATION 24 ENSURING QUALITY: PROCESS CONTROL VERSUS PRODUCT CONTROL 30 17 vii

viii Contents Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 ChapterS Finished Product Quality 32 TYPES OF REQUIREMENTS 32 ENSURING PROPER SPECIFICATION DESIGN AND CONTENT 37 Process Control 39 HAZARD ANALYSIS CRITICAL CONTROL POINTS 40 INSPECTIONrrEST PLANS 46 Raw Material Quality 54 INTRINSIC QUALITY OF SEAFOODS 54 FISH SPOILAGE 58 MAINTAINING RAW MATERIAL QUALITY 61 QUALITY ASSESSMENT 65 CHEMICAL INDICES OF BACTERIAL SPOILAGE 74 Sanitation 77 HYGIENIC PRACTICES 78 CLEAN-UP PROCEDURE 79 CHLORINATION OF WATER SUPPLIES 87 Microbiological Indicators and Seafood Processing 90 GENERAL CONCEPTS IN MICROBIOLOGY 90 BACTERIOLOGICAL INDICATORS OF SEAFOOD PLANT SANITATION AND PRODUCT QUALITY 96 Statistical Quality Control 107 DEVELOPMENT OF STATISTICAL QUALITY CONTROL 108 QUALITY IMPROVEMENT-WHAT IS THE CHALLENGE? 110 STATISTICAL QUALITY CONTROL 113

Contents IX Chapter 9 Quality Management Information System 138 COLLECTION OF DATA 139 QUALITY RECORDS 140 QUALITY REPORTS 141 QUALITY MANUAL 142 Chapter 10 Quality Cost Accounting 144 PURPOSE 145 QUALITY COST SYSTEM DESIGN 145 USES OF QUALITY COST INFORMATION 148 Chapter 11 Quality Program Implementation 153 SYSTEM IMPLEMENTATION 153 DEVELOPMENT OF PERSONNEL 155 Appendix A Internal Standard Skinless Flounder Fillets 5s 157 Appendix B External Standard Fish Inspection Regulations, 1969-Province of Newfoundland and Labrador, Canada 167 Appendix C Product Specification 177 Appendix D Hygienic Practices 179 Appendix E Recording Forms Lumpfish Roe Processing 191 Appendix F Reporting Forms Lumpfish Roe Processing 195 Index 201

Preface While there are many quality assurance books on the market, very few address the application of the concept to the seafood industry. In addition, many of the books that are available take a theoretical approach and therefore do not provide actual examples of the "fins and bones" of quality programs. The author, in teaching quality assurance over nine years, has not been able to find a textbook that is suitable as a reference text in quality assurance courses for the seafood industry. It is this situation that has prompted the preparation of this book, which takes a practical approach to the subject of quality assurance in seafood processing operations. This book can serve as either a textbook or as a reference text. As a textbook it is written for students of quality assurance at the technician, technologist, and university levels. In this role it is intended that the student will start at the beginning of the book and proceed through in sequence, so as to gain a complete understanding of the design, implementation, and operation of a quality program in seafood processing operations. It is the hope of the author that the book also functions quite well as a desk reference for the managers of seafood processing operations who need to refer occasionally to particular items or chapters. In this sense, each chapter is designed to stand alone as a discussion of a particular concept within the quality assurance discipline. Where possible, actual examples from seafood processing operations have been used to illustrate the theory being presented. These examples have come largely from the author's consulting experience with the Atlantic Canada seafood processing industry, as well as from the author's teaching experience with seafood processing personnel. Xl

XII Preface To the new student of quality assurance the book may appear to be laid out backwards. In fact, it has been designed to reflect the natural sequence used by quality practitioners when designing and implementing an effective quality program.

Acknowledgements Many people have provided invaluable assistance in the preparation of this manuscript. In particular, the author would like to sincerely thank Karen Collins for her patience and dedication in typing the manuscript, Wendy Thistle for her expertise and commitment in the preparation of the artwork found throughout the text, and Elaine Kennedy for her efforts in reviewing the manuscript as well as her continuing encouragement throughout the project. The moral support of family, friends, and colleagues throughout the project was a tremendous benefit and greatly appreciated. In particular, the sacrifices made by my wife, Judy, and two daughters, Catherine and Karen, along with their patience and continued support for the project were absolutely crucial to its successful completion. The contributions of those individuals and companies that have permitted the use of various materials from other sources is acknowledged with thanks. Appropriate reference ofthese materials has been made throughout the text. The author would also like to extend sincere thanks to his employer, The Fisheries and Marine Institute of Memorial University of Newfoundland, for its continued support and encouragement in this endeavor. Xlll