HACCP In Your Manufacturing Process

With the increasingly global nature of the food and supplement industries, quality assurance regulations have become incredibly complex. Despite this evolution, a surprising number of companies still rely on a paper based system for their hazard analysis and critical control points (HACCP) plan. HACCP is an internationally recognized system of proactivity in the management of a company’s quality and safety obligations. The FDA requires manufacturers to have some sort of HACCP in place.

How does HACCP fit in and why it’s important

There are a growing number of businesses in the industry adopting more modern solutions to a HACCP plan. Finding a business size appropriate software solution is the direction these forward thinking companies are going. The software solution or full-scale Enterprise Resource Planning (ERP) system will streamline their response to issues when they arise. A good solution will help the company maximize their manufacturing processes too.

The Centers for Disease Control and Prevention (CDC) suggests that the rates of food-borne illness have remained about the same annually in the past decade. That said, recalls have been on a rise, especially since the Food Safety Modernization Act (FSMA). The Food and Drug Administration (FDA) has more authority to monitor and regulate food and supplement manufacturers in an effort to keep the public safe. The Public Interest Research Group (PIRG) says overall, food recalls have increased 10% from 2013 to 2018.

These numbers shouldn’t frighten food and supplement manufacturers, however. PIRG goes on to say that this is likely a result of more advanced identification and detection techniques. The numbers are also likely higher due to companies executing more voluntary recalls. Recalls are more easily executed or ideally avoided through the use of well thought out HACCP plans.

Compliance doesn’t have to be hard

An ERP system, big or small, which incorporates quality management, gives a business a leg up on the competition. Companies looking to enlist the help of more advanced software can catch problems as they arise. This is to help prevent the event of a costly recall. More importantly, they more easily create a high-quality product. A solid ERP system helps with developing plans for HACCP. When an issue arises, the system aids in the development of corrective and preventative actions (CAPA)’s too.

A system integrating quality and manufacturing processes, known as Enterprise Quality Management Software (EQMS), can pave the way for growth. EQMS and ERP might have a company rethink their manufacturing process. Similarly, a company might pursue advanced certifications like SQF. To succeed, they will need to show consistent documentation and a history of current Good Manufacturing Practices (cGMP’s). Manufacturers and contractors may be requested for an audit from potential customers if they are supplying another business in the industry. A quality and safety minded ERP is a platform for any company to achieve their goals.

6 Manufacturing and Food Safety Software Must-Haves

Food Manufacturing Software

Now more than ever food and beverage manufactures are up against greater challenges. Antiquated pen-and-paper tracking is still surprisingly prevalent in even large and mid-size companies but those systems can open the door to issues when it comes to quality and food safety requirements. Alternatively, the right food safety software can help balance business profitability and FDA regulatory compliance guidelines. These are five key points to consider when looking at food and beverage manufacturing software.

1. Traceability Software for Food Manufacturing

The most essential assurance that your final product is safe and salable is being able to accurately track qualified ingredients and products through every stage of their manufacturing process. Things like tracking individual lots, bins, and ingredients ensures that your manufacturing and quality teams can be proactive in identifying and addressing issues at any point in the production cycle. That said, sometimes problems arise. Good traceability software for food manufacturing will tremendously speed up the process in the event of a recall or inspection. Integrated with your FDA regulatory compliance and food safety software you will have a record of where your components came from and what products they went into.

2. Quality Management

Quality is arguably the biggest part of the manufacturing process. After all, this is the product you’re selling. You can increase profitability and minimize the risk of recalls with an integrated quality management or ERP system as part of your business flow. With an integrated quality system you can hold an upper hand against the competition, rather than being reactive. Food safety and FDA regulatory compliance software isn’t just about following the rules. A good system will help your product to your own standards — consequently increasing profitability!

3. Inventory Maintenance and Planning

Especially when dealing with perishable goods, managing your inventory is key to maximizing production capacity. Your food and beverage manufacturing software should be able to help you manage “use by” dates and orchestrate your materials management planning and procurement. Detailed work-in-process coordination and ingredient requirements anticipation are essential to maximizing your production cycles, labor demands, and ultimate profitability.

4. Food Safety Plans and CAPA’s

Whatever product you’re manufacturing is going to have some a unique production process. Your food safety software should help you manage the Hazard Analysis and Critical Control Points (HACCP), process controls, and analysis of the goods you are producing. In the event of an audit or recall, you may have to create Corrective and Preventive Action (CAPA) plans. Managing quality and safety manually can leave you with the grueling process of trudging through binder after binder for relevant information. Conversely, an integrated food safety software system with FDA regulatory compliance in mind makes your quality management team precise and efficient in the generation of CAPA’s and food safety plans.

5. Batch Recipes and Ingredient Details  

A food and beverage manufacturing software package should be able to track all relevant information about the ingredients in your final product. Your system needs to track things like technical properties, lab results, costing information, allergens, product claims, and history. Furthermore, documentation at every step insures your product is exactly what you claim it is on the label.

6. The Right Solution at the Right Time

The decision to move forward with a software solution is not a decision to be taken lightly. Finding the one that suits your business size and the industry niche is critical. You’re trying to make your manufacturing process smoother and grow your business. A full-scale, costly, Enterprise Resource Planning (ERP) may not be right for you. Fortunately, there are plenty of excellent and capable software solutions. Moreover, there are some that integrate directly with Quickbooks. Check out some of them here and take your business to the next level.