Reviewed and Approved by Dr. Keith Belk, Professor & Monfort Endowed Chair, Colorado State University
1-Minute Summary
- Physical hazards like metal, plastic, glass, and stones are a top cause of food recalls, highlighting the importance of preventive safety and quality control.
- These hazards include materials that are inadvertently introduced before processing of produce and animals, or during food processing.
- Strategies such as maintaining good manufacturing practices, regularly maintaining equipment, and conducting risk assessments, all supported by a HACCP plan, minimize the risk of physical hazards.
- Examples of new and established technologies for detecting/eliminating physical hazards include advanced imaging, metal detectors, x-ray systems, magnets, riffle boards, and optical sorting equipment.
- Steps to take upon detection of a physical hazard include removing hazards, documenting findings, conducting thorough inspections, and managing the situation proactively. Root Cause Analysis also is important to prevent future physical hazards.
Physical Hazards are a Leading Cause of Recalls
Physical hazards in food were the third most common reason for a recall in 2023 according to the USDA Food Safety and Inspection Service. Consider, too, this popular grocery chain that pulled multiple products from its shelves in 2023 due to physical hazards such as metal and rocks.
These incidents not only alarm customers and hurt your brand, but they can lead to expensive recalls and even human injury – a FSQC professional’s worst nightmare.
This guide equips you with comprehensive knowledge and practical strategies to identify, mitigate, and manage physical hazards in food. From understanding what constitutes a physical hazard to implementing robust prevention techniques, we aim to help you ensure the highest standards of food safety.
What is a Physical Hazard in Food?
A physical hazard in food refers to any foreign object unintentionally present that can pose a risk of illness or injury when ingested.
As specifically defined by FDA, “Physical hazards are broadly classified as sharp hazards, choking hazards, and conditions of animal food hazards such as size and hardness. Injuries from physical hazards may include oral cavity damage (e.g., tooth damage or laceration of the mouth or throat), laceration or perforation of the gastrointestinal tract, and choking.”
In USDA’s Food Safety Inspection Service (FSIS) Pathogen Reduction, HACCP Systems Final Rule, physical hazards are defined as “any physical material not normally found in a food that can cause illness or injury to a person consuming the product.”
FSIS stipulates that “physical hazards in finished products can arise from several sources, such as contaminated raw materials, poorly designed or maintained facilities and equipment, faulty procedures during processing, and improper employee training and practices”. For meat products, bone and metal or lead shot in comminuted products continues to cause issues.
What are the Differences Between Physical Hazards and Other Hazards in Food?
These hazards are mostly distinct from biological hazards and chemical threats, as they reflect contamination with tangible physical materials such as metal shavings, glass fragments, or even personal items like hair or jewelry, inadvertently introduced during food processing or handling. If meat products are contaminated with lead shot, then an exception occurs and the hazard is both a chemical and a physical hazard.
“Filth” (dirt, feces, etc.) is considered a biological hazard as they can be a route for a biological pathogen. While not desirable in food products, foreign material such as insects would not be considered a physical hazard as it will not physically harm someone to eat an insect part but would be undesirable and potentially a quality/legality issue.
Examples of Physical Hazards in Food
Physical hazards in food can be varied and unexpected. Here are some common physical hazards in food examples that quality personnel should be aware of:
- Shot, needles, and darts: Enters the food chain in live animals but can escape some methods of detection during processing if not diligent.
- Hair: Can fall into food from food handlers, posing a choking hazard and a source of contamination.
- Bandages: If not properly secured, can detach from a worker and end up in food.
- Jewelry: Items like rings or earrings can accidentally fall into food during preparation.
- Staples: Sometimes found in packaging materials, they can inadvertently contaminate food products.
- Metal Shavings: Can come from the wear and tear of food processing equipment.
- Bones: Particularly in processed meats, bones can pose a choking hazard.
- Plastic Pieces: Can break off from packaging or utensils and end up in the food.
Each of these hazards can cause harm, such as choking or physical injury, and thus, their prevention and management are essential in any food safety management system. Understanding these examples helps in developing more effective strategies to mitigate the risks associated with physical hazards in food.
Causes of Physical Food Hazards
Physical hazards can enter the food chain at several locations, often due to preharvest exposures of animals to hazards, along with introduction during processing. Being aware of these causes can help FSQA personnel in developing effective prevention strategies:
- Low-Quality Raw Materials: Using substandard materials, or raw materials containing foreign object contamination (e.g., animals with embedded metal shot or darts, stones in produce, etc.) can introduce physical hazards to the food chain. Rigorous supplier qualification and material testing, such as sanitation and filth analysis, are essential to ensure the quality of raw inputs.
- Poor Personal Hygiene: Food handlers play a critical role in preventing physical hazards. Inadequate grooming standards, such as not restraining hair or wearing loose jewelry, can lead to contamination of food products.
- Faulty or Damaged Processing Equipment: Wear and tear or malfunctioning equipment can result in physical hazards such as metal shavings or plastic pieces entering the food.
Recognizing these potential sources is the first step in preventing physical hazards in food.
How Should Food Workers Prevent Physical Food Hazards from Injuring Customers?
Prevention is always preferable to reaction, especially when the safety of your customers is at risk.
Helping food workers prevent physical hazards from injuring customers starts with a comprehensive, proactive approach that integrates good supply chain management, personal hygiene, equipment maintenance, , and risk assessment, all underpinned by a robust Hazard Analysis and Critical Control Points (HACCP) plan.
Let’s look at each area more closely.
Good Personal Hygiene
Good personal hygiene is the first line of defense in preventing physical hazards in food. Key practices include:
- Trimmed Fingernails: Keep fingernails short and clean to prevent contamination.
- No Jewelry: Avoid jewelry that could fall into food, including rings, bracelets, and earrings.
- Hair Restraints: Use hairnets, caps, or other restraints to keep hair away from food.
- Proper Glove Use: Wear gloves when handling food and change them regularly to prevent cross-contamination.
- Clean Uniforms: Wear clean and appropriate clothing to reduce the risk of introducing contaminants.
- Handwashing: Regularly and thoroughly wash your hands, especially after breaks or restroom visits.
- Avoid Loose Clothing: Wear well-fitting clothing to prevent items from getting caught in equipment or falling into food.
- Cover Cuts and Wounds: Properly cover any cuts or wounds on hands or arms with bandages and wear gloves over them.
Equipment Maintenance and Facility Upkeep
Regular inspection and maintenance of processing equipment are crucial in preventing the introduction of foreign materials like metal shavings or plastic pieces. This also extends to the overall facility, where potential hazards such as peeling paint or loose ceiling tiles need to be addressed.
In fact, peeling paint, loose caulk, rust, and other potential foreign material is one of the top non-conformities our auditors identify in BRC food safety certification audits.
Regular cleaning and sanitation are essential to ensure that the environment does not contribute to food contamination.
Implementing a HACCP Plan
Incorporating physical hazard prevention into your HACCP plan is a critical aspect of food safety management. This involves identifying potential hazards in your process and establishing control measures to manage them effectively.
For example, in a dried fruit packaging facility, the HACCP or preventive controls plan might identify the packaging stage as a critical control point for metal contamination risk from machinery. To mitigate this, the plan might include:
- Regular Equipment Inspection: Scheduled checks to identify and fix wear and tear on packaging machinery.
- Metal Detection: Use of metal detectors after packaging to identify and remove any contaminated products.
- Recordkeeping and Monitoring: Keeping detailed logs of inspections and maintenance, with regular reviews to ensure the effectiveness of these measures.
Regular Risk Assessments
Conducting regular risk assessments helps identify potential areas where physical hazards could be introduced. This proactive approach involves inspecting incoming materials, assessing processes, and ensuring compliance with safety standards.
Staff Training and Awareness
Educating and training staff via food safety training courses on the importance of maintaining a safe food environment is critical. This includes understanding proper food handling and storage practices, as well as being vigilant in identifying and reporting potential hazards.
Adherence to Current Good Manufacturing Practices (cGMPs)
Following cGMPs, as outlined in regulations such as the U.S. FDA’s Title 21 CFR Part 110, is vital for ensuring food safety. These practices cover a wide array of procedures, from handwashing to avoiding cross-contamination, and maintaining clean and sanitary processing areas.
By diligently implementing these measures, food facilities can significantly reduce the occurrence of physical hazards.
It is not just about adhering to regulations but fostering a culture of safety and responsibility among all staff members, thus protecting consumers and upholding the integrity of food products.
Advanced Technologies in Detecting Physical Hazards in Food
In the ever-evolving landscape of food safety, technological advancements play a pivotal role in detecting foreign and extraneous materials (FEM) in food products. Here are some of the latest technologies being used:
- Visual Inspection and Advanced Imaging: Traditional visual inspections are now augmented with high-definition color-based and x-ray technologies. These methods enhance the detection of low-density FEM, such as plastic items, that are often difficult to identify.
- Metal Detectors: A staple in food processing, metal detectors have been improved to identify a wider range of metal types and smaller particles more effectively.
- X-Ray Equipment: X-ray technology is widely used for its ability to detect various types of physical hazards, including metal, glass, and certain types of plastics. Its versatility and precision make it invaluable in modern food safety protocols.
- Optical Sorting Equipment: Optical sorters use cameras and laser technology to inspect food products at high speeds, efficiently identifying and removing material based on size, shape, color, and structural properties.
- Sieves and Screen Separation Systems: Sieves and screens continue to be crucial for physically removing particles from food products, particularly in the processing of grains, powders, and other bulk materials.
- Magnet-based Separation: Using magnets is especially effective in extracting ferrous metal contaminants from food products.
- Other Innovative Techniques: Additional methods such as fluid-bed technology, flotation chambers, and washing steps are also used in specific contexts to remove or separate physical hazards from food products.
These technological advancements significantly enhance the ability to detect and remove physical hazards, thereby increasing the safety and quality of food products. As technology continues to advance, we can expect even more effective and efficient methods to emerge in the field of food safety.
Action Steps if Physical Food Hazards are Detected
When physical food hazards are identified, it’s crucial to take immediate and effective action to mitigate the risk and prevent harm to consumers. Here are the steps that should be followed:
- Immediate Removal of Hazard: The first step is to safely remove the physical hazard from the food, using appropriate tools like utensils or gloves to avoid further contamination. If the hazard is not easily removable, the affected food should be isolated.
- Documentation: Document every detail related to the detected hazard. This includes the type of hazard, how it was discovered, the specific food item or batch it was found in, and the initial actions taken. This documentation is vital for food traceability and for identifying the root cause to prevent future occurrences.
- Inspect for Widespread Contamination: Conduct a thorough examination of related food items or batches to ensure the hazard is not more widespread. This might involve checking similar products, equipment, or areas where the contaminated item was processed or stored.
- Notify Supervisors and Relevant Personnel: Reporting the incident to management or quality control personnel is essential. This ensures that the appropriate steps are taken to address the issue and that there’s oversight for any necessary corrective actions.
- Prevent Distribution of Contaminated Food: Under no circumstances should contaminated food be distributed or served. If there’s any doubt about the safety of a food item, it’s better to err on the side of caution and not release it for consumption.
- Investigation and Corrective Action: A thorough investigation should be conducted to understand how the hazard was introduced and to implement corrective actions to prevent recurrence. This might include revising processes, retraining staff, or making changes to equipment or suppliers.
- Review and Update Safety Protocols: Finally, review and update your food safety protocols and HACCP plan in light of the incident to strengthen your preventive measures against physical hazards.
By following these steps, food facilities can effectively manage incidents involving physical hazards, ensuring both consumer safety and compliance with food safety regulations.
Emphasizing Vigilance in Physical Hazard Prevention
The diligent management of physical hazards is fundamental to ensuring food safety. This encompasses understanding the nature of these hazards, implementing effective prevention strategies, and responding promptly and thoroughly when incidents occur.
By fostering a culture of vigilance and adherence to best practices and regulations, food industry professionals can safeguard consumer health and uphold the quality of their products.
