Jiayi's package 2 reflection

The second package that covers the safety of GM food is a very broad topic. With no previous knowledge, we have to do thorough research in order to get accurate information as there are various sources that states different stands. Through researching, I have found out many interesting facts about GM food, the techniques used, the different traits and their uses. Indeed we met many difficulties as we did not knew which resources were useful and true, thus we had to research more in and compare between difference sources.

Similarly, meeting up to discuss was a problem we faced as we all had different work schedules. We had to find a suitable date for everyone and took chances to meet up as frequent as possible to discuss our findings. It was really tiring to juggle between work and doing project but after finishing the project, I felt that we all have improve on time management and report writing skills.

With the increasing use of GM food, it is important to look into the issue of food safety as GM food may soon replace the use of conventional food. After researching, I feel that there are many pros and cons of using GM food, thus it would really be up to one's preference whether to accept consuming GM food.

Rina's package 2 reflection

GM foods are widely spread. Generally, publics’s concern on GM foods are health concerns. It is to my understanding before this project that I GM food is unsafe for consumption. I was also unaware that GM foods are incorporated in a food product.
Not only that, this project has helped me in understanding the technology of GM foods. It has helped me understanding the principles of food technology. Though this project focuses on crops that can be make into flour , along the way we, the group had also found out other examples of GM food and crops.
As a group, this project has stimulate our thinking as we brainstorm the possibilities for alternative answers for every meeting. Meeting up by sharing our part and give ideas to others of what we may know. It has been difficult for me especially when my work shift changed to afternoon shift and I was not able to come for meetings. Due to time constraint, it was almost impossible for me to finish my part. It was a bit saddening for me as I was the only one in the group doing shift work. But I did managed to grab a few hours to get the work done.
As a whole, problem based learning is difficult but no doubt it give us more opportunity to explore more. Without notes from teachers, we did feel lost in the beginning but with the guidance from the lecturers we managed to start our engines. ;)

Yanzhi's reflection for package 2

I'm glad that we have finish the project on time, Thanks to all my group mates. I would say that this package 2 is definitely more difficuit than package 1, because Genetically Modified Food was an unfamilar title for me. Although it was taught as one of the topic in a module I took, but it didn't went in depth to the individual food and it's traits, techiques. At first, we were quite lost and didn't really get what we are suppose to do, however as we continued to do research. We slowly understood the rationale behind all these controversial issues as it is really hard to conclude on either side due to its inclusion of personal health and religion which vary from case to case basis. We chose genetically modified corn (maize) as our target crop, as corn can be used in various items and most importantly corn can be made into corn flour which is the main criteria. We allocated the parts among the group mates and we met up face to face quite a few times to have sharing sessions. And from each sharing seesion there will be new knowledge to be learned, this motivates us to do ever more. Though we come from different places after work and were all tired, but we all have the same goal of finishing the report well. During each meet-up, we will also share about our working experience and how our lives have been for the week. I really enjoyed working together with my group mates. Last but not least, I feel that the group discussion board is not very effective as I would rather give the person a call or an sms which is much more efficient :)

Li Yun's Reflection for Food Safety Package 2

Time flies, weeks have passed and my group is finally done with our package 2 report.

Genetically Modified (GM) food has been very well established in today’s world. Countries such as US, Europe and South Africa have been producing their own GM crops. In Package 2, I have gained a better understanding of how GM food is started. After doing many researches from reference books, journal articles and news articles with my group mates, I managed to find out more about its pros and cons, how it had affected human health in the past, how it is produced and the methods to test if they are safe for consumption. After consolidating this information, we begin to meet up to share with one another the researchers found.

In this round of Package 2, I find it more challenging compared to Package 1. This is because some of the information found from the internet is either not updated or they are not very reliable. Therefore, we have been meeting up more often than previous package to make sure all of us are clear with the process of GM food. Jia Yi, our group leader, has also been very patient and understanding to us. She will explain to us whenever we faced with any uncertain questions and guide us through the project.

Although the question this time is tougher, I can see the improvement within the group. Whenever one person has difficulty doing the report, the other will be there to help. I believe all of us are working towards one goal, which is to do well for this project. During these past few months, although it is tiring for all, we never fail to encourage one another. Besides gaining additional knowledge in GM food, I have also built a closer relationship with my fellow mates.

Jia En's Reflection for Food Safety Package 2

Through this package, I learnt more about the concepts of Genetic Modification. Before starting my research in this area, I thought that there is only one method of modifying crops to attain GM foods. Now, I know that there are actually six different genetically modifying processes widely used in the biotech industry, three of which were used in the production of corn which is the product that my group had chosen for our report.

GM companies practiced many food safety measures such as by carrying out microbial laboratory tests and toxin detection tests on GM foods to maximize the safety of these foods. If all these methods are carried out properly, it would definitely help in reducing the risks of consumers getting foodborne illness or toxicity.

In addition to all the numerous benefits that GM foods contribute to the consumers, there are also controversial issues pertaining to GM foods. I think that the disagreement on both sides (benefits and controversies) have practical and sufficient explanation to support their judgment towards GM food production. I feel that GM foods can still be consumed occasionally so as not to exceed the ADI of these foods, increased the risks of harming the human body in the long run as well as receiving the benefits that the GM crops can provide at the same time. I also discover that GM foods must be labeled in most countries in order to allow the consumers to know the foods that they are eating but in Singapore, GM foods labeling regulations have not be established therefore explaining the reason that Singaporeans are ignorant about the fact that some of the daily foods that they consumed are actually GM foods.

The knowledge gained from doing this food safety package is extremely beneficial to us as it made us more aware of the different advanced food technology in the modernized world. All these changes that actually revolve around our daily lives are often neglected due to our hectic lives.

This 2^nd food safety package was indeed a demanding one for us as the term ‘genetically modification’ was a completely new concept for us to digest. We had not done any projects or had any modules involving Genetically Modified (GM) foods. To understand the concept relating to genetic modification, we carried out more research and read up reference books and visit useful website links. It was tough for us throughout this research period but our leader, Jiayi guided us from the start of the package till the entire completion of the report, allocating tasks to each member in a systematic manner. Communication between us improved greatly compared to the previous package as all of us are more used to our schedule of doing this project on top of having our SIP attachment.

Toxins and foodborne pathogens in corn and its related food products

Toxins

1.) Aflatoxins produced by Aspergillus aflavus

• potent liver toxins and liver carcinogens
• largest impact on corn, causing $225 loss million per year
• symptoms of toxicity includes hemorrhage, edema and live damage

* Permitted amount of aflatoxins in human food is 20ppm
# Acceptable daily intake is 100 nanogram/kg body weight

2.)Fumonisins produced by fusarium species; F. verticilliodes, F. proliferatum and F.moniliforme

• possible cause of esophageal cancer in human
• cause acute toxicity in animals
• no corn hybrid are completely resistant to this fungi

* Permitted amount of fumonisins in human food (degermed dry milled corn products with less than 2.25% fat content is 2ppm and in whole/partially degermed dry milled corn products with more than 2.25% fat content is 4ppm
#Acceptable daily intake of fumonisins is 2 microgram/kg body weight

3.) Trichothecene produced by F. graminearum, F.culmorum, F.sporotrichiodes and F.poae.

• symptoms of toxicity includes vomiting, bloody diarrhea, severe dermatitis and hemorrhage
• most susceptible organs and systems are the mucous membrane of the digestive system, the skin and the immune system.

* Permitted amount of trichothecene in human food is 0.5ppm
#Acceptable daily intake is 1 microgram/kg body weight

4.& 5.) Zearalenone and deoxynivalenol produced by Fusarium graminearum

• symptoms of toxicity includes vomiting, liver damage and reproductive defects

# Acceptable daily intake of zearalenone is 0.5 microgram/kg body weight and 1 microgram/kg body weight for deoxynivalenol

6.) Ochratoxin A produced by Aspergillus ochraceus and Penicilliu cerrucosum

• carcinogenic to human and capable of inducing oxidative DNA damage

# Acceptable daily intake of Ochratoxin A is 100 nanogram/kg body weight

Pathogens

1.) Escherichia coli

• presence indicates poor hygiene practices during processing
• cause watery diarrhea in food poisoning cases

* Microbial limit of E.coli in corn flour is 10 cfu/g

2.) Bacillus cereus

• produces enterotoxins to cause diarrheal type & emetic type of food poisoning

* Microbial limit of B.cereus in corn flour is 10cfu/g

Sources:

Food Agriculture Organisation (FAO)

World Food Programme (WFP)

Food and Drugs Association (FDA)

Review the uses of GMO from various sources

The world's largest cultivated genetically modified crops are ranked as followed:

1. Soybean
2. Corn
3. Cotton

The top few countries that cultivate genetically modified (GM) soybeans are United Sates, South Africa and Argentina. These countries used the soybeans for commonly reasons such as to feed livestock. The livestock productivity in Europe are dependent on the protein offered by the soy. During processing of the soybeans, it is pressed into oil mill and the oil that is then collected will be refined for food use. Also, soybeans are used to make many food ingredients and additives such as lecithin.

Spain, France, Czech Republic are the countries with the largest cultivation areas for genetically modified (GM) corns. A large percentage of genetically modified corns are grown for the used as animal feed. However, GM corns are also made into food products for human consumption such as cornflakes, popcorn, corn oil and food additives such as corn sugar, corn syrup. Also, corn is an important source of starch in Europe. Almost half of the starch derived from corns are used for food production and the left over are used as renewable raw material for the production of paper, packaging material, textiles, chemical, pharmaceuticals and many more.

Most genetically modified (GM) cotton can be found in USA and India. The grown of gm cotton is gradually increasing in the years in USA and India. Fiber from the cotton must be separated from the seed. The seed that is then separated can be made into cooking oil or sometimes even margarine as it is protein and oil-rich. Cotton are also used for animal feed and leftover fiber are made into food additives such as stabilizers or fillers, as it almost completely consist of cellulose.

Corn Story

Genetically Modified Corn are grown in 13 countries:

1. USA

2. Canada

3. Argentina

4. South Africa

5. Spain

6. France

7. Germany

8. Portugal

9. Czech Republic

10. Honduras

11. Philippines

12. Egypt

13. Brazil

Spain was the first country in Europe to plant GM corn and now it had extended to many more countries around the world such as in North and South America, Africa, Asia, Czech Republic, Germany and Portugal. US is the country that grows the most GM corn while Spain is the EU country with the largest cultivation area of GM corn. The following traits of corn are herbicide and pesticide tolerance.

The 4 GM processes used to produce GM corn are:

1. Electroporation

2. Biolistics

3. Whiskers-Mediated transformation

4. Bacterial carrier (Agrobacterium).

Whiskers-Mediated transformation and bacterial carrier (Agrobacterium) are the more common methods.

Some examples of GM corn are: Starlink corn, Bt11, Knock Out, NatureGard, Bt-Xtra

Principles of genetic modifying processes of CORN

Among the 6 discussed GM processes used in the previous post, 3 of them are used to produce GM corn.

1.) Electroporation
2.) Biolistics
3.) Bacteria Carriers

In addition, a less commonly used technique is used to modify GM corn.
4.) Whiskers-Mediated Transformation
This method relies on the use of silicon carbide fibres. Selected target cells, fibers and plasmid DNA are placed in a tube and mixed by vortex treatment in a prescribed manner. The main mechanism lies with the silicon carbide fibers function as needles enable the entry of DNA into cells during the mixing process. The treated corn tissue is then plated on a selection media of the regeneration of GM seedlings.

Explanatory diagram on whishers mediated transformation:

Materials needed for the modifying process:

After adding into the tube, the tube undergoes vortex treatment to allow DNA to gain entry to the target cell.

The principles of the various genetic modifying processes

There are six genetically modifying techniques widely used in the biotech industry currently.

1.) Bacterial carrier
Bacterial carriers make use of appropriate infectious bacteria such as Agrobacterium. DNA that expresses desired traits is inserted into the bacteria’s extra chromosomal (plasmid) through the use of a special heated solvent which increases the permeability of the bacteria’s cell wall. Next, the altered bacteria recover and make copies of the new gene at the same time. This is dropped into the solution and started to infect the plant cells. Plants cells are then cultivated to grow into crops with the desired traits.

2.) Calcium Phosphate Precipitation
The calcium phosphate precipitation technique exposed selected DNA to calcium phosphate that will lead to formation of tiny granules which the target cells surround, and ingest by endocytosis. Ingested granules will release DNA in the cell and be delivered to the host nuclei and chromosomes where the desired traits are expressed from.

3.) Electroporation
In the process of electroporation, a short intense electric current is flown through a solution that contains the target cells and selected DNA. The input of electric current results in the formation of small spores of the target cells so as to allow the selected DNA to access to the nuclei. This process of incorporating selected DNA into host chromosomes provide the host with new traits.

4.) Gene Silencing
The principle of gene silencing works differently from those that were discussed above. This method of modification attaches a second copy of the target gene the other way round to disrupt other genes in the target cells. In this way, the production of undesired proteins responsible for human allergies is prevented, thus ‘silencing’ the other genes. An alternative of gene silencing is to insert a foreign DNA to inactivate genes that produce the allergens.

5.) Gene Splicing
Gene splicing involves restriction enzymes in different bacteria that attack the foreign DNA. The DNA are then ‘spliced’ into pieces and prevented from entering the bacteria’s chromosome. The process of ‘splicing’ makes the DNA adhesive and pasted onto the target cell’s DNA, easing the transfer of DNA to modify traits.

6.) Biolistics
Biolistics aim to insert DNA into target cells. However, a different technique is used. Biolistics involve the firing of DNA laden microscopic particles of gold or tungsten into the target cells using a burst of gas under pressure, leaving the target altered cells to be cultivated to express desired traits.

Food safety assessment of GM food

The codex alimentarius guideline for the conduct of food safety assessment of foods produced using recombinant-DNA microorganisms address to the safety and nutritional aspects of GM food.
Recombinant-DNA Microorganism” - means bacteria, yeasts or filamentous fungi in which the genetic material has been changed through in vitro nucleic acid techniques including recombinant deoxyribonucleic acid (DNA) and direct injection of nucleic acid into cells or organelles

When a GM food is produced, safety assessments of recombinant-DNA microorganisms should document the use of related microorganisms in foods, the absence of properties known to be characteristic of pathogens in the recombinant-DNA microorganisms or the recipient strains used for constructing the recombinant-DNA microorganisms, and known adverse events involving the recipients.

Framework of safety assessment includes the following:
A) Description of the recombinant-DNA microorganism;
B) Description of the recipient microorganism and its use in food production;
C) Description of the donor organism(s);
D) Description of the genetic modification(s) including vector and construct;
E) Characterization of the genetic modification(s);
F) Safety assessment:

• expressed substances: assessment of potential toxicity and other traits related to pathogenicity;
• compositional analyses of key components;
• evaluation of metabolites;
• effects of food processing;
• assessment of immunological effects;
• assessment of viability and residence of microorganisms in the human gastrointestinal tract;
• antibiotic resistance and gene transfer; and
• nutritional modification

This framework should be in place to ensure food safety of the genetically modified food or its processed product.

Self drawn explanation diagram of Enzyme linked immunoassay (ELISA)

A colored complex is produced through the oxidization of substrate catalyze by the enzyme which hence, indicates the presence of toxins.
A spectrofluorometer is used to measure fluorescence emission when a fluorescent-labeled antibody is used.

Result analysis:
Results are read directly using an automated photometer (ELISA-reader).
A standard curve is plotted on semilogarithmic paper to find out whether the toxin is present.

Self drawn explanatory diagram of polymerase chain reaction (PCR)

A reaction mixture consisting primers, DNA polymerase and chromosomal DNA was centrifuged and placed in a thermal cycler to perform 20 cycles of PCR that undergoes denaturation, annealing and primer extension during each cycle. After which, the PCR products will be detected by agarose gel electrophoresis followed by visualization under a UV transilluminator to match with marker DNA as so to identify the foodborne pathogens.

Allocation of tasks

Yanzhi's task

• Outline the main principles used in the genetic modification process

Jingyuan and Rina's task

• Review the use of GM Food/ Ingredients from various sources

Rina, Jiaen, Liyun's task

• Discuss the benefit and controversial issues associated with the use of GM food such as the consumer’s rights, product labeling, religious/ ethnical, and environmental concerns

Jiayi and Liyun's task

• Outline the principles of various laboratory techniques used for toxin detection and the permitted limit based on acceptable daily intake and food consumption studies and,

Jiayi's task

• The principle of some microbiological techniques isolation and identification of foodborne pathogens such as DNA probes and Enzyme immunoassays

Other information:

Jingyuan's task

• Background of GM corn

Jiaen and Yanzhi's task

• Negative reports on the use of GM corn (Health issues)

Jiayi's task

• Codex Alimentarius guide on GM food

Jing Yuan's Reflection for Food Safety Package 1

From package 1, I have a deeper knowledge about the food safety issues. In this package, my group had to choose a food item from the company I’m working in, Singapore food industries (SFI) and it was the Creamy Cheese Chicken Pasta. We were met with many difficulties as not able to get hold of information that are needed such as the retorting temperature and time, the exact type of food ingredients. However, through internet, books research and continuously consultation on our colleagues, we could find some relevant information about retorting procedures. I have also gained much more knowledge about the processing of retort food product, the shelf life of the retort food product (2 years without any preservatives) and how QC personnel would have to react when a problem arise. Every processing step is very important and it requires meticulous checking at each step. If any of the processing steps were to go wrong, it would end up causing the food to be spoiled, causing consumers to fall ill and this in turn affecting the reputation of the company. It is critical to think of the potential hazards, the critical points or critical control points that are likely to be found in each processing steps or even in the ingredients alone. By noting down the potential hazards and CCPs, we will then be extra careful during processing or when checking the ingredients. This will then greatly reduce the potential spoilage of the product. However, to note down the potential hazards and the CCPs, the QC personnel has to first have the knowledge of the food product such as the commonly found bacteria on the specific food, the storage time and temperature, Good Manufacturing Practices (GMP) and the Standard Operating Procedures (SOP). But if there are still problems of food spoilage, the QC personnel should come up with the specific product recall procedures and a new HACCP plan to prevent future recurrence.

Also from package 1 project, I realized the importance of team work and communication among group mates. Without both components, the group may result in certain group members having a heavier work load. Each member was given a specific task to complete and to be handed in within the specific time frame. Hence, punctuality is another important factor that contributes to the success of the group. When one member delays her submission of work, it will not only trouble the person that is compiling it but also resulting in insufficient time for amendments. As further researching takes quite some time and this in turn, cause the whole group to rush through their work and end up producing a bad piece of work. Communication is very crucial in a group. When communication among group members is good, the group will complete the given task in the most efficient way. However, when there is communication break down, the group may end up needing another group member to substitute for original member’s work. That member who was assigned the new task could have just do it in a hurry and submit it. Therefore, it could also lead to a bad piece of work. Also, inefficient communication among group members will also result in punctuality problems and greatly reduced the group’s team work. Group work means acquiring help from one another. When any one in the group is stuck in their given task, others could lend a helping hand and this is when team work is very important. As a group, each of us cannot be selfish to only care about our own work, instead every one of us should always check with one another for the progress in work so as to help each other when in need of help. With all these factors, the group will then succeed and achieve good results.

Rina's Reflection for Food Safety Package 1

Food Safety Package 1 requires us to come up with a food product, make HACCP plan . Do a write up on the processes and find out about the rationale of each processes and identify the CCPs in the processes. Apart from that we were given a case scenario on product recall. Hence, we were required to do research on product recall.
The product that we had decided as a group is Combat ration Cheesy Chicken Pasta . A product “inspired” from Singapore Food Industries Combat ration product. We had decided on this product because we want to take a challenge to do research on a product with such difficult processes from the normally pre-packaged foods. Our curiosity encouraged us to pursue with the product.

To start, we had an online meeting. But to our dismay, our online meetings always end up fruitless and we decided to do a face-to-face meeting for easier conversations. Our first meeting was successful in a way that everyone was able to make it and contributed their ideas to fill the FILA chart and decide on a product. Tasks were delegated according to the FILA chart and we were also given a due date for each task. By doing this, we are training ourself to work as a team and finish work before due.

Doing research during internship is very difficult. Even though I end work before
others do, I always reach home lethargic and leave me no time to do research. Apart from that, I was the only person in the group who is working in shifts. I had to work on Public Holidays where the rest are’nt working. Planning is very important, we must be effective in planning our own time for school work, work and personal things. Apart from that, we had also realized that we need to do double check for all the things we do especially when our teacher claimed that he had not received our work. We had apolagized to our teacher and assure that it will not happen again. We learn from mistakes.

For the content of package 1,we had learn HACCP in our previous semester hence this is a revision for us especially in identifiying CCPs and understanding the HACCP plan. However, the challenge is to find out the actual processing steps of the product due to confidentiality. Internet and books literature are sometimes based on general information hence there are a lot of different information. I was confused of which information to extract and use as a reference for our project. Product recall is another of which we had not yet learnt. This was slightly easier than the processes steps as the information given are very straightforward. By researching about Product recall, I finally understand the different types of recall and the job scope of the authorities.

To conclude, even in the hectic lives, the outcome of work will be reflected according to the efforts we had put in. Through sleepless nights researching and waking up the next morning for work , we had finally done our report by consolidating the information we had found. Most students never liked the idea of Problem Based Learning though, deep down we know it helped us alot in working as team, generating ideas and researching skills. For the hard work everyone has done, we deserve a pat on our back =) Good Job! Keep improving!

Jia En's Reflection for Food Safety Package 1

I feel that Food safety was a challenging one compared to the two other PBL subject we had before due to the fact that all of us are attached to different placement for our SIP meaning different working schedule so it is difficult for us to meet up. With our different busy schedules as our one of our obstacle, we managed to minimize the obstacle by using the online blackboard system and MSN to discuss our project progress. We even find time out of the hectic schedule to meet up once in a while as we believed that more progress is sustained when we get to meet up and explain things out. Having experienced the PBL subject system through our previous subjects, we had become more independent in our research-searching for our own resources available in many areas (from reference books in library to internet and even to asking our colleagues at work). Tasks were distributed among us by our leader Jiayi, and then we will meet up and consolidate our ideas.

Last time I used to be someone who would easily agree with the majority. But now, I have learnt to voice out my views to the group, even if the things that I said is not agreeable among the group, I accept their feedbacks in not accepting the idea. I feel that I have learnt more things from the ‘mini’ debate that we have when we finalized something. From the different ideas and objections contribute/raised by each member of the group, we would try to utilize all the ideas by combining them to produce a better report.

The first package for Food Safety was mainly about HACCP and product recall. HACCP serves as a recap for us. Last time when I do the FPQA package, the idea of HACCP appeared to be vague in my memory due to the less heavy content of HACCP in that package. However, after doing and researching more about it for package 1, I am more familiar with the HACCP system and the different processes that are involved. Before this package, I did not know that all food product companies should have a food product recall team to perform the necessary procedures in case of emergency such as food poisoning cases. Now I can tell the procedures that a company will take should such cases will to occur and the different classes and levels of recalls involved.

Through working six full shifts a week and managing of a four credit PBL subject, I learn to prioritize my workload in a more effective way. With the cooperation from each and every individual of the group, we managed to overcome all obstacles and qualify for the exemplary tables for this very first package. We will continue to motivate and encourage each other to work hard for our remaining “Food Safety” journey.

Package 2 problem statement on genetically modified food

You are the Food Safety Officer of a multi-national food ingredient company. Your Managing Director is considering importing genetically modified (GM) food crops for further process into flour and starches. However, he needs to understand the food safety issues related to GM foods before making the decision. In addition, recent press reports on several cases of food borne illnesses associated with food contaminations have also cause concerns to your Managing Director. He would like you to include in your report the analytical techniques that could be employed for the isolation and identification of food-borne pathogens and the detection of toxins that might be present in the food products produced by your company.

As such, you are tasked to submit a detail report to him covering the following points:

• Outline the main principles used in the genetic modification process
• Review the use of GM Food/ Ingredients from various sources
• Discuss the benefit and controversial issues associated with the use of GM
food such as the consumer’s rights, product labeling, religious/ ethnical, and
environmental concerns
• Outline the principles of various laboratory techniques used for toxin detection
and the permitted limit based on acceptable daily intake and food consumption
studies and,
• the principle of some microbiological techniques isolation and identification of
foodborne pathogens such as DNA probes and Enzyme immunoassays.

The deadline for the submission of the report is 19 July 2010, 5pm

Yan Zhi's Reflection for Food Safety Package 1

Firstly, I would like to thank my team mates for all the effort. Despite of the hectic schedule we had, we manage to meet up a few times for the group discussion. We split up the work that has to be done individually and also met up as a group to compile the work. Through this project, I realized the importance of responsibility and accountability. Without these, the whole project would not have been passed up on time.

The knowledge that I have gained through this package one, was about retort technology and the modifications of process steps in order to the requirements. We were taught on HACCP and decision tree during the previous semesters, so it was easier to understand the rationale before all the tables that we have to do. Before this package one, I have never heard about retort technology and its’ advantages. As we began researching on how retorting works, I was quite amazed by the productivity and shelf-life of food sealed in retort pouches. Therefore it was quite a challenge for my group to identify the three critical control points (CCPs). Because when the food goes through the retorting process, chances of pathogens surviving will be reduced to the minimum. After much discussion and research, we decided to include sealing and metal detector as our CCPs.

For package two, the case given was much more difficult. Despite the circumstance, our group will put in more effort to complete the project with quality work. I believe through all the research and discussion, we will be about to learn further more than I expected.

Li Yun's Reflection for Food Safety Package 1

In this Food Safety Package 1, we are needed to look for a food product, to study on its processes, to provide a HACCP plan, and lastly to summarize everything in a report.

The product that we have chosen is a combat ration food named Creamy Cheesy Chicken Pasta. This food is packed in green pouches for the soldiers to consume. We got to know this product from Singapore Food Industries (SFI), which is the company Jing Yuan was attached to. That day after finalizing our food product and FILA chart, we spread our task to do research on combat ration while Jing Yuan will help to find out the product recipe and processes from her company. After consolidating the data, we met up to further discuss the project. The discussion has always been going on smoothly as most of us are active in pointing out questions and giving ideas to improve.

In this package, I have learnt a lot about combat ration foods and its production. One of the thing that suprises me was the shelf life of the food, which can be kept for 2 years in room temperature. The reason behind was due to the process called retorting. It is a high heat treatment that kills all potenial foodborne pathogens. Also, one interesting fact was that the pasta was not cooked before adding it into the pouch but cooked together during the retorting process.

However, there are also few difficulties faced. Firstly, as there is some confidential information, we are unable to get the complete information needed. Thus, Jing Yuan had to approach her colleagues several times to get more information and Yan Zhi had to try asking her colleague who has some background information on retorting food. Secondly, as I was the meeting- coordinator for my group, it was difficult to find a suitable day, time and place to meet up everyone. This is due to the difference in working shifts, company and living estate. Therefore, most of the time, we have to meet at night after our work to do the project. Though sometimes it is tough and tiring, most of us still tried our best to make it.

Overall, I think we have done a good job for Package 1 and I enjoyed working with my group mates, who are always encouraging and motivating one another. We also manage to learn from one another during every discussion meeting. I believe in the next package, we will be doing as well too!

Jia Yi's Reflection for Food Safety Package 1

In this package 1 that focuses on the HACCP plan, I have learnt about its importance in managing food safety issues. As we have already done the templates before in previous module, I am able to use knowledge that I have gained from the past to come up with work of better standard. What is different this round is that, we had to find a product which is produced by the company that we are attached to. We had to rely on Jing Yuan who is attach to Singapore Food Industry to find out the product’s recipe and processing steps. However, as such information was confidential, we met difficulties trying to find out the actual processing steps and Jing Yuan had to approach her colleagues for a few times to get the answers.

In addition, I have learnt about the recall procedures that are carried out when a food product poses threat to the consumers. I have always heard about recalls from the news such as milk powder that contains melamine. Now I know that there are different classes and levels of recall as well as the whole process of recall.

Lastly, as we had to do this project during the period of internship, we also met difficulties in meeting up to finish the project. Most of us are tired after work or have other activities, thus we had to manage our time efficiently and make use of resting time to do research. Everyone had done their part and showed efforts to make improvements to the report.

Product Recall

The recall team from Store-for-long Pte Ltd was called upon immediately. The first action the recall team took was to inform the HSA’s Enforcement Branch on the receipt of the product defect information within the 24 hours starting from the first complaint. The team then finalised the classification, level and strategy they should carry out for the recall with HSA.

The assessment of recall for this product is classified under Class 2 Recall as there were complaints from the Army Force that the soldiers suffered from diarrhoea and vomiting. This case of food poisoning was not to the extent of being in the Class 1 Recall category where a life-threatening situation is posed. For the level of recall, it has been grouped under consumer level as the complaints came from the Army Force who was the direct consumers.

After finalisation and agreement among the two parties (HSA and Store-For-Long Pte Ltd), the recall team then traced back the distribution of the products delivered to the army camp and to the soldiers. Under investigation, it was found out that the defective production batch number is 60277B. All the remaining pastas under the same production batch that have yet to be consumed were collected back to prevent more people from getting food poisoning by consumption of this defective product. Some of the collected product was sent for lab testing to find out the actual cause of food poisoning.

From the lab testing report, it was found out that a handful of the chicken in the pasta pack were uncooked on the inside and there was a positive count of salmonella It was concluded that this is a salmonella food poisoning case. The entire HACCP plan was reviewed; the time and temperature for blanching and retorting were reconsidered. It was found out that the temperature on the temperature-time log for the production batch did not coincide with the ones for blanching and retorting. The temperature-time log showed that the chicken cubes were retorted at a lower temperature. This caused the chicken to be cooked only on the surface and not the inner parts.

The recall team came together to brainstorm for corrective action to be done to improve the safety of this product. It was decided that the temperature-time log of the blanching and retorting step must be checked each time and also incorporate stirring during blanching and rotating function during retorting. It is compulsory that all staffs should undergo a basic or refresher workshop to familiarize themselves with the process of preparing this new product and reinforcement of the importance of good personal hygiene (appropriate time, temperature, Standard Operating Procedures [SOP] and Good Manufacturing Practices [GMP]). Before this new product is re-launched into the market, sufficient lab tests should be conducted to ensure that it is absolutely safe for consumption in order to reassure the Army Force that such incident will not repeat.

Retort Packaging

What is Retort Packaging?
Retort is a process that uses heat and pressure to cook food in a strong, sealed package. Because the packaging is less bulky than traditional cans and jars, foods cook more quickly, providing a better tasting product for your customer.

Advantages of Flexible Retort Packaging:•Shelf-stable and requires no refrigeration
•Larger surface area for marketing information
•More appetizing package presentation
•Better merchandising options throughout the store
•Reduced storage space
•Lighter and less expensive to ship
•Easier for customer to open, heat and use product

http://retortpackaging.com/index.html

Other resources
http://www.idspackaging.com/Common/exhib_11961/Case_File_26.pdf

Creamy Cheese Chicken Pasta

Ingredients
1. Butter
2. Full cream milk
3. Grated Cheddar Cheese
4. Water
5. Chicken Breast
6. Twisted Pasta
7. Canned Button Mushroom

Process Flow
S1,2,3. Store butter, full cream milk and cheddar cheese at 1 to 4˚C.
S4. Store chicken at -18˚C.
S5. Store twisted pasta at room temperature 27˚C.

SP1. Melt butter in jacketed vessel
SP2. Add full cream milk, cheese and water to form sauce.
SP3. Transfer into filling
SP4. Pump (ready to fill the pouch)
*sauce process step

P1. Thaw chicken at 1 to 4˚C.
P2. Wash chicken.
P3. Cut chicken into cubes.
P4. Cut chicken into cubes.
P5. Cooking using ice water bath.
P6. Weigh 160g of chicken in plastic cup.
P7. Weigh 20g of twisted pasta in plastic cup.
P8. Open the can of mushroom.
P9. Drain away the water in the mushroom.
P10. Weigh 70g of mushroom in plastic cup.
P11. Combine the chicken, twisted pasta and canned button mushroom to form pasta pre-mix.
P12. Run food through metal detector. (CCP 1)
P13. Fill in sauce into pouch.
P14. Seal pouch. (CCP 2)
P15. Retort at 121˚C for 15 minutes. (CCP 3)
P16. Cool the pouch.
P17. Store at room temperature.

Process flow chart

Combat Ration Food

Strengths of our production include:

•Extended shelf life (3 years minimum, up to 10 depending on storage)
•Lightweight and flexible, easy transport
•Easily heated for consumption
•Most competitive prices
•Flexible, customisable contents

Food to choose!

These are the following food we can choose.

Dessert
1) Barley milk dessert
2) Barley nata de coco
3) Bubur Terigu
4) Bubur Terigu with corn
5) Cocoa Red Bean With Corn Dessert
6) Green Bean Sweet Potato Dessert
7) Soya Peanut Dessert

Side dish
1) Black Pepper Mashed Potato (chicken)
2) BBQ Baked Bean with Corn (chicken sausage)
3) Chicken Ham and Potato in Smoke Sauce
4) Creamy Black Pepper Potato Chicken Stew
5) Mashed Potato with Bean (chicken stew)
6) Spicy Tomato Bean Stew
7) Portugese Potato Curry with Chicken Sausage

Rice
1) Beriani Rice wit Rendang Chicken
2) Black Sesame Chicken Glutinous Rice
3) Braised Chicken with Mushroom
4) Cabbage Rice with Chicken
5) Chicken Dumpling
6) Dried Shrimp Glutinous Rice (Chicken Sausage)
7) Green Curry Rice (Chicken)
8) Mushroom Rice with Chicken
9) Mutton Rice with Chicken
10) Nonya Curry Rice
11) Tomato Rice (Surimi Crabstick and Chicken)
12) Yellow Rice with Chicken
13) Hainanese Chicken Rice
14) Tomato Seafood Rice (Surimi Crabstick and Chicken)
15) Chili Cheese Rice (Chicken Sausage)

Package 1 problem statement on HACCP

Problem statement:

The food company that you are working for has received many complaints from customers claiming that they had fallen ill after consuming the first production batch of a new product recently launched by your company. The Mangaging Director has deemed this incident as a serious issue that has to be address immediately. He has tasked the technical team to put up a proposal on how to prevent future occurence of such problem; and to look into all potential hazards associated with the product.

As the QA cum Food Hygiene Office, you have to submit a complete report including a product recall procedure and a HACCP plan for the product to the Managing Director's Digital Drop Box by 17th May 2010.

Part 1: Introduction
Part 2: Templates 1,2,3,4
Part 3: Discussion on HACCP
Part 4: Discussion on product recall
Part 5: Conclusions & Recommendations