Food Manufacturing - May/June 2018

and/or packaging. This is ideally done at the time the system is originally installed in a production line, and then becomes one element of a complete program of validation, periodic verification and ongoing monitoring that will keep the system operating as intended and ensure that products are adequately and accurately inspected, and that accurate records of those inspections are kept.

It is critical for producers to remember, however, that the original onsite validation relates only to the specific products tested at the time. As new or additional sizes of products are developed and run on the production line, or packaging (including labeling) changes, the system will need to be revalidated for each change.

Verification

Verification is the process of periodically confirming that the inspection equipment continues to be as effective as when it was first validated. The verification process uses standard, established tests to determine whether the inspection system is still under control and continuing to operate as originally demonstrated. This verification process is conducted periodically at regular intervals to provide evidence-based confirmation that the system continues to be effective as specified. Formal performance verification is typically an annual process, to support audit requirements. It should continue throughout the productive life of the system.

Both validation of an installed system, and periodic verification of operating systems, can be conducted either internally by the end-user, or by the supplier of the equipment. Validation ands verification services are often included as part of equipment purchase contracts.

Monitoring

Routine performance monitoring, which is distinct from periodic verification, consists of a series of frequent regular performance checks, during production, completed to determine whether processes are under control and to confirm that there has not been a significant change in the system’s performance level since the last successful test. The monitoring frequency may be as often as every two hours, depending on company standards, industry standards and/or retailer codes of practice.

If the monitoring process finds that a particular device is out of specification, all product that has passed through the production line since the last successful routine performance-monitoring event must be considered suspect and reinspected.

In many cases, it is line operators that conduct online performance monitoring. However, many of today’s more sophisticated product inspection systems incorporate built-in performance monitoring software that automates this process and alerts operators when deviations occur. This valuable software feature removes any human error factor from the monitoring activity to help ensure that inspection processes are still being performed properly. It also provides documentation that will guide the end user company’s QA groups in their continuous improvement efforts, and that will also be a valuable asset in the event of an inspection visit from regulators.

Routine performance monitoring can also have a direct impact on the production line’s OEE (Overall Equipment Effectiveness). Installing a system with built-in condition monitoring capability that automatically detects when the system may need correction, and communicates that information directly to line operators, reduces the frequency needed for verification testing, maximizing the line’s production uptime.

Reliance On
The Experts

Finally, food
manufacturers and
processors should
remember that while
they are knowledgeable
experts regarding their
products, it is their
equipment suppliers
that are the experts
on the capabilities and
qualification procedures
of their equipment.
That expertise
makes them the best
source of reliable
on questions surrounding the most
effective inspection equipment type for
specific product needs, where to place
that equipment on the production line for
optimum results, and how to validate,
verify and monitor its performance.

Relying on these experts to conduct onsite validation and to advise on conducting periodic verification and ongoing performance monitoring can reduce both the time needed for the original onsite validation and the time needed for verification and ongoing monitoring procedures, thereby increasing productivity.

Companies can also rely on these experts to be knowledgeable about the most current food safety regulations and the technology that affect equipment validation. It is critical for their success that they stay current on those topics, and sharing that knowledge is a valuable part of their service.