Considering the importance of the issue
of the impending population growth that carry air travel as well as
international agreements between countries and continents, it has being
demonstrated the effectiveness of the system demonstrating in practice how they
work their analysis of points of danger and an investigation into the
operational process within the context of the food industry.
Keywords: Catering. HACCP. Safety.
Operating Process.
1. INTRODUCTION
The incessant seek for
improvements, applications of new models aiming to improve the health and
quality of food; it is present from the specific quality control systems to
feeding in the aero system. A base, or even a network of airline catering
industries, production services and distribution of food on board, effective
and appropriate whose main scope and quality inspection in their food, ensuring
the consumers integrity and health. In a specialized industry of production of
meals, tools are inserted to ensure safety in its production chain and the
pursuit of continuous improvement on processes.
The air transportation has become
the choice among international trips and business, as well linked to this
growing change, on board feeding service has become one of the key factors of
providing quality and usefulness within the catering industry. Its main goal
pervades not only on taste satisfaction, but also primordially in guarantee the
food safety.
With the application startup in its
first instance, NASA (National Aeronautics and Space Administration) as a tool
called HACCP (Hazard Analysis and Critical Control Points) has brought some
significant and positive results in its first use; it has been introduced
afterwards in other businesses/industries.
Thus, the HACCP system can be
presented as a model or technique that minimizes the possible failures and
allows a business relationship between the main active professionals of the
logistics chain, benefiting the security needed to the feeding.
This study evaluates how the HACCP
system works, its changes in organizational processes within the feeding
industry in order to analyze their behavioral impacts in everyday situations.
2. BACKGROUND
According to the company studied,
the amount of service of a large catering air is high, reaching up to around
200 flights/day, and usually the flight is composed by Captain (Pilot) and
Copilot, expressing as a whole about 400 meals, only for the technical air
staff. If we calculate the amount of
passenger in the standard class on average 150 passengers per flight, the
result will about 30,000 meals per day, plus 10,000 for business and first
class, expressing as a whole about 41,000 meals/day. It is a large amount of
production of ready-made food, even for a large company.
The revenue of a catering to an
international company (services for long journeys, more than 3 hours) average
costs R$ 13,000.00/flight, which included the airport tax, representing 8% of
the total invoice. Since national companies, about 100 flights/day, the annual
revenue reaches R$ 60,000,000.00, and the values can be predicted and already
agreed in the contract.
3. OBJECTIVE
The focus is to demonstrate the impact of technical
implementation of HACCP in an organization of supplying food to companies linked
to air passengers.
Which the specific objectives refer to:
• Provide reliable food;
• To minimize the possible occurrences in the supply;
• Ensuring quality during the process in the production chain;
• Identification the origin of inefficiency in the process;
• Improvement in food security system and operational performance.
4. PROBLEMATIC
Microbiological changes in food composition and
instances of foreign objects in meals are occurring and can be caused by an
inefficient supply chain that begins at the reception of the raw material,
through the handling, transport and distribution, compromising the security of
meals supply on board of air transport, bringing negative impacts.
5. HYPOTHESIS
Food quality commitment provided by airlines to
passengers can significantly affect satisfaction and performance of the
organization. Thus, using the HACCP technique in the process of handling and
preparing food can create behavioral changes in the operational processes, as
reduce failures and minimize the risks linked to food security, improving the
business relationship in front of the partnership between the companies and the
food industry.
6. METHODOLOGY
The study aims to survey the theoretical framework
which quality and technical matters of food handling have been addressed, where
as proof of its implementation was done a
monitoring of the process for preparing two types of meals of the same
food group (according to the tool) which will be described in the study.
Visits and observations were made where there is
manufacturing process, identifying 5 Critical Control Points from the specific
supply chain to air catering under studies, thus presenting each step used in
the industry collecting such information related to HACCP and its CCP tool
technique.
For data analysis it is listed information related to
the temperature of food - for each food group is set a minimum or maximum
temperature for non-microbiological development that may result in health
problems if eaten - and their ways of packaging and handling, thus ensuring the
meal for distribution in accordance with the safety standards.
7. THEORETICAL BASIS
7.1.
Food
Safety In The Food Industry
Many of the tools aimed at food security have been
adapted to constant technological advances and the needs of products that
require the safety health, as well as contemplation in
trade relations and especially respect for the consumer. (PERETTI; ARAÚJO,
2010).
In the catering business is noteworthy the growing
concern in relation to the duty to provide safe products to its customers,
respect for the quality and commitment of everyone involved in the process are
extremely important for achieving the goal, and cherish the corporate image.
To Capiotto and Lourenzani (2010) the Food Safety
Management System is concentrated in the administrative activities of an
organization guaranteeing consumers safe products.
For this reason the quality must be present in all
operational steps as it has become a way for businesses to possess competitive
advantage over their competitors covering even the international market.
Among the most respected models and indicated the
deployment and use of safety management in food businesses in order to feed
reliability to be offered to consumers, are the uses of the qualities of BPF
(Boas Práticas de Fabricação) determined by the Ministry of Health and
agriculture, technical HACCP (Hazard Analysis and Critical Control Points) to
ISO 22000 and PPHO (Procedimentos Padrão de Higiene Operacional). (GOBIS; CAMPANATTI,
2012).
The HACCP associated with BPF and PPHO has been revealed
as a basic model for the food industry as it ensures product safety, cost
reduction since no rework generating increased profitability of processes and profitability.
(TOBIAS; PONSANO; PINTO, 2014).
In recent decades the security of quality has undergone
major changes, the measures passed corrective to preventive. Since the
management of food security, the state intervenes to respect the consumer
regarding Food safety rules determining how a product recall and appropriate
measures against those responsible.
The HACCP model applied to catering to study follows
the procedures and criteria established in accordance with its superordinate
organ, meeting all the requirements, mainly from ANVISA (Agência Nacional de
Vigilância Sanitária).
7.2.
Air
Transport
According to Bielschowsky and Custodio (2011) the
growing demand of air transportation was mainly by economic diversity and
growth that Brazil passed between the 1920s to the early 1960s, was in this
period that the shuttle was marked by a high rise.
According to researches by the OMT (Organização
Mundial do Turismo) in the Tourism Towards 2030, the number of international
tourists will grow 3.3% annually between 2010 and 2030 surpassing 1,400 million
in 2020 and 1,800 million in 2030. (OMT, 2013). In Brazil air travel is the
primary means of locomotion tourist demands and is the most significant element
for growth and consolidation. The constant changes and needs in the modal occur
in the course of globalization, and have been implemented since the beginning
services for the convenience of passengers.
In-flight service was getting innovations over time,
thank to technologies that then arose. In Brazil, starting from nonexistent and
larger companies such as VARIG, VASP and TransBrasil introduced high-standard
services since at that time only high-income people were using such transport.
(BRITISH AIRWAYS, 2015).
7.3.
Development
Of Air Catering
The first airline to serve hot food on board was
Lufthansa in April 29, 1928, for SXF (Berlin) to CDG (Paris). The B-31 aircraft
accommodated 15 passengers and had a layout structured for providing the
service. The first air independent kitchen was developed in 1946 by the
International Dobbs paying service Delta Airlaines in Atlanta. The BELA in 1967
organized his own catering at Heathrow, was from that point that other
companies began to emerge in the market as the CaterAir International, LSG
SkyChefs, Ogden Aviation Services, Chelsea Catering, CA One Services, Gate
Gourmet and so on. (Jones, 2004).
From the twentieth century on, as all other branches
of other industries had its rise, the catering was no different. Starting its
evidences with the Zeppelin airship, to serve champagne and sandwiches, and
being structured with the first hot meal with the great German Lufthansa, creating
your own kitchen (LSG Sky Chefs) post Dobbs International.
7.4.
Catering
Operations
"In aviation, Air Catering companies are
preparing meals for airlines. They are responsible for adapting the production
of industrial kitchen to the world of aviation peculiarities ". (STETTINER
et al. 2015, p. 478).
Due to the complexity of aviation, food industry had
to adapt and create a whole system in order to be able to meet the need that
air world demands, due to this complexity and hence uniqueness of each airline,
each catering establishes its flow from operations internally waking will be
processed as requests coming from airlines and their distribution to the
clothing of the dishes.
The internal organizational hierarchy plays a key
role, since the integration of all its resources benefits the reach of global
competitiveness, as the internal guidelines of a company. (LISBON et al, 2013)
To make more efficient processes and more likely to be
administered, each operating sector has its manager, as designed in the
hierarchical pyramid:
Figure 1: Designed
in the hierarchical pyramid
The teams involved in catering are characterized by
well-defined and objective hierarchies. It is extremely important the
integration of the teams in all activities and the definition of those responsible
for each part of the process. The possible indication of a problem of focus
decision-making should be stipulated to control resumed.
7.5.
Quality
HACCP
Several companies are achieving all requirements in
order to respect the quality and commitment of everyone involved in such a
specific process in the most correct and rigorous way, therefore, several
quality tools have been developed with the aim of commitment with the consumer.
According to Junior et al. (2010) a quality management
application and its implementation in organizations which develop projects has
been perceived as epicenter of conflicts, however, the systems view of quality
with the tools allows the improvement of conditions, minimizing risks and in
favor of monitoring.
Using of tools to quality management is essential, so,
surveillance, inspection, guidelines and standards to be followed by producer
organizations and food service providers the population is given as a mandatory
factor.
The HACCP (Hazard Analysis and Critical Control Points)
is a system aimed at preventing a potential contamination, rather than just
analyzing the final product (FAO, 2011). The reasons of food contamination are
mainly the lack of proper procedures in steps coming from raw material to final
product.
We can mention the example of the incorrect handling
of food and incorrect temperatures at which each food requires, since the
micro-organisms are becoming increasingly resistant addition, the lack of
resources and training that many companies still have great need for excellence
their service.
The tool is the most appropriate to the international
quality assurance control cell which OMS (Organização Mundial de Saúde), Codex
Alimentarius, the FAO (Food and Agriculture Organization) and the European
Community and the United States require as template and guidance on production.
(INMETRO, 2009). In Brazil, in addition to these organs, it is also required by
Federal Decree 1428/93 the Ministry of Health. (BRASIL, 1993).
The Codex has the functionality to protect the health
of the population and ensure both national as international practices.
According to Ortega and Borges (2012) with regard to food hygiene, the use of
HACCP is introduced through the texts of the General Principles of Food Hygiene
of Codex in ensuring safety. The Codex defines the development of practices,
manufacturing, transportation and storage of food groups or certain foods.
Since the Boas Práticas de Fabricação (BPF) consists
of a program of standards and prerequisites aimed at certifying the quality and
safety of food products, for the implementation of HACCP in industries (TOMICH
et al. 2005). Since the lack of this practice directly influences the control
of Critical Control Points thus increasing the identification of trouble spots
in the process.
According to Silva (2013) in airline catering risks in
food are more frequent than in the conventional food industry, especially the
room temperature factor unstable, it comes to long trips in which problems may
have originated or raw material, or cold chain, hot chain, cross contamination,
handling or even inadequate methods of hygiene both in equipment such as those
involved in the process.
The danger consists of biological, chemical and
physical agents that cause harmful effects to the health of consumers (BRASIL,
1999).
The identification and analysis of risks are
characterized by different stages of management, which involves identifying and
spare characterization of scientific knowledge. (ANVISA, 2013).
The HACCP system uses standardized seven principles
that are controlled and monitored every step of the process. According to Paula
and Ravagnani (2011) seven principles are:
i.
Analyze the possible risks and their countermeasures:
identification of potential dangers from the initial process to the final
determining their probability of occurrence and prevention measures;
ii.
Highlight the critical control points: operational
steps to minimize or eliminate the danger;
iii.
Establish critical limits: principle that establishes
that all CCPs are under control;
iv.
Establish monitoring the CCP: analysis, tests and
observations;
v.
Establish corrective actions, since the CCP: it does
not comply with the standards. The actions established in this step should
ensure control of return;
vi.
Establish oversight, checking the effectiveness of
processes: audit and analysis in the validation of correct procedures of the
HACCP system are made at this stage;
vii.
Establish documentation for all procedures:
registration of all stages and monitoring.
The Critical Control Points is a stage that there is a
risk, and then applied preventive measures to control, eliminating, preventing
or reducing that fault. In airline catering in the study of food preparation
processes are done in 5 stages of Critical Points, which a according to each
food group should not be performed according to established norms. The model
used by the company is presented in the following chart:
Table 1:
Description of the 5 Steps Used the CCP – 2015
8. STUDY OF CASE
The company under investigation is the leading global
airline catering segment and its main span of service on board, it is part of a
European group between branches and head office which has more than 150
companies that are increasingly on the rise, and up to now serves in 52
countries across Asia, Africa, Europe, North and South America. In 2014 were
produced more than 600 million meals to the global aviation, from freighters,
through executive jets, which the domestic flights is the most part of the
revenue in the industry.
Its growth accrues from the high rates of flights on a
global scale, as aviation is reaching large peaks of air trips since the 90s,
aviation-related company has grown considerably in proportion to air transport.
Its focus is on the quality of operational processes
as a key point in the excellence of its services. In relation to the process of
all preparation of food to be consumed, the tool used in the production chain
is the HACCP, being used internationally by catering companies and also by
other companies in the food industry which are adopting the technique as an
improvement model in their productive chain.
The application shown in the study consists of the
steps of the Critical Control Points that at each stage and any minimal
occurrence and the probability of an eminent risk, preventive measures will be
implemented by eliminating or reducing this danger. It can be in the physical
form as hair, glass shards, nail-chips etc. or chemical form, for example,
cleaning products and poisons pests among others and finally biological risks
consisting be the most dangerous.
Visits and observations were made in the manufacturing
process sites, identifying the analysis of the 5 Critical Control Points in
supply chain, specific to air catering under study, from receipt of raw
materials to the food handling.
8.1.
CCP
01 – Reception
It is the first critical point that should be checked
on receipt of the goods. It is at this stage that there is a verification on
the conditions of the food being delivered, it should be considered some
important points, such as:
• Food temperature;
• Packaging Verification: clean and inviolate;
• Product appearance;
• Labels should contain the name of the product;
• Lot, manufacture and validity;
• Truck cleaning conditions ensuring that there are no insects or pests;
• Correct transport in cleaned boxes and pallets.
The responsible person for delivering of the goods
must follow the statutory guidance system as wearing cap, uniform and being
shaven. And the responsible for the receipt of goods has full responsibility to
ascertain such measures and write down on a sheet in case the CCP 01
documentation.
If the product does not comply, the product should be
discarded and be made to return to the supplier and the it must be notified of
the problem. It is also important to complete the claims form the supplier that
must be signed by a person responsible to the Purchasing Department. They must
withdraw two copies, because one will get the delivery, the other with the
receiving dock and original to the Department of Quality
8.2.
CCP
02 - Temperature Chambers And Enviroment
This step is important to note that bacteria do not
multiply at quite low temperatures, so to ensure the safety and preservation of
food is required to be made constant monitoring of the chambers and environment
temperature. The ambient temperature should be at 15ºC and the temperature of
cold room 5ºC and Freezers 18ºC. Since the temperature of the defrosting
chambers should not exceed the 8ºC. If it is not in the standards it should be
operated to maintain promptly.
8.3.
CCP
03 – Heat Treatment Of Food
Cooking temperature control procedure of food is an
important point, because the most part of bacteria die at high temperatures.
Foods that are cooked should reach the minimum temperature in its geometrical
center, to check that it is used a cookery thermometer.
The professional responsible for cooking must register
the temperature of all foods with no exception. If the food does not reach the
required temperature, as a corrective action the food must be reheated.
According to each food group of animal origin such as
meat, fish, poultry and eggs should be achieved the required minimum
temperature:
•
Group A (temperature + 74C - Instantaneous) - Goulash,
Bobó, Stroganoff, Burger, Poultry,
Bovine Meat, Fish and Stuffed Pasta;
•
Group B (temperature + 70 ° C - Instantaneous) -
Scrambled Eggs and omelets, shrimp, shellfish (Minced);
•
Group C (temperature + 65 ° C - Instantaneous) - Beef
and lamb meat;
•
Group D (temperature + 66C - For 1 Minute) – Whole
Beef Roast (Eyeround and roast beef);
•
Group E (temperature + 63 ° C - For 15 seconds) - Tournedor Meats (Sealed);
•
Group F (temperature + 63 ° C - For 15 seconds) -
Sliced Bacon, Loin / Built-Plated and Tenderloin to Plati Plated.
8.4.
CCP
04 - Cooling Food
Part of the process, which is done the control of time
and cooling temperature of food after they have gone through cooking. As
mentioned bacteria are very sensitive to environment and temperature. Most die
at very high temperatures and it is difficult to them to multiply in such cold
areas.
So there is in the catering what is called the Danger
Zone, which are temperatures from 10 ° C to 60 ° C, and the multiplication of
bacteria occurs. The cooling process minimizes the risk of contamination,
because the passage through Danger zone is reduced to a shortest possible time.
At the cooking process, the heating from outside to
inside is made, as the cooling is also carried out in the same way. It is very
important to measure the temperature of food in its geometrical center.
The professional responsible for firing blast chiller
sector, should make records in the CCP Form 04 daily to all kinds of food
passing through the cooking process. Remembering that the professional must be
careful to potentially dangerous products, such as meats, omelets and chicken.
No food can leave the blast chiller without having
passed through the cooling process. Since it is dangerous to use warm food, or
warm in the assembly of the dishes, as can occur multiplication of bacteria,
contaminating them.
8.5.
CCP
05 - Temperature And Food Handling Time
This is the last step of the whole process and refers
to the temperature and time of food handling. The ambient temperature in a
catering does not exceed 15 ° C and the time of preparation for each plate may
not be exceed the specified time to each dish.
Following the controls of all the CCP will be
demonstrated according to the survey in the business catering which were
applied in the stages of production in chicken and meat options.
The service for
chicken was made up of: the Chicken
Parmesan, Tomato Sauce, Mix Vegetable and Sauté Potato; and the service for
meat was made up of: Goulash Rump Steaks and Carrots, Mashed Potatoes with
Garlic, Black Olive and Carrot Stick. The total volume in the same services was
75 chicken options and 75 meat options.
8.6.
Trancking
CCP (CRITICAL CONTROL POINT)
Table 2:
Tracking of Process: Poultry and Beef
According to all tracking, steps of that food reached
the required food safety criteria, with no great risks to the health of those
who will consume them. It is important to mention that the incubation time of
the bacteria can be between 6 and 48 hours after ingestion of contaminated food
and differs according to the characteristic of the microorganism. Therefore in
cases of suspected food poisoning it is essential to be realized the
"recall” of the food consumed in the last 48 hours (previously to the
symptoms), further on the description of the symptoms. It is also important to
mention that appropriately skilled teams with common sense decision to practice
any taken precautions to minimize or oppose potential risks to health should
review the records daily.
9. CONCLUSION
According to the HACCP tool and application of its 5
Critical Control Point presented in the study was possible the analysis of an
improvement in the adequacy of the food handling, reaching the specifications
transmitting reliability which the scenery guarantees the insured product,
avoiding disagreements versus specifications.
The principles highlighted ensure the food conditions
from reception, which are checked temperatures, packing labels, dates of
manufacture and expiry, and especially the truck cleaning process, through
storage in the catering warehouse, cooking, cooling the blast chiller and
assemblage controlling the temperature and way of handling, making it possible
to identify the chemical, physical and biological risks. In fact, it was not
observed in this case as in all steps verified the product has been identified
in specifications, required norms and standards.
When preparing teams according to the specifications
and requirements of HACCP methodology, conditions to the improvement of
security and operation where it takes place, since everyone can understand and
have an overview of all integrated processes.
Thus, it was possible to notice that in addition to
bringing the benefits specified before the conduct HACCP, principles also
reflect on the safety for the passengers' integrity. Leading the good
relationship between the airline and its customer, consequently enhancing the
business relationship front of the partner company and catering, ensuring
effective gains and mainly upgrading in the quality of their operational
processes, providing comfort and integrity to the airline while paying their
board service.
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