Rework
is an unincorporated food product kept for subsequent
use or reprocessing. Examples of reworking may include:
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Handling Rework
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re-forming meat patties rejected
for being broken, underweight or improperly breaded
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reprocessing dough left over from
previous production
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repacking cookies that were
mislabeled
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re-cleaning grains that did not
meet specifications
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reprocessing cooked sausage as
pizza topping or sausage crumbles
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re-baking bread crumbs that will be
used to coat other food products, such as breaded foods
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incorporating sausage end trimmings
from one batch into the production of a new batch
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mixing production from one day into
a batch from a different day
Mishandling rework material may result in
potential hazards such as:
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presence of undeclared allergens due to cross-contamination —
for example when a product containing a specific allergen is mixed
with a product that does not contain the ingredient and labelling is
not changed to acknowledge the fact.
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contamination with pathogenic bacteria due to improper
personal hygiene or product handling practices
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growth of pathogenic bacteria due to temperature abuse — for
example, rework material that requires refrigeration is left at room
temperature overnight and used as an ingredient in the next day’s
production. Another example of rework mishandling would be to allow
frozen rework to thaw at room temperature rather than at
refrigeration temperature.
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growth of pathogenic bacteria due to time abuse — for
example, rework material stored for long period of time due to
improper stock rotation
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presence of undeclared restricted ingredients in the final
product — for example, addition of cured meat to a fresh meat
product, which should not contain curing agents
Besides these potential hazards, the addition of
rework may affect your formulation because it can modify the
nutrient content of your final product. If you need to use rework,
ensure that it does not affect the accuracy of the nutrition
declarations.
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When handling rework in your facility, note the
following:
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Identify the rework material.
Apply tags with product identification information, which may include name of the product, lot code and date of production. You
can also use color-coded containers to identify rework material.
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Store rework in a way that
prevents contamination with potential food hazards and growth of
micro-organisms
- Store rework in an appropriate environment that prevents or
minimizes food spoilage. For example, meat rework must be stored
in a temperature-controlled environment at four degrees Celsius
or less to prevent or limit the growth of microorganisms.
- Follow general good storage practices. For example:
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store rework materials off the
floor and away from walls to minimize contamination
- cover and protect rework materials
- use clean containers
- ensure storage room is adequate for storing food
products (ex: avoid pest access, permit maintenance and
cleaning)
- Establish the maximum storage time for your rework
material. For example, for meat products, the Food Safety
and Inspection Service of the United States Department of
Agriculture (USDA) recommends using rework meat only from
the immediately preceding lot or shift and only within 24
hours of that shift.
- Put controls in place to prevent storing rework material
for long periods. For example, show the amount and type of
rework on the production record. This serves as a reminder
to use the material when work resumes.
- Prevent cross-contamination with
allergens. Inappropriate use of rework
materials may result in the presence of undeclared ingredients in
final products. This may trigger allergic reactions in some people
who are sensitive to a specific ingredient or product. To prevent
cross contamination with potential allergens not listed on their
labels you may:
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Establish the maximum amount of rework material allowable in a
product to control the effect of
rework on the final formulation. The amount of rework you add should
not alter the nutrition content or the ingredient listing of the
product. Depending on the type of product, adding too much rework
material could affect the validity of the nutrition facts panel. It
could also affect the quality and shelf life of the final product.
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Develop a rework tracking system
to be able to identify the final products containing rework
materials. A rework tracking system will be necessary if a food
product is recalled because it or any of its ingredients is
identified as a health risk. If a food product is suspected of
presenting a potential hazard to the public, you will need to
identify all of its raw materials and ingredients, including rework
materials.
To keep track of your
rework material:
- develop a recording system for rework that includes the
time, quantity and processing step it was collected from, the
original lot or batch number/code and the code of the lot or
batch it was added to
- record the use of rework material from a specific lot code/batch
or production date on your daily production record
- Train your staff. Make sure you
communicate to your staff all the instructions and procedures on the
use of rework and the risks associated with the mishandling of
rework material. Post a copy of those procedures at the plant, if
necessary.
- Monitor
the use of rework. To ensure rework
material is used and handled properly, you should:
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confirm that rework material is properly identified
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confirm that rework material is stored under conditions that
protect the safety of your products (ex: correct temperature)
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observe employees handling rework to ensure they follow
proper procedures
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monitor your rework tracking system by reviewing records
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For information on the Food Safety Program contact the
CVO/Food Safety Knowledge Centre. For technical
information, call 204-795-7968 in Winnipeg; or e-mail
foodsafety@gov.mb.ca. For general information, contact your
local GO
Centre.
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