13 replies to this topic

[Doug W]

Greetings all,

I am currently working on our HACCP plan, stumbling around in the dark. We manufacture high protein snack chips and pretzels. We have a stated policy that we do not do rework. Then I was trying to actually define rework in our situation and I was stumped. Anyone want to offer a thought?

Here is an abbreviated idea of our process

soya protein, tapioca, starch (other bags in powder-like form)->Mixer->Extruder->Main dryer->Seasoner / Oiler->coating dryer->packaging

The only part where I can see this product getting reworked is if a large portion of chips or pretzels are high in moisture and we run it through the dryer a second time. Is that a REWORK? Is there an actual definition of REWORK as it relates to food production?

Thanks for any ideas,
Doug

Edited by Doug W, 15 July 2005 - 04:57 PM.

[Charles Chew]

The only part where I can see this product getting reworked is if a large portion of chips or pretzels are high in moisture and we run it through the dryer a second time.

Hi Doug,
Interesting question. Base on my interpretaton of the above situation - it is certainly an opportunity for rework as it is considered a finished product but there is hope if I can presume it has not been "packed" yet.

However, please let us know how long does it take you to get your results from the moisture analyzer and also, do you have an in-line packing facility (i.e. are the products already packed) before you decide further drying is required.

Note: Generally, the temperature control for drier is monitored so this should not be an issue unless inaccurate readings due to calibration requirment.


CHeers
Charles Chew

[Doug W]

Charles,

Interesting question. Base on my interpretaton of the above situation - it is certainly an opportunity for rework as it is considered a finished product but there is hope if I can presume it has not been "packed" yet.

The redrying would take place before the product is sealed in individual retail bags.

however, please let us know how long does it take you to get your results from the moisture analyzer and also, do you have an in-line packing facility (i.e. are the products already packed) before you decide further drying is required.

The moisture analysis is done in house and only takes a few minutes.

Generally our product goes into a tote before being packaged, although this may change in the near future. The only situation where we would redry a product, would be if the moisture analysis is taken while the product is in totes and found to be out of spec. Then we would redry the product->back into totes->to packaging.

Note: Generally, the temperature control for drier is monitored so this should not be an issue unless inaccurate readings due to calibration requirment.

Although we adhere strictly to the recipe and drying is done at temperatures that are preset per each recipe, it seems that ambient humidity and heat enters in as a factor. Minnesota temperatures range from extremes of near 100 degrees F. in summer to -25 degrees F. in the winter. Humidity ranges from rain forest to desert conditions.

Thanks for the reply,
Doug

Edited by Doug W, 18 July 2005 - 06:51 PM.

[Charles Chew]

Hi Doug,

In this case, you actually do have a step for "moisture analyzer test" on intermediate product(s) after "tote" prior to either "Rework" (if test failed) or "Packing" (if test passed).

For rework - you would need to "direct" the product back to "drying step and back to analyzer test again.

Base on the information given, this is what I would do. Hope this helps.

Cheers
Charles Chew

[Doug W]

Thanks for the replies Charles,


Here are some definitions that we received from one client that are helpful to me to figure out the difference:

rework: treatment of product by a process different than what was
originally used to produce the product

recycle: treatment of a product through a predetermined redirection of
product to a previous step in the process

reprocess: retreatment of product by the same process to provide
acceptable quality and/or food safety.

Regards,
Doug

[Simon]

Greetings all,

I am currently working on our HACCP plan, stumbling around in the dark. We manufacture high protein snack chips and pretzels. We have a stated policy that we do not do rework. Then I was trying to actually define rework in our situation and I was stumped. Anyone want to offer a thought?

Here is an abbreviated idea of our process

soya protein, tapioca, starch (other bags in powder-like form)->Mixer->Extruder->Main dryer->Seasoner / Oiler->coating dryer->packaging

The only part where I can see this product getting reworked is if a large portion of chips or pretzels are high in moisture and we run it through the dryer a second time. Is that a REWORK? Is there an actual definition of REWORK as it relates to food production?

Thanks for any ideas,
Doug

<{POST_SNAPBACK}>

Doug,

Going back to your original question above, and using your definitons below, your policy is correct "you do not do rework", but you do 'reproceess' or 'double process' - it seems a sensible explanation to me. However, as the definitons could be open to interpreation -- debate --argument, possibly with customers and/or third party auditors, is it really necessary to have the statement about rework in your policy?

Just my opinion.

Regards,
Simon

rework: treatment of product by a process different than what was
originally used to produce the product

recycle: treatment of a product through a predetermined redirection of
product to a previous step in the process

reprocess: retreatment of product by the same process to provide
acceptable quality and/or food safety.

[rheath]

Hi Doug,

I agree with Simon - on all counts.

From your earlier post you mentioned you believed that the extremes in ambient temperature/humidity had an effect on the chips.

I am curious - Does any of your test history show that you have to reprocess when you do not use totes?

I have had similar experiences in my process where extremes in ambient caused difficulties with the product. After extensive studies we found that the main problems were in two areas 1. Bulk storage tank (raw material) 2. WIP storage area.

As a result we reduced the bulk storage level & WIP level which significantly minimised the out of spec/waste/reprocess levels.

I would suspect if you could shorten your manufacturing/packing cycle reprocessing would be less likely.

Just a thought..

Regards

Richard

Edited by rheath, 20 July 2005 - 08:33 AM.

[Charles Chew]

Doug,

My interpretations of "re-work" and "re-process" are basically the same although "re-work" is often the term used when "out-of-specification products" are subject to further processing to ensure product meets intended specs.

This is also the case when "withdrawn products" are subject to re-work prior to being returned to commerce.

Nevertheless, IMO I would consider these options:
a. Include a "rework step" into the flow (which is not yr policy) - so this is OUT

b. Do not include "rework step" but include the analyzer test as a pre-emptive measure for EITHER (a)WHEN GOOD - acking - finished product OR (b)WHEN OUT - "Secondary Drying Treatment" ........

Taking this step would require you to indicate the initial drying as "Primary Drying Treatment"

ANalyzer Test is your pre-cursor to "Secondary Drying Treatment" - so, there is no rework instead "secondary treatment"

Your analyzer test parameter must of course be established.

I hope it makes sense and that I have not confused things. As for rework - you do not have to explain as there is none but you have to explain what determines "secondary drying treatment" is and when it shd be responsed.

This is meant to explain in wider details compared to earlier reply. IMO, I would take this route.

Regards
Charles Chew

[Doug W]

Charles,

Doug,
b. Do not include "rework step" but include the analyzer test as a pre-emptive measure for EITHER (a)WHEN GOOD - acking - finished product OR (b)WHEN OUT - "Secondary Drying Treatment" ........

I hope it makes sense and that I have not confused things. As for rework - you do not have to explain as there is none but you have to explain what determines "secondary drying treatment" is and when it shd be responsed.

<{POST_SNAPBACK}>

This does make sense to me. At first I was concerned that redrying (which we do) was a violation of our own policy, but after discussing it and reading your comments, I can see where we can make it part of our policy as a "secondary drying treatment".

Thanks for your comments,
---------------------------------------

is it really necessary to have the statement about rework in your policy?

Simon,

The whole rework policy came about because one of the clients that we do contract manufacturing for, wanted to be assured that we don't do rework. So I do have to formally address the question in our policy.

Thanks

-----------------------------------------

rheath,

I have had similar experiences in my process where extremes in ambient caused difficulties with the product. After extensive studies we found that the main problems were in two areas 1. Bulk storage tank (raw material) 2. WIP storage area.

I suspect that our moisture problems come about partially from extended storage in totes (1 week to 2 weeks). Right now I don't have a long enough history with the plant and the records are not that extensive, but I suspect you are right, and immediate packaging would help the situation.

Thanks all,
Doug

Edited by Doug W, 21 July 2005 - 12:56 PM.

[yorkshire]

Dear Doug,

Sorry to come in late on this topic. I must have missed this whilst on holiday.

I would agree with Charles on the rework/reprocess/recyle definition. I would class it all as one, but how you word a definition ...... .

The way we tackled it was to look at all the areas making potential "rework" and assessed the risk of reusing each one. For our products there were some allergen safety risks but mainly quality issues with using rework. We then drew up a list of permitted / not permitted rework situations (anything that isn't on one of these lists then needs to be assessed).

On the subject of redrying I once worked for a large UK crisp manufacturer and worked on developing the process control on the friers (but could be used on any cooking / drying process). We set up a NIR unit above the outfeed of the frier which was calibrated to measure moisture, fat content and colour - the controller was then set to adjust frier speed / temperature automatically. At start up there was usually some waste ( can't rework crisps ) but after that it ran pretty smoothly........

[Bradi]

Yikes!!

It looks like this thread was back in 2005.

Here I am going into 2012 review and I'm still struggling with this question..."What is the definition of ReWork"? If I take dough scraps from batch 1 and reintroduce them into batch 1 is that rework? If I take dough scraps from batch 1 and reintroduce them into batch 2, is that rework?

[Madam A. D-tor]

Dear all,

I use the term "rework" for
- products out of spec,
- products which was produced in too big amount (left over);
- intermediate product 'waste' coming from your process (e.g. dough left over after punching dough for cookies);
which are added as ingredient to produce a new batch.

E.g. broken or misformed cookies can be used as ingredient for new dough.
There should be procedures available indicating which products can be reworked in which recipes and in which amount. Also traceability records should be maintained and a risk assessment should be performed to indicate the hazards involved. (e.g. allergens)

[Madam A. D-tor]

If I take dough scraps from batch 1 and reintroduce them into batch 2, is that rework?

I would consider this as rework. traceability records, risk assessment and procedures should be available.

If I take dough scraps from batch 1 and reintroduce them into batch 1 is that rework?

This might be considered as rework. There is no risk here for contamination with allergens or other ingredients due to different recipes, neither are there traceability problems. However you need to da a risk assessment to find out if other risks are involved. E.g. physical contamination, not good mixing, etc.

Edited by Madam A. D-tor, 30 December 2011 - 08:34 AM.

[Bradi]

Thanks...Happy New Year