Additional voices on food safety audits

Posted: October 30th, 2011 - 4:26am by Doug Powell

The Denver Post also weighs in this morning on the role of third-party food safety auditors in the wake of the listeria-in-cantaloupe outbreak – big thumbs up from the auditor just before the outbreak.

It was only the latest incident when a "third-party" audit — slammed as an inherent conflict of interest by safety experts — failed to note deadly mistakes in a food operation.

• Nine people died and thousands were sickened after a salmonella outbreak at
Peanut Corporation of America in late 2008. Investigators found goods were shipped despite positive pathogen tests, as well as rodents, leaking roofs and extensive mold. An auditor before the outbreak gave the company the "superior" nod.

• FDA inspectors found filthy conditions, from overflowing manure to maggot infestations, at two Iowa farms where hundreds of millions of eggs were recalled last year. Court files show "Record of Achievement" audit certificates before the salmonella outbreaks.

• Earthbound Farm regularly got passing audits before an E. coli outbreak in greens was traced to the farm. The 2006 outbreak sickened hundreds and contributed to three deaths.

• In 2007, after an E. coli outbreak was traced to frozen beef patties from Topps Meat in New Jersey, federal inspectors found multiple problems. The company's vice president questioned "why and how personnel from his company, outside auditors or consultants failed to find these noncompliances," according to a 2007 USDA document.

• And in a 2007 salmonella outbreak linked to Veggie Booty snacks, a third-party audit swabbed the manufacturing plant for salmonella but found none. Federal inspectors later found the bacteria in snack seasoning.

Grocers are re-examining their supply systems in the wake of 28 deaths and cantaloupe's ruined reputation as a result of the Jensen Farms listeria.

Costco will require its cantaloupes to pass a "test and hold" program before they make it to the produce department, meaning a few sample cantaloupes per shipment will be swabbed for bacteria. The load won't ship until lab tests clear.

"That is greatly going to improve the overall food quality in the marketplace," said Craig Wilson, head of safety for the retailer.

Costco uses just nine third-party auditors out of the 120 to 130 available, Wilson said. Every food item in Costco stores comes from a producer inspected by one of those nine auditors.

"The real key to this is audit-company responsibility," he said. "Are they going to step in and help sort out the problem?"

Other grocery store chains were less willing to answer questions about their use of private auditors. Walmart and Safeway officials said they were always looking for ways to improve food safety but wouldn't elaborate.

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Comments

Anonymous says:

I am posting on behalf of someone else -- dp I find this article funny. Having worked on both sides of this story, both federal and industry. I will tell you it is not hard to have your plant/facility ready for a 3rd party audit. I have seen the worse of the worse plants, clean organized and ready for that dreaded 3rd party audit. I have helped plants with no QA staff for months prior, prep, clean and organize and get Gold Standard on 3rd party audits. Unlike federal inspection audits, all third party audits come with months of prior notice. Some facilities (especially those with gold standard) can schedule their audits up to 1 year in advance. This means they have months to clean and organize, and that is what they do! 2 to 3 months prior to the audit, people are brought into the plant to clean all the corners (it is disgusting what is sometimes found) and the QA staff are prioritized to cleaning up the paperwork to ensure requirements are met. As a federal inspector, I can tell you I get a real giggle out of the day and night difference that suddenly shows up at audit time. What is shocking is that the companies that hire these auditors are not aware that this is not what is done throughout the year. Follow-through does not exist, and within a few weeks we are back to where we were before the audit. But a federal inspector never announces a visit. We see things that the company's wish no one knew about. That is the danger with complacency in inspection. If a federal inspector comes at the same time everyday or month or year, then the plant is prepared (just like with 3rd party audits). Overtime the inspector begins to have an underlying assumption of how things are done, resulting with items being missed, which is why many times government agencies rotate their staff (new eyes, issues are new again). That is why government inspectors can find more, see more, and identify more than 3rd party auditors. If the companies TRULY want their 3rd party audits to be effective, they must be unannounced, at different times during the year, by different auditors. This will ensure all issues are found and addressed.

Posted on October 31st, 2011 - 12:21am

Mark Jarvis says:

Doug, There has been some interesting commentary recently about third party audits and the role of audits in general. As CEO of one of the largest auditing firms in North America, I feel compelled to share a few thoughts. Firstly, I would say that some of the auditors and the CB's they work for are very deserving of the criticism, and you don't need to be an expert to figure out that some of the things they do make no sense. Sending in auditors who have inadequate training and credentials, doing audits that clearly lack rigor, are too short (the Primus audit at Jensen Farms was reportedly done in 4 hours), are based on meaningless standards, etc. are all head scratchers. However, to some degree I think you are barking up the wrong tree. There are good and bad players in every industry, and if the major brands, both the producers and the retailers who buy from them are going to rely on third party audits, they should do a whole lot more to ensure that they are setting themselves up for success. In fact, if they really care about what they do, they should consider doing second party audits - but either way, they should pick a standard that makes sense and meets their needs, select an auditing company and auditors who can be trusted to do good work, performance manage them and follow up on their findings with a sense of urgency. That is why I believe that a "high touch, high value" auditing solution is the way to go. If you want an audit you trust, work with people you trust to do good work: its that simple. And, although I have taken heat from people in the industry for my views on this, don't be fooled into believing that the GFSI movement and the concept of "once audited, accepted everywhere" is going to fly without a major overhaul. Nobody can agree on standards, the accreditation process for Certifying Bodies is flawed, the level of execution even under the same scheme varies widely, and on and on. The fact is, there are very few audits performed even under the GFSI scheme that deserve to be "accepted everywhere" - BUT they do exist and there are companies out there that are genuinely committed to doing great audits. The problem of course, is that not everyone wants to sign up for that kind of service. Left to their own devices, most manufacturers will go for the cheapest and easiest way to get certified, and that is where the problem lies. In the final analysis, this is corporate governance issue. Food companies (a generalization of course) seem to obsess over everything else but their commitment to reasonable care, which is a monumental miss. If the Boards of Directors of major food companies are genuinely committed to healthful, nutritious, safe food; they would be far more sophisticated in their approach to understanding and managing the risk down to acceptable levels, they would have a heavy-hitting quality assurance executive reporting directly to the board with the power and budget to get things done and a mandate to build a food safety-centric culture, they would insist on having visibility and control over their supply chains, and they would never blame some crappy third party audit for their failures.

Posted on November 1st, 2011 - 2:58pm

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