Control of foreign material in glass walks and glass lists

Foreign material ranks number 2 in the top 5 recalls. How is that possible? Aren't we doing everything we can to prevent this? But are we really? In the article below, food safety expert Dirk van Loon delves deeper into the phenomenon of 'glass lists' or 'glass walks'.

How often should you conduct a glass walk?

I frequently encounter companies conducting what's commonly referred to as a glass list or glass walk. When I ask how often they perform this, responses range from monthly, once a quarter, or even once a year. There is no specific frequency prescribed for conducting glass walks in a food processing company. The frequency of glass walks should be based on a risk analysis that considers the specific circumstances of the company. A risk-based glass list is an important part of controlling foreign materials in food production.

The frequency of glass walks should be determined based on factors such as:

• The type of food product being processed.
• The presence of glass in the production environment.
• The likelihood of glass breakage.
• Previous incidents involving glass.
• The effectiveness of other preventative measures.

What is a glass list and why is it important?

The glass list is a tool for food processing companies to control the presence of glass (and hard plastic) in the production environment. This document or system is designed to ensure food safety and prevent glass particles from entering food products. The glass list serves three key functions:

1. Identification of risk sources
   A glass list helps companies identify potential sources of glass. Consider glass packaging, equipment with glass components, or other materials containing glass. Identifying these risks is the first step in preventing glass particles in your product.
2. Preventative measures
   The glass list describes preventative actions to minimize the risk of glass breakage or contamination. Examples include:
   a) Regular visual inspections of machines and packaging.
   b) The use of detection equipment that locates glass particles.
   c) Using alternative materials such as plastic or metal where possible.
3. Monitoring and controls
   A glass list also documents how and when inspections occur. Regular checks ensure that procedures are accurately followed and risks are identified early. This minimizes the chance of dangerous situations.

How do you conduct a glass walk in your production environment?

We take the glass list and then perform the entire walk. Each area is listed, and for each area, there is an overview of parts containing glass and hard plastic. An example is the clock in the canteen or the radio in the warehouse. Naturally, items such as plexiglass doors of machines and the little glass covers of pressure gauges are also on this list.

What happens if you don't conduct glass walks frequently enough?

Imagine you check the entire list once a year during a glass walk. If you then encounter something damaged – or worse – the glass of the pressure gauge above open product is missing. Repair it? Certainly. But where did the little glass cover go? Oops... A recall. But how far back do you go? A day's production, a week, a month, a whole year? Who contacts the NVWA and informs the customers? Also, don't forget to notify the certifying entity/entities that something went wrong.

How do you prevent foreign materials (glass/hard plastic) in your product?

• Design production lines where glass and/or hard plastic is NOT placed above open product. Prevention is better than cure.
• Conduct a risk-based glass list or glass walk. Thus, parts containing glass or hard plastic and located directly near open product should be checked more frequently. The frequency is based on risk. This may be before production starts, line release, daily, or another frequency. The risk determines this along with the consideration of how quickly it reaches the customer. If the release takes a few days and the product is long in transit, the chance is small that it is on the shelves, and a recall is unnecessary.
• The well-known food safety culture! That employees are aware of food safety and the dangers of glass breakage. It enhances the culture where glass breakage is always reported and controls are indeed executed and documented.

"So once again the question: are you in control of foreign material, specifically glass or hard plastic?"

If you have questions regarding this story, please do not hesitate to contact me or one of my colleagues, and we will be happy to assist you. Send me a message via my LinkedIn page or fill in the contact form.