Getting a Facelift

AIB’s most widely used, and most globally recognizable product, is, hands down, the Consolidated Standards for Food Safety. It has been in use by countless food businesses worldwide for more than 50 years as an invaluable tool. For many in the industry, the AIB Standards are a household product that food safety programs, inspection plans and training agendas are designed around.

However, a lot has changed since the Standards were last updated in 2000. Technological advancements have seen an increase in automated equipment and more reliable testing methods. Market pressures have changed product needs, introduced new foods and created a non-negotiable demand for safe food products. Today’s unified global market has impacted material sourcing and readiness and exposed emerging food safety issues in global headlines.

From a regulatory standpoint, the FDA’s Food Protection Plan, as well as the 2006 FDA white paper that emphasized allergen control, food defense and training have impacted the AIB Standards. Finally, AIB’s own focus on developing prerequisite programs to support overall food safety have all contributed to the need to significantly rethink the Consolidated Standards.

On Jan. 1, the AIB International Consolidated Standards for Inspection will take effect. The Standards revision process has been a company-wide effort that has taken more than a year and numerous experienced professionals to complete. AIB is very proud of the final product and is confident that the new Standards will be a welcome change in the industry.

THE PROCESS. In 2007, AIB’s food safety leadership began a thorough technical review and update of the content of the AIB Consolidated Standards for Food Safety. Once the technical work was completed, we then proceeded to develop additional content to support the understanding and application of the Standards. Next, using best practice instructional and document design, we created a dynamic, highly practical and visually attractive publication. As a final, critical stage, we sought detailed input from our Food Safety Advisory Board, our customers and our entire field audit staff and incorporated numerous additional changes and improvements. As a result of these events, the Consolidated Standards were redesigned.

Our main goals through the revision process were:
1. To provide an updated, more user-friendly and adaptable training tool
2. To stay current and relevant in the ever-changing food industry
3. To create an inspection-focused document
4. To meet global industry and regulatory demands
5. To reduce inconsistencies in the inspection and audit process
6. To maintain our core mission to provide fair and thorough educational food safety audits for the continuous improvement of the food industry and the increasing satisfaction of our customers

Updates to the Standards have been reviewed by every member of our audit services and food safety education team. We made sure to only make changes that are necessary, relevant and can be applied across the globe. Our entire staff has been trained on the updated Standards to ensure understanding and consistent application. We are confident that the new Standards will reduce confusion, aid program implementation and promote the general betterment of our customers and inspectors.

WHAT CHANGED? Rest assured that although much has changed in the format and visual appearance of the Standards, the underlying structure and core content, reflecting wisdom and knowledge accumulated during the past 60 years, remains intact within the new document. We worked hard during the review process to assess the ease of “operationalization” of the Standards and were highly reassured by the feedback we received.

The name: Perhaps the most noticeable change is the name. What were formerly known as the AIB Consolidated Standards are now renamed The AIB International Consolidated Standards for Inspection. AIB has always taken pride in being inspection-based. Inspections are focused on evaluating conditions and identifying issues within a facility in order to verify program effectiveness. This activity allows the inspector to evaluate program implementation based on what (s)he identifies on the floor. Inspection is a fundamental discipline because it provides a realistic assessment of a facility’s conditions at any given time.

In addition to inspecting, our inspectors also spend time evaluating written programs and reviewing documentation and records to evaluate effective implementation and execution of food safety programs. This audit approach places less emphasis on evaluating conditions within the facility and more emphasis on evaluating paperwork. The updated Standards clearly distinguish between inspection and audit criteria.

The former AIB Consolidated Standards for Food Safety are now named The AIB International Consolidated Standards for Inspection of Prerequisite and Food Safety Programs. AIB strongly believes that food facilities need to develop and implement sound Prerequisite Programs as a foundation to support food safety and HACCP. This is now clearly indicated throughout the Standards.

The size: Another very obvious change is the physical size of the Standards. In the past, the product was available as a downloadable PDF or as a 5½-inch by 8½-inch booklet. The updated Standards still are available to download, but we now offer a larger 8½-inch by 11-inch size, as well as a pocket-sized version that can be carried onto the floor as a reference tool.

The introduction: The newly written introduction describes the purpose of the Standards, why they are important to the food industry, and how to use them. This section also provides helpful information about the rating system, the difference between an inspection and an audit, and AIB International’s food safety background.

The ratings process: Great effort was put into revamping the ratings process to ensure fair scores and to provide an accurate picture of the facility on the day of the inspection. The ratings process is clearly described with examples, exceptions and helpful graphics along the way to reduce any confusion or anxiety. AIB wants to ensure that the ratings we assign truly represent the food safety level in a facility.

Mathematically it is possible to receive a Serious rating in a Category and still have an overall score above 800 (Excellent) or 900 (Superior). However, AIB believes that serious issues need to be recognized with an assigned numerical score, as well as an appropriate word rating. So, any facility receiving a Serious deficiency in any Category will have their rating lowered by one level if the total numerical value equals a Superior or Excellent. For example, if a facility receives an overall score of 850 (Excellent), but has one Serious finding in the Cleaning Practices Category, the word rating changes from an Excellent to a Satisfactory.

We have also added a Pass rating for facilities that receive an overall score between 700 and 795 with no unsatisfactory items identified.
The language: The new Standards are much more reader-friendly. The language is less “regulation-like” and more consistent and specific. This lessens the opportunity for confusion and is more effective as a training tool. The language is also more global. We have reduced the usage of words like “manner” and “provision.”

Anyone who is familiar with the Consolidated Standards will notice that we have eliminated the usage of the words “shall” and “should.” The former “shalls” are now known as Critical Requirements and “shoulds” are Minor Requirements. This will clear up any uncertainty about AIB’s expectations and allow readers to focus on important requirements at-a-glance.

The content: The new Standards include added and expanded content. Our experts considered new industry trends, new GMP requirements and information missing from the previous version. The information was added so that we can meet our customers’ needs and remain current. For example, the Integrated Pest Management Category now covers facility assessments, other guidelines, pheromone monitoring devices and wildlife control. The Adequacy Category has added requirements for Chemical Control, Allergen Control, Food Defense and Traceability.

We also consolidated the content so that topics are grouped together in one location in a logical order. This makes the Standards easier to read and navigate.
Standards level: The new design places each Standard at one level. The format lists the Category, the Standard, and then the Critical and Minor Requirements for that Standard. This will lessen confusion and ease updating and automation. An example is:

4. Integrated Pest Management (IPM) Category

4.1 IPM Program
A written IPM Program ensures the facility has effective controls and processes in place to minimize pest activity.

Critical Requirements
4.1.1 The facility has a written IPM Program.
4.1.2 The IPM Program incorporates the requirements of the facility’s other written Prerequisite and Food Safety Programs.
4.1.3 …

Minor Requirements
4.1.4 If the IPM Program development and implementation is outsourced to contractors, the Program includes responsibilities for both in-house personnel and contractors.

As you can see in the example, all Standards measure one item and are discrete. During our review, we separated some Standards and made sure that none overlapped.

Each Standard presents the core element, the reason for the requirement in italics, and then the necessary elements to meet the program requirements in numbered format with key words or phrases highlighted to help the user identify the key information.

The categories: The order of the categories has changed to better reflect the flow of the inspection process. Programs and paperwork are reviewed at the end of the inspection to verify that the findings on the floor coincide with the level of program implementation.

Two of the categories have been renamed to provide clarity and to reflect industry terminology. The Adequacy for Food Safety Category is now called Adequacy of Prerequisite and Food Safety Programs. The Pest Control Category is now called Integrated Pest Management.

Support material: The final significant change is the addition of support material to help our clients understand AIB, prepare for inspections, conduct self-inspections, address additional GFSI requirements, and learn more about Prerequisite Programs.
There are nine Appendices:
• Participating in an Inspection
• Documents to Have Ready for an Inspection
• Formal Complaint Process
• Conducting a Self-Inspection
• Non-Rated Program Enhancements
• GFSI Benchmarked Standard Audit Requirements
• Integrated Quality Systems
• Training and Education Materials
• Glossary

ROLL OUT. The AIB International Consolidated Standards for Inspection of Prerequisite and Food Safety Programs take effect Jan. 1. The Standards will be available at www.aibonline.org. The program changes and content changes will be clearly documented to help customers identify requirement changes. In the fall, AIB clients received electronic and hard copies of the Standards and be invited to participate in webinars that will explain changes and allow ample time to review and implement any necessary program changes.

Some new Standards will be available on Jan. 1, including:
• Prerequisites and Food Safety (in English, Spanish, Japanese, and Chinese)
• Beverages
• Food-Contact Packaging Manufacturing Facilities
• Food Distribution Centers
Other versions of the Standards will be available later in the year, with translations following as required. These include:
• Dairy
• Retail
• Non-food Contact Packaging Manufacturing
• Fresh Produce and Fruit Packing
• Grain Handling
• Agricultural Crops
• Fresh Cut Produce

All Consolidated Standard inspections will use the new rating system beginning Jan. 2, even if the Standards handbook has not yet been revised. For example, dairy facilities will be subject to new ratings even though The AIB International Consolidated Standards for Inspection of Dairy Facilities will not be available until later in 2009.

Many factors including the changing food safety environment and technological advancements have lead to the modernization of the AIB International Consolidated Standards for Inspection. The key outcomes of the new Standards are a more globalized content, a user-friendly format, the identification of core requirements and a tool that facilitates learning. We are confident that our customers will agree that the new format and additional tools of the new Standards will AIB

Bonnie Biegel is Director of Product Development and Kerry Beach is Publication Coordinator, AIB International.