vital calculator v2.x.y : worked examplesallergenbureau.net/wp-content/uploads/2013/11/vital...vital...

Toll Free 1800 263 829 (Australia) Toll Free 0800 263 829 (New Zealand) VITAL 2 – Example March2013Email [email protected] website www.allergenbureau.net

VITAL Calculator v2.x.y : Worked Examples

Contents page

Helpful hints for using the VITAL Calculator(i) Accessing the VITAL Calculator(ii) Downloading the VITAL Calculator(iii) Opening the VITAL Calculator(iv)Navigation tools

3-4

Example 1: Finished Product (Chicken Soup) Table 1: Recipe and Allergen Status of Raw Materials Enter Product Information Choose Relevant Allergens Concentration/Hydration VITAL Action level Grid Enter Recipe (Raw Materials) Enter Allergen Status for each Raw Material Enter Sources of Processing Cross Contact Enter Processing Impact Details Choose Relevant Summaries Reading the Summary Report

5-18

Example 2: Ingredient intended for further processing (Banana Flavour) Table 1: Recipe and Allergen Status of Raw Materials Enter Product Information Choose Relevant Allergens Concentration/Hydration VITAL Action level Grid Enter Recipe (Raw Materials) Enter Allergen Status for each Raw Material Enter Sources of Processing Cross Contact Enter Processing Impact Details Choose Relevant Summaries Reading the Summary Report

19-29

Appendix 1: Where did the information about the allergen status of ingredients come from?

30


These examples relate to the use of the VITAL calculator and are not intended as the sole document to understand the theory of VITAL. They are intended to be used in conjunction with

1. the Food Industry Guide to the Voluntary Incidental Trace Allergen Labelling (VITAL) Program Version 2.0 (‘the VITAL Procedure’) http://www.allergenbureau.net/vital/vital-downloads

2. Frequently Asked Questions – available at www.allergenbureau.net

The Allergen Bureau recommends attending training on the VITAL Program. Refer to the website for a list of Australian, New Zealand and international Allergen Bureau-endorsed VITAL trainers.http://www.allergenbureau.net/vital/vital-training


Helpful hints for using the VITAL Calculator

(i) Accessing the VITAL calculatorThe VITAL Calculator is freely available to be downloaded from the Allergen Bureau website. The calculator will be updated from time-to-time as changes are required and these changes can be tracked using the version number (denoted x & y i.e. VITAL Calculator v2.x.y). The version numbers of the calculator will be updated when there is a significant change, such as a change to a Reference Dose (i.e. the x will change) and when there are minor changes (i.e. the y will change). Ensure that the most recent version is being used. It is important to ensure that your correct email address is recorded when downloading the calculator as any key changes will be advised via email. Please contact the Allergen Bureau to advise any problems or future improvements to the calculator – this is a food industry tool so your support is key to maintaining and improving this tool.

(ii) Downloading the VITAL CalculatorNotes:

The VITAL Calculator can be freely accessed from www.allergenbureau.net At the time of writing, a version of the VITAL Calculator has not been

produced that is compatible with Mac computers or software other than Microsoft Excel.

Download the version of the calculator compatible with your version of MS Excel. Only the correct version will run without errors.

Ensure that macros are enabled – refer to the help menu of your version of Excel or your Helpdesk.

Save the calculator and then open from the saved location.

(iii) Opening the VITAL CalculatorNotes:

The VITAL Calculator contains macros and the security settings on Excel must allow macros to be run. Refer to the trouble-shooting instructions on the opening page of the VITAL Calculator. Consult your IT department if the security settings are controlled by your company.

Open the VITAL Calculator. Click on grey button called ‘Launch VITAL 2.x’ (on the ‘Calculator’ worksheet) to open the calculator. Note: there is also an option to ‘Launch VITAL 2.x in Low Res Mode’ which should be used when the calculator does not fit correctly on your screen size.

Some users may find issues when trying to open a second MS Excel document when the VITAL Calculator is running – try the following:-Open the VITAL program-To open a new instance of Excel, go to the Start Menu, choose Excel from the programs list, OR if you have a link to Excel on your desktop or tool bar,


then you can open it from there.-Use File -> Open or Ctrl + O, open up the file you wish to view

(iv) Navigation toolsNotes:

The VITAL Calculator can be navigated by “point and click” or by using the ‘TAB’ and ‘ENTER’ keys. The quickest way to enter Raw Materials is by using the ‘ENTER’ key.

The Main Menu allows access to -New Assessment: start a new assessment-Edit Assessment: use when you are opening a previous assessment in order to edit it-View: can be used to look at the information in the calculator without editing it-Calculate Action Levels: use to find Action Levels for your product-Print Reports: print summary reports from a previous assessment

Click “New Assessment” to start assessing the product The question mark icons used throughout the calculator can be clicked to

provide further information Throughout the calculator there are options to return to ‘Main Menu’, ‘Save’

and ‘Save As’. Also, in some parts of the calculator, there are options for easy navigation such as “Jump” which allows the selection of a particular raw material or processing impact.

Any opportunities for improvement, errors with the VITAL calculator or other feedback would be welcomed. Contact the Allergen Bureau through the website or email [email protected].


Example 1: Finished Product (Chicken Soup)

Refer to the VITAL Procedure section of the Food Industry Guide to the Voluntary Incidental Trace Allergen Labelling (VITAL) Program. Carry out the first seven steps of the process (pp 4-7) to determine the allergen status of the raw materials and perform a risk assessment for cross contact allergens due to processing. See Appendix 1 for details about looking for cross contact allergens.

In this example, the following recipe and allergen status of ingredients are listed in Table 1.


Table 1: Recipe and Allergen Status of Raw Materials for Example OneProduct: Condensed Chicken and Vegetable Soup Product Code:XD114 Date of Assessment: 15/6/12 Serving Size: 50gColumn 1 Column

2Column 3 Column 4 Column 5

Ingredient Name

Quantity Allergen statusIntentionally Added

Cross contact Form of cross contact allergen

(Readily Dispersible or Particulate)

Water 63.0% - -Flour 10.0% Gluten

(wheat)-

Chicken 9.0% - -Carrots 5.0% - -Celery 5.0% - -Cream Powder

3.0% Milk -

Onions 2.0% - -Maize Starch

2.0% - Soy (22ppm) Soy flour – Readily Dispersible

Salt 0.5% - -Canola Oil 0.4% - Soy (10ppm),

Peanut (15ppm)Soy and peanut oils – ReadilyDispersible

Chicken Flavour

0.05% Egg Crustacea (10ppm), Milk (10ppm), Sesame, Peanut (15ppm), Soy (50ppm)

Shrimp paste, Milk Pwdr, Peanut Oil, Soy Protein Pwdr –Readily Dispersible

Sesame Seeds – Particulate

Onion Flavour

0.05% - Crustacea (10ppm), Egg (34ppm), Milk (10ppm), Sesame, Peanut (15ppm), Soy (50ppm)

Shrimp paste, Egg Yolk Pwdr, Milk Pwdr, Peanut Oil, Soy Protein Pwdr – Readily Dispersible

Sesame Seeds - Particulate

Processing Cross Contact Detail:

Fish Soup (contains 20% cod which contains 20% fish protein) Asian Soup (contains 1.0% sesame oil which contains 22% sesame protein) Creamy Mushroom Soup (contains 10% cream which contains 2% milk protein) .Hangup – 2kgThe Condensed Chicken and Veg Soup is a minimum 500kg batch size.


Follow instructions for downloading and opening the VITAL Calculator. To begin the assessment, click on ‘New Assessment’.

Enter Product Information:

Enter

Product Name Product Reference Note: the Date of Calculation will default to the current date however it can be

changed to another relevant date as required.

Click “Next” to proceed.


Choose Relevant Allergens:

The calculator default is to select all the allergens in the box on the left hand side which are the mandatory allergens as listed in the Australia New Zealand Food Standards Code (current as at April 2012). The relevant allergens to be assessed in the VITAL assessment can be selected or deselected by clicking the box on the left hand side of their name.

‘Change Reference Dose’ box (at the bottom/middle of the screen) can be used to add new allergens and edit Reference Doses.It is important to note that the Reference Dose’s have been set by the VITAL Scientific Expert Panel and should only changed upon advice of the Allergen Bureau.


Concentration / Hydration:

In this example, neither a dehydration nor hydration factor will be used. This product, a condensed soup, is designed to be diluted by the consumer prior to consumption. However, it is more conservative to not use a dehydration factor and so no hydration factor has been used to account for where this product is used without further dilution. There is space to enter appropriate assumptions which will show assumptions behind the use (or lack of use) of any Dehydration/Hydration factor record assumptions as to the rationale for information entered. See section (viii) of the VITAL procedure for further information about determining Dehydration/Hydration factors.

Notes on the use of dehydration and hydration factors:Either

Enter dehydration factor . For example: If 10g of product weight is lost in a 100g serving size due to baking, the dehydration factor is 90%. (Dehydration factor = weight of final product / weight of original product x 100% = 90/100 x 100% = 90%. Enter ‘90’ in the Dehydration cell.) OR;

Enter hydration factor. For example: If a 100g serving size has 200mL of water added, the hydration factor is 200%. (Hydration factor = weight of water added / weight of original product x100% =200/100 x 100%. Enter 200 into the Hydration cell.) Note: Hydration factors should be used with care – where it is product that a product is used undiluted, this ‘worst case’ scenario should be used instead. OR;

Enter neither a dehydration or hydration factor.


VITAL Action Level GridEnter the Reference Amount or Serving Size for this product. Refer to the Definitions section of the VITAL Procedure for more information about setting this value. If a Reference Amount or Serving Size is not relevant for your product, refer to Example 2 of this document. Click ‘Update’ to show the relevant Action Levels.


Enter Recipe (Raw Materials)Click the ‘Add’ button to enter each raw ingredient, the ingoing percentage and where relevant, the Internal Reference. It is useful to use the ‘ENTER’ key to move to the next cell. Note the box below ‘Remove’ which shows the cumulative total of the ingredients added. The ‘Edit’ and ‘Remove’ functions can be used to amend information that has been entered. Click ‘Next’ when complete.


Enter Allergen Status for each Raw MaterialUse the ‘Next’ button to enter the allergens – note there are three pages of allergens for each raw ingredient. Further navigation options are ‘Next RM’ which will move to the next Raw Material or ‘Jump to RM’ where you can choose the Raw Material to which to move. Assumptions are required to be entered here about each Raw Material.

Where there is a cross contact allergen, select appropriate ‘Particulate’ or ‘Readily Dispersible Form’ box. Enter Concentration if required. See the Definitions section of the VITAL procedure for further information about determining whether cross contact allergens are Readily Dispersible Form or Particulate.


Note that Cumulative amt (ppm) column indicates the cumulative total for that allergen. Where an allergen is identified as Intentionally added, the column will display ‘INT’. Where identified as a particulate cross contact allergen, the column will display ‘PAR’. This column is also colour-coded – i.e. when at Action Level 1, the cell is green. When at Action Level 2, the cell is red. The “AL Transition Pt (ppm)” column shows the concentration of cross contact where there is a transition from Action Level 1 (green) to Action Level 2 (red).


Enter Sources of Processing Cross ContactSources of processing cross contact should be identified by physical audit of the processing equipment during the risk assessment. Refer to the VITAL Procedure for further information.Processing cross contact can be added to the calculator by naming individual pieces of processing equipment (E.g. Mixer, Canner etc), or by previously run product or any other method that reflects processing conditions. Enter assumptions about how the risk assessment was performed and/or any other information about how processing impact was identified and quantified.


Enter Processing Impact DetailsIn this example, the risk assessment identified that a previously run product, Fish soup, which contains 20% pureed cod (fish) may become inadvertently incorporated into the Condensed Chicken and Vegetable Soup.

The “% of allergen source in product manufactured prior” refers to the fish soup recipe which contain 20% cod (fish).

The “Qty of residual previous product (g)” refers to the 2000g (2kg) that was identified in the risk assessment as the amount of previously run product that could become incorporated into the product being assessed.

The “Protein in residue of previous product (%)” refers to the percentage of protein in the fish. This value can be obtained from the nutrition information for cod, food tables or any other trusted source. Cod is 20% protein.

The “Qty of protein in residue (mg)” is calculated automatically. The “Batch size exposed to the residue” refers to the amount of the product

being assessed that is exposed to the cross contact. This may be the batch size or a smaller amount or larger amount as identified in the risk assessment. In this case, the fish soup is homogenously mixed throughout a 500kg batch of the product being assessed.

The “Level of protein from previous product cross contact (ppm)” is calculated automatically.


Choose the relevant summariesNote: after clicking ‘Report’ the macro runs and make take a few seconds and the screen looks quite jumpy – this is the macro running.


Reading the Summary Report – Table 1


Use local regulations or other relevant instruction to complete the label declaration. This example uses the labelling format from the Australian Food and Grocery Council “Food Industry Guide to Allergen Management and Labelling – 2007 Revised Edition”. (See Figure 9.)

The ingredient statement is: Condensed Chicken and Vegetable Soup: Water, Wheat Flour, Chicken (9%), Carrots (5.0%), Celery (5.0%), Cream Powder, Onions (2.0%), Maize Starch, Salt, Canola Oil, Flavours (contains Egg).Contains Wheat, Milk & Egg.May be Present: Fish & Sesame

Figure 9: Extract from “Food Industry Guide to Allergen Management and Labelling Revised Edition”, p11.


Example 2: Ingredient intended for further processing (Banana Flavour)

Refer to the VITAL Procedure section of the Food Industry Guide to the Voluntary Incidental Trace Allergen Labelling (VITAL) Program. Carry out the first seven steps of the process (pp 4-7) to determine the allergen status of the raw materials and perform a risk assessment for cross contact allergens due to processing. See Appendix 1 for details about looking for cross contact allergens.

The recipe and allergen status of ingredients used for this example are listed in Table 2.

Table 2: Recipe and Allergen Status of Raw MaterialsProduct: Banana Flavour Product Code:XX55 Date of Assessment: 5/7/12 Serving Size: Not applicableColumn 1 Column 2 Column 3 Column 4 Column 5Ingredient Name

Quantity Allergen statusIntentionally Added

Cross contact Form of cross contact allergen

(Readily Dispersible or Particulate)

Isoamyl acetate

20.0% - -

Propylene glycol

40.0% - Soy Readily dispersible – 20ppm

Water 40.0% - -

Processing Cross Contact Detail:

None identified (as per risk assessment, refer to HACCP minutes 1/2/12) .


Enter Product Information

Enter

Product Name Product Reference Note: the Date of Calculation will default to the current date however it can be

changed to another relevant date as required.

Click “Next” to proceed.


Choose Relevant Allergens

The calculator default is to select all the allergens in the box on the left hand side which are the mandatory allergens as listed in the Australia New Zealand Food Standards Code (current as at April 2012). The relevant allergens to be assessed in the VITAL assessment can be selected or deselected by clicking the box on the left hand side of their name.

‘Change Reference Dose’ box (at the bottom/middle of the screen) can be used to add new allergens and edit Reference Doses. It is important to note that the Reference Dose’s have been set by the VITAL Scientific Expert Panel and should only changed upon advice of the Allergen Bureau.


Concentration / Hydration

In this example, a dehydration factor of 90 is used (calculations shown in notes below). There is space to enter appropriate assumptions which will show assumptions behind the use (or lack of use) of any Dehydration/Hydration factor record assumptions as to the rationale for information entered. See section (viii) of the VITAL procedure for further information about determining Dehydration/Hydration factors.

Notes on the use of dehydration and hydration factors:Either

Enter dehydration factor . For example: If 10g of product weight is lost in a 100g serving size due to baking, the dehydration factor is 90%. (Dehydration factor = weight of final product / weight of original product x 100% = 90/100 x 100% = 90%. Enter ‘90’ in the Dehydration cell.) OR;

Enter hydration factor. For example: If a 100g serving size has 200mL of water added, the hydration factor is 200%. (Hydration factor = weight of water added / weight of original product x100% =200/100 x 100%. Enter 200 into the Hydration cell.) Note: Hydration factors should be used with care – where it is product that a product is used undiluted, this ‘worst case’ scenario should be used instead. OR;

Enter neither a dehydration or hydration factor.


VITAL Action Level Grid

In this example, a Reference Amount or Serving Size is not relevant because this product is intended for further processing prior to presenting to a consumer. Click the check box “Reference Amount / Serving Size [is] not relevant:” which is above the “Next” button. Then click the “Next” button.


Enter Recipe (Raw Materials)Click the ‘Add’ button to enter each raw ingredient, the ingoing percentage and where relevant, the internal Reference. It is useful to use the ‘ENTER’ key to move to the next box. Note the box below ‘Remove’ which shows the cumulative total of the ingredients added. The ‘Edit’ and ‘Remove’ functions can be used to amend information that has been entered. Click ‘Next’ when complete.


Enter Allergen Status for each raw material:Use the ‘Next’ button to enter the allergens – note there are three pages of allergens for each raw ingredient. Further navigation options are ‘Next RM’ which will move to the next Raw Material or ‘Jump to RM’ where you can choose the Raw Material to which to move. Assumptions are required to be entered here about each Raw Material.

Where there is a cross contact allergen, select appropriate ‘Particulate’ or ‘Readily Dispersible Form’ box. Enter Concentration if required.


Enter Sources of Processing Cross ContactThese could be added by individual pieces of processing equipment or by previously run product or any other method that reflects processing conditions. Enter assumptions about how the risk assessment was performed and/or any other information about how processing impact was identified and quantified. In this examples, there is a validated and verified cleaning process between the production of each flavour and there is no cross contact from processing.


Enter Processing Impact Details:

In this example, there is no identified cross contact allergens. Refer to the Example 1 for details as to how to enter cross contact from processing where required.


Choose the relevant summariesNote: after clicking ‘Report’ the macro runs and make take a few seconds and the screen looks quite confused – this is the macro running.


Reading the Summary Report

For ingredients, the VITAL report provides a summary of the allergens identified in the product and where relevant for cross contact allergens, the total concentration and/or particulate cross contact allergens. It is recommended that these are reported in the Product Information Form and/or specification.


Appendix 1: Where did the information about the allergen status of ingredients come from?The information in Tables 1 & 2 of these examples shows the intentionally added and cross contact information for each product. Below these tables, the processing cross contact information is stated. Information about the allergen status of each ingredient and any potential cross contact allergens must be collated.

Information about the allergen status of ingredients should be requested from the supplier of each ingredient. This should include information about the

intentionally allergens (i.e. inherent) allergens in each ingredient – e.g. soy flour contains soy as an inherent allergen.; and

potential cross contact allergens in each ingredient.

Information about processing cross contact allergens is obtained from the manufacturing facility of the finished product. This information may already be available in the HACCP or Allergen Management Plan and should involve physical audit and information from relevant production, scheduling and quality assurance staff.

For further information please refer to the VITAL Procedure.

vital calculator v2.x.y : worked examplesallergenbureau.net/wp-content/uploads/2013/11/vital...vital...

Documents