Mitigating physical hazards in food processing: Risk assessment and preventive strategies

Abstract Physical contaminants in food, such as glass, metal, and plastic, can cause significant health risks and economic loss. This study explores these understudied physical hazards, aiming to provide comprehensive risk analysis and preventive solutions. Our research identified several key infiltration points in the food supply chain, including raw material sourcing and packaging stages. These hazards can be effectively mitigated by employing advanced technologies like metal detectors and optical sorting machines, along with stringent quality control measures. The findings offer valuable insights for stakeholders in the food industry, emphasizing the need for regulatory compliance and consumer education to ensure food safety.

technologies' ability to identify the most minute foreign materials.
To preserve the integrity of food items and protect consumer health, stringent adherence to quality control standards, routine inspections, and thorough testing processes are very important.
As a preventive measure, regulatory authorities play a crucial role in the food industry by establishing guidelines and standards (Kotsanopoulos & Arvanitoyannis, 2017).Governments and international organizations set the allowed levels of physical hazards in food, which also specify the duties of food producers and processors in maintaining compliance (Mortimore & Wallace, 2013).However, the effectiveness of these laws rests on their application and the food industry's readiness to embrace best voluntary practices.Additionally, educating consumers on the dangers posed by physical hazards might enable people to make informed decisions and to demand accountability from food manufacturers.This article aims to comprehensively understand physical hazards in food, their sources, potential consequences, and strategies to minimize their occurrence.

| WHAT ARE PHYS I C AL HA Z ARDS IN FO O D?
A physical hazard is any foreign matter presented in food or a naturally occurring object that can cause illness or harm to the consumer (Cavalheiro et al., 2020).Unsanitary conditions during food production, processing, storage, and distribution are associated with foreign materials.These materials are hazardous due to their sharpness, hardness, size, or shape, which may cause lacerations, perforations, wounds, or choking hazards (Bujang et al., 2020;Kenner, 2001).Fragments of glass, which can occur during handling, transportation, or improper storage of food and beverages in glass containers; metal, such as broken parts, screws, or wire bristles that can be incorporated during processing; stone or pieces of rock enter the food during harvesting or processing of agricultural products, wood coming from pallets, crates, or utensils used in food processing or storage, plastic resulted from damaged or degraded packaging materials or equipment components, bone due to inadequate deboning or processing practices of meat and fish products, hair or fibers and jewelry that occur during food handling, and insects that arises due to improper pest control measures are some common types of physical hazards in food (Cavalheiro et al., 2020;Rhodehamel, 1992).
Foreign materials can be classified into two categories: those that are unavoidable and those that can be avoided.Small, incidental, inherent, or unintentionally added foreign materials that are present in the food product despite all necessary quality assurance methods being followed and that cause minimal risk to consumers are considered unavoidable materials.Common foreign materials such as dirt on potatoes, remnants of insect fragments in figs, and stems in blueberries fall under this category.On the other hand, some foreign materials can be avoided by using proper methods.
Small glass fragments, pieces of jewelry, animal debris, and pieces of plastic are among the avoidable physical hazards that can be present in food (Singh et al., 2019).Figure 1 shows the types of physical hazards in foods.

| Sources and detection of physical hazards
Physical hazards can be introduced unintentionally into food during the process of harvesting, processing, manufacturing, packaging, handling, or transportation, from "gate to plate" or "farm to fork", or due to food tampering or intentional sabotage (Nkosi et al., 2022).However, naturally occurring physical hazards may be present in raw materials if not properly removed during harvesting or processing (Pettoello-Mantovani et al., 2021).Sand, sticks, and leaves can appear in the product together with the raw materials, as can fragments of bones in meat and fish and seeds and fruit stones in fruits (Szumicka, 2022).Foreign materials such as metal and plastic fragments may be transferred to the products during processing, packaging, or transportation (Banach et al., 2017;van Asselt et al., 2017).Due to the failure of workers to observe sanitary standards and to apply the correct protective clothes, materials such as jewelry, hair, and buttons can be present in food (Asselt et al., 2016).Also, due to not observing the principles of good manufacturing practice, glass, pieces of gypsum, or paint can be present in food (Szumicka, 2022).Table 1 shows the sources of physical hazards in foods.
Foreign materials can be detected in food through mechanical, optical, and electromagnetic interaction techniques.Mechanical shape and/or color analysis through the interaction of light (the visible part of the electromagnetic spectrum) with food products and foreign materials (Aladjadjiyan, 2006;Mohd Khairi et al., 2018).In addition, foreign materials can be detected through electromagnetic interaction by using different parts of the electromagnetic radiation spectrum, such as X-ray inspection, microwave inspection, near-infrared inspection, ultraviolet inspection, nuclear magnetic resonance, magnetic field system, electrostatic techniques, and TA B L E 1 Sources of physical hazards in foods.TA B L E 2 Techniques for detecting physical hazards in food (Aladjadjiyan, 2006).(Demaurex & Sallé, 2014;Nuutinen, 2023).

Food
Table 2 shows methods for detecting physical hazards in food.

| Consequences of physical hazards and their risk levels
Physical hazards present in food that can pose a potential risk to consumers depend on several factors.These factors include the size of the foreign material found in the food product, the type of contaminated food, the physical characteristics of the foreign material, and the consumer who is eating the food product (Nkosi et al., 2022; Table 3).While the effects of physical hazards may vary from case to case, ingesting foreign objects can result in injuries such as cuts, lacerations, internal damage, choking, or posing immediate health risks (Aladjadjiyan, 2006;Das et al., 2019).Furthermore, it can also lead to secondary infections of the mouth, tongue, gums, teeth, esophagus, and other digestive system organs (Aguiar et al., 2018;Kenner, 2001).Notably, foreign material such as hair, insects, or sand found in food products is unlikely to cause serious injuries to an exposed individual (Anggraeni et al., 2021;Singh et al., 2019).Table 4 shows the potential injuries for the main physical hazards.
Ingesting foreign materials may increase trauma for at-risk populations such as children, the elderly, the visually impaired, and postoperative patients (Aguiar et al., 2018).Evidence suggests that 1%-5% of the foreign objects ingested (swallowed) by people result in minor to serious injury (Aguiar et al., 2018;Aladjadjiyan, 2006).
Most ingested foreign objects (80%-90%) pass through the gastrointestinal tract spontaneously, with the remainder requiring removal either by endoscopy or, less frequently, surgery.For sharp objects, the risk of tissue perforation in the gastrointestinal tract is greater and requires greater surgical removal than other kinds of ingested foreign materials (Aladjadjiyan, 2006).
According to the FDA (Food and Drug Administration), mouth or throat injuries in the form of lacerations and minor dental damages are the most frequent type of injuries (Marshall et al., 2016).
On the other hand, less frequent injuries are reported on gastrointestinal distress (nausea, vomiting, and diarrhea), choking, headache, dizziness, puffy face, rash, fever, chest pain, lost voice, nosebleed, collapsed lung, seizure, pain in the arm and shoulders (Olsen, 1998).

| IMP ORTAN CE OF PRE VENTIVE ME A SURE S
Providing safe, wholesome, and nutritious food to consumers requires the participation of every individual.To accomplish this, every party involved in the food chain is responsible for every step of the processing, from the farm or food production stage through processing, storage, distribution, retail sale, and consumption.
As a result, preventing physical hazards in food is not solely the responsibility of one group but rather an obligation of collective participation (Marshall et al., 2016).Preventing physical hazards in food is a matter of safety and ethical responsibility toward consumers.When considering the prevention of physical hazards in food, legislation, and regulation have to indicate or concern the properties of food products, including their raw material, processing and packaging, handling and transportation, labeling, precautions and instructions for their use, and any guidelines relating to food products available to consumers (Szumicka, 2022).Moreover, food processors, food businesses, and food-service operators must adhere to strict regulations to prevent physical hazards and avoid legal consequences such as product recalls, fines, or closure (Marshall et al., 2016).They also have the responsibility of prioritizing consumers' welfare and safety, which involves ensuring that the food they produce is free from physical hazards that could potentially harm consumers; they need to be transparent in providing accurate labeling and information about potential allergens or foreign objects that may be present in their product.Establishment of a quality control and monitoring system, provision of continuous training to employees and establishment of clear accountability, seating strong relationship between food producers and processors in a bid to get high-quality ingredients that meet safety standards, development and implementation of continuous assessment and update system of food processing to mitigate risks associated with physical hazards, and establishment of a responsive system that promptly address the incident of physical injuries by taking corrective actions and communicate transparently with consumers are an important consideration to prevent foods from being contaminated by physical hazards.
Food products that do not meet safe levels of physical hazards can damage consumer trust and harm a company's reputation, leading to decreased sales and a long-term negative impact (Pettoello-Mantovani & Olivieri, 2022).The application of legislation on TA B L E 3 Level of physical hazards injury (Singh et al., 2019).Organization and the World Health Organization have set food standards on an international scale that cover the safety of food from field to table, complying with legal requirements.However, acceptance of these standards is voluntary and depends on the interest of individual governments in implementing them (Marshall et al., 2016;Pettoello-Mantovani et al., 2022).For instance, the FDA has established a maximum level of physical hazards in food that pose no significant risks to human health, including tiny insect parts and dirt (Aladjadjiyan, 2006).
In contrast, no particular legislation or limits exist for physical hazards such as contaminants in food in Europe (Banach et al., 2020).
This indicates that understanding the risks of physical hazards is not the same among regulatory bodies.Thus, focusing on preventing and controlling physical hazards in food is essential to ensuring consumer safety.

| Supplier control and auditing
To ensure food safety and reduce physical risks, the food sector must strictly supervise and audit its suppliers (Kotsanopoulos & Arvanitoyannis, 2017).Establishing rigorous quality control standards for suppliers, including inspection of raw materials for physical hazards (Okpala & Korzeniowska, 2021), effective implementation includes assessing and choosing suppliers based on their compliance with safety regulations, outlining expectations for hazard control, conducting routine audits, and implementing remedial measures as needed (Motarjemi & Warren, 2023).Maintaining a solid supplier relationship and consistently enhancing safety procedures require ongoing communication, performance monitoring, collaboration, and training.Processes must be regularly reviewed and updated to meet new physical hazard issues and incorporate new knowledge.

| Facility design and maintenance
Designing food processing facilities with materials resistant to physical hazards and conducting regular equipment maintenance and inspections are critical for ensuring food processing operations' safety and efficiency (Kutz, 2019).

| Good manufacturing practices
Good manufacturing practices (GMP) is crucial for the food sector to reduce physical risks.GMP covers policies and processes focus- TA B L E 4 Potential injuries of main physical hazards.

| Effective quality control
Implementing robust quality control procedures, including visual inspections, sieving, filtering, or metal detection systems.

| Traceability and recall systems
Strong traceability systems that follow products from the raw materials to the final distribution are necessary for effective quality control and mitigating food safety problems (Agrawal et al., 2018;Onyeaka et al., 2021).Maintaining accurate records and implementing traceability solutions allow for the quick identification, isolation, and recall of impacted products in the case of physical hazard incidents.By doing this, the effect on consumers is lessened, and physical hazards are kept from spreading throughout the market.

| Education and awareness
To maximize physical safety in the food business and strengthen quality control efforts, comprehensive training and education programs for staff are crucial (Mortimore & Wallace, 2013).These initiatives make sure that employees fully comprehend the relevance of identifying and avoiding physical hazards.Employees receive instructions on proper handling procedures, how to operate the equipment, and identifying any potential physical hazards that could arise through the production process.Businesses may reduce risks and maintain a safe working environment by providing staff with the appropriate information and skills (De Oliveira et al., 2016).This improves the overall quality control methods used in the production process.
Increasing awareness and implementing these strategies can enhance food safety and protect consumers from potential harm.

| CON CLUS ION
techniques detect foreign bodies by means of size or weight differences between the foreign body and the food product and use simple techniques like sieving, filtering, and centrifuging (Aladjadjiyan, 2006).Optical techniques find foreign materials by means of F I G U R E 1 Types of physical hazards in foods.
ing on supplier control, cleaning and sanitation, documentation and record-keeping, equipment maintenance, employee hygiene and training, and facility design(De Oliveira et al., 2016).Businesses can significantly lower the risk of physical hazards in food production by designing facilities with hazard prevention in mind, maintaining equipment properly, training employees on proper food handling and hygiene practices and ensuring personnel follow hygiene protocols, implementing supplier control measures, practicing effective cleaning and sanitation, and maintaining accurate records(Schoenfuss & Lillemo, 2014).GMP adoption not only promotes consumer confidence and maintains regulatory compliance, but it also guarantees food safety and quality.
Physical hazards refer to foreign objects unintentionally or in some cases as part of sabotage present in food that can cause harm or injury if consumed, such as glass, metal, stones, wood, plastic, bone fragments, insects, or other foreign materials.The sources of physical hazards can be traced to raw materials, processing and packaging, and handling and transportation.Physical hazards in food can have severe consequences for consumer health, legal compliance, and brand reputation.By understanding the sources, and potential risks and implementing preventive measures, food businesses can minimize the occurrence of physical hazards and ensure the safety of their products.Prioritizing food safety through supplier control, facility maintenance, GMP, quality control, traceability systems, and continuous education is essential to protect consumers and maintain trust in the food industry.It is, therefore, very important to understand physical hazards, implement preventive measures, and continuous improvement to assure food safety and protect consumers.To ensure food safety and safeguard consumers, the industry must comprehensively understand physical hazards, implement proactive preventive measures, and continuously strive for improvement.This requires a collaborative effort among all stakeholders involved in the food supply chain, from producers to distributors, retailers, and regulatory bodies.By publishing research, sharing best practices, and promoting knowledge exchange in this area, we can further enhance food safety practices and protect consumers from the potential harm caused by physical hazards.Continued efforts in understanding, preventing, and addressing physical hazards will contribute to a safer and more trustworthy food industry, fostering consumer confidence and satisfaction.