Field process testing and validation
Advanced support to ensure safety, quality and compliance
In the food sector, product safety depends on the company’s ability to rigorously control every stage of production. Field process testing
and validation is one of the most important tools to ensure that the processes adopted are truly effective, repeatable and comply with the requirements set by European standards, national and internationally recognised certification standards. We at Lifeanalytics support companies and operators in the supply chain every day with a technical, structured and highly specialized approach, providing direct checks in production facilities and validations based on objective data, field measurements and laboratory analysis.
Our goal is one: to make processes safe, robust and fully controlled by reducing operational risk and ensuring that products are compliant, traceable and market-ready.
Why process audits and validations are essential
In many food factories, processes are defined on paper, but not always what is expected coincides with what actually happens in production. Verifications and validations enable:
monitor the effective application of procedures;- assessing the effectiveness of hygiene prerequisites;
- measure the actual ability of CCPs and PROs to prevent or reduce hazards;
- confirm that times, temperatures, chemical and physical parameters are correct;
- to test the behaviour of personnel in real operating conditions;
- identify any discrepancies between theory and practice;
- reduce microbiological, chemical and physical risks;
- improve the overall quality of the process.
Thanks to our direct experience in factories of all sizes and categories, we offer a service able to adapt to the different levels of production complexity, from fresh to processed, from ready-to-eat to long-life products.
Process audits: measuring what actually happens in production
Process audits are systematic controls that allow to observe and evaluate the production processes in real time. Our team works directly in the field to:
- observe the operational phases and verify the correct application of procedures;
- control critical parameters such as temperature, pH, water activity, cooking or cooling times;
- analyse the hygiene prerequisites (PRP), such as sanitization, maintenance, surface cleaning, pest control;
- assess the effectiveness and appropriateness of sampling plans;
- check the management of allergens and possible cross-contamination;
- control internal traceability, batch management and traceability of semi-finished products;
- analyse records and documentation to ensure consistency and completeness.
Each activity is conducted with an objective, technical and evidence-based approach. At the end we deliver a clear, detailed and directly usable report to improve processes and align production with legal requirements and standards required by customers and the market.
Process validations: scientifically demonstrate the effectiveness of the measures taken
Validation is a fundamental step foreseen by the Codex Alimentarius, the main international standards and the European regulations. It is a matter of demonstrating, through objective evidence, that the processes are capable of achieving the expected level of safety.
With the support of our experts and accredited laboratories, we carry out validations on:
Heat treatment processes
- cooking;
- pasteurization;
- sterilisation;
- rapid killing;
- controlled cooling.
We carry out field measurements and integrate the results with microbiological analyses to demonstrate the real capacity of the process to inactivate or reduce pathogenic and interfering micro-organisms.
Non-thermal treatment processes
- acidification;
- salting;
- marination;
- fermentation processes;
- reduction of free water (aw).
We assess critical parameters, process curves and product stability by modelling microbial behaviour and verifying the effectiveness of treatments.
Sanitization and disinfection processes
We confirm the effectiveness of cleaning protocols through:
- microbiological swabs;
- ATP test;
- environmental monitoring;
- visual and documentary checks.
Validations for allergen management
We assess the ability of procedures to prevent cross-contamination through:
- sampling of areas;
- rapid tests;
- food analysis;
- assessment of flows, equipment and critical phases.
An integrated approach: field checks, regulatory expertise and laboratory analysis
Our strength lies in our ability to combine:
- technical and regulatory expertise;
- direct experience of production processes;
- microbiological and chemical analysis of our network of accredited laboratories.
This integrated approach enables us to provide a truly complete, accurate and scientifically based service.
Each validation is built on the basis of:
- objective data measured directly in the field;
- scientific references;
- microbial growth and inactivation patterns;
- european standards and technical guidelines;
- analytical evidence.
Clear, complete and immediately applicable report
At the end of the verifications and validations we release a detailed report that includes:
- results of field measurements;
- technical and regulatory analyses;
- risk assessments;
- identified non-conformities;
- operational recommendations;
- corrective and preventive actions;
- improvement plans.
The report is designed to be immediately operational and to support companies in reviewing the HACCP plan, managing CCPs and preparing for certification audits and official inspections.
Who we support
We provide our expertise to:
- food production companies;
- industrial establishments;
- laboratories and processing plants;
- companies producing ready-to-eat foods;
- operators handling fresh, processed, deep-frozen and long-life products;
- companies exporting to markets with specific requirements.
Each path is customized and built around the company’s real processes.
Your experts for process verification and validation
Relying on us means choosing a partner who can:
- analyse processes with technical expertise;
- identify critical issues and propose concrete solutions;
- validation of treatments and preventive measures;
- ensure compliance with international standards and regulations;
- improve product safety and quality;
- support preparation for certification audits.
Thanks to the strength of our network and our widespread presence in the territory, we offer a fast, reliable service that can meet the needs of any production reality.
Do you want to go deeper into the subject? Fill out the form below to request your Personalized Consultancy!