Process control is used extensively by the large meat companies to optimize processing, by maintaining process variables within a desired range. Based upon the results of process monitoring, processes may be changed to bring out-of-control processes back into control or when making changes, such as increasing or decreasing ingredient concentrations or introduction of new equipment. Process control can be applied to quality or food safety variables associated with meat products. Process control involves tracking and trending of data, statistical process control (SPC), validation and control documentation and process development. There are many training opportunities for these topics outside meat science, but there is currently not such a course designed for the meat industry.
Through tracking and trending, processors gather data during normal processing to establish a process history, and using SPC, calculate control limits for each variable, to which they compare to future processing data. The underlying concept of SPC is based upon a comparison of what is happening today during processing, to what has happened historically. SPC uses means to calculate variations to monitor and improve any process for which there are measureable parameters. Trending of these results is used to detect when something has changed or when a change is starting. Based upon these results, processes can be adjusted to more closely meet specifications or be in compliance with established limits. These process adjustments have traditionally been done manually, but automation has become an increasingly popular method for making such adjustments.