Physical hazards cover a broad range of contaminants, such as glass, metal, plastic, wood, and stones, such contamination can occur throughout the processing facility, including the receiving dock for ingredients and supplies. Physical hazards are broadly classified as “hard/sharp” physical hazards and “choking” hazards. Both categories can cause injury to the consumer. These injuries may include dental damage, laceration of the mouth or throat, laceration or perforation of the intestine, and choking and may even lead to the death. Conducting a hazard analysis is necessary to identify and evaluate known or reasonably foreseeable physical hazards (such as stones, glass, and metal fragments).  If hazard analysis identifies a known or reasonably foreseeable physical hazard that requires a preventive control, then identify and implement a preventive control for the physical hazard. FDA’s Health Hazard Evaluation Board has supported regulatory action against products with metal/glass fragments or hard plastic of 0.3 inches (7 mm) to 1.0 inches (25 mm) in length. Such fragments have been shown to be a hazard to consumers. If hazards are not properly managed they can lead to recalls which may be very expensive for a business.

Walmart, Wonder, 7-Eleven, other brands of buns recalled for plastic bits: Several well known national brands of hamburger and hot dog buns, as well as lesser-known regional brands, are under recall by Flowers Foods Inc. because pieces of hard plastic present a choking hazard.
The mega-baker issued the recall specifically because of “plastic pieces found in products,” according to the company’s recall notice posted with the Food and Drug Administration. In addition to the buns, Flowers Foods is recalling other bakery products. Read the full article at Food safety news.