How clean is your production line? 1 Presenting Hinke Dekter - - PowerPoint PPT Presentation

Environmental monitoring: How clean is your production line?

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• Presenting

– Hinke Dekter – Accountmanager (Food and Beverage)

• Moderator & QA

– Lisette de Vries – Accountmanager and Product specialist

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1895 - J.A. Boom 1995- B. Boom

Products for dairy industry

• >90.000 products
• Production facility
• 5000 m2 warehouse
• Service team

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Sampling and testing the environment and equipment within a food manufacturing facility to prevent cross contamination of the finished product from the environment.

Definition of Environmental Monitoring?

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Focus of food testing has traditionally been

• n raw materials and end product.

Now a shift to test in the food processing environment (equipment, surfaces, etc.) = Preventive focus identify and correct potential issues before they lead to a major problem or recall Raw Material End product Food Processing Processing environment

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Hygiene monitoring program Traditional microbiology Visual inspection

ATP bioluminescence/ Protein test

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ATP as an indicator of surface cleanliness. The presence of ATP on a surface indicates improper cleaning and the presence of contamination, including food residue, allergens and/or bacteria.

ATP bioluminescence

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• ATP and Protein are well established methods for the determination
• f hygiene cleanliness BUT cannot be used as a replacement for

microbiology

• Microbiology determines specific risks (pathogens , spoilers)
• ATP allows direct implementation of corrective actions
• An effective environmental monitoring program will make use of a

combination of technologies (ATP, microbiology, visual testing e.t.c.)

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Do you know where and when to swab?

Zone 1: Product contact Surfaces (Slicers, peelers, fillers, screens,

conveyor belts, employee hands, knives work tables e.t.c.)

Zone 2: Non food contact surfaces in close proximity to food and food contact surfaces (processing equipment exterior and

framework, refrigeration units, equipment control panels, switches e.tc.)

Zone 3: More remote non food contact surfaces locates in

• r near the processing areas (forklifts, wheels, return covers, walls

floors drains e.t.c.)

Zone 4: Non food contact surfaces outside the processing areas (locker rooms, cafeterias, maintenance areas e.t.c.)

No ATP

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Zone 1: Product contact Surfaces (Slicers, peelers, fillers, screens, conveyor belts, employee hands, knives work tables e.t.c.) Zone 2: Non food contact surfaces in close proximity to food and food contact surfaces (processing equipment exterior and framework, refrigeration units, equipment control panels, switches e.tc.) Zone 3: More remote non food contact surfaces locates in or near the processing areas (forklifts, wheels, return covers, walls floors drains e.t.c.) Zone 4: Non food contact surfaces outside the processing areas (locker rooms, cafeterias, maintenance areas e.t.c.) No ATP

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• Indicator organisms are a key group of
• rganisms that reflect the hygienic

status of environmental and processing equipment (not directly related to pathogen presence) and can be used to validate and verify sanitation activities

• Spoilage organisms can cause decreased

shelf-life, poor product quality, and even product recalls. These outcomes have significant economic and consumer perception consequences. Environmental Management (EM) allows companies to take a proactive approach to controlling spoilage incidents, as they can arise sporadically

• ften go unnoticed.

Indicator or spoilage organisms

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Choosing your device and technique

• If the site is a small niche that is difficult to access, a swab may be the best
• ption.
• For areas that are larger, a sponge would be best as it allows for more effective

collection through higher mechanical action.

• On easy-to-clean, flat surfaces in which a higher sensitivity test method is

desired (as low counts are expected), direct contact of a medium to the surface may be used.

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There’s no standard procedure because each case is unique, because each production site is different, because each food product is special.

….soooooo

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• Analysis of the data should take place regularly to identify trends and specific issues to

allow for appropriate corrections and corrective actions.

• Cut-off levels or acceptability limits should be user-defined, based on the risk analysis

study done before, as well as historical data.

• Presence or levels of indicator organisms above the acceptable limit demonstrate that

conditions exist that could lead to loss of process control, potentially resulting in product contamination.

Data analysis

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• For months now, a hummus

producer noticed bloating of the packaging within 1 week (on store shelves) across all of the flavors of hummus they manufactured.

• Shelf life was supposed to be 28

days

• This company did not have an

environmental monitoring program in place.

Case study

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Spoilage organisms test- Hummas natural Test site CFU/g Coock chickpeas <10 Add mix and ingredients <10 Grinder/blend 3500 Fill container 3200 Seal <10

• Sanitation
• Post sanitation

equipment swabs

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….again….soooo….

Take the time to analyze results in order to gain the full benefit of instituting an environmental monitoring for cleanliness, indicator and spoilage organisms.

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• 3M
• BD
• Difco
• Merck
• Oxoid
• Tritium
• LCG standards

Boom and microbiology

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Equipment

Chemicals

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Special thanks to…

All of you for listing and…

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