Environmental monitoring: How clean is your production line? 1
• Presenting – Hinke Dekter – Accountmanager (Food and Beverage) • Moderator & QA – Lisette de Vries – Accountmanager and Product specialist 1
1895 - J.A. Boom 1995- B. Boom Products for dairy industry • >90.000 products • Production facility 5000 m 2 warehouse • • Service team 2
Definition of Environmental Monitoring? Sampling and testing the environment and equipment within a food manufacturing facility to prevent cross contamination of the finished product from the environment. 3
Raw Focus of food testing has traditionally been Material Processing environment on raw materials and end product. Now a shift to test in the food processing Food Processing environment (equipment, surfaces, etc.) = Preventive focus identify and correct potential issues before End they lead to a major problem or recall product 4
Hygiene monitoring program 2.0 Visual inspection ATP Traditional bioluminescence/ microbiology Protein test 5
ATP bioluminescence 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. 6
• ATP and Protein are well established methods for the determination of 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.) 7
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 or near the processing areas (forklifts, wheels, return covers, walls floors drains e.t.c.) Zone 4: Non food contact surfaces outside the processing No ATP areas (locker rooms, cafeterias, maintenance areas e.t.c.) 8
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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 No ATP processing areas (locker rooms, cafeterias, maintenance areas e.t.c.) 10
Indicator or spoilage organisms • Indicator organisms are a key group of organisms 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 often go unnoticed. 12
Choosing your device and technique • If the site is a small niche that is difficult to access, a swab may be the best option. • 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. 13
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…. soooooo There’s no standard procedure because each case is unique, because each production site is different, because each food product is special. 15
Data analysis • 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. 16
Case study • 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. 17
• Sanitation Spoilage organisms test- Hummas natural • Post sanitation Test site CFU/g equipment swabs Coock chickpeas <10 Add mix and ingredients <10 Grinder/blend 3500 Fill container 3200 Seal <10 18
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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. 20
Boom and microbiology • 3M • BD • Difco • Merck • Oxoid • Tritium • LCG standards 21
Chemicals Equipment 22
Special thanks to… All of you for listing and… 23
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