Principles of Hygienic Equipment Design : Dairy Case Study Th�ough I�ple�e�tatio� of I�te��atio�al Re�ui�e�e�ts …. Contents … Four Pillars for Safe Food • Foodborne Outbreaks & Deaths in India - 2008-15 • Examples of Food Safety Incidents due to Hygienic Engineering issue • Microbiological Specs India Vs. Other Countries • Need for looking at International Standards • Food Safety Maturity Continuum @ Mother Dairy…… • Case Study on International Best Practices Implementation at Mother Dairy • – CIP – Pasteurization – Homogenization – Filling – WTP Food Safety Risk Elimination • Slide No. : 1 Date : 02 Dec 15 Presented By : Mother Dairy
Four Pillars for Safe Food As per Technical papers & case studies, most common reason for “Unsafe Food” is i nappropriate “Food Engineering” Practices (Globally as well as in India) Slide No. : 2 Date : 02 Dec 15 Presented By : Mother Dairy
Geometric increase in number of Food Borne Cases from as well as deaths in India Integrated Disease Surveillance Project (IDSP), launched by UMoH&FW, India in Nov 2004 2000 3000 1964 2636 1675 1667 1584 1585 2500 1500 2000 No. Of Outbreaks NO Of Deaths 990 1000 1500 799 1108 901 1000 810 553 500 500 120 95 77 50 0 0 2015(Till 21 2008 2009 2010 2011 2012 2013 2014 Nov'2015) No. of Outbreaks 553 799 990 1675 1584 1964 1585 1667 Death 50 120 95 77 1108 901 810 2636 Source: http://www.idsp.nic.in Number of outbreaks as well as Number of Deaths due to Food Borne Cases are on raise Slide No. : 3 Date : 02 Dec 15 Presented By : Mother Dairy
Hygienic Design Issues - Few Examples Back View Front View Un-even Inaccessible area Key Food processing equipments, supplied to Industry were found with such Hygienic Design issues Slide No. : 4 Date : 02 Dec 15 Presented By : Mother Dairy
Hygienic Design Issues - Few Examples Smooth and accessible Framework Design issue area with Inaccessible area Key Food processing equipments, supplied to Industry were found with such Hygienic Design issues Slide No. : 5 Date : 02 Dec 15 Presented By : Mother Dairy
Few examples of Food Safety Incidents due to failures to Hygienic Engineering �e�ui�e�e�ts … SNOW RECALL – JAPAN • The No.1 dairy Brand in Japan • Business: $12 billion dollars in 2000 The problem was traced to bacteria on the production line of Snow Brand's Osaku factory that processed low-fat milk. As events played out, it transpired that over 15,000 people had been affected. The bacteria concerned was staphylococcus aureus, and it was located in a valve which, although it should have been cleaned regularly, had not been. Inspections of the plant condemned hygiene standards as being appalling. Source : http://www.mallenbaker.net/csr/crisis04.html Source : http://www.foodqualitynews.com/Food-Outbreaks/Lye-contaminated-milk-recalled-in-latest-blow-to-Chinese-dairy-industry Slide No. : 6 Date : 02 Dec 15 Presented By : Mother Dairy
International Standards on Hygienic Design & Process Controls Harmonization into Mother Dairy Management System (MDMS) R Mother Dairy Management System is developed incorporating various international references to address Quality & Food Safety Requirements Process Innovations, Cross Contamination Controls as well as other key Food Safety requirements are addressed appropriately Slide No. : 7 Date : 02 Dec 15 Presented By : Mother Dairy
Pasteurized Milk Microbiological Specification – Comparison Table Different Countries M M M /g /gram M Slide No. : 8 Date : 02 Dec 15 Presented By : Mother Dairy
Trigger for Looking at “International Standards” Yet to have Hygienic Equipment Design Standards in India for Milk & Liquid Food Processing To demand equipment, meeting Hygienic Design Aspects, from Suppliers Stringent Microbiological Requirements by Food Safety Standards Authority of India (FSSAI) – - Inline with International references Market Competiveness • Proven Requirements – Hence “No Need to reinvent the Wheels” • Brand Protection from Recall / Withdrawal Situations • To minimize “Reprocessing / Rejections” due to process failures • Slide No. : 9 Date : 02 Dec 15 Presented By : Mother Dairy
Food Safety Maturity Continuum …… Through Strengthening Strictness of Control Measures “Fail Safe” System Food Safety Hazard Auto Detection & Auto Control Identification Stage ( High Degree of Strictness of Controlling a Hazard ) Auto Detection & Manual Control Control (Moderate Degree of Strictness of Measures Controlling a Hazard) Manual Detection & Manual Control (Low Degree of Strictness of Controlling a Hazard) Based on the international requirement s.... Food Safety Hazards are newly identified & Control Measures are incorporated Ele�ati�g �Deg�ee of “t�i�t�ess� of Cu��e�t Le�el to � o� � steps a�o�e Low Degree to Moderate Degree / High Degree to Fail Safe Slide No. : 10 Date : 02 Dec 15 Presented By : Mother Dairy
Hygienic Design for Effective Pasteurization of Milk …. Majority of our own and 3P plants are upgraded to process controls as per international standards Slide No. : 11 Date : 02 Dec 15 Presented By : Mother Dairy
Cross Contamination Possibilities of Pasteurized Milk & Prevention by Hygienic Design Raw Pasteurized Product Produc t Cross Contamination Regeneration Zones Majority of our own and 3P plants are upgraded to process controls as per international standards Slide No. : 12 Date : 02 Dec 15 Presented By : Mother Dairy
Key Food Safety Requirements of Pasteurization To have effective Pasteurization Milk / Liquid Foods Slide No. : 13 Date : 02 Dec 15 Presented By : Mother Dairy
Comparison of Key Food Safety Requirements of Pasteurization To Prevent Cross Contaminations during Pasteurization Liquid Foods Slide No. : 14 Date : 02 Dec 15 Presented By : Mother Dairy
Hygienic Engineering Requirements Comparison Matrix To Assure Food Safety During CIP Slide No. : 15 Date : 02 Dec 15 Presented By : Mother Dairy
Hygienic Engineering Requirements Comparison Matrix To Assure Food Safety During CIP Slide No. : 16 Date : 02 Dec 15 Presented By : Mother Dairy
Pasteurizer Holding Loop Slope…. Why ? How ? Reference Specification To attain the minimum 3A To preclude air Upward Slope from holding time it is entrapment and the lowest point of critical that the design ensure uniform USFDA – PMO the holding tube to of the holding tube product flow, the flow diversion EHEDG prohibits air from Holding tubes device being incorporated should have Canadian 2.1 cm per meter into the system. upward slope Food or Air in the system will Provide Holding Inspection 0.25 inch per feet allow individual milk Tubes slope 2.1 Agency particles to move cm per meter ) from Other Food faster through the the lowest point of holding tubes, the holding tube to Industry thereby reducing the the flow diversion Specs holding time device. Connect the Pasteurizer PHE Heating Zone outlet to the bottom of the Holding Loop so as to have upward flow. Slide No. : 17 Date : 02 Dec 15 Presented By : Mother Dairy
Holding Coil Upward Slope Requirement in Pasteurization & Sterilization of Liquid Foods Slide No. : 18 Date : 02 Dec 15 Presented By : Mother Dairy
Holding Coil Drawing With & Without Continuous Upward Slope min of 2.1 cm / meter Slide No. : 19 Date : 02 Dec 15 Presented By : Mother Dairy
Holding Coil Drawing with Continuous Upward Slope min of 2.1 cm / meter The holding tube shall be arranged to have a continuously upward slope in the direction of flow of not less than 2.1 centimeters per meter (0.25 inches per foot). Slide No. : 20 Date : 02 Dec 15 Presented By : Mother Dairy
Pasteurisation …. Time & Temperature Control • FDV Position : Holding Tube Outlet • Temperature Sensor Position : – Holding Tube Outlet, prior to FDV – To take of �Respo�se Ti�e� of the te�pe�atu�e se�so� fo� complete FDV activation • Adequate distance to be provided between Temperature Sensor Position & FDV International Ref : • USFDA PMO, • 3A • AS 3993 : 2003 • Canadian Food Inspection Agency • University of Guelph Holding Coil Slide No. : 21 Date : 02 Dec 15 Presented By : Mother Dairy
Slide No. : 22 Date : 02 Dec 15 Presented By : Mother Dairy
Slide No. : 23 Date : 02 Dec 15 Presented By : Mother Dairy
Strengthening Pasteurization Controls with Two Temperature Sensors (even in Semi auto Dairy Units) Temperature Sensor Failures Challenges As per EHEDG, FDV shall be controlled by more than 1 Sensor Forwards the milk / liquid food post achieving the right temperature in both the sensors Implemented in Delhi NCR Plants contributing to about 80% Poly Pack Milk Volu�e… Slide No. : 24 Date : 02 Dec 15 Presented By : Mother Dairy
Preventing Raw Product Siphonage into Pasteurized Product Line Slide No. : 25 Date : 02 Dec 15 Presented By : Mother Dairy
Raw Product Siphonage : Balance Tank Design Damaged FDV Seat “O” Ring Damaged FDV Seat “O” Ring Raw Milk Siphonage Slide No. : 26 Date : 02 Dec 15 Presented By : Mother Dairy
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