Best Practices in Food Safety and Sanitation
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1 Best Practices in Food Safety and Sanitation Andres Rodriguez Lozano Food Safety Specialist- Commercial Food Sanitation Sanitation Standards Hygienic Design Sanitation Expertise Sanitation Business Optimization
2 Who are we? Learning from other Industries Understanding the enemy Sanitation challenges in the Tortilla Industry Sanitation methods & technologies
3 Commercial Food Sanitation, an Intralox company, integrates strategic consulting, expertise and training to provide durable solutions to food safety and sanitation challenges for food processing plants.
4 Operational Excellence. Safe Food. Every Day.
5 My consumer experience cut Fried tortillasnachos
6 The Car Industry
7 Volkswagen Golf 1970s No airbags No air-conditioning Manual wind-down windows No power-steering No cruise control No parking assist No ABS No child-locks AM radio
8 VW Golf 2018 Airbags SRS Front (Driver & passenger); Side (front); Curtain (Front & rear) Anti-lock Braking System (ABS) Standard Blind Spot Monitoring (BSM) Standard 18 Child restraint anchor points ISOFIX x2, top tether x5 Childproof rear door locks Standard Driver Attention Alert (DAA) Standard 18 Dynamic Stability Control (DSC) Standard Electronic Brake-force Distribution (EBD) Standard Emergency Brake Assist (EBA) & Emergency Stop Signal (ESS) - Standard Parking sensors Rear 17 Rear Cross Traffic Alert (RCTA) Standard 18 Remote central locking Standard, 2 transmitters Reverse camera Standard Roll Stability Control (RSC) Standard Seat-belt warning Driver & all passengers Seat-belts (front) 3-point lap-sash with pretensioners, load limiters and height adjustable shoulder anchorages Seat-belts (second row) 3x 3-point lap-sash with pretensioners and load limiters Seat-belts (third row) 2x 3-point lap-sash Traction Control System (TCS) Standard Trailer Stability Assist (TSA) Standard Whiplash-minimising front seats Standard Satellite Navigation etc
9 What is the difference? The focus in the car industry has been on customer safety and convenience.
10 How does this tie to Food Safety?
11 Food Safety What are the hazards?
12 Biological Hazards Vegetative pathogens (Salmonella, pathogenic E. coli) Normally controlled via baking (kill step) Still will require zoning concept/separation between raw and RTE Toxin formation (pre-bake) S. aureus B. cereus Post cook addition Seasoning for tortilla chips: dairy, herbs, spices, etc
13 Chemical Hazards Allergens Gluten Seasoning: soy, milk, etc. product category date notification type notification basis notified by subject cereals and bakery products 06/01/2011 alert official control on the Ireland undeclared soya in flour tortillas from the United Kingdom market cereals and bakery products 18/02/2011 alert official control on the Ireland presence of soya in corn tortillas from the United Kingdom market confectionery 12/10/2006 information consumer complaint United Kingdom allergic reaction (presence of whey protein and oats) caused by incorrect labelling of tortilla chips from the United States nuts, nut products and seeds 20/10/2006 alert official control on the Spain undeclared milk ingredient in chilli tortilla chips from Spain market prepared dishes and snacks 18/01/2012 alert consumer complaint Finland undeclared wheat in and incorrect use of packaging (tortilla chips cheese have been packed into bags destined for tortilla chips original) for tortilla chips cheese from the United Kingdom prepared dishes and snacks 15/02/2018 alert company's own check Sweden presence of wheat in tortilla chips from Belgium
14 Physical Hazards - Foreign Materials cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products cereals and bakery products 04/01/2018 Sweden plastic fragments in frozen bread from Sweden 24/01/2018 Denmark jasmin rice from Thailand, via Germany infested with larvae of insects 09/02/2018 Netherlands plastic fragments (polymethyl methacrylate) in biscuits from the Netherlands 14/02/2018 Austria metal strips in chilled puff pastry from Austria, with raw material from Italy 23/02/2018 France glass fragments in rusks from Spain 12/03/2018 Sweden plastic fragments in bulgur from Sweden 16/03/2018 United live insects (weevil) in rice from Portugal Kingdom 20/03/2018 Denmark glass fragments in sweet berry muesli from Belgium 22/03/2018 Spain breakfast cereal from the Netherlands infested with larvae of insects 12/04/2018 United organic gluten free porridge flakes packaged in Kingdom the Netherlands infested with insects 30/04/2018 Germany sharp fragments in garlic bread and pestobread from Germany 09/05/2018 Belgium foreign bodies (white plastic/rubber texture: 0.5 x 0.5 cm) in breakfast cereals from France 04/06/2018 Poland altered organoleptic characteristics (foreign smell of mold) and dead insects in white rice from Myanmar 29/06/2018 Denmark organic whole wheat flour and organic whole wheat spelt flour from Germany infested with larvae of insects 18/07/2018 United small piece of nylon in mini bread rolls from Kingdom the United Kingdom 20/07/2018 Netherlands metal fragments (2 5 mm) in organic coconut flour from Sri Lanka Main materials; Metal, Plastic and Glass Ex. Mars 2016 recall due to plastic covering 55 countries
15 Protect your consumer Protect your Brand
16 Sanitation challenges
17 10 Principles of Hygienic Design 1. Cleanable 2. Made of compatible materials 3. Accessible for inspection, maintenance, sanitation 4. No liquid collection 5. Hollow areas hermetically sealed 6. No niches 7. Sanitary operational performance 8. Hygienic design of maintenance enclosures 9. Hygienic compatibility with other systems 10. Validated cleaning and sanitizing protocols
18 Complex / Simple Complex Simple
19 Open / Close Open Close
20 Employee Safety: What is required?
21 Hygienic Facility Design Presence of drains Flooring Type Maintenance Equipment placement Newly integrated lines Utilities
22 Hygienic Equipment Design Accessibility for cleaning Inaccessible parts: rollers, sprockets, inside conveyors Not designed for cleaning Not easily dismantled equipment for cleaning and inspection
23 Cleaning Techniques Employees not knowing the equipment Employee Retention Employee Training Sequencing and cleaning techniques CIP system knowledge
24 Maintenance Belt not replaced in a timely manner Equipment modifications creating harbourage
25 Other Challenges Time Cleaning Procedures Cost effectiveness Down-time Chemicals Tools New regulations
26 Increased Productivity Reduced changeover time Reduced cleaning time Reduced maintenance time Added production time
27 Sanitation Methods & Technologies In dry- environments
28 Dry-Wipe Cleaning Good dry-cleaning method Alcohol introduces a small amount of moisture Good for flat surfaces like frames, tables, mixers, etc. Not functional with small crack & crevices Can be used on soft metals (e.g., aluminum) Versatile tools
29 Vacuum Cleaning True dry cleaning method Industrial vacuum systems Brush & wiper extensions Always be critical on hygienic design Recommended for dusty applications Can be automated
30 Dry-Steam Cleaning Chemical free Gives that little, controllable moisture Brush & wiper extensions Always be critical on hygienic design Can get into cracks & crevices Consider soil type & level of build up Can be automated
31 Dry-Ice Cleaning Chemical free Truly dry method Lifts the soil from surface Great for detailed periodic cleaning Great for heavy/baked on soils Not always great for very moist soil Not easy to get into cracks & crevices Noisy
32 Validation
33 Disinfection Spray Quat or Quat alcohol blend Alcohol Fogging Per-acetic Acid Consider material compatibility Gas - Chlorine Dioxide Generator (expensive) Tablets (cheaper) Gas Liquid (corrosive to soft metals) Contractor Always consider material compatibility
34 Summary Industry is changing Consumer Increased number of recalls Need to be vigilant Hygienic design Sanitation
35 Thank you!
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