Preventing Contamination in Food Processing: Tackling Manufacturing Hazards & PEM

www.pmg.engineering Vol .02-Issue .08-February2023 TECH-KNOWLEDGE The Official PMG Engineering Newsletter FOOD & BEVERAGE INDUSTRY ENGINEERING & DESIGN SCIENCE & TECHNOLOGY A PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .08-February 2023 CONTENTS 1. WHITE PAPER A. Hygienic Zoning B. Pathogenic Environmental Monitoring 2. INDUSTRY BUZZ Latest Food Industry News Updates 3. WEEKS HIGHLIGHT A Look Into The Main Events Of The Week 4. DID YOU KNOW? Fascinating Food Facts To Expand Knowledge 2-5 6-7 8 9-10 PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .08-February 2023 HYGIENIC ZONING Introduction Objective is a plan that Hygienic zoning identifies and enables the required level of protection and care for the product. It involves zoning risk assessment, zoning plan and zoning verification. to determine the area that can be source of microbial or chemical contamination and to prevent it passing to production area. Hygienic zoning is created within facility based on risk of cross contamination. is It Segregation of area according to the requirement of hygiene level will have restricted access with rules and procedure set for people who are allowed entry in different level of cleanliness. The degree of hygiene control in the facility depends on the type of the operation and the analysis of the potential risk. Based on the assessment, the facility into areas with different allowable processing steps, different rules and/or procedures for persons who are allowed entry, and/or different levels of cleanliness. is divided requires operation Each manufacturing an in appropriate environmental cleanliness order to minimize risks of contamination. Buffer zones, sanitizing stations, physical (or other) barriers are often placed between the basic GMP areas to the high hygiene areas. level is to in zoning Major constrain identify and differentiate areas within a facility for product and process protection. Hygienic zoning helps in maintaining product quality in the main product flow. Apart from increasing the efficiency it also has advantage from safety prospective as zoning prevent contamination of the product. of micro-contamination Prevention the environment, the equipment, raw & packaging materials, people and product. Prevention of foreign body contamination, whatever the size and nature, of the environment, the equipment, the raw & pack materials, people and the product. of Type of Hygienic Zoning 1.Basic zones: Zone B: are area which require basic level of hygienic design requirements. It encompasses areas in which products are produced that are not susceptible to contamination or that are protected in their final packages. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION READ MORE.... Vol .02-Issue .08-February 2023 PLATE HEAT EXCHANGER Zone B0: are outside the building area, within the perimeter of the site where the objective is to control or reduce hazards created by unauthorized personnel entry and hazards created by water, dirt, dust and presence of animals. Zone B1: includes warehouses that store both raw materials and packed processed products, offices, workshops, power supply areas, canteens and redundant buildings/rooms. The objective is to control or reduce hazards created by birds and pests. 2.Medium Hygiene Zone is sufficient. in which medium Zone M: are area level of It hygienic design requirements includes process areas where products are produced that are susceptible to contamination, but where the consumer group is not especially sensitive and where no further microbial growth is possible in the product in the supply chain. In this area, product might be the environment, during sampling and during the opening of equipment to clear blockages. The objective is to control or reduce the creation of hazardous sources that can affect an associated area of higher zone classification. The protection of the interior of food processing equipment from contamination when exposed to the atmosphere. exposed to 3.High Hygiene Zone Zone H: are area where the highest level of hygiene is required. A “High Hygiene” room in food processing is the equivalent of a cleanroom, must be completely contained. Zone H is typical for open processing, where even short exposure of product to the atmosphere can result in a food safety that are hazard. Products and processed or stored and are destined for a highly susceptible consumer group (e.g., infant nutrition), are instant in nature or ready for consumption. ingredients is objective The product contamination hazards and to protect the interior of food processing equipment from exposure to atmosphere. control all to preventive against Zoning Risk Assessment: Zoning can be done only after correct assessment of risk. On the basis of risk, the areas can be segregated into different zones. For assessment, one has to look into each and every factors that can affect the quality of product in unwanted way. While risk assessment, a be complete considered including microbiological, chemical, allergen, physical or pest infestation. Not only these but there are other factors as well which need to be combated with like allergens. Part from these factors area not coming under production area should also be taken into consideration such as maintenance areas and equipment storage area, both temporary and permanent. approach factors should Key Components of Zoning: Zoning plan consists of zoning map, local procedure including rules for each zone, identification of barriers both physical and virtual and verification plan. Zoning maps indication of hygienic zone, typically people movement i.e., deciding the entry/exit points, material movement, waste movement i.e., its collection and exit points. Major factor being deciding barriers and transitions between zones to maintain hygiene. include identified should be Zones through clearly marking, signage or physical barriers at transitions to and entry/exit points. Entry requirements production areas and transitions between zones should be clearly defined for people and materials. Site zoning plan should be supported by a verification plan with activities defined as appropriate for the site. Staff should understand which routines apply to their job function and activities. Visitors, contractors, service providers, other 3rd parties should be informed of the zoning plan prior to entry. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .08-February 2023 PATHOGENIC ENVIRONMENTAL MONITORING Introduction Requirement Guarantee of chance of recontamination of food product cannot be given even after the effective application of HACCP and GMP. Even after following all required hygienic practices there are chances of food with recontamination of microbiological infestation, that might be due to addition of ingredient after kill treatment or from the processing room or from any other source. Microbiological contaminations can be either non- pathogenic or pathogenic microorganisms. Various pathogenic microorganisms such as E. coli, Listeria monocytogenes, and Salmonella spp. are potent contaminants food-handling environments. Pathogenic Environmental monitoring prevent possible microbial contamination of food products for the by proper and scheduled monitoring presence of pathogenic microbes. It does not make food safe, rather, it helps in making systematic approach reduce or eliminate pathogenic contamination in a timely manner. to in for determining The most effective the tool effectiveness of a facility’s Salmonella controls is the implementation of an aggressive Pathogen Environmental Monitoring Program (PEM). A PEM is an on-going measure of the effectiveness of the overall Salmonella control program in the plant but it should be noted that itself a Salmonella control program. It provides feedback on where efforts need to be directed for the overall control program. is not, in it 1.Team: For coming up with systematic approach there is requirement for a proper team which can look after whole program including setting up program, implementation and validation of the program at every fixed is important to have a team with mixed functionality. Team should consist of a team leader, quality manager, microbiologist, incharge, operations manager, plant engineer, maintenance head and line supervisor. All should have clear understanding of process and potential risks that can lead to pathogenic contamination. interval of time. sanitation It Areas where facility is exposed 2.Hygienic zones of control assessment: To determine Primary Pathogen Control Area (PPCA) there should be a hygienic zone in post-lethality, assessment. treated/finished product the to environment they are marked as high hygiene or high risk area. Zoning is to identify areas of high the and manufacturing operation and hence spreading of pathogens into the PPCA can be prevented, where protection of the exposed post-lethality product is critical. Hygiene zone assessment of the entire facility should be followed by creating a color- coded mapping of the facility. the product within risk low to READ MORE.... PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .02-Issue .06-February 2023 3.Sanitary Zoning: In the sanitary zoning concept, the plant operations are divided into four zones based on level of risk. Microbial Growth Niches (e.g. roaster) and before Zone 1: Areas in plant that are direct product contact surfaces after the lethality or microbial the reduction step product is sealed in the primary package. . If there is no lethality step in the process - sites where the to plant equipment and product the primary environment prior packaging is exposed to sealing in Zone 2: Non-product (near) contact areas in the plant that are closely adjacent to product contact surfaces. surfaces like equipment exterior, under & equipment framework, drip pans/shields/housings, lights, control rail refrigeration unit’s/drip pans, conveyors, systems and pipes directly over zone 1 surfaces, computer screens, maintenance tools, drains located directly under equipment, motors located adjacent to lines. panels/buttons, overhead Zone 3: Non-product contact surfaces that are in open post-lethality product processing areas, but no closely adjacent to zone 1 surfaces. These surfaces have the possibility of leading to product recontamination like floors, walls, ceilings, hoses, pallets, drains, foot baths/ mats, brooms/ mops, condensate drip pans, trolleys, forklifts, walk- along, carts and toolboxes Zone 4: Areas that are more remote from post lethality product processing areas. If these areas are not maintained in good hygienic condition can lead to cross-contamination of zone 1– 3 areas. for determining The most effective the tool effectiveness of a facility’s Salmonella controls is implementation of an aggressive Pathogen the Environmental Monitoring Program (PEM). A PEM is an on-going measure of the effectiveness of the overall Salmonella control program in the plant but it should be noted that itself a Salmonella control program. It provides feedback on where efforts need to be directed for the overall control program. is not, in it Corrective action for Positive Results In case of positive results facility should have a pre-determined action plan that would be implemented in the event of a Salmonella, Listeria positive result. The action plan should be specific for each of the four zones and include type of immediate corrective actions to be taken by zone, actions to be taken to verify Salmonella/Listeria has been eliminated from the area in question, a root cause analysis to find the source of the contamination so that it can be prevented in the future. Pathogen event (Salmonella/Listeria) positive, the response team should conduct an in-depth investigation looking at any maintenance disruptions/activities, in-plant construction, unplanned down time and other non- standard production activities (e.g. R&D plant trial) the of In a PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter FOOD INDUSTRY INDUSTRY BUZZ New olive oil coffee beverages are described as "transformative" by Starbucks CEO Howard Schultz. Coca-Cola releases the first flavour from their 2023 creations—Coca-Cola Move Howard Schultz, the interim CEO of Starbucks, told CNBC's Jim Cramer on Tuesday that the company's new line of coffee drinks with olive oil infusions might upend the market. According to Schultz, "This is a pivotal moment in the history of our firm introducing a new category, a new platform." He said that Starbucks' new olive-oil coffee, which he came up with following an inspiring trip to Sicily, will gradually increase the company's revenue. In addition to olive oil coffee, Starbucks will soon offer an Oleato espresso martini in a few Italian locations as well as Seattle and New York. Coca-Cola says that Coca-Cola Move, their newest Creations flavour, "brings to life the transformational power of music." According to Coca-Cola, its partner on the flavour, Rosala has "transcended borders and genres in music, fashion, and more" from her start as a classically trained flamenco artist in Spain to her ascension to the status of a global a pop sensation. remarkable packaging the contrasts of the artist's persona, from the austere black that symbolises her assertive elegance to the brilliant pink that is inspired by her lively and creative nature. Coca-Cola Move that embraces has PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Diversifying food production can help diversify diets. By 2030, the dairy food industry will generate $1,346.32 billion | CAGR: 6.5 In order to assist people diversify their diets, the Confederation of Indian Industry (CII) held the Global Debate on Food Systems Transformation, which placed an emphasis on changing the way food is produced and marketed. The Global Alliance for Better Nutrition and CII's Food and Agricultural Centre of Excellence (FACE) collaborated to plan the event (GAIN). With an emphasis on the connections between people, the environment, and prosperity, the engagement aims to establish the background, shed light on the components of food systems transformation, and implant a vision for applying a food systems approach to achieve the Sustainable Development Goals. 2022 REVENUE GROWTH FOR CARGILL OF 23% TO $165 BILLION According to a recent analysis by Polaris Market Research, the size of the worldwide dairy foods industry is anticipated to reach USD 1,346.32 billion by 2030. The study offers a thorough understanding of the present market dynamics and offers insights on potential future market expansion. Throughout the course of the projection period, it is anticipated that factors such rising consumer disposable income, greater health consciousness, expanded milk production in developing nations, and rising consumption of protein-enriched meals would all help to drive demand for the products Dry spell since November likely to harm tea production, prices to rise. The output of first flush premium teas is likely to be affected by a protracted dry period that has affected the Assam and West Bengal tea estates since November. Major tea farmers predicted that first flush tea production will decrease by 25% if it doesn't rain in the following 10 days, which could result in a price hike for retail customers. The first flush teas are made between February and April and typically have a milder, flowery, fresh, sharp, and astringent flavour because they are more fragile and tender. PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION N O N - T E C H N I C A L C O N T E N T WEEKS HIGHLIGHT 20 FEBRUARY WORLD DAY OF SOCIAL JUSTICE World Day of Social Justice (Social Justice Equality Day) is an is celebrated on February 20, international day recognizing the need to promote social justice, which includes efforts to tackle issues such as poverty, exclusion, gender inequality, unemployment, human rights, and social protections. 21 FEBRUARY INTERNATIONA L MOTHER LANGUAGE DAY International Mother Language Day is celebrated every year on 21st February. The purpose of celebrating this day is to promote the awareness of language and cultural diversity all across the world. Languages are the most powerful way to preserve and develop culture and to promote it all across the world. DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Y R A U R B E F PMG DID YOU KNOW? Fact 1 Biotin, also called vitamin B₇, is one of the B vitamins. It is involved in a wide range of metabolic processes, both in humans and in other organisms, primarily fats, carbohydrates, and amino acids. the utilization of related to T E C H N I C A L C O N T E N T Fact 2 Biological value captures how readily the digested protein can be used in protein synthesis in the cells of the organism. Proteins are the major source of nitrogen in food. Y R A U R B E F PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter T E C H N I C A L C O N T E N T 1/3 2/3 Fact 3 The “E numbers” in the ingredients list of your packaged foods replace the chemical or common name of particular food additives. These are used to enhance the colour, flavour, texture or prevent food from spoiling. Food additives have been used for centuries. 3/3 Y R A U R B E F PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter T E C H N I C A L C O N T E N T 1/3 2/3 Fact 4 Parboiled rice is rice that has been partially boiled in the husk. The three basic steps of parboiling are - 1. Soaking 2. Steaming 3. Drying. These steps make the rice easier to process by hand, while also boosting its nutritional profile. 3/3 Y R A U R B E F PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter T E C H N I C A L C O N T E N T 1/2 2/2 Fact 4 Because corn spikelet's are borne in pairs, and each spikelet produces two florets: one fertile and one sterile, the row number is always an even number. Stress at a specific stage in development could theoretically result in an ear with an odd number of rows, but this is unusual enough to make headlines. Y R A U R B E F PMG DESIGN+BUILD FOOD FACTORIES. ONE STOP ENGINEERING SOLUTION Vol .01 Newsletter Vol .02-Issue .08-February 2023 PMG ENGINEERING About PMG About PMG Delivering End-to-End Engineering Design & Construction Management in Food & Beverage Industry MAKING CUSTOMERS THE INDUSTRY LEADERS ENGINEERING MUST CREATE BUSINESS VALUE MEET THE EXPECTATIONS OF ALL STAKEHOLDERS OPTIMAL ENGINEERING Website Link Click Here Follow Us on