Jane Nock Group Technical Manager jane.nock@in2food.co.za What we - - PowerPoint PPT Presentation

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Jane Nock Group Technical Manager jane.nock@in2food.co.za What we - - PowerPoint PPT Presentation

Oct 27, 2023 373 likes •589 views

Jane Nock Group Technical Manager jane.nock@in2food.co.za What we Do -1500 plus RTE,RTRH, RTC PRODUCE PREPARED FOODS LONGLIFE Long Life soups Pillow Pack Salad Leaf Sandwiches & Wraps Long Life sauces

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Jane Nock Group Technical Manager jane.nock@in2food.co.za

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What we Do -1500 plus RTE,RTRH, RTC

PRODUCE PREPARED FOODS LONGLIFE

  • Pillow Pack Salad Leaf
  • Prepared Vegetables
  • Prepared Salads
  • Salad additions
  • Prepared fruit
  • Micro leaves
  • Baby veg
  • Strawberries
  • Sandwiches & Wraps
  • Hot eating To Go products
  • Prepared Soups
  • Prepared Sauces
  • Delicatessen Products
  • Ready Meals
  • Quiches
  • Pizza’s
  • Seafood
  • Fresh Juice
  • HPP Juice
  • Long Life soups
  • Long Life sauces
  • Potato crisp Snacks
  • Other bases for Snacks
  • Frozen fruit and veg
  • Biscuits
  • Soft eating dried fruit
  • Mayonnaise products
  • Avocado pulp
  • Avocado IQF
  • Pop chips
  • Steel cut oats
  • Rusks
  • Ambient Cakes
  • Hot fill Juices
  • Donuts
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SLIDE 3

Zero Tolerance is “State of Mind”

Stop concentrating on negative results…… ANY species of Listeria in Environment or product is an ISSUE……… We must adopt a new attitude

NO ACCEPTANCE

Investigate the “Presence Results”

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Past Strategies

Operation Desert Operation Noah “White Snow”

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Present Strategy

Listeria Champions Listeria Mapping Training Mandatory Listeria Management Procedures Monthly meetings – multi-disciplined team Food Safety checklist KPIs Science! Fabric risk assessments Barrier risk assessments Pathogen cleaning protocol Micro testing Listeria / cleaning audits

Risk Assessment Of: Site: Bilsthorpe Jane Nock/Ian Dorsey Area Checked Dirty side Breaking Room P C M RISK Action Required Person Responsible Scheduled date for completion Corrective Action Completed Re- assessed Risk No extraction causing condensation above P2, Currently managed vis clean x x 4 Investigate air flues/non used extraction grills Ian Dorsey Mar-13 Requires Capex but managed by overhead cleaning Replace engineers door with plastic door x x 2 New door Ian Dorsey Oct-12 Ordered Put door in between low care and filter room x x 2 New door Ian Dorsey Clean side Breaking Room P C M RISK Action Required Person Responsible Scheduled date for completion Corrective Action Completed Re- assessed Risk Can we please find away of using covers instead of tape for hi-lighting trip hazards tape is unacceptable x 2 Investigate and replace tape Ian Dorsey Nov-12 Mobile Wash P C M RISK Action Required Person Responsible Scheduled date for completion Corrective Action Completed Re- assessed Risk Extraction required X 4 Obtain quote Ian Dorsey Cage washer investigation instead of pressure washing for 2013 x x 4 Obtain quote Ian Dorsey Process room P C M RISK Action Required Person Responsible Scheduled date for completion Corrective Action Completed Re- assessed Risk 31.08.12 Redundant pipes looks unslightly hinders high level clean x 2 Remove redundant pipes Ian Dorsey Ongoing Ongoing 2 Service valves in poor state x 2 Paint service valves Ian Dorsey 18.07.11 Ongoing 2 flaking paint on bottoms of girders and some parts of ceiling above plant 3 re galvanise paint x 2 Replace/repaint stairs Ian Dorsey 18.07.11 started to Repaint 2 Rusty girders x 2 Repaint girders Ian Dorsey 18.07.11 Ongoing 2 Sky lights need cleaning on roof x x 2 Clean Ian Dorsey Sep-12 Lagging requires repair above tanks x 4 Replace damaged lagging Ian Dorsey Sep-12 Chills and Chill corrider P C M RISK Action Required Person Responsible Scheduled date for completion Corrective Action Completed Re- assessed Risk 31.08.12 Main chill wall panels badly damaged cannot clean x x 4 Clad in stainless Ian Dorsey ? Requires Capex but as low risk not a priority 4 Fabric Manager: Start Date 31.08.12 HAZARD
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Listeria- Hot spot Mapping

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KPI- Listeria

SUMMARY OF LISTERIA TESTING

LISTERIA FINAL PRODUCT TOTAL SWABS PREPARED PLANT PRODUCE PLANT FOOD CONTACT SWABS NON-FOOD CONTACT SWABS RAW MATERIALS INGREDIENT COMPONENTS AVERAGE % Total tested 516 1293 299 217 626 667 190 583 Total L.spp 6 10 34 8 28 Total L.mono <10 2 11 4 3 Total L.mono 53 9 27 2 1 Total negative 494 1141 281 213 574 567 180 533 L.spp % fail 0% 2% 5% 4% 5% 3% L.mono <10 % fail 0% 0% 4% 2% 0% 0% 0% 1% 1% L.mono % fail 0% 4% 0% 0% 1% 4% 1% 0.2% 1% Negative % 96% 88% 94% 98% 92% 85% 95% 91% 92%

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Strip your equipment where you didn’t think possible! 70:30 RULE –Food Contact: Non Food Contact You can increase your level of testing by swabbing several areas as a composite swab Swab During production (DP) After Production (AP) but must wait 1- 2 hours after cleaning Swab could be neutralised and give you false NEGATIVE!

Swabbing

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Control in High Care/Risk

Barrier -High Risk Facilities are fully segregated from Low care Separate personnel entrances and Change Rooms Separate drains Barrier Integrity- Full wall Barriers Colour coding equipment Captive equipment Sculleries –Non Food Contact and Food Contact Positive Air pressure* Decontamination

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Date

24.1.13

Review Due

24.1.14

Supplier

Riverside

Technologist

Bola Sokoya

Signed Signed

Transfer points

Is the Gap the minimum size Is the Door alarmed Is there a procedure in place Is there an airlock

Is the barrier full floor to ceiling around the gap

Are

  • peratives

trained

Further Action Required

Completion date Travelling

  • ven

yes N/A Yes No Yes Yes No spray tunnel Yes No Yes No Yes Yes No Rack return Yes No Yes Yes Yes No Fire Door Yes Yes Yes No Yes Yes No Wrapping line gaps No N/A N/A No Yes Yes Yes Jun-13 Air Filters N/A N/A No N/A N/A Yes No Water Filters N/A N/A Yes N/A N/A Yes No

STEP 2A

Barrier Integrity Risk Assessment & Action Plan

What controls are in place to maintain the barrier integrity?

If YES, detail the agreed action

Gap from Line X to be made smaller to be size of largest product passing through it

Walk barrier & mark on factory plan, type in all the points where the barrier could be breached list is not exhaustive, can add more control criteria if required

document & date any agreed action & timescales

look at your ambers & decide if action is required to improve integrity

Barrier Risk Assessments

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Fabrication & Equipment

Lack Low Care High Care standards Poor Fabrication Drains not separate from high Care – poor design Lack of full Physical barriers-Full wall barrier segregation Poor Equipment design Extraction and condensation Hose pipe design – High pressure Poor Scullery Design Walls /floor junctions Evaporation Chiller units Cleaning equipment Lack of new technologies

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Poor Equipment Design Photos

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Fabrication- Good design

Drain design Wall floor junctions plastic bumpers Services all in one place Stainless rack with fixed coat hooks Separate flow and sinks no tray washes for Use non food contact and Food contact Use of curtains for non food contact

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Cross Contamination by the Movement of people and equipment

  • Production equipment- Must be captive
  • Tables/stands- hollow legs
  • Electrical cabinets/line services
  • Drainage from equipment
  • Wheels/dolavs/pallets/Floor Lugs- stop using
  • Chopping boards/knives- use different colours
  • People- no moment from low care to high risk
  • Boots, hands
  • Separate handwashing/entrances
  • Space and access around / under equipment
  • Product movement from chillers
  • Equipment design
  • Floor to food contact- Floor Fairy!
  • Water! Keep as dry as possible
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How Often

  • A full clean and disinfection every 24 hours
  • Provide the right equipment/chemicals and number of people

TIME-The cleaning window may become squeezed- NEVER compromise on cleaning window ever! Having a schedule for everything - not missing tasks

  • Organisation & sequencing of cleaning
  • Engineers available for stripping equipment
  • Walk away standards
  • No partial Cleans
  • Challenge the standard of cleaning

Sequence of cleaning Always top down, left to right, right to left. In Process Cleaning

  • Product changeovers / high soiling lines
  • Essential to keep debris and micro loading low Scheduled in production plan
  • Only clean when raw materials are off the line/ out of the area
  • Minimum use of water, even no water - sani wipes are often sufficient
  • Separate hygiene staff, or full change of gloves/sleeves/ bibs & hand wash

Fundamental Principles of Cleaning

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Pathogen Cleaning Protocol

Alternate chemical Regime for 3 -7 Days- until 3 consecutive clear results Change detergents to break down biofilms- Caustic to an Acid based detergent- But you will still need to use degreaser first! NB You may see rise in failures when biofilms break down before improvement Alternate disinfectants increase from 1-3% to 3-5% Approved sanitisers – efficacy- proof they work! Byotrol QFS- no DDAC- Primary Sanitiser must be used Vortex- PPA Betane Plus(contains DDAC so only can be used for NFC) Tego 2001- (cant get in SA) In Production additional Measures 'Military' style discipline 2 hourly disinfection route with 1OOppm Free Chlorine Or (1 or 2% terminal disinfectant as above Change squeegee trough disinfectant every 2 hours Disinfectant wipe door handles every 2 hours

  • Record on a chart & keep on display in the relevant area
Door Handles , c,,,u Handle _... sanitisation point
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Use of Biofinders

  • INNOGIENE and iTRAM Hygiene
  • Can detect build up of film you cannot see!
  • Detect Biofilm detecting catalog – H²O²
  • Enzymes – Preservatives
  • Technical detail – deactivate at PM
  • Life cycle 60°C contact TEMPERATURE
  • Enzymes used in spray:
  • a-Amylase
  • Subtilisn
  • Protease
  • These enzymes are sensitive to temperature

and denature above 60 deg C.

  • They are also extremely sensitive to pH.
  • CAUTION- NFC ONLY
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Retailer

  • How Often do they clean and disinfect

shelves?

  • Weekly
  • Maintenance every 6 months
  • Customer contact- Risk
  • Picks up puts down
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FUTURE RISKS!

Raw Materials- High Risk

  • Fruit
  • Vegetables

Water Quality- Shortage

  • Source
  • Contamination

Legislation Changes

  • We need to find it to Manage it!

Donations- The Vulnerable!

Pathogens and Norovirus

  • Don’t loose focus on the rest!
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Any Questions

Thank you