Principles of Hygienic Equipment Design : Dairy Case Study Though - - PowerPoint PPT Presentation

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Principles of Hygienic Equipment Design : Dairy Case Study Though - - PowerPoint PPT Presentation

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Principles of Hygienic Equipment Design : Dairy Case Study Though Ipleetatio of Iteatioal Reuieets . Contents Four Pillars for Safe Food Foodborne Outbreaks & Deaths in India - 2008-15

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SLIDE 1 Slide No. : 1 Date : 02 Dec 15 Presented By : Mother Dairy

Principles of Hygienic Equipment Design : Dairy Case Study

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

Though Ipleetatio of Iteatioal Reuieets ….

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SLIDE 2 Slide No. : 2 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

inappropriate “Food Engineering” Practices (Globally as well as in India)
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SLIDE 3 Slide No. : 3 Date : 02 Dec 15 Presented By : Mother Dairy

Source: http://www.idsp.nic.in

2008 2009 2010 2011 2012 2013 2014 2015(Till 21 Nov'2015)
  • No. of Outbreaks
553 799 990 1675 1584 1964 1585 1667 Death 50 120 95 77 1108 901 810 2636 553 799 990 1675 1584 1964 1585 1667 50 120 95 77 1108 901 810 2636 500 1000 1500 2000 2500 3000 500 1000 1500 2000 NO Of Deaths
  • No. Of Outbreaks

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

 Number of outbreaks as well as Number of Deaths due to Food Borne Cases are on raise

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SLIDE 4 Slide No. : 4 Date : 02 Dec 15 Presented By : Mother Dairy

Front View Back View Un-even Inaccessible area

Hygienic Design Issues - Few Examples

Key Food processing equipments, supplied to Industry were found with

such Hygienic Design issues

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SLIDE 5 Slide No. : 5 Date : 02 Dec 15 Presented By : Mother Dairy

Hygienic Design Issues - Few Examples

Framework Design issue with Inaccessible area Smooth and accessible area

Key Food processing equipments, supplied to Industry were found with

such Hygienic Design issues

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SLIDE 6 Slide No. : 6 Date : 02 Dec 15 Presented By : Mother Dairy

Few examples of Food Safety Incidents due to failures to Hygienic Engineering euieets …

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

  • ver 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. SNOW RECALL – JAPAN

  • The No.1 dairy Brand in Japan
  • Business: $12 billion dollars in 2000
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
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SLIDE 7 Slide No. : 7 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

  • ther key Food Safety requirements are addressed

appropriately

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SLIDE 8 Slide No. : 8 Date : 02 Dec 15 Presented By : Mother Dairy

Pasteurized Milk Microbiological Specification – Comparison Table Different Countries

/g M M M M /gram
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SLIDE 9 Slide No. : 9 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
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SLIDE 10 Slide No. : 10 Date : 02 Dec 15 Presented By : Mother Dairy

Food Safety Maturity Continuum……

Through Strengthening Strictness of Control Measures

Food Safety Hazard Identification Stage Control Measures

Auto Detection & Manual Control

(Moderate Degree of Strictness of Controlling a Hazard)

Manual Detection & Manual Control

(Low Degree of Strictness of Controlling a Hazard)

“Fail Safe” System

Auto Detection & Auto Control

(High Degree of Strictness of

Controlling a Hazard)

Based on the international requirement s....

Food Safety Hazards are newly identified & Control Measures are incorporated  Eleatig Degee of “titess of Cuet Leel to o steps aoe Low Degree to Moderate Degree / High Degree to Fail Safe

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SLIDE 11 Slide No. : 11 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

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SLIDE 12 Slide No. : 12 Date : 02 Dec 15 Presented By : Mother Dairy Pasteurized Product Raw Produc t Regeneration Zones

Cross Contamination Possibilities of Pasteurized Milk & Prevention by Hygienic Design

Cross Contamination Majority of our own and 3P plants are upgraded to process controls as per international standards

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SLIDE 13 Slide No. : 13 Date : 02 Dec 15 Presented By : Mother Dairy

Key Food Safety Requirements of Pasteurization To have effective Pasteurization Milk / Liquid Foods

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SLIDE 14 Slide No. : 14 Date : 02 Dec 15 Presented By : Mother Dairy

Comparison of Key Food Safety Requirements of Pasteurization

To Prevent Cross Contaminations during Pasteurization Liquid Foods

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SLIDE 15 Slide No. : 15 Date : 02 Dec 15 Presented By : Mother Dairy

Hygienic Engineering Requirements Comparison Matrix

To Assure Food Safety During CIP

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SLIDE 16 Slide No. : 16 Date : 02 Dec 15 Presented By : Mother Dairy

Hygienic Engineering Requirements Comparison Matrix

To Assure Food Safety During CIP

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SLIDE 17 Slide No. : 17 Date : 02 Dec 15 Presented By : Mother Dairy

Pasteurizer Holding Loop Slope….

Why ? How ? Reference Specification  To attain the minimum holding time it is critical that the design
  • f the holding tube
prohibits air from being incorporated into the system.  Air in the system will allow individual milk particles to move faster through the holding tubes, thereby reducing the holding time To preclude air entrapment and ensure uniform product flow, Holding tubes should have upward slope  Provide Holding Tubes slope 2.1 cm per meter ) from the lowest point of the holding tube to the flow diversion device.  Connect the Pasteurizer PHE Heating Zone
  • utlet to the
bottom of the Holding Loop so as to have upward flow.  3A USFDA – PMO  EHEDG  Canadian Food Inspection Agency  Other Food Industry Specs Upward Slope from the lowest point of the holding tube to the flow diversion device  2.1 cm per meter
  • r
0.25 inch per feet
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SLIDE 18 Slide No. : 18 Date : 02 Dec 15 Presented By : Mother Dairy

Holding Coil Upward Slope Requirement in Pasteurization & Sterilization of Liquid Foods

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SLIDE 19 Slide No. : 19 Date : 02 Dec 15 Presented By : Mother Dairy

Holding Coil Drawing With & Without Continuous Upward Slope min of 2.1 cm / meter

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SLIDE 20 Slide No. : 20 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).
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SLIDE 21 Slide No. : 21 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 Respose Tie of the tepeatue seso fo complete FDV activation

  • Adequate distance to be provided between Temperature

Sensor Position & FDV

Holding Coil

International Ref :
  • USFDA PMO,
  • 3A
  • AS 3993 : 2003
  • Canadian Food Inspection Agency
  • University of Guelph
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SLIDE 22 Slide No. : 22 Date : 02 Dec 15 Presented By : Mother Dairy
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SLIDE 23 Slide No. : 23 Date : 02 Dec 15 Presented By : Mother Dairy
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SLIDE 24 Slide No. : 24 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 Volue…

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SLIDE 25 Slide No. : 25 Date : 02 Dec 15 Presented By : Mother Dairy

Preventing Raw Product Siphonage into Pasteurized Product Line

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SLIDE 26 Slide No. : 26 Date : 02 Dec 15 Presented By : Mother Dairy

Raw Product Siphonage : Balance Tank Design

Raw Milk Siphonage

Damaged FDV Seat “O” Ring Damaged FDV Seat “O” Ring
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SLIDE 27 Slide No. : 27 Date : 02 Dec 15 Presented By : Mother Dairy

“iphoage of Ra Milk i ase O Rig Failue

“O” Ring Failure Balance Tank Chilling Zone Heating Zone Homogenizer Clarifier Double Seat Mix-proof Valve as Heating FDV Holding Tube Cooling FDV Vacuum Breaker “OFF” Back Pressure Valve REG Bypass Valves are “Closed” Timing Pump Feed Pump REG - 1 REG - 2
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SLIDE 28 Slide No. : 28 Date : 02 Dec 15 Presented By : Mother Dairy

Divert Line Connection to Balance Tank

 

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SLIDE 29 Slide No. : 29 Date : 02 Dec 15 Presented By : Mother Dairy

Balance Tank Design to prevent Raw Milk Siphonage

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SLIDE 30 Slide No. : 30 Date : 02 Dec 15 Presented By : Mother Dairy

Prevention of Unacceptable re-infection of Pasteurized Product – FDV with Double Seat Configuration

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SLIDE 31 Slide No. : 31 Date : 02 Dec 15 Presented By : Mother Dairy

Single Seat FDV Design & limitations

FDV – Seat “O” Rings FDV – Seat “O” Rings FDV – Teflon Gasket Damaged FDV Seat “O” Ring Damaged FDV Seat “O” Ring

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SLIDE 32 Slide No. : 32 Date : 02 Dec 15 Presented By : Mother Dairy

Option # 1 : Primary & Secondary Seat Valve Set Up for FDV Operation

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SLIDE 33 Slide No. : 33 Date : 02 Dec 15 Presented By : Mother Dairy

Prevention of Unacceptable Re-infection of Pasteurized Product – FDV with Double Seat Configuration

 The Mix proof valve is a completely Hygienic Double Seat Valve  Simultaneous processes in the two bodies of the valve by providing interface between the two fluids  Thus, preventing the possibility of product contamination

Leakage from Upper chamber through Leak Path during one of the Seal Failure Water hammer during Process Balanced Mix-proof Valve
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SLIDE 34 Slide No. : 34 Date : 02 Dec 15 Presented By : Mother Dairy

Post Pasteurization Contamination Control

  • Why ?
– Pasteurized Product is separated with the medium by the plates having thickness 0.6 mm – Microbes are in the medium (Raw Product / Cooling Medium) – To Avoid cross Contamination of Pasteurized Product from raw product & cooling medium  Maintain Positive Pressure in the Pasteurized Product Side  Install Booster Pump, Back Pressure Valve & Pressure Monitoring Devices Pasteurized Product Raw Product

Regeneration Zones

Pasteurized Product Cooling Medium

Cooling Zones

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SLIDE 35 Slide No. : 35 Date : 02 Dec 15 Presented By : Mother Dairy

Pasteurizer Layout

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SLIDE 36 Slide No. : 36 Date : 02 Dec 15 Presented By : Mother Dairy
  • Maintaining Positive

Pressure in Pasteurized Milk Side

– Equipped with booster pump – Equipped with back pressure valve – Equipped with sanitary type pressure gauges – Raw Milk Inlet pressure is generally about 2.5 Bar & IBT pressure is about 3 bar – If the Pasteurized milk pressure in the cooling PHE outlet falls below 3 bar, then alarm should be activated & system should get shut off with in next 1 min

Positive Pressure in Pasteurized Milk side – Semi Auto Units

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SLIDE 37 Slide No. : 37 Date : 02 Dec 15 Presented By : Mother Dairy RECUPERATION TANK HOT WATER TANK 850C HOT CAUSTIC LYE TANK 60°-770C 1.0-1.5% SUPPLY RETURN A B D T S F R E S H W A T E R

CIP Kitchen Schematic - Tank Orientation Generally observed at liquid food industries ….

PHE-A PHE-B PUMP-A @ 20M3/hr PUMP-B @ 20M3/hr A . CIP Circuit 1 B . CIP Circuit 2 W .Treated Water Inlet, D . Drain, F . Flow Meter, S . Steam Inlet, T . Condensate Outlet F Food Safety Hazards are,
  • Cross Contamination during Final Rinse step, since fresh water pass through the pipeline, where in Recup Water Flow
  • Cross Contamination during Final Rinse step, in case of Valve failures in Caustic / Acid / Recup Tanks
Food Safety Hazards are,
  • Absence of Cross Contamination controls, during Final Rinse step, while fresh water pass through the pipeline , where in
Recup Water has flown
  • Cross Contamination during Final Rinse step, in case of Valve failures in Caustic / Acid / Recup Tanks
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SLIDE 38 Slide No. : 38 Date : 02 Dec 15 Presented By : Mother Dairy

Cross Contamination Controls in CIP System due to Valve Failures in the Tanks

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SLIDE 39 Slide No. : 39 Date : 02 Dec 15 Presented By : Mother Dairy 39

Option # 1 : CIP Tank Connection with Safe Flow Valves

Equipped with two seals In case of any seal failure, leakage can be detected

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SLIDE 40 Slide No. : 40 Date : 02 Dec 15 Presented By : Mother Dairy

Safety Drain valve System

Equipped with double valve drain provision In case of seal failure of any of the valves, leakage can be detected at the drain valve

Option # 2 : CIP Tank Connection with Single Seat Valves

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SLIDE 41 Slide No. : 41 Date : 02 Dec 15 Presented By : Mother Dairy

Required Turbulence Velocity for CIP

1,5 m/s

 5T Strategy for Safe CIP – Time, Temp, Titer, Turbulence & Technology Most important and highly neglected one is Turbulence

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SLIDE 42 Slide No. : 42 Date : 02 Dec 15 Presented By : Mother Dairy

 CIP of CIP tanks Shall help to upkeep the CIP kitchen

CIP of CIP Taks ….

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SLIDE 43 Slide No. : 43 Date : 02 Dec 15 Presented By : Mother Dairy

Hot Water Sanitation – Through Heat Recovery Tube

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SLIDE 44 Slide No. : 44 Date : 02 Dec 15 Presented By : Mother Dairy  Use of Fresh Hot Water for every CIP to prevent contaminants (Microbiological / Physical / Chemical) during Hot Water Sanitation.  Energy efficient system, as only the loop volume i.e. 800 to 1200 liters of hot water to be heated to 80°C – 90°C prior to Sanitation step.  Since Fresh Hot Water is used for every CIP, it is not necessary to have Final Rinse step. Hence about 3,000 to 4,000 Liters of Fresh Water per CIP shall be saved.  Final Rinse time is Nil / negligible Vs Traditional Design.

Heat Recovery Tube for Hot Water Sanitation :

Better Food Safety along with Optimizing Natural Resources

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SLIDE 45 Slide No. : 45 Date : 02 Dec 15 Presented By : Mother Dairy

Effect of Dead Ends in CIP Supply & Return Lines…

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SLIDE 46 Slide No. : 46 Date : 02 Dec 15 Presented By : Mother Dairy

CIP Supply & Return Headers

Effect of Dead Ends in CIP Supply & Return Lines…

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SLIDE 47 Slide No. : 47 Date : 02 Dec 15 Presented By : Mother Dairy

Homogenizer - Internal Recirculation Line Hygienic Design

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SLIDE 48 Slide No. : 48 Date : 02 Dec 15 Presented By : Mother Dairy

Homogenizer - Internal Recirculation Line Hygienic Design

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SLIDE 49 Slide No. : 49 Date : 02 Dec 15 Presented By : Mother Dairy

Type of Dead Ends and Actions Taken

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SLIDE 50 Slide No. : 50 Date : 02 Dec 15 Presented By : Mother Dairy

Cleaning & Sanitation Time of Silos @ Mother Dairy

Before & After 6 Sigma Project

Improvements 29 min  PMST CIP time is reduced by 29 min / CIP  Sigma Level 1.5 to 3.9  Water Saving - 25 KL/Day  Power Saving - 10 KWH / Day  Steam Saving - 600 Kgs / Day Improvements 28 min  PMST CIP time is reduced by 28 min  Sigma Level 1.2 to 2.8  Water Saving - 20 KL/Day  Power Saving -10 KWH /Day  Steam Saving - 400 Kgs /Day
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SLIDE 51 Slide No. : 51 Date : 02 Dec 15 Presented By : Mother Dairy

Designing Sand & Carbon Filters with Dead End < 1D in Filter Feed Line & Back Wash Lines

Carbon Filter Design with Dead End: While Filtatio is ON E A Inside flow B C F Rinse & Backwash Drain D Valves are in Ope Position : While Filtration : A,Fand D are in Open position While Rinsing : A,C and D are in Openposition G Freeboard 500MM Water Inlet Man Hole Air Vent <1D Leakage detection any of valves B or C to avoid chlorinated water by pass Lively Dead End Carbon Filter Design with Hygienic Design: While Filtatio is ON E A Inside flow B C F Rinse & Backwash Drain D Valves are in Ope Position : While Filtration : A,Fand D are in Open position While Rinsing : A,C and D are in Openposition G Freeboard 500MM Water Inlet Man Hole Air Vent <1D Leakage detection any of valves B or C to avoid chlorinated water by pass #1
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SLIDE 52 Slide No. : 52 Date : 02 Dec 15 Presented By : Mother Dairy

Mother Dairy Innovation Cete’s Reie Papes on Hygienic Design of Pasteurizer were published by JHED, Europe , (EHEDG - Macedonia Region)

  • n May 13 & Nov 14
1st Review Paper – May 13 2nd Review Paper – Nov 14
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SLIDE 53 Slide No. : 53 Date : 02 Dec 15 Presented By : Mother Dairy

Food “afety Risk Eliiatio….

Fight with the Risk

Damage is likely

Control the Risk

Failure of Control shall be Disastrous

Understand the Risk

Rule the Risk

Understanding the risk and adopting Fail “afe Control Measures though Hygienic Engineering shall be, the best option for Risk Elimination

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SLIDE 54 Slide No. : 54 Date : 02 Dec 15 Presented By : Mother Dairy

“uay…

 Food safety excellence is achievable, through..

  • Implementing Hygienic Engineering requirements in each

process to address the various newly Identified Control Measures

  • Adopting Food Safety Maturity Continuum Model - escalating

to Fail “afe

 Quality & Food Safety are hard to define, impossible to measure, easy to recognize