E N V I R O N M E N T A LM O N I T O R I N G

For BRC Global Standard for Food Safety

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Hello & Welcome

Robust environmental monitoring plans are a cornerstone of the BRC Global Standards for Food Safety (BRCGS).

Environmental monitoring programs can serve multiple, often complimentary, purposes, encompassing a range of different tests which are in place to assist in production of safe and high quality food. Risk based environmental monitoring programs identify potential food safety risks in production, allowing them to be properly managed to prevent product contamination.Effective monitoring is used to confirm the efficacy of cleaning and hygiene and prevent product contamination by acting as an early warning system.Gem Scientific have been working with businesses within the food production industry for over 20 years, giving us unique insights into implementing a range of monitoring and management tools. In this document we will be looking at different onsite testing regimes which can be used in your monitoring routines including ATP monitoring, microorganism indicator tests, allergen detection and pathogen and spoilage organism testing.

Justin Welton

Managing Director, Gem Scientific

HYGIENE AND HOUSEKEEPING

Limits of acceptable and unacceptable cleaning performance

BRCGS Clause 4.11.3 has defined a number of ways, depending on the area, with risks assessed primarily on whether it needs to be a clean processing environment (where a ‘visually clean’ may be sufficient) or a sterile food contact surface (where all traces of allergen or other cross contaminants must be removed).

Further environmental monitoring (to comply with BRCGS Clause 4.11.8 Hygiene and Housekeeping: Environmental Monitoring) must include these aspects a minimum:

• Sampling protocol

• Identification of sample locations

• Frequency of tests

• Target organism(s) (e.g. pathogens, spoilage organisms and/or indicator organisms)

• Test methods (e.g. settle plates, rapid testing and swabs)

• Recording and evaluation of results.

More rigorous tests to assess the level of hygiene may be defined several ways including ATP bioluminescence systems, microbiological indicator tests or allergen detection tests.

Using these types of environmental monitoring tests also allows you to verify or validate cleaning when managing a specific hazard (e.g. allergen cross contamination).

Combining these different test methods allows you to build a robust environmental monitoring and hygiene management plan.

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There is no universal blueprint for an environmental monitoring program. Individual companies design and structure their programs based on their own specific manufacturing environment and hazard analysis.

The development of an environmental monitoring programme starts with mapping out the production process, highlighting zones and specific areas within equipment which are susceptible to higher hygiene risk. Once this is completed test points can be defined throughout to monitor cleanliness and control the risks of potential contamination.

While establishing test points it should be decided if some points will be monitored using ATP system, by microbiological samples (both onsite or sent off to an external lab) or both.

Other considerations when determining test point locations linked to key inspection points include which stage of the manufacturing process they fall and their risk level. Areas can be broken down into different zones to easily identify the risks they pose based on their proximity to the food and cross-contamination risks, and the ease of cleaning and the condition of the surface being tested:

PLANNINGDeveloping an envionmental monitoring plan

• High risk food contact areas (e.g. slicers, hoppers, conveyor belts, knives, drains, condensate from chillers and freezers)

• Proximity non-direct food contact areas (e.g. equipment control panels, chiller door handles, equipment framework)

• Remote non-food contact areas (e.g. hand carts, forklift trucks, floors, walls)

• Outside areas (e.g. staff rooms, canteens, warehousing for finished product)

• Assessing the risks of surfaces, the material, porosity, age, accessibility, damage (scratches and marks) and overall condition must be taken into consideration. Limitations are also dependent of whether the surface is in an area considered to be clean processing or sterile food contact.

Through a hazard risk analysis which considers these areas, companies can use an environmental monitoring program to monitor potential risks and make proactive changes to reduce them. Each company will have its own prerogative based on the raw materials and end products being produced.

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ATP hygiene verification systems use bioluminescence technology to identify and measure adenosine triphosphate, commonly known as ATP. Using ATP monitoring can included as part of BRCGS Clause 4.11.3.

ATP is an energy molecule found in all plant, animal and microbial cells and it fuels metabolic processes. All organic matter (living or once-living) contains ATP, including food, bacteria, mould, and other microorganisms.

ATP testing devices contain a natural enzyme found in fireflies. This enzyme, called luciferase, produces a simple

ATP monitoring can help you verify that hard to clean areas, such as piping nozzels, are free of organic matter.

bioluminescence (light-producing) reaction when it comes into contact with ATP. Using bioluminescence technology, ATP luminometers can measure extremely low levels of ATP collected with testing devices.

Measuring the amount of bioluminescence from an ATP reaction on an activated swab provides an excellent indication of surface cleanliness. The quantity of light generated by the reaction is directly proportional to the amount of ATP present in the sample.

ATP HYGIENE MONITORING AND

VERIFICATION

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Residue from production which remains on a surface after poor cleaning can encourage microorganism growth which leads to spoilage, risk of food poisoning and shelf life reduction.

ATP monitoring is ideal for use and an early risk indicator for inadequate removal of organic residue. As an established method of testing hygiene, it is used widely as a verification method for hygiene cleaning, but it cannot be used as a replacement for microbiological testing.

ATP tests assess the level of cleanliness

which in turn relates to an increase of microbial contamination.

Determining the sampling frequency and ATP cut off levels will differ from business to business based on their own risk analysis.

Although some ATP system manufactures will give guides to acceptable levels based on type of product being manufactured these should be used as a jumping off point for establishing in house levels.

A more common approach to customising pass/fail levels is through

doing before and after testing over a period and including levels after conducting a deep clean to show what RLU levels are achievable.

Through this approach, over time that RLU levels are brought down to an agreed acceptable level and then maintain this level consistently.

Using data trending software, this approach can be expanded on by conducting statistical analysis of the ATP results over time. Through the use of data trending software which is provided with ATP systems results can be tracked allowing cleaning

consistency to be scrutinised.

Repeat problem areas are highlighted giving companies valuable insight to potential hazards and areas where cleaning protocols need to be assessed further. For example, if the data shows erratic results the cleaning regime is highly variable and should be examined more closely to see why.

There are several ATP systems available to the UK market, but the most widely regarded are the 3M Clean-Trace™ LM1 Hygiene Monitoring and Management System and the Hygiena EnSURE Touch Monitoring System.

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3M™ CLEAN-TRACE™ HYGIENE MONITORING AND MANAGEMENT SYSTEM

Production plants across the UK are achieving the highest levels of product quality, safety and environmental hygiene with the help of 3M’s hygiene monitoring and management system.

The 3M Clean-Trace hygiene monitoring and management system is a complete system of products consisting of a handheld luminometer, compatible test swabs and a powerful new software platform.

• Audit ready system with seamless reporting

• All Your HACCP results in one place

• Colour touch screen works seamlessly even when you’re wearing gloves

• Wireless data transfer through Bluetooth or Wi-Fi

• Unique user IDs

• Watch lists pin point problems at a glance

• Easy-to-use dashboard

• Upload photos of test points to your sample plans

• Ergonomically Designed for one handed operation

• 23 Languages

3M Clean-Trace Hygiene Monitoring Software

The 3M Clean-Trace hygiene monitoring software turns data into information, helping you identify root causes and take action quickly.

Now even easier to use and more intuitive with convenient wireless and networking capabilities. Put your data to work identifying workplace trends, optimising productivity and adding value to the process.

3M Clean-Trace ATP Tests

3M Clean-Trace ATP tests feature an intuitive design that’s easy to use and implement, with a long, flexible shape, allowing you to swab even difficult-to-reach areas.

HYGIENA™ ENSURE™ TOUCH HYGIENE MONITORING SYSTEM

Today’s food safety professionals face significant challenges: complex supply chains, increased audit and inspection scrutiny, and the ever-present risk of contamination and recall.

Hygiena EnSURE Touch is the next-generation quality monitoring system. It provides rapid and accurate sanitation verification to support your HACCP program.

Hygiena ATP Test Swabs

Hygiena’s ATP Snap devices are made of fewer components than any other device. Hygiena’s patented Snap-Valve™ technology eliminates the need for additional compartments that require foil seals.

• Run a quick test in as few as two touches

• Create testing points with customised fields and pass/fail limits on the go

• Easily group testing locations into plans

• Manage user access to differentiate personnel

• Easily view testing results and trend analysis

• Factory-calibrated and preset checks to stay GMP/ISO-compliant

• Test and show results for organisms

• Customise settings for language, custom fields, test types, and simulate competitor RLU limits

Hygiena SureTrend™ Cloud Analysis Software

SureTrend Cloud is an easy-to-use data analysis software that comes with every EnSURE Touch.

Available in both cloud-based and desktop formats, SureTrend Cloud enables users to monitor, track, and trend testing results across multiple facilities, and schedule automatic reports making risk management more accessible than ever.

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Hygiena MicroSnap™ Indicator Organism Tests

Hygiena’s MicroSnap Indicator Organism Tests bridge the time gap between ATP and bacterial culture results with convenient, same-shift tests for:

Hygiena InSite Listeria is an easy-to-use, self-contained, environmental tests for the detection of Listeria species in food processing environments.

The test contains a liquid media formulated with growth enhancers, antibiotics and chromogenic compounds specific to the growth of Listeria species. A colour change from yellow to light brown/black is presumptive positive.

Hygiena InSite™ Listeria Tests

Hygiena InSite L. mono Glo TestsHygiena InSite L. mono Glo is a screening test for Listeria species and Listeria monocytogenes, intended to be used for environmental monitoring in food processing environments after cleaning. InSITE L. mono Glo provides qualitative results for low and high levels of Listeria in 24 to 48 hours.

Presumptive positive samples for Listeria species which exhibit green fluorescence under ultraviolet light indicate that the sample is presumptive positive for Listeria monocytogenes.

• E. coli• Coliform

• Enterobacteriaceae• Total viable count (TVC)

MicroSnap is a rapid bioluminogenic test method for the detection and enumeration of bacteria, giving actionable same-day test results.

The MicroSnap test platform consists of an Enrichment Device containing a specific growth medium and a Detection Device containing a bioluminogenic (light-producing) substrate.

When MicroSnap detects the specific microorganism, light is emitted and measured with Hygiena’s EnSURE luminometer.

• Easy-to-use with no preparation Large sponge tip maximizes sample collection

• Easy to interpret – brown/black indicates the presence of Listeria species

• Eliminates costly outside laboratory fees• Self-contained tube eliminates the risk of

contamination• Positive results in as little as 24 hours and

confirmed negative results in 48 hours

Hygiena InSite Salmonella TestsHygiena InSite Salmonella is an easy-to-use, self-contained, environmental Salmonella spp. test. Each device contains a liquid medium formulated with growth enhancers and chromogenic compounds selective for Salmonella species. A change in colour after 24-48 hours of incubation is considered presumptive positive for Salmonella species.

• Large 2.5-inch foam swab for maximum sample Write-on swab label for easy sample identification

• Presumptive positive results are available in as little as 24 hours 

• Sensitive to 1-10 CFU• Delivers results in 24 - 48 hours• Cost-effective environmental monitoring

solution• Colour-changing device is easy to interpret

By taking a proactive approach to microorganism testing companies can mitigate problems before they arise.

BRCGS 4.11.8 identifies requirements for incorporating testing into an environmental monitoring program allows for continual assessment of cleaning protocols at a microbial level.

Effective programs can be used to prevent contamination by acting as an early warning before they affect products.

Sampling and testing will differ from site to site depending on the risks assessed but all sites should have establish sampling protocols, identified test locations based on proximity to food contact areas, hard to clean areas, known problem spots (if they have previously tested positive).

Target organisms and pathogens should also have been established based on the risks presented in the environment.

These may include specific pathogens (e.g. Listeria spp in wet environments or Enterbacteriaceae in dry environments), specific spoilage organisms (e.g. yeast or mould) or indicator organisms (e.g. total plate count, total coliforms).

With advances in technology indicator organism and pathogen testing can now be conducted on site with test such as Hygiena Microsnap and InSite Tests.

If the facility has laboratory testing capabilities onsite specific spoilage organism tests can be conducted using 3M Petrifilm Plates.

MICROORGANISM INDICATOR TESTING

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3M™ Petrifilm™ Plates

Sustainable Science for the Modern Laboratory

If you are still using agar dishes for microbial indicator testing you’re missing a big opportunity to not only boost your laboratory’s productivity and accuracy but also help meet your company’s sustainability goals.

Ready to use, reliable and compact, 3M Petrifilm Plates have streamlined, standardised and simplified microbial indicator testing for the food industry and can reduce your environmental impact compared to agar plates.

When comparing**, raw materials, manufacturing, packaging, use and waste of agar methods versus Petrifilm count plates, Petrifilm was found to use:

This sustainable alternative to traditional agar methods can help you to reduce water and energy consumption, waste and greenhouse gas emissions.

*3M Petrifilm count plate impact summary (274 plants; 1994–1998). 3M internal.**“Reduction in Primary Energy Demand, Blue Water Consumption and Greenhouse Gas Emissions from 3M Petrifilm Plates Compared to Traditional Microbiological Analysis Method,” Jason Howland, 3M Environmental Laboratory and Hannah Bakken, 3M Food Safety

Modern Food Testing in Three Simple Steps1. Inoculate: No media preparation as plates are ready to inoculate2. Incubate: A compact incubator is all you need3. Interpret: Indicator dyes facilitate colony counting

3M Petrifilm Plates eliminate the need to store bulky agar dishes or instruments as each slim pack is less than an inch thick. Each pack offers consistent, uniform testing media.

Just open it up and get right to work. Find new freedom with time to focus on what’s really important: quality and efficiency.

It’s the convenient, efficient, space-saving way to test in the modern food system. With significant productivity and performance advantages over traditional agar plates, 3M Petrifilm Plates have become the standard in microbial indicator testing for food production companies all over the world.

Using Petrifilm plates can have considerable time and cost advantages for your business. A study* of food processing plants showed:

• Converting from agar to Petrifilm count plates can cut laboratory costs by an average of 45%

• An average increase of 80.5% in QA personnel efficiency • Petrifilm count plates can provide data in about half the time of

traditional agar methods• Shelf-stable and nearly as thin as paper, Petrifilm count plates

take up to 85% less counter and storage space

• 76% less energy • 79% less water

3M™ Petrifilm™ Plate ReaderBy automatically reading and counting six widely used Petrifilm plates, this compact instrument can help you improve plate count accuracy, consistency and speed, while raising your laboratory’s productivity and reducing costs.

3M™ Petrifilm™ Plate Portfolio

Automates logging of 128 symbology barcode labels and allows details related to the technician, food type, food lot and dilution schemes to be electronically stored.

Data can also be easily exported to LIMS, Excel and other reporting tools.

These easy-to-use plates with enhanced features can produce results faster than traditional methods, so you can confidently make time-sensitive decisions.

• Fast results (4 seconds/plate)• Reduces the chance of human error• Software automatically calculates, counts and

manages data• Works with Aerobic, Rapid Aerobic, Coliform, E.

coli/Coliform, Enterobacteriaceae and Select E. coli 3M Petrifilm Plates.

• 75% less greenhouse gas emitted • 66% less waste produced

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Allergen management takes place at multiple points in production, starting with a raw material assessment, then production line and personnel cross contamination then through to end-product testing.

BRCGS 5.3 concerns allergen management and the systems in place to manage the allergenic materials and minimise the risk of contamination, with clause 5.3.8 specifically addressing allergen cleaning regimes.

As legislation requires that the presence of food allergens to be clearly labelled on packaging, allergen management

to to eliminate and prevent cross contamination is crucial.

Where there is risk on production lines of this happening risk assessments, line management and, management and monitoring plans must be in place.

The use of specific allergen testing allows users to target and identify the proteins within the chosen allergenic food.

Antibody based rapid lateral flow device (LFD) tests can be used for detection or enzyme-linked immunosorbent assay (ELISA) tests to quantify proteins

present on a surface.

Processing food can also affect the recognition of the target proteins, for example the heat treatment of food.

Where multiple allergens are handled on site, different methods of detection, cleaning and validation may be required, and the effectiveness of cleaning procedures must be validated and documented.

Validation should be done by accredited testing methods and wherever possible quantifiable. Lateral flow tests and ATP testing can be used but are suitable for

verification only.

As well as being used for environmental monitoring, many LFD allergen tests from Hygiena and 3M can be used on raw product, liquid and solid end-product and CIP rinse water to detect allergen residue.

Corrective action based on allergen testing results as part of environmental monitoring will depend on the company’s own risk assessment and planning, with identification of contamination sources and corrective action for cleaning methods and in line with product labelling.

ALLERGEN MANAGEMENT

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3M Allergen Protein Rapid Tests Hygiena AllerTox® Sticks

• Almond• ß-Lactoglobulin• Casein• Cashew• Coconut

• Crustacean• Egg• Fish• Gliadin• Gluten

• Hazelnut• Multi-Treenut• Mustard• Peanut• Pecan

• Pistachio• Sesame• Soy• Total Milk• Walnut

Single-use, lateral flow devices work rapidly to show the presence of the specific allergen you are testing for.

As well as being used as part of environmental monitoring monitoring both 3M Allergen Protein Rapid Tests and Hygiena Alertox Sticks can be used for allergen detection in:

Rapid Lateral Flow Allergen Tests

• Almond• Beta-Lactoglobulin• Bovine Casein• Bovine Total Milk• Brazil Nut• Casein• Cashew

• Coconut• Crustacean• Egg• Egg White • Fish• Hazelnut• Lupine

• Lysozyme• Macadamia• Milk• Mollusc• Mustard• Peanut• Pecan

• Pine Nut• Pistachio• Sesame• Soy• Walnut

The ELISA Sandwich is a technique usually used for the analysis of substances found at very low concentrations. This, combined with the high specificity and sensitivity of the antibodies used in these tests, allows this method to quantify allergens in all types of food and drinks precisely.

Gem Scientific can supply food allergen ELISA tests, from manufacturers including 3M and Hygiena, for the following parameters:

Enzyme-Linked Immunosorbent Assay (ELISA) Allergen Tests

• CIP rinse water• Raw ingredients

• Liquid end-product• Solid end-product

Specific, single use lateral flow allergen tests are available from 3M, Hygiena and Neogeon the following parameters:

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Environmental monitoring to meet BRCGS is a rigorous and multipronged methodology that requires diligent and well thought out management plans.

Through this approach companies can meet the high levels of food safety expected of them while being flexible to make changes and be proactive in their approach to hygiene, microbial and allergen testing.

At Gem Scientific we are continuing our commitment to providing the food and beverage production industry with high-quality and innovative testing products.

We understand that every company has its own set of risks to manage and our aim is to provide a range of flexible tests and equipment to meet them.

We are proud to provide a personal service that’s tailored entirely around your business. Our team work with companies to understand their unique requirements, then offer bespoke solutions to suit you.

Contact us today to discuss how we can help you work towards your environmental monitoring goals.

GEM SCIENTIFIC: HERE TO HELP

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01924 444 577 | gemscientific.co.uk | hello@gemscientific.co.uk