funding opportunity announcement january 3, … capacity... · • the hygienic design of the food...

AFDO - FD152 Capacity Development Funding Opportunity

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FUNDING OPPORTUNITY ANNOUNCEMENT Developing Capacity to Deliver FDA FD152 Food Processing and Technology Course

January 3, 2018

The Association of Food and Drug Officials (AFDO) in cooperation with the U.S. Food and Drug Administration (FDA) is pleased to announce the availability of one-time funding to assist in the development of the capacity to deliver FDA’s FD152 Food Processing and Technology course.

Eligibility: This funding opportunity is being made available to State Manufactured Food Safety Programs that wish to partner and work collaboratively with an academic institution to develop the capacity to deliver the FD152 course within their geographic region.

The Food Processing and Technology Course (FD152) is a 4.5-day course that provides an overview of the basic principles in food processing, technology, and associated equipment used to ensure the safety of manufactured foods. Course work includes detailed studies of food microbiology, food characteristics and properties, food chemistry, thermal processing and heat transfer, fluid flow, emerging technologies, preservation technologies, fillers and packaging technology. Extensive “hands-on” experience with processing equipment is provided in a pilot laboratory setting. The skills and knowledge obtained by Investigators through this course will provide a strong foundation in food safety inspections for manufactured foods.

FD152 Objectives: Upon completion of the course, participants will be able to:

1. Identify the factors and characteristics affecting the growth, control and destruction of microorganisms.

2. Describe the basic principles of heat transfer. 3. Describe the interaction of food, product formulation, and microorganisms as applied

to food processing and packaging 4. Identify the various types of processing equipment, instrumentation, and technology

associated with food manufacturing, and their corresponding characteristics and problematic areas.

5. Describe the use and characteristics of emerging food processing technologies. 6. Identify the characteristics of packaging materials, including design, integrity, and

protective properties for managing risks associated with processed foods.

FD152 Target Audience: This course is designed for FDA investigators, state inspectors, compliance officers, and supervisors who are actively engaged in the regulation and inspection of food manufacturing plants, or who review or take compliance action on inspection reports. This course is a prerequisite for advanced food regulatory courses and those seeking level II food certification.

Delivery of the course requires access to a variety of food processing equipment so that students can become familiar with the equipment, its operation, teardown, and sanitation. Applicants for these funds must agree to provide the FD152 curriculum in its entirety, as it


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was developed and intended to be delivered by FDA. Equipment covered during the course can vary slightly based on course location, to address the types of regional food manufacturing operations and equipment used within the geographic region where the course is being offered. The equipment list must be approved by either AFDO personnel or the FDA ORA OTED Training Officer in charge of this course, prior to course delivery. Course delivery will be coordinated with FDA’s Office of Training, Education and Development (OTED), who will provide access to the course curriculum, course roster template, certificates of completion based on the completed course roster, and the course exam. The intent of this funding is to assist the state and academic institution in developing instructors, acquiring the necessary equipment, supporting travel of instructors to FD152 train-the-trainer courses, and initiating the capacity to deliver the FD152 course. Funding for the ongoing delivery of the course will not be available. FD152 courses are currently offered in North Carolina, Indiana, and California. Funding applications will be evaluated to ensure that development of the new training programs will be geographically dispersed throughout the United States and will not adversely affect the delivery of existing courses. Funding: Up to a maximum of $50,000 per proposal. AFDO anticipates funding will be available for 5-6 proposals. Proposal Due Date: January 31, 2018, at 8:00 PM Eastern Time Proposal Submission: Proposals must be submitted electronically to the Manufactured

Food Training Grant Program at: http://afdo.org/mfgrants/ . Proposal Content::

1. Be sure to fully answer all questions in the online grant application portal (grant portal), providing enough detail for AFDO and FDA to make fully-informed decisions regarding the readiness of your program to deliver FD152.

2. In the Required Documents section of the grant portal, upload at minimum: a. A Curriculum Vitae (CV) for each of the proposed instructors for the course; and b. A list of the Course Equipment that makes clear the equipment already on-hand

and available for use with the academic institution, and the equipment that will be purchased using award funds (an FD152 Equipment List Template is provided at http://afdo.org/mfgrants/ ).

3. In the BUDGET WORKSHEET(S) AND VERIFICATION section of the grant portal, be sure to create a comprehensive Budget Worksheet that covers all funds requested. Use the Budget Narrative section to provide additional details that fully explain your proposed expenditures.

Award and Project Dates: Project Awards are expected to be made in March 2018 and the expected project completion date is December 31, 2018. A summary of the course content, equipment demonstration, practical exercises, and equipment list is available below.

http://afdo.org/mfgrants/

http://afdo.org/mfgrants/


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FD152 Food Processing and Technology Course Course Content and Topics

Course Lecture Components

• Introduction to Food Processing and Technology (30 minutes) • Safety in Food Processing (90 minutes) • Food Plant Utilities (30 minutes) • The Hygienic Design of the Food Processing Plant (45 minutes) • Process Controls in Food Processing (30 minutes) • Postharvest Handling and Preparation of Foods Processing (45 minutes) • Mechanical Transport and Storage (60 minutes) • Separations in Foods Processing (60 minutes) • Mixing, Emulsification, and Size Reduction (60 minutes) • Heat Transfer (105 minutes) • Thermal Processing (75 minutes) • Non-Thermal Processing (60 minutes) • Evaporation & Dehydration (90 minutes) • Refrigeration and Freezing (30 minutes) • Acidification, Fermentation, Smoking and Curing (60 minutes) • Food Packaging and Food Packaging Equipment (60 minutes)

Hands-on Demonstration Topics and Practical Exercises

• Introduction to Food Processing and Technology (15 minutes) o Pilot Plant Policies and Procedures o Pilot Plant Overview

• The Hygienic Design of the Food Processing Plant (60 minutes) o Hygienic Design of Equipment Exercise

• Process Controls in Food Processing (90 minutes) o Hands-on demonstration of equipment process controls

• Mechanical Transport and Storage (135 minutes) o Hands-on demonstration of mechanical transport and storage equipment

• Separations and Mixing (90 minutes) o Hands-on demonstration of separations and mixing equipment

• Heat Transfer (120 minutes) o Hands-on demonstration of heat transfer equipment

• Thermal Processing (150 minutes) o Hands-on demonstration of thermal processing equipment

• Extrusion, Non-Thermal Processing and Dehydration/Evaporation (105 minutes) o Hands-on demonstration of extrusion, non-thermal, dehydration, and

evaporation equipment • Food Packaging and Food Packaging Equipment (150 minutes)

o Hands-on demonstration of food packaging and food packaging equipment o Metal, Glass, Flexible Containers Defect Classification


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FD152 Food Processing and Technology Equipment List

Note: The size of pilot processing laboratory equipment must be at least capable of manufacturing pilot scale batches (generally, one-tenth of a full production scale batch). Not all of the equipment listed below is required, however, highlighted equipment marked with an asterisk (*) are deemed the highest priority for a successful delivery of the FD152 course. Some equipment may satisfy more than one bulleted category.

• Water activity meter • pH meter • Viscosity meter • Refractometer • Electro conductivity Test Equipment • Recording Temperature Devices and Thermocouples • Resistance Temperature Detectors/Devices (RTDs) and Data-loggers

• Food processing equipment with hygienic design faults (e.g. stagnant areas or dead spaces)*

• Food processing equipment that can be used to demonstrate clean-in-place (CIP) and clean-out-of-place (COP)*

• Boiler o Fire Tube o Water tube

• Examples of food processing equipment that utilize compressed air

• Examples of food processing equipment that utilize recirculating process water

• Food processing equipment that can demonstration the following process controls below:

o Manual Control o Automatic Control o On/Off (Two Position Controller) o Proportional Controller (P-controller) o Proportional Integral (PI) Controller o Proportional Integral Derivative (PID) Controller o Programmable Logic Controller (PLC)

• Examples of raw material dry cleaning equipment utilized in food processing (e.g. screens, aspiration, magnetic, electrostatic)

• Examples of raw material wet cleaning equipment utilized in food processing (e.g. fruit washing conveyor)

• Examples of raw material peeling equipment utilized in food processing (e.g. steam, lye, brine, abrasion peeling, mechanical knives)

• Examples of raw material sorting equipment utilized in food processing ( e.g. color sorter imagining system)

• Examples of raw material blanchers (e.g. water blancher, steam blancher) • Grinder (rotating grater disks)


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• Examples of pumps utilized in food processing (cutaway examples for demonstration preferred)

o Piston Pump* o Lobe-rotor pump* o Progressive/Eccentric-screw Pump* o High-Pressure Pump (Homogenizer- Cherry-Burrell, APV or similar)* o Peristaltic Pump (Hose Pump)* o Centrifugal Pump* o Aseptic Pump (Fristam or equivalent)

• Examples of valves utilized in food processing (cutaway examples for demonstration preferred)

o Flow Diversion valve* o Butterfly valve* o Gate valve* o Globe valve* o Ball valve* o Petcock valve* o Check valve* o Seat valve o Mixproof valve o Plug valve o Diaphragm valve o Control valve o Valve clusters (multiple valves controlled by a PLC) o Back pressure valve o Steam seal

• Examples of conveyors utilized in food processing (cutaway examples for demonstration preferred)

o Pneumatic Conveyor o Hydraulic Conveyor o Uniform Belt Conveyor o Segmented Belt Conveyor o Roll and Skate Wheel Conveyor o Chain Conveyor o Screw Conveyor* o Vibratory Conveyor

• Examples of food (in-process) storage utilized in food processing (cutaway examples for demonstration preferred)

o Bins and Silos o Vats and Vessels o Tanks

• Pressure Filters o Plate-and-frame filter press o Horizontal plate filter o Shell-and-leaf filter o Edge Filter


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• Vacuum Filters o Rotary drum vacuum filter o Rotary vacuum disk filter

• Centrifugal Filters (Filtering Centrifugal, Basket Centrifuges) o Batch centrifugal filter o Continuous centrifugal filter

• Liquid-Liquid Centrifugal Separators o Tubular bowl centrifuge o Disk bowl centrifuge

• Solid-Liquid Centrifugal Separators o Solid bowl centrifuge (clarifier) o Nozzle-discharge centrifuge o Self-opening centrifuge o Decanting centrifuge

• Batch Presses o Box and Pot Press o Curb and Cage Press o Bladder Press

• Continuous Presses o Screw Press o Roller Press o Belt Press o Juice Reamer

• Fruit Juice Expression o Rack and Frame Press o Wilmes Press o Screw Press o Bucher Press o Belt Press o Accordion press o Screening Centrifuge

• Extraction o Single-Stage Extractor o Multi-stage Extractor o Multistage Moving Bed Extractor

• Stemmer/ crushers (rotating drum with large holes • Finisher • De-aerator • De-oiled • Decanters • Distillation Equipment

o Batch Distillation o Continuous Distillation (Fractionating) Columns

• Crystallization Equipment o Cooling Crystallizer o Evaporative Crystallizer


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• Filtration Sizes o Reverse Osmosis (RO)(hyperfiltration) o Nanofiltration o Ultrafiltration o Microfiltration

• Types of filtration o Reverse Osmosis Unit* o Nano Filtration Unit o Ultra Filtration Unit o Microfiltration Unit* o Carbon and gravel beds

• Types of filter systems o Plate disc or Multi-disc* o Spiral* o Hollow fiber* o Ceramic o Cartridge* o Plate and Frame or Filter Press

• Types of filter media o Hollow fiber membrane o Cast membrane o Sintered Metal o Fibrous o Ceramic membrane

• Ion-Exchange Equipment • Electrodialysis System • Examples of mixers utilized in food processing (cutaway examples for demonstration

preferred) o Paddle Mixer* o Turbine Mixer o Propeller Mixer o Pan (Bowl, Can) Mixers o Kneaders (Dispersers, Masticators) o Static Inline Mixers* o Horizontal Screw and Ribbon Mixers* o Vertical Screw Mixers o Tumbling Mixers o Fluidized Bed Mixers o Turbine agitators o Z-blade mixer o Sonic Mixer

• Examples of homogenizers utilized in food processing (cutaway examples for demonstration preferred)

o Pressure Homogenizers o Hydroshear Homogenizers o Membrane Homogenizers


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o Ultrasonic Homogenizers • Roller Mills (Crushing Rolls) • Impact (Percussion) Mills

o Hammer mill o Beater bar mill o Comminuting mill o Pin (pin-disk) mill o Fluid energy (jet) mill

• Attrition Mills o Buhrstone mill o Single-disk attrition mill o Double-disk attrition mill o The Foos mill o Colloid mill

• Tumbling Mills o Ball mills o Rod mills

• Extruder o Single Screw o Twin Screw

• Transparent tube that can demonstrate laminar flow of product through the tube • Transparent tube that can demonstrate turbulent flow of product through the tube • Steam injection unit (cutaway example for demonstration)* • Steam infusion system* • Plate Heat Exchanger (De-Laval or similar) for heating and cooling (minimum 2 – 3

sections)* o Extra plates showing different surface flow configurations

• Tubular Heat Exchangers (Stork, Cherry Burrell, Contherm or similar) o Triple Tube Design (cutaway example for demonstration)* o Double Tube Design (cutaway example for demonstration)* o Multi-tube Design

• Scraped Surface Heat Exchanger (cutaway example for demonstration)* o Extra blades - carbon, steel, and plastic for hands-on demonstration

• Tube-in-Shell Heat Exchanger • Examples of baking and roasting ovens utilized in food processing • Examples of Fry equipment utilized in food processing

o Batch Frying Equipment o Continuous Frying Equipment o Pressure Fryers o Vacuum Fryers

• Examples of kettles utilized in food processing o Steam Kettle* o Agitated Kettle

• HTST Pasteurization Equipment • Tunnel (Spray) Pasteurizers • Examples of retort types utilized in food processing:


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o Vertical or Horizontal Still Steam Retort* o Crateless Retort o Still Water Immersion Retort o Continuous Agitating Retort o Discontinuous Agitating Retort o Steam/Air Retort o Water spray/Cascade Retort o Hydrostatic Retort

• Aseptic Processing System • Examples of equipment associated with Microwave processing (e.g. Microwave

Sterilizer) • Examples of equipment associated with Dialectic Heating Processing • Examples of equipment associated with Ohmic Heating Processing (e.g. Ohmic

Processor) • Examples of equipment associated with the following Irradiation Processing:

o Ionizing ▪ Gamma ▪ E-beam ▪ X-ray

o Non-ionizing ▪ UV light (e.g. UV Sterilizer/ UV Processing Unit) ▪ Radio frequency (e.g. Radio Frequency Processor)

• Examples of equipment associated with High Pressure Processing (e.g. High-Pressure Processor)

• Examples of equipment associated with Ozonization Processing (e.g. Ozone Generator) • Single-Effect Vacuum Evaporators

o Vacuum Pans o Short Tube Vacuum Evaporators o Long-Tube Evaporators o Plate Evaporators o Agitated Thin Film Evaporators o Centrifugal Evaporators o Refractance Window Evaporator o Scraped Surface Evaporator (Convap)

• Hot Air Drying of Solid Food Pieces o Cabinet (Tray) Dryer o Tunnel Dryer o Conveyor Belt Dryer o Bin Dryer o Fluidized Bed Dryer o Pneumatic (Flash) Dryer o Rotary Dryer

• Drying Solid Foods by Contact with a Heated Surface o Vacuum Cabinet (Tray or Shelf) Dryer o Double Cone Vacuum Dryer o Freeze Drying Solid


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o Cabinet (Batch) Freeze Dryer o Tunnel (Semi-continuous) Freeze Dryer o Continuous-Freeze Dryers o Vacuum Spray Freeze Dryer

• Drying Food Liquids and Slurries in Heated Air o Spray Drying o Drying Liquids and Slurries by Direct Contact with a Heated Surface o Drum (Roller, Film) Dryer o Vacuum Band (Belt) Dryer o Refractance Window Drying System

• Examples of Cooling equipment utilized in food processing o Cooling of Solids

· Hydrocooling · Vacuum-Cooling · Surface Contact Cooling · Tunnel Cooling

o Cooling of Liquid · Plate Heat Exchangers · Scrape Surface Heat Exchangers · Jacketed Vessels · Shell and Coil Equipment · Vacuum Cooling Equipment · Combination Cooling with Mixing

• Plate Contact Systems • Gas Contact Refrigerators • Immersion and Liquid Contact Refrigeration • Cryogenic Freezing • Examples of Fermentation Systems utilized in in food processing • Temperature controlled chambers • Form-Fill-Seal Equipment

o Vertical form-fill-seal machine for sachets o Vertical form-fill-seal machine for pillow packs o Horizontal form-fill-seal machine for sachets o Horizontal form-fill-seal machine for pillow packs

• Thermoforming • Blow Molding • Injection Molding • Compression Molding • Examples of types of fillers utilized in food processing

o Siphon o Vacuum o Pressure o Counter Pressure o Piston

· Check Valve Piston · Rotary Valve Piston


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o Servo Driven Pump o Powder/ non-liquid

· Net Weight · Auger · Cup/Volumetric/Gravimetric (pocket fillers)

o Solbern Tumbler Filler o Aseptic Filler with capability to demonstrating filling of Tetra-Pak, Combibloc,

Scholle or Inpaca containers* o Thermoform cup filling (e.g. Hassia) o Retort pouch filler/sealer

• Tetra-Pak, Combibloc, Hassia, retort pouch sealing equipment that seals by: o Induction o Impulse o Ultrasonic o Heat bar

• Mechanical Vacuum • Reduced Oxygen Packaging/Modified atmosphere packaging system • Single Head Double Seamer* • Bottle capper system • Examples of labeling equipment utilized in food processing • Examples of glass containers

o Lug or twist cap glass container* o Press-on Twist-off (PT) cap glass container* o Continuous Thread Closure (CTC) glass container*

• Examples of glass container defects o Glass container with crushed lug* o Closed glass container with product over the edge of finish “wicking” o Glass container with titled or cocked cap o Glass container with pinhole in cap*

• Examples of flexible containers o 3-side seal flexible pouch* o 4-side seal flexible pouch o Semi-rigid Fusion sealed bowl or tray* o Semi-rigid container with double seam metal ends o Semi-rigid paperboard carton* o Semi-rigid erect fill paper carton

• Examples of flexible container defects o Pouch with fracture o Pouch with leaker o Swollen pouch o Pouch with channel leaker* o Pouch with contaminated seal o Pouch with seal wrinkle* o Pouch with blister in seal area* o Pouch with convolution in seal area o Pouch with waffling


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o Semi-rigid container with cut o Semi-rigid container with incomplete seal o Semi-rigid container with channel leaker o Semi-rigid container with contaminated seal o Semi-rigid container with abrasion o Semi-rigid container with uneven impression in seal area o Crushed semi-rigid container o Semi-rigid container with body abrasion o Semi-rigid container with foreign matter inclusion (imbedded) o Semi-rigid paperboard carton with corner leaker o Semi-rigid paperboard carton with pull tab leaker o Crushed semi-rigid paperboard carton o Semi-rigid paperboard carton with loose tab

• Examples of types of metal containers o 2-piece Drawn & Iron (tin free steel bodies & lids)* o 3-piece welded (tin free or tin coated steel)* o 3-piece soldered (tin coated steel; tin solder)*

• Examples of types of metal container defects o Buckle* o Sweller

· Flipper · Springer · Soft Swell · Hard Swell*

o False seam o Knocked down end curl* o Veer (Spur)* o Cut over or Fractured seam o Cable Cut (Cut seam) o Deadhead (Skidder) o Incomplete double seam o Severe dent o Rusted can