think hygienic production design is everything hygenic... · dmri test of prototype • stop/test...
TRANSCRIPT
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Think hygienic production – design is everything
Director Food Safety, Lene Meinert, PhD
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NO! Mindset
Hygienic production
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Focus on the technological solution, then…
One way to do it:
DMRI test of prototype
• Stop/test
• Refine the design
• Lessons learned
3D derinding machine for loins
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Good hygienic design
▪ Ensures good cleaning of the equipment
▪ Decreases the risk of growth and contamination of (harmful) microorganisms
▪ Promotes good production hygiene, which is the cornerstone of food safety
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▪ Shelf life (global export)
BUT
▪ Costs: Money as well as time
37 million €/year in the Danish meat industry
▪ Equipment: Wears out and breaks down
▪ Environment - water and chemicals
Cleaning is not just about food safety
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The basics of cleaning
Cleaning agents
Time Temperature
Mechanical actions
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The basics of cleaning
Cleaning agents
Time Temperature
Mechanical actions
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The basics of cleaning
Quality inspection
• Audits
Management
• Dialog
• Protocols
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Interesting
Production efficiency throughout
the production line is continuously
optimised – not cleaning
Is it due to
Legislation?
Customers?
Cleaning by tradition
Traditional cleaning and disinfection
in the meat industry for years
1. Prepare equipment for cleaning
2. Initial rinsing/scrubbing
3. Foam
4. Rinsing
5. Disinfection
6. Rinsing
7. Drying (time and energy)
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▪ Increased production time (24/7)
▪ Cleaning has to be faster/differentiated
▪ Retain high international position
▪ Competiveness – high quality of the meat
▪ Continuous pressure on meat producers
to provide longer shelf life
Cleaning 4.0 – conditions
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▪ Re-thinking and improving efficiency in traditional daily cleaning
▪ Support improved utilisation of the production facilities
▪ Less repairs due to damage caused by cleaning
▪ 20% reduction in the consumption of water, energy and chemicals
Cleaning 4.0 – how to get there
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Water consumption today
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1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010 2012
l/ p
ig
Pig slaughterWater consumption l/pig
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▪ Cleaning amounts to 25% of the total water consumption
▪ 80% is used for initial rinsing
▪ The goal is to save water of drinking quality
▪ ”Fit for use” water applications – characterize water quality, risk analysis
▪ Legislation opens up for the reuse of water
Water consumption 4.0
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DMRI ideas and results
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Disinfection of knives without chemicals
Water system:
• Initial rinsing at 42°C
• Sterilize at 82°C
• Final rinse (cooling) at 42°C
It needs to look clean, and it needs to work
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It needs to look clean, is coating the answer?
85 min
3½ hours
60 min42°C water / 82°C water / 42°C water0.5 sec. / 0.5 sec. / 0.5 sec.
42°C water / Neuthox 35 ppm / 42°C water0.5 sec. / 0.5 sec. / 0.5 sec.
42°C water / Inspexx 210, 300 ppm / 42°C water1 sec. / 1 sec. / 1 sec.
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Sterilise with 82°C hot water • Rinse with water at 42°C• Sterilise with 82°C hot water• Chill with water at 42°C
It needs to look clean
Robot for loosening the backbone
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Differentiated cleaning
▪ Different requirements in different areas
▪ Development of procedures for in-process cleaning
▪ Establishment of frequency cleaning as “daily” cleaning
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Frequency cleaning
• In-process cleaning
• Cleaning of critical spots
• Simple removal of meat residues
• Wiping surfaces
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Daily cleaning – microbial baseline
Wizard knife - trimmings
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Daily cleaning – microbial baseline
▪ 13 production lines during production (2-18 h)
▪ Targeted warm surfaces
▪ RESULTS:
▪ No increase in bacterial count during production
▪ The bacterial load reflects the product handled
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Bacteria growth on surfaces
▪ Simulating continuous production (no cleaning stops)
▪ Conveyor belt, no product flow
▪ Thin and thick layer of meat residues
▪ Inoculate with pathogens or spoilers
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Microbial growth on surfaces
• Growth initiated in 0-23 hours
• Significant growth after 1-2 days
• Growth depends on:
• pH 5.4 (loin) - pH 6.3 (fore end)
• Drying (survive, inactivate) – new problem
• In-process cleaning needed
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Production time and shelf life of cooked meat products
Simulating continuous production – effect of bacteria count
• Sampling of cooked meat during a production of 100 h
• Normal procedure: cleaning surfaces during production (IPA-cloth)
• Test of frequency cleaning on critical spots
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Production time and shelf life
Using frequency cleaning
▪ Significantly reduced the number of bacteria naturally
present on the meat at the time of packing
▪ Provided extended shelf life
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DMRIpredict.dk
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Process control – the future
Perspectives
• Identify routes of contamination (spoilage 16S, pathogens WGS)
• Bacterial make-up in production environment and products (16S)
• Control the process (e.g. fermentation)
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Take home messages
• The rethinking of cleaning is needed
• Water consumption reduced by reuse
• Frequency cleaning can prolong production hours
• Know your critical (hot) spots
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Thank you for your attention
See you during the tour of DMRI