Handbook of Hygiene Control in the Food Industry (Woodhead Publishing in Food Science and Technology)

Developments such as the demand for minimally-processed foods have placed a renewed emphasis on good hygienic practices in the food industry. As a result there has been a wealth of new research in this area. Improving Hygiene in the Food Industry provides a comprehensive summary of the key trends and issues in food hygiene research. Part 1 reviews research on the range of contamination risks faced by food processors. Building on this foundation, Part 2 discusses current trends in the design both of buildings and types of food processing equipment, from heating and packaging equipment to valves, pipes and sensors. Key issues in effective hygiene management are then covered in Part 3, from risk analysis, good manufacturing practice, and standard operating procedures (SOPs) to improving cleaning and decontamination techniques. The final part of the book reviews developments in ways of monitoring the effectiveness of hygiene operations, from testing surface cleanability to sampling techniques and hygiene auditing. Like Hygiene in the Food Industry, this volume will be a standard reference for the food industry in ensuring the highest standards of hygiene in food production. Contents......Page 6 Contributor contact details......Page 18 Preface......Page 24 1.1 Introduction: the evolution of food hygiene......Page 26 1.2 Definitions of hygiene......Page 36 1.3 Sources of food contamination......Page 38 1.4 Hygiene control measures in food processing......Page 42 1.5 Future trends......Page 46 1.6 References......Page 49 Part I Risks......Page 54 2.1 Introduction: the risk of microbial foodborne disease......Page 56 2.2 The control of food safety......Page 62 2.3 Using food safety objectives to manage microbial risks......Page 63 2.5 References......Page 69 3.1 Introduction: biofilm formation and detection......Page 71 3.2 Pathogens in biofilms......Page 75 3.3 Biofilms and microbial contamination in food processing......Page 82 3.4 Prevention of biofilm formation and biofilm removal......Page 83 3.5 Future trends......Page 85 3.6 Sources of further information and advice......Page 86 3.7 References......Page 87 4.1 Introduction: disinfection methods......Page 94 4.2 Factors influencing the effectiveness of cleaning and disinfection......Page 95 4.3 Strategies for optimisation of cleaning and disinfection......Page 103 4.4 Types of pathogen response......Page 107 4.5 Predicting microbial resistance......Page 109 4.6 Future trends......Page 111 4.8 References......Page 113 5.1 Introduction......Page 118 5.2 Factors affecting aerosol contamination......Page 119 5.3 Aerosol generation......Page 120 5.4 Aerosol dispersal......Page 121 5.5 Ways to reduce the risk from airborne contamination......Page 123 5.7 Sources of further information and advice......Page 125 5.8 References......Page 126 6.1 Introduction......Page 128 6.2 Risk perceptions of cunsumers are not the same as technical risk assessments......Page 129 6.3 Risk perception and barriers to effective risk communication......Page 132 6.4 Developing an effective risk communication strategy......Page 133 6.6 The need for more intensive cooperation between natural and social scientists......Page 137 6.7 Conclusions......Page 140 6.8 References......Page 141 Part II Improving design......Page 146 7.1 Introduction: sanitation and design......Page 148 7.2 Applying the HACCP concept to building design......Page 150 7.3 Site selection and plant layout......Page 152 7.5 Landscaping and the surrounding area......Page 153 7.6 Roof areas......Page 155 7.7 Loading bays......Page 156 7.8 Entry/exit points and external lighting......Page 157 7.9 Inside the plant......Page 158 7.10 Future trends......Page 170 7.11 Bibliography......Page 172 8.1 Introduction......Page 173 8.2 Barrier 1: Site......Page 175 8.3 Barrier 2: Factory building......Page 176 8.4 Barrier 3: High-care/risk areas......Page 180 8.5 Barrier 4: Finished product enclosure......Page 190 8.6 References......Page 192 9.2 What are floors made of?......Page 193 9.3 Requirements for flooring materials......Page 198 9.4 Test methods......Page 203 9.5 Construction of floors......Page 205 9.7 Sources of further information and advice......Page 206 9.8 References......Page 207 10.2 Exterior walls......Page 210 10.3 Interior walls......Page 213 10.4 Bibliography......Page 215 11.1 Introduction: the hygienic performance of closed equipment......Page 216 11.2 The importance of flow parameters in hygienic performance......Page 217 11.3 Computational fluid dynamics models for optimising hygiene......Page 222 11.4 Applications of computational fluid dynamics in improved hygienic design......Page 225 11.5 Future trends......Page 232 11.6 Sources of further information and advice......Page 233 11.7 References......Page 234 12.1 Introduction......Page 237 12.2 Heat exchanger design......Page 238 12.3 Developments in heat exchanger design......Page 240 12.4 Future trends......Page 242 12.5 Conclusions......Page 243 12.6 References......Page 244 13.2 Dry particulate materials and hygienic processing......Page 245 13.3 Cleaning regimes......Page 246 13.4 Design principles......Page 247 13.5 Types of equipment in dry material handling areas......Page 251 13.7 References......Page 252 14.1 Introduction......Page 253 14.3 Application of ISO 14159......Page 254 14.4 Other standards and guidelines......Page 262 14.5 Conclusion......Page 263 15.1 Introduction......Page 264 15.2 Hygienic zoning......Page 265 15.3 Hygienic electrical design principles......Page 267 15.4 Installation requirements for medium hygiene areas......Page 269 15.5 Installation requirements for high-hygiene areas......Page 275 15.6 General requirements for construction materials......Page 282 15.7 Future trends......Page 286 15.9 Appendix: abbreviations......Page 287 16.2 Valve types......Page 288 16.3 Hygienic aspects of valve design......Page 293 16.4 Current guidelines, standards, and references......Page 297 17.2 Piping design: good practice......Page 298 17.3 Materials of construction......Page 299 17.4 Product recovery......Page 300 17.5 Microbial growth in piping systems......Page 301 17.6 Plant design......Page 302 17.7 References......Page 303 18.2 Components used in pumps......Page 304 18.3 Cleanability, surface finish and other requirements......Page 309 18.5 Summary......Page 310 18.6 Bibliography......Page 311 19.1 Introduction......Page 312 19.2 Sensor types......Page 314 19.3 Common industrial applications and future trends......Page 323 19.4 References......Page 326 Part III Improving hygiene management and methods......Page 332 20.1 Introduction......Page 334 20.2 Quality management and risk assessment......Page 337 20.3 Examples of risk assessments......Page 341 20.4 Future trends......Page 346 20.6 References......Page 347 21.1 Introduction......Page 349 21.2 Effective manufacturing operations and food control......Page 352 21.3 Personnel and training......Page 354 21.5 Premises, equipment, product and process design......Page 355 21.6 Manufacturing and operating procedures......Page 356 21.7 Ingredients and packaging materials......Page 357 21.8 Managing prodiuction operations: intermediate and finished products......Page 360 21.9 Storage and movement of product......Page 361 21.10 Special requirements for certain foods......Page 362 21.11 Rejection of product and complaints handling......Page 365 21.12 Product recall and other emergency procedures......Page 367 21.14 Good control laboratory practice (GLP)......Page 369 21.15 Future trends......Page 371 21.16 References......Page 372 22.1 Introduction: defining standard operating propcedures (SOPs)......Page 373 22.2 They key components of SOPs and SOP programs......Page 374 22.3 SOP requirements under regulatory HACCP programs......Page 380 22.4 Common problems in implementing SOPs effectively......Page 383 22.5 Sources of further information......Page 385 22.6 References......Page 386 23.1 Introduction......Page 388 23.2 Food allergy and product safety......Page 389 23.3 Management of food allergy risks......Page 391 23.4 Role of allergen detection and other considerations......Page 394 23.5 Future trends......Page 399 23.6 References......Page 400 24.1 Introduction......Page 403 24.2 Potential microbiological problems with packaging......Page 405 24.3 Improving hygienic production and management......Page 411 24.4 Future trends......Page 416 24.6 References......Page 417 25.2 Legislation......Page 421 25.3 Implementation of the current legislation......Page 422 25.4 Examples......Page 423 25.5 Temperature management......Page 424 25.6 Avoiding cross-contamination......Page 428 25.7 Future trends......Page 429 25.9 References and notes......Page 430 26.1 Introduction......Page 432 26.2 The grain bulk as an ecosystem......Page 433 26.3 Moisture migration in the grain bulk......Page 436 26.4 Dry- and wet-grain heating......Page 437 26.5 Insects in stored products......Page 439 26.6 Measures of control......Page 442 26.7 Future trends......Page 448 26.9 Bibliography......Page 449 27.1 Introduction: limitations in current CIP systems......Page 450 27.2 Cleaning and disinfection parameters......Page 451 27.3 Factors determining the effectiveness of a CIP system......Page 454 27.4 Improving CIP systems......Page 463 27.5 Future trends......Page 468 27.6 References and further reading......Page 469 28.1 Introduction......Page 470 28.2 Best practices in developing an effective COP process......Page 471 28.3 Defining the process......Page 472 28.4 Elaboration of process parameters......Page 473 28.5 Validation......Page 488 28.6 Records and process documentation......Page 489 28.7 Summary......Page 490 28.8 Bibliography......Page 491 29.1 Introduction......Page 493 29.2 Processing effects on fouling and cleaning......Page 497 29.3 Investigations into cleaning process parameters......Page 504 29.4 Ways of improving cleaning......Page 511 29.5 Conclusions......Page 515 29.7 References......Page 516 30.1 Introduction to cleaning tanks......Page 522 30.2 Factors affecting cleaning efficacy......Page 523 30.3 Hygienic design test methods......Page 526 30.4 Detecting the cleanliness of tanks......Page 527 30.5 Using computational fluid dynamics (CFD) to assess cleanability of closed process lines......Page 528 30.7 References......Page 529 31.1 Introduction......Page 532 31.2 Historical uses of ozone......Page 534 31.4 Undesirable effects of ozone......Page 535 31.5 Practical applications of ozone......Page 536 31.8 Sources of further information and advice......Page 538 31.9 References......Page 539 32.1 Introduction......Page 541 32.2 Enzyme-based cleaning procedures......Page 543 32.3 Laboratory trials of enzyme-based cleaning......Page 547 32.4 Field trials......Page 556 32.5 Risks......Page 559 32.6 Future trends......Page 560 32.7 References......Page 562 33.1 Introduction to contamination analysis in the food industry......Page 564 33.2 Different types of contamination analyses......Page 565 33.3 Listeria monocytogenes contamination in food processing environments......Page 568 33.4 Psychtotrophic lactic acid bacterium contamination in meat processing environments......Page 572 33.5 Applying knowledge from contamination analysis to improve hygienic food manufacturing......Page 575 33.8 References......Page 576 34.1 Introduction......Page 581 34.2 Microorganisms......Page 582 34.3 Hygienic surfaces......Page 585 34.4 Organic salt......Page 589 34.5 Future trends......Page 592 34.8 References......Page 593 35.1 Introduction......Page 597 35.2 Background......Page 598 35.3 Current approaches to monitoring......Page 599 35.4 Laboratory/pilot-scale studies......Page 606 35.5 Industry requirements and potential benefits......Page 609 35.7 Conclusions......Page 610 35.8 References......Page 611 36.1 Introduction......Page 613 36.2 Microbiological surface sampling......Page 621 36.3 Non-microbiological surface sampling......Page 628 36.4 Monitoring/sampling protocols and strategies......Page 633 36.5 Future trends......Page 639 36.6 References......Page 641 37.1 Introduction......Page 644 37.2 Microbial viability in the air......Page 645 37.3 Why, how and what to sample......Page 646 37.4 Bioaerosols and bioaerosol samplers......Page 647 37.5 Air sampling methods......Page 649 37.6 Bioaerosol assay methods......Page 657 37.7 Interpretation of bioaerosol results......Page 660 37.8 Future trends......Page 661 37.9 References and further reading......Page 662 38.1 Introduction......Page 666 38.2 Types of biocidal products......Page 667 38.3 Criteria for testing biocidal action......Page 676 38.4 Tests for disinfectants and sanitisers......Page 681 38.5 Test limitations and scope for improvement......Page 686 38.6 Future trends......Page 688 38.7 Sources of further information and advice......Page 689 38.8 References......Page 690 39.1 Introduction......Page 697 39.2 General issues in tracing of cleaning solutions and hygiene products......Page 698 39.3 Particular issues in tracing of hygiene products......Page 700 39.5 Future trends......Page 708 40.1 Introduction......Page 709 40.3 Auditing and the hierarchy of a controlled system......Page 711 40.4 Purposes of an auditing system......Page 713 40.5 Designing a system for improvement audits......Page 714 40.6 Performing the audit......Page 715 40.7 References......Page 721 Index......Page 722 Annotation This important wide-ranging book complements the highly successful Hygiene in food processing by reviewing the key recent research on improving hygiene in food processing plants. Part 1 considers the latest research on contamination risks such as biofilms and how they can be assessed. Part 2 reviews ways of improving hygienic design of both buildings and equipment, including such key topics as clean room technology. The final part of the book discusses ways of improving hygiene practice and management, with chapters on areas such as cleaning and monitoring techniques. CONTENTS Part 1 Risks: Range of microbial risks in food processing; Biofilm risks; Pathogen resistance to sanitisers; Aerosols as a contamination risk; Consumer perceptions of risks from food. Part 2 Improving design: Improving building design; Improving zoning within food processing plants; Improving the design of floors; Improving design of walls; Improving the hygienic design of closed equipment, heating equipment, equipment handling dry materials, packaging equipment, electrical equipment, valves, pipes, pumps, sensors. Part 3 Improving hygiene management and methods: Risk assessment in hygiene management; Good Manufacturing Practice (GMP) in the food industry; The use of Standard Operating Procedures (SOPs); Managing risks from allergenic residues; Managing contamination risks from food packaging materials; Improving hygiene in food transportation; Improving control of insects in food processing; Improving cleaning in place (CIP); Improving cleaning out of place (COP); Improving cleaning of heat exchangers; Improving cleaning of tanks; Ozone decontamination in hygiene management; Enzymatic cleaning in food processing; Contamination routes and analysis in food processing environments; Testing surface cleanability in food processing; Improving the monitoring of fouling, cleaning and disinfection in closed process plant; Improving surface sampling and detection of contamination; Improving air sampling; Testing effectiveness of disinfectants and sanitisers; Traceability of disinfectants and sanitisers; Improving hygiene auditing Developments such as the demand for minimally-processed foods have placed a renewed emphasis on good hygienic practices in the food industry. As a result there has been a wealth of new research in this area. Complementing Woodhead’s best-selling Hygiene in the food industry, which reviews current best practice in hygienic design and operation, Handbook of hygiene control in the food industry provides a comprehensive summary of the key trends and issues in food hygiene research. Developments go fast: results of the R&D meanwhile have been applied or are being implemented as this book goes to print.

Part one reviews research on the range of contamination risks faced by food processors. Building on this foundation, Part two discusses current trends in the design both of buildings and types of food processing equipment, from heating and packaging equipment to valves, pipes and sensors. Key issues in effective hygiene management are then covered in part three, from risk analysis, good manufacturing practice and standard operating procedures (SOPs) to improving cleaning and decontamination techniques. The final part of the book reviews developments in ways of monitoring the effectiveness of hygiene operations, from testing surface cleanability to sampling techniques and hygiene auditing.

Like Hygiene in the food industry, this book is a standard reference for the food industry in ensuring the highest standards of hygiene in food production.

• Standard reference on high hygiene standards for the food industry
• Provides a comprehensive summary of the key trends in food hygiene research
• Effective hygiene management strategies are explored