Proper cleaning tools can increase plant hygiene and make it easier for food processing facility staff to do their job. Finding the right brushes for each job is easier when you understand the role bristle stiffness, brush type, and bristle/block attachment play in how a brush functions.
Hygienic Design of Brushes
Drilled and stapled brushes are made by drilling a hole into the brush block and stapling bristles into it. Higher quality versions will have only small gaps near the attachment point, making it less likely for contaminants to become trapped. Low-quality versions may have issues with bristles falling out and will have larger gaps around the fiber attachment points, making it easier for microorganisms to hide and multiply. For many food processing needs, a high-quality version of this type of brush is appropriate.
Resin-set brushes pose a variety of hygiene concerns. For this brush, holes are drilled in the block, filaments are stapled into them, and resin is added for extra bristle security. Resin itself isn’t approved for food contact and often gets trapped in between bristles and falls out, creating a source of contamination. This type of brush isn’t suitable for food manufacturing.
Ultra Safe Technology (UST) brushes from Vikan improve bristle retention and brush hygiene. These innovative brushes have a unique construction and design. Bristles are fully molded into individual bristle security units. Those units are then molded directly into the brush block, eliminating holes, gaps, and contamination traps. Because of this production technique, bristle security units can be arranged in patterns that allow brushes to be cleaned easily while maximizing cleaning efficiency. These ultra-hygienic brushes are ideal for food production plants that make infant formula, baby food, and ready-to-eat food.
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Maintaining hygienic standards is easier when employees have access to the right tools for the job, including the proper brooms. The staff in charge of cleaning will be better able to carry out cleaning tasks effectively and efficiently when they have tools that are fit-for-purpose.
Hygienic Design of Brooms
Drilled and stapled brooms are produced with the traditional method of folding bristles and stapling them into a block. This creates a tight fit that holds bristles in place. When a tool is well-designed, there are minimal places for contaminants to hide in and multiply. However, bristles have been known to fall out, though less frequently on better-quality tools. For most food industry purposes, this provides a high level of hygiene and supports sanitation efforts.
Resin-set brooms have cropped up in recent years, but they present a host of hygiene concerns—namely, that the resin itself isn’t approved for food contact and have been known to fall out of the broom, creating and spreading its own contamination. This type of broom isn’t recommended for food processing.
Ultra Safe Technology (UST) brooms from Vikan are state-of-the-art tools that have a unique design and construction that improves bristle retention and hygiene. Bristles are fully molded into bristle security units in patterns that maximize efficiency while allowing the broom itself to be cleaned easier. This level of hygiene is appropriate for facilities that require a higher level of cleanliness, such as ready-to-eat food, baby food, and infant formula processing plants.
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Handwashing in the food industry is one of the first lines of defense in food safety. Along with being a consumer health risk, inadequate personal hygiene can lead to costly and reputation-destroying recalls. However, it’s not just the responsibility of individual employees to ensure proper handwashing procedures are followed. Managers must cultivate a culture of food safety where taking time-off from lines to wash up is encouraged. Facilities also must be equipped with adequate hand washing stations.
Not only will setting the scene and creating the culture for effective handwashing help protect consumers, it will also help protect your business.
When to Wash
Employees knowing when to wash their hands is just as important as knowing how to properly wash them. High-visibility signs posted around the facility can teach and remind employees about handwashing.
Signs posted around the facility make for great reminders, but the topic should also be covered in training seminars. Don’t forget to translate instructions in whatever languages required to communicate with all of your employees.
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Food production facilities often rely on color coding their tools and workstations to create zones of control. These zones can designate areas where allergens are used to prevent cross-contact incidents, separate raw – from finished products to avoid cross-contamination issues, or visually represent different shifts to account for concerning potential direct-contamination trends. Color coding is generally easy to understand and provides a universal language for people of all levels of literacy -and – language background.
However, for 1 in 12 men and 1 in 200 women, some colors may be difficult or impossible to discern. Color-blindness comes in many forms, but the most common type is partial color-blindness, where the person can’t distinguish between a couple or a few colors. Of those, the two forms of red/green color-blindness: deuteranopia (reduced sensitivity to red light) and protanopia (reduced sensitivity to green light), occur most frequently. That doesn’t imply color coding as a zoning solution doesn’t work for color-blind employees, but it does mean that colors should be chosen carefully to avoid the most common color-blindness pairings.
Continue reading “Food Safety Culture – Color-Coding for the Color-Blind”
As an AFDO industry member, Remco Products Corporation is proud to have participated in the 121st Association of Food and Drug Officials Conference this June. Over 400 members from federal, state, and local agencies, as well as members of industry groups, trade associations, consumer organizations, and academia, made the trip to Houston for the recent conference.
AFDO has, over time, become a recognized voice in promoting uniform, simplified, and efficient laws, regulations and guidelines related to food safety and public health. Their humble beginning predates the existence of the FDA by 10 years when in 1896, two state commissioners from Michigan and Ohio met in Toledo to discuss the difficulties of manufacturing food in one state and shipping it to another, where the same product may not have complied with the local statutory regulations.
The push for states to collaborate and come to a mutually acceptable solution eventually resulted in a streamlined regulatory solution across the states. With time, AFDO became a forerunner in publishing model codes and guidance for various foods, which have been used to formulate aligned state regulations. The defining moment arrived in 1998, when AFDO was the first to offer a vision of a national Integrated Food Safety System (IFSS) that would empower state and local authorities to collaborate effectively with their federal counterparts. The crowning glory came with the passage of FSMA in 2011, which shifted the FDA’s focus from the reactive to the preventive mode of addressing food safety risks, which also mandated the adoption of IFSS across the food supply network.
Continue reading “AFDO Journeys Toward the Integrated Food Safety System Vision”
HACCP and HARPC share more than just four letters. They’re both food safety standards based on prevention, but they do differ on execution. Their differences and their similarities aren’t as important as the way they fit together for most food processors, though. A HARPC plan shouldn’t be considered as a replacement, but as a necessary upgrade to the conventional HACCP plan. Understanding how the systems fit together is the first step toward implementing both.
|(1) Is the preventative approach based on a standard, guideline or a set of laws?
|Based on a guideline recommended by CODEX and NACMCF
||Based on FSMA act and principally, the Final Rule for Preventive Controls for Human Food
|(2) What food safety risks are considered using the preventative approach?
|Conventional – Biological, Chemical, and Physical
||Beyond the conventional risks for actual and potential food safety hazards
|(3) What is the goal of the preventative approach?
|To prevent, eliminate (or) reduce hazards to a safe level (in that priority)
||Preventive controls that prevent or significantly minimize “known or reasonably foreseeable” risks
|(4) Who is primarily responsible for the development and maintenance of the preventive plan?
|Primarily, a competent HACCP coordinator with assistance from multidisciplinary team
||Trained Preventive Controls Qualified Individual (PCQI) as described in the FSMA Act
|(5) At what frequency is the preventive plan being reviewed by the facility?
|At least once a year, or when required
||At least once in 3 years, or when required
|(6) The plan is mandatory for what type of establishments?
|For FDA and USDA mandated establishments, or when required for certification purposes
||For all establishments along the food supply chain that serve U.S. consumers, unless exempted
|(7) The plan is excluded or exempted for what type of establishments?
|Unless mandated or required for certification, HACCP is voluntary, and GMPs are mandatory
||Exemption list is provided by FDA, but this does not exempt facilities from following at least CGMPs
|(8) Who is the interested party here? For whom is the plan for?
|Stakeholders: auditors, inspectors, and customers
|(9) What is the documented approach for making the preventive plan?
|12 Steps of HACCP (includes 7 Principles)
||7 Steps of Developing a HARPC Plan
HARPC as an Upgrade to HACCP
HACCP, or Hazard Analysis Critical Control Points, is already widely used due to requirements from retailers, auditing standards, and inspectors, though the USDA and the FDA only mandate it for meat, seafood, and juice products. As a global standard conceptualized the 1960s, HACCP has been continually developed and updated. HACCP requires a multi-disciplinary team for implementation and follows prescriptive steps.
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The FDA’s final rule on the sanitary transportation of food went into effect June 6, 2016. Though larger carriers, shippers, and receivers should have their compliance plans in place, smaller companies (fewer than 500 employees and less than $27.5 million in annual receipts) still have two years from the rule publication date to comply with the requirements.
This final rule—the sixth of seven rulemakings for FSMA—was based on a combination of the Sanitary Transportation of Food Act of 2005 and about 240 submissions from transportation companies, food safety organizations, consumer advocacy groups, and more.
The rulemaking has been proposed to ensure:
- Proper refrigeration during transportation of foods that require it;
- That vehicles and food storage are adequately cleaned and sanitized; and
- That there is adequate protection for food during transport.
Waivers have been proposed to exempt carriers, shippers, and receivers who hold valid permits and are inspected under National Conference on Interstate Milk Shipments (NCIMS) Grade ‘‘A’’ Milk Safety Program only when they’re shipping Grade A milk and milk products. The exemption should also apply to retail and food service operations that hold valid permits only when they are engaged in transportation operations as receivers, or as shippers and carriers in operations in which food is relinquished to consumers after transportation from the establishment.
Continue reading “FDA Final Rule on the Sanitary Transportation of Food Compliance Gains Momentum”
The goal of any good sanitation plan is to minimize cross-contamination and cross-contact through better hygiene and cleaning practices. But—what happens when workers can’t feasibly reach that tall ceiling fixture or get a brush to follow the curves of a spiraling pipe? If employees don’t have the right tools for the job, they’ll end up improvising sub-par solutions, or—even worse—they just won’t clean that area.
Here are some examples of specialty tools solving common cleaning problems in food processing plants:
Standard handles just aren’t going to reach all the way up a factory’s walls. Use a telescopic handle to clean walls top-to-bottom. Because they’ll need to be adjusted many times, handles should be easy to extend and shorten. Ideally, they should also be hollow to minimize weight for worker comfort and to make the handles easier to control at longer lengths.
Ceiling and pipe condensation
Sometimes handled by makeshift tools like a sock on a telescopic pole, cleaning condensation is vital to food safety and deserves its own tool. Condensation dripping into food or processing equipment can lead to microbial cross-contamination and a costly recall. Use a condensation squeegee to prevent drops from forming and falling into products. A condensation squeegee catches and drains water from overhead into either tubing or bottles to keep products safe.
Continue reading “Common Food Industry Cleaning Problems Solved”
Sort, straighten, shine, standardize, and sustain. These five principles comprise the 5S lean manufacturing method that originated in Japan. While 5S can help any organization, the principles contained in the alliterative method should especially appeal to those in food processing for its ability to promote food safety through a clean, safe, and organized workplace.
5S principles are based on the idea that a well organized and clean workplace increases employee satisfaction, promotes worker safety, and decreases product waste. 5S relies on everything having its own place that’s easily identifiable. Like color-coding, 5S uses the idea of a “visual factory” that lets workers know at a glance where tools are and where they should be put back after they’re cleaning.
For the sort step, work areas should be cleared of things that aren’t needed daily. Discard junk that’s broken or simply not needed, along with broken tools. Items that are needed, but only on an infrequent basis, should be moved to storage. If an item is misplaced or stored illogically, it should be moved to a more convenient location.
Sorting can help minimize chances of cross-contamination and cross-contact by sorting food-contact and non-food-contact items apart from each other.
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Remco Products presents Food Industry Counsel’s FDA Inspection Checklist as a part of our commitment to bringing our audience the best information in the food industry. We don’t endorse any legal services or provide legal advice. For legal services or advice, please consult your attorney. You can also contact Shawn Stevens, the author of this post, at email@example.com.
What to do Before, During and After Your Next FDA Inspection
Food Industry Counsel, LLC is pleased to provide you with the most comprehensive and useful FDA Inspection Checklist available. With the passage of the Food Safety Modernization Act (FSMA), the Food and Drug Administration (FDA) was given the mission of overhauling the safety of the nation’s food supply. The new FSMA regulations written by FDA are now coming into effect, and the agency is now aggressively enforcing its new rules during routine inspections. Within the coming years, FDA Investigators will conduct an onsite inspection of every food facility in the U.S.
Here are FDA’s new enforcement priorities during routine unannounced inspections:
(1) To carefully critique each company’s written food safety programs and verification records to ensure they are compliant with the new FSMA requirements;
(2) To conduct extensive Zone 1, Zone 2, Zone 3 and Zone 4 microbiological sampling inside all food facilities to find evidence of pathogenic contamination;
Continue reading “FDA Inspection Checklist”