Sanitary Standards in Bakery Equipment

Sponsored by the FPSA Bakery CouncilBy Bob BrandonSeptember 24, 2014

Brandon Food Machinery Consulting, LLCBrandonFoodMachineryConsulting.comrgbrandon@yahoo.com

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Why now – Sanitary Concerns in Bakeries

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FSMA - Food Safety Modernization Act was signed into law in January 2011Emphasis on the Food manufacturer as responsible for food safety preventive controls.A new approach to prevention, HACCP.FDA recall authority, Records requirements.

Social Media – Instant Reporting

Because the public asked why: Over the past few years, high-profile outbreaks related to various foods, from spinach and peanut products, eggs, to cantaloupe have underscored the need to make continuous improvements in food safety. And FDA inspectors can take samples and generate the DNA “fingerprinting” of the Salmonella bacteria.

A primary reason for this change in food policy is the increasingly global and complex food supply chain. Products and ingredients in the U.S. food supply now come from every part of the world.

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What FSMA didMajor emphasis on wording: define “microorganisms” to mean yeasts, molds,

bacteria, viruses, protozoa, and microscopic parasites and includes species having public health significance.

would define “food-contact surfaces” to mean those surfaces that contact human food and those surfaces from which drainage,…... Proposed § 117.3 would also specify that “food-contact surfaces” includes utensils and food-contact surfaces of equipment.

would also specify that the safe moisture level for a food is related to its water activity (a w), and that an a w will be considered safe for a food if adequate data are available that demonstrate that the food =< the given a w will not support the growth of undesirable microorganisms.

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More Words are better that an RTE food includes food that “reasonably appears

to be suitable for consumption without cooking by the consumer.” For example, it is well known that consumers eat raw cookie dough; an outbreak of foodborne illness caused by E. coli O157:H7 has been linked to consumption of raw cookie dough. It also is well known that consumers use dried soup mix in RTE form as a component of a dip; multiple dried soup mix products were recalled due to the potential for contamination with Salmonella

FDA is proposing to define the term “preventive controls” to mean those risk-based, reasonably appropriate procedures, practices, and processes that a person knowledgeable about the safe manufacturing, processing, packing, or holding of food would employ to significantly minimize or prevent the hazards identified under the hazard analysis that are consistent with the current scientific understanding of safe food manufacturing, processing, packing, or holding at the time of the analysis.

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My Background EE degree but now a whatever it takes engineer.

Kraft Foods - Oscar Mayer – Pizza Sr. Engineer Feb 1999 - Jan 2010

◦Trained in Kraft , Oscar Mayer, Sanitary equipment design for USDA equipment.

Nestle - Pizza. Corporate Project Manager/Engineer. Jan 2010 to July 2012◦Trained in Nestle Hygienic equipment design.

Consultant Brandon Food Machinery Consulting, LLC - July 2012 to Present◦Rep for :Anritsu –Metal detectors, check weighers

and package x-ray detection equipment. Vincit Group – Sanitary services and solutions.

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Food Safety in the IndustryFPSA represents the entire

industry with these councils: ◦Bakery◦Beverage◦Dairy ◦Prepared Foods represents suppliers to the fresh

and processed fruits and vegetable industry

◦Meat– Meat Industry Suppliers Alliance (MISA),

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Most of these Groups had before FSMA a sanitary design/prevention document

Meat – American Meat Institute, AMI Checklist and 10 Principles of Sanitary Design

Dairy – 3AAll Factories – Safe Quality Foods (SQF) 213 pages

Bakery.. ???

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Bakery Industry Standards History Baking Industry Sanitation Standards Committee (BISSC) and American Society of Baking In

1949, the BISSC was formed with representatives from six national organizations serving the baking industry: American Bakers Association, American Institute of Baking (AIB), BEMA, the baking industry suppliers association, Biscuit and Cracker Manufacturers Association and the Retail Bakers of America.

Although the original purpose was to develop and publish voluntary standards for the design and construction of bakery equipment has not changed, its sanitation standards have been revised and rewritten over the years to reflect developments in the industry. The BISSC standards were published together in a single booklet in 1977, 1981, 1986, 1990, 1994 and 1998.

In 2002, the Baking Industry Sanitation Standards Committee revised its sanitation standards. That revision served as the basis for the 2003 standard. This 2008 standard was developed under the committee procedures of the American National Standards Institute (ANSI) to address the sanitation issues of machine design and operation. Current safety requirements published by the (ANSI/Z50.1-2006) are independently from this standard and nothing in this standard is designed to supersede safety requirements.

ANSI/ASB/Z50.2-2013 Standard for Bakery Equipment –

Sanitation Requirements This 2013 revision, sponsored by the American Society of Baking, brings

the standard up to date with the latest development in the baking industry.

All new installations of bakery machinery and equipment, individual items of new equipment, and new design, are to conform to the requirements of this standard

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ANSI/ASB/Z50.2-2013 started in 2011Equipment Producers: 15Equipment Users 15General Interest 15

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Risks to Food Safety in Baked goods is:

Being free of pathogens and:Free from unlabeled allergensPossible Gluten freeFree from foreign materialCompliance with regulatory & GMPsCompliance with your own policyHaving a cleanable facility and

equipmentA sanitary environmentA pest Free environment

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Concentrate on the equipment

New EquipmentLegacy Equipment

◦ANSI Z50.2 standard is not intended to be retroactive in its application to existing installations, but when modifying existing equipment, the modification shall conform to the standard covering this equipment.

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What type of Equipment?Bakery Industry has it’s buzz

words,,, FMSA says anything used to process food.

ANSI Z50.2 says in 30 pages, 39 Items: Proofer, Mixer, Icing Machines, Fillers, depositers, Divider, Rounder, Depanner, Delidder, Troughs, ….Ovens (6 different types)

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Sanitary Equipment Design is (or can be): SubjectiveHard WorkTrial and ErrorSimple - if done correctlyA CompromiseExpensive for Serial #1Less Expensive to operate and

clean and maintain - TCO Provide an advantage to the owner

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Simple and Sanitary

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Some Sanitary Tricks (KISS)

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What not to do

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More Good Ideas

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Good Equipment Design - Done? Not YetNeed a team of:

Chemical SupplierSanitation teamQuality inspectors (Swab) Validated cleaning Safety Team and Safety Standards OperatorsContinuous Improvement (CI) Team Welders / FittersEngineersManagementThe Equipment Supplier – to provide CI updates

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CertificationAmerican Society of Baking (ASB) owns the

ANSI Z50.2 STD. Baking Industry Sanitation Standards Committee (BISSC) owns the certification process.◦ 2 Options , Self Certification or 3rd Party

Verification AMI/GMA – Uses a checklist, can be arbitrary 3A – More detailed/costly than ANSI, also Self

Certification or 3rd Party Verification NSF/UL – Equipment and facility on a RFQ

basisEuropean Hygienic Engineering & Design Group

(EHEDG) works with 3A

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More FSMA to come