Skip to Content
Exit

Category Archive: Food Processing

Tag Archive: Food Processing

  1. Battling Listeria Monocytogenes Bacteria in Food Processing Facilities

    Leave a Comment

    Editor’s Note: This content was last updated 3/13/24.

    Food processing facilities must maintain rigorous control over bacterial contamination within their premises. According to the U.S. Department of Agriculture’s (USDA) Food Safety and Inspection Service (FSIS), facilities handling ready-to-eat meat and poultry products face a significant risk of Listeria monocytogenes (Lm) contamination. This bacterium commonly infiltrates meat products and thrives in moist environments, as noted by Science Daily.

    Annually, Lm infections result in over 1,600 illnesses, 1,500 hospitalizations, and 260 fatalities. While Listeriosis is less common than E. coli and Salmonella infections, it still poses a threat to consumers.

    Using efficient equipment to control Listeria

    Efficient equipment is crucial for controlling Listeria growth. Lm can proliferate at temperatures as low as 31.3°F and exhibits characteristics conducive to high-volume growth, according to the USDA. Given the low threshold for contamination, food processing facilities must ensure their heat exchangers maintain precise temperature control to prevent Lm growth.

    While food processing plants typically maintain efficient microbiological control, equipment can inadvertently harbor moisture and transmit Lm. Kornacki Microbiology Solutions, Inc. explains that areas with trapped residues near the product stream pose a risk. These areas could include poorly sealed positive displacement pumps or inadequately designed valves, both of which may lead to Lm transmission.

    Temperature can make all the difference

    Temperature regulation is paramount in preventing Listeria contamination. Kornacki outlines various risk levels associated with Listeria contamination in food products. For instance, a cooling site exposed to a molten cheese product at 135°F could become contaminated by wet areas in the facility, such as floors or ceiling watermarks. Adjusting heating temperatures is crucial, as different Lm strains require varying heat levels for eradication. Utilizing sanitary stainless steel heat exchangers allows facilities to accommodate different temperature ranges, thereby enhancing product safety.

    For decades, Enerquip has been at the forefront of designing and fabricating shell and tube heat exchangers tailored to the stringent demands of the sanitary market. Our exchangers play a vital role in various applications, including cheese and milk pasteurization, beer cooling and wort heating, beverage pasteurization, ultra-high temperature sterilization, bottled water treatment, liquid egg processing, and beyond.

    If you’re seeking top-quality sanitary shell and tube heat exchangers, we encourage you to get in touch with us or request a quote today.

     

    From the Enerquip Blog

  2. Why floor space is vital for food processing facilities

    Leave a Comment

    Food processing facilities have to ensure the highest safety standards while handling food products for consumption. Bacteria can grow in damp areas or on equipment if it is not properly cleaned. While this all might sound simple and basic enough, floor space is actually very critical to a processing plant’s operations.

    Easily cleanable materials

    The U.S. Food and Drug Administration’s Guidance Regulation report for Retail Food Protection explained that surface characteristics for indoor areas have to be both smooth and cleanable. The report added that areas that are highly prone to moisture such as food preparation areas, walk-in refrigerators, bathrooms or washing areas should have nonabsorbent surfaces for easier cleaning.

    “Walls and ceilings may be constructed of a material that protects the interior from the weather and windblown dust and debris,” the FDA report stated.

    Flooring and spacing

    The factory floor material should be smooth, waterproof and hard with an anti-slip finishing preventing injuries, the Food and Beverage Reporter stated. Additionally, some processing facilities that work with meat cutting should have cutting done in separate rooms to prevent any cross contamination on the facility’s other products.

    “In open food areas in particular, a high performance and functional floor which fulfills the requirements of the HACCP International Food Standard (IFS), those for volatile organic compounds (VOCs) and also workplace safety, forms the basis for quality and high-value products in the meat industry,” said Gary Johnson, business section manager for Performance Flooring, according to the source.

    The spaces in these areas have to be open so workers are able to move around heavy machinery and other large pieces of equipment, comfortably and safely. The open spaces also allow for easier cleaning so stray food products don’t get lost or avoided during cleaning periods.

    Certain pieces of equipment can take up large amounts of space in food processing facilities. However, larger critical pieces of equipment like shell and tube heat exchangers can be customized specifically to the facility to create more floor space throughout a manufacturing facility. They can also be mounted vertically, overhead, or in a mezzanine area.

    Handling multiple cleanings

    Flooring and process equipment has to be able to withstand numerous cleanings since sanitary practices are followed each and every day, since food processing facilities are able to build up bacteria quickly.

    “Puddling of cleaning solutions, if allowed to evaporate, may lead to deposits on the surface and ‘water marks’ which can be hard to remove subsequently,” Johnson said, according to Food and Beverage Reporter. “It follows that removal of cleaning solutions and adequate rinsing is required to keep your floor looking its best. Contaminants that could quickly spoil food must be removed with suitable processes in defined cleaning cycles.”

    Proper walkways and spaces

    For food processing facilities, finished food products could be contaminated when exposed to raw products nearby. According to Food and Agriculture Organization of the United Nations, facilities have to create appropriate walkways for unpackaged food and finished products so they do not rest or move around one another.

    To create these types of spaces, customizing heat exchangers to fit appropriately in the facility could clear enough room to make necessary walkways. When it comes to food preparation, sanitation, cleaning and efficient use of floor space are all necessary.

    Editor’s note: This content was originally published in 2015 but was updated in 2024.

    More from the Enerquip Blog

  3. Massachusetts seafood processing facility warned by FDA about temperature control

    Leave a Comment

    Food processing plants rely heavily on precise temperature control to maintain the shape, flavor, and safety of their products. This is crucial not only for preserving quality but also for ensuring the well-being of both workers and consumers. Raw materials like eggs, milk, cheese, and meat require meticulous handling within these facilities, as emphasized in the book Postharvest Handling and Preparation of Foods for Processing.

    In recent years, a seafood-processing plant based in Massachusetts came under scrutiny from the U.S. Food and Drug Administration (FDA) due to multiple violations of seafood Hazard Analysis and Critical Control Point (HACCP) guidelines. Specifically, the company’s pasteurized canned crab meat was found to be compromised, prompting regulatory intervention.

    A significant concern was the inadequate control of hazards associated with clostridium botulinum toxin formation—a bacterium notorious for its potentially fatal consequences. Despite advancements in food safety, such violations continue to challenge the integrity of food processing facilities.

    Clostridium botulinum toxin can induce severe symptoms, including vertigo, double vision, and respiratory distress, shortly after consumption. In extreme cases, paralysis and fatalities can occur. These risks persist due to lapses in storage, distribution, and processing practices.

    What causes clostridium botulinum toxin formation?

    The formation of clostridium botulinum toxin is primarily caused by improper storage, distribution, and processing practices by food processors, as highlighted by the FDA. To mitigate these risks, the FDA recommends various strategies, including limiting bacterial introduction post-pasteurization and ensuring proper temperature control during processing.

    To achieve optimal temperature control, manufacturers must invest in high-quality sanitary shell and tube heat exchangers. This equipment ensures food is heated and controlled at the correct temperature, thereby minimizing the risk of bacterial contamination.

    Seafood plant ordered to monitor temperatures

    As for the Massachusetts seafood facility, the FDA said it must keep efficient records of continuous temperature-monitoring devices, Food and Safety News reported.

    “Specifically, your corrective action plan does not include procedures to bring affected products back under temperature control or procedures to investigate the root cause of the deviation to ensure control of the process,” the FDA warning letter stated.

    In essence, the imperative for maintaining optimal temperature control remains as pressing in 2024 as ever before. By leveraging advanced equipment such as sanitary shell and tube heat exchangers, food processors can uphold the highest standards of quality and safety, safeguarding both consumer well-being and industry reputation.

    Editor’s note: This content was originally published in 2015 but was updated in 2024.

    More from the Enerquip Blog

  4. Poultry liquid a major cause of campylobacter outbreaks in processing plants

    Leave a Comment

    One of the biggest concerns for food processing plants is battling bacteria on equipment and other surfaces. According to a recent study by the Institute of Food Research, liquids from chicken carcasses in poultry products can lead to a persistent increase in campylobacter.

    Campylobacter is a common bacteria found in raw or undercooked poultry meat or cross-contamination items, the U.S. Center for Disease Control reported. Annually, the bacterium affects more than 1.5 million people, and food processing plants work diligently to protect consumers from the illness.

    Helen Brown, lead on the IFR study, said these infectious liquids are often collected through defrosting stages for chicken carcasses. The bacteria can attach to glass, polystyrene and stainless steel to form biofilms and threaten work environments.

    “We have discovered that this increase in biofilm formation was due to chicken juice coating the surfaces we used with a protein-rich film,” said Brown, according to the report. “This film then makes it much easier for the campylobacter bacteria to attach to the surface, and it provides them with an additional rich food source.”

    Easy-to-clean equipment is essential

    Campylobacter are not necessarily long-lasting or tough bacteria, but they are often protected by a thin coating that keeps them alive. According to the IFR report, the bacteria stay alive since they are more resistant to disinfection treatments and antimicrobials.

    Food processing plants need proper equipment so bacteria can be easily killed off at the right temperature.

    Shell and tube heat exchangers provide food processing facilities with equipment that can heat products enough to eliminate the appropriate bacteria, and the stainless steel forged equipment makes the cleaning process easier.

    The ability to clean massive equipment in food processing facilities remains one of the most important ways to eliminate cases of campylobacter.

    “This study highlights the importance of thorough cleaning of food preparation surfaces to limit the potential of bacteria to form biofilms,” Brown said in the IFR report.

    With more attention on preventing food-based bacterium outbreaks in processing facilities, the IFR hopes the additional insight will prevent more cases since many locations are prone to these illnesses. Supermarket shelves, deli or meat areas, food processing facilities, and poultry delivery areas can spread the bacteria or cross-contaminate other products if the meat is not handled correctly.

    Want to talk through your thermal processing needs? Meet Enerquip’s Sales Engineers.

    More from the Enerquip Blog

    This post was last updated 1/22/24.