5 Questions with Lauren Devlin

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QA Specialist, Nestlé Quality Assurance Center

April 8, 2021

One of the biggest threats a food company can face is a food safety incident leading to a product recall with potential harm of consumers. A proactive approach to mitigate risk is an Environmental Monitoring (EM) Program as a part of pathogen monitoring programs. Lauren Devlin, a QA Specialist from Nestlé Quality Assurance Center discusses key considerations for an effective EM program.

1 What are pathogen monitoring programs?

Pathogen monitoring programs are used to verify hygienic controls and elements of a Food Safety Management System, including monitoring of raw materials, process environment, and line health. An EM program is a way of verifying that food safety systems related to line health and process environment are working as intended.

2 Why is an EM program important in the overall pathogen monitoring program?

EM aims at early detection of pathogens and out of specification hygiene indicators to allow for action to be taken, prior to product being impacted. EM data can be used to provide insight into the microbial population of a facility and identify improvement opportunities for pre-requisite programs. While EM does not prevent pathogens from entering a facility, it does mitigate risk of product contamination.

3 What are components of a robust EM program?

They are site selection and testing plan (type/frequency of testing). These components are determined by performing a risk assessment to assign the sampling zone of each site (see question 4). A robust EM program will also include an evaluation of sampling technique, tools, analytical methods, data management/interpretation, and corrective action procedures. It is recommended to re-evaluate your program annually concomitantly with your HACCP plan and ideally with a food safety expert outside your plan to enhance the effectiveness.

4 How are sample zones determined for my program sites?

Sampling zones are determined by risk to product contamination. Zone classification will help determine the type/frequency of testing for a site. Zone 1 is direct product contact surfaces (indicators). Zone 2 is non-product contact, but near product (indicators and pathogens). Zone 3 is non-product contact and not adjacent to product (indicators and pathogens). Zone 4 is Remote areas (pathogens).

5 How much should I invest in my EM?

A tricky, but important, question. The cost is based on a microbiology food safety risk assessment and financial risk analysis. Always keep in mind, the EM cost is insignificant compared to the immediate and long-term cost of a finished product contamination.

5 Questions with Paul Gaertner

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President, Detectapro Products, LLC.

April 8, 2021

Object detection is at the heart of all QA efforts in any food processing facility. Detectapro’s metal and X-ray detectable products are a critical tool in helping achieve success. Paul Gaertner, President of Detectapro Products, LLC., has been helping food processors work towards 0% foreign object contamination for more than 18 years.

1 What is object detection all about?

Object detection is the ability of the object being used, a pen for example, to be detected in the food processing environment. Object detection, or in our case, metal/X-ray detectable products, work in conjunction with detection devices used on the processing line. If an object falls into the food being processed, detection units placed above the line detect the foreign object and reject it, keeping the final product contaminant free.

2 How does object detection work with BRC 8?

BRC 8, section 4.9.6.2 is the requirement regarding small parts, stating: “Pens used in open product areas shall be controlled to minimize risk of physical contamination (e.g., designed without small parts and detectable by foreign body detection equipment).” Our pens are 100% detectable and abide to the language in the BRC 8 section 4.9.6.2. Unlike our competitors, all our products are molded without metal springs or other small parts. Other items such as cable ties, markers, scrapers, knives and key hole tags comply to section BRC8 and have no small parts.

3 Can Detectapro create new products that are metal detectable?

Detectapro offers a wide range of in-stock metal detectable products. However, when custom applications are needed, we rise to the challenge. A great example is our custom-imprinted Key Hole Tags. Originally available in one size, we worked with the distributor and the end user to create various sizes (up to 3-by-12 inches) with custom four-color printing on both sides.

4 How detectable are your products?

All of our products are 100% detectable when using metal and X-ray detection systems. The key in detecting our metal-detectable products lies with the ratio of the aperture to the size of the product. Every product is different, and every detectable fragment size need is different. A good starting point is a 3mm fragment. However, you have to consider what the product is and take into account the different environmental variables. Ice cream, for example, may change its density and moisture levels throughout the processing and packaging cycle. This creates a need for the sensitivity being measured at the geometric center of the machine’s aperture to change from one machine on the line to the next.

5 Where are your products produced?

All of our products are produced in the U.S. and the U.K. Because of this practice, our products also carry liability insurance. (Products produced in China, Eastern Europe and India do not carry liability insurance.) Many of our products are created through injection molding. By molding our products in the U.S. and the U.K., we are able to oversee the process. We never mold using a compromised mold allowing us to deliver the highest quality product to you, every time. This process helps you as you work toward achieving zero percent foreign object contamination.

5 Questions with Emily Kaufman

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President, Emport, LLC

April 8, 2021

Allergen management is a constantly evolving field. New regulations and new technologies continue to make food safer for the food-allergic consumer — but it can all be quite confusing! Since introducing the GlutenTox Pro kit to North America in 2011, Emport LLC has helped guide countless gluten-free and allergen-free manufacturers in the quest for safe food. To celebrate their ten-year anniversary, Emport LLC’s Emily Kaufman explains some need-to-know concepts for allergen safety.

1 Do I need to treat gluten and allergens differently?

In the U.S., gluten labeling is voluntary. By choosing to label products as gluten-free, you’re held to a strict limit of unavoidable cross-contact from wheat, rye, and barley. Allergen labeling — including wheat, but not barley or rye — is mandatory. Thanks to FALCPA and FSMA, facilities must carefully manage all risk from major allergens. Luckily, there’s considerable overlap in best practices for allergens and gluten.

2 I keep hearing about validation and verification. Are they not the same?

They are not. You validate a program or a product to prove it works. You verify an action to prove it happened. For example, validating your allergen cleaning protocol ensures its effectiveness. Verification ensures that your team correctly ran the protocol today.

3 What can a third-party lab do that my team can’t?

Especially for challenging matrices, a lab can help validate your test kits and/or cleaning program. They can also help investigate any positive on-site results. Generally, labs analyze allergens via ELISA, antibody-based tests that look for protein and provide quantitative results. Sometimes a lab will do PCR testing instead, to look for an allergen by looking for DNA.

4 What types of on-site allergen test kits are there?

For facilities with limited time, equipment, or technical staff, lateral flow devices (LFDs) are a good choice. They help determine the presence or absence of a specific allergen and require little-to-no equipment. Plus, LFDs are relatively quick and can often be used for both products and surfaces. Some facilities supplement with general protein swabs, which are neither as sensitive nor as specific as LFDs.

5 How do I figure out which test kits are right for my facility?

If your team can’t use a particular kit correctly, or the kit can’t detect the allergen correctly, then you’re wasting time and money. A reputable vendor should be happy to talk through your unique needs; at Emport, we’ve always been eager to learn about our customers’ challenges. That includes thinking about matrix validation, pointing out any limitations or modifications to be mindful of, and supporting staff training.

5 Questions with Jerry Heath, BCE

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Senior Technical Specialist, IFC

April 8, 2021

Have you ever wondered why or when fumigation could support your operations? While fumigation has been seen as a last resort, it shouldn’t be, considering fumigation quickly eliminates pests for a clean start. Join IFC’s Senior Technical Specialist, Jerry Heath, BCE, as we explore how fumigation can be a cost-effective tool in modern pest management programs, especially in critical situations.

1 What type of pest situations can a fumigation help resolve?

Quick and versatile, fumigation is a pest elimination tool for emergency situations, pre-shipment, quarantine requirements, and in comprehensive pest management programs. From whole facilities to bins or trailers, fumigants penetrate deep into materials, equipment, and harborages where all pest life stages may be present. Fumigation is the tool to reset pest populations and create an environment suitable for pest prevention through sustainable Integrated Pest Management (IPM) strategies going forward.

2 How does a fumigation work?

Fumigation targets pests with an effective fumigant gas to reset pest populations to zero and to jump-start your pest management program. Planning with a professional pest management provider is critical for regulatory compliance, safety, and the right products and supplies. Fumigant gas diffuses throughout the space to penetrate contents based on target pests, temperature, and space volume, with gas concentration readings taken over time to assure performance criteria have been met. The fumigated space and materials are ventilated following strict procedures so that the gas is quickly aerated to safe ambient conditions.

3 What is the overall benefit to a fumigation?

No other kind of pest management treatment can provide such broad-spectrum effectiveness approaching 100% efficacy so quickly. Fumigation resets the pest populations to zero, assuring that product and shipments will be free of infestation. Fumigation also allows for a reset in certain challenging situations, providing time for correcting conducive conditions, implementation of enhanced sanitation approaches, and IPM program elements. Fumigation helps maintain product quality, ultimately protecting brand reputations.

4 What are some of the common fumigation concerns IFC has heard?

Safety, cost, and downtime for a fumigation treatment are all concerns that we share with our clients. Regulatory compliance, technical support, and extensive fumigation experience are three areas where IFC excels. We work closely with our clients to ensure employees and products are protected. Getting your facility back up and running in a pest-free, safe environment is our top priority.

5 How can a fumigation support a facility long term?

Pest pressure can be inevitable due to surroundings, ingredients, processes and potentially facility structural conditions. Fumigation provides fast remediation by bringing pests’ populations to zero, and it is a proven pest management program solution. With the initial resolution, an IPM Plan should be incorporated into the ongoing sanitation program of the facility, supporting future audits and overall maintenance.

5 Questions with Amit M. Kheradia

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Technical Support Manager, Remco

April 8, 2021

Besides lowering product quality, the presence of foreign material, like glass, plastic, metal, or wood in food can act as physical hazards that may harm consumers. Remco’s Technical Support Manager Amit M. Kheradia emphasizes that implementing proper tool programs for selection, use, cleaning, storage, care and replacement can reduce foreign material contamination in food facilities.

1 Why is foreign material contamination control a critical regulatory and global standards requirement?

Recently, millions of dollars worth of food products have been recalled due to foreign matter contamination, according to the FDA and FSIS. Historically, these recalls have ranged from between 9.9-37.9% of all food recalls. The most commonly implicated products are meat and poultry, snack, bakery, and prepared foods, and therefore, regulations and standards work towards contamination control, which minimizes adverse impact to public health and also improves product quality.

2 When does a foreign material become a significant food safety hazard?

FDA classifies a physical hazard as any sharp, hard, or sizable foreign object (7-25 mm in length) capable of causing choking, injury, or trauma to a consumer. Moreover, any deleterious foreign matter presence, e.g., dirt, insect parts, feces, or toxic substances, can also lead to a Class I or Class II product recall.

3 How can color-coded tools help to minimize oreign material contamination events?

Color-coding can make it easier to identify tools and possible contaminants. For instance, in a dairy plant, avoid using white or yellow tools since any chipped or dropped material may get masked by the food. Instead, use a contrasting color for easy identification.

4 What difference can metal-detectable tools make in controlling foreign material contaminants?

This depends on risk. For example, using a metal detectable scoop on a conveyor that transfers food products into a grinder may be a good choice. In this example, a well-positioned and calibrated metal detector can salvage a dropped tool before it ends up in the grind. However, using metal detectable brush bristles has been proven by Vikan Company study to cause more harm than good. These bristles tend to be more brittle and are difficult to detect due to their size.

5 In what other ways can Remco assist facilities in their foreign material contamination control programs?

As a part of Vikan, Remco has a wealth of experienced staff members, a robust knowledge center, and a solid customer support system. We can help you find the right tools for the job that are well suited for your operating conditions and hygienically designed. We also offer training and support on contamination control.

5 Questions with Lauren Devlin

Sponsored Content - Ask the Experts

1 What are pathogen monitoring programs?

2 Why is an EM program important in the overall pathogen monitoring program?

3 What are components of a robust EM program?

4 How are sample zones determined for my program sites?

5 How much should I invest in my EM?

5 Questions with Paul Gaertner

Sponsored Content - Ask the Experts

1 What is object detection all about?

2 How does object detection work with BRC 8?

3 Can Detectapro create new products that are metal detectable?

4 How detectable are your products?

5 Where are your products produced?

5 Questions with Emily Kaufman

Sponsored Content - Ask the Experts

1 Do I need to treat gluten and allergens differently?

2 I keep hearing about validation and verification. Are they not the same?

3 What can a third-party lab do that my team can’t?

4 What types of on-site allergen test kits are there?

5 How do I figure out which test kits are right for my facility?

5 Questions with Jerry Heath, BCE

Sponsored Content - Ask the Experts

1 What type of pest situations can a fumigation help resolve?

2 How does a fumigation work?

3 What is the overall benefit to a fumigation?

4 What are some of the common fumigation concerns IFC has heard?

5 How can a fumigation support a facility long term?

5 Questions with Amit M. Kheradia

Sponsored Content - Ask the Experts

1 Why is foreign material contamination control a critical regulatory and global standards requirement?

2 When does a foreign material become a significant food safety hazard?

3 How can color-coded tools help to minimize oreign material contamination events?

4 What difference can metal-detectable tools make in controlling foreign material contaminants?

5 In what other ways can Remco assist facilities in their foreign material contamination control programs?

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