Hygienic and Safe Food Processing Workshop

1

• Hygienic and Safe Food Processing Workshop
• CTC Center Lundazi
• May 2007
• Carmen I. Moraru and Catalin Moraru

2

• Part I
• Basic Food Hygiene Workshop
• Carmen I. Moraru

3
Basic personal hygiene practices during food
processing

• Trainees at the Lundazi COMACO Processing Center

4
Practicing proper hand washing

• Demonstration of proper hand washing procedure
  using the Germ Glo kit

5
Surface cleaning
Station 1
Station 2
Station 4
Station 3
6
Checking the efficiency of surface cleaning
7
How did we do?
Some did well the first time
some are not there yet!

• High
• Low

8
To complete the picture dressed for success and
food safety!
Respirator and hard hat for personal protection
necessary when working in the grain handling
facility

• Proper attire for working in a food processing
  facility

9

• Part II
• Food Processing and Food Product Development
• Carmen Moraru and Catalin Moraru

10
The peanut butter process

• Identified issues
• Hygiene standards have improved considerably
  since last visit, but still need improvement
• Quality problems with the peanut butter
• Phase separation
• Oil leakages

11
The peanut butter process in 2005
Roasting
Location dust in the yard
Peanut butter processing
Peanut grading
12
The peanut butter process

• Sharing of the processing space with the oil
  extraction was a serious contamination source for
  the peanut butter

13
The peanut butter process - 2007

• Peanut cleaning

Peanut processing
14
The peanut butter process - Solutions offered -

• Further improvement of hygiene and safety
  standards
• The workshop offered information and guidance for
  improving personal hygiene and safe processing
  practices. Key
• Proper hand washing
• Proper personnel attire
• Proper cleaning of equipment and
  utensils
• Pest control
• Some relatively easy to make space design changes
  suggested details included in the report

15
After training everyone is wearing proper
clothing

• From workers

To the plant manager
16
Preventative safety checks- Pathogen testing of
the peanut butter -

• Qualitative fast tests performed for Salmonella
  and E. coli
• Negative results for tests performed on May 25,
  2007

No color change of the test strips
17
Experimental runs for quality improvement of
peanut butter

• Degree of peanut crushing diminished ? coarser
  peanut butter expected to minimize oil separation
• Suggestions for the emulsification process made
  (i.e. use lower temperatures)

• Shelf life study under way to evaluate the effect
  of the modified process

18
Oil leakage problems

• Phase separation is the main cause for leakages
• Reduced phase separation will also reduce the
  leakage problems

• Additionally
• Jar closure not very tight
• Jars not tamper - proof
• Suggested solution
• Aluminum foil discs can be heat-sealed using a
  hot clothes iron on top of the jars. Simple and
  effective.
• Issue current lids will not allow any seal to be
  used, due to the ridge that protrudes into jar.
  The ridge is meant to provide a good closure, but
  not working well.

19
Rice processing

• De-hulling and polishing

Transportation
20
Manual grading
21
more grading
22
Issues in rice processing

• Large percentage of breakages as a result of
  polishing
• Economic losses
• Need for solutions for the utilization of broken
  rice, other than converting it into rice flour
  (which does not have much market potential)
• Presence of husks in the finished rice
• Significant manual grading required
• Time consuming and costly

23
Evaluation of rice processing operations

• The milling process was evaluated, both
  qualitatively and quantitatively
• Issues
• Large amounts of broken rice
• Whole kernels found in the broken rice
• Quantitative data included in the report
• Identified cause design flaws of the de-hulling
  and polishing equipment

24
Solutions offered1. Improvement of rice milling
operations

• Reduction of breakages can be achieved by
• Increasing the gap between the metal rotor and
  the metal ridge that caused kernel shearing
• Hypothesis tested and validated less breakages
  obtained after increasing the gap by 0.5 mm
• Further optimization required

• Cleaner rice could be obtained after a low-cost
  re-design of the ventilation system of the rice
  mill
• Equipment design changes suggested
• A drawing of the suggested change was
  incorporated in the report

25
Solutions offered1. Improvement of rice milling
operations contd.

• More drastic results could be obtained by
  reversing the utilization of the two stages of
  the rice mills
• Use the current polishing stage (lower stage) for
  de-hulling. The lower stage abrasive drum will
  lead to better de-hulling than the upper rubber
  rollers
• Use the current de-hulling stage (upper stage)
  for polishing. The rubber rollers will not break
  the rice and will allow for proper kernel-to
  kernel friction required in polishing

Upper stage
Lower stage

• This, combined with the improved ventilation,
  could reduce drastically the percentage of broken
  rice and will also lead to much cleaner rice
• Preliminary testing gave very promising results.
  Quantitative data was included in the report.

26
Solutions offered2. Processing of value added
products

• Obtaining puffed rice products by extrusion could
  be a solution
• Challenge current configuration of the extruder
  does not allow high temperature high shear
  extrusion for puffing applications
• Issues to be addressed in the future
• Retrofit the extruder with proper barrel heating
  and proper dies, as well as temperature
  monitoring capabilities
• Technical issues related to adding a new product
  line
• Define and formulate exactly the product/products
  that will be manufactured (product development)
• Packaging, storage, and distribution solutions
  identified before production starts
• Significant extruder cleaning required between
  products if multiple products will be
  manufactured with the same extruder
• Economical questions
• Is there a market for such products?
• Will such a significant undertaking pay off?

27
Solutions offered 3. Other suggestions for value
added products

• Easy to make snacks can be made with limited
  investment
• Issue will only use up small amounts of broken
  rice
• Products developed during the workshop
  (suggestions)

Rice balls (crispy shell, soft core)
Cooked broken rice
Rice candy made out of toasted broken rice and
caramel
Crispy rice chips
28
Soy processing

• Soy milk production kicked-off during the
  workshop
• Some flavored versions developed. Some could
  be very successful
• Challenges
• Minor equipment troubles
• Water quality
• Proper packaging
• Refrigeration and distribution channels required

29
Tofu making

• Tofu made out of soy milk during workshop
• Product liked by a small panel of local people
  (CTC employees)
• Serving suggestions for incorporation
  in local diet provided

30
Soy processing by extrusion

• Another possibility
• Meat analogs (or soy bits) could be made if the
  extruder is retrofitted with either heating
  capabilities or steam injection
• Special die required as well

31
Soy processing options available with current
equipment

• Soy milk (plain or flavored) and tofu
• Byproducts okara and whey, respectively.
  Solutions for byproduct utilization required as
  well
• Prospects good