automation & food safety. host bill kinross publisher, meatingplace moderator mike fielding...
TRANSCRIPT
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AUTOMATION & FOOD SAFETY
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HOST Bill KinrossPublisher, Meatingplace
MODERATOR Mike FieldingEditor, Meatingplace
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THE ROLE IN AUTOMATION
Jonathan HolmesResearch EngineerGeorgia Tech Research Institute
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Topics
• Overview of research at the Georgia Tech Research Institute’s Food Processing Technology Division
• Challenges of working in food processing environments
• Automation in food processing• Impacts of automation on food safety
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GTRI Food Processing Technology Division Overview
Supported by the state of Georgia through the Agricultural Technology Research Program as well as some industry funding with a focus on the poultry industry with research associated with other industries such as baked goods. GTRI’s research also extends into worker safety, water quality, food safety, and sensor development.
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Automation Challenges in Food Processing
• Daily cleaning routines involve highly caustic cleaners applied at high temperature and pressure
• Food products are non-uniform and conformal making end effector design difficult
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Automation in Food Processing
• Automation is not mechanization• Automatic control involves
integration of sensors and often results in a complex system integration effort
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Automation Challenges in Food Processing• Sensor integration
challenging due to environmental constraints – especially machine vision tools
• Low profit margins require cost effective solutions
• IP69K approval not available for many electronics IP69K Test Diagram
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Selection of Drive Components and Materials
Servo Motors
Product Conveyance Pneumatic Components
Drive Components
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Automation Design for Food Processing• Several good sources of hygienic design guidelines
– American Meat Institute, European Hygienic Engineering and Design Group, and National Sanitation Foundation among others
• GTRI has performed extensive tests on automation equipment resulting in guidelines for the design of automation equipment in food processing
• “Guidelines for Designing Washdown Robots for Meat Packaging Applications” published in Trends in Food Science & Technology (Volume 21, Issue 3)– Addresses packaging considerations associated with material
selection, bearings, belts, manufacturing processes, and general design guidelines
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Design Guideline Examples
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Automation Effects on Food Safety
• Positive effects are clear– Removing the worker can reduce the level of pathogens– Possibility to introduce automated cleaning solutions
• Research in this area will continue to bring new and viable solutions to the market
IMPLEMENT AUTOMATION PROPERLY AND WITH CAUTION:When improperly implemented, automation of processes can
cause a number of problems ranging from significant down time in operation to actually increasing the existence of pathogens
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EQUIPMENT SPECIFICATIONS
Fred HayesDirector of Technical Services - Packaging Machinery Manufacturers Institute
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Food Safety Machinery Issues
What is at stake
Problem areas
Standards and Guidance Docs
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Risks• Foodborne Illness– E. Coli– Listeria– Salmonella
• Allergens• Cross contamination
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Foodborne Illnesses
• Outbreaks– <5% of the total illness– Get all the media attention– Source of the attribution data
• Sporadic Illness– >95% of illness– Virtually no attribution data– No media coverage
• Are things getting worse?
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Outbreaks 1998 - 2007
(CSPI Outbreak Alert – 2009)
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PCA salmonella
contaminationRecall of 1800 products impacting 250 BRANDS
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Number of Bacteria
Time1
2
48
51264
4,05632,768
262,144
12:0012:00
12:4012:20
2:001:00
4:003:00
5:00 6:00
7:00
MICROBES DIVIDE & MULTIPLY RAPIDLY
2,097,152
Time
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FLOW & LINKAGES
EN ISO 14159-1-2008
Guiding Standard
AMI 10 Principles
Communication / training tool
Equipment Manufacturers
Processors
AMI 10 Principle Check List - A Tool to Promote & share common expectations
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1 - Clean to a Microbiological level~ 47 uinch
A scratch on a piece of stainless steel acts a harborage point for Listeria.
Courtesy Univ. Wisconsin, Madison
2 - Made of Compatible Materials
6061 Aluminum
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3 - Accessible for Inspection, Maintenance, Cleaning & Sanitation
4 - No Product or Liquid Collection
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5 - Hollow Areas are Hermetically Sealed
Hardware improperly mounted to frame by bolting through tubing.
6 - No Niches
Multiple Pulleys that are not easily removable for cleaning
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7 - Sanitary Operational Performance
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8. Hygienic Design of Maintenance Enclosures
View from back side
Fully Enclosed Supply line
From This To This
Previous Design Sanitary Redesign
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9 - Hygienic Compatibility with Other Plant SystemsDesign of equipment must ensure hygienic compatibility with other equipment and systems, e.g., electrical, hydraulics, steam, air, water.
10 - Validate Cleaning & Sanitizing ProtocolsThe procedures prescribed for cleaning and sanitation must be clearly written, designed and proven to be effective and efficient. Chemicals recommended for cleaning & sanitation must be compatible with the equipment, as well as compatible with the manufacturing environment.
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Standards and Guidance
EN ISO 14159-1 2008 Safety of machinery
Hygiene requirements for the design of machinery
AMI 10 principles of sanitary design
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SPONSOR SLIDE #2
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RAPID MICROBIOLOGICAL TESTING
Jim DicksonProfessor, Dept. of Animal Science - Iowa State University
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Outline
• Sampling• Methods of detection• What do we mean by rapid?• Results• Automation
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Sampling
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Robust Sampling
• “Given its shortcomings and the presumed low occurrence of this pathogen, the N-60 sample size and design may not be adequate for detecting E. coli O157:H7 in beef trim.”
• UNITED STATES DEPARTMENT OF AGRICULTURE OFFICE OF INSPECTOR GENERAL (24 Feb 2011)
Iowa State University
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Methods to Detect Microorganisms in Foods
• Quantitativesome regulatory standards are based on quantitative measures (e.g. population of bacteria allowed in raw milk; E. coli Biotype I on carcasses)
• Qualitative some regulatory standards are based on qualitative measures (e.g. presence/absence of E. coli allowed in pasteurized milk)
Iowa State University
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Quantitative Sample Analysis Flow Diagram
Collect SampleTransport to Laboratory
Analyze Sample(incubate)
Prepare Sample
Results
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Qualitative Sample Analysis Flow Diagram
Collect SampleTransport to Laboratory
Pre-Enrich Sample
Prepare Sample
Select Enrich Sample
Analyze Sample
Presumptive Result
Confirmed Result
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What do we mean by “rapid”?
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Sample Collection
Collect SampleTransport to Laboratory
Pre-Enrich Sample
Prepare Sample
Select Enrich Sample
Analyze Sample
Presumptive Result
Confirmed Result
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Sample Handling• Collection• Transport• Chain of Custody• Sample preparation
Iowa State University
IN OUT
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Sample Enrichment
Collect SampleTransport to Laboratory
Pre-Enrich Sample
Prepare Sample
Select Enrich Sample
Analyze Sample
Presumptive Result
Confirmed Result
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Sample Enrichment
• Pre- and Selective enrichment steps often combined
• Typically 8 to 24 hours
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Analyze Sample
Collect SampleTransport to Laboratory
Pre-Enrich Sample
Prepare Sample
Select Enrich Sample
Analyze Sample
Presumptive Result
Confirmed Result
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Analyze Sample
• The “rapid” in rapid methods
• ELISA – “dipstick” test – 10 min
• PCR – “molecular” test – 3 1/2 – 5 hours
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Analyze Sample
• Factors to consider - technical– Sensitivity and Specificity
• Factors to consider - pragmatic– Number of samples per day or week– Training of personnel– Cost (equipment, supplies, etc)
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Results
• Presumptive vs. Confirmed– a positive result usually requires confirmation
• What is confirmation?– Traditional bacteriology – isolate and identify a
culture
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Isolation and Identification
• Conventional Bacteriology– Selective media– Biochemical reactions
Iowa State University 2009
www.mc.maricopa.edu/~johnson/labtools/Dbiochem/3mac.jpg
www.bacto.com.au/images/crystal_c.jpg
www.rapidmicrobiology.com/news/1054h29p.JPG
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Automation
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Automation• What can be automated?– Sample analysis– Culture identification
• Why?– Labor costs– Consistency– Throughput
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Conclusions
• “Rapid” is– Collect and Transport to lab – 30 min to 24-28h– Sample preparation and enrichment – 10 -26 h– Sample analysis – 3 ½ - 5 h
• Total – 14 hours to 2 ½ days• Confirm Result- 1 ½ - 2 days
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QUESTIONS & ANSWERS
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FOR MORE INFORMATIONJonathan Holmes: [email protected]
Fred Hayes: [email protected] Dickson: [email protected]
Lisa Keefe: [email protected] McDowell: [email protected]
Weber: [email protected]: [email protected]
Webinar recording and PowerPoint presentation will be emailed to you within 48 hours. For more information:
www.meatingplace.com/webinars