Pasteurizer Operator
Certification Training
2015
Presented by:
WDATCP - Division of Food Safety
In Partnership with:
Wisconsin Association for Food Protection
Welcome & Introduction
Steve Stoner
Wisconsin Department of Agriculture,
Trade & Consumer Protection
Logistics
Introduction
• ATCP 80 Administrative Code
Requirement
• Provide an Overview of Pasteurization
Systems
• Review Basic Pasteurization System
Components and Parameters.
Overview
• This is a refresher course for experienced
operators, designed as an overview of the
basic science, design and the operation of
milk pasteurization systems.
• Successful completion of the exam, given at
the end of the days course, is required to meet
the intent of ATCP 80.40(3)(b), Wisconsin
Administrative Code
– A score of 80% or higher.
Agenda
• Welcome & Introduction• Microbiology of Raw Milk• Video• Vat Pasteurization Components• HTST Pasteurization• Records• Testing & Sealing• CIP• Summary & Questions• Exam
Definitions
• Milk
• Pasteurization
• Product Contact Surface
• Non-Product Contact Surface
• Flow Promoting Device
Milk Microbiology
S.A. RankinUW-Madison
F.X. MilaniJeneil Biotech
There are a few Critical Control Points in a dairy –pasteurization is one – why?
Pasteurization
• The process of heating every particle of milk product to
legal pasteurization temperature and holding it
continuously at or above that temperature for at least the
specified legal holding time in equipment that is properly
designed and properly operated.
Types of Microorganisms• Bacteria
• Rickettsiae
• Molds
• Yeasts
• Viruses
• Cocci (round) • Bacilli (Rod)
What bacteria look like
D. McMahon, Utah State University
Good to know names
• Thermophiles 122-140°F
• Mesophiles 86-98°F
• Psychrotrophs 50-86°F
• Thermoduric - survive or endure pasteurization
• SPC – Standard Plate Count (all aerobic bacteria)
• Coliform – indicators of sanitation (virtually eliminated in
pasteurization, so if you find in finished product…what happened?)
• Pathogens – cause illness (virtually eliminated in pasteurization, so
if you find in finished product…what happened?)
Pathogens – Cause Disease
• Salmonella
• Escherichia coli O157:H7
• Listeria monocytogenes
• Campylobacter jejuni
• Etc.
Pathogens in Raw Milk (VT)
Pathogen % of samples (+)
Listeria 6.0
E. coli 0157:H7 4.6
Yersinia 0
Salmonella 2.0
Pathogens in Raw Milk (MN/SD)
Pathogen % of samples (+)
Salmonella 6.1
E. coli 3.8
L. monocytogenes 4.6
Campylobacter 9.2
Yersinia 6.1
S. aureus 8.4
Raw Milk at the Farm (MN/SD)
• 32% of samples were + for 1 or more pathogens
• 60% of producers drink raw milk
• 34% of producers had pathogens present in milk they drank
Pathogens in Dairy Plant Areas
Area Listeria (+) Yersinia (+)
Process floors 17.0 12.0
Cooler floors 27.0 20.9
Entry floors 17.2 27.7
Footbaths 12.0 4.0
Other floors 26.3 15.8
Non-contact 8.1 5.4
Where do microbes come from?
Soil
Pests
Ingredients
Food contact surfaces
Water
Air
Personnel (you!)
Packaging
Farm/Animal
Many bacteria thrive in milk – raw or pasteurized
Micro Tests for Raw Milk
• Standard Plate Count (SPC)– measure of total aerobic bacteria
• Coliforms– cleanliness of cows
• Lab Pasteurized Count (LPC)– measure of thermoduric bacteria
• Preliminary Incubation Count (PIC)– poor sanitation or refrigeration
• Rapid Psychrotrophic Count (RPC)– index of cleaning & sanitation
• Heat Resistant Sporeforming Psychrotroph (HRSP)– E.g. Bacillus spores
• Etc
Grade A Raw Milk Standards
• SPC not exceeding 100,000/ml
• SPC <300,000/ml prior to pasteurization
Grade B Raw Milk Standards
• SPC not exceeding 300,000/ml
• SPC <750,000/ml prior to pasteurization
How bacteria grow
• Reproduce via binary fission (2n)
(n = #generations)
generation time
Plotting microbial growth (2n)
0
10000
20000
30000
40000
50000
60000
20
min
40
min
60
min
80
min
100
min
120
min
140
min
160
min
180
min
200
min
Mic
robes (
CF
U)
How bacteria die
0
1000
2000
3000
4000
5000
1 2 3 4 5 6 7 8 9 10
growth
death
Time
Popula
tion
Microbial death at >140°F
Time (min)
# S
urv
ivors
1
10
1000
100
1 2 3 4 5
Heat resistance
Temperature
Tim
eStaph toxinPsychrotroph enzymes
Why pasteurization?
• Main purpose: eliminate bacterial pathogens
• Other effects:– Reduction of spoilage microflora/some enzymes (increase
shelf life)
– Allows defined bacteria to grow, reduces competition
• Not a remedy for poor quality milk
• Some bacterial toxins are not inactivated with heat (reason for raw milk storage CCP)
40 -140 rule
Gro
wth
rate
0
40°F 140°F
-
+
DEATH!
Pasteurization…
• Virtually eliminates bacterial pathogens
• Virtually eliminates many spoilage bacterial, but not all
• Does not render milk sterile, i.e. many bacteria survive pasteurization
Milk Microbiology
S.A. RankinUW-Madison
F.X. MilaniJeneil Biotech
DVD Presentation
Vat Pasteurization
Presenter:
Bob Carrier
Food & Dairy SpecialistWisconsin Department of Agriculture, Trade and Consumer Protection
Division of Food Safety
ConsiderationsVat versus HTST
PROS CONS
Low investment Not energy efficient
Low maintenance High operator demand
Fewer moving parts Low volume production
Simple design Low automation
Can process small volumes
Time and Temperature
Relationships
Product
Vat
Time Temp
HTST
Time Temp
Milk, skim milk, or buttermilk
30 min 145°
15 sec 161°
Cream and fluid dairy products w/ > 10% milkfat
30 min 150°
15 sec 166°
Condensed dairy products & High total solids products (>18%)
30 min 150°
15 sec 166°
Time and Temperature
Relationships
Product
Vat
Time Temp
HTST
Time Temp
Cream for butter
30 min 165°
15 sec 185°
Frozen dessert mixes & Egg Nog
30 min 155°
15 sec 180° 25 sec 175°
Process Cheese*
30 sec 150°
*Typically processed in a process cheese cooker, not a conventional vat pasteurizer.
Vat Pasteurizer Components• Vat design (3-A Sanitary Standard 24-03 Non-Coil Type Batch Pasteurizers)
– Smooth ̶ Free draining
• Cover design– Overlapping ̶ Raised lip for all openings
• Leak detect valves (may not be present on smaller vats)– Close coupled (1 diameter) ̶ Leak detect grooves ̶ Stop pin– Outlet valve designed to prevent leakage to pasteurized side
• Indicating & air space thermometers (digital or mercury in glass)– Easy to read ̶ No split in column
• Recording thermometer• Air space heating (if used)
– Sanitary heated air or steam– Sloped to exclude condensate from vat
• Agitation– Continuous operation during pasteurization
Cover Design
Overlapping cover and raised lip for all openings
Leak Detect Valve CLOSE-COUPLED VALVE TO ASSURE PROPER HEATING OF
PRODUCT IN VALVE
(a less than or equal to d)
Example: If the diameter of the outlet valve is 2” then the distance from the inside wall of the vat to the valve closure must be no more than 2”.
a
d
SOLID STAINLESS STEEL VALVE TO CONDUCT HEAT
Leak Detect Valve
OPENCLOSED
REQUIRED POSITIONING PIN
SOLID STAINLESS CONSTRUCTION FOR GOOD HEAT TRANSFER
CLOSE-COUPLED TO VAT BODY WITH APPROVED PROPERLY FITTED GASKET
LEAK DETECT GROOVES MUST NOT BE BLOCKED WITH LUBRICANTSTo detect leakage past the closed valve seat. To drain out the valve cavity so all product is fully pasteurized.
45
Indicating ThermometerMercury in Glass (MIG)
or Digital (DRT)
Indicating Thermometers• Product
– Sensor adequately submerged in product to reflect accurate product temperature
– Span of not less than 25°F including pasteurization temperature ±5°F
– Graduated in divisions of at least 1°F (electronic 0.1°F)• Mercury column magnified to a width of 0.0625 inch for readability
– Accurate within ±0.5°F
• Airspace– Bottom of sensor 2 to 3½ inches below underside of top
cover and at least 1 inch above product level– Span of not less than 25°F including 150°F ±5°F– Graduated in divisions of at least 2°F (electronic 0.1°F)
• Mercury column magnified to a width of 0.0625 inch for readability
– Accurate within ±1°F (electronic ±0.5°F)
48
49
Raised Opening In Tank Top
Rubber Umbrella Shield
Agitator Shaft
Air Space Thermometer
VAT PASTEURIZERMust be at least 1”
above product
OverlappingCover Design
2 to 3½” from top of vat
Vat Recording Thermometer• Sensor adequately submerged in product to reflect
accurate product temperature• Span of not less than 20°F including pasteurization
temperature ±5°F• Graduated in divisions of 1°F
– May be 2°F if used solely to process products above 160°F
• Time scale not to exceed 12 hours, in divisions of not more than 10 minutes.
• Accurate within 1°F – May be 2°F if scaled divisions are 2°F as provided above– Must not register higher than the indicating thermometer
• Electronic or spring driven– Must keep accurate time
• A method of puncturing chart paper to hold securely and prevent tampering
Vat Recording Thermometer
Install pre-printed charts at the proper timeline
Use the correct chart.
With self-printing chart recorders be sure they are set to the correct time
CHART IN 1 DEGREE F INCRUMENTS
TIME LINE GRADUATED IN 10 MINUTE INTERVALS
12-HOUR ROTATION
REQUIRED CHART INFORMATION WILL BE DISCUSSED LATER IN THIS
TRAINING SESSION
All in one Vat Electronic Controls Anderson AJ 300
• Installed according to M-b-364• Chart recorder displays & records:
o Air Space Temperatureo Product Temperature
• The air space & product probes have digital displayso Serves as indicating thermometer
Vat Recording Chart
Date
Pasteurizer identification
Product temperature
Pasteurization holding period
Filling & emptying time(if applicable)
Airspace indicator reading at start & end of holding period
Product indicator reading at start of holding period
Product name & quantity
Unusual occurrences
Dairy plant name/number
Initials of operator
Air Space Heating
• Conventional Steam Heating
– Sanitary design meeting 3A Standards
– Culinary steam meeting 3A Standards
– Approved boiler water compounds as listed in the Code of Federal Regulations
• Alternative Air Space Heating Systems
– Must be reviewed and approved prior to using. Special considerations must be made on each specific system.
– Types:
• Kettle type steam generator
• Electric element with motive air distribution system
Air Space Heating Requirements• Air space must be kept at least 5°F above the
minimum legal pasteurization temperature for the product being processed.– May be accomplished with or without the use of an air
space heater.
• 30 minute process does not start until both proper air space and product temperatures are achieved.– BOTH temperatures must be maintained for 30
consecutive minutes.– If either temperature drops below the minimum
required temperature or if the cover to the vat is opened at any time, then the 30 minute holding time must start over.
Product & Air Space Pasteurization Temperature Requirements
ProductMinimum Product
TemperatureMinimum Air Space
TemperatureMilk, skim milk, or buttermilk 145°F 150°FCream & fluid dairy products with >10% milkfat
150°F 155°F
Condensed dairy products & High total solids products (>18%)
150°F 155°F
Cream for butter 165°F 170°FFrozen dessert mixes & Egg Nog 155°F 160°F
Culinary Steam for Air Space Heating
STEAM SPREADER
PRESSURE GUAGE
PRESSURE REGULATORSANITARY PIPING
61
Operational Considerations
The 30 minute holding time can only start once:– All raw milk fill lines are disconnected.
– All product components have been added to the batch. This includes any liquid sugar and sweeteners, water, milk powders and all other dairy products, flavorings, stabilizers, cocoa products, emulsifiers, and vitamins.
– Ports, covers, and openings are closed or protected.
– Outlet valve is fully closed with the pasteurized product line already disconnected prior to filling the vat.
– Product temperature is at or above legal minimum pasteurization temperature.
– Airspace temperature is at least 5°F above legal minimum pasteurization temperature.
64
Anything wrong here?
Questions?
HTST PASTEURIZERS
Part 1
Constant Level Tank
To
Holding Tube
Presenter: Dale Osuldsen
HTST Pasteurization Components
• Constant Level Tank
• Raw Milk Regenerative Section
• Timing Pump or Timing System
– Positive Displacement
• Rotary Lobe Pump
• Homogenizer (Piston)
– Centrifugal Pump w. Metering System
• Heating Section
• Holding Tube
STLR
Safety
Temperature
Limit
Recorder
HTST Pasteurization Components
CONSTANT LEVEL TANK
Constant Level Tanks
• Purpose/Function
– Supply milk to HTST at constant pressure
– Eliminate air in the system
– Raw side of regenerator drain point
– Recirculation of sub-legal milk
– CIP supply tank
Constant Level Tanks
• Design Criteria
– Sanitary construction(stainless steel, finish, radii, overlapping covers, etc.)
– Separation of raw and pasteurized milk(proper air gap to divert, leak detect, & recirculation line)
– Overflow below the lowest level of milk
in the raw regeneration section
– Outlet line remains flooded(even when tank is empty)
Raised
Bridge
(air gap)
CONSTANT LEVEL OR BALANCE TANK
Hinged Cover
Site
Glass
Recirculation
Flow Line
Leak Detect Line Flow Divert
Line
Bottom Pitched To Drain
Flooded Outlet
Port
Product
Inlet
Maximum Fill/
Overflow Level
Constant Level Tank
HTST Pasteurization
Components
RAW
SIDE
REGENERATOR
Raw Milk Regenerator
• Purpose/Function
– Preheats raw milk by counter
current flow to hot pasteurized
milk
– Cools outgoing pasteurized milk
– Saves energy $
Raw Milk Regenerator
• Design Criteria
– Meet 3-A Standards
– At least 1psi less than
pasteurized side at all times
– Allow drainage of raw milk to
constant level tank
– Deflector plate(s) drilled to allow
drainage
REGEN
H
E
A
T
E
R
BOTTOM OF REGEN
SECTION OF PRESS
MUST BE HIGHER
THAN THE BALANCE
TANK OVERFLOWBalance Tank Booster Pump
CHANGE OF DIRECTION
BLOCKING PLATE(S)
1/16” DRAIN HOLE AT
LOWEST POINT OF
THE CHANGE OF
DIRECTION PLATE(S)
ON THE RAW SIDE
OUT
IN
HTST COMPONENT LAYOUT
No PD pump, or
fully closable valve
allowed in this line
1/16” Hole in Deflector Plate
Raw Milk Regenerative Section
REGENERATOR
SECTION
HTST Pasteurization Components
RAW
SIDE
TIMING PUMP
Timing Systems
• Purpose/Function
–Produce a constant rate of
flow through hold tube
Timing Systems
• Point to remember
–Holding time is inversely
proportional to the flow rate
• Speeding up flow/pump
shortens hold time
• Slowing down flow/pump
increases hold time
Timing Systems
• Design choices
1. Sets a maximum flow rate
determined mechanically
• PD Pumps OR
2. Senses flow & diverts FDD
if flow rate is exceeded
• Meter based
Mechanical Timing
System Types
• Positive Displacement Pumps
–Rotary (Lobe) Pumps
–Single Speed-Gear or Belt
–Variable Speed-Belt or VFD
–Piston Type
–Homogenizer
Single Speed PD Timing Pump
Variable Speed PD Pumps
Mechanical belt
adjustment levers with
sealed stop points
Variable Frequency Drive
PD Pumps
P.D.P. - Rotary Type(Positive Displacement Pump)
Positive
Pressure
Negative
Pressure
Piston Pump
INLET
OUTLET
Meter Based Timing Systems
• Flow meter senses the product
flow rate
• Flow meter sends proportional
signal to alarm & recorder
• Recorder records flow
• Flow alarm diverts FDD if flow
exceeds preset value or loss of
signal
Meter Based Timing System
Types
• Single Speed
• Variable Speed
Meter Based Timing Systems
• Single speed
– Centrifugal pump (60Hz)
– Magnetic flow meter / Transmitter
– Flow control valve• Closes on loss of power
– Transmitter
– Flow recorder / Controller w/ alarms
– Time Delay Relay
– Flow diversion device
MBTS - Single Speed Pump
NORMALLY
CLOSED FLOW
CONTROL VALVE
FLOW METER
SINGLE SPEED
CENTRIFUGAL TIMING PUMP
SFLR
Meter Based Timing Systems
• Variable speed
– Centrifugal pump
– Variable Frequency Drive
– Magnetic flow meter / Transmitter
– Sanitary check valve
– Flow recorder / controller w/ alarms
– Time Delay Relay
– Flow diversion device
MBTS - Variable Speed Pump
VARIABLE SPEED
CENTRIFUGAL TIMING PUMP
SANITARY CHECK
OR NORMALLY
CLOSED VALVE
FLOW METER
PAST
REGEN
SFLR
Centrifugal Timing Pump with Magnetic
Flow Meter
FLOW METER
Timing Pump
HTST Pasteurization Components
RAW
SIDE HEATER
Heating Section
• Purpose/Function
–Heating of milk to legal
temperature prior to hold tube
Heating Section
• Design
– Sanitary Construction
– Capable of heating product to the
minimum legal temperature or
higher, at the maximum flow rate
Plate Heat Exchanger
Heating Section
Tubular Heat Exchanger
HTST Pasteurization Components
RAW
SIDEHOLD
TUBE
Holding Tube
• Purpose/function
– Hold heated product for the
required length of time (hold time)
Holding Tube
• Design
– Sanitary design
– Permanently supported at ¼” per foot upward slope
– Non-alterable
– Begins at upward slope at salt injection port & ends at FDD
– No more than 1° F variation in temperature
Gravity pushes down on the
product causing the air to be forced
out & the tube to remain full
The Leading Edge of the Product
Falls Backwards on itself Creating
Turbulence Maintaining Good
Temperature Uniformity
Holding Tube
• Holding time
Defined as “the minimum legal length
of time product is to be held in the
hold tube at a minimum legal
temperature at a constant flow rate
to assure proper pasteurization”.
– Determined by flow rate and
length of tube
HOLDING TUBE
Salt Injection Port
HTST Pasteurizers Part 2
Indicating Thermometer
to the Vacuum Breaker
Presenter: Mike Schreiber
HTST Pasteurization Components -Continued
• Indicating Thermometer
• Safety Thermal Limit Recorder (STLR)
• Flow Diversion Device (FDD)
– Single Stem
– Dual Stem Devices
• Pasteurized Milk Regenerative Section
• Vacuum Breaker
. HTST Pasteurizer with a Positive Displacement Rotary Timing Pump
Indicating Thermometers
Types of Indicating Thermometers
• Mercury in Glass
RTD Thermometer Control Box & RTD Probe
Indicating Thermometer• Reference Thermometer
Provides a accurate reading of the temperature of product in the holding tube;
Is the “Legal” thermometer that the Operator uses to pasteurize by;
Provides means to check accuracy of recording thermometer (Beginning of production run and chart change).
Indicating Thermometer• Location - As Close As Possible to the STLR
Sensor
• Accuracy +/- .5° F
• Response time - 4 seconds or less.
• Scale .5° F Divisions
Safety Thermal Limited Recorder (STLR)
• Chart Scale – PMO Requirements– 1° Temperature Divisions
– 12 Hour Chart – 15 Minute Divisions
– Use the Correct Chart
• Time Accuracy
– Correct elapsed time
– 12 hour chart
STLR RTD
• Sensor/RTD
– Location - Within 18”, upstream of FDD
– Accuracy - Within 1° F & not higher than indicating thermometer
– Response time - 5 seconds or less.
STLR Recorder Functions
• Controls FDD Based on Temperature
• The chart is a legal document-correct time placement
• Records Temperature of Product
• Event Pen Records Position of FDD
Flow Diversion Devices
(FDD)
Purpose of FDD
• To provide an automatic fail-safe method of control to prevent sub-legal (raw) milk from entering the pasteurized side of the HTST system
Flow Diversion Devices-All• Controls Direction of Flow
– Divert or Forward Flow
• Position is Controlled by:– STLR (legal temperature)
– SFLR (legal flow in meter based systems)
• Two Valve Seats
• Visible Leak Detect System Between Valve Seats
• Failsafe– Spring to Close
– Microswitch
FDD- Failsafe Features• Spring to Close
– FDD will Divert upon loss of air pressure or electrical power
• Micro-switch will Not allow the Timing Pump to run if the valve is,
– Not Assembled Properly at sub legal temperatures
– Not Fully Diverted
Single Stem FDD
Actuator
Valve body
Divert
Inlet
Forward FlowLeak Detects
Single Stem FDD
• Two Seats and Leak Detect in One Valve
• This Type of Valve Must Be Disassembled and Manually Cleaned
Dual Stem FDD
Dual Stem FDD
• Two 3-way Valves
– Divert Valve
– Leak Detect Valve
• Sight Glass located in line to balance tank. Purpose is to be able to see FDV seat failure.
• This Type of Valve Is Designed for CIP Cleaning
Dual Stem FDD-Modes
• Product– Normal Processing Mode, valves are
controlled by STLR & SFLR
• Inspect– No Flow Through System Allowed
• CIP– If Timing Pump Runs in CIP- A Ten Minute
Delay Is Required
Reverse Acting FDD
Divert and Leak Detect Valve Lines
• Both must slope to drain
• Divert line maybe restricted
• Leak Detect line:–Free discharge, no restriction
–Line discharging to constant level tank must have visible means of leak detection
Where does the FDD get its signal from to allow Forward
Flow???Answer:
Which forward divert device
line is required to have a sight
glass?
A. Forward Divert Valve
B. Leak Detect Valve
Pasteurized Milk Regenerative Section - Function
• Hot Pasteurized Milk is cooled by Heating the Cold Incoming Milk
• One Thickness of Metal Separates Raw and Pasteurized Milk
• Pasteurized Milk must always be at a Higher Pressure than the Raw Milk
Past. PressureTransducer
PressureDifferentialSwitch
Differential Pressure Switch
Regenerator Pressures Devices
Maintaining Pressure Relationships - Design
• The overflow of Balance Tank must be lower than level of milk in Regenerator
• Raw milk must enter the bottom of the Regenerator and freely drain back to the Balance Tank
• All Raw Milk Diverter Plates must be drilled to allow downstream plates to drain
• Pasteurized Milk downstream of the Regenerator shall rise at least 12” above the highest point of Raw Milk and open to the atmosphere
Maintaining Pressure Relationships - Pumps
• The Timing Pump must be located between the outlet of Raw Regenerator and Holding Tube
• No pump, except a properly installed Booster Pump may be installed between Balance Tank and Raw Regenerator
• No Flow Promoting Device can be located between the outlet of the Pasteurized Regenerator and the Vacuum Breaker
Which one is legal to see
during operation?
A. Raw Pasteurize
30 50
A. Raw Pasteurize
31 20
Vacuum Breakers
• Atmospheric devices
• Purpose
• Placement in System
• No Positive Shut-off Valves installed prior to the VB
Vacuum BreakersPurpose
To help maintain proper pressure relationships in milk-to-milk regenerator sections or to prevent a negative pressure between the FDD and any downstream flow promoting device.
Vacuum BreakersManual Cleaned CIP Cleaned
Vents Closed
Open to
Atmosphere
OPEN
Air
Enters
Vacuum Breaker• Maintains proper Pressure Relationships
• Requires daily hand cleaning to ensure proper function
• Spring to close vacuum breakers are not allowed
Vacuum Breaker
Alpha Laval-Tri Clover CIPable
Vacuum Breaker
Air In
CIP Out
Vacuum Breaker Installation
• Installed after the Pasteurized Milk Regenerator
• Pasteurized milk shall rise to a vertical elevation of 12 inches above the highest raw milk level
Mechanically CleanableVacuum Breaker
• Installation requirements
– Installed in a vertical position
– Installed on a horizontal milk line
– Vent/CIP discharge tube open to atmosphere 12 inches above any raw milk in the system.
Vacuum Breaker12” Above highestRaw Milk in system
PasteurizedRegenerator
Pasteurizer Records
Presenter:
Michelle Steinmetz
Record Keeping
• Dairy plants must keep a record of all products
pasteurized
• Records are reviewed as a part of routine inspections and
whenever a seal is broken
• Very important to keep good records. Documentation is
proof!
Vat Recording Chart
Information
• Vat Pasteurization• Date
• Name of plant/Number 55-
• Identification of pasteurizer or location (if more
than one)
• Name and quantity of product
• Signature or initials of operator (helpful if legible)
• Record of any unusual occurrences
Vat Recording Chart Information
continued…• Continuous temperature recording (NO OVERLAPPING)
• Pasteurization holding time of each product
• Temperature reading of the airspace thermometer
• Temperature reading of the Indicating thermometer at the
start of the holding period.
Must Clearly Show Minimum 30 Minutes
Uninterrupted Process (Start 30 Min Process All Over)
Be at Minimum Legal Temperature for Product
Being Pasteurized (Example: Milk ≥145 F)
Airspace must be at least 5 F Above Min Legal
(Example: Milk Process Air Space ≥ 150 F)
30 Min. Process Time Does Not Start Until Both
Indicating & Air Space Requirements Are Met
Vat Recording Chart
Information
No More Than 10
Minute Time Line
Intervals
12 Hour
Chart
Rotation
Stop Fill
For Vat Process Temperatures of Less Than 160F
1 Degree F
Graduations
Start
Emptying
Air Space ≥ 150F
and Ind- 145F
OK to Start 30
Minute Process
Air Space ≥ 150F
OK to Stop 30
Minute Process
Example: Fluid Milk
Pasteurization =
145F/ 30 min.
HTST Recording Chart
Information
• STLR Recording Chart• Date
• Name of plant/Number 55-
• Identification of pasteurizer or location (if more than
one)
• Name and quantity of product
• Signature or initials of operator (helpful if legible)
• Record of any unusual occurrences
HTST Recording Chart
Information continued
• STLR recording chart
• A continuous record of temperature (NO
OVERLAPPING)
• Indicating thermometer temperature
• Cut-in temperature
• Cut-out temperature
• Documentation of forward flow
On Water
(H2O)
Product
Start
Water Flush
CIP
Ind. Check
Made
FDD Event Pen Trace
Temperature Pen Trace
Temperature drop triggers
Event Pen on same Timeline
MINIMUM of 4 Timelines per Hour,
15 minute increments
This Chart has 10 minute- OK
1° F Chart Increments
163F
Flow Recording Chart Information Meter based timing
• SFLR • Date
• Pasteurizer Identification
• The Type and Amount of Product Processed
• Any Unusual Occurrences
• Plant Name and Location
• A continuous record of the flow rate
• A continuous record of the flow alarm status.
(Flow Event Pen)
Example of a chart that
is printed as the
information is recorded
Honeywell Tru-Line
Recorder
Important to confirm
that date & clock time
are correct! Can be
adjusted without
breaking the
regulatory seal.
Record Keeping
• Use the Correct Chart & Pen Tips
• Recording charts cannot contain overlapping
information (Replace Prior to 12 hour Time-lapse)
• Records shall be kept for a period of
6 months or until the product is no longer in
commerce
OTHER RELATED
PASTEURIZATION RECORDS
• Phosphatase test results to support product
safety during broken seal situations.
• Recommend documentation of corrective
actions taken (repairs, replacement,
reprogramming), of any health related
controls on a pasteurization system at
anytime, but especially when a regulatory
seal has been removed.
OTHER RELATED
PASTEURIZATION RECORDS
• Recommend documentation of product
action taken (Segregation, QA Hold Order,
Recall, Disposal, (landfill, fish bait), etc.) as
a result of any loss or malfunction of any
health related pasteurization system
control.
• The better the documentation the more
effective it is in determining product safety,
both, for Industry and Regulatory.
Remember: If you didn’t document it, then it never happened.
TESTING & SEALING
-AND-
BROKEN SEALSPresenter:
Anne Frank
Food & Dairy SpecialistWisconsin Department of Agriculture,
Trade & Consumer Protection
Division of Food Safety
WHY TEST AND SEAL PASTEURIZATION
EQUIPMENT?
Testing and sealing is required by:
• FDA– Quarterly for Grade A plants
– PMO Appendix I
• USDA– 6 months
– Inspection guide item B5 (B)
• WDATCP– Quarterly for Grade A plants
– Annually for Grade B plants
– ATCP 80.52(5)
• Industry– QC, HACCP, SQF, Customer Auditors
PURPOSE OF TESTING & SEALING
• To determine if controls are operating
according to standards
• To satisfy regulatory requirements
• To help ensure safe product to the public
• To provide evidence that settings have not
been changed– (Offers only reasonable security against accidental changes)
WHAT IS TESTED?
• Thermometers & temperature monitoring
devices
• Flow diversion device (FDD)
• Regenerative heating pressure controls
• Cut-in and cut-out
• Continuous flow holding time (salt timing)
• Computerized controls
• Other required tests
– Electromagnetic interference
WHAT IS SEALED?
• Digital reference thermometer (DRT)
• Temperature recorder (STLR)
• Flow Recorder (SFLR)
• Temperature sensors– STLR RTD
– DRT RTD
• Differential pressure switch/display
• Pressure sensors– Raw pressure sensor
– Pasteurized pressure sensor
STLR=Safety Temperature Limit Recorder
SFLR=Safety Flow Limit Recorder
RTD=Resistance Temperature Detector
WHAT IS SEALED?• Timing system
– Timing pump (positive displacement pumps)
– Variable frequency drives
– Flow meters/transmitters/alarms
• Flow diversion device (FDD) timers– Inspect, CIP, valve flush, & timing pump off delay timers
• Programmable Logic Controls (PLC)– PLC & terminal strip connections
– R to I converter
– Pump control relays
• Any Other Public Health Control– Valve solenoids (if they have a manual override feature)
– Pump control variable frequency drives (VFD)
(cont.)
EXAMPLESAnderson AV9900 STLR
Seals
EXAMPLES Seal
ABB
Commander
1900
TEMPERATURE RTD
Seal
EXAMPLES
Variable speed positive displacement timing pumps
SealSpeed Control
EXAMPLES
Anderson DPC
DRT Seals
PLC
R/I
CONVERTER
PLC CONNECTION
TERMINAL STRIP
PUMP
RELAYS
SEAL TYPES USEDPlastic seal with
80 pound fishing
line or stainless
steel wire
Stainless wire with
lead seal
(DISCONTINUED, some still
present on previously
sealed components)
Pasteurizer
Test Report
Seal
locations with
seal numbers
WHERE ARE THE SEALS?
SEAL LOCATIONS 1. STLR (0298) 2. STLR RTD (0279)
3. DRT (1603) 4. DRT RTD (1692) 5. DPC (0989) 6. RAW PRESSURE SENSOR (0963) 7. PAST. PRESSURE SENSOR (0914) 8. SFLR (1234)
9. FLOW TRANSMITTER (0293) 10. PLC (1683) 11. TIMING PUMP VFD (1677)
12. BOOSTER PUMP VFD (1668) 13. 14.
15. 16. 17.
ABBREVIATIONS USED: • DRT – Digital Reference Thermometer • DPC –Differential Pressure Controller for booster pump • PLC – Programmable Logic Controller (computer) • RTD – Resistance Temperature Detector (temperature sensor) • SFLR – Safety Flow Limit Recorder (flow recorder) • STLR – Safety Thermal Limit Recorder (temperature recorder) • VFD – Variable Frequency Drive
PASTEURIZER MALFUNTION
BROKEN SEALSReport a malfunction when a pasteurizing system
malfunctions to the possible detriment of public health or
safety.
What does that mean?
• Identified issues such as:– Seals missing after maintenance or cleaning
– Cut-in or cut-out temperature below legal minimum
– Improper valve function
– Holding time below legal minimum
• Pay attention to:– Raw pressure reading below zero
– Pasteurized pressure not maintaining ≥ 1 PSI above raw pressure
when going into divert flow
– Flow alarm malfunction• Unexplained diversions from flow alarm
• Vat or tank fill times faster than usual
– Recording pen malfunction
BROKEN SEAL OR PUBLIC HEALTH
MALFUNCTION DETECTED
First & Foremost – STOP PRODUCTION
ATCP 80.52(6) REQUIRES:
1. NOTIFICATION
Contact area Food & Dairy Specialist within 2 hours– Telephone
– Fax
Submit broken seal report within 5 business days– Fax: 715-839-3867
– Mail: 718 W Clairemont Ave, Ste 128 Eau Claire WI 54701
BROKEN
SEAL
REPORT
Broken Seal Report Page 2:
Broken Seal Report Page 2 continued:
WHEN A SEAL IS BROKEN
ATCP 80.52(6) REQUIRES:
2. REPAIR & VERIFY PROPER
FUNCTION
Make repairs or adjustments.
Verify proper function of system prior to resumption
of production. Page 2 of Broken Seal Report:
Not a list of all verifications that may be necessary,
But it is a useful starting point or general guide.
HTST operation supervised by a certified operator.
WHEN A SEAL IS BROKEN
ATCP 80.52(6) REQUIRES:
3. DOCUMENTATION
Document Proper Function
• Verify and document that the control is working properly
Conduct Phosphatase Testing
• White milk products only– Whey, flavored products, and colored products exempt
• Is only a component to verification of proper pasteurization
PHOSPHATASE TESTING
• White milk products only
– Taken directly from the pasteurization system
• Collected at least every 4 hours of production
• Stored at 45°F until tested
• Tested within 48 hours
• Approved test methods
– In an IMS or state certified lab for Grade A
– By a trained individual for Grade B
– Verification of a positive result must be done in an IMS or state certified lab
PHOSPHATASE TEST RESULTS
• Less than 350 milli-units per liter
– Negative
– Good
• 350 milli-units per liter or greater
– Positive
– Bad
– Place product on hold immediately and initiate
recall if product has left the plant
– Notify DATCP immediately
FOOD & DAIRY SPECIALIST
FOLLOW-UP• Set date to test & reseal the system
– Within 10 days of broken seal
• Verify proper function of equipment
– Improper function = potentially unsafe product
– Product put on hold and follow-up by Sanitarian
• Review phosphatase records
– Positive phosphatase = unsafe product
– Product put on hold and follow-up by Sanitarian
• Proper function and negative phosphatase
– System resealed and placed back in normal operation
SANITARIAN ACTION ON
UNREPORTED BROKEN SEALS• Confirm product requires legal pasteurization
• Review phosphatase test results (if available)
• Notify supervisor and area Food & Dairy Specialist
• Place all products on hold
– If no proof of safety
• Release hold
– Re-pasteurize product if possible
– May age cheese 60 days if standard of identity allows
– Divert to an approved process
– Issue disposal agreement if no other option works
• Unusual Cases
– Supervisor & Specialist follow up
QUESTIONS?
ECOLAB
HTST
SANITATION PROCESS
Allan Ver Voort
Ecolab Food and Beverage
ECOLAB
WHY CLEAN
AND SANITZE
YOUR HTST?
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TO PROTECT PRODUCT
QUALITY AND SAFETY
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The Enemies
SPOILAGE ORGANISMS: Poor Quality
Shelf Life
Customer Dissatisfaction
PATHOGENS: Food Safety
Illness
Death
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Could This Be Your Plant?
Could This Be Your Plant?
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PROPER CLEANING
COMPLETELY REMOVES
ALL SOILS ON THE HTST
Product Contact Surfaces
Environmental (Exterior Surfaces)
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CLEANERS
Designed to Remove
the HTST Soils
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SOILS IN THE HTST
FAT
PROTEIN
CARBOHYDRATES
MINERALS
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FAT
Removed by:
Temperature Ten degrees over production temperature
Alkaline Cleaner (caustic) Concentration designed for your system
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PROTEIN
Removed by:
Alkaline or Acid Cleaners
Oxidizing Agents (Chlorine) Typically not used on HTST Units
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Carbohydrates
Removed by: Alkaline Cleaners
Acid Cleaners
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Minerals
Removed by: Acid Cleaners
Specifically Designed Cleaners
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Cleaning Procedures
(SSOPs)
CLEANING PROCEDURES
SSOPs
Sanitation Standard Operating Procedures
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SSOPs Developed Based On:
Product
Ingredients
Equipment Design
Process Time
Process Temperature Differential
4X4 Process
Other (Water, Energy, Time, etc.)
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Must Follow Specific
SSOPs Developed
for Your HTST
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Cleaning is a
4 X 4 Process
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Cleaning Steps
1. Pre-Rinse
2. Alkaline Wash
3. Acid Wash
4. Sanitize
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Cleaning Factors
1. Time
2. Temperature
3. Mechanical Action
4. Concentration
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Four Factors
Concentration
Temperature
Time
Mechanical
Action
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Concentration
Temperature
Time
Mechanical
Action
ConcentrationConcentration
Time
TimeTime
TemperatureTemperature
Mechanical
Action
Mechanical
Action
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Time and Concentration
Developed into SSOP
Depends on Time of Production Run
Production Temperature Differential
Type of Product Run (Soils)
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Cleaner Concentrations
The combination of 4 factors on this unit
Build in margin for varying conditions
Assure clean equipment
Control Cost
Adjust for solution loss
Developed into SSOP
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Mechanical Action - Flow
Try to attain 1.5 times production flow
If Using a Timing Pump Which Uses Impellers then Remove and Clean Them
Install CIP pump
If washed with Homo -- use bypass
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Temperature
Usually 10 Degrees Above Process
Caustic Wash is More Temperature Dependant for Thorough Cleaning
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PRERINSE
Most Important Step of the Wash
Done Immediately after Production
Removes 75-85% of the Soil
May do Caustic Pre-Wash
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WASH
Mid Day Flush
Conventional
Over- Ride
Single Phase
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Mid-Day Flush
Rinse
Light Caustic Flush
Rinse
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CONVENTIONAL
Pre-Rinse
Caustic
Rinse
Acid
Post-Rinse
Sanitize
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OVER-RIDE
Pre-Rinse
Acid Wash
Alkaline Wash
Post-Rinse
Sanitize
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SINGLE-PHASE
Pre-Rinse
Alkaline Wash
Post-Rinse
Sanitize
During The Wash:
All Valves Must Pulse to Clean the Valve Seats and Heads as Well as Divert Lines
Maintain Minimum Concentrations, Temperatures and Flows Throughout
Not Required But Prefer Concentrations Written on Recording Chart.
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New Technologies:
Research done on Spore and Biofilm survival in the HTST + Lines
Affects Product Quality and Shelf Life
Special Products and Procedures
Introduced in 2015
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HTST SANITATION
Sanitizing the HTST
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Why Sanitize?
Product Safety
Product Quality Flavor
Shelf Life
Comply with Regulatory Standards
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System Must be
Completely Cleaned
before it can be
Sanitized
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Sanitizing:
Eliminates 99.999% of Organisms
But does not sterilize the equipment
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Sanitizing Requires the
Use of Potable Water
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Sanitizing Cycle
Must Be:
Separate from Cleaning Steps
Done before Startup
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Sanitizing Must Follow SSOP
Concentration
Time
Temperature
Contact all Surfaces
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SANITIZERS
Hot Water PMO – Min. 170º for 5 minutes
IDF – Min. 185º for 15 minutes
Chlorine
Peroxyacetic Sanitizer
Others
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HTST SANITATION
Verification
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Need to Assure Proper
Cleaning & Sanitizing
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VERIFICATION
Product Quality -- Too Late
Inspection
Check Wash Recording Chart
Heat Transfer - Indirect
ATP
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HTST SANITATION
Summary
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Summary:
Important to Follow the SSOP
– Make Sure You Get a Good Pre-rinse
– Follow Proper Time, Flow, Conc. Time
– Increased Concentrations are Not Always Better
Especially on Over-Ride
– Sanitize Before Startup With Proper Concentrations
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PROPER SANITATION PROGRAM
Helps Assure Product Safety
Regulatory Compliance
Helps Meet Customer Expectations
Protects Your Reputation (Brand Name)
Consumer Acceptance of Your Product
Financial Protection for You and Co.
Job Security
ECOLAB
HTST SANITATION
Questions???
Summary & Questions
Presenter:
Panel Discussion
Summary
• Provided a Basic Overview of Pasteurization Systems
• Set Down the Ground Work for the HTST Operator’s Qualification Exam
• Feedback on Training Session
Where to get more information
• Milk Pasteurization and Process Control School - UW Madison
• Milk Pasteurization Short Course- UW River Falls
• Milk Pasteurization,Controls and Tests -FDA State Training Branch
• 3-A Accepted Practice 603-07
• Food & Dairy Specialists
QUESTIONS?
THANK YOU