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

– E-mail

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

ECOLAB

PROTEIN

Removed by:

Alkaline or Acid Cleaners

Oxidizing Agents (Chlorine) Typically not used on HTST Units

ECOLAB

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

ECOLAB

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SSOPs Developed Based On:

Product

Ingredients

Equipment Design

Process Time

Process Temperature Differential

4X4 Process

Other (Water, Energy, Time, etc.)

ECOLAB

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

ECOLAB

Time and Concentration

Developed into SSOP

Depends on Time of Production Run

Production Temperature Differential

Type of Product Run (Soils)

ECOLAB

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

ECOLAB

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

ECOLAB

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.

ECOLAB

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

ECOLAB

ECOLAB

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

ECOLAB

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