Optimising Your

Safe Food Production

Beatrice Conde-Petit
Matthias Graeber

Bhler AG
European Food Safety & Quality Summit
May 26 27, 2016, Huis ter Duin, NL

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 Food Safety: old and new challenges

Salmonella in dry food Foreignmaterials

Foreign materials

1 m
Janice Haney Carr, Centers for Disease Control and Prevention, USA

Myxotoxins the silent threat New regulations & private standards

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Technologies for safe food processing for sustainable value chains

Value

- control food safety hazards

- build trust & transparency
- high line efficiency & reduced waste

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 Designing safety into processing
Example: processing line for roasted almond in chocolate

storage/
storage cleaning sorting roasting sorting molding packing distribution consumption

SAFE FOOD
chocolate Building TRUST !
safety of
raw material High hygiene zone

free of pathogenic bacteria

Validated kill step

Roasting as CCP
(CCP, Critical control point)

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 Overview

Advanced optical sorting for food safety

Detection & removal of foreign material

Mycotoxin reduction

Upgrading of traditional thermal processes:

CCP for microbial inactivation

Roasting of almond as validated kill step

Hygienic design of equipment/ facilities

The value of hygienic design

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 Foreign Materials as Food Safety hazard.

A foreign material is something that the consumer perceives

as being alien to food but can also harm consumers

Glass Plastic Stones Metals Wood Paper

Foreign
Insects Bones Shells Sticks Hairs
kernels

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Classification of Foreign Materials.
FDA Guide.

Critical
hard or sharp objects 7mm to 25mm in ready to eat product

Hazardous
hard or sharp objects 7mm to 25mm in product requiring
further preparation, or
hard or sharp objects <7mm in food intended for high risk
group (e.g. infants), or
hard or sharp objects over 25mm

Unwanted
Any other foreign material

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Effective cleaning in nut processing
Solid lines of defence to remove foreign materials

1 Intake

2 Elevator
6
3 Separator Classifier MTRB
C
3
4 Drum magnet DFRT

7 5 Destoner MTSC
6 Aspiration channel MVSH

7 Aspiration filter MVRT

4
8 Airlock MPSN
2 D A Coarse contaminants

8 B Fine contaminants
5 C Aspiration (dust, shells, )
B A F D Metal particles
1 E
E High-density material

F Dust and dirt

Product to SORTEX

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SORTEX Optical Sorters.

High sorting performance.

High efficiency in defect detection & removal
Detection:
- Visible (PROfile technology)
- Near infrared (InGaAs technology)
- Shape & dimension deviation
Removal:
- Precision in removal of defective
product by pneumatic ejectors
High capacity (10-30 t/h)
Easy to use
Hygienic design for efficient wet cleaning
Low maintenance and running costs

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Example - Robusta coffee.
SORTEX A ColorVision InGaAs

Defects: Dark/rotten beans, stones, sticks, corn.

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Uncompromising foreign material detection

- Detects subtle colour defects.

- Detects the smallest of defects.
- Wide range of custom built cameras.
- Delivers optimised cost effective solutions.
- Custom designed for the highest colour registration and stability.

Enhanced InGaAs cameras target foreign material found during the process.

Visible camera Enhanced InGaAs camera

1 Cardboard, 2 Plastic, 3 Wood
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Precision sorting of grains & seeds: the starting point for safe food

Mycotoxin
contamination

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Mycotoxin
Aflatoxin B1 is the most toxic mycotoxin found on maize and peanuts

Mold on raw material

high risk of mycotoxin
Aflatoxin B1

Toxic for humans and animals Global

25000 - 150000 liver cancer cases/y
legal limits 0.1 20 ppb (1 ppb = 1 g/kg)
Increasing problem in Southern Europe

liver cancer data: Y. Liu, F. Wu, Environmental Health Perspectives, 118 (2010)
x

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Mold growth on raw material brings the risk of mycotoxin formation

Spoilage of raw material Vector for mold infection Mycotoxins

(field or storage) Maximum limits set for
several mycotoxins

Deoxynivalenol (DON)

5 m

Visible mold contamination Spores Aflatoxin B1 Aflatoxin M1

Milk

Macroscopic level Microscopic level Molecular level

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Bhlers history of mycotoxin reduction

1980

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Pre- and post harvest mycotoxin management
For safe and high value food and feed products
Avoid fungal infection

inhibit fungal growth

remove contaminated fractions

Food and feed
Field and harvest Grain reception facility Transport and storage Mill processing

Good agricultural Pre-cleaning Safe storage Monitoring

practice Monitoring
Stabilization Monitoring Cleaning
Chemical and biological Mycotoxin reduction in
(drying)
control - Size and density processing
Precision farming Cleaning separation
Feed additives
Resistant varieties - Size and density - Aspiration
separation - Optical sorting
Statistical models
- Aspiration
- Surface cleaning
- Optical sorting
Conditioning
Grinding
Monitoring
Bran separation

Bhler Solution Storage

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Pre- and post harvest mycotoxin management
For safe and high value food and feed products
Avoid fungal infection

inhibit fungal growth

remove contaminated fractions

Food and feed
Field and harvest Grain reception facility Transport and storage Mill processing

Good agricultural Pre-cleaning Safe storage Monitoring

practice Monitoring
Stabilization Monitoring Cleaning
Chemical and biological Mycotoxin reduction in
(drying)
control - Size and density processing
Precision farming Cleaning separation
Feed additives
Resistant varieties - Size and density - Aspiration
separation - Optical sorting
Statistical models
- Aspiration
- Surface cleaning
- Optical sorting
Conditioning
Grinding
Monitoring
Bran separation

Bhler Solution Storage

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Case study on reduction of aflatoxin in maize
2013 Italy

Study on the cleaning of maize for reduction of Aflatoxin

Combination of mechanical cleaning, aspiration & optical sorting.

Line capacity: 15 t/h

Project in collaboration with Institute of Sciences of Food

Production (ISPA-CNR) in Bari (I)

Sampling and analysis according of official methods (EC

Commission Regulation no. 401/2006 and AOAC Official Method 2005.008).

Selected results:

Reduction Aflatoxin B1: 62.0 ppb auf 13.5 ppb

Reject : 6.2%

Reduction Aflatoxin B1: 28.8 ppb auf 4.5 ppb

Reject : 6.6%

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 Case study
Upgrading of maize (biomass quality) for feed application

DON Mycotoxin concentrations (ppb)

10160
Input corn 1900
5810

Reject 64790
Dust 22800
24370
5.5 %
25660 DON
Brokens 4070
22680 ZEA

18570
FB1+FB2
15.6 % Low density 7010
19270 Upgrading of raw material for feed quality

27620
2.8 % Reject SORTEX 10060
7860

1780
Cleaned corn 220
1830

23 % total reject
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Consistent reduction of mycotoxin levels

Mycotoxin level Demonstrated reduction

84% Aflatoxin B1
82% DON
Size separation
88% ZEA
69% Fumonisins
Aspiration

Density sep.

Small & broken Optical sorting

Dust & husks

Shrivelled

Target level Visual fungal signatures

Removed affected product (%)

x

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Sorter as sensor IoT enabled access to sorting statistics
Opportunity for quality and supply chain management?

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 http://mycotoxin-
reduction.buhlergroup.com/hp2/Startseite.htm?ITServ=C73f15d6
X154edb51b52X6c23

Metrics behind grain cleaning

are the key to generate value &
sustainable business

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Salmonella is the game changer in the dry food industry

Salmonella
survives for years in dry environment
relatively thermostable
a few cells can induce illness.
quickly multiply in presence of water (aw > 0.95)

2007
1 m
USA: Mandatory Janice Haney Carr, Centers for
Disease Control and Prevention
pasteurization of USA
almonds ( 4 log )

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What are the options to pasteurize nuts?

Dedicated steam
pasteurization step

Controlled
Kill step
condensation
processing

Upgrade roasting
to a validated kill step

Kill step Roasting

x

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 Upgrading thermal processes into trusted kill steps
Combining process monitoring with inactivation kinetics knowledge

Energy Temperature Realtime log kill

consumption

Processing Intelligence

Roasting
as kill step

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 Upgrading thermal processes into trusted kill steps
Building a physical validation protocol

Partnerships
for innovation

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Building safety into dry food processing
Opportunity to validate other traditional thermal processes

Other
processes
Drying
Kilning
of oats
Cooking
Heat extrusion
treatment
Dry
of feed
roasting
of nuts

2015 2016 2016 2016 2017 2018

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 Designing safety into processing
Example: processing line for roasted almond in chocolate

storage/
storage cleaning sorting roasting sorting molding packing distribution consumption

SAFE FOOD
chocolate Building TRUST !

High hygiene zone

free of pathogenic bacteria

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Sortex with highest hygienic design level
Combining food safety risk reduction with highest operation efficiency

ACCESSIBLE NO NICHES/ CREVICES Food COMPATIBLE

for efficient WET cleaning to avoid harboring of and durable materials
contamination

Slopped surfaces for Chute opens up for Hygienic fixings Stainless steel air set
easy run off cleaning

Hygienic Chute in
Open receptacle to Open angle stainless Hygienic cable fixings
UHMW-PE
ease cleaning steel frame
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Comprehensive approach to safe food processing
Preventive approach to control hazards

Raw material control Hygienic design

Facility Design from Keep dry (war on water)
roof to drain Cleaning & disinfection
Prevent Avoid
entrance multiplication

Kill Avoid Factory design & zoning

Heat treatment or remove transfer Air/ water/ waste
Chemicals management
Alternative technologies Hygienic design
Cleaning & disinfection Personnel hygiene
Adapted from Warren, B. (2012), IAFP's European Symposium on Food Safety 21-23 May 2012 in Warsaw, Poland.

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 www.buhlergroup.com

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