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Low risk-high risk-high care production risk zones


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#1 NicNac

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Posted 25 October 2017 - 08:42 PM

Hi,

 

We're producing liquid products which have had a heat treatment of more then 2 minutes at 72°C. Afterwards the product is cooled down and immediately frozen in and packed. The product needs to be stored frozen and needs to be defrosted before consumption.

 

Now my question is if I check the decision tree appendix 2 of the BRC standard I would mention no on step three so I would only have low risk area's.  But others are telling me I should have a high risk area from cooling till product is packed.

 

What do you consider is the most logic?

 

Best regards,


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#2 Madam A. D-tor

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Posted 25 October 2017 - 09:36 PM

Dear Niwel,

 

For question 3 you should answer yes. The question is

Does the product support the growth of pathogens or the survival of pathogens, which could be subsequently grow during the normal storage or use of the product unless stored chilled or frozen?

 

it is my experience that this question seems to be misunderstand very often. Both in English as in Dutch language.

What they mean (for chilled/frozen food) is

if the product need to be stored chilled or frozen and it is not, are the product parameters (Aw, pH, salt%, sugar%, preservatives, etc) such that pathogens can grow or survive?

 

I do not know what your product is, but I think the answer will be yes.

Also check out appendix 2, first page, last paragraph:

 

 

HIGH RISK (CHILLED AND FROZEN)

This is a physically segregated area (see below) designed to a high hygiene standard where practices relating to personnel, ingredients, equipment, packaging and environment aim to prevent contamination by pathogenic micro-organisms. Products which require handling in a high-risk area meet all of the following:

• The finished products require chilling or freezing during storage to preserve food safety.
• All components have received a full cook1 process to a minimum of 70ºC for 2 minutes or equivalent (see Appendix 3) before entry to the area.
• The finished products are vulnerable to the growth of pathogens (e.g. Listeria species) or the survival of pathogens, which could subsequently grow during the normal storage or use of the product (e.g. if a frozen product is defrosted but not immediately consumed).
• The finished products are ready to eat2 or ready to heat3 or, on the basis of known consumer use, are likely to be eaten without adequate cooking.

Examples of products considered as high risk include cooked sliced meats and fully cooked prepared meals.


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Madam A. D-tor

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#3 Charles.C

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Posted 26 October 2017 - 02:27 AM

Hi niwal,

 

I agree with previous Post but, as indicated, the conclusion is restricted due for example to -

 

Product = ?

Detailed Process = ?

 

The BRC document F048 on Understanding High Risk/Care offers "Risk" advice on a range of Product Types/Processes. Maybe have a look.


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Charles.C


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#4 NicNac

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Posted 26 October 2017 - 09:31 PM

Dear Niwel,

 

For question 3 you should answer yes. The question is

Does the product support the growth of pathogens or the survival of pathogens, which could be subsequently grow during the normal storage or use of the product unless stored chilled or frozen?

 

it is my experience that this question seems to be misunderstand very often. Both in English as in Dutch language.

What they mean (for chilled/frozen food) is

if the product need to be stored chilled or frozen and it is not, are the product parameters (Aw, pH, salt%, sugar%, preservatives, etc) such that pathogens can grow or survive?

 

I do not know what your product is, but I think the answer will be yes.

Also check out appendix 2, first page, last paragraph:

 

 

Hi niwal,

 

I agree with previous Post but, as indicated, the conclusion is restricted due for example to -

 

Product = ?

Detailed Process = ?

 

The BRC document F048 on Understanding High Risk/Care offers "Risk" advice on a range of Product Types/Processes. Maybe have a look.

 

Thank you for your detailed reply.  Yes this means that for this type of products we would need to have a high risk area. Now just after the heating the product is put in a buffer tank > 50°C and mostly even >63°C and afterwards it pumped over threw pipes pass a sieve, cooled down < 20°C  by backward flow tube cooling system and then again put in a buffer tank  and pumped  on a belt to freeze the product in right away.  Is the high risk area then from the first buffer tank til the product is frozen in or is even the area after freezing till product is packed in final packaging need to be considered as a high Risk area.

 

Also in the flow of  transformation of fresh fruit into frozen fruit + packing it. Is in this situation then also a high Care area needed?

 

Best regards,


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#5 Charles.C

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Posted 27 October 2017 - 12:39 AM

Hi NicNac,

 

IMEX (not fruit) the High-Risk area starts at interface between raw/cooked and continues to point of Final packing.

 

Also in the flow of  transformation of fresh fruit into frozen fruit + packing it. Is in this situation then also a high Care area needed?

are you still referring to same cooking flowchart or ?


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Charles.C


#6 NicNac

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Posted 27 October 2017 - 05:20 AM

Hi NicNac,

 

IMEX (not fruit) the High-Risk area starts at interface between raw/cooked and continues to point of Final packing.

 

are you still referring to same cooking flowchart or ?

 

yes same decision tree of BRC  both frozen products, one is cooked, fruit is uncooked. Both both are just defrosted before consumption.


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#7 Charles.C

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Posted 27 October 2017 - 05:58 AM

yes same decision tree of BRC  both frozen products, one is cooked, fruit is uncooked. Both both are just defrosted before consumption.

 

Hi NicNac,

 

Assuming 2nd one is labelled RTE, probably high care. See attachment.

 

Attached File  prepared fruit.pdf   88.46KB   22 downloads


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Charles.C


#8 NicNac

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Posted 27 October 2017 - 02:42 PM

Hi NicNac,

 

Assuming 2nd one is labelled RTE, probably high care. See attachment.

 

attachicon.gifprepared fruit.pdf

Thx  I will need to buy the book :-)


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#9 Madam A. D-tor

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Posted 27 October 2017 - 09:19 PM

[...]. Now just after the heating the product is put in a buffer tank > 50°C and mostly even >63°C and afterwards it pumped over threw pipes pass a sieve, cooled down < 20°C  by backward flow tube cooling system and then again put in a buffer tank  and pumped  on a belt to freeze the product in right away.  Is the high risk area then from the first buffer tank til the product is frozen in or is even the area after freezing till product is packed in final packaging need to be considered as a high Risk area.

Dear Nic Nac.

I am not sure but from your description it  seems that after heating the product is enclosed in pipelines and not open to the area.

The second question of the decision tree is if the product are open to the environment. If the answer is no, the area is an enclosed product area.

For every production area you should do the decision tree.

If indeed after and during heating the products are in pipes until the portioning on the belt freezer, then from the portioning on the belt freezer until closed package again is de High Risk Area. If, however all the processes are conducted in one area, the whole area is high risk.


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Madam A. D-tor

#10 Madam A. D-tor

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Posted 27 October 2017 - 09:58 PM

 

Also in the flow of  transformation of fresh fruit into frozen fruit + packing it. Is in this situation then also a high Care area needed?

 

This depends on the fruits and the processings involved in the transformation.

For some fruits the pH is to low to support the growth. But pathogens are known to survive on the surface of fruits.

There have been cases of frozen fruits contaminated with pathogens. Check out the RASFF.

 

Following the decision tree I would say that the area is high care.


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#11 Charles.C

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Posted 28 October 2017 - 05:39 AM

Thx  I will need to buy the book :-)

 

Hi NicNac,

 

No need, source document is here -

 

http://www.ifsqn.com...rd/#entry103992

 

@Madame A. D-tor,

I deduced (see my BRC attachment Post7) that for raw RTE (chilled/frozen [class6]) items this case is apparently more "customer-driven" rather than tree-based. But it's only my interpretation of BRC's document. My related query to OP was unanswered.


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Charles.C


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#12 NicNac

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Posted 07 November 2017 - 09:20 PM

This depends on the fruits and the processings involved in the transformation.

For some fruits the pH is to low to support the growth. But pathogens are known to survive on the surface of fruits.

There have been cases of frozen fruits contaminated with pathogens. Check out the RASFF.

 

Following the decision tree I would say that the area is high care.

 and if you just wash, cut and freeze in fruit? 


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#13 NicNac

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Posted 07 November 2017 - 09:26 PM

Dear Nic Nac.

I am not sure but from your description it  seems that after heating the product is enclosed in pipelines and not open to the area.

The second question of the decision tree is if the product are open to the environment. If the answer is no, the area is an enclosed product area.

For every production area you should do the decision tree.

If indeed after and during heating the products are in pipes until the portioning on the belt freezer, then from the portioning on the belt freezer until closed package again is de High Risk Area. If, however all the processes are conducted in one area, the whole area is high risk.

 

Hi Madam A.D-tor,

 

The product of intrest are  frozen smoothies.

So if you would put on the pack that the products need to be defrosted in the microwave and be consumed right away would this not be enough?

Taken the below sentence into account about the final product preparation mode and consumption.

 

• The finished products are vulnerable to the growth of pathogens (e.g. Listeria species) or the survival of pathogens, which could subsequently grow during the normal storage or use of the product (e.g. if a frozen product is defrosted but not immediately consumed).

 

Best regards,
 


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