4 replies to this topic

[imadoughguy]

We make fresh glazed donuts all day and we continuously run our spiral conveyor through a tank filled with water in order to remove glaze run-off that would otherwise dry and flake off and make a mess of the donuts as they travel up the spiral.

 

Auditor asked how we keep the water in the tank from becoming a "bacterial soup" as it is not emptied until the end of the day, which is about 12 hours of continuous belt running.  We have a float valve that lets a little fresh water in the tank as needed due to some water being carried away by the conveyor belt.

 

We can't keep the water hot enough to prevent bacteria formation and growth ( I believe 130 degrees minimum? ) so we inject quat into the water supply to get a 200ppm solution. Problem is the spiral conveyor belt really doesn't have time to dry 100% completely before more donuts go on to the conveyor belt.

 

1) Is there a quat level (or other bacteria inhibitor) that is ok for food contact that will also keep the water bacteria free?

2) Is there a better solution than adding quat to the water in the first place?

 

Thanks for any suggestions.

 

Phil

[Charles.C]

Dear imadoughguy,

 

Sounds pretty ugly.

 

I'm more familiar with continuous, horizontal belt freezers, single/multi-stage. There are design variations but one method is to spray water across the returning belt at exit using a row of nozzles. No re-use of water. May relate to surrounding  temperature level also.

Complete system is cleaned/sanitized at end of shift (day).

 

I hope with yr system that the doughnuts are not in direct contact with the belt.

 

Rgds / Charles.C

[imadoughguy]

Thanks Charles, that is the #1 rated suggestion so far. Yes, my donuts ride on the conveyor belt.

 

My Sanitation Chemical Supplier has suggested a chemical that has Sodium Peroxide in it. They spray veggies with it and do not have a rinse step so I should be able to add to water.  Have to make sure the seals and bearings can handle it though. :-)

 

It has also been suggested that the water is not a problem in the first place, I will need to run some samples to the lab at the end of the day and see whats in the water that could be a problem.

 

Any suggestions what to test for? Basically its glaze (sugar) and fried yeast donut particulates that are getting in the water throughout the day.

 

Tks

 

Phil

[Charles.C]

Thanks Charles, that is the #1 rated suggestion so far. Yes, my donuts ride on the conveyor belt.

 

My Sanitation Chemical Supplier has suggested a chemical that has Sodium Peroxide in it. They spray veggies with it and do not have a rinse step so I should be able to add to water.  Have to make sure the seals and bearings can handle it though. :-)

 

It has also been suggested that the water is not a problem in the first place, I will need to run some samples to the lab at the end of the day and see whats in the water that could be a problem.

 

Any suggestions what to test for? Basically its glaze (sugar) and fried yeast donut particulates that are getting in the water throughout the day.

 

Tks

 

Phil

 

Dear imadoughguy,

 

Not very familiar with doughnut technology but i guess the “usual suspects” from a product quality POV are the hygienic micros as listed in yr typical specification (eg coliforms et al). A significant APC count is presumably an immediate sign for worry + presumably the liquid appearance. i daresay from yr initial comments that you have accumulated micro. data and observational assessments already.

 

The nozzle system I mentioned is used for freezing battered/breaded items and I agree that the belts can get in a mess, but maybe, solid, horizontal designs, far less though. Swings and roundabouts.

 

I seem to recall spiral units typically hv "in-line" washing stages but yours sounds a truly complicated set-up to maintain. IMEX, first target for complaints / advice is usually the machine disributor. They have usually played with everything. 

 

As you probably guessed, my own initial reservation is towards adding QAC to the belt / product. i have no doubt that commercial products are invariably validated/approved for their designated usage but attachments like those below would worry me for a no-rinse scenario. Perhaps (slightly) less-so if there was a rinse tank as well.

 

 

 Quaternary Ammonium Compounds (QACs) on foodstuffs.pdf   371.62KB   12 downloads

 Quaternary ammonium compounds, AESAN.pdf   80.47KB   10 downloads

 

Rgds / Charles.C

 

PS - i have worked  with hydrogen peroxide solutions. Workers were not too happy from memory, skin handling factors, although it is a common (but weaker) product from the pharmacist shop. Also typically not so cheap but I guess quats are not cheap either. You cannot use hypochlorites due tainting or the problem is the lack of detergent action ?

 

I am guessing solid peroxides will be quite combustible based on my experiences with storage of high-test hypochlorites.

 

PPS - it sometimes seems to me that veggies are sprayed with almost everything.

Edited by Charles.C, 20 October 2013 - 05:53 AM.
revised / expanded

[KTD]

Dear imadoughguy -

     Since your process is FDA regulated, you should be able to use any of the santizers/sanitizer blends identified by FDA in 21 CFR 178.1010 from a regulatory standpoint. You should be able to do an internet search for suppliers of those santizers of interest and can pick their brains for suggestions based on your process.

     Along with Charles' suggestion regarding water nozzles, you might be able to use air nozzles after the dip tank to avoid having to contain and dispose of the water spray.