11 replies to this topic

[LGreen]

I'm looking for some insight on testing in a popcorn plant.  The popcorn would have additional flavoring such as savory flavors and caramel coating.  What have others testing for pre-op testing, CIP, COP and finished product quality testing.

[Aliali]

I don't have much experience with popcorn..i would imagine a popcorn plant is a dry clean plant .. Salmonella loves dry environments, This is the first bacteria I can think of. 

It also depends the level of automation in the plant. if an intensive labour handling is involved in the process,  Staphylococcus and E.coli are good indicative organisms.

 

if your CCP is after mixing with flavours, the risk is lower comparing with the flavours are mixed after your CCP. The HACCP team should analyse and rate the hazards, which will give you some ideas of risks, consequently, quality and food safety checks.

 

these are just my thoughts.  

[Charles.C]

I'm looking for some insight on testing in a popcorn plant.  The popcorn would have additional flavoring such as savory flavors and caramel coating.  What have others testing for pre-op testing, CIP, COP and finished product quality testing.

 

A query of extremely wide scope.

 

So what is the Product Specification ?( = basic Product testing requirements) ?

 

Basically you are enquiring about GMP and HACCP.

 

GMP requirements are summarised in CFR 110. I believe FDA also offer sample audit checklists.

 

HACCP requirements will depend on yr haccp plan. Do you have one ? Again presumably required to comply with FDA expectations.

 

CIP will presumably relate to the specific CIP process in use. Normally afaik provided by the supplier of the CIP system ?

[MsMars]

Since this was posted under an introductory thread, I'm going to ask because I'm curious...  

1. Midwestern popcorn? Perhaps in my region!

2. Serious question - are you third party certified? 

 

I'm initially thinking you will need to do some sanitation verification but as far as environmental testing you'll want to hit the obvious - Salmonella & Listeria.  Frequency will be based upon risk and area (pre and post lethality, zone, etc.)  Finished product testing - I'm not familiar with the confectionery side of things, but probably also going to depend on type of product - confectionery will have different testing requirements vs. a dairy-based powder I would think.

[moskito]

Hi,

 

do you know that we have had a huge recall last year due to tropane alcaloide contamination in Europe/Germany?

 

https://webgate.ec.e...&cleanSearch=1#

 

Rgds

moskito

[MsMars]

Hi,

 

do you know that we have had a huge recall last year due to tropane alcaloide contamination in Europe/Germany?

 

https://webgate.ec.e...&cleanSearch=1#

 

Rgds

moskito

 

Unless OP is importing, I don't believe I've heard of this issue in the US, let alone with a taller crop such as corn. Although a bit off-topic, interesting reading. I use scopolamine patches for motion sickness when flying. 

[kfromNE]

Do you bring in kernels in and then process it to make popcorn? If so, then mycotoxins may be a concern. 

 

https://www.cafpa.co...ing-Meeting.pdf

 

As for potential contaminants - https://www.fda.gov/.../99581/download

[Charles.C]

Hi LGreen,

 

Any more comments ?

 

Was there a specific FS Standard involved ?

[LGreen]

Do you bring in kernels in and then process it to make popcorn? If so, then mycotoxins may be a concern. 

 

https://www.cafpa.co...ing-Meeting.pdf

 

As for potential contaminants - https://www.fda.gov/.../99581/download

Yes,   We will be brining kernels in with a popping process and to make the finished product.  

Working on the HACCP and GMP plan to make sure I don't miss any CCP that may or may not be obvious..

[LGreen]

Hi LGreen,

 

Any more comments ?

 

Was there a specific FS Standard involved ?

 

I'm working on the QC plan for BRC standards.

[Charles.C]

I'm working on the QC plan for BRC standards.

Thks.

By Quality Control, I presume you refer to clause 5.6.1.1 et seq ? eg

 

There shall be a scheduled programme of product testing which may include microbiological, chemical, physical and organoleptic testing according to risk. The methods, frequency and specified limits shall be documented.

 

 

This, similarly to the inclusion of  "quality' in clause 3.5.1.1 is, IMO, an example of BRC Stupidity, ie why are organoleptic aspects included in a (nominal) Food Safety Standard ?

 

Regarding "according to risk", a trivial interpretation of this from a safety POV  would presumably lead to exclusion of requirements relating solely to organoleptic factors.

 

I suggest you proffer a minimalized response regarding "quality" aspects.

[FoodSafetyPlanet]

Hi L-

 

I focused on seed testing by suppliers and allergen testing during changeovers. Finished product testing was done 2x a year, mainly because we were direct to consumer so it was not required as often.