6 replies to this topic

[Frank from NJ]

Hello!

We manufacture syrups for consumer and food service application. We have internally done APC and Yeast & Mold analysis of our thermally processed syrups for a number of years, using a membrane filtration method and a 1 gram product sample from each batch. We have also done coliform testing on our process water and a few other products as well.  When we get a minor count, we re-test another of the retainer bottles from the same production run and invariably find no count. Some of our lower sugar/calorie syrups are categorized as acidified foods. We also do environmental swabbing of food contact surfaces.

We also send samples annually to an outside lab as a check.

Based on the fact that our results are almost always <1 CFU/gram, I would like to get your thoughts on ipossibly reducing  the frequency of testing to perhaps one batch per day, or perhaps eliminating it altogehter?

[Frank from NJ]

Hello!

We manufacture syrups for consumer and food service application. We have internally done APC and Yeast & Mold analysis of our thermally processed syrups for a number of years, using a membrane filtration method and a 1 gram product sample from each batch. We have also done coliform testing on our process water and a few other products as well.  When we get a minor count, we re-test another of the retainer bottles from the same production run and invariably find no count. Some of our lower sugar/calorie syrups are categorized as acidified foods. We also do environmental swabbing of food contact surfaces.

We also send samples annually to an outside lab as a check.

Based on the fact that our results are almost always <1 CFU/gram, I would like to get your thoughts on ipossibly reducing  the frequency of testing to perhaps one batch per day, or perhaps eliminating it altogehter?

[Brothbro]

Hi FrankM, 

 

To what degree are your syrups thermally processed (ie pasteurization, commercial sterility, etc)? What is your current microbial load specification for your syrups?

Edited by Brothbro, 29 June 2022 - 11:12 PM.

[hello.fizz]

Hi FrankM, we make a similar sounding product, with low Aw, a low pH and stored at ambient temperature. We do not test every batch and at our inaugural HACCP audit last year (we only have HACCP) the auditor was happy with the schedule we have in place. 

 

It would be interesting for you to see if there is any historical reference or risk analysis to why each batch is tested. Unless it is a specific customer requirement, it does sound like it is above and beyond, but I acknowledge I am very new to the syrup space. 

[Frank from NJ]

Hi Brothbro.

Our syrups are batch processed to 190F for 25 minutes. The microbial load prior to processing is pretty low.

[Frank from NJ]

Thanks hello.fizz! I will look further into this.

[Brothbro]

Hi FrankM,

 

I have worked in thermal processing commercially sterile of broth/soups, but not syrups. In my experience, a long history without out-of-spec micro results would not justify skip-lot testing, but could justify a reduction in the number of samples taken per batch. I would expect that micro testing of your product would be a key metric in monitoring the effectiveness of your CCP (time/temperature of processing).

 

Without micro testing, you would need to rely entirely on the time/temperature data of your monitoring equipment. Have these time/temperature CCPs been validated to produce a certain result in your product? Additionally, is there not some risk for post-processing contamination in your product that could be identified through micro testing (package integrity issues)? 

 

Personally I would not remove the micro testing requirement on every batch, but like I mentioned my experience is more with commercial sterility in low-acid foods, which are higher risk than your product.