13 replies to this topic

[dysprosium]

I work in an alcoholic beverage industry that bottles mostly wines but also some sweeter carbonated alcohol beverages.  

 

Currently, if the line stops due to equipment breakdown we allow 4 hours down- anything beyond that time requires a lines to be re-sanitized.

 

Curious what others follow and if there are any actual documented recommendations, GMPs, standards or research articles published on what times might be considered acceptable during a downtime event before re-sanitation is required.

[SHQuality]

What is the reasoning behind this thought process?

I'm actually more worried about the fact that 4 hours downtime due to breakdown of equipment seems to be a common for you.

[dysprosium]

I never said it was common.  It's incredibly uncommon at our site, but we are a multi location producer and are being requested to standardize across all sites.  Each allows for different times down before re-sanitizing.  

Edited by dysprosium, 15 February 2023 - 11:50 PM.

[SHQuality]

Sorry for the misunderstanding. Still, I would compare the reasoning behind each site's reasoning and standardize towards the reason that makes most sense.

Is the line isolated from outside contamination?

Is the reasoning based on ongoing fermentation during filling?

[Sayed M Naim Khalid]

I will conduct site specific risk assessment. Based on the result of risk assessment and the type of machine, I will decide the need and frequency for sanitizing the equipment. You cannot have one solution for all sites, unless all sites are replicate /copy of each other. 

 

Example:

Site A. this site has dry ingredient storage for beer manufacturing e.g. malt, yeast, barely . It has a conveyor belt (machine). 

Site B. This site only makes glass bottles and tin can of various sizes for beer. it has glass melting machines and molds.

Site C. This site has heating (boiling hop) CCP and filtration step as CCP. It has filters and a machine for thermal process. 

 

Do you think you will need the same frequency of cleaning and sanitation for every site in my examples? 

[dysprosium]

Apologies I should have been more clear- we are looking to standardize idle time permitted on our bottling lines at all sites before a resanitation is required.  Each site bottles wines of similar types.

 

Bottling areas are in their own part of the facility and not near processing /fermenting areas which are in different parts of building and other buildings.

Edited by dysprosium, 16 February 2023 - 05:36 PM.

[Gelato Quality Lead]

Not sure if this is an answer to your question, but you could validate the four hours idle time by swabbing at specified intervals and determine based on the swab results if there is an increased risk in extending the idle time.

 

Typically, when we have a breakdown, we clear everything out right away because we do not want the product to become contaminated through the maintenance that is occurring. It is also in our programs to do a complete clean after any maintenance or repairs on the machines.

[Tony-C]

Hi dysprosium,

 

Any requirement on re-sanitation after downtime will be down to the product sensitivity to deterioration, your products do not seem to be at risk of deterioration.

 

An example where I would be more concerned would be with fresh high-risk RTE products packed in a non-temperature controlled environment where it may be an hour or less downtime before re-sanitation was required. The main issue here would be temperature abuse and any effect on the product quality and shelf life.

 

For downtime where there have been interventions that may have affected or have the potential to affect product or food contact surfaces then I would expect to see re-sanitation.

 

I would be sampling the 1^st saleable product off after the downtime or interventions, as described above, to determine any effect on the product and that information can guide you on the level of downtime that is acceptable before re-sanitation.

 

Kind regards,

 

Tony

[sqflady]

Look at the regulations for your product.  For dairy products, a line must be re-sanitized after 72 hours of idle.  That means it is cleaned and sanitized and then not used right away.  If more than 72 hours idle, you must re-sanitize before running product.

[AJL]

Hi SQF lady, can you direct me to where I can read more about this, sounds interesting.

[sqflady]

Hi AJL,

For dairy products in the USA, we refer to the PMO (Pasteurized Milk Ordinance).  

 

You can download it here:

https://www.fda.gov/...14169/download 

 

Your industry may have something similar.  

[AJL]

Hi SQF lady - are you referring to page 75 of the ordinance?

 

When you say 72 hours of being idle - is it idle with product on the line or idle, after CIP/cleaning?

 

How do you think one should best define guidelines for how long a clean line can remain idle, before it should be re-sanitised?

Thanks in advance :) 

[sqflady]

I am unable to locate the exact reference but when a cleaned and sanitized line is idle (without product), it needs to be re-sanitized before use if the idle time is greater than 72 hours.

[AJL]

Thanks SQF lady. I am in a discussion with my HACCP team about this bit I really need a reference. I read the milk ordinance but didn't pick it up in tbere