7 replies to this topic

[anainbite]

We have an issue with a production of almond cookies. The cookies where sent to a lab after conducting a pilot test run for a shelf life study. The results determined that the cookie would be good for a year. We ran the production and after 45 days the cookie has mold. What is the correct chain of responsability and how should we aproach the client, the lab etc?

The formula was given by the client.

The manufacturing was performed with the clients specs and we measured PH and water activity before packaging. Everything seemed to be on place. As of now we have conducted an investigation and it would seem that the cookie did not have such shelf life.

We already recalled and fortunate enough the product was not sent out to the market.

What are we missing here?

[Scampi]

Did the client gas flush the packaging and you did not?

 

Did the lab perform accelerated shelf life originally to determine 1 year or was it just a "guesstimate"   

 

were those cookies that went to the lab from YOUR facility or did another bakery make them?

[G M]

We have an issue with a production of almond cookies. The cookies where sent to a lab after conducting a pilot test run for a shelf life study. The results determined that the cookie would be good for a year. We ran the production and after 45 days the cookie has mold. What is the correct chain of responsability and how should we aproach the client, the lab etc?

The formula was given by the client.

The manufacturing was performed with the clients specs and we measured PH and water activity before packaging. Everything seemed to be on place. As of now we have conducted an investigation and it would seem that the cookie did not have such shelf life.

We already recalled and fortunate enough the product was not sent out to the market.

What are we missing here?

 

As Scampi suggests, there could be some property in the test batch that was not accounted for in the specification.  Was the validation study sample produced at your facility, or the clients?

[anainbite]

Thank you for replying. The tryout test was made at our facility and from here was sent to a lab.

Yes, gas flushed test and production.

yes, accelerated test

yes from our facility

[BM5]

When you say at your facility, was this from a full factory trial or in an NPD kitchen trial? Do you carry out pack and seal integrity checks and gas level checks? Be open and honest with your client, they'll appreciate it and it will allow you to work together to find the root cause. Have you carried out any mould testing on raw materials at all? Was the cooking process sufficient?

 

What was the length of time of the accelerated test? What's your target moisture level?

[jfrey123]

Same equipment used for the test and the production?  Any concerns about sanitation prior to pre-op?

[chrisrushworth]

I would start by testing the raw materials.
 

When you say you have performed a SL test, i assume you have performed MULTIPLE composite samples? Start, middle & end?

 

Were storage conditions the same for the lab as for your distribution holding (Ie Ambient 12-24°?)

 

Is this a new product? Or have you got EOL samples from other runs you could have tested to validate the 365 days?

 

Have you retained other samples from the NPD/1st pro run? Can you send to UKAS lab for verification?

[GMO]

Do you have retained samples from your production run?  Did they have mould?

 

It seems odd to have mould on cookies.  Unless the moisture content was really high.  

I suppose there are a few possibilities and what I'd do is get a team together to brainstorm potential causes.  Things I'd think about would be:

• High moisture at manufacturing (accuracy of measurement?)
• Hygroscopic product absorbing moisture during life (damage to packaging?  Dryness of gas flushing process?)
• Moisture trapped within the packaging (I've seen this in bread packaging before when it was packed hot.)
• Spores in the environment?
• Anything in the recipe which could be breaking down or crystallising so that you get moisture being "freed up" from solutes?  
• Potential the accelerated shelf life process wasn't designed to accurately replicate reality (albeit if the moisture were low enough that shouldn't be an issue.)

 

Do you have a US equivalent to Campden BRI?  I.e. a research organisation?  Not that Campden are as good as they were but you just know there would be a cookie (biscuit in UK English) expert there who you could talk to.  Although if you're gas flushing these, if that is to control moisture it does suggest you might have been on the raggedy edge of what's possible.

 

Another thing a more expert person than me could wade in on... For bacteria I'd definitely be interested in water activity but water activity and total moisture are not the same thing.  Aw is heavily impacted by solutes.  It would be really interesting to do some total moisture testing on your product.  Because I have a gut feel that could be quite important.