5 replies to this topic

[bEvvy]

I could really use some help from your experienced minds.

 

Our company (a beverage co-packer) has bought a cup filling machine - single serve cups, 110ml/3.5 fl oz - the type of cup that is served on airplanes, with a polyester pull-away seal/lid.

 

The plan is to fill cold with orange and apple juice from concentrate.

We are normally a hot fill plant, so I have no experience in any of this and experience in the company in general in this area is very limited. A recipe has been created with 0.05% potassium sorbate as a preservative.

Shelf life is 45 days.

 

My issues: 

 

Potassium sorbate. Is this effective at a dose of 0.05% - most literature seems to suggest 1-2% for fruit juices.

In addition to this - I don't believe it is effective in controlling bacteria. Are we leaving ourselves wide open to bacterial spoilage, seeing the product is not pasteurised and are there any other ways to control bacterial load/spoilage other than pasteurisation.

 

Temperature. The cup label (commissioned by customer) recommends storage below 4ºC. We mix with chilled water, but as the filling process takes a long time, the juice temp will go up to 15-17ºC during the day, with no option to keep it chilled in the meantime. We are being pushed to keep the temperature as low as possible (which is proving impossible in a southern hemisphere summer) but the reasoning for this is purely anecdotal and not backed by research and/or literature either way.

 

Shelf life. Again, purely anecdotal and based on what the customer wants. I have mentioned that we should hold stock from initial productions onsite until the end of shelf life to verify (and also send to lab), but have been told that there is no time for this.

 

In short - there is nothing in the process that feels comfortable to me in any way. Perhaps I'm being too cautious, but I feel my concerns are valid and not addressing them could leave us wide open for a serious incident.

 

In your experienced opinions, what would be the ideal process here to make the safest product possible?

[Scampi]

Step 1-use pasteurized juice

 

Step 2- if that isn't an option, walk away from the project

 

https://inspection.c...ices-and-ciders

 

https://www.fda.gov/...-guidance-first

[G M]

Is the customer who is dictating specifications also contractually taking all the liability for it?

 

Just because they want it doesn't mean its safe.

[GMO]

If it's from concentrate then the juice portion will be pasteurised, however, you are doing so presumably diluting the product.  Is that correct?  

 

Can I ask where in the world you are as it might help for organisations who can help you.

 

But, briefly, if you're in the UK here are a couple I'd suggest:

 

The British Soft Drinks Association

Campden BRI - Science and technology for the food and drink industry

 

Also this resource is AMAZING.  (You need to add your email address but it's free.  For those who know the dairy processing handbook, this is the same but for orange juice.) Tetra Pak Orange Book | Tetra Pak United Kingdom

 

A lot will depend upon the pH of your juice as to how much risk there is but there are two other things sites doing what you're doing would have in place:

 

Water treatment, yes, even if you're using potable water, it's not hygienic enough for ingredient use for beverages.  Also be mindful of the Coca Cola EPP example of where water treatment (I'm assuming) went a bit wrong.  I'd also expect the whole mix with the water and syrup to be pasteurised together ideally much as mentioned earlier.  The risk of post process contamination is going to be there at your supplier and in your process.

 

Packaging disinfection.  For some processes, the packaging will be disinfected in an aseptic filling process.  This is particularly important where mould growth is possible.  But that probably means a whole different filler.

 

For the percentage and mode of action on the sorbate?  I'm not expert enough I'm afraid but if you have a look and consult some of the above resources you might find someone who is.

[AZuzack]

You absolutely have to run Shelf-life on the initial production.  Definitely keep the samples to evaluate for spoilage not for pathogens.  

 

Have you done your HACCP plan and risk assessments?  Those should indicate some Critical Control points like product temperature below 50F or time constraints for those temperatures as well as a need for increased aseptic protocols to prevent contaminating the equipment or packaging materials. 

 

Has production considered smaller batches so that less juice is exposed to the warmer temperatures for a smaller amount of time.  

 

Have you conducted any microbial modeling to show how much growth could occur for the current process taking all day?  I know this isn't USDA product but USDA only allows raw meat to sit in the 50-130F range for 6 hours before it is cooked to lethality.  I've had to model a lot of scenarios for a process that seared meat that then had to cool before it could be vacuum packed and had to wait to be batched to be cooked to lethality.  6 hour time windows were based on Sear time and line had to undergo sanitation every 3 hours (took 2-3hours in an oven to reach lethality).  

 

Have you considered testing with a Hygenia system or something like that would give you pathogen results same day?  

[Jimimacintire]

Your Fears are real.

https://en.wikipedia...remic syndrome.