11 replies to this topic

[2005PR]

We did the microbiological testing in UHT and found that their is 2000 cfu/ml aerobic plate count in 200 ml tetrapack. And that packet was puffed. And there were presence of spores too. Is it possible that a pack can burst with this level of count?? If yes, how is it possible and what is the reason??
Thankss

[GMO]

Work through it step by step using RCA methods.  Rule things out one by one.  Look for evidence that you know that each step was compliant.  For example, can you get pasteuriser temperature traces?  How do you know there isn't shadowing on the disinfection?  How do you know you didn't have leakers?

[Tony-C]

Hi 2005PR,

 

 

Welcome to the IFSQN forums.

 

The count seems low for a blown pack.

 

If this was a whole batch then this is likely to be a process or sterility failure. It is also possible that there were thermoduric spores present in the raw material that have survived the process (you can test for those).

 

If it was a single pack then it is more likely damaged or poorly formed pack, you can do dye testing and destructive check of the packaging to check that out.

 

Kind regards,

 

Tony

[GMO]

Good point Tony.  Did you test for yeasts 200SPR?

[2005PR]

No

[GMO]

It might be worth specifically testing for yeasts if you still have the sample.  Also I'm not so sure that's a low count for a blown pack, at least without asking the lab.  They wouldn't have been expecting a count that high I assume and so would not have heavily diluted?  But I'm not a micro expert.

 

It would be really helpful to your RCA to understand what it was that has caused your pack to blow.  If it's something thermoduric as Tony has suggested, that points to a different issue than if it's something that should have been killed by your heat treatment.

 

Also I really would see if you can get the traces from the heat process.  It will at least show you if there was anything else happening, any temperature drop etc, even if you have failsafes for it.  

 

I'd basically work through the RCA step by step and get evidence that each was not an issue.  So things like:

 

Set up and initial disinfection / sterilisation processes
Heat process

Any diverts if they occurred

Steam supply to the line

Disinfection processes for packaging, no shadowing

Sealing

Any evidence that you can find that there was no intervention into any sterile zones of the machine

Environmental testing

Product testing from retained samples

 

I'm sure you can think of more.

[2005PR]

Yeast and Mould is absent in the UHT .

 

But spores present are 2, 40,000 cfu/ml and APC is 1500 cfu/ml. Is it possible still packet can blow with this amount of count? Also, do spore can contribute to the packet puffing??? If yes, then is their any refrence for that? help will be really appreciated.

[Tony-C]

Hi 2005PR,

 

You didn’t state if this was a whole batch or a few isolated packs? Also is this UHT milk?

 

Gas producing spore-forming bacteria in UHT products include Bacillus and Clostridium species. 

 

Kind regards,

 

Tony

[2005PR]

Hi 2005PR,

 

You didn’t state if this was a whole batch or a few isolated packs? Also is this UHT milk?

 

Gas producing spore-forming bacteria in UHT products include Bacillus and Clostridium species. 

 

Kind regards,

 

Tony

 

Hi Sir,

 

Actually, the problem is in the entire batch. Many packets are getting puffed daily and some seems to be normal, but it is visible that the packets are puffing slowly. Also, the sample is UHT Mango buttermilk. Spores are coming in high amount. Also, should we check acidophilus bacteria in this?? 

 And I want to ask if spores can convert to APC soon and can blow the pack or only spores are possible for gas formation and puffing of packets.

[GMO]

Spores will need to germinate and start growing for gas production.

 

Are you working through the potential root causes?  A whole batch issue suggests something pretty fundamental has failed.

[2005PR]

Spores will need to germinate and start growing for gas production.
 
Are you working through the potential root causes?  A whole batch issue suggests something pretty fundamental has failed.

Yes Sir. Trying to fibd out the root cause. Thermophilic spores are 150 cfu/ml and mesohiloc spores are 200000 cfu/ml

[Tony-C]

Hi Sir,

 

Actually, the problem is in the entire batch. Many packets are getting puffed daily and some seems to be normal, but it is visible that the packets are puffing slowly. Also, the sample is UHT Mango buttermilk. Spores are coming in high amount. Also, should we check acidophilus bacteria in this?? 

 And I want to ask if spores can convert to APC soon and can blow the pack or only spores are possible for gas formation and puffing of packets.

 

Hi 2005PR,

 

Buttermilk is notorious for hanging around for a while and being of poor microbiological quality, so is buttermilk powder. Which are you using as an ingredient and is that where you are finding the spore formers?

 

Kind regards,

 

Tony