EFFECTIVENESS OF CLEANING REGIMENS FOR REMOVING PEANUT, MILK AND EGG RESIDUE FROM PILOT-SCALE CEREAL BAR AND MUFFIN PROCESSING LINES

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Description

Allergen cross-contact can be caused by inadequate cleaning of shared processing equipment. The objectives of this project were to evaluate the effectiveness of cleaning regimens on removing allergenic food residue from a pilot-scale cereal bar and muffin processing lines and measure the levels... Show moreAllergen cross-contact can be caused by inadequate cleaning of shared processing equipment. The objectives of this project were to evaluate the effectiveness of cleaning regimens on removing allergenic food residue from a pilot-scale cereal bar and muffin processing lines and measure the levels of allergens (peanut, milk and egg) transferred into allergen-free (control) cereal bars and muffins processed on an inadequately cleaned processing line. Another object was to investigate the analytical methods used (conventional ATP, sensitive ATP, total protein and lateral flow) to evaluate the effectiveness of allergen cleaning procedures. Cereal bars and muffins containing peanut flour, nonfat dry milk and egg powder (1000 or 5000 􀈝g/g for cereal bar and 100 or 5000 􀈝g/g for muffin) were manufactured on a pilot-scale processing line followed by one of four cleaning regimens: 1) push-through with control cereal bar dough or muffin batter, 2) scraping the equipment surfaces with rubber scrapers, 3) a rinse with hot (54-60°C) water until “visibly clean” and 4) a full cleaning cycle with alkaline detergent followed by use of a sanitizer. The adequacy of the cleaning treatments was assessed by swabbing locations (3 swabs/location) on the processing lines (cereal bar: mixer, depositor, conveyor belt; muffin: mixer, depositor, nozzle) followed by analysis of swabs with peanut-, milk-, and egg-specific lateral flow devices (LFDs). The cereal bar crosscontact study involved obtaining samples of the sheeted control dough transferred over the conveyor belt at 2 min intervals over a 30 min time span, or after approximately 100 kg of cereal bar dough was processed over the line previously contaminated with 5000 􀈝g/g allergen-incurred cereal bars. Similarly, allergen cross-contact from the contaminated muffin processing line into control muffins was measured by collecting xi 750g of control muffin batter until a total of 36 kg of batter were deposited. This was followed by allergen analysis of cereal bar and muffin samples (before and after baking) using quantitative ELISA kits. Results of LFD tests indicated that hot water rinse was effective for cereal bar processing line but not for the muffin line. Only the full cleaning cycle was effective at removing allergenic food residues for both processing lines. During the cross-contact study, substantial levels of peanut, milk and egg were detected in samples obtained both before and after baking. Cereal bar dough produced on the contaminated lines contained up to 71.9 ± 48.9 μg/g egg, 23.3 ± 1.3 μg/g milk, and 5.0 ± 0.4 μg/g peanut and as high as 2929.7 ± 98.8 μg/g egg, 1894.9 ± 87.7 μg/g milk, and 193.2 ± 20.6 μg/g peanut in muffin batter. Overall, these results illustrate the importance of validated cleaning protocols for preventing allergen cross-contact on shared processing lines.
M.S. in Food Safety and Technology, July 2014 Show less

Details
Department

NCFST / National Center for Food Safety and Technology

Title

EFFECTIVENESS OF CLEANING REGIMENS FOR REMOVING PEANUT, MILK AND EGG RESIDUE FROM PILOT-SCALE CEREAL BAR AND MUFFIN PROCESSING LINES

Institution

Illinois Institute of Technology

Creator(s)

Zhang, Xi

Date

2014
2014-07

Description

Allergen cross-contact can be caused by inadequate cleaning of shared processing equipment. The objectives of this project were to evaluate the effectiveness of cleaning regimens on removing... Show moreAllergen cross-contact can be caused by inadequate cleaning of shared processing equipment. The objectives of this project were to evaluate the effectiveness of cleaning regimens on removing allergenic food residue from a pilot-scale cereal bar and muffin processing lines and measure the levels of allergens (peanut, milk and egg) transferred into allergen-free (control) cereal bars and muffins processed on an inadequately cleaned processing line. Another object was to investigate the analytical methods used (conventional ATP, sensitive ATP, total protein and lateral flow) to evaluate the effectiveness of allergen cleaning procedures. Cereal bars and muffins containing peanut flour, nonfat dry milk and egg powder (1000 or 5000 􀈝g/g for cereal bar and 100 or 5000 􀈝g/g for muffin) were manufactured on a pilot-scale processing line followed by one of four cleaning regimens: 1) push-through with control cereal bar dough or muffin batter, 2) scraping the equipment surfaces with rubber scrapers, 3) a rinse with hot (54-60°C) water until “visibly clean” and 4) a full cleaning cycle with alkaline detergent followed by use of a sanitizer. The adequacy of the cleaning treatments was assessed by swabbing locations (3 swabs/location) on the processing lines (cereal bar: mixer, depositor, conveyor belt; muffin: mixer, depositor, nozzle) followed by analysis of swabs with peanut-, milk-, and egg-specific lateral flow devices (LFDs). The cereal bar crosscontact study involved obtaining samples of the sheeted control dough transferred over the conveyor belt at 2 min intervals over a 30 min time span, or after approximately 100 kg of cereal bar dough was processed over the line previously contaminated with 5000 􀈝g/g allergen-incurred cereal bars. Similarly, allergen cross-contact from the contaminated muffin processing line into control muffins was measured by collecting xi 750g of control muffin batter until a total of 36 kg of batter were deposited. This was followed by allergen analysis of cereal bar and muffin samples (before and after baking) using quantitative ELISA kits. Results of LFD tests indicated that hot water rinse was effective for cereal bar processing line but not for the muffin line. Only the full cleaning cycle was effective at removing allergenic food residues for both processing lines. During the cross-contact study, substantial levels of peanut, milk and egg were detected in samples obtained both before and after baking. Cereal bar dough produced on the contaminated lines contained up to 71.9 ± 48.9 μg/g egg, 23.3 ± 1.3 μg/g milk, and 5.0 ± 0.4 μg/g peanut and as high as 2929.7 ± 98.8 μg/g egg, 1894.9 ± 87.7 μg/g milk, and 193.2 ± 20.6 μg/g peanut in muffin batter. Overall, these results illustrate the importance of validated cleaning protocols for preventing allergen cross-contact on shared processing lines. Show less

Type

Thesis

File type

application/pdf

Access

Restricted Access

Rights

In Copyright
http://rightsstatements.org/page/InC/1.0/

Identifier

http://hdl.handle.net/10560/3379

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