Food processing facility sanitation is an integral part of good manufacturing
practices. Effective sanitation aids in ensuring the wholesomeness, safety, and
quality of shell eggs. The negative impacts on food safety and egg quality
are a result of microbial growth. Research has shown that ineffective
cleaning and sanitation practices or programs can lead to reduced quality
duration or potential product contamination. Residual microorganisms
can lead to egg spoilage or foodborne illness. Most of this training series
will focus on the United States Department of Agriculture Agricultural
Marketing Service pre-operational sanitation inspection expectations.
However, remember that the Food and Drug Administration has oversight of consumer
shell eggs in the United States as stated in 21 CFR 117.
Additionally, customers accrediting organizations (such as Safe Quality Food,
British Retail Consortium Global Standard and others) as well as state and
local regulatory agencies may have additional facility sanitation
expectations that can impact your facility. AMS sanitation requirements are
meant to protect the integrity of the USDA grademark
by requiring additional sanitation expectations at facilities that
utilize AMS voluntary grading services. To meet these goals,
AMS inspectors will assess for voluntary grading program requirements during the
pre operational sanitation inspection and throughout processing operations by
utilizing organoleptic inspection assessments. While AMS may review
microbial test results as part of certain export programs, AMS does not
conduct nor require swabbing or biological testing during routine
sanitation assessments. So what is organoleptic inspection? Organoleptic
inspection assessments include sight, smell, and touch. However, microbial
growth will not always be seen, smelled, or felt.
>> Critical areas are defined as
equipment with potential surface contact with eggs or come in contact with wash
water or air blown to dry the eggs. Non-critical areas are defined as areas
that are not likely to imminently affect product quality. Non-critical does not
mean it is not important. Non-critical unsatisfactory conditions
should be addressed after the processing line has been started unless unable to
safely do so during processing. Egg processing facilities shall be
thoroughly clean at the end of each operating day. The term reasonably clean
is applied during the egg processing shift to indicate that equipment and
processing areas are maintained with minimum egg meat accumulation. More
explanation of these terms is presented in the introduction module. In this
module, examples will be used to illustrate the unsatisfactory and
satisfactory condition of various components associated with the farm belt.
While the farm belt is not considered critical during pre operational
sanitation inspection, it is important to remember that egregious conditions or
reoccurring unsatisfactory conditions of a non-critical element can become
critical. Beginning January 2020, all portions of
the farm belt within the egg processing facility must be available and
accessible for assessment during pre operational sanitation inspection.
The farm belt within the egg processing facility must be clean each day prior to
processing. The design of farm belts to bring eggs into the facility can be
simple or complex. The relatively simple and straightforward farm belt enter the
facility progressing directly to the processing line. Complex farm belts
may encompass multiple belts of varying lengths that enter the facility
separately before joining at the accumulator. Understanding the nuances of
general design will assist in both successful cleaning and inspection of
farm belts. Farm belts can be comprised of various materials including plastics,
metal, and rubber. These materials may be shaped as rods, grid, or solid sheets. Each
type of material presents unique challenges for cleaning. Facility
management should determine the appropriate method to clean the
respective belting material. More information on accumulator sanitation
and expectations is available in the accumulator training module. AMS
personnel must be able to assess farm belts in a safe manner.
Temporary elevated platforms used in sanitation assessments should be
designed to safely support personnel by reducing the risk of falling and
preventing unstable conditions. Common ladders and stools not specifically
designed for safety in the food processing environment should not be
used for assessment. Facilities with overhead belting should work with AMS
local supervisors to come up with a safe assessment method for their particular
system, which could include utilizing cameras, video, or other assessment
methods. The farm belt will fall under AMS sanitation requirements from the
point it enters the facility. Curtains and mechanical components present as the
farm belt enters the processing facility need to be well maintained and kept in a
clean condition. Areas that are used to store carts, chemicals, or other
processing equipment are considered to be part of the processing facility. Farm
belts which traverse through these areas must be clean
each day. Also, non-solid barriers such as ropes, chains, or painted lines are not
sufficient to delineate farm and processing areas. If egg processors or
inspectors have questions regarding which portions of a farm belt are
covered under pre operational sanitation inspection, the local AMS supervisor
should be consulted. The farm belt should be cleaned and assessed from all sides.
This would include the frame, belt, and guards as well as any drip pans,
drivetrains, legs, or mounts used to suspend the farm belt. In this example,
one side of the farm belt is clean and satisfactory. Walking around to the other
side and viewing the same section of the belt shows unsatisfactory conditions. It
is less than ideal to utilize the space under the farm belt as storage.
When items are stored under the farm belts, steps must be taken to mitigate debris
from soiling stored items and flooring. Appropriate mitigation may include the
use of metal pans or other barriers. However, these barriers must be
maintained in a clean condition as we see here.
Large amounts of egg, shells, and organic matter left in the pans overnight or
before the next day's processing would be an unsatisfactory finding. This could
lead to an unsatisfactory critical finding if allowed to persist. Paper
barriers would also be suitable to mitigate debris or soiling underneath
the farm belt. Similar to other materials, paper should be cleaned prior to the
start of processing. This is a satisfactory non critical finding for
paper under a farm belt. Copious amounts of soiling would be unsatisfactory
non-critical. If the surface appears to have not been cleaned, it can
be raised to critical and asked to be corrected before processing begins. Farm
belts may be designed in a manner that makes assessment challenging. Here we see
a stacked system with approximately seven incoming farm belts that could be
difficult to assess. USDA personnel should work with plant management and
their supervisors to determine acceptable assessment methods. New
construction design should allow for easy assessment of the farm belt within
the processing facility. USDA supervisors can be contacted with any questions. Not
all farm belts will be new in appearance. The expectation is simply that they
remain free of excess debris and organic material. This farm belt has experienced
wear and discoloration, but is still satisfactory for pre operational
sanitation standards. This example shows a well worn polymer farm belt. While the
discoloration would not be cause for unsatisfactory findings, the large amount
of organic matter under the eggs and along the edge of the belt would be
cause for an unsatisfactory finding on a non-critical area. When assessing the
underside of the farm belt, be sure to evaluate tensioners, crossbars, braces,
feet, gears, and drive belts. The build-up of organic material on the tensioner in
the front right would be an unsatisfactory non critical finding.
It is understood that farm belts may have small amounts of dust or debris. This
would not be cause for an unsatisfactory finding. The current belt is an example
of a satisfactory non-critical finding. Here we see
a rod style farm belt that has residual egg meat on the rods and structural
components. This would be an unsatisfactory non critical finding
during pre operational inspection. Curtains associated with farm belts
should also be cleaned. Curtains such as this one that are worn or have
build up are unsatisfactory and non-critical. This curtain should either
be cleaned or replaced. Farm belts that have built up of dust, dander, and other
materials from the houses are unsatisfactory.
Here we see rods that have organic buildup flaking from their surface. This
is an unsatisfactory finding in a non critical area. The portion of the farm
belt in this area of the facility should be more thoroughly cleaned
during the next cleaning and sanitation cycle. Here we see another unsatisfactory
finding due to the residual egg meat on the portion of farm belt present in the
processing facility. Not only can we see egg meat on the belt surface, we also see
egg meat accumulation on the Teflon transition plate before the transfer
plate. This would be unsatisfactory non-critical. Any farm belt mechanical
structures within the processing facility must also remain in a clean
condition. The mechanical unit on the left is an example of a satisfactory
non-critical finding. The unit on the right has buildup and debris which would
lead to an unsatisfactory non-critical finding. Tarnished, non pitted surfaces
are not considered unsatisfactory during pre operational sanitation inspection.
This is another example of a polymer farm belt that has been satisfactorily
cleaned and is readily accessible for the portion within the processing
facility. While the farm belt is considered non-critical during
pre-operational sanitation inspection, it is important for the transport of eggs to
the processing line. When unsatisfactory findings occur, extra care should be
taken during the subsequent cleaning shift to ensure the portion within the
processing facility is satisfactory for the next day's pre operational
assessment. Continued unsatisfactory findings or egregious conditions could
elevate findings to critical, preventing the start of the processing line.
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