THE HYGIENE FACTOR – GETTING IT RIGHT FREE EBOOK DOWNLOAD

THE HYGIENE FACTOR – GETTING IT RIGHT FREE EBOOK DOWNLOAD

WHEN IT COMES TO THE
PRODUCTION AND MANUFACTURE OF FOOD, HYGIENIC EQUIPMENT DESIGN IS KEY.

Benjamin Franklin’s famous warning that ‘’Glass, china, and reputation, are easily cracked, and never well mended” applies to food manufacturing more than any other business. Especially given almost 50 million Americans a year are affected by food-borne pathogens.

Contamination issues, whether to pathogens or allergens, can be what ‘cracks’ the reputation of a chocolate and bar manufacturer. According to the FDA’s Reportable Food Registry in its most recent report, undeclared allergens increased from 30% to 47% of all reporting between 2009 and 2014, with the bakery and snack-related commodities the biggest source.

Since the introduction of the Food Safety Modernization Act, firms have been under increasing pressure to get their production processes right, to adopt a preventative rather than a responsive approach to hygiene.

It’s with this proactive approach to hygiene firmly front-of-mind that we’ve put together a new eBook: The Hygiene Factor. It’s an introduction to applying hygienic design principles to bar manufacturing equipment.

There’s lots of expert, technical advice available on hygienic design principles for food manufacturers from reputable advisers and organisations. What our guide provides is a pragmatic overview of what you need to consider in terms of hygiene when you are acquiring new bar and chocolate machinery. It’s based on PTL’s 30 years of experience PTL in working with bar and chocolate manufacturers.

The eBook includes these key areas:

  • The factors driving change – there’s been growing awareness over the last decade of the risks of foodborne diseases, and a significant regulatory response has followed.
  • The shift from response to prevention – investing in preventative action is a worthwhile investment, especially since there’s greater involvement from regulatory and advisory bodies in the area of hygienic processing.
  • What constitutes hygienic equipment design – the ten principles for food manufacturing equipment.
  • The PTL way – our equipment is designed to several international standards; our focus goes beyond the equipment itself, as sanitation and hygiene are primary factors for us.

For quality food manufacturers, hygiene is a key element that trickles down all the way through the manufacturing process.

Everything that is constructed, installed, manufactured, handled and cleaned is done with this key factor in mind: is it hygienic? What are the elements we see world class manufacturers focus on? Our new eBook is aimed at providing practical guidance around this critical area.

Safe food production starts and ends with hygiene. The reputation of a food manufacturer hinges on their ability to control hygiene to the highest standards and prevent contamination.

WHY HYGIENIC EQUIPMENT DESIGN IS CRUCIAL TO SOLVING A $10 MILLION PROBLEM

WHY HYGIENIC EQUIPMENT DESIGN IS CRUCIAL TO SOLVING A $10 MILLION PROBLEM

RISE OF THE ALLERGENS

As humans we are becoming increasingly susceptible to allergens. Research from the US Centers for Disease Control and Prevention estimate that 32 million Americans have food allergies, including 5.6 million children under age 18. That’s one in 13 children, or roughly two in every classroom.

The Food Safety Modernization Act (FSMA) includes prevention of allergen contamination as an explicit part of good practice when it comes to food processing – it’s not just about food borne pathogens. That’s because of an increasing awareness that a number of these can be life threatening. Allergens are usually grouped into the ‘big eight’ and all of their derivatives:

  • Peanuts
  • Tree nuts (almonds, cashews, pine nuts etc.)
  • Milk
  • Eggs
  • Crustaceans (crab, lobster etc.)
  • Fish
  • Soy
  • Wheat

In New Zealand, there were 66 food recalls in 2018, a sharp increase from previous years. A New Zealand Food Safety (NZFS) spokeswoman said this was due to the enhanced awareness of allergens and their potential impacts. The New Zealand Food and Grocery Council (FGC) says these recalls are costing New Zealand’s biggest manufacturing sector millions.

On a much larger scale the same trend is true for the US. According to the US Department of Agriculture Food Safety and Inspection Services, undeclared allergens are the leading cause of recalls across the country. Recent research by the Food Marketing Institute shows that the average cost of a recall to a food manufacturer can add up to $10 million in direct costs.

The proactive approach to allergen contamination, which the FSMA encourages, is to build good hygiene practice into the design and manufacture of food processing equipment.

So what sort of production equipment will minimise the possibility of contamination from pathogens or allergens, while enabling maximum production capacity?

At PTL, our equipment is designed to several international standards; our focus goes beyond the equipment itself, as sanitation and hygiene are primary factors for us. The materials we use to build the equipment always meet strict industry allergen standards. We make sure that:

Any equipment we design and build minimises or eliminates bacterial build-up. Our attention to detail, no matter how minute, ensures that, if properly cleaned, contamination is eliminated.

The materials we use to build the equipment always meet strict industry allergen standards.

We know that washing on-line can be troublesome. Our equipment offers fast and easy changeovers and wash-down options.

Cleaning is more contained with this method.

We ensure that all surfaces are smooth, sharp edges are removed, and operator safety is taken into account.

Non-product contact surfaces are also designed with hygiene in mind because even with the highest standards of containment, bacteria can still travel from one part of the facility to another.

We also provide direction and guidance on how best to clean the equipment post-deployment, to ensure that hygiene standards are always met.

Safe food production starts and ends with hygiene. Your reputation as a food manufacturer hinges on your ability to control hygiene to the highest standards, prevent contamination and eliminate allergen hazards.

If you’d like to find out more about PTL’s hygienic approach to equipment design, we’ve recently developed an eBook you might find interesting: The Hygiene Factor. Or, just drop us a line to start a discussion.

MODULAR – FLEXIBLE – HYGIENIC BAR MACHINERY

MODULAR – FLEXIBLE – HYGIENIC BAR MACHINERY

BAR MACHINERY DESIGNED TO ADDRESS YOUR PAIN POINTS

As a food manufacturer or co-manufacturing operation, absolute consistency is what you want from your bar production. When it comes to buying bar line equipment, you need something to meet your specific needs.

Barline machinery shouldn’t be one-size-fits-all. An ‘off the shelf’ barline won’t have the flexibility to adapt to the individual needs of a food processing facility. Every company has different requirements, meaning the equipment they use should be able to change to fit those requirements, not the other way around.

That’s why PTL offers barline machinery that’s modular, flexible and hygienic. We also focus on waste reduction capabilities while gaining production efficiencies.

PTL’s bar machinery offers the full process section of the line: forming, compression, sprinkling, multi-layering, cooling, cutting and enrobing. From full production lines to individual machines, PTL can design a tailored solution for a facility’s specific needs, including:

  • Forming – rollers, sprinklers, pickers, and sandwich systems
  • Cooling – tunnels and belt washers
  • Cutting – slitters, spreaders and guillotines
  • Enrobing – enrobers, melters, temperers and sieve systems

What sets PTL apart is a collaborative approach. We know the industry inside and out, and from the beginning we work together with our customers to meet and solve their specific challenges. We view it as essential to understand your business and equipment needs, and from your first contact with us, we make sure you’re an integral part of the process, which start with an introduction to your project team, who you’ll work with throughout to make sure the solution we design is tailored specifically for you. The steps they take you through are:

  • Confirmation of scope, timeline and milestones
  • Design
  • Manufacture
  • Factory acceptance testing (FAT)
  • Installation and commissioning by PTL technicians
  • Ongoing support and direct access to the technical team

Throughout the process, our technical team maintains an open communication channel. For us, it’s essential that you’re fully involved because then we can be sure the solution you’re getting is exactly what you need.

Once installed in your facility, the unique design of PTL equipment will help with your performance efficiency. Our bar line machinery and equipment includes features that reduce and even eliminate waste that is often typical in the bar manufacturing process. This means dollar savings and that there’s less likelihood of waste products building up to compromise hygiene. For example, the cutting feature has slitter side tracking, which minimises or eliminates side trim.

In terms of production output, our bar machinery includes features that improve that output; specifically cleaning reduction, changeover reduction and end product accuracy, again resulting in increased uptime and dollar savings.

The equipment is also designed with hygiene in mind. We understand that hygiene is an over-arching, all-important element when it comes to food processing, and it’s a vital governing factor in how we design and build bar line equipment. Anything we design and build minimises or eliminates bacterial build-up. Our attention to detail ensures that, if properly cleaned, contamination is eliminated. The materials we use to build the equipment meet allergen standards on a consistent basis, and we offer fast and easy changeovers and wash-down options.

Our equipment is backed up with technical expertise and support; it’s part of our core offering. We provide direct access to the expertise you need, and we’re highly responsive. But don’t just take our word for it; here’s what Fred Grep, Director of Engineering for Hearthside Food Solutions had to say about us:

“PTL’s equipment and approach to customer service enables us to create a competitive advantage. By being open to our modifications and design change requests, we can create superior solutions for customers and gain increased flexibility in our operations. Their equipment reliability and exceptional sanitary design are outstanding.”

Read more customer success stories here.

We believe firmly in a collaborative approach, and are committed to innovation when it comes to equipment design. We’re here to assist you through every aspect of your project, ensuring your food production facility is using the highest quality equipment possible.

You can find out more about our bar machinery here. Or, just drop us a line to start a discussion.