7 Best Practices for Designing a Clean-in-Place System

A clean-in-place (CIP) system is a cost-effective and time-saving tool that rinses and washes the inside surfaces of food processing piping and equipment without mechanical disassembly. When designed well, a CIP system improves sanitation and enhances food safety while both simplifying the cleaning process for plant operators and reducing downtime. It automates what has traditionally been a laborious and time-consuming manual process of disassembling the piping, hand-cleaning each component and reassembling equipment.

In addition to lost revenue from halted production, improperly cleaned equipment can spread foodborne contaminants from batch to batch, which is dangerous to consumers and can lead to recalls that directly impact a company’s bottom line and reputation.

If you’re considering investing in a CIP system for your facility, it’s important to ensure you’re getting a design that is reliable and up-to-date. Your process design team should consider the overall needs of your operation, including changeover efficiency, water conservation and how the design will affect the complexity of the system.

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Should You Automate Your Packaging Process to Meet Growing Demand?

Food and beverage companies have seen a major increase in demand for their products in the past few years. The COVID-19 shutdowns changed consumer habits: Instead of dining out or ordering takeout, consumers spent more money having their groceries delivered, making their own meals at home and discovering new food and beverage products. 

This increase in demand is driving many food manufacturers to consider automating their packaging processes to improve efficiency. However, choosing the right level of automation takes time and research. There is no one-size-fits-all approach, since the level of implementation will impact your initial costs as well as your return on investment. 

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Hoses Are The Arteries of Food Production: Have You Selected Wisely?

6 takeaways from a recent Food Processing webinar

Like the human body is dependent upon veins and arteries to support a beating heart, so are food-grade hoses vital to safely connecting various stages of production to an uncompromised finished product.  

Safety is the number one priority of every food processor, and as such owners need to protect the safety of the food they handle every step of the way.

Selecting the correct hoses is essential to success, especially when there are a variety of hoses on the market created for a range of applications, from distilleries to dairies. The specification process becomes paramount: A poorly chosen hose can easily become a weak link in a plant’s food safety program, and even prove a danger to employees.

Degradation from fats and oils is a perpetual battle in maintaining the integrity of hoses, as are other conditions, such as functioning under high pressure as well as the high temperatures of the liquids they transport. Abrasion from machines and flooring within the facility is an added consideration that is sometimes overlooked. 

Food Processing magazine hosted a webinar in December discussing the importance of food-grade hoses for food production. Food Processing magazine editor-in-chief Dave Fusaro led a conversation on the topic alongside two experts from Parker Hannifin Corporation: Matthew Davis, business development manager of the Hose Products Division, and Dylan Shamakian, sales manager of Fluid Connectors Group Hose Products Division. 

Here are some of the most important things to consider when choosing the right hose to keep employees and products safe:

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Wraparound or RSC Packaging? How Case Design Can Impact Your Bottom Line

The accelerated expansion of e-commerce over the past five years paired with ongoing supply chain constraints have affected a crucial area of food and beverage processing: packaging.

The price of corrugated has been steadily increasing for years, but recent data from the Bureau of Labor Statistics reveals a sharp spike in cost since the onset of the COVID-19 pandemic. The cost of corrugated and solid fiber box manufacturing products reached an all-time high in February 2022.

In the face of significant price increases, owners must be strategic and intentional with material purchases and investments. This is the perfect time to reevaluate your facility’s current packaging process, including whether a change in case style could help optimize your process and save money.

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Your Checklist for Updating Your Facility’s Risk Management Program

Facilities, including food and beverage manufacturers, that use certain flammable and toxic substances in amounts that exceed threshold quantities must have a documented Risk Management Plan (RMP) per Environmental Protection Agency (EPA) requirements. Companies must update and resubmit their RMP at least every five years.

The EPA requires each facility to review all sections of their RMP, update where appropriate, and certify that the entire RMP is accurate and complete.

According to the EPA’s checklist, here are the key elements that should be reviewed for resubmission:

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Food Safety: 7 Pest Hotspots to Monitor

It’s no secret that food processing facilities, warehouses and distribution centers must maintain high standards to ensure food safety. If pests infiltrate a workspace, every area of production is at risk. Not only can pests carry diseases that threaten health and safety, an infestation could also lead to product loss, product recall, reputation damage, product liability lawsuits and a facility’s shutdown.

The Centers for Disease Control and Prevention (CDC) estimates nearly 48 million Americans get sick from foodborne diseases every year, while thousands more are hospitalized or even die from them. 

Understanding the threats, developing a robust pest prevention strategy and recognizing when it’s time to call for help are vital to protecting your operations, staff and customers.

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Are HEPA Filters the Best Choice for Your Facility?

Billions of particles can lace unconditioned air with dust, dirt, bacteria and viruses. That’s why your food plant’s air filters are crucial to preventing contamination and ensuring food safety. But when it comes to filtration, more isn’t necessarily better, especially when it comes to high-efficiency particulate air (HEPA) filters. HEPA filters are a necessity for many plant environments, but the level of filtration can vary, potentially making certain options expensive overkill for others.

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Preventing a Botulism Recall Before it Happens

Most of us were taught during childhood not to eat canned food from dented or bulging cans to avoid botulism poisoning. But according to the Centers for Disease Control (CDC), only 7% of botulism outbreaks between 1950 and 1996 were traced to commercially processed foods. The prospect of cans causing botulism poisoning carries such notoriety due to a widely publicized botulism outbreak in 1919 linked to a shipment of canned black olives that killed 18 people in a handful of states. This instilled widespread fear of botulism coming from canned goods into the psyche of American consumers — a fear that has been passed on from generation to generation.

In the aftermath of the outbreak, a consortium of canned food producers, scientific experts and government officials came together to develop strict regulations and establish state inspection services for canned foods processing. Not only did these regulations form the basis of what we now know as the nation’s food safety system, they restored the public’s confidence in canned foods and in the national food industry.

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Food Traceability: 5 Business Benefits When Switching from Manual to Digital Recordkeeping

In a recent post, I summarized the new traceability requirements recommended by the U.S. Food and Drug Administration (FDA). The proposed rule would require additional recordkeeping for those who manufacture, process, pack or store foods included on the FDA’s new Food Traceability List. 

The thought of new government regulations can often elicit groans from manufacturers, but rather than view this as another hoop to jump through, food and beverage companies should take a long view: It’s really an opportunity to improve product quality, boost efficiency and reduce manufacturing costs.

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The FSMA Proposed Rule for Food Traceability (in a Nutshell)

The U.S. Food and Drug Administration (FDA) is proposing additional traceability recordkeeping requirements for those who manufacture, process, pack or store foods included on the Agency’s new Food Traceability List. The proposed rule is a key component of its New Era of Smarter Food Safety Blueprint and would implement Section 204(d) of the Food Safety Modernization Act (FSMA).

The additional recordkeeping requirements would apply not only to foods specifically listed on the Food Traceability List, but also to products that contain these foods as ingredients. Let’s look at what’s included:

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