Category Archives: Extension Updates

Spring Brings Exciting Training Opportunities

Take advantage of the below spring workshop offerings and plan your training for the year by checking out our online course calendar. In addition to our these upcoming workshops, our Dairy Science and Sanitation, HACCP, and Vat Pasteurization courses are fully online with rolling admission. For questions related to these workshops, registration, or facility training options, please reach out to Louise Felker at LMF226@CORNELL.EDU

Open now, Limited Space Available: The Science of Cheese– The Science of Cheese workshop is designed for cheese manufacturers or others interested in the basic concepts of cheese making.  The online session is available beginning March 24, 2021, and the live video conference session will be held on April 21, 2021. This course covers cheese culture basics, raw milk quality, cheese defects, cleaning and sanitizing, affinage, food safety, basic cheese making techniques, a virtual cheese make, and sensory evaluation. Cheese samples for evaluation will be shipped to each participant’s location.

Opens April 12th: The Science of Yogurt– The workshop will provide participants with information in key areas related to milk quality and its impact on finished dairy products, product evaluation and defects, ingredients in cultured dairy products, and product processing and formulation. Online lectures are available beginning April 12th with an instructor-led virtual session on May 11th.

April 13th-15th: HTST Pasteurizer Workshop All required regulatory tests for HTST pasteurizers will be discussed and presented in a hands-on format to meet the training requirements for performing HTST system testing under the NY State Broken Seal Policy. Additional topics include UHT systems, dairy microbiology, product safety, and cleaning and sanitizing. This workshop will be held virtually.

April 20th: Dairy Lab Seminar This 4-hour online seminar provides dairy laboratory personnel with regulatory, procedural and scientific updates This program is designed for those actively working in dairy product testing and quality assurance programs, but may be of interest to Certified Milk Inspectors, plant receivers, and other plant personnel

May 12th-14th: Preventive Controls for Human FoodThis instructor-led online course will fulfill the FDA Requirements for FSMA Qualified Individual Training through the Food Safety Preventive Controls Alliance and AFDO. The course will include opportunities for participants to review the final rule and participate in classroom exercises to better understand the regulation. At the conclusion of the course, participants will receive a certificate issued by the Association of Food and Drug Officials (AFDO) certifying their training as a Preventive Controls Qualified Individual.

From Predictive Modeling to Plant Auditing, We’ve Got you Covered

In our last feature, we highlighted the diversity of services offered by our extension and laboratory teams that can help your organization. Our team members’ vast expertise in a broad range of categories makes these services possible. Our team’s collaboration with industry has allowed us to focus our skills and resources on what is needed in the field. If you have a question or would like to utilize our resources, reach out to any member of our team- chances are we can help. Read more about our team members and their expertise below:

  • Dr. Martin Wiedmann- Gellert Family Professor in Food Safety: With his training as both a veterinarian and food scientist, Martin’s programs focus on a comprehensive and interdisciplinary farm-to-table approach to food safety and quality. Martin also serves as co-director of the New York State Integrated Food Safety Center of Excellence. Extension efforts in the area of dairy processing and dairy microbiology focus on the production of safe and high quality fluid milk, cheese, yogurt, and other fermented dairy products in New York State. Food safety extension efforts cut across commodities and include training as well as applied field research with dairy, seafood, meat, and produce producers as well as processors as well as retail establishments. Expertise: Listeria monocytogenes, Salmonella, whole genome sequencing, environmental monitoring, microbial sampling and testing. He regularly visits plants to audit or help develop pathogen environmental programs or to do mock FDA swabathons and mock outbreak investigations. Companies also often ask him to be on calls with FDA, particularly if the calls involve Listeria and/or whole genome sequencing.

 

  • Dr. Nicole Martin– Associate Director of the Milk Quality Improvement Program: Nicole’s research interests include the transmission, control and detection of dairy-associated spoilage microorganisms and pathogens. Specific areas of focus include; i) characterization and tracking of sporeforming bacteria from the farm environment throughout dairy foods processing systems; ii) detection and evaluation of post-processing contaminants in dairy foods; iii) development of environmental monitoring programs for pathogens and spoilage microorganisms in dairy processing facilities, and; iv) development of molecular methods for characterization of dairy associated fungal contaminants. Expertise: Sporeforming bacteria, Indicator organisms, raw milk quality, processed dairy product quality, spoilage

 

  • Dr. Sam Alcaine– Assistant Professor:  Sam’s research program focuses on enhancing dairy sustainability through microbiology. His lab focuses on two key areas: i) the use of bacteria, phage, and their metabolic products (enzymes, bacteriocins, organic acids, etc) to control spoilage and pathogenic microorganisms and thus prevent dairy product loss and waste; and ii) the use microbial fermentations to transform underutilized or wasted dairy by-products into valued-added foods and ingredients.  Expertise:  Dairy microbiology; food safety; microbial fermentations; protective cultures and enzymes.

 

  • Dr. Aljosa Trmcic– Extension Associate: Al is an experienced food microbiologist specializing in dairy quality and safety with a demonstrated history of serving the dairy industry domestically and abroad through work in academia and government. As part of his support to the dairy industry, he is involved in research on reducing the spoilage of fluid milk and cheese with a large focus on how predictive mathematical modeling can help in this process. Expertise: Dairy microbiology; dairy processing; dairy chemistry; food fermentation; starter and protective cultures; food safety; environmental monitoring; mathematical modeling and risk assessment.

 

  • Kimberly Bukowski– Extension Professional: ​ Kimberly Bukowski is part of the Dairy Food Science Extension team at Cornell University where she provides leadership for the Dairy Foods Certificate Program, including program oversight, marketing, and development. Kim also provides Global Food Safety Initiative (GFSI) consulting and training to the industry. She is a certified Safe Quality Foods (SQF) Auditor and Trainer. She is a lead instructor for FSPCA Preventive Controls and FSVP and has performed workshops for the “Preventive controls qualified individual” and FSVP. Kim’s career in the dairy food industry includes working in dairy quality and processing, plant management, brand development, and building a facility to manufacture and sell ice cream.  She managed the Borden’s Ice Cream Plant, the Cornell Dairy Plant, Kimberly’s Ice Cream and has performed 3rd party audits in over 150 plants in the US. Expertise: Dairy plant auditing; food safety systems; GFSI-Safe Quality Foods; good manufacturing practices; dairy manufacturing; ice cream; FSMA Preventive Controls

 

  • Rob Ralyea– Senior Extension Associate: Rob offers individual assistance to processors and milk plant operators to help troubleshoot specific problems to improve the safety, quality, and consumer acceptability of milk and milk products. He works with NYS Agriculture and Markets in providing annual updates for dairy specialists, conducts training programs for Dairy Processing Plant Superintendents, provides resource information for small entrepreneurs starting dairy processing businesses involving cows, goats or sheep and participates on dairy industry committees concerned with equipment, processing and the environment. Rob also oversees the Food Production and Development Laboratory, Cornell University’s state-of-the-art food research space. Expertise: Dairy systems environmental microbiology, dairy processing microbiology, product processing and regulations; small-scale dairy production, food defense and risk assessment, FSMA Preventive Controls Trainer, recognized Process Authority, cheese processing, cheese judging, dairy product development.

 

  •  Anika Gianforte– Dairy Processing Specialist: Anika works directly with dairy processors to assist them with troubleshooting issues and developing food safety and quality tools for the production of superior and safe dairy products. She works with both new and established processors to communicate resources, develop programs, or provide training. She also focuses on assisting fluid milk manufacturers in expanding the shelf-life of their products through processing best practices. Anika works collaboratively with dairy processors, regulatory agencies, economic development agencies, and suppliers to promote economic development in dairy foods manufacturing and to deliver additional economic resources to dairy plants. Anika received her BS in Food Science and MPS in Food and Agricultural Economics from Cornell University. Expertise: Dairy foods systems; dairy product manufacturing; food safety systems; FSMA Preventive Controls Trainer; economic development

 

  • Karen Ospina– Dairy Processing Specialist: ​ Karen is a native of Colombia, and a graduate of Veterinary school from Universidad San Martin in Bogota – Colombia. She has a background in milk production quality control and uses her dairy experience to assist new and existing dairy processors in reaching their goals. Karen focuses on assisting dairy manufacturers with the development of improved good manufacturing practices and standard operating procedures, and assists in troubleshooting quality issues. She also works specifically with fluid milk manufacturers on continuous improvement of fluid milk shelf-life. Leveraging her Spanish language skills, Karen is also able to assist processors in New York and beyond by translating important resources and training material. By delivering dairy processing workshops in Spanish, Karen is able to reach an audience that is currently underserved.  Expertise: Spanish translation; food safety systems; good manufacturing practices 

 

 

Services to Know About in 2021

There are many services offered through our Extension Program, the Food Safety Laboratory, and the Expertise of our team that can help your organization, whether it’s to address an acute or persistent food safety or quality issues, to prepare for an audit,  to implement or improve continuous improvement or troubleshooting procedures, or to develop improved training programs for a team or for individuals that you want to grow in your organization. We can help you take things off your to-do list in 2021.

The list below encompasses many of the services we encourage businesses to take advantage of. If your organization is interested in any of the services listed below, or more specific support not outlined below, please reach out to Anika Gianforte at adz8@cornell.edu at any point, or submit a request through our website. We also encourage individuals and organizations to reach out to us with any questions or issues through our “Ask an Expert” platform. These questions will be directed to the appropriate team member. These services in combination with our workshop programming allow us to equip food businesses with knowledge and tools to flourish.

  • Lab for Molecular Typing: The lab offers a wide variety of technologies to subtype, identify, and characterize microorganisms to the genus, species, subspecies, and subtype level including Pulsed Field Gel Electrophoresis (PFGE) and Whole Genome Sequencing (WGS). Services are strictly confidential. We do not submit isolates or patterns to the CDC unless specifically requested by the submitter/customer. A considerable number of companies use our services to enhance their environmental monitoring programs or to help troubleshoot microbiological issues.
  • Pathogen Environmental Monitoring Validation Services: We are available to review or assist in the development of your pathogen environmental monitoring programs. We also validate environmental monitoring programs through plant visits with collection of samples; this will help you determine whether your program is designed and implemented correctly to identify any issues you may have; we can also design these visits to represent mock FDA “swabathons”, helping you ensure your company is ready for a visit by the FDA or another regulatory agency.
  • Process Authority Review: For those who require a scheduled process to begin processing a dairy food product, our team member Rob Ralyea will review your proposed process for food safety. This process review will then be submitted to your regulatory authority for their approval. We also will refer you to other Cornell process authorities if you need help with non-dairy processes.
  • Food Safety Plan Review: Our team members are instructors of both HACCP and Preventive Controls for Human Food curricula, and are qualified to review or assist in developing your facility’s food safety plan. This service is useful for facilities who have an existing plan, are in the process of developing a new plan, or who are modifying their HACCP plan to meet the requirements of a FSMA food safety plan.
  • Gap Audit: Gap audits are used to identify areas for improvement in your food safety or quality system, and are a great way to prepare for a GFSI audit. Kimberly Bukowski, who is also an SQF auditor, visits your facility to evaluate both documentation and personnel/operational practices to help identify gaps in your systems.
  • On-site consulting: Extension personnel visit and consult with dairy processors to help troubleshoot or improve the food safety and quality of their products. Examples include visits to assess technical issues including quality, spoilage, or food safety concerns, food defense plan review, and special project consultation, and documentation review.
  • Milk Quality Improvement Program: Offers targeted fee-for-service microbiological and sensory testing to assist dairy processors with troubleshooting quality issues. Services include testing for groups of spoilage organisms, identification and subtyping, defect identification, and more.
  • Sensory Evaluation Center: Services include Consumer Acceptability, Preference, and Discrimination Testing. In addition, the program provides consultations in all matters related to sensory product testing: appropriateness of particular test methods, study sample size, questionnaire design, statistics, and analyses, sample blinding, and serving sizes, to name a few.
  • Institute for Food Safety COVID-19 Resources: This website is consistently updated with relevant resources and information for the food industry. Resources include information on upcoming industry office hours, weekly videos, templates and trainings, and updates on laws, regulations, and regulatory guidance.
  • On-farm Rapid Response Team: Offers timely assistance to NY dairy processors to troubleshoot farm related quality and safety issues  ​
  • Alcaine Research Group (ARG) Dairy Lab: Quality control, waste reduction, and new product development opportunities
  • Food Processing Development Laboratory (FPDL): The Cornell Food Processing Development Laboratory (FPDL) is a licensed dairy plant in NY State and offers a unique food product development and manufacturing space that allows individuals and companies to perform research, develop new products, and start new food related businesses. Recognizing the diverse needs of industry, we offer an opportunity to utilize this facility under four different types of arrangements (see flyer here):
    1. Product Testing: For small scale pilot research projects that can be completed in 100 days or less.
    2. Cheese and Dairy Product Incubator: Designed for companies who do not have an existing facility, the FPDL can be used for initial product development and production.
    3. Cheese and Dairy Product Incubator (Level II): Designed for companies who do not have an existing facility, but have done prior product development or for companies that have an existing facility but require an outside facility for specialized needs.
    4. Contract Manufacturing and Product Development: For small scale manufacturing and pilot production (e.g. identifying processing issues, optimizing processes prior to large scale manufacturing, samples for market research).

 

If you need help with anything else that is not listed here, please also contact us – we probably have the resources to help you.

Dairy Extension Courses Move Online

Dairy Foods Extension, to continue to meet dairy processors training needs, has moved several courses to online formats during the current NYS ‘Pause.’

The online self-paced Dairy Science and Sanitation Workshop is tailored to dairy processing personnel and is designed to help participants understand the basic principles of dairy science and safety, as well as emphasize dairy processing establishment needs related to dairy sanitation to ensure that proper programs are conducted in their establishments. This course has rolling admission open beginning May 4, 2020. You may begin the course once your registration and payment are confirmed. Participants have 4 weeks to complete the course, either at home or their facility. Registrations are accepted at any time.

A 4-day (4 hours/day) instructor-led online FSMA Preventive Controls for Human Food Qualified Individual course will fulfill the FDA Requirements for FSMA Qualified Individual Training through the Food Safety Preventive Controls Alliance and AFDO. The course, scheduled for June 16-19, 2020 will include opportunities for participants to review the final rule and participate in classroom exercises to better understand the regulation. At the conclusion of the course, participants will receive a certificate issued by the Association of Food and Drug Officials (AFDO) certifying their training as a Preventive Controls Qualified Individual. Registration is open now.

Other courses scheduled for the spring and early summer have been rescheduled to autumn dates. Additional online programming is being added to the training roster. Visit our calendar for updates.

The Indsutry 4.0 Revolution by Sam Alcaine

Hey Siri…

Are you ready for the revolution? No, this isn’t some University Professor’s political opinion piece, it’s a question about the state of your business. At home you might be getting comfortable using your iPhone to track your daily exercise, or asking Alexa to dim the living room lights, but what happens when you get to your dairy facility? Some of you might be nodding knowingly and others suspiciously.

Many are calling this change Industry 4.0; it represents the culmination of interconnected yet dispersed computing technologies to make manufacturing smart. What does that mean? It means using arrays of linked sensors around the plant – ones that monitor key parameters like temperature, phage levels, or conductivity – to optimize your processing conditions to increase yields or dynamically manage inventory ordering for packaging and ingredients. It means analyzing the composition of the milk while it’s being collected at the farms and comparing it against the formulations of incoming product orders from your customers to decide the most efficient order and volumes of production. It means leveraging AI to systematically adjust sanitation parameters to learn how to improve the effectiveness of your environmental cleaning program. It is the buzz words of Internet of Things (IotT), Machine Learning, Enterprise Resource Planning (ERP), Artificial Intelligence (AI), Cloud Computing, Blockchain, Smart Sensors, Augmented Reality (AR) to list a few. These are of course big promises, and the devil is in the implementation. My lab is only four years old, and we have five computer systems for different analytical equipment, and it’s not always easy linking the data from them together. The challenge of meaningful connecting quality, production, and ordering systems in a facility that has added them piecemeal over 40 years is even bigger. It doesn’t mean it can’t be done, there are new businesses popping up every day to help you successfully make the change.

This new industrial revolution will change the dairy industry and how it is run. In fact, it already is, and so to those of you curiously nodding, I encourage you to start with a google search. If you’d like to know more, email us. If many of you feel there’s a need for a deeper dive with experts from the front lines of the revolution in dairy, let us know, and we can work on putting together a more formal seminar on Industry 4.0. Email me at alcaine@cornell.edu 

Hey Siri, set our appointment…

Employee Illness Plan- Kimberly Bukowski

Employee Illness Plan
By Kimberly Bukowski

 

Do you have a plan in place if an employee is sick?

When we think about Food Safety, the first word that comes to mind is Prevention. Along with prevention is a plan to make it happen. We are all quite aware of the headlines and the frightening Coronavirus outbreak. None of us want to think about this affecting our business, our employees, or our customers.

When we think about any illness that may affect our employees we need to have a system in place for making you aware of the issue. Do you have an Illness and Injury (Hygiene) Policy for your employees? Have they been trained? I have told my staff that I can solve any problem if I am aware of it. You will want to encourage your employees to report any illnesses and then as the owner, you can make the decision as to what you will do.  Here is an example of what I am referring to:

Illness and Injury Policy

1.0 Purpose

The purpose of the Illness and Injury Notification Policy is to provide guidance for employees and staff of the ____(Fill in the Blank)___ as to the appropriate steps to take to preclude transmissions of foodborne illness or communicable diseases and report physical cuts and sores by informing an appropriate manager or other “person-in-charge” (PIC). All steps will be taken to ensure the safety of our products by removing affected employees/staff from any production-related area.

2.0 Employee/Staff Responsibility

All employees shall follow the reporting requirements involving symptoms, diagnosis, and high-risk conditions. All employees subject to the required work restrictions or exclusions that are imposed upon them as specified herein and shall comply with these requirements as well as follow good hygienic practices at all times.

3.0 Policy

All employees and staff shall report if they are experiencing any of the following symptoms to their PIC.

   Fever   Sore throat with fever
   Vomiting   Lesions/Cuts
   Diarrhea   Shingles
   Jaundice

Employees/staff should also notify their PIC whenever diagnosed by a healthcare provider as being ill with any of the following diseases that can be transmitted through food or person-to-person by casual contact such as:

   Strep infection    Influenza
   Staph infection    Norovirus
   Norwalk virus    Escherichia coli
   Salmonellosis    Hepatitis A
   Listeriosis    Coronavirus

Employees are to maintain a high degree of personal cleanliness and are to conform to good hygienic practices when working in foodservice establishments. Employees are to wash their hands and exposed area of arms thoroughly with soap and warm water before starting work, and as often as may be necessary to remove soil and contamination.

4.0 Other Risk Conditions
Care must be taken when:

  • Exposure to or suspicion of causing any confirmed outbreak involving the above illnesses
  • A member of their household is diagnosed with any of the above illnesses
  • A member of their household is attending or working in a setting that is experiencing a confirmed outbreak of the above illnesses

5.0 PIC Responsibility
No person is to work in a food service establishment:

  • in a capacity which can result in contamination of food or food-contact surfaces with disease-causing organisms
  • while infected with a disease in a communicable form capable of transmission by food
  • who is otherwise a carrier of organisms that cause such disease
  • while afflicted with a boil or infected wound
  • Employees are to wash hands thoroughly after using the toilet, smoking, sneezing, coughing, eating, drinking or otherwise soiling their hands before returning to work. Employees are to keep their fingernails clean and neatly trimmed.
  • The PIC will continue to promote and reinforce awareness of this policy to all food employees on a regular basis to ensure it is being followed.
  • Training will be performed by the _____(Fill in the Blank)______ initially for new employees and annually thereafter

Implementing a guidance document and training your employees are the first steps you can take to help prevent any contamination of your business, employees and customers. And to quote my mom when I was growing up, “Did you wash your hands?”.

New Team Member of Dairy Foods Extension: Aljosa “Al” Trmcic

Welcoming Aljosa Trmcic as
the Dairy Program Extension Associate

We are pleased to welcome Aljosa- or Al as we like to call him- to Cornell as the new Dairy Program Extension Associate where he will be immersed in all our extension and research activities including fluid milk Voluntary Shelf-Life (VSL) Program, our oldest program that marks the beginning of Milk Quality Improvement Program and Dairy Extension work at Cornell University.

Al is not all that new to Dairy Foods Extension.  During his time as a Postdoctoral Associate in Cornell’s Milk Quality Improvement Program he contributed to a number of on-site and off-site workshops as well as worked with two artisan cheese producers as part of Cornell’s dairy business incubator. Al is returning to join our team after working for nearly four years in different academic and government roles in Canada one of which was as a Food Safety and Dairy Specialist at the British Columbia Centre for Disease Control.

Dr. Aljosa Trmcic received a degree in Food Technology from University of Ljubljana, Slovenia and a joined doctoral degree in Food Biotechnology from both University of Ljubljana and AgroParisTech, France. His is passionate about all aspects of food microbiology and has more than 10 years of research experience working with beneficial, spoilage and pathogenic microbes relevant to the dairy industry.

Although his work has involved a lot of detailed science he made sure to always remain connected to his basic training as a Food Technologist and the Dairy Industry. Through his work in four different countries he has been involved in different aspects of teaching, assessing, standardizing and implementing dairy production procedures as well as developing different dairy products.

 

Recent Publications: January 2020

Lawton, M.R., K.G. Jencarelli, S.M. Kozak, and S.D. Alcaine. “Short Communication: Evaluation of Commercial Meat Cultures to Inhibit Listeria Monocytogenes in a Fresh Cheese Laboratory Model.” Journal of Dairy Science, 2019. https://doi.org/10.3168/jds.2019-17203

Li, Theresa, and Robin Dando. “Impact of Common Food Labels on Consumer Liking in Vanilla Yogurt.” Foods 8, no. 11 (November 2019): 584. https://doi.org/10.3390/foods8110584

Liu, Yaowei, Wenjin Zhang, Keyu Wang, Yulong Bao, Joe Mac Regenstein, and Peng Zhou. “Correction to: Fabrication of Gel-like Emulsions with Whey Protein Isolate Using Microfluidization: Rheological Properties and 3D Printing Performance.” Food and Bioprocess Technology, November 5, 2019. https://doi.org/10.1007/s11947-019-02356-1

‘Stockinghall’!!! BEST IN SHOW at the American Cheese Society Convention – 2019!

‘Stockinghall’!!! BEST IN SHOW at the American Cheese Society Convention – 2019!

In 2014, Murray’s Cheese coordinated with Cornell and Old Chatham Creamery on the idea of developing an original cheese recipe. After some trial and error (which all product development entails), we hit it out of the park–using milk from Old Chatham Creamery, the clothbound cheddar we know as ‘Stockinghall’ emerged.   This award-winning cheddar, named ACS 2019’s Best in Show, was the first Best in Show win for any NY cheese in the 36 year history of the contest, beating out almost 2,000 entries this year from across the western hemisphere. This work was all done in the Cornell University’s Food Processing & Development Laboratory (FPDL) and up until September of this year, ‘Stockinghall’ has been made at Cornell (in October it transitioned to the new Old Chatham plant in Groton, NY). Other cheeses developed in the FPDL have won both State and National awards, but we cannot disclose the company names because of Non-Disclosure Agreements we have in place.

The FPDL is housed within the Department of Food Science (College of Agriculture and Life Sciences) in Stocking Hall on Cornell’s Ithaca, NY, campus. It is a fully licensed dairy plant inspected by NY State Department of Agriculture and Markets. The FPDL serves as a statewide center for food and dairy product development and cutting-edge food processing research. It is a key resource supporting the long-term sustainability of value-added agricultural businesses (and their suppliers) across New York State. As such, our goal is to help promote and grow dairy processing opportunities in New York State and to provide opportunities for agricultural producers to develop and market value-added products. The successful establishment and expansion of local, value added products also encourages the creation and expansion of other local businesses (farmer’s markets, restaurants, agri-tourism, marketing, etc.).

We know that starting a dairy plant costs a lot of money in facilities, equipment, and all that goes along with putting together a proper food processing facility. To facilitate the success of dairy start-up companies and promote growth in the dairy industry, we offer a dairy processing incubator program. To qualify, you must be in NY State and be a small dairy business or be aspiring to start a business in dairy processing in NY. This is not an open ended proposition, as you must sign agreements with Cornell University indicating your desire to start and grow a dairy processing-type business. You must have an approved business plan in place within 3 months of starting, and you must be planning to move out of our facility into your own facility within 12-18 months. You provide the labor (although we do have Food Science students/interns available to assist in production), and for set fees, we provide equipment for you to use. We will help with small product development projects provided you already have the concept. If you want us to do full blown product development, the fees go up commensurate with the work.

We also provide contract manufacturing support to start-up companies as well as support for established manufacturers who aim to develop new and innovative products. Examples of product development and research projects supported by the FPDL include dairy-based puddings, drinkable yogurts, fermented dairy beverages, flavored egg nog and other dairy related products. Our small-scale equipment makes the FPDL excellent for product formulation test runs that mimic real life production. These smaller batches are also conducive for consumer and shelf life testing.

We have the capability of manufacturing most dairy (and some non-dairy) products using a wide variety of operations. We have the only university operated Greek yogurt separator in the country, and also have the ability to pasteurize, ultra-pasteurize, evaporate, spray dry, and ferment (cheeses, yogurts, etc.). If you are interested in any of these programs or would like more information on the facility, please contact Rob Ralyea at rdr10@cornell.edu.

“From the Trenches”- Part 2
What does it mean if my team or a regulatory authority finds a pathogen in my plant?

By Rob Ralyea
Read Part 1 here

It’s Friday afternoon, and you (and your food safety team if you have one) have just put the finishing touches on your Food Safety Plan (FSP). An item of specific concern to you are the requirements for sanitation preventive controls. Sanitation preventive controls are procedures, practices, and processes to ensure that the facility is maintained in a sanitary condition to minimize or prevent hazards such as environmental pathogens, hazards from employees handling food, and food allergen hazards. So the question arises in your mind, how do I do that?

Well, first a cleaning and sanitation record would have to be generated. So, for every piece of equipment, surface, etc, there should be a record of who cleaned what and when. There should also be a record of who verified that it was done and done properly. Here is an example form, but any form that you develop and use must fit your situation.

 

That brings us to the definition of verification, which are activities required to ensure that preventive controls are consistently implemented and effective in minimizing hazards. Examples of verification activities include scientifically validating process preventive controls to ensure that the control measure is capable of effectively controlling an identified hazard and calibrating (or checking the accuracy of) process monitoring and verification instruments such as thermometers. Verification activities also include reviewing records to ensure that monitoring and corrective actions (if necessary) are being conducted. Verification activities must be documented. Product testing and environmental monitoring are also possible verification activities, required as appropriate to the food, facility, nature of the preventive control, and the role of that control in the facility’s food safety system. Environmental monitoring is required if the contamination of a ready-to-eat food with an environmental pathogen is a hazard the facility identified as requiring a preventive control. So, if you have a sanitation preventive control identified in your FSP, you will need an environmental monitoring program.

The next questions are, what does my pathogen environmental monitoring (PEM) program look like? Where do I sample? How many samples do I need to take? What pathogen am I looking for? Am I only looking for one pathogen or several? There is no ‘book answer’ to any of these questions. They are all plant specific. Your PEM sampling is a complicated task and can’t be completely covered in an extension newsletter article. Volume of samples is generally based on square footage, but if you are a very small producer, going bankrupt via laboratory bills because you are taking voluminous numbers of samples doesn’t make sense either. Truth be told, that could be said for large plants as well. Sampling smart is the best solution which means taking samples that are going to be indicative of the true pathogen content of the environment.   Generally speaking, most dairy plants should at a minimum, be looking for Listeria monocytogenes or in some cases Listeria species at a minimum. Some plants may also consider looking for other pathogens like Escherichia coli or Salmonella species, depending on what they might be doing in their plant (if you use ingredients that might bring these into the plant, for example). The very first thing you should do is put in place an SOP that outlines what actions you will take if you find a sampling location that is positive for a pathogen and then follow it when the need arises.

Finding a pathogen in the plant environment is not the end of the world. As a matter of fact, if it’s in the plant, you want to find it and eradicate it before it can spread. As mentioned, you should have a protocol on how to react to positives. If it’s in the environment itself, you don’t have to notify anyone, but you do have to react to the finding. If you do finished product testing or testing of Zone 1 surfaces (Food Contact Surfaces) and have a positive finding, you should notify the regulatory authority. If the product has left your control, you are required to notify the regulatory authority. This brings up the philosophical argument, to do or not to do finished product/Zone 1 testing. First, if your PEM program is working, you might find target organisms sporadically in zone 3 or zone 4 locations.   Your goal is to find it and get rid of it before it ever gets to zone1/zone 2 locations. In that case, technically, you should never find a target organism in finished product or in a zone 1 location. If you do, your program is not well designed and is obviously not working. Then again, if you don’t test finished products or zone 1 locations, you will not find positives. Meanwhile, the FDA tests finished products from store shelves randomly, and they have found positives. That is NOT how you want to find out that your PEM program is failing. Having said all of that, the company has to decide whether they want to do finished product/zone 1 testing. Currently there is no legal requirement to do it.

If you want more in-depth training on the topic of Pathogen Environmental Monitoring, there will be a workshop at Cornell University December 5-6. You can enroll here: https://dairyextension.foodscience.cornell.edu/content/1205-0619-pathogen-environmental-monitoring-workshop-0/