The operators know it well, that magical button we push that cleans everything as if we alone possess supernatural powers!  But in fact, do we?  It’s been my experience that we do not.  While it’s safe to say the chemicals or heat are doing much of the work, it still is dependable on several factors as to whether a system is getting cleaned properly or not.  Take for example a cultured dairy plant that wanted to run a non-cultured product through their system.  After cleaning and sanitizing their system completely, the non-cultured product over shelf life started to exhibit the same flavor, smell and texture of some of the cultured products they made. Not only that, we were able to culture out of those products their original culture organisms. Without a doubt, they had biofilms of their product cultures adhering to the surfaces within their system.  Oddly enough, this was a surprise to them.  Then again, not many cultured plants will attempt to run a non-cultured product in a cultured product plant.  Whether you’re a cultured plant or a fresh product dairy processor, it’s possible to have low level biofilms in your systems, it just tends to be more obvious in fresh product plants (no competition).

Often, plants don’t pay any attention to their CIP systems, however there are a few things that come into play that you need to think about.  The power/speed of the circulation pump is critical to give you the volume of flow required to adequately clean and sanitize an enclosed CIP loop.  Restrictions and expansions in piping can change the velocity of cleaning solutions.  When cleaning volume of flow and turbulence are important.  If you are unsure you are getting proper flow, your chemical supplier should have an instrument that they can hook up to the outside of your lines to check the actual flow during CIP.  If you have restrictions/expansions, I recommend testing the flow in several different locations within the CIP loop.  And always remember the acronym TACT, which are the four tenets of cleaning:  Temperature of the solution, Action of flow through the CIP circuit (speed/turbulence), Concentration of chemical, and Time of contact.

It seems that people’s time is becoming increasingly valuable. Our team is acutely aware that the companies we serve seem to be doing more with less: less resources, less people, and with an ongoing wave of retirements, less widespread and institutional expertise. At the same time, the food industry continues to grow and develop. Food processing employees will continue to need training to generally operate, meet regulatory and audit requirements, and remain preferred places of employment.

With the above-mentioned limitations, it is more important than ever that employee training hits on the precise topics that are needed. We pride ourselves on building strong, long-term relationships with our industry partners to deliver best-in-class training to employees. Please reach out to us to create a training plan for 2023 and beyond. Below are several strategies we use to become your preferred training provider.

• Certificate Program: Our Dairy Foods Certificate Program is rounding out its 10-year anniversary and is the cornerstone of our programming. The certificate program is a great option for general employee training regardless of the type of dairy products that are made at a facility. It is also a fantastic tool for individual employee development and advancement. Courses are offered regularly, and many can be done on-site.
• Customized Training: While we have standard course offerings through our certificate program, some organizations need more curated content to fit their needs. We can use our existing programs as building blocks to make customized courses, or we can create something entirely new. In-person customized trainings are typically done on-site, but can also be offered on our campus. If a virtual platform is preferred, we can arrange for the content to be disseminated live, or through a self-paced virtual program. We ask that companies reach out to us with plenty of lead time for customized training so that we can develop the best content possible.
• Online or in–person: In this day in age, there doesn’t seem to be a one-size-fits-all approach to what works best. Online training has its clear efficiencies, but the in-person human connection can’t be totally replaced. Our team is willing to work with companies to find the right balance of online or in-person training to fit the needs of their culture.
• Onboarding training capabilities: There is plenty of literature stating that a strong onboarding system improves employee longevity and retention. While onboarding isn’t limited to food safety training, it is a key component of any food processing job. Our programs go into the “why” behind plant operations, and we have specific online programs that are ideal for required basic GMP and Food Safety Training.
• We get to know you: As trainers, there is a true benefit to knowing your audience and the environment your audience is working in. The more our team is able to interact with an organization, the deeper our understanding is, and that helps us curate the best content for the needs of those employees.
• The land-grant advantage: Cornell University is a land-grant institution, meaning that we are charged with advancing the lives and livelihoods of the state’s citizens through teaching, research and public service. As such, our Milk Quality Improvement Program and Food Safety Laboratory provide us with up-to-date, relevant research for industry, and our training team is able to take that knowledge and share it with industry through training. In turn, our extension team provides feedback to our researchers on the challenges that the industry is facing. This dynamic gives us and the companies we serve a key advantage. Companies are also able to take advantage of our laboratory services and consulting services, making us a one-stop shop for many of your food safety and quality needs.

Please reach out to lmf226@cornell.edu to schedule a consultation on any of your training needs.

Take Advantage of Our Dairy Foods Extension Services

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 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 Louise Felker at lmf226@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 the 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 – it is likely that we have the resources to help you.

Gram Negative Bacteria Infographic

Practical tip of the month

Nicole Martin

Gram-negatives provide more information about post-pasteurization contamination than coliforms

Do you want to improve your fluid milk quality? Start testing your finished product for total Gram-negative bacteria in addition to coliforms.

It’s not surprising that after a century of monitoring processed dairy products for coliforms, much of the industry has become adept at eliminating these contaminants. In our long-term monitoring program, the Voluntary Shelf-Life (VSL) program, we’ve seen coliform prevalence in pasteurized fluid milk steadily drop over the last 20 years. But that doesn’t mean that rates of post-pasteurization contamination (PPC) in fluid milk have declined, on the contrary, this is still a major issue for many fluid milk processors. So, you may be asking yourself if coliforms are not frequently detected in the finished product, how do we know there is PPC? The answer starts with the bacterial cell wall. There are two main types of bacterial cell walls, we call these Gram-positive and Gram-negative – named for Danish bacteriologist Hans Christian Gram who developed a method for classifying bacteria by their cell wall properties. The important difference between Gram-positive and Gram-negative bacteria as it pertains to PPC, is that Gram-negative bacteria are very heat sensitive, meaning they are easily killed by pasteurization. When Gram-negative bacteria are detected in pasteurized dairy products it’s very likely that they were introduced after the heat treatment – they are therefore indicators of PPC.

In current fluid milk supplies, the primary types of bacteria that are contaminating pasteurized fluid milk after pasteurization are non-coliform Gram-negative bacteria, especially Pseudomonas. In fact, a recent study from the Milk Quality Improvement Program determined that of 132 samples with PPC, Pseudomonas was the primary cause in 101 of those samples. Fluid milk processors who aren’t testing for Gram-negative bacteria are not likely to catch PPC when it happens – this leads to marketplace failures and unhappy customers.

If you’re convinced that monitoring your pasteurized fluid milk for Gram-negative bacteria is the right move, there are a couple of methods that you can use. The standard method for detection of Gram-negative bacteria uses Crystal Violet Tetrazolium Agar (CVTA), but this method may be challenging for processors without the capability of making traditional agar in-house. Fortunately, our team recently developed a method to detect Gram-negative bacteria in fluid milk by modifying the Coliform Petrifilm method. In short, simply incubating Coliform Petrifilm for an additional 24 hours (a total of 48 hours) then counting any growth, with or without gas production, provides a simple way to quickly determine if the product is contaminated with Gram-negative bacteria like Pseudomonas.

We’ve seen great results from fluid milk processors who implement Gram-negative testing in their overall quality program. If you have any questions on how to get started with this method, feel free to reach out for more information.

Practical Tip of the Month

Gas Production in Cheese

Cheesemakers are tasked with making a product that has a life of its own while also trying to be as consistent as possible. There are several types of issues that can arise that lead to unwanted gas production, ultimately causing cheese blowing, flavor and odor defects, and the creation of slits and cracks. These issues are costly to plants, and leave consumers with an unpleasant taste in their mouth (literally)!

The below table outlines several different types of these issues, their sources, the types of cheeses that are impacted, and hallmark characteristics of these gassy issues.

For further questions about cheese defects, please reach out to Dr. Sam Alcaine, alcaine@cornell.edu or Rob Ralyea, rdr10@cornell.edu.

Aljosa Trmcic

When I write articles and scientific papers, I find it difficult to do a proper critical review of my own work because I am so intimate with the sentences and ideas behind them that during review I often switch to just reciting the text by heart instead of truly reading it. What I need is a fresh pair of eyes to read the text for the first time and put every single detail to proper scrutiny. The same way I am intimate with my sentences and ideas, dairy industry workers are intimate with their environment, equipment and work. This intimacy means that any deviation from the usual state of their environment, equipment and work will either be immediately noticed, or it will never be noticed because it soon becomes part of the usual state. So, the same way I need fresh pair of eyes to review my text, the dairy industry workers need a fresh pair of eyes to review their environment, equipment and work.

First example is a problem with post-pasteurization contamination (PPC) that persisted in one of the fluid milk processing plants for months. Since the PPC problem did not seem sporadic and a relatively similar spoilage was observed across all fluid milk processed each day the multiple different fillers used by the processor were excluded as the main cause of the problem. Instead, the p-tanks, used to store pasteurized product before filling, were again and again identified as the most likely source, but what part of the p-tanks exactly was the source the workers were not able to determine. They determined each investigation that integrity of the p-tanks was not compromised in any way and the cleaning and sanitation procedures were appropriate. It took that fresh pair of eyes to determine that membrane pressure sensor, used to monitor product volume in the p-tank, was leaking and retained a lot of solid residues in the sensor port. While the sensor is designed to seal the port opening and have only the membrane of the sensor exposed to the product, it will only seal properly if the integrity of the rubber gasket surrounding the membrane is not compromised. Fresh pair of eyes identified that the sensor includes a gasket and needs to be checked and maintained regularly. Since then, the processor put the tank pressure/level sensors on their regular PM schedule and the rest is PPC history.

Second example is a food safety one; troubleshooting persistence of Listeria in a dairy processing environment. A processor with a five-star environmental monitoring program is dealing with persistent strain of Listeria in one the drains; 15 drains present in the processing environment only one continuously comes back positive for an entire year. It took again a fresh pair of eyes, or better yet fingers, to detect a small crack in the drain that leads to a large opening behind the drain wall. A niche that never gets scrubbed and provides Listeria with plenty of food to grow and persist in the environment. Since then, the processor replaced the drain to eliminate the crack as well as the open space behind it and rest is persistent pathogen contamination history.

So, when you look upon your perfect environment, equipment and work keep in mind the value of putting it all under additional scrutiny by taking another look with a fresh pair of eyes; and let us know if you want Cornell’s Dairy Foods Extension to be those eyes for you.

Aljosa Trmcic

On May 18 & 19, 2022 Milk Quality Improvement Program traveled to Austin, Texas to attend DairyTech;  a conference on dairy technology innovations organized by IDFA. What promises to be an annual event aligns perfectly with the mission of MQIP; as the leaders in Digital Dairy, we are working on assisting the dairy industry in adopting the technologies of tomorrow and help them enter the fourth industrial revolution popularly referred to as the Industry 4.0. IDFA featured at the conference some of the hot topics and success stories in dairy technology innovation and the common word connecting all of it was “data” and everything about how data can be captured, stored, analyzed, and used to provide added value to the company.

First hot topic of the conference was Data Analytics where one of the companies introduced a process of determining the optimal number, type, and quantity of products a food company should be manufacturing in any given situation. The data analyzed in this process covers all aspects of food processing including (i) the price and composition of all incoming ingredients, (ii) the ingredients and ingredient components needed to make each product, (iii) the costs of making each product, and (iv) the price of the product on the market. Using advanced statistics and computer modeling, for example machine learning and artificial intelligence, the company has been able to make recommendations on the optimal processing plan to minimize the cost and waste while maximizing the profit of the entre food company. MQIP has been taking similar statistics and computer modeling approaches to develop free tools that can be used to evaluate interventions that reduce spoilage and optimize the processing plan (click here for more details). Some of the open-access tools that are already available on our Digital Dairy page can be used to predict spoilage of both milk and cheese and there are others that are currently being developed.

One of the companies that participated in the conference introduced improvements to their Laboratory Information Management System (LIMS) and encouraged entire dairy industry to move away from paper-based records which are still very common in many aspects of the dairy production, processing, and distribution. While digitization, transformation of analog information to digital, can already be considered a beneficial step, the ultimate goal is for each operation and dairy industry as a whole to embrace digitalization. Digitalization goes a step further from digitization by transforming the process of collecting and using the data itself; for example, instead of writing the pH of your yogurt on your paper make-sheet, you would type it into the make-sheet on your tablet and eliminate the paper step, or better yet have pH meter display the measurement directly into your make-sheet on your tablet and eliminate the copying part altogether. LIMS and similar electronic systems represent the key to successful digitalization of the dairy industry and the base for using the true potential of predictive modeling. A vision MQIP has is that information captured in electronic systems like LIMS could immediately be used in the type of predictive models we are developing to more accurately predict characteristics of each product batch. For example, results of spore testing on raw milk, post-pasteurization testing on pasteurized milk, and electronic temperature recordings along the entire milk supply chain could be used to provide accurate information to the end consumer about expected shelf-life of that specific jug of milk they want to buy in the grocery store.

One downside of digital transformation and replacing paper records with electronic ones is that we are not just making all this information more accessible within our organization but also potentially to people outside of our organization that want to take and misuse this information. Cyber-attacks are real and dairy industry is not speared from this risk. Therefore Industry 4.0 and IDFA consider cybersecurity equally important aspect of digital transformation. The DairyTech conference featured several experts in cybersecurity who together provided some of the most important actions you can do when cybersecurity crisis hits, and they say the first step is to seek legal counsel and engage law enforcement as soon as possible. While knowing what to do during attack is important, as always, prevention and knowing what to do so the attack does not occur in the first place is even more important; the experts say that the cyber-attackers are not only motivated by the value of the data but also by the ease of getting access to this data. You can see it similar as motivation for stealing your bicycle; it is only a matter of time when it will get stolen if you don’t keep it locked.

New technologies including digital technologies offer number of benefits to the dairy industry and will be inevitable part of the overall transformation of the dairy industry, but these technologies will need to be safe, effective, and promising for the companies for them to invest and implement these new technologies. The Milk Quality Improvement Program is continuously searching for new technologies that might be of interest to the dairy industry and are also directly supporting the transformation by developing new digital solutions. Feel free to reach out to us with any questions or concerns by emailing Aljosa Trmcic at at543@cornell.edu or Rob Ralyea at rdr10@cornell.edu.

Efraim Shachter
Commercial Analyst

 We all enter a pre-formed world and want to both understand it and find a place in it that makes sense. For as long as I can remember, I have been interested in understanding how the everyday items with which I interact came to be. When I became old enough to surf the web, much of my free time became dedicated to researching the scientific processes and historical development of common foods, in particular. I became increasingly fascinated by cheese, due to the milestone in food preservation technology that its development represented, the many chemical processes involved in its production, and the iconic cultural significance that many types of cheese have throughout the world. In 8^th grade I taught a Food Science elective class to my peers during which we made mozzarella, butter, and ice cream, among other foods, and I would explain the scientific processes taking place. It was around that time that I visited a family friend’s dairy farm in Okeechobee, Florida and became intrigued by the dairy industry. I then began working at a summer camp; taking care of the barn animals, milking the goats, and making chevre cheese with the campers.

In undergrad at Cornell, I majored in Food Science, and then decided to minor in Business, after multiple advisory council members emphasized the need to integrate business objectives within product development. I had two internships: one was an R&D internship for Mondelez International and the other was R&D for a startup company in Israel called Amai Proteins. Amai is a designer protein company, and while I was there we were working on a sweet protein similar to Monellin for food industry applications. On campus, a few CALS friends and I decided to revive ChocTech, the chocolate and confections technology club, where we made chocolate from scratch, explored the historical relevance of chocolate, and learned to appreciate the unique flavor notes of chocolates made from cocoa sourced from different parts of the world. My ongoing interest in dairy manifested through working for a semester at the FPDL making cheese twice a week before my first class, volunteering in the teaching barn, muck raking and milking for the late, warmly remembered Dr. Michael Thonney, in exchange for 2 gallons of sheep milk to use to make cheese and yogurt in my apartment, and more formally by taking AEM 3040 Dairy Markets and Policy. At the time of my graduation, I was in the process of trying to facilitate the cheese club’s use of the FPDL to make a batch of a traditional sheep’s milk cheese, sourced from the teaching barn. Perhaps someone will continue this pleasantly unifying effort.

I am currently in a management training program at Dairy Farmers of America (DFA). My title is Rotational Commercial Analyst. I have completed a 7 month rotation in International Sales and now split my time between Springfield, Missouri and Kansas City, working as an R&D Scientist. My work consists of developing specialty dairy powders, dairy concentrates/pastes, and dairy flavors for companies throughout the world. I have also had the privilege to work with some innovative dairy beverages and snacks. These dairy products all add value to the milk provided by DFA’s farmers, which helps them to continue to produce their life-giving product.

Overall, at Cornell, I did not feel that my studies were particularly dairy focused. I felt that the Cornell food science program covered the gamut of food science topics fairly equally. As a sophomore transfer to Cornell, I was exempt from Professor Chris Loss’s FDSC 1101, a very popular class that fills up with seniors from throughout Cornell, after the reserved seats are given to Food Science freshman. Professor Loss kindly allowed me to audit the class and join a team for the ice cream development competition. During my team’s (“Currant Events”) pilot plant trial in the FPDL, I learned that some students get to actually work in the plant making Big Red Cheddar! I was determined to be one of those students and signed up for FDSC 4970 with Mr. Rob Ralyea. I learned a lot from working in the pilot plant and from my discussions about cheese and the dairy industry with Mr. Ralyea. Over the course of the rest of my time at Cornell, Mr. Ralyea encouraged me to apply for various Dairy awards and scholarships, three of which I was awarded, allowing me to begin to get to know the many faces of the dairy industry.