QUALITY & SAFETY

HAZARD ANALYSIS AND CRITICAL CONTROL POINT (HACCP)

The Hazard Analysis Critical Control Point (HACCP) system is a fundamental and proactive approach used in food and beverage processing industries to ensure food safety. It involves the systematic identification, assessment, and control of physical, chemical, and biological hazards during production, processing, and distribution stages.

Compliance with HACCP standards is often a regulatory requirement in many jurisdictions and is recognized globally as a critical tool for maintaining food safety.

PRINCIPLES OF HACCP

In order to reduce product contamination, food and beverage manufacturers in Europe are required to practice hygiene legislation (EU 852/2004) based around the principles of the Hazard Analysis of Critical Control Points (HACCP) framework.

The HACCP system is based on seven principles: conducting a hazard analysis, identifying critical control points (CCPs), establishing critical limits for each CCP, monitoring the CCPs, establishing corrective actions, verification procedures to confirm the HACCP system is working effectively, and documentation and record-keeping. By identifying potential hazards early in the process, it allows manufacturers to take necessary steps to prevent, eliminate, or reduce these risks to acceptable levels, thereby ensuring the production of safe food and beverages.

COMPRESSED AIR AS A CRITICAL CONTROL POINT

In food and beverage processing, the Hazard Analysis Critical Control Point (HACCP) system must consider the use of compressed air, as it can potentially introduce contaminants into the production process. Compressed air is often used in various stages of food production, including ingredient preparation, processing, packaging, and transport. If not properly treated and monitored, it can carry moisture, oil, and particulates, which can compromise the safety and quality of the end product. Therefore, within a HACCP plan, the use of compressed air should be identified as a critical control point (CCP).

This means establishing critical limits for air purity, implementing procedures for regular monitoring and testing of compressed air, and having corrective actions in place should the air fail to meet the set standards. This ensures that the compressed air used in the process is free from contaminants, thereby safeguarding the safety and quality of the food and beverage products.

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STERILE GAS AS A CRITICAL CONTROL POINT

Sterile gas filters play a crucial role in the food and beverage industry, and their proper function and maintenance should be addressed within a Hazard Analysis Critical Control Point (HACCP) plan. These filters are used to remove bacteria and phage from gases that come into direct contact with food products or the processing environment, such as compressed air or gases used in Modified Atmosphere Packaging (MAP).

Within a HACCP plan, the sterile gas filtration system should be identified as a critical control point (CCP). This means setting critical limits for filter efficiency, establishing procedures for regular inspection and replacement of filters, and developing corrective actions if the filters fail to meet the defined standards. The integrity of the sterile gas filters is paramount to prevent microbial contamination and ensure the safety and quality of the food and beverage products. Documentation and record-keeping of filter maintenance and validation are also essential components of the HACCP system.

To quickly and accurately identify filter failures, Parker has developed Valairdata 4. This fully automated, portable integrity test unit has been designed to provide fast and reliable filter integrity testing in-situ, enabling operators to quickly identify any filter failures with minimal disruption to aseptic process operations. 

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STERILE LIQUID AS A CRITICAL CONTROL POINT

Validation of liquid membrane filtration in the HACCP system is crucial to ensure the efficacy and reliability of this critical control point. Liquid bacterial challenge testing of Parker’s range of BEVPOR liquid membrane filters is carried out based upon methodologies outlined in ASTM F838 ‘Standard Test Method for Determining Bacterial Retention of Membrane Filters Utilized for Liquid Filtration”. Under these test conditions, the test filter is challenged with a minimum of 107 viable Brevundimonas diminuta (ATCC 19146) per square centimetre of effective filtration area. Any organisms that pass through the test filter are collected and cultured on the surface of analytical discs. The filter retention is quantified by expressing the filter’s efficiency to remove the challenge organism from the challenge suspension as a Log Reduction Value (LRV).

EUROPEAN INDUSTRIAL GASES ASSOCIATION (EIGA)

Food grade nitrogen is used for a multitude of applications within the food and beverage industry. In most instances, gas is in direct contact with the food product. To ensure product safety, mandatory regulations are in place across the globe, specifying a minimum standard of gas to protect human health. While there is a slight variance in food grade gas specifications from region to region, cooperation amongst regulatory and advisory bodies is helping to produce a uniform standard.

Within Europe, EIGA – the European Industrial Gases Association - is instrumental in providing guidance on industrial gases legislature to the European Commission, which is then made into law by the European Parliament and implemented by member states.

What is EIGA?

“EIGA: European Industrial Gases Association - AISBL

The European Industrial Gases Association, EIGA, is a safety and technically oriented organization representing the vast majority of European and a number of non-European companies producing and distributing industrial, medical and food gases. EIGA is an International Non-Profit Organization (AISBL).

The member companies closely co-operate in safety and technical matters concerning production, transport, storage and application to achieve the highest level of safety and environmental care of the handling of gases. EIGA also initiates the development of appropriate standards and provides standardization bodies with technological expertise.

EIGA fully co-operates with all National Industrial Gas Associations and Regional Industrial Gas Associations around the world such as AIGA (Singapore), ANZIGA (Australia/New Zealand), CGA (USA), JIMGA (Japan), SACGA (South Africa), which are all associated members to EIGA.

FOOD GRADE NITROGEN APPLICATIONS

EIGA describes three main applications for food grade nitrogen:

As an “additive” – Specifically as used in modified atmosphere packaging (MAP).

As a “processing aid” - used for mixing and conveying, for example.

As an “Ingredient” - injected into beers, coffee, and sodas to create nitrogenated beverages or into creams and desserts to increase bulk and lightness.

Of these descriptions, “processing aid” and “ingredient” do not have any specific purity criteria other than they must be of a standard to ensure the safety and protection of human health.

Nitrogen gas used as an “additive” however, has extremely specific purity criteria that is European statute. This means it is unlawful to use nitrogen gas that does not comply as an additive.

The purity specification is detailed within European Commission regulation 231/2012 of March 12th 2012. This also allocates nitrogen gas used as a food additive and “E” number – E941

Food additive E941 specification purity limits

Commission Regulation (EU) No 231 / 2012 of 9th March 2012

Laying down specifications for food additives listed in Annexes II & III to Regulation (EC) No 1333 / 2008 of the European Parliament and of the Council.

EIGA
  • NITROGEN* ≥99%v
  • OXYGEN ≤1%vX
  • WATER ≤0.05%v (500ppmV)

*99% including other inert gases such as noble gases (argon mainly)

Impurities:

  • CARBON MONOXIDE ≤10 ppmV
  • METHANE AND OTHER HYDROCARBONS (AS METHANE) ≤100ppmV
  • NITROGEN MONOXIDE AND NITROGEN DIOXIDE ≤10ppmV

BRITISH COMPRESSED AIR SOCIETY (BCAS) FOOD & BEVERAGE GRADE COMPRESSED AIR BEST PRACTICE GUIDELINE 102-1

This best practice guideline is aimed at food manufacturers and was developed to provide enough detail to complement the existing FSMS scheme PRPs and be implemented as an oPRP, thus eliminating the need for multiple CCPs around the manufacturing facility.

The British Compressed Air Society (BCAS) Food and Beverage Grade Compressed Air Best Practice Guideline 102-1 covers:

  • PRPs - compressed air
  • Development of a compressed air strategy
  • Compressed air contamination (hazards)
  • Sources of the compressed air contamination
  • Relevant international standards relating to compressed air
  • Overview of the compressed air treatment technologies required to achieve food & beverage grade compressed air
  • A detailed specification for compressed air based upon usage (application)
  • Direct contact
  • In-direct contact
  • Non-food contact
  • All linked to ISO 8573-1:2010, the international standard for compressed air purity
  • An explanation as to why each specification was chosen
  • Use of HACCP & PRPs
  • Recommendations towards compressed air system testing, service, maintenance & documentation
  • Auditor’s notes
  • The Best Practice Guideline can be applied to the use of compressed air in all food and beverage manufacturing facilities, however, it does not cover the quality of other gases used e.g. CO2 or nitrogen as these are covered by other standards.
  • Following the Best Practice Guideline is not mandatory and not required by law.
  • However, following the Best Practice Guideline allows a manufacturer to show due diligence, should a ‘quality incident’ reach a court of law.
  • The Best Practice Guideline can also be applied to ingredient suppliers should they use compressed air in their manufacturing, transportation or packaging processes.
  • Although produced by the British Compressed Air Society, it should not be viewed solely as a document for use in the United Kingdom.
  • In the absence of any European or Global recommendations or standards relating to compressed air use in the food and beverage industry, the Best Practice Guideline can be implemented in any country to protect both the consumer and the manufacturer.
BCAS

THE INTERNATIONAL SOCIETY OF BEVERAGE TECHNOLOGISTS (ISBT)

The International Society of Beverage Technologists, ISBT (formerly SSDT) was founded in Washington, D.C. in 1953 and now consists of over 1,000 members worldwide. It is unique in being the only organization whose sole interest is the technical and scientific aspects of soft drinks and beverages. The ISBT mission statement is to provide a networking forum for technical collaboration focused on expanding expertise and advancing beverage science. Focus areas of activity include, but are not limited to, beverage formulation, production, packaging, equipment, and distribution.

Parker (and the former domnick hunter) have been a contributing member of the technical gases committee since the 1990’s. With a focus towards beverage gases, the technical committee activities include preparation of papers and seminars for presentation at the annual meeting, preparation of quality industry guidelines, best practices, and procedures, discussion of mutual technical issues, new packaging, new equipment developments, etc.

ISBT

3RD PARTY VALIDATION

Parker Food and Beverage Compressed Air Treatment Products

Parker GSFE filtration and dryer ranges have been designed to provide compressed air quality that meets or exceeds the classification levels shown in BCAS Best Practice Guideline 102-1 for Food and Beverage Grade Compressed Air.

Recommended Parker purification equipment for Food and Beverage Grade Compressed Air (In accordance with BCAS Best Practice Guideline 102-1).

INDEPENDENTLY VERIFIED PERFORMANCE

Filtration performance of the Parker OIL-X range has been independently verified by LRQA.

Parker OIL-X Liquid Separators - Grade WS

Liquid separator performance has been tested in accordance with ISO 12500-4 and ISO 8573-9.

Parker OIL-X Coalescing Filters - Grades AO & AA

Oil aerosol and particulate reduction performance has been tested in accordance with ISO 12500-1, ISO 8573-2 and ISO 8573-4.

Parker OIL-X Dry Particulate Filters - Grades AO (M) & AA (M)

Dry particulate reduction performance has been tested in accordance with ISO 8573-4.

Parker OIL-X Adsorption Filters - Grade OVR

Oil vapour reduction performance has been tested in accordance with ISO 8573-5.

Parker FBP Treatment Systems - Modular Heatless & Heatless Low Energy Adsorption Dryers

Drying performance of the adsorption dryers used in Parker FBP Treatment systems has been tested in accordance with ISO 7183, the international standard for the testing of compressed air dryers and has been independently verified by LRQA (formerly Lloyds Register)

FOOD SAFETY - MATERIALS OF CONSTRUCTION

In addition to the independently verified performance validation of the Parker filtration and FBP Treatment Systems mentioned, the materials used in the construction of those ranges are suitable for use in food and beverage manufacturing and have been independently certified as FDA Title 21 CFR Compliant and EC1935-2004 exempt.

FILTER INTEGRITY TESTING

LIQUID MEMBRANE FILTER INTEGRITY TESTING

Monitor performance of membrane filters to ensure they are not damaged, fit for purpose, and capable of providing the necessary degree of microbial control. Effective final stabilization of beer is assured only when filters have been selected properly, used inside the recommended limits and haven’t suffered damage during use. It is essential that filter performance is monitored and results recorded. This is achieved through routine integrity testing using the BEVCHECK range of instruments.

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STERILE GAS FILTER INTEGRITY TESTING

The performance of sterile gas filter systems is critical to a plant’s Quality Assurance objective of protecting their product from contamination during production and packaging. The ongoing performance of sterilizing grade gas filters can be checked by routine integrity testing as part of their HACCP plan. The aerosol challenge test, performed by Parker’s Valairdata 4 provides a number of process advantages by being capable of testing both depth and membrane sterile gas filters in-situ, quickly and easily.

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ANALYTICAL GAS SYSTEMS

Parker is a leading provider of high purity gas generators for the analytical instrument market, specialising in Gas Systems tailored to meet the precise gas requirements of all major Analytical Instrument manufacturers. By collaborating with laboratory partners across diverse sectors, Parker delivers industry-leading solutions that ensure consistent accuracy through a reliable, on-demand supply of various analytical gases.

PARKER GAS GENERATORS BENEFITS

The advantages of Parker Laboratory Gas Generators are multi-faceted. They encompass the assurance of consistent gas quality and pressure, contributing to enhanced stability and greater reproducibility of analytical results. The convenience factor is significant, eliminating the need for changing gas cylinders or dealing with liquid dewars. With a 24/7 on-demand supply capability, laboratories can generate gas precisely when needed. Safety is paramount, as the generators eradicate high-pressure gas cylinders and liquid dewars from the laboratory environment, reducing manual handling and minimizing Health and Safety risks. From a financial perspective, the cost benefits are notable, with a payback period of less than 18 months in most cases, minimal ongoing maintenance costs, and the elimination of expenses related to gas, delivery, and rental charges.

LC-MS

In the field of Liquid Chromatography-Mass Spectrometry (LC-MS) for food analysis, nitrogen plays a pivotal role as a nebulizing gas to facilitate the formation of fine droplets from liquid samples. This aids in efficient ionization of analytes before entering the mass spectrometer for detection and analysis. Moreover, nitrogen can serve as a collision gas in the mass spectrometer’s collision cell, assisting in the fragmentation of ions for additional structural information. Ensuring a consistent, safe supply of high-purity LC-MS grade gases, Parker’s NitroFlow Lab and LC-MS series meet stringent quality criteria while being user-friendly, cost-efficient, and reliable.

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GAS CHROMATOGRAPHY

Gas Chromatography (GC) is a cornerstone in ensuring the safety, quality, and nutritional content of food. Hydrogen, as a carrier gas, and zero air, purified air with no hydrocarbons or impurities, are indispensable in this process. Parker’s Gas Chromatography product lines, including H-MD-Carrier, H-Fuel, UHPZA, UHPN2, UHPZN2, are designed to provide an effective and reliable supply of gases for Gas Chromatography applications in the food industry.

Beyond analysis, gas chromatography plays a pivotal role in the food industry's nutritional assessment. Running food products through chromatography columns allows for a comprehensive understanding of the levels of essential components such as vitamins, proteins, preservatives, additives, and fats. This information is crucial not only for manufacturers but also for nutritionists and governmental bodies responsible for ensuring food quality and safety.

Nutritional labelling, a critical aspect of food testing and analysis, heavily relies on chromatography results. When consumers read a food label, much of the nutritional information is derived from the meticulous analysis conducted through chromatography. This process allows food companies to verify the content of nutrients, proteins, vitamins, preservatives, and more, ensuring transparency and compliance with regulatory standards. Additionally, chromatography aids in preventing the consumption of spoiled foods, which could lead to severe gastrointestinal problems and diseases.

The detection of contaminants is another crucial application of gas chromatography in the food industry. Food manufacturers uphold strict standards regarding substances like additives, pesticides, and contaminants. Gas chromatography is employed to identify and monitor these substances, ensuring that the levels comply with regulatory limits. Manufacturers may also use chromatography to break down the exact composition of ingredients, contributing to quality control measures that assess the aroma, flavour, authenticity, and overall sensory characteristics of food products. In essence, Parker's gas chromatography solutions play an indispensable role in maintaining the highest standards of quality, safety, and nutritional accuracy in the food industry.

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