4 Things to Know Before Purchasing A Metal Detector For Your Facility

The call for safety is at an all-time high. Many things need to be taken into consideration when it comes to the safety of our products. One of the most dangerous, yet furthest in the back of people’s mind, is metal detection. We all work with surfaces of either stainless steel or copper. These surfaces have the ability to be chipped, scraped and gouged, producing minute particles of metal that can be dangerous to human consumption. In this excerpt from an article in RCI’s Kettle Talk magazine, Caleb Ramm with Candy House Gourmet identifies four considerations when adding a metal detector to your facility.

Purchasing

When purchasing a metal detector, make sure to buy from a company that supplies ample training and support to ensure you get the most out of your investment. For a metal detector to be truly effective, constant observation and calibration are key.

Placement

Another consideration when purchasing a metal detector for your facility, is to determine the best placement based on your needs. Companies that only enrobe candies or produce on a line may want to place a metal detector at the end of the line, so that the product will pass through before packaging.

Others run their packaged products through the metal detector, which will detect metal that may be in or on the box itself. Placing the metal detector away from the enrober, in its own designated area may make it easier to access it at all times.

Calibration

When you set up a new product, you are given test cards that have ferrous, non-ferrous and stainless-steel samples to use to calibrate your machine. The smaller the particle you calibrate to, the smaller the particle the machine has the ability to detect.

Elimination

When a product is identified as contaminated, it is recommended to pull the entire batch and re-test it until all particle have been located and removed from the finished product.

We all want the best for our customers, and look for any way to improve upon this. Safety in confectionery doesn’t just stop in production. Pass on the safety to your customers as well.

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Pro Tips for Effective Equipment Maintenance and Cleaning

COVID-19 is a reminder of how quickly pathogens can spread and the importance of good manufacturing practices to protect your customers and your employees. RCI member, Jim Bourne with Hilliard’s Chocolate Systems shares pro tips for maintaining and cleaning your chocolate equipment.

Today’s food safety regulations regarding sanitation, allergens and labeling are being aggressively enforced at the local, state and federal levels. Keep good records of what cleaning is performed and when it’s done. Inspectors like to see this information recorded.

Equipment Maintenance

By having the chocolate equipment in good operating condition, it will help avoid possible contamination from the equipment and avoid down time. Talk with the machine manufacturer to discuss maintenance, such as lubrication with a food-grade lubricant, replacement of worn parts and wear items such as belt drives.

Create a chart to detail periodic inspections and repairs to the machinery. When a machine is not operating properly or making a new noise, investigate and repair the problem to avoid down time. Developing problems rarely get better on their own. Since cleaning is a big part of maintenance, do periodic break downs of equipment to inspect, clean and locate any issues.

Equipment Cleaning

Scheduling a few minutes each day for daily and periodic cleaning will help equipment run more efficiently and reduce the risk of contaminated product. As a fat-based food, chocolate can be easily compromised by heat, strong odors, allergens and moisture. Fortunately, chocolate has a very low moisture content and low water activity, so it is less likely to support pathogens on its own. The low moisture also means chocolate equipment does not need a complete breakdown and cleaning daily as other equipment does, such as ice cream equipment.

Cleaning methods for eliminating allergens and pathogens in chocolate equipment can be divided into two categories; dry cleaning and wet cleaning. Dry cleaning does not use water, so cleaning is done by scraping chocolate out, vacuuming out solid chocolate bits and wiping down equipment with alcohol wipes. This method is best for machine parts that can be disassembled.

Larger machines are often cleaned intact by flushing the system with melted cocoa butter to access pipes, pumps and hard-to-reach areas. Wet cleaning involves the use of warm to hot water and liquid sanitizers. The water and sanitizer will introduce moisture, so each component being wet cleaned must be completely dry before reassembly. Be sure to use sanitizers that do not have a strong fragrance, otherwise the fragrance can be picked up by the chocolate.

Wet cleaning pipes, pumps and other restricted areas can also be problematic if moisture is introduced in the cleaning process, but not removed. Introducing moisture presents a higher risk of pathogen and mold growth, so it is important that all surfaces that are wet cleaned are completely dry.

Daily Cleaning

At the end of the day, raise the chocolate temperature to break the temper. Run the untempered chocolate through the pumping system and the wire belt, because untempered chocolate is less likely to crystalize overnight. The cooling belts can be cleaned and dried while they are running. Avoid using excessive water and use only damp cleaning cloths, drying afterwards. If the equipment has screens to filter out debris, clean them at least daily. Drain chocolate from the curtain hopper and wire mesh belt into the tank to prevent the chocolate from setting up and causing problems on start up. Clean any non-chocolate materials such as nuts, sea salt and toppings from the machine. Also, clean floors and walls around and under the equipment daily.

Periodic Full Cleaning

Periodic full cleanings are a necessity. You should assess your own situation and risk to determine how frequently to perform a full cleaning. Are you more likely, in your operation, to introduce moisture, allergens or contaminants to the equipment and the chocolate? The more likely you are to be compromised, the more often you should do a complete breakdown, cleaning and drying.

Be aware that moisture or other contaminants can also be introduced by other means. Excessive moisture from centers or toppings can cause issues. HVAC in the plant can poorly filter dust or dehumidify the air. Clean and check the cooling tunnels and air blowers to eliminate condensation and dust problems.

There are operations that do a full break down quarterly, monthly and even weekly, depending on their own situation. Operations that perform very few full cleanings put themselves at the greatest risk. Following good manufacturing processes will help you protect your customers, your employees and your business.

Crave more? If you like what you read here, look for the "Subscribe now" box on the right to enter your email address and start receiving weekly tips, like this, delivered straight to your email inbox. RCI's Tip of the Week blog is just one of the many resources we offer to help candy makers refine their craft and build upon their business and marketing practices.

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Tip #330: COVID-19 (Coronavirus) Guidance for Retail Confectioners

Small businesses are currently facing unprecedented operational challenges. Due to recent cancellations of major sporting events and festivals, school closures and more people working from home, there’s no doubt consumers are reluctant to leave their homes—let alone visit their favorite local businesses. Not only does COVID-19 (coronavirus) pose a threat to public health, it will have an unprecedented impact on small businesses and the economy.

What you can do now:
Keep reading as we review five steps you can take now, as business owners and operators, to protect your business, staff, customers and local communities based on recommendations by The Centers for Disease Control and Prevention (CDC) and other authoritative health and governmental agencies.

•  Educate yourself and your team.
•  Create a communication plan.
•  Protect your business.
•  Embrace new forms of commerce.
•  Stay connected with fellow retail confectioners.

Educate yourself and your staff: Guidance for Businesses and Employers from CDC

As a leader of your business, it is crucial to obtain information about COVID-19 (coronavirus) from authoritative health and governmental agencies, such as The Centers for Disease Control and Prevention (CDC).

The CDC offers the most up-to-date information on COVID-19. Click here to view guidance from the CDC for employers to help prevent workplace exposures to COVID-19. This guidance also provides planning considerations if there are more widespread, community outbreaks.

To prevent stigma and discrimination in the workplace, the CDC recommends using only the guidance provided on its COVID-19 web page to properly determine risk. Do not make determinations of risk based on race or country of origin, and be sure to maintain confidentiality of people with confirmed COVID-19. There is much more to learn about the transmissibility, severity and other features of COVID-19 and investigations are ongoing.

Open communication with employees is key to educate and train your team on how to best prevent exposure to COVID-19 in the workplace. See below for links to additional resources addressing common questions:

https://www.cdc.gov/coronavirus/2019-ncov/downloads/2019-ncov-factsheet.pdf

https://www.fda.gov/emergency-preparedness-and-response/mcm-issues/coronavirus-disease-2019-covid-19-frequently-asked-questions.

Create a communication plan

According to the Small Business Administration, “it’s critical to communicate openly with your customers about the status of your operations, what protective measures you’ve implemented, and how they (as customers) will be protected when they visit your business.”

The U.S. Chamber has compiled a Coronavirus Response Kit for businesses and workers across the country, encouraging American businesses to follow data-based guidance from the CDC and state and local officials. See examples of how RCI members are communicating their new and ongoing protocols in their businesses below.

Protect your business: Guidance from SBA

The Small Business Administration (SBA) is working directly with state governors to provide targeted, low-interest loans to small businesses and non-profits that have been severely impacted by COVID-19. The SBA’s Economic Injury Disaster Loan program provides small businesses with working capital loans of up to $2 million that can provide vital economic support to small businesses to help overcome the temporary loss of revenue they are experiencing.

Find more information on the SBA’s Economic Injury Disaster Loans at: SBA.gov/Disaster. To view a full list of other local and national resources available through the Small Business Administration, visit their website.

Embrace new ways of commerce.

By providing creative and safe alternatives for consumers to continue to do business with you, may help alleviate some of the financial strain caused by current health concerns, while also helping to reduce the risk of exposure to you and your staff by consumers. Remind patrons that stocking up on a few sweet treats from their favorite, local candy shop may be just what they need to provide comfort and a constant during this time of uncertainty.

Many businesses are encouraging patrons to place orders online for home delivery and offering new grab-and-go options so customers don’t even have to leave the comforts of their vehicle. While others are encouraging consumers to support local businesses by purchasing gift cards. See below for examples of creative ways RCI members are embracing new forms of commerce to ensure business as (sort-of) usual goes on.

Stay connected.

For over 100 years, RCI has been a community for retail confectioners and their suppliers to connect with each other and learn from shared knowledge and experiences. If you have questions about what fellow retail confectioners are doing, we encourage you to subscribe RCI’s online forum, List Serve, to post questions and reply to others’ questions. We invite you to also follow RCI’s Facebook page for industry and association updates. As always, feel free to direct your questions to RCI staff at info@retailconfectioners.org

Crave more? If you like what you read here, look for the "Subscribe now" box on the right to enter your email address and start receiving weekly tips, like this, delivered straight to your email inbox. RCI's Tip of the Week blog is just one of the many resources we offer to help candy makers refine their craft and build upon their business and marketing practices.

Not a member? Click here to learn how RCI can help you build your sweet business.

Tip #329: 4 Ways to Improve Quality Control Practices

It doesn’t matter how great your confections look or taste if your business does not place an emphasis on food safety and quality control. This week’s blog post identifies four ways to ensure the safety and quality of your products with practices that you could start today.

Identify Risks

To best prevent potential hazards during the making of any food products, it is important to identify areas of potential risk. Create a Hazard Analysis of Critical Control Points (HACCP) plan to prevent biological, chemical and physical hazards during the production process that could cause a threat to food safety. RCI members, login to watch a video on how to properly identify potential risks and develop an effective HACCP plan in the past education presentation, A Practical Approach to HACCP Planning (click link to view).

Train Employees on Proper Hygiene

“Proper hand hygiene is the food [manufacturer’s] first line of defense against food contamination,” said Jim Grubb of GOJO Industries. “Bacteria, viruses, and parasites can be transmitted from person to person and from persons to food, so health and hygiene of the workforce is extremely important,” (Quality Assurance Magazine).

When identifying areas for potential risk effecting food safety, it is important to also look at current staff hygiene procedures. Since poor employee hygiene practices can lead to contamination, don’t assume staff members are washing their hands properly and at the appropriate times. Common problems with employee hygiene practices include poor hand washing practices, not washing at the right location in comparison to the production areas; manual sinks that are not kept clean; using cold water temperatures for hand washing and a poor overall food safety culture. Click here for tools and resources to train your staff on proper hand washing.

Use Both Wet and Dry-Cleaning Methods

Did you know limiting the use of water is one of the primary means of controlling pathogens in low moisture food establishments (foodprotection.org)? You are probably already using wet cleaning and sanitation methods which utilizes water and/or detergents to remove residue. When wet cleaning, it is extremely important that even the nooks and crannies of machinery is dry, because it is in these hard-to-reach places where bacteria can be difficult to remove and when water is present bacteria can grow.

The benefit to employing dry cleaning and sanitation methods, is that it allows you to remove food residue with little or no water application, significantly reducing the opportunity for bacterial growth. Dry cleaning can be as simple as surface cleaning with a vacuum or alcohol-based wipes. More detailed cleaning may be performed with a steam cleaner or dry ice cleaner.

When determining which method of cleaning is best, it is important to assess the risk level of the area in need of cleaning. Different areas of your facility may have a different level of risk, just as different ingredients would. It is important to understand what you are trying to remove when cleaning or sanitizing different work stations. According to Quality Assurance Magazine, it is essential to ensure all products used to clean and sanitize food-contact surfaces are approved by the Environment Protection Agency (EPA) in addition to being verified and validated.

Collect Retention Samples

It is important to know and understand the shelf life of your products and collecting retention samples is the best way to test product limitations, so you can adjust recipe formulations if issues arise or advise customers on the best timeframe to enjoy your products.

When testing the shelf life of your product, variables, like packaging, must remain the same. For example, when testing your products, make sure they are stored in the same packaging they would be sold in. If they are shrink wrapped before selling (which is highly recommended), shrink wrap the product before storing them for testing. Anticipate how your customers would store your products, if not consumed right away. Would they store them in the refrigerator or in the pantry? Consider a reasonable length of time a consumer may store your products before consuming them. If you are unsure, ask a small group of loyal customers or friends and family.

Over time, enlist experienced tasters (this could be staff members or, again, frequent customers) to review your products for consistency and quality. If you run into issues with product quality, RCI members can login to pose questions to fellow members on RCI’s online forum, List Serve.

This week’s tips may require extra work, however, the benefits of taking a proactive approach to quality assurance often outweigh the risks of not practicing such precautions. Comment below on practices your company employs to help ensure your products are consistently safe for consumption.

Crave more? If you like what you read here, look for the "Subscribe now" box on the right to enter your email address and start receiving weekly tips, like this, delivered straight to your email inbox. RCI's Tip of the Week blog is just one of the many resources we offer to help candy makers refine their craft and build upon their business and marketing practices.

Not a member? Click here to learn how RCI can help you build your sweet business.

Throwback Tip #230: Refresh Your FSMA Knowledge

It has been eight years since the Food Safety Modernization Act (FSMA) was signed into law, which also means if you manufacture food and operate with less than $1 million in sales, September 2018 was the deadline to comply with the FDA's regulations. This week's tip offers a refresher on FSMA in an excerpt from an article written by Michael Koch of Morley Candy Makers/Sanders Candy for RCI's Kettle Talk magazine, plus tips for next steps.

WHAT IS FSMA?

FSMA was designed to shift the focus on food safety from responding to contamination issues to a more proactive approach of preventing contamination before it happens. Through the passing of this law the FDA has gained more leverage in its ability monitor and control the safety of our food supply chain.

In September of 2015 the FDA published its "Preventive Controls for Human Food" guidelines. As part of FSMA, it outlines the mandatory requirements being placed on all food manufacturers to have and implement a written food safety plan. FSMA requires that your plan be written and managed by a qualified individual. Individuals must complete a certification course to become a qualified food safety administrator.

PREVENTATIVE CONTROLS

Hazard Analysis and Risk-Based Preventive Controls (HARPC) is a documented food safety program that addresses hazard risks with preventive controls for every food product you handle in your facility to ensure it will not become contaminated and unfit for human consumption.

VERIFY EFFECTIVENESS

Continuing to verify the effectiveness of your plan ensures preventive controls are consistently implemented and sufficient. Verification includes evaluating the accuracy of process monitoring, calibrating instruments, such as thermometers, and reviewing records to verify monitoring and corrective actions are completed. Product testing and environmental monitoring by a certified third party are also reliable verification methods.

RECALL PROCEDURES

Your plan must contain details on your recall procedures. If a contaminated product is shipped, you must be able to identify where the product has gone and have the ability to perform a recall. A recall plan should include the procedures for identifying the contaminated product. Having important contact information in the plan will help move the process forward. Contacts should include the local health department, local FDA office, news media and anyone else that you may deem important to the process.

FSMA covers a much greater spectrum of the food chain and more details than covered in this brief post. The realm of information and procedures that you are responsible for also cover such things as your supply chain management, good manufacturing practices, corrective actions and etc. The FSMA is no small task and it is designed to protect the consumer from obtaining contaminated products.

WHAT NOW?

Co-chair of the FSMA Operations Team Steering Committee and director of FDA’s Food and Feed Program in the Office of Regulatory Affairs, Joann Givens shares next steps for food facilities now that compliance dates have passed for most small businesses.

“The best thing that people in the food industry can do is take the measures required by the new rules – not just the letter of the law but what it represents in terms of transforming the food safety system. They should look at the big picture, at areas in which they could be vulnerable and proactively take action. Promptly responding to problems, even if they aren’t yet violations, can prevent them from getting to the point at which there is a concern about the safety of the food.”

Joann also stresses the importance of a thorough system for documenting what you do. “The better the records, the more a company can demonstrate that it is meeting the legal standard.” With the right processes and procedures in place you’re better equipped to prevent problems before they arise. Joann recommends creating some redundancy in your system, “if one measure fails, another can take its place.”

In order to operate a successful candy making business, it is essential that you are knowledgeable on federal regulations and take the proper action to ensure you are in compliance with FSMA guidelines. Click here for more resources and updates.

Crave more? If you like what you read here, look for the "Subscribe now" box on the right to enter your email address and start receiving weekly tips, like this, delivered straight to your email inbox. Plus, review past blog posts for quick and actionable tips to apply to your business. RCI's Tip of the Week blog is just one of the many resources we offer to help candy makers refine their craft and build upon their business and marketing practices.

Not a member? Click here to learn how RCI can help you build your sweet business.

Throwback Tip #230: Refresh Your FSMA Knowledge

It has been seven years since the Food Safety Modernization Act (FSMA) was signed into law, which also means if you manufacture food and operate with less than $1 million in sales, September 17, 2018 is the deadline to comply with the FDA's regulations. This week's tip offers a refresher on FSMA and its requirements in an excerpt from an article written by Michael Koch of Morley Candy Makers/Sanders Candy for RCI's Kettle Talk magazine.

Click here for further clarification on compliance dates.

WHAT IS FSMA?

FSMA was designed to shift the focus on food safety from responding to contamination issues to a more proactive approach of preventing contamination before it happens. Through the passing of this law the FDA has gained more leverage in its ability monitor and control the safety of our food supply chain.

In September of 2015 the FDA published its "Preventive Controls for Human Food" guidelines. As part of FSMA, it outlines the mandatory requirements being placed on all food manufacturers to have and implement a written food safety plan.

Before putting a plan together, first, identify the individual or individuals in your organization that are going to administer your program. FSMA requires that your plan be written and managed by a qualified individual. Currently the only way to verify that an individual is qualified is to have your food safety administrator attend a certification course.

IDENTIFY HAZARDS

Hazard Analysis and Risk-Based Preventive Controls (HARPC) is a documented food safety program that you need to develop and implement for your facility. The first step toward developing a HARPC is to conduct a hazard analysis for every food product you handle in your facility—this is not limited to the items that you manufacture. The second step is to put in place preventive controls for each food product to ensure it will not become contaminated and unfit for human consumption.

VERIFY PLAN’S EFFECTIVENESS

Verifying the effectiveness of your plan ensures preventive controls are consistently implemented and sufficient. Verification includes evaluating the accuracy of process monitoring, calibrating instruments, such as thermometers, and reviewing records to verify monitoring and corrective actions are completed. Product testing and environmental monitoring by a certified third party are also reliable verification methods.

CREATE RECALL PROCEDURES

Your plan must contain details on your recall procedures. If a contaminated product is shipped, you must be able to identify where the product has gone and have the ability to perform a recall. A recall plan should include the procedures for identifying the contaminated product. Having important contact information in the plan will help move the process forward. Contacts should include the local health department, local FDA office, news media and anyone else that you may deem important to the process.

FSMA covers a much greater spectrum of the food chain and more details than covered in this brief post. The realm of information and procedures that you are responsible for also cover such things as your supply chain management, good manufacturing practices, corrective actions and etc. The FSMA is no small task and it is designed to protect the consumer from obtaining contaminated products.

In order to operate a successful candy making business, it is essential that you are knowledgeable on federal regulations and take the proper action to ensure you are in compliance with FSMA guidelines. Click here for more resources and updates.          

Stay connected with RCI through Facebook for more tips and inspiration dedicated to the retail candy maker. Not a member? Click here to learn how RCI can help you build your sweet business.