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  1. Massachusetts seafood processing facility warned by FDA about temperature control

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    Food processing plants rely heavily on precise temperature control to maintain the shape, flavor, and safety of their products. This is crucial not only for preserving quality but also for ensuring the well-being of both workers and consumers. Raw materials like eggs, milk, cheese, and meat require meticulous handling within these facilities, as emphasized in the book Postharvest Handling and Preparation of Foods for Processing.

    In recent years, a seafood-processing plant based in Massachusetts came under scrutiny from the U.S. Food and Drug Administration (FDA) due to multiple violations of seafood Hazard Analysis and Critical Control Point (HACCP) guidelines. Specifically, the company’s pasteurized canned crab meat was found to be compromised, prompting regulatory intervention.

    A significant concern was the inadequate control of hazards associated with clostridium botulinum toxin formation—a bacterium notorious for its potentially fatal consequences. Despite advancements in food safety, such violations continue to challenge the integrity of food processing facilities.

    Clostridium botulinum toxin can induce severe symptoms, including vertigo, double vision, and respiratory distress, shortly after consumption. In extreme cases, paralysis and fatalities can occur. These risks persist due to lapses in storage, distribution, and processing practices.

    What causes clostridium botulinum toxin formation?

    The formation of clostridium botulinum toxin is primarily caused by improper storage, distribution, and processing practices by food processors, as highlighted by the FDA. To mitigate these risks, the FDA recommends various strategies, including limiting bacterial introduction post-pasteurization and ensuring proper temperature control during processing.

    To achieve optimal temperature control, manufacturers must invest in high-quality sanitary shell and tube heat exchangers. This equipment ensures food is heated and controlled at the correct temperature, thereby minimizing the risk of bacterial contamination.

    Seafood plant ordered to monitor temperatures

    As for the Massachusetts seafood facility, the FDA said it must keep efficient records of continuous temperature-monitoring devices, Food and Safety News reported.

    “Specifically, your corrective action plan does not include procedures to bring affected products back under temperature control or procedures to investigate the root cause of the deviation to ensure control of the process,” the FDA warning letter stated.

    In essence, the imperative for maintaining optimal temperature control remains as pressing in 2024 as ever before. By leveraging advanced equipment such as sanitary shell and tube heat exchangers, food processors can uphold the highest standards of quality and safety, safeguarding both consumer well-being and industry reputation.

    Editor’s note: This content was originally published in 2015 but was updated in 2024.

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  2. Microbreweries gaining ground in the beer making industry

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    Over the past 15 years, there has been explosive growth in the number of microbreweries elevating the American drinking experience. According to the U.S. Brewers Association, an impressive 13.2% of the beer market, equivalent to $28.4 billion, now proudly belongs to these innovative microbreweries.

    As the market continues to flourish and competition reaches new heights, breweries find themselves compelled to invest in cutting-edge processing equipment that promises a substantial return on investment. Among the indispensable tools shaping the brewing landscape, the shell and tube heat exchanger stands out as a workhorse in ensuring quality and precision.

    The Vital Role of Custom Shell and Tube Heat Exchangers in Elevating Microbrewery Quality

    When using a heat exchanger where two liquids are involved, the heat exchanger uses heat from one fluid in the shell of the exchanger to warm or cool the other liquid in the tubes of the exchanger. Learn how to choose a heat exchanger for your brewing process.

    In the world of brewing, the heat exchanger plays a pivotal role in the art of yeast manipulation. Yeast, a crucial ingredient in beer, harbors bacteria that needs careful handling. Enter the custom shell and tube heat exchanger, the unsung hero ensuring the elimination of harmful bacteria without compromising the essence of the product.

    Having a custom shell and tube heat exchanger allows breweries to reach proper temperatures to kill off the bacteria without damaging the state of the product. According to Serious Eats, there is such a thing as “friendly yeast,” which can be introduced to add numerous flavors while breaking down the sugar. Heating these products can kill off the appropriate yeast needed to craft beer. According to Brew Like a Pro, cleaning and sanitation is essential for the “cool side” of the beer-making process because the thermophilic bacteria can multiply and double every 20 minutes. Enter the stage of the brewing process where precision is not just a preference but a necessity. The rolling action of the boil, the heartbeat of brewing, demands a level of precision only achievable through custom heat exchanger solutions.

    Looking for a heat exchanger solution in your brewing process? Contact us today.

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    This post was last updated 1/22/24.

  3. Preserving ethanol equipment with faster cleanups

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    Prepare for plant downtime

    Ethanol processing plants must ensure their equipment can withstand months of products running through shell and tube heat exchangers. This process builds up dirt and grime on the equipment, which must be cleaned periodically. According to Ethanol Producer Magazine, facilities have to prepare for cleanings in advance to ensure downtime for the process is limited.

    Matt Werzyn, maintenance manager for Louis Dreyfus Commodities, Elkhorn Valley Ethanol LLC, explained that ethanol processing facilities must ensure they schedule downtime for the cleaning process, the source reported. The plant managers must follow through with the deep cleanse; otherwise, the facilities will see downtime from grime and dirt buildup.

    The cleaning process must be quick and simple. If there are too many steps, the plant could be shut down for multiple days for repairs and equipment maintenance. In addition, certain metals and alloys tend to corrode over time, Engineer’s Edge reported. Finally, some of the chemicals and gases used with heat exchangers in ethanol processing plants can damage the metal.

    That’s why investing in stainless steel shell and tube heat exchangers is essential. According to the source, stainless steel is much easier to clean and can withstand multiple cleanings.

    Carbon steel is typically used in manufacturing plants but has a somewhat weak passivity, leading to rusting and corrosion. However, stainless steel contains additional alloy elements that increase corrosion resistance and provide more strength over time. This can deliver a quicker return on investment for processing facilities that frequently replace heat exchangers.

    Fouled equipment slows plants down

    Werzyn added that once equipment becomes fouled or dirtier, there are other consequences for plant operation, Ethanol Producer Magazine reported.

    “As we get closer to shut down, there is a definite performance decrease and an increase in the required energies needed to run the process,” said Werzyn. “If duct lines are not cleaned over a long period of time, duct fires can result, which can be very expensive, if not destructive, if they occur.”

    Equipment needs regular cleaning to last and perform required duties at its highest level. Werzyn said keeping equipment continuously clean could help save a lot of money in the grand scheme of things, the source stated.

    Need a stainless heat exchanger solution? Reach out to an Enerquip Sales Engineer today.

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    This post was last updated 1/22/24.

  4. Poultry liquid a major cause of campylobacter outbreaks in processing plants

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    One of the biggest concerns for food processing plants is battling bacteria on equipment and other surfaces. According to a recent study by the Institute of Food Research, liquids from chicken carcasses in poultry products can lead to a persistent increase in campylobacter.

    Campylobacter is a common bacteria found in raw or undercooked poultry meat or cross-contamination items, the U.S. Center for Disease Control reported. Annually, the bacterium affects more than 1.5 million people, and food processing plants work diligently to protect consumers from the illness.

    Helen Brown, lead on the IFR study, said these infectious liquids are often collected through defrosting stages for chicken carcasses. The bacteria can attach to glass, polystyrene and stainless steel to form biofilms and threaten work environments.

    “We have discovered that this increase in biofilm formation was due to chicken juice coating the surfaces we used with a protein-rich film,” said Brown, according to the report. “This film then makes it much easier for the campylobacter bacteria to attach to the surface, and it provides them with an additional rich food source.”

    Easy-to-clean equipment is essential

    Campylobacter are not necessarily long-lasting or tough bacteria, but they are often protected by a thin coating that keeps them alive. According to the IFR report, the bacteria stay alive since they are more resistant to disinfection treatments and antimicrobials.

    Food processing plants need proper equipment so bacteria can be easily killed off at the right temperature.

    Shell and tube heat exchangers provide food processing facilities with equipment that can heat products enough to eliminate the appropriate bacteria, and the stainless steel forged equipment makes the cleaning process easier.

    The ability to clean massive equipment in food processing facilities remains one of the most important ways to eliminate cases of campylobacter.

    “This study highlights the importance of thorough cleaning of food preparation surfaces to limit the potential of bacteria to form biofilms,” Brown said in the IFR report.

    With more attention on preventing food-based bacterium outbreaks in processing facilities, the IFR hopes the additional insight will prevent more cases since many locations are prone to these illnesses. Supermarket shelves, deli or meat areas, food processing facilities, and poultry delivery areas can spread the bacteria or cross-contaminate other products if the meat is not handled correctly.

    Want to talk through your thermal processing needs? Meet Enerquip’s Sales Engineers.

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    This post was last updated 1/22/24.