26 January 2023

3 contamination case studies in the packaging area: FILL good's support

Thanks to FILL good, we can provide support in the event of contamination in the packaging area. For a quick and effective response.

FILL good is an extremely valuable resource, both for Galdi and our customers.

Being able to rely on specialist consulting services in the event of product contamination is essential to quickly identify and solve the problem.

In the event of contamination within the packaging area, FILL good's microbiologists are on hand to provide technical support, advice on how to best resolve the issue, as well as additional training.

Both the experience gained by FILL good from past incidents and the know-how shared with Galdi specialists enable us to speed up the troubleshooting process and restore optimal hygienic conditions.

Below we share 3 contamination events in the packaging area and how they were resolved

CASE 1 - MOULD CONTAMINATION

Product type: dairy products

Problem: 17% of manufactured cartons tested positive for moulds.

Troubleshooting: under the on-site supervision of FILL good's microbiologist, the following actions were taken:

  • Verification of CIP/SIP cycles
  • ATP swab tests to check cleaning procedures
  • Analysis of the product and of the water used for the packaging machine
  • Disassembly of machine parts thought to be potentially causing the problem

Resolution: Effective troubleshooting enabled us to quickly identify the problem, which was caused by the failure to replace the HEPA filters, despite the pressure gauge flagging an anomaly. A reduction in the filtering capacity had caused airborne fungi to enter the system.

Tests conducted after the filers had been replaced showed that the problem was resolved.

CASE 2 - SHELF LIFE PROBLEMS DUE TO PH ALTERATION

Product type: dairy products

Problem: desired shelf life could not be achieved due to contamination, which was causing a pH alteration in 20% of product samples.

Troubleshooting: through microbial testing, enterobacteria were detected in contaminated samples. FILL good's microbiologist checked CIP/SIP cycle logs with operators. Several concurrent factors were identified as the cause:

  • CIP cycles being too short
  • Inaccurate cleaning in some areas of the machine
  • Cleaning operations not complying with correct procedures

Resolution: after a thorough cleaning of the machine, operators received additional food safety training, also covering best practices to achieve compliance with hygiene standards in the packaging area.

CASE 3 - CONTAMINATION CAUSED BY PSEUDOMONAS BACTERIA

Product type: liquid egg

Problem: presence of Pseudomonas bacteria in 24% of product samples.

Troubleshooting: after discussing the problem with the customer, FILL good's microbiologist paid a visit to the factory and conducted thorough testing, including:

  • Assessment of daily procedures performed by operators
  • Completion of cleaning cycles and ATP swab tests for cleaning verification
  • Investigation into quality of water used in the process and pasteuriser inspection
  • Disassembly of components, thought to be (through past experience) potential causes of the problem.

The source of contamination was the water used for cooling, which did not meet the quality and drinking water standards required by Galdi.

Resolution: the installation of a water disinfection system by the customer has solved the problem.

FILL GOOD'S SUPPORT

Besides providing advice in the event of contamination in the packaging area, FILL good can be a strategic resource, offering a range of highly specialised services, such as:

For more details about FILL good's services, please CONTACT US!