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Good
Manufacturing Practices (GMPs)
[From
the Michigan Apple Cider Advisory Committee]
Choose a link below to view key areas
for each topic.
a.
Definitions
b. Facility Requirements
c. Employees
d. Harvesting
e. Receiving
f. Inspection
g. Washing and Brushing
h. Crushing and Pressing
i. Post Pressing
i. Off Season
Primary
Principle: Apple cider producers
are food processors and must meet the same standards as other ready-to-eat
food processors.
Scope of GMPs: These standards apply
to the production of pasteurized and unpasteurized cider and juice products
which are not shelf stable (products which require refrigeration after
production). Production standards for shelf stable products have been
previously developed in other documents and regulations
DEFINITIONS
- Dropped Apples:
Apples that have contacted the ground in any manner in the orchard,
storage cooler, pressing room, or any other area. Where prudent precautions
have not been taken to maintain separation of tree-picked and dropped
apples, all apples shall be considered to be dropped apples
- Fresh or
Unpasteurized: Apple cider or juice which is produced by methods
which do not include processing steps which have been shown to result
in a 5-log reduction (99.999%) of disease causing microorganisms
- Pasteurized:
Apple cider or juice which has been sufficiently heat or otherwise
treated to result in a 5-log reduction (99.999%) of disease causing
microorganisms. If heat pasteurization is done, do the time/temperature parameters meet either 1) FDA-milk (at least 160°F for at least 15 seconds) or 2) Cornell University-cider (at least 160°F for at least 6 seconds for batches containing <50% Red Delicious apples, at least 160°F for at least 11 seconds or at least 170°F for at least 2 seconds for batches with > Red Delicious apples) or 3) UW Madison (at least 155°F for at least 14 seconds) recommendations? If the answer to this question is yes, then the cider may be labeled as "pasteurized" and the warning label is not necessary.
- Tree-Picked
Apples:
Apples which have been picked directly from the tree and segregated
from dropped apples under sanitary conditions
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Facility
Requirements
- [R285.553.18(1)]
The processing facility must be adequately screened to eliminate insect
and rodent entry. Cold storage door plastic curtains are effective
where entrance is by forklift. During the cider processing season,
overhead garage door openings can be framed in with temporary screened
panels and a walk-in door provided. Temporary screens should be tight
fitting and constructed in a manner that allows the garage doors to
be closed whenever desired. [R285.553.4(e)]
Completely
enclosed toilet facilities must be provided and should be conveniently
located near the work area. A sign must be placed in the bathroom
reminding employees to wash their hands after using the lavatory.
Conveniently located hand washing facilities must be provided and
must have hot and cold running water and soap available. Also, there
should be disposable towels and covered trash containers. [R285.553.10(1)]
Walls and ceilings should be light colored for easier cleaning and
to provide better lighting on all work surfaces. Adequate lighting
must be provided. All interior lights must be shielded to prevent
pieces of glass getting into food in the event of bulb or tube breakage.
[R285.553.4(a)] [R285.553.4(c)]
Grounds and buildings surrounding the cider operation must be free
of conditions that may result in contamination of the product. This
includes improperly stored equipment or spray materials, litter, waste,
uncut weeds & grass, and other rodent or pest harborage. [R285.553.3(1)(a)]
Disposal of all wash and wastewater not into a municipal sewerage
or septic tank system must be in accordance with Michigan Department
of Environmental Quality regulations. [R285.553.8]
Equipment, utensils, chemicals, and supplies not used in food processing
must be stored in an area clearly separated from those used in food
processing. [R285.553.4(b)]
All food contact surfaces must be constructed of food-grade materials
that are safe, durable, corrosion-resistant, non-absorbent, and can
be easily cleaned and sanitized. [R285.553.5(1)]
Copper and copper alloys must not be used in contact with apple cider.
[R285.553.5(1)]
All food contact equipment and supplies (examples: racks, cloths)
must be stored off the floor in a well-ventilated location that minimizes
the potential for contamination. [R285.553.16]
Hot and cold potable, running water must be available in all processing
areas. Sufficient volume and water pressure must be available to dislodge
particles of fruit and film from all surfaces. A high pressure washer
is highly recommended. [R285.553.7]
If well water is used, it must be tested by the appropriate public
health agency at least annually. The test should be done within 2
months prior to the commencement of seasonal apple cider operations.
[R285.553.20]
All tubing carrying cider must be approved for food use. Plastic tubing
should be transparent for ease of inspection and cleaning. Tubing
must be protected from abrasion or breakage and should be easy to
replace. Tubing must be as continuous as possible with couplings kept
to a minimum and should be positioned so that no pockets of liquid
remain when the tubing is rinsed (self-draining). Disassembling, cleaning,
and sanitizing of tubing, clamps, couplings, and connections must
be performed at least after each day's run and prior to use following
extended interruption. [R285.553.5], [R285.553.15]
The use of insecticides and rodenticide is permitted only under such
precautions and restrictions as will prevent the contamination of
food or packaging material with illegal residues. If used within the
processing area, precautions must be taken to protect all raw ingredients
and packaging materials. After spraying and before commencement of
any food-processing operation, all food contact surfaces must be thoroughly
cleaned and sanitized. [R285.553.14]
Since pesticide regulations are constantly changing, be sure to know
the current status of regulations regarding any pesticide used in
and around your operation. For further information about insecticides
and rodenticide, contact the Michigan Department of Agriculture, Pesticide
and Plant Pest Management Division at (517) 373-1087.
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Employees
- A person must
be assigned the responsibility to supervise the overall sanitation
of the facility. [R285.553.18(1)]
To prevent contamination of food products, all persons working in
the processing and filling areas must wear clean outer garments, maintain
a high degree of personal cleanliness and conform to hygienic practices
while on duty. Hands must be washed thoroughly before starting work,
after each absence from the working area, between operations, and
any other time when they have become soiled. All jewelry, except wedding
bands, should be removed. Hair restraints (hairnets, headbands, caps,
etc.) must be worn. If gloves are used, they must be designed for
food handling operations. Whenever personnel change from non-food
contact or cleaning operation to food contact operation, the individual
must replace gloves or wash hands thoroughly before resuming food-contact
operations. [R285.553.25]
Tobacco in any form must not be used in rooms where food or food ingredients
are processed, handled or stored. [R285.553.25]
A person who has diarrhea, or is a carrier of a communicable disease
that can be transmitted by food (examples: skin boils, sores, infected
wounds), is prohibited from working with cider apples or in the processing
area. [R285.553.24]
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Harvesting
- Steps can be
taken in the orchard to minimize microbial contamination of apples.
Harvest dropped apples as frequently as possible and keep separate
from tree-picked apples. Care should be taken during collection to
prevent the contact of rotten apples with wholesome fruit.
Dropped apples must not be used for the production of fresh cider,
but may be used where processing includes steps shown to effectively
reduce the pathogenic microbial population in the resulting product
by at least 5 logarithms (99.999% destruction).
Good hygienic practices should be used by those collecting apples
and toilet and hand washing facilities should be readily accessible
to field workers.
Know the quality of the apples from which you will be making your
cider. Only clean wholesome apples should be used. The use of written
contract specifications is highly recommended for cider producers
who purchase cider apples.
Visibly clean containers must be used to harvest and transport apples.
Containers should be maintained and inspected continually.
Unpasteurized apple cider must not be made from apples of orchards
fertilized with human or animal wastes.
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Receiving
- If cider apples
are purchased, adequate records should be kept of incoming lots, which
identify the date of purchase and source of apples used to produce
each lot of cider.
Accurate records can limit product recalls and producer liability
in the event of an outbreak.Apples for processing should be kept in
an enclosed area or otherwise protected from insects, rodents, and
other pests.
Animals (cats, birds, dogs, wild animals, etc.) are prohibited from
processing and storage areas of the building. [R285.553.14]
Apple containers must be inspected upon receipt and before apples
are used to assure the containers are free of visible filth which
may contaminate the apples. [R285.553.25(3)].
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Inspection
- All apples must
be inspected before washing and brushing. Only intact, wholesome,
tree picked fruit shall be used in the production of fresh or unpasteurized
apple cider. Wormy, decayed, or rotten fruit must be discarded before
entering the washing step. [R285.553.18(2)]
If used, flume water must contain an adequate level of a sanitizer
to prevent heavily soiled apples from spreading contamination via
wash water.
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Washing
and Brushing
- Apples must
be effectively washed and thoroughly cleaned (free of visible filth
and debris) using a wet brusher before crushing. This can be accomplished
as part of the grading operation. [R285.553.18(2)]
Pressed pomace must be properly disposed of immediately. Pomace residue
must not be left overnight in the processing area. Pomace residue
removal helps control insects and rodents on the property. [R285.553.12]
If additives like sodium benzoate and potassium sorbate are used,
care must be taken to assure they are weighed properly and added at
safe & effective levels.
Use of a food grade detergent and sanitizer to further reduce biological
contamination is recommended. Be sure to use in accordance with the
manufacturer's specifications.
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Crushing
and Pressing
- Crushing and
pressing equipment must be cleaned and sanitized prior to start-up
and at the end of each day of operation at a minimum. [R285.553.15(1)]
Equipment must be dismantled or disassembled as needed to insure adequate
cleaning and sanitizing. [R285.553.18(6)]
Press cloths must be specifically designed for cider production, made
of durable materials, and be replaced when necessary. During processing,
the cloths must be handled in a sanitary manner, which includes hanging
the cloths on a line or placing them in a clean container off the
floor between runs. At the end of each day's operation, all press
cloths must be washed, rinsed, sanitized, and dried. The cloths may
be dried by spreading them on a clean line in a well ventilated and
screened area away from flies and vermin. If a washing machine or
dryer is used, it must be dedicated solely for the cloths and not
for personal and work clothing. [R285.553.15(1)]
Press racks must be made of food-grade plastic or hardwood, which
has been maintained free of excessive cracks or crevices. Poorly maintained
equipment can be impossible to clean and sanitize adequately. [R285.553.5(1)]
Keep press racks off the floor at all times. At the end of each day,
all used press racks should be cleaned, sanitized, and allowed to
dry. [R285.553.15(1)]
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Post
Pressing
- Cider must be
bottled using new containers and caps, which have been properly stored
to be free of dust, debris, and insects. Inspect containers carefully
before filling. Refilling used, consumer containers risks contamination
of filling equipment and cider and can take place only in a manner
approved by the department. [R285.553.15(4)]
Use microbiological testing procedures on production batches to identify
sanitation failures or product contamination. While end product testing
may not be a complete assurance that the cider is free of pathogens,
indicator organisms such as coliforms or generic E.
coli may help determine if adequate and consistent sanitation
is being practiced. Testing may also play a role in HACCP
plan verification and establishing a quality history. (Testing by
an operator where necessary is a requirement under [R285.553.20].)
Retail containers must be properly labeled with the following information:·
Product identity - (Apple Cider) · Ingredients -- if additives are
used, the function must be indicated. For example, "potassium sorbate
(a preservative)" or "preserved with sodium benzoate". · Sell-by Date
· Name, address, city, state, and zip code of manufacturer, packer,
or distributor ·
Net quantity [MCLA 289.717]A "Keep Refrigerated" statement should
appear on the label.
You must clearly identify containers of non-shelf stable cider or
juice as either "Pasteurized" or "Unpasteurized". as either "Pasteurized"
or "Unpasteurized".
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Off
Season
- During the off-season,
press racks and cloths should be stored so that birds, animals, insects,
etc. are unable to come in contact with them. Thoroughly clean, sanitize,
and dry racks and cloths before storage.
For more information about Good Manufacturing Practices for Michigan
Apple Cider, contact the Food and Dairy Division, Michigan Department
of Agriculture, P.O. Box 30017, Lansing, MI, 48909 or call 517-373-1060
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