Cornell Dairy Foods Extension Program Syllabus High Temperature Short Time (HTST) Workshop

Transcription

1 Cornell Dairy Foods Extension Program Syllabus High Temperature Short Time (HTST) Workshop Instructors: Course Organizer - Steve Murphy, Sr. Extension Associate; scm4@cornell.edu; phone: (607) Instructors and contributors to this course include representatives of NY State Agriculture & Markets; guest instructors from industry and outside academia; and extension and dairy plant staff of. Course Contact: Janene Lucia; jgg3@cornell.edu; phone: (607) Overview: This course provides instruction on the operation and regulatory requirements for HTST pasteurization. It includes hands-on exercises and demonstrations designed to give participants practical skills in HTST system testing. The course meets the training requirement for dairy plant employees who participate in the NY State HTST Broken Seal Program (e.g., testing HTST equipment after repairs). It also fulfills the pasteurization course requirement (alternative to vat pasteurization workshop) for the Dairy Foods Extension Certificate Programs (attached). The workshop can be taken as a stand-alone training program. It is a 2.5 day course, offered at least twice a year on the Cornell campus. A course program outline follows. Learning Outcomes: This course will provide attendees with information in the key program areas listed below. Basic Dairy Microbiology/Food Safety (brief overview); Participants Will: - Know the basics of dairy microbiology important to dairy product quality including factors that influence microbial growth of both desirable (e.g., starter cultures) and undesirable (e.g., spoilage and pathogens that cause illness) microorganisms and how to reduce undesirable contamination risks. - Understand the importance of pasteurization and sanitation procedures in controlling food borne pathogens and spoilage organisms associated with raw milk and dairy products. Unit Operations in High Temperature Short Time Pasteurization (HTST); Participants Will: - Learn the key processing steps and components and their functions in HTST systems including all sections of the HTST plate heat exchanger; timing and booster pumps; homogenization; separation and standardization; and flow diversion devices. - Understand HTST control systems and how they provide assurance of proper pasteurization. Regulatory Requirements and Testing of HTST Systems; Participants Will: - Understand the general requirements and where to find specific regulatory information (e.g., the Pasteurized Milk Ordinance PMO) on the operation and testing of legal HTST pasteurization systems. - Know the requirements of the NYS Broken Seal Program. - Learn through hands-on exercises and demonstrations the required HTST system tests that ensure proper operation and milk product safety, including flow diversion valve tests, indicating and recording thermometer checks; safety thermal limit recorder operation; flow rate determinations and others. Cleaning, Sanitation & Maintenance for HTST Systems; Participants Will: - Understand the importance of cleaning, sanitation and maintenance programs as applied to HTST systems and associated equipment. Evaluation: A pre-test will be administered to determine the incoming knowledge base of course participants on HTST concepts. A post-test will be given at the end of the course addressing materials covered in the training. Participants must receive a passing grade on the post-test in order to receive a Certificate of Completion that is recognized by NY State as meeting the training requirement for the Broken Seal Program. A Certificate of Completion for this workshop is also required to satisfy the pasteurization course requirement (alternative is the vat pasteurization course) for those enrolled in a Cornell Dairy Foods Certificate Program. As part of the Certificate Program, questions pertaining to materials covered in this course will be asked in the final exam required for completion of the respective certificate programs for fluid milk, cultured products and cheese.

2 DAY 1 HTST PASTEURIZER OPERATOR WORKSHOP Cornell University, Department of Food Science & NYS Agriculture and Markets Cornell University, Ithaca, NY PROGRAM DRAFT 9:15 am Registration & Coffee (please sign in on arrival) 9:30 am Welcome, goals and objectives Hosts: Cornell University 9:45 am Program Review: Pre-Test Staff 10:15 am Why Pasteurize: Basics of Dairy Microbiology & Product Quality 10:45 am BREAK 11:00 am Why Pasteurize: Product Safety 11:30 am Equipment System Design & Control 12:15 pm LUNCH Provided 1:15 pm Equipment System Design & Control (continued) 2:30 pm BREAK 2:45 pm HTST Recording Charts; Exercise and Review 3:45 pm HTST Instrumentation for Control 5:15 pm End of Session Day 2 8:00 am Coffee & Questions 8:15 am NYS Requirements for Operating with a Broken Regulatory Seal; Review of Regulatory Tests for HTST 10:00 am BREAK 10:15 am HTST Testing: Demonstrations & Hands-On Breakout Sessions Participants will rotate in assigned groups through 5 stations set up to demonstrate regulatory requirements and HTST testing procedures with hands-on participation. Breakout sessions described on the next page:

3 HTST PROGRAM Page 2 DAY 2 (continued) 10:15 am Breakout Session 1 A. Safety Thermal Limit Recording (STLR) Device - accuracy; cut-in/cut-out; event pen/flow meter alarms; chart requirements; system set-up and calibration procedures (Anderson 9900 STLR) B. HTST Holding Time & Flow Rates ** - salt test; holding tube slope; and can fill; HTST system operation run & overview C. Safety Thermal Limit Recording (STLR) Device - thermometric response; electronic magnetic interference; chart requirements with mag-flow recording parameters; system set-up, pen-lift adjustments/functions and calibration procedures (ABB STLR) D. Flow Diversion Device - Valve Testing - leak detection; valve seat control; device assembly; response time; time delay E. Pressure Differential & DART Thermometers - testing pressure sensors; calibration; inter-wiring; digital reference thermometer overview 11:15 am Breakout Session 2 Group Switch 12:15 pm LUNCH Provided 1:15 pm Breakout Session 3 Group Switch 2:15 pm Breakout Session 4 Group Switch 3:15 pm BREAK 3:30 pm Breakout Session 5 Group Switch ** Station B DAY 3 UP/UHT/HHST Sequence Logic Demo for Group(s) with personnel from UP/UHT/HHST 8:15 am Coffee and Questions 8:30 am NYS Broken Seal Policy Review; Phosphatase Testing and Sampling - Regulatory Requirements 9:00 am Cleaning & Sanitizing HTST and Product Distribution Systems 10:15 am BREAK 10:30 am Maintenance of HTST Systems Academic Partner 11:15 am Program Review: Post-Test Staff 11:45 am Review/Q & A/Certificate Distribution & Adjourn Staff

4 Cornell Dairy Foods Extension Certificate Program Core Competencies & Learning Objectives Basic Dairy Sanitation & Safety Certificate (3-day course): Basic Dairy Microbiology/Food Safety Overview Good Manufacturing Practices / Dairy Sanitation Milk Composition & Unit Processing Operations Dairy Regulations/Food Safety Modernization Act *Required Prerequisite Course for Dairy Foods Extension Certificate Programs. Offered as a stand-alone GMP training program. Fluid Milk Processing for Quality & Safety Certificate Core Competencies: Regulations for Grade A Milk Milk Microbiology from Farm to Table Factors Influencing Raw Milk Quality Unit Operations for Processing & Packaging Fluid Milk Quality & Shelf-life of Fluid Milk Evaluating Milk Shelf-life & Quality; Trouble Shooting Defects Procedures to Improve & Maintain Optimum Shelf-life Ensuring Product Safety through HACCP and GMP Principles Yogurt and Fermented Dairy Products (Basic/Advanced Certificate) Core Competencies (Basic): Milk Quality & Basic Chemistry Basic Dairy Microbiology Starter Cultures for Fermented Products Product Processing & Formulation Product Evaluation & Defects Product Safety & Protection Record Keeping/Observations Dairy Sanitation Core Competencies (Advanced*): Advanced Applications in Fermented Milk Processing Technology Product Development Product Evaluation & Quality Assurance Cheese and Cheese Products (Basic/Advanced Certificate) Core Competencies (Basic): Milk Quality & Basic Chemistry Basic Dairy Microbiology Starter Cultures for Cheese Varieties Standardization & Processing Options Curd Handling Techniques Molding, Brining & Curing Record Keeping/Observations Dairy Sanitation Core Competencies (Advanced*): Advanced Concepts in Cheese Manufacture Cheese Grading & Quality Assurance Microbiology & Biochemistry of Cheese Manufacture & Aging

5 Cornell Dairy Foods Extension Certificate Program Curriculum & Requirements Fluid Milk Processing for Quality & Safety Certificate Yogurt and Fermented Dairy Products Certificates Cheese and Cheese Products Certificates Curriculum & Requirements: HACCP for Dairy (2.5 days) Fluid Milk Processing for Quality & Safety (2 days) Written Test Basic Curriculum & Requirements: Cornell s Basic Cultured Products Workshop (2.5 days) Advanced Curriculum & Requirements*: Must Complete the Basic Certificate Requirements Proven Experience with Fermented Milk Products (2+ years) Cornell s Advanced Cultured Products Workshop (3 days) Written Test & Oral Review Basic Curriculum & Requirements: Cornell s Basic Cheese Making Workshop (2 days) Advanced Curriculum & Requirements*: Must Complete the Basic Certificate Requirements Proven Experience with Cheese Products (2+ years) Cornell s Advanced Cheese Products Workshop (3 days) Written Test & Oral Review To obtain a Dairy Foods Extension Certificate, candidates must successfully complete all curriculum requirements and tests. All training courses offered by the CU Dairy Foods Extension Program may be taken as stand-alone programs. Cornell University Dairy Foods Extension Certificate Program For more detailed information or to enroll in the program contact: Janene Lucia Department of Food Science jgg3@cornell.edu Stocking Hall Ithaca, NY This Certificate Program is offered by the Cornell University Department of Food Science Dairy Foods Extension Team. The program is designed to provide trained personnel for the dairy industry and is open to all interested parties.