Engineer Food Processing Safety flashcards

32 cards. Read the term and the definition here. The deck at the top of this page is optional.

D-value

Time at a specified temperature required to reduce a microbial population by 90 percent, or one log cycle. It is the basis for calculating thermal process times.

z-value

Temperature change in degrees Celsius that produces a tenfold change in the D-value. It describes how sensitive an organism is to temperature changes.

F0 value

Equivalent lethality at 121.1 degrees Celsius with a z-value of 10 degrees Celsius. It is computed from the time-temperature curve accumulated during a thermal process.

12-D botulinum cook

A thermal process reducing Clostridium botulinum spores by twelve log cycles, the classical minimum for low-acid canned foods. It corresponds to F0 of about 2.52 minutes.

Low-acid canned food

A food with pH greater than 4.6 and water activity greater than 0.85 that is thermally processed and hermetically sealed. It requires a filed scheduled process under 21 CFR 113.

Acidified food

A food with a natural pH above 4.6 that is acidified to pH 4.6 or below. Equilibrium pH must be verified, and the product is regulated under 21 CFR 114.

Cold spot

The location in a container or product that heats most slowly during thermal processing. Thermocouples are placed there to confirm the scheduled process is achieved.

Heat penetration study

A study in which thermocouples record product temperature at the cold spot during processing. The data are used to calculate lethality and establish the scheduled process.

HTST pasteurization

High-temperature short-time pasteurization of milk at 72 degrees Celsius for 15 seconds. It reduces pathogens such as Coxiella burnetii and is verified by phosphatase testing.

Listeria monocytogenes

A psychrotrophic pathogen that grows at refrigeration temperatures and is salt tolerant. It causes listeriosis and is controlled by validated lethality and post-lethality environmental controls.

Spore-formers

Bacteria such as Clostridium and Bacillus that form heat-resistant spores. They survive pasteurization and are controlled by pH, water activity, refrigeration, or sterilization.

Predictive microbiology

Mathematical models that estimate microbial growth, survival, and inactivation from temperature, pH, and water activity. Models must be validated against the actual food matrix.

Biofilm

A structured community of microorganisms attached to a surface and embedded in an extracellular matrix. Biofilms resist sanitizers and require mechanical removal during cleaning.

CIP cleaning

Clean-in-place circulation of detergent and rinse water through equipment at controlled flow, temperature, and concentration. Flow velocity provides the mechanical action needed to remove soil.

Sanitizer contact time

The wet time a sanitizer must remain on a clean surface to achieve the intended log reduction. Inadequate contact time or residual soil reduces effectiveness.

ATP swab

An adenosine triphosphate test that rapidly indicates residual organic soil on a surface. It is a cleaning verification tool, not a microbial test.

Hygienic design

Equipment constructed with smooth, non-porous, corrosion-resistant surfaces, radiused corners, and drainability. It allows effective cleaning and prevents harborage of microorganisms.

Sesame allergen

Sesame was added to the US major allergen list in 2023. It must be declared in ingredient lists, and cross-contact controls apply to sesame-containing products.

Allergen cross-contact

The unintended transfer of an allergenic protein from a food containing the allergen to a food that should not contain it. It is controlled by validated cleaning and scheduling.

Allergen cleaning validation

Use of specific ELISA or lateral-flow tests for the target protein to prove cleaning removes the allergen. General protein swabs are not sufficient.

Contains statement

A voluntary or required declaration listing the major allergens present in a food. It supplements the ingredient list and does not replace allergen control programs.

Metal detection

Inspection using a magnetic and electromagnetic field to detect ferrous, non-ferrous, and stainless steel contaminants. It is verified with certified test pieces at defined intervals.

X-ray inspection

Inspection that detects metal, glass, bone, and dense plastic by density differences. It can also verify fill level and count but is less effective for low-density materials.

Food-grade lubricant

An H1 lubricant approved for incidental food contact, or an H2 lubricant for non-contact applications. Non-food-grade lubricants are prohibited in production areas.

Glass and brittle plastic register

An inventory of glass and brittle plastic items in production areas. It supports breakage procedures that hold product and inspect the line for fragments.

HACCP seven principles

Hazard analysis, CCP determination, critical limits, monitoring, corrective actions, verification, and recordkeeping. These principles form the structure of a HACCP plan.

Critical limit

A measurable value that separates acceptable from unacceptable at a critical control point. It must be validated and monitored at a defined frequency.

Validation versus verification

Validation provides evidence that a control measure can achieve the intended food safety outcome. Verification confirms the measure is working as intended in practice.

PCQI

Preventive Controls Qualified Individual who has completed training and develops or oversees the food safety plan under the FSMA Preventive Controls Rule.

FSMA Preventive Controls

The US rule in 21 CFR 117 requiring a written food safety plan with hazard analysis, preventive controls, supply-chain program, recall plan, and monitoring.

Environmental monitoring zones

Zone 1 is food contact, Zone 2 is adjacent non-contact, Zone 3 is remote non-contact, and Zone 4 is outside processing. Sampling targets Listeria in ready-to-eat environments.

Zone 1 positive

A Listeria-positive result on a food contact surface. It triggers product hold, risk assessment, intensified cleaning, and root-cause investigation before release.