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H YGIENE C ONCEPT

OF THE S UGAR I NDUSTRY

V EREIN DER Z UCKERINDUSTRIE

H YGIENE C ONCEPT

OF THE S UGAR I NDUSTRY

V EREIN DER Z UCKERINDUSTRIE 2006

P REFACE TO FIRST EDITION

P REFACETOFIRST EDITION

In the last few years,questions of hygienehavegained significanceasefforts of providing more systematic food safety intensified. This is reflected,inparticular, by the papers of and also thedifferent directivesofthe .

Theseregulations account for the more stringent requirements on in theface of aconstantly growing international goods tradeinasmuch as,more than in the past, business operators themselves will be calledupontoimplement andgivesha- pe to the requirementsoffood hygiene principles andpractices as forth in theseregula- tions; at the same time,however, implementationcan take amore direct bearing on practicalnecessities.The factthatmeasures designed to guaranteesafefoodstuffsare formulated by businessoperators themselves will be acentral aspectinthe future.

The present HygieneConcept reflects this situation, which translates the requirements of the Community HygieneDirective (93/43/EEC)intothe sugarindustry'sown specific hy- gienerequirements.Because of theproduction process involved andits properties,su- garisasafe foodstuff in itself, and thehygiene directive and implementation of thehy- gieneConcept give additional systematic and comprehensive support.

If notalreadyintegrated into thequality managementsystems of business operations, the HygieneConcept will now gradually be translated into thepracticalworkofproduction plants.

Bonn, March 1996 P REFACE TO SECOND EDITION

P REFACETOSECONDEDITIO N

The Hygiene Conceptofthe SugarIndustry of 1996/1997 hasbeensystematically im- plementedinall companiesinthe German industry andhas found great accep- tancefrommanysides in thepast fewyears.

The concepthas proved to be appropriate forsatisfying therequirements of Directive 93/43/EEC on the hygiene of foodstuffs with regardtothe needs of the sugarindustry.

The extensive reform of European Hygiene Lawhas now rendered it necessary to adapt the conceptinview of changes to the general legal conditions.

The objectiveofthis reform is theimplementationofthe concept “From Farm to Fork”, as well as the consolidation andsimplification of the existinghygiene provisions.

Of relevance to the sugarindustryisRegulation (EC) No.852/2004 of theEuropean Par- liament andthe Council dated 29 April 2004onthe hygiene of foodstuffs, which came in- to force on 20 May2004 andhas been in practice since1Januar y2006. This regulation replacesDirective93/43/EEC on the hygieneoffoodstuffs.

Significant changes in comparison with the previousprovisions are the inclusionofpri- mary production and compliancewiththe principles and conceptsofRegulation (EC) No. 178/2002 layingdownthe generalprinciplesand requirements of food law.

Basedonthe new legalposition the Hygiene Concept of theSugar Industry has been re- visedand is nowavailableinasecondedition.

Bonn, March 2006 T ABLE OF CONTENTS 5

T ABLEOFCONTENTS

1. Introduction...... 6

2. Scope of applicationofthe HygieneConcept...... 6

3. Primary production...... 7

4. Sugar extraction...... 8 4.1Production process...... 8 4.2Specialsugar products ...... 10

5. Hygienerequirements of sugar extraction ...... 11 5.1 General requirements forfactory hygiene ...... 11 5.1.1 Premises/environment...... 11 5.1.2 Sanitary facilities ...... 11 5.1.3Cleaning ...... 11 5.1.4 Pest control ...... 12 5.1.5Water supply ...... 12 5.1.6 Wastewater ...... 13 5.1.7 Waste...... 13 5.2 Specialrequirements for factory hygiene ...... 13 5.2.1Requirements forjuice extraction, purification and thickening...... 13 5.2.2 Requirements forcrystallisation, drying, sieving, further processing and storage...... 13 5.2.3Requirements of packaging and storage of products for sale ...... 14 5.2.4 Reprocessing/Rework ...... 14 5.2.5 Requirements of loading and transportation...... 15 5.3 Personal hygiene...... 15 5.3.1 Personalhygienemeasures...... 15 5.3.2 Hygiene training ...... 16 6 I NTRODUCTION/SCOPEOFAPPLICATION OF THE H YGIENE C ONCEPT

1. I NTRODUCTION With this HygieneConcept the compa- However, theproducts of the sugar in- nies of the sugar industry in Germany dustryand theirproperties, themanu- have presented ajoint approachtothe facturing processes and theprocedures implementation of Regulation (EC) No. involvedinthe sugarfactoriesare com- 852/2004 on thehygiene of foodstuffs. parable so that asector-wide interpreta- tion of European Hygiene Law is possi- Each companyisitself responsiblefor ble. In all companiesthe implementation the implementation of therequirements is integrated into the structure of aqual- of EuropeanHygieneLaw –including ity managementsystem. the application of the HACCPconcept – whilst at thesame time takingintoac- count itsown specific conditions on site.

2. S COPE OF APPLICATION OF THE H YGIENE C ONCEPT Regulation (EC) No. 852/2004 formulates cial sugar products andalso includes sto- general hygieneprovisions forfood com- rage and transportation. panies at all levels of thefood chain, in- cluding primary production. The HACCPconcept of thesugar indus- try, which is described in aseparatevol- The main focusofthe Hygiene Concept ume,has also beenupdatedbecause of comprises both thesugar extraction pro- the changes to the European Hygiene cess as well as the manufacture of spe- Law. P RIMARY PRODUCTION 7

3. P RIMARYPRODUCTION Regulation (EC) No. 852/2004 on the The tests carried out by the working hygiene of foodstuffsfirst formulateshy- groups form the basis foradviceonplant gienerequirementsfor food business protection,the useoffertilizers andvari- operators at thelevel of primarypro- ety selection (Chap. II No. 5). duction. In this regard, Annex Icontains Plantprotection: general hygiene requirements thatmust The companies of the sugar industry be observed in thecontext of primary andthe growers’associations work out production.Theserequirements refer joint recommendationsfor tackling particularly to cultivation, transportation weedsand pests as well as forthe andrecord-keeping. treatmentoffoliar diseases (Chap. II Even though theprovisionslisted in An- No. 3a). nexIdo notapplytothe sugar industry Fielddocumentation: buttoevery individual beetgrower, the The beet growers have acontractualob- pointsthatare characteristicfor co- ligation to maintain asystem of fielddo- operation between the sugar industry cumentation in which theseed used, the andthe beet growers will be addressed application of fertilisers and plant pro- below. tectants are documented,aswell as, The basic principle of this cooperation is where applicable, additional measures the contractual relationship (beet de- that have been taken,e.g.for soil culti- livery contract, sector agreement) that vation (Chap. III Nos.7and 9). exists between every beetgrower and Beet cleaning: the sugar industry. In order to reducethe amountofsoilre- The following points assist thebeet sidue thesugarbeets are usually pre- growers withthe implementation of the cleaned at the edge of thefield before requirements of Annex I 1). loading (Chap. II No.5b).

Advice: Transportation of sugar beets: Adviceisprovided to beet growers in Contractual agreements require that ve- cooperationbetween the sugar industry, hicles are suitable for the transportation growers’ associations,workinggroups of sugar beetsand,where necessary, held jointly by both groups and also the arecleanedbefore loading(Chap. II officialagricultural advisory agencies. No.5).

1) Where the lawisreferred to in this chapter, referenceismade to the relevant passages in Annex I (Primary Production)ofRegulation (EC) No.852/2004. 8 S UGAR EXTRACTION

4. S UGAR EXTRACTION

4.1 P RODUCTIONPROCESS

The aim of sugar extraction is to extr act that canthenbeseparated offbyfilter- the sucrose from thesugar beet in a ing. This leaves aclear, light yellow liq- crystalline, pure form. uid, thethin juice. Theresidue that has been filtered off is pressed to carbonata- Preparation of beets: tion lime and marketed as fertiliser. The sugar beets, whichhave already been pre-cleaned in thefields,are sto- Juicethickening: redtemporarily in thesugar factories on Water is then extracted from thethin beet storageunits. On conveyor belts or juice in amulti-stage evaporation station flumesthe beets aretransported to the under pressure and at high tempera- beet washer, where any remaining soil is tures (120 to 130 °C)until thesugar con- removed and anytopsand stones are tent of the resulting juice is between70 separated off. Soil, tops andstonesare and 75 %. removed fromthe washwater and fedto Crystallisation, drying, sieving, storage: furtheruse.The beets are sliced into Solid sucrose is extractedfromthe thick smallpieces in theslicing machines. juice by meansofcrystallisation. Extraction: In thefirst stagethe thick juiceisre- In acontinuous counter-current extrac- duced at temperatures of around 80 °C tion processusing water the thin slices and under alight vacuum to agiven dry of beet(cossettes) heated to around substancecontent. The mixture is then 70 °C are desugarized.This creates a inoculated with smallsugarcrystals as 15 %sugar solutionthatisknown as seedcrystalswhich growinthe course rawjuice. The desugarizedcossettes of the crystallisation process. When the (beet pulps) are marketed as animal crystal content reaches approximately feed. 55 %the process is interrupted.The Juice purification: mixture of crystals and syrup is passed The raw juicecontains apart fromsugar viaintermediate tanks into thecentri- other components of sugar beet. Some fuges wherecrystals and syrupare of thesecomponents precipitate by add- separated. Thissugar –whitesugar –is ing of lime and carbon dioxide. The dried, sieved and then stored temporar- generated calcium carbonatesurrounds ily in thesilo to await further processing. the precipitated non-sugar components S UGAR EXTRACTION 9

Then in two subsequent crystallisation in theproductionofanimalfeed,yeast stages the syrup is further desugarized. and alcohol. The sugar stored temporar- The so extracted sugar is dissolved and ily in the silos is sieved according to c us- crystallised again.Refined sugar is the tomerrequirements and distributed ei- productofthis second crystallisation ther as looseorpackaged goods. stage. This tooisdried and sieved and putinstorage in thedesignated silosto Furtherprocessing: await further processing. In the third Some of the sugar is processed to make crystallisationstage thesyrup obtained cubesugar, icing sugar, jelly sugaror is molasses,whichisusedfor example other specialities.

Sugar beets

Preparationofbeets (washing and slicing)

Juice extraction Desugarizedbeetpulps (extraction of sugar from slicedbeet) (animal feed)

Juicepurification (separation of non-sugarcomponents)

Juicethickening Carbonatationlime (removal of water)

Crystallisation

Drying Molasses

Sieving

Sugar (white sugarand refined sugar)

Storage, further processing

Figure:Simplified diagramofsugarextraction 10 S UGAR EXTRACTION

Because of this production processthe The sterilizationconditions during sugar quality of thesugar beethas no effect on production and especiallythroughoutthe the sugar quality thatisobtainedwith a crystallization process ensure that the high level of constancy. This is asignifi- product sugar is produced to ahigh level cant difference in comparison with many of purity (minimum 99.7 %accordingto other foodstuffs(vegetables,, sal- theEC- Directive)and micro- ads, , milk),whichcan usually be biological safety,sothatitcan be kept consumed immediately,orafter only foranunlimited period whenstoredap- minimal preparation, meaning thatthe propriately. quality of theraw materials is crucial to the quality of the end product.

4.2 S PECIAL SUGARPRODUCTS

Sugar is used by thefoodprocessing in- and dissolving of sugar, themixing of dustry and by the final consumer; it is al- sugar with ingredients and specialcrys- so araw materialfor products of further tallisationprocedures. These products processingmanufacturedbythe sugar are, forexample, icingsugar, cube industry itself. The methods forthe ma- sugar, liquid sugars, jelly sugars,fon- nufactureofproducts of furthersugar dant,brown sugars, sugars and processinginclude the milling,pressing fructose. H YGIENE REQUIREMENTS OF SUGAR EXTRACTION 11

5. H YGIENEREQUIREMENTS OF SUGAREXTRACTION In thefollowing is described how the The conceptisdivided into general re- sugar industry is satisfying therequire- quirementsand special requirements for ments of AnnexIIofRegulation(EC) factory hygieneaswell as into personal No.852/2004 on thehygiene of food- hygienemeasures. stuffs2).

5.1 G ENERALREQUIREMENTS FOR FACTORY HYGIENE

5.1.1 Premises/environment suchthat there is no direct access from Industrial premises are kept clean. In or- thetoilets to the production rooms. dertoachieve this maintenanceand The toilets are fitted with flushing, sepa- cleaning measures areimplemented rateventilation andhand-washing facili- (see 5.1.3)(Chap. INos. 1and 2a). ties (Chap. INo. 3). For processes whichtakeplace in non- Allwashhand basins have hotand cold closed or only partially closed systems, running waterplus everything required action is taken to protectagainst nega- forthe hygienic washingand dryingof tive effects.Doors and windows are kept hands (e. g. liquid soap,disinfectant, closed to prevent the penetration of dirt disposable hand towels)(Chap.INo. 4). andpests. Where necessary, windows areprovided with -proofscreens 5.1.3 Cleaning (Chap. II No.1d). Cleaning is carriedout with theappro- All buildingshaveeither natural or artifi- priate equipmentindifferentwaysand cial lighting. Where lightfittings arelo- with varyingdegrees of frequencyinthe catedinrooms containing open product- individual areas.Inthisrespect consid- carrying sectionsofthe plant then these eration is given to,for example, theex- are fitted with protectionagainst shatter- tent to whichthe machineryand equip- ing glass (Chap. INo. 7). ment in use in therooms in question can affectthe hygiene of the endproducts. 5.1.2 Sanitary facilities The cleaning measures carried outare Toilets for employees arelocated within of apreventive nature to avoid build-up easy reachofthe work station.Inareas of dirt before any pestsand micro- dealing withthe post-crystallisation sta- organismscan become established as a ge the structure of the building is always result.

2) Wherethe lawisreferredtointhischapter,referenceismadetothe relevant passages in Annex II of Regulation (EC) No.852/2004. 12 H YGIENE REQUIREMENTS OF SUGAR EXTRACTION

The type of cleaning is stipulated in If necessary,steps are takentoeradi- cleaning plans. At sugar extraction in cate anypests. In this case authorised post-crystallisation areas special con- pest eradicationagents areused.These sideration is givenincleaning plansto preparationsare only used by people places wheredirt could collectorcon- who arefamiliarwith the correct way to densation water could form.Dry,damp handle them. Theyare usedaccording or wet cleaning methodsare used if ne- to aspecific plan andthe process is do- cessary. cumented(Chap. IX No.4).

Checks are performed to seethat These measuresare implementedin cleaningplans are being observedand suchaway thatany detrimental effects plans updated if need be: on the foodstuffsare avoided (Chap. IX,  areas (and equipment) to be No. 4). cleaned,  typeand frequency of cleaningtobe 5.1.5 Watersupply carriedout, Duringthe sugar extraction process lar-  responsibilities for carrying out the ge quantitiesofvapour condensation cleaning, occur in the heating and thickening sta-  arrangements formonitoring. ges,which is then pipedincircuits and re-used.The vapour condensate is a Where cleaning or disinfection agents distillate that,because of thehigh pro- are used forspecial purposes, adequate cesstemperaturesofupto125 °C,is rinsing of themachinery is carried outto safe from amicrobiological point of view. ensure that any residue from theagent used does not affectthe product (rinsing When theexternal and internal systems programme).Suchagents are stored arefilled initiallywater is obtained from outside the production rooms (Chap.1 an external supplier or thecompany’s Nos. 2a,bandc,Chap.IINo. 2, Chap. own well. Because of thenatureofthe V1a, c, d). production process it is not necessary to use drinkingwater (Chap. VIINo. 3). 5.1.4 Pest control Factory sitesand buildings undergo, if Water of drinking waterquality is used necessary,systematicpreventive pest forthe manufacture of special products. control measures by specialcompanies If needbethis wateristreated for spe- from outside.The action takenisaccord- cial purposes(e. g. demineralised) ing to the requirements of the individual (Chap. VII No. 1a). Exceptions maybe areas.Pestcontrol measures mainly made to this rule provided theperfect concern rodents and (Chap.1 hygienequality of theend productis No. 2c). guaranteed. H YGIENE REQUIREMENTS OF SUGAR EXTRACTION 13

5.1.6Waste water Otherwaste is collected in the produc- Waste waterisdrawn off in such away tion rooms in the containers provided – thatacontact with theproductisimpos- closable if necessary –and placed at sible(Chap.INo.2,10). designatedlocations for collection (Chap. VI Nos. 1-4). 5.1.7 Waste As theentire sugarbeetisused thereis no waste fromthe sugarextraction process.

5.2SPECIAL REQUIREMENTS FORFACTORYHYGIENE

The hygienerequirements listedbelow stepstoprotect the product hygienically are supplementary to thegeneral re- fromimpairment, in particularbythe am- quirements,and where necessary pro- bientair (Chap. 1No. 2c). Floors are vide more precise details. kept perfectly clean.Wet cleaning is pos- sible in the entire area;however the dry- 5.2.1Requirements for juice ing areaaswellasthe silos andthe pro- extraction, purification and duction rooms for sugarsievingand for thickening themanufacture of products forfurther Theprocess stages of juice extraction, processingshould only be wetcleanedin juicepurification and juicethickeningare exceptional circumstances(Chap.INo. 2 fullyautomatic and take place to agreat andChap. II No.1a). extent in closed systems. Becauseofthe high pH values and temperatures in- Equipment, windows, doors, walls and volved in theseprocesses the juicehas ceilingsare designed to avoid dirt collect- been sterilised by the time it is passed on ing and to be easytoclean. In places to thecrystallisationarea. where moisture canbedeposited on walls, checksare carriedout to seeif Duetothe continuous manufacturing mould is forming and if necessary action process systems carrying the product is to be taken to treat thearea (e. g. with canonly be cleaned at thestart andthe fungicidal paint) (Chap.IINo. Ib-f, Chap. endofacampaign (Chap. 1Nos.1 VNo.1 b). and2). Ceilings arekept in good condition. This 5.2.2 Requirements for crystalli- applies especially to areas above open sation,drying, sieving, further processing and storage transportationelements after centrifuga- tion.Where condensed waterforms on After centrifugation thesugar is present ceilingsand beams action taken in- in itscrystalline form. As therest of the volves,for example, covering,ventilation process is notcarried outexclusively in andcleaning (Chap.IINo. 1c). closed systems,itisnecessary to take 14 H YGIENE REQUIREMENTS OF SUGAR EXTRACTION

The cleaning and,ifnecessary, also dis- The filters in the tanksare cleaned, disin- infection of machinery and equipment fectedand replacedatset intervals (suchastransport elements andmag- (Chap. INo. 2a,Chap. VNo. 1). neticseparators)isstipulatedincleaning 5.2.3 Requirements of packaging plans. Care mustbetakenduring clean- and storage of products for sale ing to ensure thatthere is no negative ef- Products for sale and packaging materi- fectonthe nextproduction step.When als are storedinsuchaway as to avoid cleaning aroundequipment particular ca- anycontamination of the product (Chap. I re mustbetaken to cleanthe spaces and No.2c, Chap. XNo. 2). corners behindand between equipment (Chap. VNo. 1and Chap.INo. 2). The storagerooms are keptcleanand dry(Chap. INo. 1). The formation of condensed water inside silosisprevented by theprovision of in- The temperatureand humidity in thesto- sulation, heating andventilationfor the rage roomsiskept at an appropriate le- silos. The air used for heatingand venti- vel (Chap.INo. 2d). lation is passed through filters.The filters are serviced andthe filter materialre- Doors to the outside, including loading placed if necessary. Thefilters in the su- ramps, arekept closedasfar as possible gardryingand dust removalequipment (Chap.INo. 2c). are also servicedorreplaced (Chap.I No. 2and No. 5). 5.2.4 Reprocessing/Rework Sugarthataccumulates in various places In addition special companyrequire- after the crystallisationprocessand also ments apply dependingonthe product in the packaging andstoragearea (e.g. andthe equipment. sugar incrustationsfromthe silo, sugar accumulating on packaging machines)is For instance, storage tanks forliquid collected in marked bins and reintro- sugars are cleaned after emptying. The frequency as well as the cleaning and duced into the production process –after disinfectionproceduresare specified. first being cleaned if necessary. H YGIENE REQUIREMENTS OF SUGAR EXTRACTION 15

5.2.5Requirements of loading and foodstuffs it mustundergo appropriate transportation cleaningbefore it is filled. Information is Sugar and products of further processing provided about the goodscarried and the are transported bothlooseand pack- cleaning operations that havebeen car- aged. ried out(Chap. IV No. 1, 5).

Theloading station for both solid andliq- Packagedgoods are to be transported in uidproducts for sale plus the surrounding such away as to keepthe riskofcon- area is kept clean, dryand tidy (Chap. I tamination to aminimum (Chap. IV,Nos. No. 1). 1, 6).

Loose intermediary products and prod- Where transportationiscarried outby ucts forsaleinsolid andliquid form are third parties theyare obligedtoobserve transported in silo lorriesand tankers that the foodlaw provisions. Random inspec- are intendedexclusively for the transpor- tionsare carried out to checkthat the re- tation of foodstuffs andare permanently quirementsare being observed. Vehicles marked with thenotice“forfoodstuffs that do not complywiththe requirements only”(Chap.IVNos.2,4). arerejected.

When avehicle switchestocarrying loo- se sugarproducts after transportingother

5.3 P ERSONALHYGIENE

Personal cleanliness andanawareness the areasfor crystallisation,storage, of the hygienic behaviour of the employ- manufacture of further processingprod- eesinafactory haveboth adirectand ucts, packaging and loose loading (Chap. indirect influence on the hygienic status VIII No.1). of thefactory andthe product. Micro- organisms arealso broughtinto thefac- Employees wear clean,appropriate work tory and spread by employees(e. g. on clothing andheadgear (Chap. VIII No. 1). skin and hair). Changing rooms are provided forthis purposewhere necessary (Chap. I 5.3.1Personal hygiene measures No.9). The requirements of personalhygiene Special regulations that are determined aredeterminedbythe needs of theindi- on site apply to certain areas. vidual areas, with special requirementsin 16 H YGIENE REQUIREMENTS OF SUGAR EXTRACTION

Employees are giveninstructions each 5.3.2 Hygiene training timebefore entering asiloand mustwear Employees are given regulartrainingin the clothing provided. mattersoffood hygiene (Chap. XII No.1). Food anddrinks are only kept and con- sumed in therooms or areas provided for Hygienetraining foremployeesinvolved that purpose. in the areas of crystallisation,storage, preparationofdifferent commercial gra- is only permitted in designated des, manufacture of special products, rooms. packaging andloose loading basically in- cludes the following: Personal hygiene measuresinclude amongst others,washing hands before  generalinformationonthe subjectof starting work,after breaks,after usingthe food hygiene, toilet and after performing tasksinwhich  principles of staffhygiene, the hands become dirty, as well as be-  special behaviour for hygiene in fore carryingout repairs and handling the one’sown work area, equipment(Chap. VIII No.1).  hygieneand cleaning measures in the factory. Lesionsonthe skin and wounds are cov- ered immediatelywith asuitable dressing Regular inspectionsare carried outto (Chap.VIII No. 2). checkthat these and otherinternal com- pany hygiene instructionsare being ob- served. I MPRINT

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March2006