Pennsylvania Department of Agriculture Bureau of Food Safety & Laboratory Services 717-787-4315 www.EatSafePA.com Guidelines for Apple Cider/ Juice Processors in PA This document provides general guidelines for PA apple cider and juice processors to help them with manufacturing a safe and wholesome juice both fresh and treated. It is intended only as a guide to understand how to apply general food regulations in a cider-production setting. For more information, see list of resources and references below. Apple cider and juice processors are regulated under the Food Safety Act (3Pa. C.S.A. §§5721-5737) which adopts all the federal regulations (CFR’s). Cider processors are subject to the Good Manufacturing Practices (GMPs) and, if applicable, to the provisions found in 21 CFR 120 – Hazard Analysis & Critical Control Point System (HACCP). PDA Registration: All Apple Cider and juice producers in PA shall register with PA Department of Agriculture and pay an annual registration fee of $35.00. For more information contact PDA or visit: http://www.agriculture.pa.gov/consumer_protection/FoodSafety/Pages/default.aspx FDA Registration: All facilities engaged in manufacturing, processing, packing, or holding food for consumption in the United States are required to register their facilities with FDA. (section 415 of the Federal FD&C) For more information contact FDA at 1-800-216-7331 or 301-575-0156 or visit their website at: http://www.fda.gov/Food/GuidanceRegulation/FoodFacilityRegistration/default.htm Definitions: Fresh, Raw, Unpasteurized, or Untreated: Any juice produced by methods which do not include processing steps which have been shown to result in a 5-log (99.999%) reduction of disease causing microorganisms. HACCP: Hazard Analysis Critical Control Points - A systematic approach to the identification, evaluation, and control of food safety hazards that can adversely affect the safety of food products. UV treated: A juice that has been produced by a method that includes exposure of apple cider to ultraviolet light at a level shown to achieve a 5-log (99.999%) reduction of the pertinent microorganism. High Pressure Processing (HPP): A non-heat treatment technique by which products, already sealed in its final package, are introduced into a vessel and subjected to a high level of isostatic pressure (up to 600 MPa/ 87,000 psi) transmitted by water. Patulin: A mycotoxin produced by certain species of molds that grow on a variety of fruits such as apples, peaches and pears but they are most often associated with brown rot on apples. Dropped Apples: Apples that have contacted the ground in any manner in the orchard, storage cooler, pressing room or any other area. Rev. 12/2017 Guidance for Apple Cider/ Juice Producers in PA 1 General Requirements ___________________________________________________________________ Physical Structure of Facility: Cider processing operations must be conducted in a separate, enclosed room or building. The food processing room must have impervious walls and ceilings, the floors must be made of continuous sealed concrete or other equally impervious and cleanable materials provided with adequate floor drains. 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. 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 and grass, and other rodent or pest harborage. Grounds must be properly drained. Pest Control: The processing areas must be adequately screened to eliminate insect and rodent entry. Outer openings must be protected by closed, tight-fitting windows; solid tight- fitting doors or properly designed and installed air curtains or other effective means to prevent pest entry. The use of insecticides, rodenticides and other pest control measures shall be permitted only under such precautions and restrictions as will prevent the contamination of the product, and as legally applied, under the PA Pesticide Control Act, by a certified Pest Control Operator, if applicable. Equipment and Utensils: Equipment and utensils shall be adequate for their intended use. 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. Utensils and equipment made of galvanized metal, copper and copper alloys must not be used to process or store apple cider or juice products. No container containing lead, lead-containing paint, or lead solder should be used. Under no circumstances should a container which has ever contained a hazardous material be used. 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). Sanitation: Hot and cold potable 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. Plumbing systems must be installed and maintained according to Law. An effective cleaning schedule shall be implemented at all times to maintain the integrity of the products. All utensils and product contact surfaces of equipment used in processing or handling the product shall be cleaned prior to use and following any interruption during which utensils and contact surfaces may have become contaminated. 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. Chemical cleaners and sanitizers used in food processing operations must be food grade and approved. Rev. 12/2017 Guidance for Apple Cider/ Juice Producers in PA 2 Water, Sewer, and Waste: The water supply shall be ample for all operations (e.g. processing, cleaning, etc.) and shall be obtained from an approved source, either through a municipal supply or private well. Private water supplies must be tested annually preferably prior the commencement of seasonal apple cider operations. PDA water testing Protocol for Apple Cider processors: ▪ Initial testing for Coliform (1 sample) and Nitrate/Nitrite (1sample) ▪ Continual testing for Coliform - Annually ▪ Continual testing for Nitrate/Nitrite will be based on initial results. All wash and wastewater must be disposed of in an approved manner (e.g. septic system, municipal sewer system) Pressed pomace must be disposed of properly and in a timely manner. Waste products must be removed from the premises at a frequency that will minimize the development of objectionable odors and other conditions that attract or harbor insects and rodents. Storage facilities: Storage of equipment, utensils, chemicals, and supplies not used in food processing must be in an area clearly separated from storage of food processing items. All food contact equipment and supplies (examples: racks, cloths, tubing) must be stored off the floor at least 6 inches in a well-ventilated location that minimizes the potential for contamination from splash, dust or other contaminates. These items cannot be stored in toilet or mechanical rooms. 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. All cleaning and sanitizing chemicals used in food processing must be stored separately from non- processing chemicals and other hazardous materials (e.g. pesticides). All chemicals shall be kept in original containers, used and stored properly so as to prevent contamination of food. Sanitary facilities: Toilet facilities must be provided and should be conveniently located near the work area. A sign or poster should be posted at all hand washing facilities to remind employees to wash hands. 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. Employee Health & Hygiene: A person in charge must be assigned the responsibility to supervise the overall sanitation of the facility. The person in charge must ensure that employees working in the food operations are trained in and follow the good manufacturing and hygienic practices. 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