Objectives. Schedule of Events ~ Morning. From the UK Dean of the College of Agriculture, Food and Environment

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1 Homebased Microprocessor Workshop A Collaborative Effort Between University of Kentucky Cooperative Extension Service Kentucky Department for Public Health Kentucky Department of Agriculture Kentucky Farm Bureau From Kentucky s Public Health Commissioner Once you complete this class and become a Certified Homebased Microprocessor, you will have indicated your willingness to enter into a unique partnership with the Department for Public Health. As a Homebased Microprocessor, you assume the responsibility for protecting the public s health through full compliance with all applicable food safety rules and current Good Manufacturing Procedures. -Stephanie Mayfield Gibson, MD, FCAP From Kentucky s Agriculture Commissioner Congratulations on attending the Homebased Microprocessor Workshop. Upon completion, you will be able to offer quality value-added products while capturing more of the retail food dollar and strengthening your local economy. The valuable information learned while attending will ensure that your products meet important safety standards and contribute to the success of this venture. -James R. Comer 1

2 From the UK Dean of the College of Agriculture, Food and Environment The Homebased Microprocessor Certificate is a unique opportunity for you to diversify and increase your product sales; promote local value-added foods; and improve the farm to table connection. But upon completion of the workshop you are indicating that you are willing to accept the responsibility of following research-based methods and recommendations to produce safe, wholesome value-added foods. -M. Scott Smith, PhD Objectives The participant will be able to: Understand requirements of home-based food processing enacted by House Bill 391 and Farmers Market Regulation (902 KAR ); Understand the microbiology of home canned foods; Apply correct methods of processing to home canned foods; and Keep records for product protection. Schedule of Events ~ Morning Kentucky Regulations Overview Meet the Environmental Health Team Farmers Market Food Safety & Sanitation Principles of Home Canning Exam ~ Part 1 2

3 Schedule of Events ~ Afternoon Microbiology of Home Canned Foods Low Acid Foods High Acid Foods Records for Product Protection Exam ~ Part 2 Wrap-Up & Evaluation Exam Requirements You must attend all of the workshop. You must take both exams. 70% is the passing score for both exams. You may retake each exam only once. Kentucky Regulations House Bill 391 Enacted March 10, 2003 Signed into Law November 1, 2003 Live in Kentucky Homebased Processor Homebased Microprocessor 3

4 Implications of HB 391 & Farmers Market Legislation HB 391 creates some exceptions to food manufacturing program requirements. Allows specific food items to be prepared in the home kitchen. IMPORTANT! DOES NOT ALLOW ANYONE TO PRODUCE ANYTHING TO SELL ANYWHERE. HB 391 has some restrictions and stipulations! HB 391 ~ Farm Friendly Legislation Must be a Kentucky resident who has grown the primary ingredients of the product. The ingredients must be home-grown fruits, vegetables, nuts or herbs. The use of home-grown eggs or dairy products is not allowed. 4

5 Farm Friendly Legislation Final product must contain a primary Kentucky-grown ingredient, grown, harvested, processed and marketed by a farmer who lives in Kentucky. Locations to Sell From 1. The Farm 2. Farmers Markets that are listed with Kentucky Department of Agriculture Roadside Stands certified by Kentucky Farm Bureau. Prohibited Locations Restaurants Grocery Stores Retail Markets Gift Shops Wholesale Sales Mail Order Sales Internet Sales Interstate Sales 5

6 Two Types of Processors Homebased Processors Low risk products such as jams, jellies, baked goods and syrups Homebased Microprocessors High risk products such as pickles, salsas and pressure canned vegetables Homebased Processors Acceptable products for Homebased Processors The primary ingredient (fruit, vegetable, nut or herb) in all products sold by the homebased processor must be grown by the processor. Cut fruits and vegetables Prepackaged mixed greens Dried fruits, vegetables, nuts or herbs Jams, jellies, preserves and fruit butters Bread, cakes, pies and cookies that contain a fruit, vegetable, nut or herb Homebased Microprocessors Acceptable products for Homebased Microprocessors using an approved recipe Salsa Barbecue sauce Herbal vinegars Pickled fruits or vegetables Pressure canned vegetables Low sugar or no sugar jams and jellies Refrigerated products, such as fresh salsa, refrigerator pickles, pesto and products stored in oil, are not considered a processed food and cannot be sold by a Homebased Microprocessor. 6

7 Two Separate Applications To sell as both a Homebased Processor and Homebased Microprocessor, you must complete both applications. They are not transferable. Prohibited Food Items Potentially hazardous foods, including but not limited to. 1. Crème filled pies, custard, custard pies, pies with meringue topping 2. Cheesecake 3. Cream, custard, and meringue pastries 4. Raw seed sprouts 5. Garlic-in-oil mixtures 6. Vacuum packaged foods 7. Baby foods When Can I Start? Successfully complete HBM workshop. Obtain approval for each recipe from Dr. Sandra Bastin at a cost of $5 per recipe. Submit draft labels and approved recipes to the Food Safety Branch. Complete application and send, along with $50, to the Food Safety Branch. Signing the application means you will follow all rules and regulations. 7

8 Recipe Approval Page 1 Product name Ingredient listing Ingredient descriptors Ingredient measurement Procedures Yield Canner type Jar size Food Labeling Name and address of operation Common name of food product Ingredients in descending order by weight Net weight or volume Statement in 10 point type This product is home-produced and processed. Date product processed Both Homebased Processors and Microprocessors must comply with required labeling requirements. Label Example Page 2 8

9 Application Page 3 The Commercial Food Manufacturing Permit ~ A Step Beyond The commercial food manufacturing permit allows sales to Restaurants and Direct-to-Consumer Sales (Gift Shops) Wholesale Interstate (across state lines) Internet Farmers Markets and Roadside Stands This Permit requires use of a permitted or community shared-use kitchen. For Additional Information on Commercial Opportunities Food Safety Branch Attn: Shadrick Adams 275 E Main Street HS1CF Frankfort, KY Shadrick.Adams@ky.gov (502)

10 In the Kitchen In the kitchen during microprocessing No pets No children under 12 No laundry being done No personal cooking taking place Three compartment sink for washing, rinsing and sanitizing - portable tubs are acceptable Separate hand washing facilities Water Supply Water must be from a public water system! OR The use of wells, springs and cisterns must be approved through the Kentucky Division of Water at prior to becoming a Homebased Microprocessor. Insurance Do I need insurance? What kind do I need? Property Liability Business income How much do I need? Additional Resources U.S. Small Business Administration Insurance Information Institute 10

11 Food Safety A Dual Role The inspector s job is To assist the operator in maintaining the highest standards of food safety; AND To assist the operator in ensuring that the consumer obtains a product that is fresh, wholesome, and free of adulteration. Food Safety Inspections Annual inspection Following a complaint Samples may be taken! Farmers Market Food Safety & Sanitation PUT FOOD SAFETY FIRST! Growers should use agricultural production chemicals properly. Growers should reduce the risks of potential contamination. Food handlers should practice good personal hygiene. 11

12 Reducing Risks of Contamination Minimize animal waste exposure. Only use potable water. Do not use fields for trash dumping. Clean and sanitize food contact surfaces. Keep animals at least 20 feet away from food. Use only approved recipes. County Extension Offices are a wealth of information. Food Safety Factors FOOD PEOPLE FACILITIES The Safe Food Handler HAND WASHING! HAND WASHING! HAND WASHING! Keep yourself neat, clean and healthy. Protect food from open cuts or sores. Avoid smoking, eating or drinking. Keep all equipment and surfaces clean. 12

13 Safe Processed Food TIME & TEMPERATURE! TIME & TEMPERATURE! TIME & TEMPERATURE! Use an approved recipe. Use the proper equipment. Use the appropriate methods. FOOD DANGER ZONE KEEP HOT FOOD HOT! KEEP COLD FOOD COLD! 13

14 Dishwashing Steps Pre-rinse or scrape WASH RINSE SANITIZE AIR DRYING Sanitizing A sanitizer concentration of 50 to 100 parts per million, as stated in the law is equal to 1 tablespoon unscented bleach per gallon of water Dishwasher Sanitizing To use the dishwasher to wash, rinse and sanitize, the dishwasher must have a true sanitizing cycle on it. Your owner s guide will have these details. 14

15 Controlling Food Hazards Hazard Analysis Critical Control Points CHEMICAL PHYSICAL BIOLOGICAL Good Manufacturing Practices Prevent the growth of Clostridium botulinum Know the Law Read the law! Be familiar with the law! 15

16 Principles of Home Canning Select good quality ingredients and foods. Wash hands, produce, equipment, and work surfaces as needed. Use research-based recipes and methods. SAFE GOOD-TASTING PRODUCTS! SHELF STABILITY! Shelf Stability Heat processing destroys bacteria that may grow in the home canned product during non-refrigerated storage and distribution. Refrigerated home canned products are not considered shelf stable. Steps of Home Canning 1. Gather appropriate ingredients, supplies and equipment. 2. Follow approved recipe. 3. Place the food in Mason-type canning jars. (No mayonnaise jars!) 4. Remove air bubbles. 5. Wipe jar rims. 6. Apply self-sealing two-piece lids with screw bands. 7. If using a pressure canner, place jars into canner, vent canner and bring up to specified pressure. If using a boiling water bath canner, place jars into boiling water that is two inches above the jars. 8. Use a timer for the amount of time called for in your recipe; the required time to destroy spoilage microorganisms and inactivate enzymes. 9. Cool jars properly to form a vacuum seal. 16

17 Approved Recipes Approved recipes depend upon a scientifically determined time and temperature process. Use Proper Equipment Pressure Canner pounds pressure Boiling Water Bath Canner 212 F All vegetables Pickled fruits or vegetables, tomatoes, salsa, barbecue sauce, hot sauce, herbal vinegars, low- or no-sugar jams and jellies Improper Equipment A pressure cooker cannot be used as a pressure canner! 17

18 Ball Blue Book Processing Times Page 4 Boiling Water Bath Canner Tomatoes Packed in Water Pints 40 minutes Quarts 45 minutes Tomatoes Packed in Juice Pints and Quarts 1 hour 25 minutes Pressure Canner at 10 pounds pressure Tomatoes Packed in Water Pints and Quarts 10 minutes Tomatoes Packed in Juice Pints and Quarts 25 minutes Raw Pack Hot Pack Headspace Equipment and Utensils Low acid foods (all vegetables) must be processed in a pressure canner. The pressure canner must be manufactured after USDA recommends annual calibration of dial gauge pressure canners. A timing device must be available. Mason-type home canning jars with self-sealing two piece lids with screw bands must be used. Home Canning Basics LOW ACID FOODS HIGH ACID FOODS 18

19 Home Canning Basics Low acid foods* High acid foods ph 4.6 ph 4.6 All fresh Fruit, pickles, relishes, vegetables jams, jellies, fruit Process 240 F for butters, tomatoes specified time acidified with lemon Pressure canner juice Process 212 F for specified time Boiling water bath canner Heat Processing PROCESS CONTAINER BACTERIA Temperature Distribution Heat Penetration Target Spoilage Bacteria Slowest Heating Region SOLID LIQUID 19

20 Heat Distribution Test Inadequate Venting Vent Closed Temperature TC-1 TC-2 TC-3 TC-4 Steam Up - Process Starts Time (Minutes) - After Steam On Source: Canned Foods by The Food Processors Institute, 1995 Heat Distribution Test Proper Venting Temperature Source: Canned Foods by The Food Processors Institute, 1995 Vent Closed Time (Minutes) - After Steam On TC-1 TC-2 TC-3 TC-4 Steam Up - Process Starts Canning Basics High Acid Foods Process high acid foods in a boiling water bath canner. ph of of 4.6 or lower Fruits, pickled vegetables, sauerkraut, jams, jellies, and tomatoes acidified with lemon juice are high acid foods. 20

21 Canning Basics Low Acid Foods Process low acid foods in a pressure canner. ph of higher than 4.6 Fresh vegetables and tomatoes are low acid foods. Canning Basics Terminology Altitude Bacteria Botulism Canning High Acid Foods Low Acid Foods Venting or Exhausting Head space Heat Processing Hermetic Seal Open Kettle Canning Boiling Water Canner Pressure Canner ph Water Activity (A w ) EXAM I REVIEW 21

22 Exam Time Part 1 15 Questions Take Your Time! Microbiology of Home Canned Foods Food Safety during the food production process will prevent contamination of the food that will make someone sick. Food Quality is a product that tastes and looks good. Bacteria of Concern Clostridium botulinum 22

23 History of Food Processing 1810 Nicholas Appert 1860 Louis Pasteur 1895 Food Microbiology Research began at the Massachusetts Institute of Technology Principles of Home Canning Place the food in appropriate canning jars and then seal them with two-piece vacuum lids; Heat the filled jars to the specified temperature for the food using the right type of canner; Process for the required time to destroy spoilage microorganisms and inactivate enzymes; Cool jars properly so excess air is vented from the jars to form a vacuum seal. Home Canning Basics Low acid foods ph 4.6 Process under pressure at 240 F for specified time Pressure canner High acid foods ph 4.6 Fruit, pickles, relishes, jams, jellies, fruit butters, tomatoes acidified with lemon juice Process in boiling water at 212 F for specified time Boiling water bath canner 23

24 Heat Processing PROCESS CONTAINER BACTERIA Temperature Distribution Heat Penetration Target Spoilage Bacteria Characteristics and Behaviors of Microorganisms Mold Bacteria Viruses Yeast Parasites Molds Mold growth may remove the acid condition used to inhibit the growth of Clostridium botulinum. 24

25 Yeasts The growth of yeasts produces alcohol and carbon dioxide gas which swells the container often causing the seal on the container to unseal. Foodborne Illness Page 5-6 Requirements for Bacteria to Grow Food Acidity (ph) Time Temperature Oxygen Moisture (A w = water activity) 25

26 Reproduction of Bacteria Billions Growth of Bacteria Stationary Phase Decline Phase Log Phase Lag Phase Time Mobility 26

27 Temperature and Bacterial Growth Bacteria Reproduce Rapidly 140 F 120 F 60 F 40 F DANGER ZONE Bacteria survive and grow 40ºF - 140ºF Temperature Requirements Mesophilic Bacteria Grow best F Clostridium botulinum of concern Thermophilic Bacteria Grow best F Spoilage bacteria Food & Moisture Requirements Minimum required for bacteria to grow PHF Soft cheese Dry egg noodles PHF = Potentially Hazardous Foods Flours Jams Candy jellies Crisp cooked bacon 0.85 Meats poultry Raw bacon Distilled water 27

28 ph of Common Foods HIGH ACID LOW ACID Pressure Canner Low Acid Foods Bacteria will not grow well at a ph below 4.6 Water Bath Canner High Acid Foods 4.6 Potentially hazardous foods (ph = ) Oxygen Requirements Aerobic Anaerobic Facultative Bacteria Vegetative With Spores 28

29 Bacterial Spoilage Incipient spoilage Contamination after processing Inadequate heat processing Short time, low temperature, no venting Thermophilic bacterial spoilage Bacterial Spoilage Indications Abnormal appearance of the container; Unusual appearance or abnormal odor of food product; Product mushiness or off-color; and Cloudiness or other signs of abnormal conditions in the liquid portion. Non Bacterial Spoilage Chemical reaction of food components with metals in water Overfilling of container Improper headspace Zero or low vacuum 29

30 Ingredients in Acid Foods Salt acts as a preservative and adds flavor and crispness to pickles. Table salt may cause cloudiness. Iodized salt may darken pickles. Vinegar acts as a preservative and adds a tart flavor. ALWAYS use 5% acidity vinegar. NEVER dilute or decrease in a recipe. Sugar acts as a sweetener. Spices add flavor. ph of Common Foods HIGH ACID LOW ACID Potentially hazardous foods (ph = ) 4.6 Bacteria will not grow well at a ph below 4.6 ph Measurement Digital ph meter inexpensive and more accurate. FDA allows ph paper at ph

31 Low Acid versus High Acid Foods Low acid foods depend on heat processes under pressure to destroy Clostridium botulinum. High acid foods depend on the ph of the food to prevent the growth of Clostridium botulinum. Deviation from Approved Recipe Although USDA recommends that a product may be reprocessed within 24 hours, the Farmers Market Regulation does not allow this as an option. If the product is not made according to the approved recipe, it cannot be sold. Records for Product Protection Food Safety Branch HBM Certification HBM Workshop Certificate Approved recipes Labels Equipment manufacturer s manual Processing records of HBM home canning activities Verification of dial gauge accuracy 31

32 Record Sheet Page 7 Kentucky Farm Bureau Roadside Farm Market Contact roadside@kyfb.com Sharon Spencer Farmers Market Marketing Specialist sharon.spencer@ky.gov Kentucky Department of Agriculture s Value-Added Horticulture Marketing Program sponsors the Kentucky Proud logo program. Kentucky producers who meet the requirements may use the logo on their products and take advantage of the extensive statewide marketing program designed to encourage shoppers to choose Kentucky Proud 32

33 Kentucky Agriculture GAP Program Bill Holleran Sampling Certificate Adam Watson (502) Homebased Microprocessor Contacts Page 8 Dr. Sandra S. Bastin, RD, LD, CCE Extension Professor OR Debbie Clouthier, Extension Associate University of Kentucky sbastin@uky.edu debbie.clouthier@uky.edu Shadrick Adams Homebased Processing and Microprocessing Kentucky Food Safety Branch Shadrick.Adams@ky.gov EXAM II REVIEW 33

34 Exam Time Part 2 15 Questions Take Your Time! 34