QualiTru Blog

What Drives Sampling? | QualiTru Sampling Systems

Thu, 29 Oct 2020 05:00:00 GMT

What Drives Sampling?

Posted October 29, 2020

Someone told me that you need to do something that scares you every day. While I understand the logic, I like to believe that you need to surround yourself with people who challenge you every day.

Working in an industry that some may describe as being slow to change can be challenging at times. However, my experience has been that Quality Managers, Process Engineers, and farmers have an innate drive to make improvements. They seek to develop the industry to improve safer and more innovative products. Even better than that, they also influence the people around them to make improvements.

The reality is that I am influenced by the people who surround me. I strive to keep positive and progressive minds and experts around me. I find that it improves my work as I also need to carve out better solutions. In a broader sense, having a progressive mindset leads to improvement and quality of life. Why wouldn’t anyone want to improve their performance and overall wellbeing?

Working on sampling in the dairy and liquid food industry can sometimes be challenging. In-process sampling is still somewhat undefined. There are no overarching in-process sampling plans, let alone sample data maps from production to processing to reference. One of the closest universal references for a systematic preventative approach to food safety is the Hazard Analysis and Critical Control Points (HACCP). Improving on that concept is the Sample HACCP (SHACCP), which applies this tool that maps out the risk areas of a typical process flow from taking the sample to sample reception in the laboratory.

The Quality managers, engineers, and farmers I work with have been very aware of this missing risk assessment area. Thus, they are developing their own sets of sample collection standards. Going beyond the question of “Is this sample right or wrong,” they are now more confident and accurate in their process verification and product quality. By not waiting to solve an issue or respond to a worst-case scenario, they bring in systems that prevent risks, optimize their process, and strengthen quality. These adopted practices are proactive rather than reactive.

There are areas where in-process sampling has been an entirely foreign topic, let alone the need for aseptic sampling. Some of our partners are carving out a new conversation and quality culture for sampling. These are conversations about how you use data to track your process or monitor product quality over time. In many cases, there are no systems set up to trend this type of analysis. It takes the extra step of developing new procedures or standards to get to that level.

Farmers and veterinarians improve herd health, nutrition or sanitation practices by integrating representative sampling into their daily or weekly rhythm despite no government requirement. They are looking to continually improve the quality of their herds’ milk and health by integrating acceptable practices and assessments of somatic cells, hygiene, butterfat, or other nutrition indicators overtime to make constant improvement. This is done out of their drive for improvements.

I am proud to be a part of a community that challenges the ‘status quo’ in food safety through sound practices and proven systems. It not only makes work more rewarding, but it also makes me more confident in the food we choose to eat.

Anne Bigalke is the VP of International Markets at QualiTru Sampling Systems. Find out a little more about her on QualiTru’s Our Team page. Visit Our Blog for other articles Anne has produced.

By Anne Bigalke
VP of International Markets, QualiTru Sampling Systems
anne@qualitru.com Follow Anne on LinkedIn

The SHACCP Explained | QualiTru Sampling Systems

Wed, 30 Sep 2020 05:00:00 GMT

The SHACCP Explained

Posted September 30, 2020

I trust we all know HACCP. HACCP and me go back a long way; as a matter of fact, we were conceived in the same year! When I came across HACCP during my student years, I thought it was really boring; HACCP being methodical, slow and elaborate and me being young and restless. However these days, HACCP has become a big part of my professional life and I have applied the HACCP principles in many different ways. This means I must have changed somewhat, because I don’t believe the HACCP principles have changed since their inception.

The basic premise of HACCP is this: if we have a process, we can map this process and ask ourselves at each process step: “how do we control this step and what can go wrong?”. Once we have identified those things that can go wrong (the “hazards”), we can start thinking about how these hazards could effect the outcome of our process (determine risk) and what additional controls we can introduce to strengthen the process.

HACCP is a risk-based, preventive tool and the idea of SHACCP is to apply this tool on our diagnostics process. To illustrate, lets map a typical process flow from taking the sample to the sample reception in the laboratory:

As you can see, we already have quite a few process steps, and we haven’t even included sub-sampling or the laboratory yet! Putting on our SHACCP hat, we can now start thinking about the hazards that may affect our sample integrity, and ultimately, our test result. Let’s throw in some risks I have seen during my career.

Materials

Do we have the right sample container?
Do we have the correct sample tool?
Will the sample be representative?
What are the potential risks of my sample tool?
Have we got the right disinfectant?

Labeling Sample

Do we have an exact labeling protocol?
Do we pre-label or label Just-In-Time?
Do we capture all the information?

Taking Sample

Have we clearly defined our method?
Is it an aseptic technique?
Does the sampler disinfect their hands?
Does the sampler operate the sampling equipment correctly?
Do we have adequate training and clear procedures?

Storage

Are samples stored in a controlled environment?
Are samples stored in a clean environment?
How long are samples stored?

And the list goes on!

As you can see, my preferred way to identify hazards is by asking questions. Ideally, we do this with a team, which should include a sampler and a laboratory technician, to get the most comprehensive list.

Finding a whole list of hazards may feel overwhelming. However, most items on the list will already be controlled in some form and not be a significant risk. For example, we may have a system with pre-labeled sample containers, which are issued each day, and the only hazard that remains is that the operator fills the right box at the right time.

So, how do we turn a hazard into a risk? Let’s look at the sample transfer time. If we ship our samples to an off-site laboratory, a danger is that we encounter delays as a result of traffic disruptions. To determine the risk of the transfer delay hazard on our sample, we can use likelihood versus impact.

For sensitive, non-stable food samples, the impact of a significant transfer delay may be microbiological growth or decline in the sample with the micro test result likely to be affected. The likelihood of the delay depends on where you are in the world; however, even in rural New Zealand, we have experienced some significant delays due to weather events. That means if we have a sensitive sample and a likelihood of transfer delays, the transfer delay hazard has turned into an actual risk for our sample integrity.

So, what can we do? How do we strengthen our controls of the diagnostic process transfer step and manage this transfer delay risk? One thought would be to instruct the laboratory monitor the “sample to receipt” time for our sensitive micro samples and not test if it exceeds X hours. This change in expectations is because the sample would no longer reflect the actual process conditions, and the test result may be false.

What happens if we decide to test the sample anyway? After all, it was chilled, right? Well, we may not only pay for an inaccurate test result but also run the risk of getting an unpleasant surprise. Particularly when it comes to food safety tests, you should never take the risk of testing a compromised sample, because you will need to act, even if you can subsequently point to a significant transfer delay!

Only if we submit accurate samples will we get value for money, gain confidence in the results, and become more accepting of the outcomes, even when they are unexpected.

By Jack van der Sanden
Guest Contributing Blogger, QualiTru Sampling Systems
jack.vds@xtra.co.nz Follow Jack on LinkedIn

Meet Jack.

Jack van der Sanden has over 30 years of experience in the global food industry across the supply chain. He previously worked as the General Manager of Food Safety & Quality Assurance at Fonterra. There he redesigned the company’s food safety and quality standards for HACCP and EPM, with an extensive review of the manufacturing process. Today, Jack enjoys spending more time in the garden and shares his knowledge and expertise with selective projects. We are excited to work with Jack and pick his brain about in-process, hygienic sampling.

Read the first two of three articles in Jack’s series:

The Sample – Our Weakest Link!?

The Diagnostics Process

The New Normal for QualiTru | QualiTru Sampling Systems

Mon, 28 Sep 2020 05:00:00 GMT

The New Normal for QualiTru

Posted September 28, 2020

I’m guessing that many of you reading this blog might agree that a new language has developed while living through a global pandemic. Many of us would also likely agree that referring to the ‘new normal’ is becoming just tiring.

But, what exactly does a ‘new normal’ really mean?

For many of us, it means that we are balancing a new life while sequestered at home with kids and work. It also means postponing that special trip or canceling the anticipated family gatherings.

More than a change in pace, it is the never-ending question: When will we get a vaccine, and when will this finally end? This question strings all of the regions we work in together.

Australia and New Zealand are going into the second round of ‘lockdown.’ In Europe, many home offices are becoming the standard. In Canada and parts of Latin America, we see some businesses beginning to have face-to-face meetings, but following strict safety rules. “Can you hear me?” has become the new greeting as we continue to meet on different online platforms.

What is the ‘new normal’ for QualiTru?

We, like our international partners, have moved meetings to online platforms while trying to balance new work-life challenges. Calvin Guyer, our CEO, has instituted a weekly two-hour break policy for employees to go for a walk or take a long lunch to help balance the new lifestyle changes. For our customers and partners, we’ve tried to find creative ways to connect and improve our support with training.

Three new things you can expect from us:

Shipping: We’ve seen significant increases in shipping costs, so we are implementing new options for shipping providers to help cut the costs and simplify shipping. Contact our sales team to learn more.

Training: We’ve expanded our online training to ensure compliance with Standard Operating Procedures (SOPs).

a. Proper needle insertion: Meet Lori Hamerly, our Quality Manager, and watch Proper Septa Insertion for QualiTru Stainless Ports

b. Self-check: Done with the training, what’s next? Use this questionnaire and answer key to verify your sample collectors’ understanding of the SOPs.

Community: Recognizing the need to extend our reach and provide additional expertise to the sampling community, we cultivate our worldwide partnerships.

a. Jack van der Sanden: Jack shares his food safety expertise from New Zealand. He has over 30 years of experience in the global food industry across the supply chain. He previously worked as the General Manager of Food Safety & Quality Assurance at Fonterra. There he redesigned the company’s food safety and quality standards for hazard analysis and critical control points (HACCP) with an extensive review of the manufacturing process. A sample of his expertise is shared in his blogs The Sample – Our Weakest Link!? and The Diagnostics Process.

b. University of Georgia & La Pampa in Argentina: We partnered with these universities to assess farm inline sanitation and herd health with our representative sampling system. Watch this video and hear from Federico Macazaga, a veterinarian at the research farm, about pen sampling – in Spanish. Universidad Nacional de La Pampa and University of Georgia Line Study

Our ‘new normal’ is still evolving, but aspects are hopefully bringing better changes for everyone.

Reach out at sales@qualitru.com and 651-501-2337 to let us know suggestions for other improvements to make your sampling process a little easier.

Anne Bigalke is the VP of International Markets at QualiTru Sampling Systems. Find out a little more about her on QualiTru’s Our Team page. Visit Our Blog for other articles Anne has produced.

By Anne Bigalke
VP of International Markets, QualiTru Sampling Systems
anne@qualitru.com Follow Anne on LinkedIn

The Diagnostics Process | QualiTru Sampling Systems

Tue, 22 Sep 2020 05:00:00 GMT

The Diagnostics Process

Posted September 22, 2020

If we trust the sampling and testing process, we are more confident in the result and can make informed decisions.

During the latter part of my career, I ended up in food safety and quality roles. I occasionally faced the dreaded phone call from the laboratory with the message, “We found X!” X was, of course, a food safety test parameter that had never given us any bother before. During this kind of phone call, you start realizing the importance of the diagnostics process.

When you are informed that X is in your product, two things happen:

An immediate financial hit because you cannot retest for food safety, and the product has to be dumped.
All-round excitement, because finding X is rare, and from where could it have come?

One of the first questions routinely asked when trying to find X is whether the test result is valid. Alas, it’s a human bias to accept results when they are as expected and to challenge results only when they are out of range. Suddenly the diagnostics process is in the spotlight. The laboratory might face the heat since it found and reported X, but the diagnostics process starts well before the actual test result.

The diagnostics process, as I see it, is the process from sampling through to the result, which involves:

Taking the sample
Handling the sample
Testing the sample
Processing and reporting the result

Generally, the process involves multiple parties and interfaces with an important decision at the end.

When it comes to the dairy industry’s diagnostics process, I have argued that the taking and handling of the samples may well be the weakest link.

Taking the Sample

In my previous article The Sample – Our Weakest Link!?, I mentioned some challenges around the person taking the sample. Often, the sampling plan has not been reviewed for some time, and the samplers have had minimal training; however, there are some other, perhaps less apparent areas we should explore.

Is the sample genuinely representative of the production run? I have noted that composite in-line samplers are getting very common these days, and they can be a step up from traditional grab samples. However, when composite sample bags are not changed in a timely manner, they fill up and will have very little sample of the last part of the run. What about those milk silos?

One flawed assumption is that dairy fluids will mix in a silo, and silo contents are considered homogenous. Well, it turns out that agitation and mixing are often not very useful, resulting in layering and separation in the silo. Both cases do not result in a representative sample.

There’s also a sample point design.

I’m fascinated with the latest diagnostic tools in the laboratory. Particularly, microbiological testing is going through a revolution. Unfortunately, bacteria are also the first to contaminate your sample. Dirty sample points like worn septum rubbers, poorly cleaned sample taps, or unhygienic utensils can easily lead to a contaminated sample and a “false” result (which is the actual result on an invalid sample). So perhaps, when you consider purchasing the latest micro-test equipment, you may wish to consider your process sampling technology as well.

When it comes to sampling practices, I have rarely come across a full review of the sampling protocols, tools, and techniques to identify sampling gaps. That is the case until X comes knocking, and the sampling practices get our full attention.

Handling the Sample

Samples sometimes enter “no-man’s land”; this is the zone where samplers have done their job, and the laboratory has not yet formally accepted the sample for testing.

I became acutely aware of the importance of sample handling when our laboratory was seeking ISO17025 accreditation. Our stance towards incoming samples was this: if it is labelled right, looks right, and is at the right temperature, we test it – no questions asked. The accreditation process forced us to take a good look at all the sample handling steps, including the management of the sample fridge in the factory control room.

It is essential to manage the interfaces in the diagnostics process. If those interfaces are poorly defined, your “no-man’s land,” like a poorly managed sample fridge, may well affect your sample integrity.

Another critical step in sample handling is sub-sampling. This is when those big composite bags are split up for the different tests. I trust most of us are well aware of the risk of sample contamination during a sub-sampling step. Yet, from what I’ve seen, sub-sampling rooms can be the “poor cousin” in the diagnostics process, and all that stands between X and your product is the skills of a diligent technician.

To me, understanding and improving the sampling and handling steps of the diagnostics process are some of the most beneficial actions we can take. How about drawing a “sample flow,” identifying all potential contamination hazards in our diagnostics process, something like a Sample Hazard Analysis Critical Control Point (SHACCP)?

Remember, our food business will only pay for the test if the sample is submitted! Only if we submit accurate samples will we get value for our money, gain confidence in the results, and become more accepting of the outcomes, even when they are unexpected.

By Jack van der Sanden
Guest Contributing Blogger, QualiTru Sampling Systems
jack.vds@xtra.co.nz Follow Jack on LinkedIn

Meet Jack.

Reflections of a Milkmaid | QualiTru Sampling Systems

Wed, 29 Jul 2020 05:00:00 GMT

Reflections of a Milkmaid

Posted July 29, 2020

While the Coronavirus has brought many surprises, one of the best take-aways so far is reconnecting with friends, family and colleagues. My friends from outside the dairy industry refer to me as a ‘milkmaid,’ because of my career and my celebrated love of cheese. Thinking of this, I decided to look up the history of milkmaids.

It turns out that historically, women have been very involved in the dairy industry. Milkmaids were girls and women who were tasked with milking cows, as well as producing cheese, butter and cream in some large milking houses. References to milkmaids go as far back as 995 AD.

There is a legacy claim that in 1796 a milkmaid named Sarah Nelms played a role in the development of Edward Jenner’s vaccine for smallpox in England. Reportedly, fluid from her cowpox blister was injected into a young boy, thereby protecting him from a subsequent injection of the much more serious and potentially deadly smallpox virus. Thus, the first vaccination was born. Mr. Jenner deserved big credit for developing a vaccine that wiped out the dreaded disease, while Sarah’s contribution got little notice. It is not a story of collaboration.

Certainly, cultures and norms have changed drastically since the 18^th century. This much is still true. Many women work in the dairy industry, serving in many capacities. This is also true. It is hard to escape some of the inherent challenges that women face across the various dairy-related industries. There are many women and men who recognize this and are actively working to promote collaboration and inclusion in the industry.

I want to highlight two women whom I admire for their expertise and proactive attitudes. They continue to teach me a lot about how to navigate this industry that I have grown to love.

Kirsten Howe, Executive Technical Support Specialist at Ecolab, one of the busiest people I know, opened her calendar every time I had questions about training opportunities or gram-positive vs. negative bacteria. You can see how much respect and fun she has with her work when you enter her office filled with photos of colleagues and a constantly ringing phone. I love hearing her stories about being one of the first women to carry a hard helmet on a plane and about entering dairy plants that didn’t have a women’s bathroom.

Deb Boyke, Outreach Program Manager at the Center for Dairy Research, is a master when it comes to understanding the industry’s needs and has an expansive network. She connected me with some of the industry’s experts when I was looking to build better partnerships. She has a keen understanding of the industry and can pull together the right people to come up with better opportunities. More importantly, she does it with a big smile. Her positive influence extends beyond dairy as she works in industry groups outside her normal arena.

Women have always played important, if often unsung roles, in the dairy industry. Working in a nurturing industry that provides so many opportunities, more than ever, men and women need to build on our commonalities. We can all reflect on history and then redefine how we choose to participate today.

Anne Bigalke is the VP of International Markets at QualiTru Sampling Systems. Find out a little more about her on QualiTru’s Our Team page. Visit Our Blog for other articles Anne has produced.

By Anne Bigalke
VP of International Markets, QualiTru Sampling Systems
anne@qualitru.com Follow Anne on LinkedIn

Aseptic Sampling - A Key to Earned Trust and Transparency | QualiTru

Admin — Fri, 29 May 2020 05:00:00 GMT

Aseptic Sampling – A Key to Earned Trust and Transparency

Posted May 29, 2020

Prior to Covid-19 travel restrictions, I made a visit to the Czech Republic. It was an eye-opening experience in the value of relationships, but also the range of trust in dairy.

The Czech Republic has a growing dairy industry and some of the largest farms in Europe, with 1,000 head of dairy cows and some even larger farms.

Working with FarmSystem, QualiTru’s new service partner in the Czech Republic, I visited farms and dairy plants to learn about their current sampling procedures and to piece together the Quality data chain.

We found that farmers relied on payment data automatically collected off the back of the truck. Equally, plants relied on that data to determine their operations. In fact, one plant we visited based their production process on the protein and fat of the sample in the receiving bay.

Coming from the US where the payment sample is constantly questioned, I found this sense of trust, both admirable and confusing.

How could the farmer know that they were paid adequately and fairly? Can the Quality Manager really know that the farmer is producing the safest milk possible?

This process is not unique to the Czech Republic; in fact, most of Europe is more or less the same. Milk is picked up by the truck driver and a sample is automatically collected from the truck. The farmer and plant agree that the automated sample is correct.

Farmers may collect herd health samples monthly or occasionally evaluate bulk tanks. Plants may take raw milk samples more frequently, but that is solely based on management’s proactiveness. The data from the sample is used for component and microdata (bacteria counts). However, if the sample is not collected aseptically, the microdata is likely to not be accurate.

In the US this process is not standard, or at least not yet. The collected payment data varies between states. The truck driver either collects the sample from the silo or inline prior to the truck. Alternately, it may be collected in the receiving bay at the plant from a line or dipper. These procedures have their own sets of questions and potential for problems, but that is for another post.

In one way, I admire the level of autonomy and trust between processors and farmers. However, it is a bit disheartening to know that many products do not have controls throughout the process to monitor for microbiological risks. I don’t believe it is intentional, rather the opposite. There appears to be inadequate education and awareness of how to collect accurate samples and appropriately analyze the data.

Hopefully with more conversations that ask the right questions, we will get closer to a perfect balance of well documented and trusted supply chains. Central to those discussions is that microbiological data is only as accurate as the sample and that sampling equipment and procedures need be designed to not contaminate product samples (aseptic sampling).

Read more about FarmSystem
Read more about truck sampling

Anne Bigalke is the VP of International Markets at QualiTru Sampling Systems. Find out a little more about her on QualiTru’s Our Team page. Visit Our Blog for other articles Anne has produced.

By Anne Bigalke
VP of International Markets, QualiTru Sampling Systems
anne@qualitru.com Follow Anne on LinkedIn

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QualiTru Blog

What Drives Sampling? | QualiTru Sampling Systems

What Drives Sampling?

The SHACCP Explained | QualiTru Sampling Systems

The SHACCP Explained

Materials

Labeling Sample

Taking Sample

Storage

Meet Jack.

The New Normal for QualiTru | QualiTru Sampling Systems

The New Normal for QualiTru

But, what exactly does a ‘new normal’ really mean?

What is the ‘new normal’ for QualiTru?

Three new things you can expect from us:

The Diagnostics Process | QualiTru Sampling Systems

The Diagnostics Process

Taking the Sample

Handling the Sample

Meet Jack.

Reflections of a Milkmaid | QualiTru Sampling Systems

Reflections of a Milkmaid

Aseptic Sampling - A Key to Earned Trust and Transparency | QualiTru

Aseptic Sampling – A Key to Earned Trust and Transparency

aseptic-sampling-dairy-industry | QualiTru Sampling Systems

aseptic-sampling-dairy-industry

QualiTru-new-service-partner-FarmSystem | QualiTru Sampling Systems

QualiTru-new-service-partner-FarmSystem

aseptic-sampling-dairy-industry | QualiTru Sampling Systems

aseptic-sampling-dairy-industry

QualiTru-new-service-partner-FarmSystem | QualiTru Sampling Systems

QualiTru-new-service-partner-FarmSystem

The Diagnostics Process | QualiTru Sampling Systems

The Diagnostics Process