Alabama Administrative Code › Title 420 - ALABAMA STATE BOARD OF HEALTH › Chapter 420-3-16 - PRODUCTION, PROCESSING, HANDLING OR DISTRIBUTION OF MILK, MILK PRODUCTS AND FROZEN DESSERTS › APPENDICES › Appendix I - PASTEURIZATION EQUIPMENT AND CONTROLS - TESTS

Current through Register Vol. 42, No. 9, June 28, 2024
I.
TESTING APPARATUS SPECIFICATIONS TEST
				  THERMOMETER
Type:
1.
Mercury or Non-toxic
				  Liquid-in-Glass-Actuated:
Readily cleanable; plain front; enameled back;
				  length at least 30.5 centimeters (12 inches); immersion point to be etched on
				  stem and mercury or non-toxic liquid to stand in contraction chamber at 0°C
				  (32°F). Non-toxic liquid-in-glass-actuated thermometers shall have accuracy
				  and reliability equivalent to mercury thermometers.
Scale Range:
At least 7°C (12°F) below
				  and 7°C (12°F) above the pasteurization temperature at which the
				  operating thermometer is used, with extensions of the scale on either side
				  permitted and protected against damage at 149°C (300°F).
Temperature Represented by Smallest Scale
				  Division:
0.1°C (0.2°F).
Number of Degrees per 25 Millimeters (1 inch) of
				  Scale:
Not more than 4°C or not more than 6°F.
Accuracy:
Within ± 0.1°C (±
				  0.2°F), throughout specified scale range. The accuracy shall be checked
				  against a thermometer which has been tested by or is traceable to NIST.
Bulb:
Corning normal or equally suitable
				  thermometric glass.
Case:
Suitable to provide protection during
				  transit and periods when not in use.
2.
Digital Test Thermometer:
Hand-held; high
				  accuracy digital thermometer; and battery or AC line powered. Calibration is
				  protected from unauthorized changes.
Range:
-18°C to 149°C (0ºF to
				  300°F); temperature represented by smallest scale division, 0.01°C or
				  ºF and digital display.
Accuracy:
System accuracy of: ±
				  0.056°C (± 0.100°F); Probe accuracy of: ± 0.05°C
				  (± 0.09°F); repeatability of ± 0.005°C (±
				  0.009°F); three (3) month stability: ± 0.025°C (±
				  0.045°F). Thermometer accuracy from 0°C to 150°C (32ºF to
				  302°F): ± 0.05°C (± 0.09°F). Calibration uncertainty:
				  ± 0.0047°C (± 0.00846°F). The accuracy shall be checked
				  against a thermometer which has been tested by or is traceable to NIST. This
				  calibration shall be performed annually by a properly trained representative of
				  an "Official Laboratory" or an "Officially Designated Laboratory"; or by a
				  qualified representative of a thermometer manufacturer; or by a properly
				  trained Health Officer. The calibration protocol/SOP shall be developed by the
				  Health Officer in cooperation with the thermometer manufacturer and FDA.
				  Documentation of the identity of the properly trained Health Officer shall be
				  maintained by the Health Officer. A signed certificate of calibration for the
				  digital thermometer shall be maintained with the unit.
Self-Diagnostic Circuitry:
Circuitry shall
				  provide constant monitoring of all sensing, input, and conditioning circuits.
				  The diagnostic circuitry should be capable of identifying the probe and its
				  calibration information. Without a correct connection of the probe, the display
				  shall alert the operator and no temperature will be displayed.
Electro-magnetic Compatibility:
Shall be
				  documented for these devices for their intended use and available to the Health
				  Officer. Units to be used in the "field" shall have been tested for heavy
				  industrial standards, as specified in the European Electromagnetic
				  Compatibility Directive.
Immersion:
Minimum immersion point shall be
				  marked on the probe. During control tests, the probes shall be immersed to
				  equal depths in a water or oil bath.
Case:
Suitable to provide protection during
				  transit and periods when not in use.
GENERAL PURPOSE THERMOMETER
Type:
Pocket type.
Scale Range:
1°C (30°F) to 100°C
				  (212°F), with extensions of the scale on either side permitted. Protected
				  against damage at 105°C (220°F).
Temperature Represented by Smallest Scale Division:
1°C (2°F).
Accuracy:
Within ± 1°C (±
				  2°F), throughout the specified scale range. Checked periodically against a
				  known accurate thermometer.
In the case of mercury actuated general-purpose thermometers,
				  the following additional specifications shall apply:
Magnification of Mercury Column:
To apparent
				  width of not less than 1.6 millimeter (0.0625 of an inch).
Number of Degrees per Inch of Scale:
Not more
				  than 29°C or not more than 52°F.
Case:
Metal, provided with a fountain pen
				  clip.
Bulb:
Corning normal or equally suitable
				  thermometric glass.
ELECTRICAL CONDUCTIVITY MEASURING DEVICES
Type:
Manual or automatic.
Conductivity:
Capable of detecting change
				  produced by the addition of ten (10) ppm of sodium chloride, in water of 100
				  ppm of hardness.
Electrodes:
Standard.
Automatic Instruments:
Electric clock, time
				  divisions not over 0.2 of a second.
TIME MEASURING DEVICE
An accurate time measuring device may include but is not
				  limited to a stopwatch, digital watch, conductivity device timer, and any other
				  device which keeps time accurately.
STOPWATCH
Type:
Open face, indicating fractional
				  seconds.
Accuracy:
Accurate to 0.2 of a second.
Hands:
Sweep hand, if applicable, one complete
				  turn every sixty (60) seconds or less.
Scale:
Divisions of not over 0.2 of a
				  second.
Crown:
Depression of crown or push button
				  starts, stops, and resets to zero.
II.
TEST PROCEDURES
Pasteurization equipment tests listed and referenced below
				  shall be performed by the Health Officer; or in the case of HACCP listed milk
				  plants, qualified industry personnel, acceptable to the Health Officer, as
				  cited in Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program, authorized
				  by the Health Officer, as cited in Rule
				  420-3-16-.10 (21-22). The results
				  of the tests shall be recorded on appropriate forms and filed as the Health
				  Officer shall direct (refer to Appendix M of these rules). Regulatory seals
				  shall be installed where required at the commissioning of a new pasteurization
				  system. If the public health control(s) is within a computer system used to
				  manage the functions of the public health control device(s) that operate the
				  pasteurization system, the computer shall be in compliance with Appendix H, VI
				  of these rules before the access to the computer program is sealed. Whenever a
				  regulatory seal has been broken, the pasteurization equipment shall be
				  re-sealed after the appropriate testing has been conducted by the Health
				  Officer or qualified industry personnel in compliance with Rule
				  420-3-16-.10 (21-22) and are
				  found to be in compliance with the applicable test procedure(s).
Note:
If the pasteurization system fails one (1)
				  or more of the required tests, the pasteurization system shall not be allowed
				  to operate until the cause of this failure has been corrected and compliance
				  has been verified by the Health Officer; or in the case of HACCP listed milk
				  plants, qualified industry personnel acceptable to the Health Officer in
				  compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program, authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
If it is required to break a regulatory seal to conduct any
				  of the following tests, it shall be replaced by the Health Officer or HACCP
				  qualified personnel acceptable to the Health Officer after testing has been
				  completed and compliance has been verified.
Note:
For various pieces of equipment approved
				  for pasteurization systems, testing procedures which have been reviewed
				  specifically for that equipment are included within the FDA accepted operations
				  manual for the equipment and/or within the Memorandum of Milk Ordinance
				  Equipment Compliance (M-b) issued upon FDA's review and acceptance of the
				  equipment. These testing procedures shall be used.
TEST 1
INDICATING THERMOMETERS - TEMPERATURE
				  ACCURACY
Reference:
Rule
				  420-3-16-.10 (17-18) and Rule
				  420-3-16-.10 (21-22)
Application:
To all indicating thermometers,
				  including airspace thermometers if applicable, used for the measurement of milk
				  and/or milk product temperature during pasteurization and/or
				  ultra-pasteurization. Do not run this test if the liquid column has been split
				  or the capillary tube is broken.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the thermometer has been repaired and/or
				  replaced; or whenever the regulatory seal on a digital sensing element or a
				  digital control box has been broken.
Criteria:
Within ± 0.25ºC (±
				  0.5ºF) for pasteurization and ultra-pasteurization indicating thermometers
				  and ± 0.5ºC (± 1ºF) for airspace thermometers, in a
				  specified scale range; provided, that on a batch pasteurizer used solely for
				  thirty (30) minute pasteurization of milk and/or milk products at temperatures
				  above 71°C (160°F), the indicating thermometer shall be accurate to
				  within ± 0.5°C (± 1°F).
Apparatus:
1. Test thermometer meeting the specifications cited in
				  Section I of this appendix.
2. Water, oil or other suitable media bath and
				  agitator.
3. Suitable means of heating the media bath.
Method:
Both the indicating and/or airspace
				  thermometer, if applicable, and test thermometer shall be exposed to water,
				  oil, or other suitable media of a uniform temperature. The indicating
				  thermometer and/or airspace thermometer, if applicable, reading is compared to
				  the reading of the test thermometer.
Procedure:
1. Prepare a media bath by raising the temperature of the
				  media to within 2°C (3°F) of the lowest sealed cut-out pasteurization
				  or ultra-pasteurization temperature or minimum legal indicating or airspace
				  temperature for batch pasteurization.
2. Stabilize the media bath temperature and agitate
				  rapidly.
3. Continue agitation and insert the indicating and/or
				  airspace thermometer, if applicable, and test thermometer to the indicated
				  immersion point.
4. Compare the thermometer readings at a temperature within
				  the test range.
5. Repeat the comparison of the thermometer readings.
6. If the results of this test are outside the
Criteria
noted above, the indicating thermometer or airspace
				  thermometer, if applicable, shall be adjusted by milk plant personnel to agree
				  with the test thermometer, retest and record the action taken on the
				  appropriate form.
7. When compliance is achieved and/or verified, record the
				  thermometer readings from both comparisons and record the thermometer
				  identification or location on the appropriate form.
8. Re-seal as appropriate the sensing elements and control
				  boxes of the digital thermometers.
Action:
If the pasteurization or
				  ultra-pasteurization system fails this test, the pasteurization or
				  ultra-pasteurization system shall not be allowed to operate until the cause of
				  this failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel, acceptable to the Health Officer, in compliance with Rule
				  420-3-16-.10 (21-22) or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 2
TEMPERATURE RECORDING AND RECORDER-CONTROLLER
				  THERMOMETERS - TEMPERATURE ACCURACY
Reference:
Rule
				  420-3-16-.10 (17-18) and Rule
				  420-3-16-.10 (21-22)
Application:
To all temperature recording and
				  recorder-controller thermometers used to record milk and/or milk product
				  temperatures during pasteurization and/or ultra-pasteurization, except those
				  which are electronic or computer controlled.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the sensing element has been repaired
				  and/or replaced; or whenever the regulatory seal has been broken.
Criteria:
Within ± 0.5°C (±
				  1°F), in a specified scale range as described in Procedure 1 below;
				  provided, that on a batch pasteurizer used solely for thirty (30) minute
				  pasteurization of milk and/or milk products at temperatures above 71°C
				  (160°F), the temperature recording thermometer shall be accurate to within
				  ± 1°C (± 2°F) between 71°C (160°F) and 77°C
				  (170°F).
Apparatus:
1. The indicating thermometer which was previously tested
				  against a known accurate test thermometer.
2. Water, oil, or other suitable media bath and
				  agitator.
3. Suitable means of heating the media bath.
4. Ice.
Note:
When this test is performed on temperature
				  recorder-controllers used with HHST pasteurization systems that operate at or
				  above the boiling point of water, an oil or other suitable media bath shall be
				  substituted for the processing (operating) temperature water mentioned in
Procedures 1, 4, 5, 6, and 7
as well as the boiling water
				  mentioned in
Procedures 2, 3 and 5
. The temperature of the oil
				  bath that is used in place of the boiling water shall be above the normal
				  operating range but below the highest temperature division on the chart.
Method:
The testing of a temperature recording
				  or recorder-controller thermometer for temperature accuracy involves the
				  determination of whether or not the temperature pen-arm will return to within
				  ± 0.5ºC (± 1ºF) or ± 1°C (± 2°F)
				  as provided for in the
Criteria
above, of its previous setting,
				  after exposure to high heat and melting ice.
Procedure:
1. Heat a media bath to a constant temperature utilizing one
				  (1) of the following temperatures:
a. Lowest sealed cut-out pasteurization temperature;
				  or
b. Minimum legal indicating or airspace pasteurization
				  temperature for batch pasteurization; provided, that on a batch pasteurizer
				  used solely for thirty (30) minute pasteurization of milk and/or milk products
				  at temperatures above 71°C (160°F), this test shall be conducted with a
				  media bath temperature above 71°C (160°F) and below 77°C
				  (170°F).
Immerse the temperature recording or recorder-controller
				  thermometer sensing element into the media bath. After a stabilization period
				  of five (5) minutes, if necessary adjust the temperature re-cording or
				  recorder-controller thermometer pen to read exactly as the previously tested
				  indicating thermometer. The media bath shall be rapidly agitated throughout
				  this stabilization period.
2. Prepare a second media bath by heating the media bath to
				  the boiling point of water, or in the case of HHST pasteurization systems, to a
				  temperature above the normal operating range but below the highest temperature
				  division on the chart, and maintain temperature. Prepare a third media bath
				  with ice and water. Place all media baths within working distance of the
				  temperature recording or recorder-controller thermometer temperature-sensing
				  element(s).
3. Immerse the temperature recording or recorder-controller
				  thermometer sensing element into the hot media bath as prepared in
Procedure 2
, above, for not less than five (5) minutes.
4. Remove the temperature recording or recorder-controller
				  thermometer sensing element from the hot media bath and immerse it in the media
				  bath as prepared in
Procedure 1
above. Allow a five (5) minute
				  stabilization period for both the indicating and temperature recording or
				  recorder-controller thermometers. Compare the readings of the indicating and
				  temperature recording or recorder-controller thermometers. The temperature
				  recording or recorder-controller thermometer reading shall be within ±
				  0.5ºC (± 1ºF) or ± 1°C (± 2°F) as
				  provided for in the Criteria above, of the indicating thermometer
				  reading.
5. Remove the temperature recording or recorder-controller
				  thermometer sensing element from the media bath in the temperature range for
				  the process being used and immerse it in the ice and water bath for not less
				  than five (5) minutes.
6. Remove the temperature recording or recorder-controller
				  thermometer sensing element from the ice and water bath and immerse it in the
				  media bath as prepared in
Procedure 1
above. Allow a five (5)
				  minute stabilization period for both the indicating and temperature recording
				  or recorder-controller thermometers. Compare the readings of the indicating and
				  temperature recording or recorder-controller thermometers. The temperature
				  recording or recorder-controller thermometer reading shall be within ±
				  0.5°C (± 1°F) or ± 1°C (± 2°F) as provided
				  for in the
Criteria
above, of the indicating thermometer
				  reading.
7. When compliance is achieved and/or verified, re-seal the
				  thermometer sensing elements and recorder-controller as necessary and record
				  the indicating and temperature recording thermometer or recorder-controller
				  thermometer readings obtained from
Procedures 1, 4, and 6
above on
				  the appropriate form.
Action:
If the temperature recording or
				  recorder-controller thermometer pen does not return to ± 0.5°C
				  (± 1°F) or ± 1°C (± 2°F) as provided in
Procedures 4 and 6
above, the temperature recording or
				  recorder-controller thermometer shall be repaired or replaced by milk plant
				  personnel. If the pasteurization or ultra-pasteurization system fails this
				  test, the pasteurization or ultra-pasteurization system shall not be allowed to
				  operate until the cause of this failure has been corrected and compliance has
				  been verified by the Health Officer; or in the case of HACCP listed milk
				  plants, qualified industry personnel acceptable to the Health Officer in
				  compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 3
TEMPERATURE RECORDING AND RECORDER-CONTROLLER
				  THERMOMETERS - TIME ACCURACY
Reference:
Rule
				  420-3-16-.10 (17-18) and Rule
				  420-3-16-.10 (21-22)
Application:
To all temperature recording and
				  recorder-controller thermometers used to record the time of pasteurization
				  and/or ultra-pasteurization.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the temperature recorder-controller
				  thermometer or programmable recording thermometer has been repaired and/or
				  replaced; or whenever the regulatory seal on a temperature recorder-controller
				  thermometer or programmable recording thermometer or sensing element has been
				  broken.
Criteria:
The recorded time of pasteurization or
				  ultra-pasteurization shall not exceed the true elapsed time.
Apparatus:
An accurate time measuring
				  device.
Method:
A comparison of the recorded time over a
				  period of not less than thirty (30) minutes with an accurate time measuring
				  device.
Procedure:
1. Determine if the recording chart is appropriate for the
				  temperature recording or recorder-controller thermometer. Ensure that the
				  recording chart pen is aligned with the time arc of the recording chart at both
				  the center and the outside edge.
2. Inscribe a reference mark at the pen point on the
				  recording chart and record the time.
3. At the end of thirty (30) minutes utilizing an accurate
				  time measuring device, inscribe a second reference mark at the pen point
				  position on the recording chart.
4. Determine the distance between the two (2) reference marks
				  and compare the distance with the time-scale divisions on the recording chart
				  at the same temperature.
5. Re-seal the sensing elements and recorder-controller as
				  necessary; enter the results on the recording chart and initial the recording
				  chart; and record the beginning and ending times on the appropriate
				  Form.
Action:
If the recorded time is incorrect, the
				  temperature recording or recorder-controller thermometer device shall be
				  adjusted or repaired by milk plant personnel. If the pasteurization or
				  ultra-pasteurization system fails this test, the pasteurization or
				  ultra-pasteurization system shall not be allowed to operate until the cause of
				  this failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 4
TEMPERATURE RECORDING AND RECORDER-CONTROLLER
				  THERMOMETERS -CHECKED AGAINST INDICATING THERMOMETER
Reference:
Rule
				  420-3-16-.10 (17-18) and Rule
				  420-3-16-.10 (21-22)
Application:
To all temperature recording and
				  recorder-controller thermometers used to record milk and/or milk product
				  temperatures during pasteurization or ultra-pasteurization, and for batch
				  pasteurizer digital combination airspace/recording thermometers with a
				  continuous recording of the airspace temperature and where the airspace
				  temperature is read and recorded on the recording chart only at the start of
				  the pasteurization holding period.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the temperature recording or
				  recorder-controller thermometer has been repaired and/or replaced; whenever the
				  regulatory seal has been broken; and daily and immediately after a recording
				  chart has been changed by milk plant personnel.
Criteria:
The temperature recording thermometer
				  and recorder-controller thermometer shall not read higher than the indicating
				  or airspace thermometer which were previously tested against a known accurate
				  test thermometer.
Apparatus:
No supplementary materials
				  required.
Method:
This test requires only that the reading
				  of the temperature recording thermometer, recorder-controller thermometer, or
				  airspace recording thermometer be compared with the indicating thermometer at a
				  time when both are exposed to a stabilized temperature at or above the minimum
				  legal pasteurization temperature.
Procedure:
1. When the indicating and temperature recording or
				  recorder-controller thermometer temperature readings are stabilized at or above
				  the minimum legal pasteurization temperature, read the indicating
				  thermometer.
2. For batch pasteurizers, when the airspace indicating and
				  recording temperature readings are stabilized at or above the minimum legal
				  pasteurization temperature, read the airspace thermometer.
3. Immediately enter the results; the time at which this
				  comparison was made; and initial the recording chart. This may be accomplished
				  by inscribing a line intersecting the recorded temperature arc at the pen
				  location or any other method acceptable to the Health Officer.
4. Record the observed indicating and temperature recording
				  thermometer or recorder-controller thermometer readings on the appropriate
				  form.
Action:
If the temperature recording thermometer
				  or recorder-controller thermometer reads higher than the indicating
				  thermometer, the pen or temperature adjusting mechanism shall be adjusted by
				  milk plant personnel to agree with the indicating thermometer. If after
				  adjustment the temperature recording thermometer or recorder-controller
				  thermometer fails this test, the pasteurization or ultra-pasteurization system
				  shall not be allowed to operate until the cause of this failure has been
				  corrected and compliance has been verified by the Health Officer; or in the
				  case of HACCP listed milk plants, qualified industry personnel acceptable to
				  the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22), or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 5
FDD - PROPER ASSEMBLY AND FUNCTION
Reference:
Rule
				  420-3-16-.10(18);
				  Rule 420-3-16-.10 (21-22)
Application:
5.1 to 5.4 and 5.6 to 5.8 below
				  apply to all FDDs used with continuous-flow pasteurization systems. 5.5 and 5.9
				  below apply only to FDDs used with HTST pasteurization systems.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the FDD has been repaired and/or
				  replaced; or whenever the regulatory seal(s) has been broken.
Criteria:
The FDD shall function as required in
				  all operating situations and shall de-energize the timing pump and all other
				  flow-promoting devices capable of causing flow through the FDD, in the event of
				  a FDD malfunction or when the FDD is incorrectly assembled.
5.1 LEAKAGE PAST THE VALVE SEAT(S)
Apparatus:
Suitable tools for the disassembly of
				  the FDD and any connected sanitary piping.
Method:
Observe the valve seat(s) for
				  leakage.
Procedure:
1. With the pasteurization system operating on water, place
				  the FDD in the diverted-flow position.
a. For single stem FDDs, disconnect the forward-flow sanitary
				  piping and observe the valve seat for leakage. Check the leak escape ports to
				  see if they are open; or
b. For dual stem FDDs, observe the leak-detect line discharge
				  or sight glass for leakage.
2. Record the results of the test on the appropriate
				  form.
Action:
If leakage is observed, suitable repairs
				  shall be made to the FDD by milk plant personnel. If after adjustment and/or
				  repair the FDD fails this test, the pasteurization system shall not be allowed
				  to operate until the cause of this failure has been corrected and compliance
				  has been verified by the Health Officer; or in the case of HACCP listed milk
				  plants, qualified industry personnel acceptable to the Health Officer in
				  compliance with Rules
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rules
				  420-3-16-.10 (21-22).
5.2 OPERATION OF THE VALVE STEM(S)
Apparatus:
Suitable tools for tightening the
				  packing nut on the valve stem of a single stem FDD.
Method:
Observe the valve stem(s) for ease of
				  movement.
Procedure:
1. For single stem FDDs, tighten the valve stem packing nut
				  as much as possible. Operate the pasteurization system at maximum operating
				  pressure and place the FDD in both forward and diverted-flow several times. The
				  valve stem shall move freely in both forward and diverted-flow positions when
				  the stem-packing nut is fully tightened. Note the freedom of action of the
				  valve stem.
2. For dual stem FDDs, operate the pasteurization system at
				  maximum operating pressure and place the FDD in both forward and diverted-flow
				  several times. The valve stems shall move freely in both forward and
				  diverted-flow positions. Note the freedom of action of the valve stems.
3. Record the results of the test on the appropriate
				  form.
Action:
If the valve stem(s) action is sluggish,
				  suitable adjustment or repair shall be made by milk plant personnel. If after
				  adjustment and/or repair the FDD fails this test, the pasteurization system
				  shall not be allowed to operate until the cause of this failure has been
				  corrected and compliance has been verified by the Health Officer; or in the
				  case of HACCP listed milk plants, qualified industry personnel acceptable to
				  the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
5.3 DEVICE ASSEMBLY - SINGLE STEM FDD
Apparatus:
Suitable tools for the disassembly of
				  the FDD and any connected sanitary piping.
Method:
When the FDD is improperly assembled and
				  in diverted-flow, below the cut-out temperature, observe the function of the
				  timing pump and all other flow-promoting devices capable of causing flow
				  through the FDD.
Procedure:
1. With the pasteurization system in operation, in "Process"
				  mode, and below the cut-in temperature, unscrew by one-half (1/2) turn, the 13H
				  hex nut that holds the top of the valve to the valve body. This shall
				  de-energize the timing pump and all other flow-promoting devices which are
				  capable of causing flow through the FDD. In addition, separators and/or
				  downstream vacuum sources shall be effectively valved-out of the pasteurization
				  system. This test shall be conducted without any sanitary piping connected to
				  the forward-flow port of the FDD. This allows for the movement of the top of
				  the valve when the hex nut is loosened. Re-tighten the 13H hex nut.
2. With the pasteurization system in operation, in "Process"
				  mode, and below the cut-in temperature, remove the connecting key which is
				  located at the base of the valve stem. The timing pump and all other
				  flow-promoting devices which are capable of causing flow through the FDD shall
				  be de-energized. In addition, separators and/or downstream vacuum sources shall
				  be effectively valved-out of the pasteurization system.
3. Attempt to restart each flow-promoting device capable of
				  causing flow through the FDD. None of these flow-promoting devices shall start
				  or operate. Separators and/or downstream vacuum sources shall remain
				  effectively valved-out of the pasteurization system.
4. Record the results of the test on the appropriate
				  form.
Action:
If any flow-promoting device fails to
				  respond as indicated above, an immediate check of the FDD assembly and wiring
				  is required by milk plant personnel to locate and correct the cause of the
				  failure. If after adjustment and/or repair the FDD fails this test, the
				  pasteurization system shall not be allowed to operate until the cause of this
				  failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
5.4 DEVICE ASSEMBLY - DUAL STEM DEVICE
Note:
the test procedure presented in this
				  section is typical of tests accepted by FDA for various specific types of FDDs.
				  Testing details, which may vary, are provided in individual FDD operator's
				  manuals that have been reviewed by the FDA and are specified by part number in
				  FDA's M-bs. In each of these M-b accepted test methods, if the words "metering
				  pump" or "timing pump" are used they shall be understood to mean "timing pump
				  and all other flow-promoting devices, which are capable of causing flow through
				  the FDD."
Apparatus:
No supplementary materials
				  required.
Method:
Observe the function of the timing pump
				  and all other flow-promoting devices which are capable of causing flow through
				  the FDD when the FDD is improperly assembled.
Procedure:
1. With the FDD in diverted-flow caused by temperature, and
				  the FDD is properly assembled, move the FDD to the forward-flow position by
				  moving the switch to the "Inspect" mode and disconnect the valve stem from the
				  actuator of the valve being tested.
2. Move the FDD to the diverted-flow position by moving the
				  switch to the "Product" mode and turn on the timing pump and all other
				  flow-promoting devices which are capable of causing flow through the FDD. The
				  timing pump and all other flow-promoting devices shall be de- energized and
				  shall not run. If any flow-promoting device which is capable of causing flow
				  through the FDD starts momentarily and then stops running, it may indicate the
				  improper wiring of the one (1) second time delay as allowed for in
				  16p.(B)2.b.(10). In addition, separators and/or downstream vacuum sources shall
				  remain effectively valved-out of the pasteurization system. Move the switch to
				  the "Inspect" mode and properly reassemble the FDD. Start the timing pump and
				  all other flow-promoting devices which are capable of causing flow through the
				  FDD to determine if the FDD has been properly reassembled.
3. Repeat this procedure for the other actuator.
4. Record the results of the test on the appropriate
				  form.
Action:
If any of the flow-promoting devices
				  which are capable of causing flow through the FDD fail to respond as indicated,
				  an immediate check of the FDD assembly and wiring shall be conducted by milk
				  plant personnel to locate and correct the problem. If after adjustment and/or
				  repair the FDD fails this test, the pasteurization system shall not be allowed
				  to operate until the cause of this failure has been corrected and compliance
				  has been verified by the Health Officer; or in the case of HACCP listed milk
				  plants, qualified industry personnel acceptable to the Health Officer in
				  compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
5.5 MANUAL DIVERSION
Apparatus:
No supplementary materials
				  required.
Method:
Observe that the appropriate responses
				  in
Procedures 1 and 2
, as required below, have occurred during the
				  activation and deactivation of manual diversion.
Procedure:
1. With the HTST pasteurization system in operation and the
				  FDD in the forward-flow position, activate the manual divert control.
a. The FDD shall assume the diverted-flow position.
b. Any flow-promoting device downstream from the FDD, which
				  is capable of causing flow through the FDD shall be de-energized.
c. Any separator and/or vacuum source downstream from the FDD
				  shall be effectively valved-out.
2. If a booster pump is installed in the HTST pasteurization
				  system and the pasteurization system is in operation with the FDD in the
				  forward-flow position:
a. Activate the manual divert control. The booster pump shall
				  be de-energized. The required minimum pressure differential of at least 6.9 kPa
				  (1 psi) between raw milk and/or milk product and pasteurized milk and/or milk
				  product in the regenerator shall be maintained.
b. After the raw pressure reaches zero (0) psi, deactivate
				  the manual divert control and observe that the required minimum pressure
				  differential of at least 6.9 kPa (1 psi) between raw milk and/or milk product
				  and pasteurized milk and/or milk product in the regenerator has been
				  maintained.
Action:
If the above described required actions
				  do not occur, or the required pressure differential between raw and pasteurized
				  milk and/or milk product is not maintained, the HTST pasteurization system
				  shall be immediately reviewed and evaluated by milk plant personnel and the
				  indicated deficiencies corrected or proper adjustments made. If after
				  adjustment and/or repair the FDD fails this test, the pasteurization system
				  shall not be allowed to operate until the cause of this failure has been
				  corrected and compliance has been verified by the Health Officer; or in the
				  case of HACCP listed milk plants, qualified industry personnel acceptable to
				  the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
5.6 RESPONSE TIME
Apparatus:
1. Water, oil or other suitable media bath and
				  agitator.
2. Suitable means of heating the media bath.
3. An accurate time measuring device.
Method:
Determine that the elapsed time does not
				  exceed one (1) second between the instant of the activation of the FDD control
				  mechanism at cut-out temperature, on declining temperature, and the instant the
				  FDD takes the fully diverted-flow position.
Procedure:
1. With the water, oil, or suitable media bath at a
				  temperature above cut-out temperature, allow the water, oil, or other suitable
				  media to cool gradually. The moment the cut-out mechanism is activated, start
				  the accurate time measuring device. The moment the FDD takes the fully-diverted
				  position, stop the accurate time measuring device.
2. Record the results of the test on the appropriate
				  form.
Action:
If the response time exceeds one (1)
				  second, immediate action shall be taken by milk plant personnel to correct this
				  FDD deficiency. If after adjustment and/or repair the FDD fails this test, the
				  pasteurization system shall not be allowed to operate until the cause of this
				  failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
5.7 TIME DELAY INTERLOCK WITH TIMING PUMP AND OTHER
				  FLOW PROMOTING DEVICES
Application:
To all dual stem FDDs with a manual
				  forward-flow control switch.
Apparatus:
No supplementary materials
				  required.
Method:
Determine that the FDD does not assume a
				  manually induced forward-flow position while the timing pump or any other
				  flow-promoting device which is capable of causing flow through the FDD is
				  operating.
Procedure:
With the pasteurization system
				  operating in forward-flow, move the control switch to the "Inspect" position
				  and observe that the following events automatically occur in sequence:
1. The FDD immediately moves to the diverted-flow position
				  and the timing pump and all other flow-promoting devices, which are capable of
				  causing flow through the FDD, are de-energized, or in the case of separators
				  and/or downstream vacuum sources, are effectively valved-out of the
				  pasteurization system.
2. The FDD remains in the diverted-flow position until the
				  timing pump and all other flow-promoting devices which are capable of causing
				  flow through the FDD have completely stopped running or in the case of a
				  separator and/or downstream vacuum sources, are effectively valved-out of the
				  pasteurization system.
3. Then the FDD shall assume the forward-flow
				  position.
4. Record the results of the test on the appropriate form and
				  seal the control enclosure.
Action:
If the above sequence of events do not
				  occur, either a timer adjustment or wiring change is required to be made by
				  pasteurization plant personnel. If after adjustment and/or repair the FDD fails
				  this test, the pasteurization system shall not be allowed to operate until the
				  cause of this failure has been corrected and compliance has been verified by
				  the Health Officer; or in the case of HACCP listed milk plants, qualified
				  industry personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
5.8 CIP TIME DELAY RELAY
Application:
To all continuous-flow
				  pasteurization systems in which it is desired to run any flow-promoting devices
				  during the CIP cycle.
Criteria:
When the mode switch on the FDD is
				  moved from "Process" to "CIP," the FDD shall move immediately to the
				  diverted-flow position. It shall remain in the diverted-flow position for at
				  least ten (10) minutes, with all public health controls required in the
				  "Process" mode functioning, before starting its normal cycling in the "CIP"
				  mode. In HTST pasteurization systems, the booster pump shall be de-energized,
				  separators between raw regenerator sections and separators and/or vacuum
				  sources downstream of the FDD shall be effectively valved-out of the
				  pasteurization system during the required ten (10) minute time delay.
Apparatus:
An accurate time measuring
				  device.
Method:
Determine that the set point on the
				  "CIP" time delay is equal to or greater than the required ten (10) minutes by
				  observing the time when the FDD moves to the forward-flow position or is again
				  capable of moving to the forward-flow position.
Procedure:
1. Operate the pasteurization system in forward-flow, with
				  the mode switch on the FDD controls in the "Process" position, using water
				  above the minimum legal pasteurization temperature. For magnetic flow meter
				  based timing systems, operate the system at a flow-rate below the flow alarm
				  set point and above the low-flow or loss-of-signal alarm set point.
Note:
The appropriate temperature sensing
				  elements may be placed in a water, oil, or other suitable media bath to
				  simulate the normal pasteurization temperature within the holding tube as an
				  alternative to heating the water in the pasteurization system above the minimum
				  legal pasteurization temperature.
2. Move the mode switch on the FDD control to the "CIP"
				  position. The FDD shall move immediately to the diverted-flow position. Start
				  the accurate time measuring device when the FDD moves to the diverted-flow
				  position. Confirm that all public health controls required in diverted flow in
				  the "Process" mode are functioning.
3. Stop the accurate time measuring device when the FDD moves
				  to the forward-flow position or is again capable of moving to the forward-flow
				  position. At this time, the pasteurization system may be operated without the
				  FDD controls normally required during the "Process" mode during product
				  processing.
4. Record the results of the test on the appropriate
				  form.
5. Re-seal the regulatory enclosure over the time
				  delay.
Action:
If the FDD does not remain in the
				  diverted-flow position for at least the required ten (10) minutes after the FDD
				  mode switch is moved from "Process" to "CIP," increase the set point on the
				  time delay and repeat this test procedure. All public health controls required
				  when the pasteurization system is in "Process" mode and in diverted-flow shall
				  be functional during this required ten (10) minutes. If the above does not
				  occur, either a timer adjustment or wiring change is required to be made by
				  milk plant personnel. If after adjustment and/or repair the FDD fails this
				  test, the pasteurization system shall not be allowed to operate until the cause
				  of this failure has been corrected and compliance has been verified by the
				  Health Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
5.9 LEAK-DETECT VALVE FLUSH - TIME DELAY
Application:
To HTST continuous-flow
				  pasteurization systems in which the space between the divert and leak-detect
				  valves is not self-draining when the FDD is in the diverted-flow
				  position.
Criteria:
The space between the divert and
				  leak-detect valves shall be flushed for at least one (1) second and not more
				  than five (5) seconds after the divert valve moves to the forward-flow position
				  and before the leak-detect valve moves to the forward-flow position.
The maximum of five (5) seconds delay is not applicable
				  if:
1. The minimum acceptable pasteurization holding time in
				  diverted-flow can be achieved without the use of any restriction in the divert
				  line; or
2. The timing system is magnetic flow meter based.
Apparatus:
An accurate time measuring
				  device.
Method:
Observe the movement of the divert and
				  leak-detect valves to the forward-flow position and measure the time interval
				  between the movement of the two (2) valves.
Procedure:
1. Move the FDD from the diverted-flow position to the
				  forward-flow position either by:
a. Raising the temperature above the cut-in set point;
				  or
Note:
The appropriate temperature sensing
				  elements may be placed in a water, oil, or other suitable media bath to
				  simulate the normal pasteurization temperature within the holding tube as an
				  alternative to heating the water in the pasteurization system above the minimum
				  legal pasteurization temperature.
b. Operating the HTST pasteurization system above the cut-in
				  temperature in manual divert mode and then deactivate the manual divert
				  control.
2. When the divert valve begins to move to the forward-flow
				  position, start the accurate time measuring device.
3. When the leak-detect valve begins to move to the
				  forward-flow position, stop the accurate time measuring device.
4. Record the elapsed time on the appropriate form.
5. If the elapsed time is at or above one (1) second and at
				  or below five (5) seconds, except as noted in the exceptions in the
Criteria
above, seal the time delay as required.
Action:
If the elapsed time is less than one (1)
				  second or greater than five (5) seconds, except as noted in the exceptions in
				  the
Criteria
above, appropriate changes to the pasteurization
				  system or pasteurization system's FDD controls shall be made by milk plant
				  personnel. If after adjustment and/or repair the FDD fails this test, the
				  pasteurization system shall not be allowed to operate until the cause of this
				  failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 6
BATCH (VAT) PASTEURIZER LEAK-PROTECTOR OUTLET
				  VALVE
Reference:
Rule
				  420-3-16-.10(17)
				  and Rule 420-3-16-.10 (21-22)
Application:
To all batch (vat) pasteurizers
				  that have an outlet valve.
Frequency:
Upon installation; and at least once
				  each three (3) months thereafter.
Criteria:
No leakage past the outlet valve seat
				  in the closed position.
Apparatus:
No supplementary materials
				  required.
Method:
By observing whether or not leakage past
				  the outlet valve seat occurs when pressure is exerted against the upstream face
				  of the outlet valve.
Procedure:
1. Utilizing milk, milk products, or water, fill the batch
				  (vat) pasteurizer to the normal operation level.
2. Observe the outlet valve in the closed position and
				  determine whether or not milk, milk product, or water, respectively, is leaking
				  past the outlet valve seat into the valve outlet.
3. Record the results of the test on the appropriate
				  form.
Action:
If leakage past the outlet valve seat
				  occurs in the closed position, the outlet valve plug shall be repaired or
				  replaced by milk plant personnel. If the outlet valve fails this test, the
				  batch (vat) pasteurizer shall not be allowed to operate until the cause of this
				  failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rules
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rules
				  420-3-16-.10 (21-22).
TEST 7
INDICATING THERMOMETERS LOCATED WITHIN HTST
				  PASTEURIZATION SYSTEMS - THERMOMETRIC RESPONSE
Reference:
Rule
				  420-3-16-.10(18)
				  and Rule 420-3-16-.10 (21-22)
Application:
To all HTST pasteurization systems,
				  except for those in which the FDD is located downstream of the pasteurized
				  regenerator section(s) and/or the final cooler section.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the indicating thermometer has been
				  repaired and/or replaced; or whenever the regulatory seal on a digital sensing
				  element or digital control box has been broken.
Criteria:
Four (4) seconds or less.
Apparatus:
1. Accurate time measuring device.
2. The indicating thermometer, which was previously tested
				  against a known accurate test thermometer.
3. Water, oil or other suitable media bath and
				  agitator.
4. Suitable means of heating the media bath.
5. Ice and water media bath.
Method:
The measuring of the time required for
				  the reading of the indicating thermometer being tested to increase 7°C
				  (12°F) through a specified temperature range. This temperature range shall
				  include the minimum legal pasteurization temperature(s). If there are multiple
				  cut-in temperatures and one (1) or more are separated by more than 7°C
				  (12°F), this test shall also be conducted for any cut-in temperature(s) not
				  included within the initial 7°C (12°F) range as addressed in
Procedure 1
below.
Procedure:
1. Immerse the indicating thermometer in the media bath which
				  has been heated to a temperature at least 11°C (19°F) higher than the
				  minimum scale reading on the indicating thermometer. The media bath temperature
				  shall be 4°C (7°F) higher than the highest pasteurization temperature
				  set point (cut-in temperature) for which the indicating thermometer is being
				  used.
2. Immerse the indicating thermometer in an ice and water
				  media bath for several seconds to cool it.
Note:
Continuous agitation of the heated media
				  bath during the performance of
Procedures 3, 4 and 5
is required.
				  The elapsed time between the end of
Procedure 1
and the beginning
				  of
Procedure 3
shall not exceed fifteen (15) seconds, unless a
				  constant temperature media bath is used to prevent the heated media bath from
				  cooling significantly.
3. Insert the indicating thermometer into the heated media
				  bath to the proper indicating thermometer bulb immersion depth.
4. Start the accurate time measuring device when the
				  indicating thermometer reads 11°C (19°F) below the heated media bath
				  temperature.
5. Stop the accurate time measuring device when the
				  indicating thermometer reads 4°C (7°F) below the heated media bath
				  temperature.
6. Record the results of the test on the appropriate
				  form.
For Example:
For an indicating thermometer used
				  at pasteurization temperature set points of 71.7°C (161°F) and
				  74.4°C (166°F), a media bath at a temperature of 78.3°C (173°F)
				  could be used. 11°C (19°F) lower than a 78.3°C (173°F) media
				  bath would be 67.8°C (154°F); 4°C (7°F) lower than a 78.3°C
				  (173°F) media bath would be 74.4°C (166°F). Hence, after immersing
				  the indicating thermometer that has been previously cooled in the ice and water
				  media bath into the 78.3°C (173°F) bath, the accurate time measuring
				  device is started when the thermometer reads 67.8°C (154°F) and the
				  accurate time measuring device is stopped when it reads 74.3°C
				  (166°F).
Note:
The example included the pasteurization
				  temperature set points of 71.7°C (161°F) and 74.4°C (166°F). If
				  the pasteurization temperature set points had been 71.7°C (161°F) and
				  79.4°C (175°F), it would not have been possible to include both set
				  points within a 7°C (12°F) span. With these set points of 71.7°C
				  (161°F) and 79.4°C (175°F), the test would have to be conducted
				  separately for each set point.
Action:
If the response time exceeds four (4)
				  seconds, the indicating thermometer shall be repaired or replaced by milk plant
				  personnel. If the thermometer fails this test, the pasteurization system shall
				  not be allowed to operate until the cause of this failure has been corrected
				  and compliance has been verified by the Health Officer; or in the case of HACCP
				  listed milk plants, qualified industry personnel acceptable to the Health
				  Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 8
TEMPERATURE RECORDER-CONTROLLER THERMOMETERS -
				  THERMOMETRIC RESPONSE
Reference:
Rule
				  420-3-16-.10(18)
				  and Rule 420-3-16-.10 (21-22)
Application:
To all HTST continuous-flow
				  pasteurization systems, except for those in which the FDD is located downstream
				  of the pasteurized regenerator section(s) and/or the final cooler
				  section.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the temperature recorder-controller
				  thermometer has been repaired and/or replaced; or whenever the regulatory seal
				  has been broken.
Criteria:
Five (5) seconds or less.
Apparatus:
1. Accurate time measuring device.
2. The indicating thermometer, which was previously tested
				  against a known accurate test thermometer.
3. Water, oil or other suitable media bath and
				  agitator.
4. Suitable means of heating the media bath.
Method:
Measure the time interval between the
				  instant when the temperature recorder-controller thermometer reads 7°C
				  (12°F) below the cut-in temperature and the moment of cut-in by the
				  temperature recorder-controller. This time interval measurement is made when
				  the temperature recorder-controller sensing element is immersed in a rapidly
				  agitated media bath maintained at 4°C (7°F) above the cut-in
				  temperature.
Procedure:
1. Check and, if necessary, adjust the pen-arm setting of the
				  temperature recorder-controller thermometer to read the same as the indicating
				  thermometer at pasteurization temperature.
2. Allow the temperature recorder-controller sensing element
				  to cool to room temperature.
3. Heat the media bath to 4°C (7°F) above the cut-in
				  temperature while continuously agitating the media bath to ensure a uniform
				  temperature.
4. Immerse the temperature recorder-controller sensing
				  element in the media bath. Continue agitation during
Procedures 5 and 6
below.
5. Start the accurate time measuring device when the
				  temperature recorder-controller thermometer reaches a temperature of 7°C
				  (12°F) below the cut-in temperature.
6. Stop the accurate time measuring device when the
				  temperature recorder-controller cuts in.
7. Record the results of the test on the appropriate
				  form.
8. Repeat
Procedures 1 through 7
for each
				  temperature cut-in set point.
Action:
If the response time exceeds five (5)
				  seconds, the temperature recorder-controller shall be repaired or replaced by
				  milk plant personnel. If the temperature recorder-controller fails this test,
				  the pasteurization system shall not be allowed to operate until the cause of
				  this failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 9
REGENERATOR PRESSURE CONTROLS
Reference: Rule
				  420-3-16-.10(19)
				  and Rule 420-3-16-.10
				  (21-22)
9.1 PRESSURE SWITCHES
Application:
To all pressure switches
				  controlling the operation of a booster pump on HTST pasteurization systems with
				  a regenerator section(s).
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever there is any change to the booster pump
				  or the pressure switch circuit; or whenever the regulatory seal has been
				  broken.
Criteria:
The booster pump shall not operate
				  unless there is at least a 6.9 kPa (1 psi) pressure differential on the
				  pasteurized milk and/or milk product side of the regenerator section.
Apparatus:
1. A sanitary pressure gauge.
2. Pneumatic testing device, for checking and adjusting the
				  pressure switch settings.
Note:
A simple pneumatic testing device may be
				  made from a sanitary tee with a cap on one outlet of the tee that is drilled
				  and tapped and fitted in sequence from the cap with an air bleeder valve, an
				  air pressure reducing valve (suggested range 0-60 psi), and a quick disconnect
				  fitting for attaching a pneumatic device to a milk plant airline.
3. A test light of proper voltage placed in-series with the
				  pressure switch contact and in parallel with the booster pump starter.
Method:
Check and make the adjustment of the
				  pressure switch to prevent the operation of the booster pump, unless the
				  pressure of the pasteurized milk and/or milk product side of the regenerator
				  section is greater by at least 6.9 kPa (1 psi) than any pressure that may be
				  generated by the booster pump.
Procedure:
1. Determine the maximum pressure of the booster pump.
a. Install the sanitary pressure gauge in a tee at the
				  discharge of the booster pump.
b. Operate the pasteurization system on water with the FDD in
				  forward-flow, the timing pump operating at the minimum speed possible, and the
				  booster pump operating at its maximum speed. If a separator and/or vacuum
				  equipment is located between the raw outlet of the regenerator section and the
				  timing pump, the separator and/or vacuum equipment shall be effectively
				  valved-out of the pasteurization system.
c. Determine the maximum pressure indicated by the pressure
				  gauge under these conditions.
2. Check and set the pressure switch.
a. Disconnect the pressure switch to be tested from the
				  pasteurization system and connect it to one (1) of the outlets of the pneumatic
				  testing device sanitary tee.
b. Connect the sanitary pressure gauge to the third outlet of
				  the sanitary tee.
c. Close the air pressure regulating valve and fully open the
				  air bleeder valve. Slowly manipulate these valves to bring the air pressure in
				  the pneumatic testing device within the desired range.
Note:
By careful manipulation of the air
				  pressure reducing valve and the air bleeder valve, the air pressure in the
				  pneumatic testing device may be regulated slowly and precisely. When operating
				  the pneumatic testing device, care shall be taken to avoid exposing the
				  pressure switch and the sanitary pressure gauge to excessive pressure that
				  might cause damage to the pressure switch.
d. Remove the regulatory seal and cover to expose the
				  adjustment mechanism on the pressure switch.
e. Operate the pneumatic testing device and determine the
				  pressure gauge reading at the booster pump start point on the pressure switch,
				  which will light the test light. If the pressure switch is short circuited, the
				  test light will be lit before the air pressure is applied.
f. The booster pump start point shall be adjusted, if
				  necessary, so as to occur at a pressure gauge reading at least 6.9 kPa (1 psi)
				  greater than the maximum booster pump operating pressure, as determined under
				  Step 1 of this
Procedure
. If an adjustment is necessary, refer to
				  the manufacturer's instructions for the adjusting procedures. After adjustment,
				  recheck the booster pump start point.
g. Replace the cover, seal the pressure switch, and put the
				  pressure switch sensing element back at its original location.
3. Identify the motor, casing, and impeller of the booster
				  pump.
4. Record the maximum booster pump pressure, the pressure
				  switch setting and the identity of the motor casing and impeller of the booster
				  pump on the appropriate form.
Action:
If the pressure switch fails this test,
				  the pasteurization system shall not be allowed to operate until the cause of
				  this failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
9.2 DIFFERENTIAL PRESSURE CONTROLLER
Application:
Test 9.2.1 applies to all
				  differential pressure controllers used to control the operation of booster
				  pumps within HTST pasteurization systems or used to control the operation of
				  FDDs on HHST and HTST pasteurization systems with the FDD located downstream of
				  the pasteurized regenerator section(s) and/or the final cooler section.
Test 9.2.2 applies only to HTST pasteurization systems with
				  the FDD located immediately following the holding tube.
Test 9.2.3 applies to the testing of continuous-flow
				  pasteurization systems in which the differential pressure controller is used to
				  control the operation of the FDD.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the differential pressure controller is
				  adjusted or repaired; or whenever the regulatory seal has been broken.
Criteria:
The booster pump shall not operate, or
				  the pasteurization system shall not operate in forward-flow, unless the milk
				  and/or milk product pressure in the pasteurized side of the regenerator
				  section(s) is at least 6.9 kPa (1 psi) greater than the milk and/or milk
				  product pressure in the raw side of the regenerator section(s). When the
				  differential pressure controller is used to control the FDD on HHST
				  pasteurization systems, and improper pressure occurs in the regenerator
				  section(s), the FDD shall move to the diverted-flow position and remain in
				  diverted-flow until the proper pressures are re-established in the regenerator
				  section(s) and all milk and/or milk product-contact surfaces between the
				  holding tube and the FDD have been held at or above the minimum legal
				  pasteurization temperature continuously and simultaneously for at least the
				  required time.
Apparatus:
1. A sanitary pressure gauge.
2. Pneumatic testing device described in Test
9.1
				  PRESSURE SWITCHES
can be used for checking and adjusting the
				  differential pressure switch setting.
3. Water, oil or other suitable media bath and
				  agitator.
4. Suitable means of heating the media bath (refer to Test
				  9.2.2).
5. Test light (refer to Test 9.2.3).
Method:
The differential pressure switch is
				  checked and adjusted to prevent the operation of the booster pump, or prevent
				  forward-flow, unless the milk and/or milk product pressure in the pasteurized
				  side of the regenerator section(s) is at least 6.9 kPa (1 psi) greater than the
				  pressure in the raw side of the regenerator section(s).
9.2.1 CALIBRATION OF THE DIFFERENTIAL PRESSURE
				  CONTROLLER SENSING ELEMENTS
Procedure:
1. Loosen the sanitary pipeline connections to both
				  differential pressure controller pressure sensing elements and wait for any
				  liquid to drain through the loose sanitary pipeline connections. Both pointers
				  or digital displays shall be within 3.5 kPa (0.5 psi) of 0 kPa (0 psi). If not,
				  adjust the pointer(s) or the digital display(s) to read 0 kPa (0 psi).
2. Remove both differential pressure controller sensing
				  elements from the pasteurization system and mount them on a testing tee which
				  is connected either at the discharge of the booster pump or at the pneumatic
				  testing device. Note the separation between the two (2) pointers or digital
				  displays. A change in elevation of the differential pressure controller sensing
				  elements may cause some change in the 0 kPa (0 psi) readings. Turn on the
				  booster pump switch and activate the test switch/button to operate the booster
				  pump, or if the pneumatic testing device is used in lieu of the booster pump,
				  adjust the air pressure to the normal operating pressure of the booster pump.
				  Note that the pointers or digital display reading separation is within 6.9 kPa
				  (1 psi) of that observed before the pressure was applied.
3. Record the results of the test on the appropriate
				  form.
Action:
If the differential pressure controller
				  fails to respond as indicated above, an immediate check of the differential
				  pressure controller is required by milk plant personnel to correct the cause of
				  the failure. If after adjustment and/or repair the differential pressure
				  controller fails this test, the pasteurization system shall not be allowed to
				  operate until the cause of this failure has been corrected and compliance has
				  been verified by the Health Officer; or in the case of HACCP listed milk
				  plants, qualified industry personnel acceptable to the Health Officer in
				  compliance with Rules
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rules
				  420-3-16-.10 (21-22).
9.2.2 HTST - INTERWIRING OF THE DIFFERENTIAL PRESSURE
				  CONTROLLER WITH THE BOOSTER PUMP
Method:
Determine if the booster pump stops
				  running when the pressure differential is not properly maintained in the
				  regenerator section(s).
Procedure:
1. Connect the pasteurized regenerator section differential
				  pressure controller sensing element to a testing tee with the other end of the
				  testing tee capped.
Note:
If there is water in the HTST
				  pasteurization system, ensure that the recorder-controller sensing element and
				  the pasteurized regenerator section differential pressure controller sensing
				  element ports are capped before the timing pump is turned on.
2. Turn on the timing pump and the booster pump.
3. Place the recorder-controller sensing element in a hot
				  media bath which is above the cut-in temperature.
4. Increase the air supply on the testing tee to provide an
				  adequate pressure differential to start the booster pump. The booster pump
				  shall start running.
5. Decrease the air supply to the testing tee until the
				  pasteurized milk and/or milk product differential pressure controller sensing
				  element pressure is less than 14 kPa (2 psi) greater than the pressure on the
				  raw milk and/or milk product side differential pressure controller sensing
				  element. The booster pump shall stop running. Ensure that the FDD remains in
				  the forward-flow position and the timing pump continues to operate.
6. Record the results of the test on the appropriate
				  form.
Action:
If the booster pump fails to stop
				  running when the pressure differential is not maintained, milk plant personnel
				  shall determine and correct the problem. If after adjustment and/or repair the
				  differential pressure controller fails this test, the pasteurization system
				  shall not be allowed to operate until the cause of this failure has been
				  corrected and compliance has been verified by the Health Officer; or in the
				  case of HACCP listed milk plants, qualified industry personnel acceptable to
				  the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
9.2.3 INTERWIRING OF THE DIFFERENTIAL PRESSURE
				  CONTROLLER WITH THE FDD IN AN HHST CONTINUOUS-FLOW PASTEURIZATION
				  SYSTEM
Application:
To all differential pressure
				  controllers used to control the operation of FDDs on HHST continuous-flow
				  pasteurization systems with the FDD located downstream of the pasteurized
				  regenerator section(s) and/or final cooler section.
Method:
The differential pressure controller is
				  checked and adjusted to prevent forward-flow unless the milk and/or milk
				  product pressure in the pasteurized side of the regenerator section(s) is at
				  least 6.9 kPa (1 psi) greater than the pressure in the raw milk and/or milk
				  product side of the regenerator section(s). In the case of milk and/or milk
				  product-to-water-to-milk or milk product regenerators protected on the
				  pasteurized side of the regenerator section(s), the "water side" of the
				  regenerator section(s) shall be considered to be the "raw product side" for
				  purposes of this test.
Procedure:
1. Wire the test light in series with the signal from the
				  differential pressure controller to the FDD.
2. Calibrate the differential pressure controller and sensing
				  elements. (Use Test 9.2.1.)
3. Adjust the pressure on the differential pressure
				  controller sensing elements to their normal operating pressures, with the
				  pasteurized milk and/or milk product pressure at least 14 kPa (2 psi) higher
				  than the raw milk and/or milk product pressure.
a. The test light shall be lit. If not, increase the
				  pasteurized milk and/or milk product pressure or lower the raw milk and/or milk
				  product pressure until the test light is lit.
b. Gradually lower the pasteurized milk and/or milk product
				  pressure or raise the raw milk and/or milk product pressure until the test
				  light turns off.
c. The test light shall turn off when the pasteurized milk
				  and/or milk product pressure is at least 14 kPa (2 psi) higher than the raw
				  milk and/or milk product pressure.
d. Note the pressure differential at the point the test light
				  turns off.
e. Gradually raise the pasteurized milk and/or milk product
				  pressure or lower the raw milk and/or milk product pressure until the test
				  light turns on.
f. The test light shall not turn on until the pasteurized
				  milk and/or milk product pressure is at least 14 kPa (2 psi) higher than the
				  raw milk and/or milk product pressure. Note the pressure differential at the
				  point the test light turns off.
Note:
This test may be completed using a
				  pneumatic testing device capable of producing pressure differentials on the
				  sensing elements duplicating the conditions described above.
4. Record the results of the test on the appropriate
				  forms.
Action:
If the differential pressure controller
				  fails to respond as indicated above, an immediate check of the differential
				  pressure controller is required by milk plant personnel to locate and correct
				  the problem. If after adjustment and/or repair the differential pressure
				  controller fails this test, the pasteurization system shall not be allowed to
				  operate until the cause of this failure has been corrected and compliance has
				  been verified by the Health Officer; or in the case of HACCP listed milk
				  plants, qualified industry personnel acceptable to the Health Officer in
				  compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
9.3 ADDITIONAL HTST PASTEURIZATION SYSTEM TESTS FOR
				  BOOSTER PUMPS - INTERWIRING
Application:
To all booster pumps used for HTST
				  pasteurization systems where the FDD is located immediately downstream of the
				  holding tube, except that Test 9.3.2 is not required to be performed on
				  magnetic flow meter based timing systems.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever there is any change to the booster pump
				  or the booster pump interwiring; or when the regulatory seal has been
				  broken.
Criteria:
The booster pump shall be wired so it
				  cannot operate if the FDD is in the diverted-flow position or if the timing
				  pump is not in operation.
Apparatus:
1. A sanitary pressure gauge.
2. Pneumatic testing device, described in Test 9.1 Pressure
				  Switches, can be used for checking and adjusting the differential pressure
				  controller setting (refer to Test 9.1).
3. Water, oil or other suitable media bath and
				  agitator.
4. Suitable means of heating the media bath.
9.3.1 BOOSTER PUMPS-INTERWIRED WITH FDD
Method:
Determine if the booster pump stops
				  running by dropping the temperature and causing the FDD to divert.
Procedure:
1. Connect the pasteurized regenerator section(s)
				  differential pressure controller sensing element to a testing tee with the
				  other end of the testing tee capped.
Note:
If there is water in the HTST
				  pasteurization system, ensure that the recorder-controller sensing element and
				  the pasteurized regenerator section(s) differential pressure controller sensing
				  element ports are capped before the timing pump is turned on.
2. Turn on the timing pump and the booster pump.
3. Place the recorder-controller sensing element in a hot
				  media bath which is above the cut-in temperature.
4. Increase the air supply on the testing tee to provide an
				  adequate pressure differential to start the booster pump. The booster pump
				  shall start running.
5. Remove the recorder-controller sensing element from the
				  hot media bath.
6. When the FDD moves to the diverted-flow position, the
				  booster pump shall stop running. Ensure that the pressure differential remains
				  greater than or equal to 6.9 kPa (1 psi) and the other flow-promoting devices
				  which are capable of causing flow through the FDD in the timing system continue
				  to operate.
7. Record the results of the test on the appropriate
				  form.
Action:
If the booster pump fails to stop
				  running when the FDD is in the diverted-flow position, milk plant personnel
				  shall determine and correct the cause. If after adjustment and/or repair the
				  booster pump fails this test, the pasteurization system shall not be allowed to
				  operate until the cause of this failure has been corrected and compliance has
				  been verified by the Health Officer; or in the case of HACCP listed milk
				  plants, qualified industry personnel acceptable to the Health Officer in
				  compliance with Rule
				  420-3-16-.10 (21-22) or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
9.3.2 BOOSTER PUMPS - INTERWIRED WITH THE TIMING
				  PUMP
Method:
Determine if the booster pump stops
				  running when the timing pump is not running.
Procedure:
1. Connect the pasteurized regenerator section(s)
				  differential pressure controller sensing element to a testing tee with the
				  other end of the testing tee capped.
Note:
If there is water in the HTST
				  pasteurization system, ensure that the recorder-controller sensing element and
				  the pasteurized regenerator section(s) differential pressure controller sensing
				  element ports are capped before the timing pump is turned on.
2. Turn on the timing pump and the booster pump.
3. Place the recorder-controller sensing element in a hot
				  media bath which is above the cut-in temperature.
4. Increase the air supply on the testing tee to provide an
				  adequate pressure differential to start the booster pump. The booster pump
				  shall start running.
5. Turn off the timing pump. The booster pump shall stop
				  running. Ensure that the pressure differential remains adequate and the FDD
				  remains in the forward-flow position.
6. Record the results of the test on the appropriate
				  form.
Action:
If the booster pump fails to stop
				  running when the timing pump is not running, milk plant personnel shall
				  determine and correct the cause. If after adjustment and/or repair the booster
				  pump fails this test, the pasteurization system shall not be allowed to operate
				  until the cause of this failure has been corrected and compliance has been
				  verified by the Health Officer; or in the case of HACCP listed milk plants,
				  qualified industry personnel acceptable to the Health Officer in compliance
				  with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 10
MILK OR MILK PRODUCT-FLOW CONTROLS AND THE MILK OR MILK
				  PRODUCT TEMPERATURE AT CUT-IN AND CUT-OUT
References:
Rule
				  420-3-16-.10(18)
				  and Rule 420-3-16-.10 (21-22)
Frequency:
Milk and/or milk product flow
				  controls shall be tested for the milk and/or milk product temperature at cut-in
				  and cut-out by one (1) of the following applicable tests at the frequency
				  prescribed.
Apparatus:
1. Water, oil or other suitable media bath and
				  agitator.
2. Suitable means of heating the media bath.
3. Test light for Tests 10.2 and 10.3.
10.1 HTST PASTEURIZATION SYSTEMS
Application:
To all recorder-controllers used in
				  connection with HTST pasteurization systems, except those in which the FDD is
				  located downstream from the pasteurized regenerator section(s) and/or final
				  cooler section.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the recorder-controller and/or
				  recorder-controller thermometer has been repaired and/or replaced; or whenever
				  the regulatory seal has been broken; and daily by a milk plant's pasteurization
				  system operator.
Criteria:
Forward-flow cannot be achieved until
				  at least the minimum legal pasteurization temperature has been reached. Flow
				  shall be diverted before the temperature drops below the minimum legal
				  pasteurization temperature.
Method:
By observing the actual temperature of
				  the indicating thermometer at the instant forward-flow starts (cut-in) and
				  forward-flow stops (cut-out).
Procedure:
1.
Cut-in Temperature:
a. While milk, milk product, or water is completely flooding
				  the sensing elements of the recorder-controller and the indicating thermometer,
				  which was previously tested against a known accurate test thermometer, increase
				  the heat gradually so as to raise the temperature of the milk, milk product, or
				  water at a rate not to exceed 0.5°C (1°F) per thirty (30) seconds. If a
				  water, oil, or other suitable media bath is used in place of milk, milk
				  product, or water flowing through the pasteurization system, the water, oil, or
				  other suitable media bath shall be adequately and continuously agitated during
				  this test.
b. Observe the indicating thermometer reading at the moment
				  forward-flow begins, i.e., the FDD moves. Observe that the recorder-controller
				  event pen reading is synchronized with the recording pen on the same reference
				  arc as on the recording chart.
c. Immediately record and identify on the recording chart the
				  observed indicating thermometer temperature reading at cut-in and initial the
				  recording chart. This may be accomplished by inscribing a line intersecting the
				  recorded temperature arc at the pen location or any other method acceptable to
				  the Health Officer.
2.
Cut-out Temperature:
a. After the cut-in temperature has been determined, and
				  while the milk, milk product, or water is above the cut-in temperature, allow
				  the milk, milk product, or water to cool slowly at a rate not to exceed
				  0.5°C (1°F) per thirty (30) seconds. If a water, oil, or other suitable
				  media bath is used in place of milk, milk product, or water flowing through the
				  pasteurization system, the water, oil, or other suitable media bath shall be
				  adequately and continuously agitated during this test.
b. Observe the indicating thermometer reading at the moment
				  flow is diverted. Observe that the recorder-controller event pen reading is
				  synchronized with the recording pen on the same reference arc as on the
				  recording chart.
c. Immediately record and identify on the recording chart the
				  observed indicating thermometer temperature reading at cut-out and initial the
				  recording chart. This may be accomplished by inscribing a line intersecting the
				  recorded temperature arc at the pen location or any other method acceptable to
				  the Health Officer.
3. Record the results of both the cut-in and cut-out tests on
				  the appropriate form.
Action:
If the cut-in and/or cut-out indicating
				  thermometer reading is below the minimum legal pasteurization temperature, the
				  cut-in and/or cut-out setting(s) shall be adjusted by milk plant personnel. If
				  after adjustment the cut-in and/or cut-out temperature(s) fail this test, the
				  pasteurization system shall not be allowed to operate until the cause of this
				  failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
10.2 PASTEURIZATION SYSTEMS USING INDIRECT
				  HEATING
Application:
To all HHST and HTST
				  continuous-flow pasteurization systems with the FDD located downstream of the
				  pasteurized regenerator section(s) and/or the final cooler section using
				  indirect heating.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the recorder-controller and/or
				  recorder-controller thermometer has been repaired and/or replaced; or whenever
				  the recorder-controller thermometer regulatory seal has been broken.
Criteria:
The pasteurization system shall not
				  operate in forward-flow unless the minimum legal pasteurization temperature has
				  been achieved in the holding tube and at the FDD. The milk and/or milk product
				  flow shall be diverted before the temperature falls below the minimum legal
				  pasteurization temperature in the holding tube.
Method:
The cut-in and cut-out temperatures as
				  read from the indicating thermometer located within the pasteurization system
				  are determined using a media bath and the sensing elements from the holding
				  tube and the FDD.
Procedure:
1.
Cut-in Temperature:
a. Wire the test light in series with the control contacts of
				  the holding tube recorder-controller sensing element. Immerse the
				  recorder-controller and holding tube indicating sensing elements in the media
				  bath. Raise the media bath temperature at a rate not to exceed 0.5°C
				  (1°F) per thirty (30) seconds. Observe the temperature reading on the
				  indicating thermometer when the test light comes on, which is the cut-in
				  temperature.
b. Record the observed indicating thermometer cut-in reading
				  on the appropriate form.
2.
Cut-out Temperature:
a. After the cut-in temperature has been determined and while
				  the media bath is above the cut-in temperature, allow the media bath to cool
				  slowly at a rate not to exceed 0.5°C (1°F) per thirty (30) seconds.
				  Observe the temperature reading on the recorder-controller when the test light
				  goes out, which is the cut-out temperature. Determine that the cut-out
				  temperature on the recorder-controller is equivalent to or greater than the
				  minimum legal pasteurization temperature.
b. Record the observed indicating thermometer cut-out reading
				  on the appropriate form.
3. Repeat the procedure for the FDD sensing element. Rewire
				  the test light in series with the control contacts for the FDD sensing
				  element.
Action:
Whenever adjustment is necessary, refer
				  to the manufacturer's instructions. Retest the cut-in and cut-out temperatures
				  after any adjustment, repair, replacement, or whenever the regulatory seal has
				  been broken. If after adjustment the cut-in and/or cut-out temperature(s) fail
				  this test, the pasteurization system shall not be allowed to operate until the
				  cause of this failure has been corrected and compliance has been verified by
				  the Health Officer; or in the case of HACCP listed milk plants, qualified
				  industry personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
10.3 PASTEURIZATION SYSTEMS USING DIRECT
				  HEATING
Application:
To all HHST and HTST
				  continuous-flow pasteurization systems with the FDD located downstream of the
				  pasteurized regenerator section(s) and/or the final cooler section using direct
				  heating.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the recorder-controller and/or
				  recorder-controller thermometer has been repaired and/or replaced; or whenever
				  the recorder-controller thermometer regulatory seal has been broken.
Criteria:
The pasteurization system shall not
				  operate in forward-flow unless the minimum legal pasteurization temperature has
				  been achieved in the holding tube, at the vacuum chamber, and at the FDD. The
				  milk and/or milk product flow shall be diverted before the temperature falls
				  below the minimum legal pasteurization temperature in the holding tube.
Method:
The cut-in and cut-out temperatures as
				  read from the indicating thermometer located within the pasteurization system
				  are determined using a media bath and the sensing elements from the holding
				  tube, vacuum chamber and the FDD.
Procedure:
1.
Cut-in Temperature:
a. Wire the test light in series with the control contacts of
				  the holding tube recorder-controller sensing element. Immerse the
				  recorder-controller and holding tube indicating sensing elements in the media
				  bath. Raise the media bath temperature at a rate not to exceed 0.5°C
				  (1°F) per thirty (30) seconds. Observe the temperature reading on the
				  indicating thermometer when the test light comes on, which is the cut-in
				  temperature.
b. Record the observed indicating thermometer cut-in reading
				  on the appropriate form.
2.
Cut-out Temperature:
a. After the cut-in temperature has been determined and while
				  the media bath is above the cut-in temperature, allow the media bath to cool
				  slowly at a rate not to exceed 0.5°C (1°F) per thirty (30) seconds.
				  Observe the temperature reading on the recorder-controller when the test light
				  goes out, which is the cut-out temperature. Determine that the cut-out
				  temperature on the recorder-controller is equivalent to or greater than the
				  minimum legal pasteurization temperature.
b. Record the observed indicating thermometer cut-out reading
				  on the appropriate form.
3. Repeat the procedure for the other two (2) sensing
				  elements, from the vacuum chamber, and the FDD. Rewire the test light in series
				  with the control contacts for each sensing element, respectively.
Action:
Whenever adjustment is necessary, refer
				  to the manufacturer's instructions. Retest the cut-in and cut-out temperatures
				  after any adjustment, repair, replacement, or whenever the regulatory seal has
				  been broken. If after adjustment the cut-in and/or cut-out temperature(s) fail
				  this test, the pasteurization system shall not be allowed to operate until the
				  cause of this failure has been corrected and compliance has been verified by
				  the Health Officer; or in the case of HACCP listed milk plants, qualified
				  industry personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22),
TEST 11
CONTINUOUS-FLOW PASTEURIZATION SYSTEM HOLDING TUBES -
				  PASTEURIZATION HOLDING TIME
(Continuous-flow pasteurization system holding tubes shall be
				  tested for pasteurization holding times by one [1] of the following applicable
				  tests.)
Reference:
Rule
				  420-3-16-.10(18)
				  and Rule 420-3-16-.10 (21-22)
11.1 HTST PASTEURIZATION SYSTEMS
(Except for magnetic flow meter based timing systems.)
Application:
To all HTST continuous-flow
				  pasteurization systems employing a pasteurization holding time of fifteen (15)
				  seconds or longer, except for magnetic flow meter based timing systems.
Frequency:
Upon installation; at least once each
				  six (6) months thereafter; whenever any alteration is made affecting the
				  pasteurization holding time, the velocity of the flow, such as the replacement
				  of the timing pump, motor, belt, drive or driven pulleys, or a decrease in the
				  number of HTST pasteurization system heat-exchange plates or the capacity of
				  the holding tube; whenever a check of the capacity of the holding tube
				  indicates a speedup; or whenever the regulatory seal on the timing pump speed
				  setting has been broken.
Criteria:
Every particle of milk and/or milk
				  product shall be held for at least a minimum legal pasteurization holding time
				  of fifteen (15) seconds or twenty-five (25) seconds, respectively in both
				  forward-flow and diverted-flow.
Apparatus:
1. An electrical conductivity measuring device, which is
				  capable of detecting a change in conductivity and is equipped with standard
				  electrodes.
2. Table salt (sodium chloride) or other appropriate
				  conductive solution.
3. A suitable apparatus for injecting the salt solution or
				  other appropriate conductive solution into the holding tube.
4. An accurate time measuring device.
Method:
The pasteurization holding time is
				  determined by timing the interval for an injected trace substance such as
				  sodium chloride to pass through the entire length of the legal holding tube.
				  Although the time interval of the fastest particle of milk and/or milk product
				  is desired, this conductivity test is performed using water. The results
				  obtained when using water are converted to the milk and/or milk product flow
				  pasteurization holding time, using either the volume or weight formulation, as
				  shown below, since a timing pump may not deliver the same amount of milk and/or
				  milk product as it does water.
Procedure:
1. Operate the pasteurization system on water, with all
				  flow-promoting devices which are capable of causing flow through the FDD,
				  operating at their maximum capacity and all flow-impeding devices adjusted or
				  bypassed to provide the minimum amount of resistance to the flow through the
				  pasteurization system. There shall not be any leakage on the suction side of
				  the timing pump.
Note:
In pasteurization systems equipped with a
				  pressure relief valve located between the timing pump and the beginning of the
				  holding tube, this test shall not be performed if the pressure relief valve is
				  observed to be leaking.
a. For a variable speed timing pump adjust the timing pump to
				  its maximum capacity, preferably with a new belt and full size
				  impellers.
b. For a homogenizer used as the timing pump, check the
				  homogenizer for its regulatory seal(s) and gears or pulley
				  identification.
c. For alternating current (AC) variable speed timing pump,
				  check the timing pump's control box for its regulatory seal(s).
Note:
For pasteurization systems that employ a
				  liquid ingredient injection (slurry) system as described in Appendix H, the
				  slurry injection pump shall be energized and running at its maximum speed and
				  the slurry supply tank shall be completely filled with water.
2. If utilizing an electrical conductivity measuring device
				  that is equipped with two (2) standard electrodes, install one (1) electrode at
				  the beginning of the legal holding tube and the other electrode at the end of
				  the legal holding tube. If utilizing an electrical conductivity measuring
				  device that is equipped with a single standard electrode, install the electrode
				  at the end of the legal holding tube.
3. Operate the pasteurization system using water at or above
				  the minimum legal pasteurization temperature with the FDD in the forward-flow
				  position.
4. Quickly inject a saturated sodium chloride or other
				  appropriate conductive solution into the inlet at the beginning of the legal
				  holding tube.
5. The accurate time measuring device shall start at the
				  moment when the conductivity solution is injected. This may be accomplished by
				  detecting a change in conductivity at the beginning of the holding tube when
				  utilizing two (2) electrodes or by a switch placed at the beginning of the
				  holding tube synchronized with the injection process when utilizing a single
				  electrode placed at the end of the holding tube.
6. The accurate time measuring device shall stop when it
				  detects a change in conductivity at the end of the legal holding tube.
7. Repeat this test six (6) or more times, until six (6)
				  consecutive results are within 0.5 seconds of each other. The average of these
				  six (6) consecutive tests is the pasteurization holding time for water in
				  forward-flow.
Note:
When consistent test readings cannot be
				  obtained, purge the pasteurization system, check the testing instruments and
				  connections, and check for any air leakage on the suction side of the timing
				  pump. Repeat
Procedure 7
. When consistent readings cannot be
				  obtained after repeating
Procedure 7
, use the fastest time
				  obtained from any of these tests as the pasteurization holding time for water
				  in forward-flow.
8. Record all of the pasteurization holding time results for
				  water in forward-flow as conducted in
Procedure 7
above and the
				  average of these six (6) consecutive tests on the appropriate form.
9. Repeat
Procedures 3 through 7
above for the
				  pasteurization holding time for water in diverted-flow.
10. Record all of the pasteurization holding time results for
				  water in diverted-flow as conducted in
Procedure 9
above on the
				  appropriate form.
11. Complete a, b, or c below as appropriate:
a. For all gear driven timing pumps, complete
Procedures 12 through 16 below
.
b. For those homogenizers used as timing pumps, when the
				  measured pasteurization holding time for water is less than 120 percent of the
				  minimum legal pasteurization holding time, complete
Procedures 12 through
				  16
below.
c. For those homogenizers used as timing pumps, when the
				  measured pasteurization holding time for water is 120 percent or more of the
				  minimum legal pasteurization holding time,
Procedure 12
is
				  optional and
Procedure 13 through 16
below are not
				  required.
12. With the timing pump at the same speed and all other
				  flow-promoting devices which are capable of causing flow through the FDD and
				  flow-impeding devices adjusted as cited in
Procedure 1
, determine
				  the time it takes to fill a 38 liter (10 gallon) can with a measured weight or
				  volume of water, using the pasteurization system discharge outlet with the same
				  head pressure as is normally used during the operation of the pasteurization
				  system. Average the filling times for several trials (minimum of three
				  [3]).
Note:
Since flow rates of a large capacity unit
				  make it very difficult to determine the time it takes to fill a 38 liter (10
				  gallon) can with a measured weight or volume of water, it is recommended that a
				  calibrated tank of considerable size be used. It is also acceptable to use any
				  other means to determine a measured weight or volume of water.
13. Record all of the can fill time results and the average
				  time it takes to fill a 38 liter (10 gallon) can or other means as described in
				  the
Note:
above with a measured weight or volume of water for
Procedure 12
above on the appropriate form.
14. Repeat
Procedure 12
above using milk.
15. Record the average time it takes to fill a 38 liter (10
				  gallon) can or other means used with a measured weight or volume of milk for
Procedure 14
above on the appropriate form.
16. Compute the pasteurization holding time for milk from one
				  (1) of the following formulas either by volume or by weight. Compute separately
				  for forward-flow and diverted-flow.
BY VOLUME
The adjusted pasteurization holding time for milk is equal
				  to:
The pasteurization holding time for water, times the quotient
				  of the time it takes to deliver a volume of milk, divided by the time it takes
				  to deliver the same volume of water.
Tm = Tw(Vm/Vw)
Where: Tm = Adjusted product pasteurization holding time for
				  milk.
Tw = Pasteurization holding time for water, the salt (sodium
				  chloride or other appropriate conductive solution) test results.
Vm = Time, usually in seconds, that it takes to pump a known
				  volume of milk.
Vw = Time, usually in seconds, that it takes to pump the same
				  volume of water.
BY WEIGHT (Using specific gravity):
The adjusted pasteurization holding time for milk is equal
				  to:
The specific gravity of milk, times the pasteurization
				  holding time for water, times the quotient of the time it takes to deliver a
				  measured weight of milk, divided by the time it takes to deliver the same
				  weight of water.
Tm = 1.032xTw(Wm/Ww)
Where: Tm = Adjusted product pasteurization holding time for
				  milk.
1.032 = The specific gravity of milk
Note:
If another milk product is used, use the
				  appropriate specific gravity.
Tw = Pasteurization holding time for water, the salt (sodium
				  chloride or other appropriate conductive solution) test results.
Wm = Time, usually in seconds, that it takes to pump a
				  measured weight of milk.
Ww = Time, usually in seconds, that it takes to pump the same
				  measured weight of water.
17. Record the computed adjusted pasteurization holding time
				  for forward-flow and divert-flow for milk using either the formula for volume
				  or weight as identified in
Procedure 16
above on the appropriate
				  form.
Action:
When the computed adjusted
				  pasteurization holding time for milk is less than the minimum legal
				  pasteurization holding time, either in forward-flow or diverted-flow, the speed
				  of the timing pump shall be reduced or an adjustment shall be made to the
				  length or diameter of the holding tube and Test 11.1 shall be repeated until a
				  satisfactory pasteurization holding time is achieved. If an orifice
				  (restrictor) is required to be installed in the FDD divert line to comply with
				  the minimum legal pasteurization holding time in diverted-flow, there shall not
				  be any excessive pressure exerted on the underside of the valve seat of the
				  FDD. Variable speed drives shall be sealed for motors on timing pumps that do
				  not provide a constant speed as provided for in Rule
				  420-3-16-.10(18)(J)2.
				  If after adjustment the pasteurization holding time fails this test, the
				  pasteurization system shall not be allowed to operate until the cause of this
				  failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
11.2A CONTINUOUS-FLOW PASTEURIZATION SYSTEMS UTILIZING
				  A MAGNETIC FLOW METER BASED TIMING SYSTEM - PASTEURIZATION HOLDING
				  TIME
Application:
To all HTST continuous-flow
				  pasteurization systems with a magnetic flow meter based timing system used in
				  lieu of a timing pump.
Frequency:
Upon installation; at least once each
				  six (6) months thereafter; whenever any alteration is made affecting the
				  pasteurization holding time, the velocity of the flow or the capacity of
				  holding tube; or whenever a check of the capacity indicates a speed up; or
				  whenever the regulatory seal on the flow alarm has been broken.
Criteria:
Every particle of milk and/or milk
				  product shall be held for at least a minimum legal pasteurization holding time
				  of fifteen (15) seconds or twenty-five (25) seconds, respectively in both
				  forward-flow and diverted-flow.
Apparatus
:
1. An electrical conductivity measuring device which is
				  capable of detecting a change in conductivity and is equipped with standard
				  electrodes.
2. Table salt (sodium chloride) or other appropriate
				  conductive solution.
3. A suitable apparatus for injecting the salt solution or
				  other appropriate conductive solution into the holding tube.
4. An accurate time measuring device.
5. Water, oil or other suitable media bath and
				  agitator.
6. Suitable means of heating the media bath.
Method:
The pasteurization holding time is
				  determined by timing the interval for an injected trace substance, such as
				  sodium chloride, to pass through the entire length of the legal holding
				  tube.
Procedure:
Utilize either
TEST OPTION I
or
TEST
				  OPTION II
.
Note:
In pasteurization systems equipped with a
				  pressure relief valve located between the timing pump and the beginning of the
				  holding tube, this test shall not be performed if the pressure relief valve is
				  observed to be leaking.
TEST OPTION I:
1. Adjust the set point on the high flow alarm above the
				  estimated acceptable flow rate or bypass the high flow alarm.
2. Adjust the set point on the flow recorder-controller to a
				  flow rate estimated to yield an acceptable pasteurization holding time.
3. Install one (1) electrode at the beginning of the legal
				  holding tube and the other electrode at the end of the legal holding
				  tube.
4. Operate the pasteurization system using water at or above
				  the minimum legal pasteurization temperature, with the FDD in the forward-flow
				  position.
Note:
The appropriate temperature sensing
				  elements may be placed in a water, oil, or other suitable media bath to
				  simulate the minimum legal pasteurization temperature in the holding tube as an
				  alternative method to the heating of water in the pasteurization system above
				  the minimum legal pasteurization temperature.
5. Quickly inject a saturated sodium chloride or other
				  appropriate conductive solution into the inlet at the beginning of the legal
				  holding tube.
6. The accurate time measuring device shall start when it
				  detects a change in conductivity at the beginning of the legal holding
				  tube.
7. The accurate time measuring device shall stop when it
				  detects a change in conductivity at the end of the legal holding tube.
8. Repeat this test six (6) or more times, until six (6)
				  consecutive results are within 0.5 seconds of each other. The average of these
				  six (6) consecutive tests is the pasteurization holding time for water in
				  forward-flow.
Note:
If six (6) consecutive tests cannot be
				  achieved within 0.5 seconds of each other, refer to
Action
below.
9. Record all of the pasteurization holding time results for
				  water in forward-flow as conducted in
Procedure 8
above and the
				  average of these six (6) consecutive tests on the appropriate form.
10. This procedure is not a required test; it is at the
				  option of the Health Officer. With the flow rate recorder-controller at the
				  same set point as in
Procedure 2
, determine the time it takes to
				  fill a 38 liter (10 gallon) can with a measured weight or volume of water using
				  the pasteurization system discharge outlet with the same head pressure as is
				  normally used during the operation of the pasteurization system. Average the
				  time of several trials (minimum of three [3]). Since flow rates of a large
				  capacity unit make it very difficult to determine the time it takes to fill a
				  38 liter (10 gallon) can with a measured weight or volume of water, it is
				  suggested that a calibrated tank of considerable size be used. It is also
				  acceptable to use any other means to determine a measured weight or volume of
				  water.
11. If the Health Officer chooses to conduct
Procedure
				  10
above, record all of the can fill time results and the average time
				  it takes to fill a 38 liter (10 gallon) can or other means used with a measured
				  weight or volume of milk for
Procedure 10
above on the appropriate
				  form.
TEST OPTION II:
1. If utilizing an electrical conductivity measuring device
				  that is equipped with two (2) standard electrodes, install one (1) electrode at
				  the beginning of the legal holding tube and the other electrode at the end of
				  the legal holding tube. If utilizing an electrical conductivity measuring
				  device that is equipped with a single standard electrode, install the electrode
				  at the end of the legal holding tube.
2. Operate the pasteurization system using water with the FDD
				  in the divert-flow position at a flow rate just above the high flow alarm set
				  point.
3. Quickly inject a saturated sodium chloride or other
				  appropriate conductive solution into the inlet at the beginning of the legal
				  holding tube.
4. The accurate time measuring device shall start at the
				  moment when the conductivity solution is injected. This may be accomplished by
				  detecting a change in conductivity at the beginning of the holding tube when
				  utilizing two (2) electrodes or by a switch placed at the beginning of the
				  holding tube synchronized with the injection process when utilizing a single
				  electrode placed at the end of the holding tube.
5. The accurate time measuring device shall stop when it
				  detects a change in conductivity at the end of the legal holding tube.
6. Repeat this test six (6) or more times, until six (6)
				  consecutive results are within 0.5 seconds of each other. The average of these
				  six (6) consecutive tests is the pasteurization holding time for water in
				  diverted-flow.
Note:
If six (6) consecutive tests cannot be
				  achieved within 0.5 seconds of each other, refer to
Action
below.
7. Record all of the pasteurization holding time results for
				  water in diverted-flow as conducted in
Procedure 6
above and the
				  average of these six (6) consecutive tests on the appropriate form.
8. If the minimum legal pasteurization holding time is
				  achieved in diverted-flow when conducting
TEST OPTION II
, all
				  flows through the pasteurization system below the high flow alarm set point
				  will meet the required minimum legal pasteurization holding time in forward-
				  flow. Proceed to
Procedure 10
below.
9. If the test results when conducting
TEST OPTION II
are not all above the required minimum legal pasteurization holding
				  time in diverted-flow,
TEST
OPTION I
shall be
				  conducted.
10. This procedure is not a required test; it is at the
				  option of the Health Officer. With the flow rate recorder-controller at the
				  same set point as in
Procedure 2
, determine the time it takes to
				  fill a 38 liter (10 gallon) can with a measured weight or volume of water using
				  the pasteurization system discharge outlet with the same head pressure as is
				  normally used during the operation of the pasteurization system. Average the
				  time of several trials (minimum of three [3]). Since flow rates of a large
				  capacity unit make it very difficult to determine the time it takes to fill a
				  38 liter (10 gallon) can with a measured weight or volume of water, it is
				  suggested that a calibrated tank of considerable size be used. It is also
				  acceptable to use any other means to determine a measured weight or volume of
				  water.
11. If the Health Officer chooses to conduct
Procedure
				  10
above, record all of the can fill time results and the average time
				  it takes to fill a 38 liter (10 gallon) can or other means used with a measured
				  weight or volume of milk for
Procedure 10
above on the appropriate
				  form.
Action:
When the computed pasteurization holding
				  time for milk is less than the minimum legal pasteurization holding time in
				  diverted-flow, the set point on the flow rate recorder-controller shall be
				  decreased, or an adjustment shall be made in the length or diameter of the
				  legal holding tube by milk plant personnel to correct the pasteurization
				  holding time, and
TEST OPTION I
shall be repeated until a
				  satisfactory pasteurization holding time is achieved. If after adjustment the
				  pasteurization system fails this test, the pasteurization system shall not be
				  allowed to operate until the cause of this failure has been corrected and
				  compliance has been verified by the Health Officer; or in the case of HACCP
				  listed milk plants, qualified industry personnel acceptable to the Health
				  Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
11.2B CONTINUOUS-FLOW PASTEURIZATION SYSTEMS UTILIZING
				  A MAGNETIC FLOW METER BASED TIMING SYSTEM - HOLDING TUBES AND HIGH FLOW
				  ALARM
Application:
To all continuous-flow
				  pasteurization systems using a magnetic flow meter based timing system in lieu
				  of a timing pump.
Frequency:
Upon installation; at least once each
				  six (6) months thereafter; whenever any alteration is made affecting the
				  pasteurization holding time, the velocity of the flow, or the capacity of the
				  holding tube; whenever a check of the capacity of the holding tube indicates a
				  speedup; or whenever the regulatory seal on the high flow alarm has been
				  broken.
Criteria:
Whenever the high flow rate equals or
				  exceeds the value at which the pasteurization holding time was measured, the
				  high flow alarm shall cause the FDD to assume the diverted-flow position, even
				  though the temperature of the milk and/or milk product in the holding tube is
				  above the minimum legal pasteurization temperature.
Apparatus:
No supplementary materials
				  required.
Method:
The high flow alarm set point shall be
				  set so that flow is diverted when the flow rate equals or exceeds the value at
				  which the pasteurization holding time was measured or calculated.
Procedure:
1. Operate the pasteurization system using water above the
				  minimum legal pasteurization temperature in forward-flow at a flow rate below
				  the high flow alarm set point.
Note:
The appropriate temperature sensing
				  elements may be placed in a water, oil, or other suitable media bath to
				  simulate the processing pasteurization temperature within the holding tube as
				  an alternative to heating water in the pasteurization system above the minimum
				  legal pasteurization temperature.
2. Slowly raise the flow rate of the pasteurization system
				  until the following occur:
a. The frequency pen(s) on the STLR and the flow rate
				  recorder-controller(s) indicate that the FDD is in the diverted-flow
				  position.
b. Observe that the FDD moved to the diverted-flow
				  position.
3. Record the rate of flow; the set point of the high flow
				  alarm; and the temperature on the STLR at the occurrence of flow-diversion for
				  this test on the appropriate form.
Action:
If the FDD does not move to the
				  diverted-flow position when the frequency pen of the flow rate
				  recorder-controller indicates a flow-diversion, milk plant personnel shall make
				  a modification to the FDD or the STLR recorder-controller as required. If after
				  adjustment the pasteurization system fails this test, the pasteurization system
				  shall not be allowed to operate until the cause of this failure has been
				  corrected and compliance has been verified by the Health Officer; or in the
				  case of HACCP listed milk plants, qualified industry personnel acceptable to
				  the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
11.2C CONTINUOUS-FLOW PASTEURIZATION SYSTEMS UTILIZING
				  A MAGNETIC FLOW METER BASED TIMING SYSTEM - HOLDING TUBES AND LOW
				  FLOW/LOSS-OF-SIGNAL ALARM
Application:
To all continuous-flow
				  pasteurization systems using a magnetic flow meter based timing system in lieu
				  of a timing pump.
Frequency:
Upon installation; at least once each
				  six (6) months thereafter; whenever any alteration is made affecting the flow
				  rate in the holding tube; or whenever the regulatory seal on the low
				  flow/loss-of-signal flow alarm has been broken.
Criteria:
Forward-flow occurs only when flow
				  rates are above the low flow/loss-of-signal alarm set point.
Apparatus:
No supplementary materials
				  required.
Method:
By observing the actions of the
				  frequency pen on the flow rate recorder-controller and the position of the
				  FDD.
Procedure:
1. Operate the pasteurization system using water in
				  forward-flow at a flow rate below the high flow alarm set point and above the
				  low flow/loss-of-signal alarm set point.
Note:
The appropriate temperature sensing
				  elements may be placed in a water, oil, or other suitable media bath to
				  simulate the processing pasteurization temperature within the holding tube as
				  an alternative to heating water in the pasteurization system above the minimum
				  legal pasteurization temperature.
2. Disrupt the power to the magnetic flow meter to activate
				  the loss-of-signal alarm or decrease the flow through the flow meter to a flow
				  rate below the low flow alarm set point. Observe that the FDD assumes the
				  diverted-flow position and that the frequency pen(s) on the STLR and the flow
				  rate recorder-controller(s) assumed the diverted-flow position.
3. Record the results of this test and the low
				  flow/loss-of-signal alarm set point, if applicable, on the appropriate
				  form.
Action:
If the FDD does not divert or the
				  frequency pens do not assume the diverted-flow position, milk plant personnel
				  shall make an adjustment to the low flow/loss-of-signal alarm or a modification
				  to the FDD, the STLR, or flow rate recorder-controller as required. If after
				  adjustment the pasteurization system fails this test, the pasteurization system
				  shall not be allowed to operate until the cause of this failure has been
				  corrected and compliance has been verified by the Health Officer; or in the
				  case of HACCP listed milk plants, qualified industry personnel acceptable to
				  the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
11.2D CONTINUOUS-FLOW PASTEURIZATION SYSTEMS UTILIZING
				  A MAGNETIC FLOW METER BASED TIMING SYSTEM - HOLDING TUBES AND FLOW RATE CUT-IN
				  AND CUT-OUT
Application:
To all HTST continuous-flow
				  pasteurization systems using a magnetic flow meter based timing system in lieu
				  of a timing pump.
Frequency:
Upon installation; at least once each
				  six (6) months thereafter; whenever any alteration is made affecting the
				  pasteurization holding time, the velocity of the flow or the capacity of the
				  holding tube; whenever a check of the capacity of the holding tube indicates a
				  speedup; or whenever the regulatory seal on the high flow and/or low
				  flow/loss-of-signal alarm(s) has been broken.
Criteria:
Forward-flow occurs only when flow
				  rates are below the high flow alarm set point and above the low
				  flow/loss-of-signal alarm set point.
Apparatus:
No supplementary materials
				  required.
Method:
By observing the flow rate
				  recorder-controller's readings along with the action of the frequency pen on
				  the flow rate recorder-controller and the position of the FDD.
Procedure:
1. Operate the pasteurization system using water above the
				  minimum legal pasteurization temperature in forward-flow at a flow rate below
				  the high flow alarm set point and above the low flow/loss-of-signal alarm set
				  point.
Note:
The appropriate temperature sensing
				  elements may be placed in a water, oil, or other suitable media bath to
				  simulate the processing pasteurization temperature within the holding tube as
				  an alternative to heating water in the pasteurization system above the minimum
				  legal pasteurization temperature.
2. Using the flow rate recorder-controller, slowly increase
				  the flow rate until the frequency pen on the flow rate recorder-controller
				  indicates a flow-diversion because the high flow alarm set point had been
				  exceeded. The FDD shall assume the diverted-flow position. Observe the flow
				  rate reading from the flow rate recorder-controller the instant forward-flow
				  cut-out occurs, as indicated by the flow rate recorder-controller's frequency
				  pen.
3. With the pasteurization system operating on water above
				  the minimum legal pasteurization temperature and with the FDD in the
				  diverted-flow position due to exceeding the high flow alarm set point, slowly
				  decrease the flow rate until the frequency pen on the flow rate
				  recorder-controller indicates the start of the FDD's forward-flow movement,
				  which indicates the flow rate cut-in point. Because of the time delay described
				  in Test 11.2E, the FDD will not move immediately to the forward-flow position.
				  Observe the flow rate reading from the flow rate recorder-controller the
				  instant flow rate cut-in occurs, as indicated by the flow rate
				  recorder-controller's frequency pen.
4. Record the flow rate cut-in and cut-out results of this
				  test on the appropriate form.
Action:
If the flow rate cut-in or cut-out
				  point(s) occurs at a flow rate equal to or greater than the value at which the
				  pasteurization holding time was measured, milk plant personnel shall adjust the
				  high flow alarm to a lower set point and this test shall be repeated. If after
				  adjustment the pasteurization system fails this test, the pasteurization system
				  shall not be allowed to operate until the cause of this failure has been
				  corrected and compliance has been verified by the Health Officer; or in the
				  case of HACCP listed milk plants, qualified industry personnel acceptable to
				  the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
11.2E CONTINUOUS-FLOW PASTEURIZATION SYSTEMS UTILIZING
				  A MAGNETIC FLOW METER BASED TIMING SYSTEM -HOLDING TUBES AND TIME
				  DELAY
Application:
To all HTST continuous-flow
				  pasteurization systems with a FDD located at the end of the holding tube that
				  use a MFMBTS in lieu of a timing pump.
Frequency:
Upon installation; at least once each
				  six (6) months thereafter; whenever any alteration is made affecting the
				  pasteurization holding time, the velocity of the flow, or the capacity of the
				  holding tube; whenever a check of the capacity of the holding tube indicates a
				  speedup; or whenever the regulatory seal on the flow alarm has been
				  broken.
Criteria:
Following the determination of the
				  flow rate cut-in as described in Test 11.2D, forward-flow shall not occur until
				  all milk and/or milk product in the holding tube has been held at or above the
				  minimum legal pasteurization temperature for at least the minimum legal
				  pasteurization holding time.
Apparatus:
An accurate time measuring
				  device.
Method:
Set the time delay equal to or greater
				  than the minimum legal pasteurization holding time.
Procedure:
1. Operate the pasteurization system using water above the
				  minimum legal pasteurization temperature in forward-flow at a flow rate below
				  the high flow alarm set point and above the low flow/loss-of-signal alarm set
				  point.
Note:
The appropriate temperature sensing
				  elements may be placed in a water, oil, or other suitable media bath to
				  simulate the processing pasteurization temperature within the holding tube as
				  an alternative to heating water in the pasteurization system above the minimum
				  legal pasteurization temperature.
2. Using the flow rate recorder-controller, slowly increase
				  the flow rate until the frequency pen on the flow rate recorder-controller
				  indicates a flow-diversion and the FDD moves to the diverted-flow position.
				  There shall not be any time delay between the movements of the flow rate
				  recorder-controller's frequency pen and the FDD.
3. With the pasteurization system operating on water above
				  the minimum legal pasteurization temperature and with the FDD in the
				  diverted-flow position due to exceeding the high flow alarm set point, slowly
				  decrease the flow rate.
4. Start the accurate time measuring device the instant the
				  flow rate recorder-controller's frequency pen indicates flow rate
				  cut-in.
5. Stop the accurate time measuring device the instant the
				  FDD starts to move to the forward-flow position.
6. Record the results of this test on the appropriate
				  form.
Action:
If the time delay is less than the
				  minimum pasteurization holding time, milk plant personnel shall increase the
				  time setting on the time delay and Test 11.2E shall be repeated. If after
				  adjustment the pasteurization system fails this test, the pasteurization system
				  shall not be allowed to operate until the cause of this failure has been
				  corrected and compliance has been verified by the Health Officer; or in the
				  case of HACCP listed milk plants, qualified industry personnel acceptable to
				  the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
11.2F CONTINUOUS-FLOW PASTEURIZATION SYSTEMS UTILIZING
				  A MAGNETIC FLOW METER BASED TIMING SYSTEM - HIGH FLOW ALARM RESPONSE
				  TIME
Application:
To all continuous-flow
				  pasteurization (HTST) systems using a magnetic flow meter based timing system
				  in lieu of a timing pump.
Frequency:
Upon installation; at least once each
				  six (6) months thereafter; whenever any alteration is made affecting the
				  pasteurization holding time, the velocity of the flow, or the capacity of the
				  holding tube; whenever a check of the capacity of the holding tube indicates a
				  speedup; or whenever the regulatory seal on the flow alarm has been
				  broken.
Criteria:
When the flow rate equals or exceeds
				  the value at which the pasteurization holding time was measured, the high flow
				  alarm shall cause the FDD to assume the diverted-flow position within one (1)
				  second.
Apparatus:
An accurate time measuring
				  device.
Method:
Rapidly increase the flow rate to exceed
				  the high flow alarm and verify that the FDD moves to the diverted-flow position
				  within one (1) second.
Procedure:
1. Operate the pasteurization system, using water above the
				  minimum legal pasteurization temperature, in forward-flow at a flow rate 25
				  percent below the high flow alarm set point as determined in Test 11.2B
Procedure 2
.
Note:
The appropriate temperature sensing
				  elements may be placed in a water, oil, or other suitable media bath to
				  simulate the processing pasteurization temperature within the holding tube as
				  an alternative to heating water in the pasteurization system above the minimum
				  legal pasteurization temperature. The observation and recording of the high
				  flow alarm response time shall be conducted as described in
Procedures 3
				  through 6
below.
2. Identify the high flow alarm set point on the flow rate
				  recorder-controller chart. This may be accomplished by inscribing a line
				  intersecting the recorded flow arc at the pen location or any other method
				  acceptable to the Health Officer.
3. Increase the pasteurization system flow rate as rapidly as
				  practical to a point above the high flow alarm set point.
4. Start the accurate time measuring device when the flow
				  rate recorder-controller's recording pen exceeds the high flow alarm set
				  point.
5. Stop the accurate time measuring device when the FDD has
				  moved to the diverted-flow position.
6. Record the high flow alarm response time on the
				  appropriate form.
Action:
If the response time exceeds one (1)
				  second, immediate action shall be taken by milk plant personnel to correct this
				  FDD deficiency. If after adjustment the pasteurization system fails this test,
				  the pasteurization system shall not be allowed to operate until the cause of
				  this failure has been corrected and compliance has been verified by the Health
				  Officer; or in the case of HACCP listed milk plants, qualified industry
				  personnel acceptable to the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
11.3 CALCULATED PASTEURIZATION HOLDING TIME FOR HHST
				  PASTEURIZATION SYSTEMS USING INDIRECT HEATING
Application:
To all HHST pasteurization systems
				  using indirect heating.
Frequency:
Upon installation; at least once each
				  six (6) months thereafter; whenever any alteration is made affecting the
				  pasteurization holding time, the velocity of the flow, such as the replacement
				  of the timing pump, motor, belt, drive or driven pulley, decrease in the number
				  of HHST pasteurization system heat-exchange plates, or the capacity of the
				  holding tube; whenever a check of the capacity of the holding tube indicates a
				  speedup; or whenever the regulatory seal on the timing pump speed setting has
				  been broken.
Criteria:
Every particle of milk and/or milk
				  product shall be held for the applicable minimum pasteurization holding time in
				  both the forward-flow and diverted-flow positions.
Apparatus:
No supplementary materials
				  required.
Method:
For this test, fully developed laminar
				  flow is assumed and the required holding tube length shall be calculated from
				  an experimental determination of the pumping rate. An experimental
				  determination of the pumping rate can be accomplished by determining the time
				  required for the pasteurization system to fill a vessel of a known volume;
				  converting these data by division to obtain the flow rate in gallons per
				  second; and then multiplying this value, by the proper value referenced in
				  Table 14 to determine the required holding tube length.
TABLE 14
Holding Tube Length - HHST Pasteurization
								System-Indirect Heating at a Pumping Rate of 1 gallon/second
Pasteurization Holding
Tubing Size
(inches)
Time
s ec.)
2
2-1/2
3
Holding Tube Length
(inches)
1.0
168.0
105.0
71.4
0.5
84.0
52.4
35.7
0.1
16.8
10.5
7.14
0.05
8.4
5.24
3.57
0.01
1.68
1.05
.714
Procedure:
1. Operate the pasteurization system on water, in
				  forward-flow, with all flow-promoting devices, which are capable of causing
				  flow through the FDD operating at their maximum capacity and all flow-impeding
				  devices adjusted or bypassed to provide the minimum amount of resistance to the
				  flow through the pasteurization system.
There shall not be any leakage on the suction side of the
				  timing pump.
a. For a variable speed timing pump, adjust the timing pump
				  to its maximum capacity, preferably with a new belt and full size
				  impellers.
b. For a homogenizer used as the timing pump, check the
				  homogenizer for its regulatory seal(s) and gears or pulley
				  identification.
c. For AC variable speed timing pump, check the timing pump's
				  control box for its regulatory seal(s).
Note:
For pasteurization systems that employ a
				  liquid ingredient injection (slurry) system as described in Appendix H, the
				  slurry injection pump shall be energized and running at its maximum speed and
				  the slurry supply tank shall be completely filled with water.
2. Measure the time required to deliver a known volume of
				  water at the discharge outlet of the pasteurization system. Repeat the test
				  until the measurements are consistent.
3. Repeat
Procedures 1 and 2
in diverted-flow by
				  collecting the water at the pasteurization system's diverted-flow
				  discharge.
Note: Procedure 3
is not required for HHST
				  pasteurization systems with magnetic flow meter based timing systems.
4. Select the highest flow rate, the shortest delivery time
				  for the known volume, and calculate the flow rate in gallons per second by
				  dividing the known volume by the time required to collect the known volume.
				  Multiply this value with the appropriate value referenced in Table 14 to
				  determine the required holding tube length for the pasteurization
				  system.
5. The holding tube may include fittings. The centerline
				  length of the fitting is treated as an equivalent length of straight pipe. The
				  centerline distance may be measured by forming a flexible steel tape along the
				  centerline of the fitting. Determine the total length of the holding tube by
				  adding the equivalent lengths of the fittings to the measured lengths of
				  straight pipe.
Note:
The holding tube shall be arranged to have
				  a continuously upward slope in the direction of flow of not less than 2.1
				  centimeters (0.25 of an inch) per foot. If the indicating temperature sensing
				  element is located at the beginning of the holding tube, the entire length of
				  the holding tube shall be protected against heat loss by a material that is
				  impervious to water.
6. When the actual holding tube length is equivalent to or
				  greater than the calculated minimum holding tube length, record the number and
				  type of fittings, the number and length of straight pipe, the holding tube
				  configuration, and the results on the appropriate Form. If the actual holding
				  tube length is not equivalent or greater than the calculated minimum holding
				  tube length, refer to
Action
noted below.
Alternate Procedure for Measuring the Flow Rate:
Suspend a sanitary dipstick in the constant-level tank and operate the
				  pasteurization system at its maximum flow capacity. Record the time that is
				  required for the water level in the constant-level tank to drop two (2)
				  identified graduations on the dipstick. The volume of water is calculated from
				  the dimensions of the constant-level tank and the drop in water level. The flow
				  rate is determined as follows:
1. Divide the volume of water, in gallons, removed from the
				  constant-level tank by the time, in seconds, required to remove the volume of
				  water.
2. Then use this flow rate to calculate the required holding
				  tube length as provided in
Procedures 3 and 4
above.
Alternate Procedures for the Determination of the
				  Holding Tube Length for Non-Standard Pipe Size:
The holding tube length
				  may be accurately calculated from the following equation:
L = 588 Qt/D2
Where: L = Holding tube length (inches)
Q = Pumping rate (gallons per second)
t = Pasteurization holding time standard (seconds)
D = Internal diameter of the holding tube (inches)
Note:
Table 15 provides the internal pipe
				  diameters for piping in a HHST pasteurization system's holding tube with
				  nominal external diameters of 2.0, 2.5, 3.0, and 4.0 inches. Internal diameters
				  for pasteurization system's holding tubes designed for high pressure and for
				  holding tubes with external piping sizes not listed in Table 15, shall be
				  individually determined and the minimum holding tube length calculated using
				  the above formula.
TABLE 15
Table 15. Dimension for Standard Stainless
								Steel Sanitary Tubing1
Nominal External
								Diameter2
Internal
								Diameter2
2.0
1.87
2.5
2.37
3.0
2.87
4.0
3.83
Abstracted from Table 6.1 "Pipe and Heat Exchanger Tube
				  Dimensions," Fundamentals of Food Process Engineering, 1979, R. T. Toledo, AVI
				  Press 
				  1Measurements are in inches.
After the minimum required holding tube length is obtained
				  from the calculation above, the length of the holding tube is measured to
				  determine that it is at least as long as the calculated length. Record the
				  number and type of fittings, the number and length of straight pipe, and the
				  holding tube configuration results on the appropriate form.
Action:
If the length of the holding tube is
				  shorter than the calculated required minimum length, reseal the timing system
				  at a slower maximum speed based on new calculations with this slower maximum
				  speed or have milk plant personnel lengthen the holding tube, or both, and
				  repeat the test procedure previously used. If after adjustment the
				  pasteurization system fails this test, the pasteurization system shall not be
				  allowed to operate until the cause of this failure has been corrected and
				  compliance has been verified by the Health Officer; or in the case of HACCP
				  listed milk plants, qualified industry personnel acceptable to the Health
				  Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
11.4 CALCULATED PASTEURIZATION HOLDING TIME FOR HHST
				  PASTEURIZATION SYSTEMS USING DIRECT HEATING
Application:
To all HHST pasteurization systems
				  using direct heating.
Frequency:
Upon installation; at least once each
				  six (6) months thereafter; whenever any alteration is made affecting the
				  pasteurization holding time, the velocity of the flow, such as replacement of
				  the timing pump, motor, belt, drive or driven pulley, decrease in number of
				  heat-exchange plates, or the capacity of the holding tube; whenever a check of
				  the capacity of the holding tube indicates a speedup; or whenever the
				  regulatory seal on the timing pump speed setting has been broken.
Criteria:
Every particle of milk and/or milk
				  product shall be held for the appropriate minimum pasteurization holding time
				  in both the forward-flow and diverted-flow positions.
Apparatus:
No supplementary materials
				  required.
Method:
For this test, fully developed laminar
				  flow and a temperature increase by the steam injection of 49°C (120°F)
				  are assumed and the processor chooses the temperature-time standard and the
				  required holding tube length is calculated from an experimental determination
				  of the pumping rate.
Procedure:
1. Operate the pasteurization system on water in forward-flow
				  with all flow-promoting devices which are capable of causing flow through the
				  FDD operating at their maximum capacity and all flow-impeding devices adjusted
				  or bypassed to provide the minimum amount of resistance to the flow through the
				  pasteurization system. There shall not be any leakage on the suction side of
				  the timing pump.
a. For a variable speed timing pump, adjust the timing pump
				  to its maximum capacity, preferably with a new belt and full size
				  impellers.
b. For a homogenizer used as the timing pump, check the
				  homogenizer for its regulatory seal(s) and gears or pulley
				  identification.
c. For AC variable speed timing pump, check the timing pump's
				  control box for its regulatory seal(s).
d. When vacuum equipment is present, operate the vacuum
				  equipment at maximum vacuum rate.
Note:
For pasteurization systems that employ a
				  liquid ingredient injection (slurry) system as described in Appendix H, the
				  slurry injection pump shall be energized and running at its maximum speed and
				  the slurry supply tank shall be completely filled with water.
2. Measure the time required to deliver a known volume of
				  water at the discharge outlet of the pasteurization system. Repeat the test
				  until the measurements are consistent.
3. Repeat
Procedures 1 and 2
in diverted-flow by
				  collecting the water at the pasteurization system's diverted-flow
				  discharge.
Note: Procedure 3
is not required for HHST
				  pasteurization systems with magnetic flow meter based timing systems.
4. Select the highest flow rate, the shortest delivery time
				  for the known volume and calculate the flow rate in gallons per second by
				  dividing the known volume by the time required to collect the known volume.
				  Multiply this value with the appropriate value referenced in Table 16 to
				  determine the required holding tube length for the pasteurization
				  system.
TABLE 16
Holding Tube Length - HHST Pasteurization
								System-Direct Heating at a Pumping Rate of 1 gallon/second
Pasteurization Holding Time
Tubing Size
(inches)
2
2-1/2
3
Holding Tube Length
(inches)
1.0
188.0
118.0
80.0
0.5
94.0
59.0
40.0
0.1
18.8
11.8
8.0
0.05
9.40
5.90
4.0
0.01
1.88
1.18
0.8
5. The holding tube may include fittings. The center line
				  length of the fitting is treated as an equivalent length of straight pipe. The
				  center line distance may be measured by forming a flexible steel tape along the
				  center line of the fitting. Determine the total length of the holding tube by
				  adding the equivalent lengths of the fittings to the measured lengths of
				  straight pipe.
Note:
The holding tube shall be arranged to have
				  a continuously upward slope in the direction of flow of not less than 2.1
				  centimeters (0.25 of an inch) per foot. If the indicating temperature sensing
				  element is located at the beginning of the holding tube, the entire length of
				  the holding tube shall be protected against heat loss by a material that is
				  impervious to water.
6. When the actual holding tube length is equivalent to or
				  greater than the calculated minimum holding tube length, record the number and
				  type of fittings, the number and length of straight pipe, the holding tube
				  configuration, and the results on the appropriate form. If the actual holding
				  tube length is not equivalent or greater than the calculated minimum holding
				  tube length, refer to
Action
noted below.
Alternate Procedure for Measuring the Flow Rate:
Suspend a sanitary dipstick in the constant-level tank and operate the
				  pasteurization system at its maximum flow capacity. Record the time that is
				  required for the water level in the constant-level tank to drop two (2)
				  identified graduations on the dipstick. The volume of water is calculated from
				  the dimensions of the constant-level tank and the drop in water level. The flow
				  rate is determined as follows:
1. Divide the volume of water, in gallons, removed from the
				  constant-level tank by the time, in seconds, required to remove the volume of
				  water.
2. Then use this flow rate to calculate the required holding
				  tube length as provided in
Procedures 3 and 4
above.
Alternate Procedures for the Determination of the
				  Holding Tube Length for Non-Standard Pipe Size:
The holding tube length may also be accurately calculated
				  from the following equation:
L = (588 Qt x
				  1.12)/D2
Where: L = Holding tube length (inches)
Q = Pumping rate (gallons per second)
t = Pasteurization holding time standard (seconds)
1.12 = 12% expansion for steam
D = Internal diameter of the holding tube (inches)
Note:
Table 15 provides the internal pipe
				  diameters for piping in a HHST pasteurization system's holding tube with
				  nominal external diameters of 2.0, 2.5, 3.0, and 4.0 inches. Internal diameters
				  for pasteurization system's holding tubes designed for high pressure and for
				  holding tubes with external piping sizes not listed in Table 15 shall be
				  individually determined and the minimum holding tube length calculated using
				  the above formula.
After the minimum required holding tube length is obtained
				  from the calculation above, the length of the holding tube is measured to
				  determine that it is at least as long as the calculated length. Record the
				  number and type of fittings, the number and length of straight pipe, and the
				  holding tube configuration results on the appropriate form.
Action:
If the length of the holding tube is
				  shorter than the calculated required minimum length, reseal the timing system
				  at a slower maximum speed based on new calculations with this slower maximum
				  speed or have milk plant personnel lengthen the holding tube, or both, and
				  repeat the test procedure previously used. If after adjustment the
				  pasteurization system fails this test, the pasteurization system shall not be
				  allowed to operate until the cause of this failure has been corrected and
				  compliance has been verified by the Health Officer; or in the case of HACCP
				  listed milk plants, qualified industry personnel acceptable to the Health
				  Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
11.5 HHST PASTEURIZATION SYSTEMS HOLDING TIME USING
				  DIRECT STEAM INFUSION HEATING WITH A STEAM PRESSURE RELIEF POP-OFF VALVE AND A
				  VACUUM CHAMBER ORIFICE IN PLACE OF A TIMING PUMP
Application:
To all HHST pasteurization systems
				  using direct steam infusion heating and using a steam pressure relief pop-off
				  valve and a vacuum chamber orifice in place of a timing pump.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the steam infusion shell or feed line,
				  pressure relief pop-off valve, or vacuum chamber orifice has been repaired or
				  replaced; or whenever the regulatory seal has been broken.
Criteria:
Every particle of milk and/or milk
				  product shall be held for the applicable minimum pasteurization holding time in
				  both the forward-flow and diverted-flow positions.
Apparatus:
No supplementary materials
				  required.
Method:
1. The steam infusion shell or feed line shall be equipped
				  with a pressure relief pop-off valve. This pressure relief pop-off valve shall
				  be located and sized so that the total pressure inside the steam infusion shell
				  or feed line can never exceed the set point on this pressure relief pop-off
				  valve.
2. An orifice or restriction which is permanently installed
				  in a noticeable fitting shall be placed in the holding tube just prior to the
				  vacuum chamber. The opening in the orifice or restriction shall be sized to
				  ensure a minimum milk and/or milk product residence pasteurization holding time
				  at least as long as that specified in the chosen HHST pasteurization
				  standard.
3. The size of the opening in the orifice or restriction and
				  the setting of the pressure relief valve shall be determined by trial and
				  error. Once an appropriate maximum flow rate has been determined and a minimum
				  legal pasteurization holding time has been calculated, both the orifice or
				  restriction and the steam pressure setting on the pressure relief pop-off valve
				  shall be sealed by the Health Officer so that neither can be changed or
				  altered.
Procedure:
1. Operate the pasteurization system on water in forward-flow
				  with all flow-promoting devices, which are capable of causing flow through the
				  FDD operating at their maximum capacity and all flow-impeding devices adjusted
				  or bypassed to provide the minimum amount of resistance to the flow through the
				  pasteurization system.
There shall not be any leakage on the suction side of the
				  timing pump.
a. For a variable speed timing pump, adjust the timing pump
				  to its maximum capacity, preferably with a new belt and full size
				  impellers.
b. For a homogenizer used as the timing pump, check the
				  homogenizer for its regulatory seal(s) and gears or pulley
				  identification.
c. For AC variable speed timing pump, check the timing pump's
				  control box for its regulatory seal(s).
Note:
For pasteurization systems that employ a
				  liquid ingredient injection (slurry) system as described in Appendix H, the
				  slurry injection pump shall be energized and running at its maximum speed and
				  the slurry supply tank shall be completely filled with water.
2. The steam pressure in the steam infusion shell or feed
				  line shall be raised to a level just below the pressure relief pop-off point of
				  the pressure relief pop-off valve.
3. Any back-pressure valves or other variable restrictions in
				  the holding tube shall be placed into the fully open position.
4. All air bleeds to the vacuum chamber shall be closed so
				  that the vacuum chamber will be operating under maximum vacuum.
5. Operate the pasteurization system at its maximum flow for
				  approximately fifteen (15) minutes to purge air from the pasteurization
				  system.
6. Measure the time required to deliver a known volume of
				  water at the discharge outlet of the pasteurization system. Repeat the test
				  until the measurements are consistent.
7. Repeat
Procedures 1 through 5
in
				  diverted-flow by collecting the water at the pasteurization system's
				  diverted-flow discharge.
Note: Procedure 7
is not required for HHST
				  pasteurization systems with magnetic flow meter based timing systems.
8. Select the highest flow rate, the shortest delivery time
				  for the known volume, and calculate the flow rate in gallons per second by
				  dividing the known volume by the time required to collect the known volume.
				  Multiply this value with the appropriate value referenced in Table 16 to
				  determine the required holding tube length for the pasteurization
				  system.
9. The holding tube may include fittings. The centerline
				  length of the fitting is treated as an equivalent length of straight pipe. The
				  centerline distance may be measured by forming a flexible steel tape along the
				  centerline of the fitting. Determine the total length of the holding tube by
				  adding the equivalent lengths of the fittings to the measured lengths of
				  straight pipe.
Note:
The holding tube shall be arranged to have
				  a continuously upward slope in the direction of flow of not less than 2.1
				  centimeters (0.25 of an inch) per foot. If the indicating temperature sensing
				  element is located at the beginning of the holding tube, the entire length of
				  the holding tube shall be protected against heat loss by a material that is
				  impervious to water.
10. If the actual holding tube length is equivalent to or
				  greater than the calculated minimum holding tube length, record the number and
				  type of fittings, the number and length of straight pipes, and the holding tube
				  configuration and results on the appropriate form.
Action:
If the length of the holding tube is
				  shorter than the calculated required minimum length, reseal the timing system
				  at a slower maximum speed based on new calculations with this slower maximum
				  speed or have milk plant personnel lengthen the holding tube, or both, and
				  repeat the test procedure previously used. If after adjustment the
				  pasteurization system fails this test, the pasteurization system shall not be
				  allowed to operate until the cause of this failure has been corrected and
				  compliance has been verified by the Health Officer; or in the case of HACCP
				  listed milk plants, qualified industry personnel acceptable to the Health
				  Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 12
THERMAL-LIMIT-CONTROLLER FOR CONTROL - SEQUENCE
				  LOGIC
References:
Rule
				  420-3-16-.10(18)
				  and Rule 420-3-16-.10 (21-22)
Thermal-limit-controllers used with HTST and HHST
				  pasteurization systems that have the FDD located downstream of the pasteurized
				  regenerator section(s) and/or cooler section shall be tested by one (1) of the
				  following applicable tests at the frequency prescribed.
12.1 PASTEURIZATION - INDIRECT HEATING
Application:
To all HTST and HHST pasteurization
				  systems that have the FDD located downstream of the pasteurized regenerator
				  section(s) and/or cooler section and using indirect heating.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the thermal-limit-controller has been
				  repaired or replaced; or whenever the regulatory seal has been broken.
Criteria:
The pasteurization system shall not
				  operate in forward-flow until the milk and/or milk product-contact surfaces
				  downstream from the holding tube have been sanitized. Upon start-up, milk
				  and/or milk product-contact surfaces shall be exposed to fluid at the
				  applicable required pasteurization temperature for at least the applicable
				  required pasteurization or sterilization time. If any public health control
				  causes the FDD to assume the diverted-flow position due to incorrect
				  temperature, pressure, or flow, forward-flow shall not be re-achieved until the
				  milk and/or milk product-contact surfaces downstream from the holding tube have
				  been re-sanitized or re-sterilized as appropriate.
Apparatus:
A constant temperature bath of water,
				  oil, or other suitable media and the test light from the pneumatic testing
				  device described in Test 9.1
PRESSURE SWITCHES
may be used to
				  check the control-sequence logic of the thermal-limit-controller.
Method:
The control-sequence logic of the
				  thermal-limit-controller is determined by monitoring the electric signal from
				  the thermal-limit-controller during a series of immersions and removals of the
				  two (2) sensing elements located at the FDD and in the holding tube from a
				  media bath heated above the cut-in temperature.
Procedure:
1. Heat the media bath to a constant temperature, a few
				  degrees above the cut-in temperature of the thermal-limit-controller. Wire the
				  test light in series with the signal from the thermal-limit-controller to the
				  FDD.
Note:
Some processors may have time delays built
				  into their control logic in excess of that required for public health reasons.
				  If so equipped, by-pass these time delays or account for their effect in
				  delaying forward-flow.
2. Immerse the sensing element from the FDD into the media
				  bath, which is above the cut-in temperature. The test light shall remain unlit,
				  indicating diverted-flow. Leave this sensing element in the media bath.
3. Immerse the sensing element from the holding tube into the
				  media bath. The test light shall light up, indicating forward-flow after a
				  minimum time delay of one (1) second for continuous-flow pasteurization
				  systems.
4. Remove the sensing element from the FDD from the media
				  bath. The test light shall remain lit, indicating forward-flow.
5. Remove the sensing element from the holding tube from the
				  media bath. The test light shall turn off immediately, indicating
				  diverted-flow.
6. Re-immerse the sensing element from the holding tube into
				  the media bath. The test light shall remain unlit, indicating
				  diverted-flow.
7. Record the results of the test on the appropriate
				  form.
Action:
If the control-sequence logic of the
				  thermal-limit-controller does not follow these
Procedures
, the
				  instrument shall be reconfigured to conform to this logic. If after
				  reconfiguration, the pasteurization system fails this test, the pasteurization
				  system shall not be allowed to operate until the cause of this failure has been
				  corrected and compliance has been verified by the Health Officer; or in the
				  case of HACCP listed milk plants, qualified industry personnel acceptable to
				  the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
12.2 PASTEURIZATION - DIRECT HEATING
Application:
To all HTST and HHST pasteurization
				  systems that have the FDD located downstream of the pasteurized regenerator
				  section(s) and/or cooler section and using direct heating.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the thermal-limit-controller has been
				  repaired or replaced; or whenever the regulatory seal has been broken.
Criteria:
The pasteurization system shall not
				  operate in forward-flow until the milk and/or milk product-contact surfaces
				  downstream from the holding tube have been sanitized. Upon start-up, milk
				  and/or milk product-contact surfaces shall be exposed to fluid at the
				  applicable required pasteurization temperature for at least the applicable
				  required pasteurization or sterilization time. If the milk and/or milk product
				  temperature falls below the applicable pasteurization standard in the holding
				  tube, forward-flow shall not be re-achieved until the milk and/or milk
				  product-contact surfaces downstream from the holding tube have been
				  re-sanitized or re-sterilized as appropriate.
Apparatus:
A constant temperature bath of water,
				  oil, or other suitable media and the test light from the pneumatic testing
				  device described in Test 9.1
PRESSURE SWITCHES
can be used to
				  check the control-sequence logic of the thermal-limit-controller.
Method:
The control-sequence logic of the
				  thermal-limit-controller is determined by monitoring the electric signal from
				  the thermal-limit-controller during a series of immersions and removals of the
				  three (3) sensing elements, located at the FDD, vacuum chamber, and in the
				  holding tube from a media bath heated above the cut-in temperature.
Procedure
:
1. Heat a media bath to a constant temperature, a few degrees
				  above the cut-in temperature on the thermal-limit-controller. Wire the test
				  light in series with the signal from the thermal-limit-controller to the
				  FDD.
Note:
Some processors have time delays built
				  into their control logic in excess of that required for public health reasons.
				  If so equipped, bypass these time delays or account for their effect in
				  delaying forward-flow. Before performing this test, make sure the pressure
				  switches which shall be closed to achieve forward-flow have also been
				  bypassed.
2. Immerse the sensing element from the FDD into the media
				  bath, which is above the cut-in temperature. The test light shall remain unlit,
				  indicating diverted-flow. Remove this sensing element from the media
				  bath.
3. Immerse the sensing element from the vacuum chamber into
				  the media bath. The test light shall remain unlit, indicating diverted-flow.
				  Remove this sensing element from the media bath.
4. Immerse the two (2) sensing elements from the vacuum
				  chamber and the FDD into the media bath. The test light shall remain unlit,
				  indicating diverted-flow. Leave these two (2) sensing elements in the media
				  bath.
5. Immerse the third sensing element from the holding tube
				  into the media bath. The test light shall light up, indicating forward-flow,
				  after a minimum time delay of one (1) second for continuous-flow pasteurization
				  systems.
6. Remove the sensing element from the FDD from the media
				  bath. The test light shall remain lit, indicating forward-flow.
7. Remove the sensing element from the vacuum chamber from
				  the media bath. The test light shall remain lit, indicating
				  forward-flow.
8. Remove the remaining sensing element from the holding tube
				  from the media bath. The test light shall immediately turn off, indicating
				  diverted-flow.
9. Re-immerse the sensing element from the holding tube into
				  the media bath. The test light shall remain unlit, indicating
				  diverted-flow.
10. Record the results of the test on the appropriate
				  form.
Action:
If the control-sequence logic of the
				  thermal-limit-controller does not follow these
Procedures
, the
				  instrument shall be reconfigured to conform to this logic. If after
				  reconfiguration the pasteurization system fails this test, the pasteurization
				  system shall not be allowed to operate until the cause of this failure has been
				  corrected and compliance has been verified by the Health Officer; or in the
				  case of HACCP listed milk plants, qualified industry personnel acceptable to
				  the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 13
SETTING OF CONTROL SWITCHES FOR MILK AND/OR MILK
				  PRODUCT PRESSURE IN THE HOLDING TUBE
Reference:
Rule
				  420-3-16-.10(18)
				  and Rule 420-3-16-.10 (21-22)
Application:
To all HHST pasteurization systems
				  which are capable of operating with milk and/or milk product in forward-flow
				  mode with less than 518 kPa (75 psig) pressure in the holding tube.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the pressure switch has been repaired or
				  replaced; whenever the operating temperature is changed; or whenever the
				  pressure switch regulatory seal has been broken.
Criteria:
The pasteurization system shall not
				  operate in forward-flow unless the product pressure in the holding tube is at
				  least 69 kPa (10 psi) above the boiling pressure of the milk and/or milk
				  product.
Apparatus:
The sanitary pressure gauge and the
				  pneumatic testing device described in Test 9.1
PRESSURE SWITCHES
can be used for checking and adjusting the pressure switch setting.
Method:
The pressure switch is checked and
				  adjusted so as to prevent forward-flow unless the milk and/or milk product
				  pressure in the holding tube is at least 69 kPa (10 psi) above the boiling
				  pressure of the milk and/or milk product.
Procedure:
1. Using Figure 57 determine the pressure switch setting
				  necessary for the operating temperature being used in the pasteurization
				  system; do not use the diversion temperature. Install the sanitary pressure
				  gauge and the pressure switch sensing element on the pneumatic testing
				  device.
2. Remove the regulatory seal and cover to expose the
				  adjustment mechanism on the pressure switch. Place the test light in series
				  with the pressure switch contacts or use some other method to monitor the
				  cut-in signal.
3. Apply air pressure to the pressure switch sensing element
				  and determine the pressure gauge reading at the cut-in point of the pressure
				  switch, which shall turn on the test light. If the pressure switch is short
				  circuited, the test light will light up before the air pressure is
				  applied.
4. Determine that the cut-in pressure on the pressure switch
				  is equivalent to or greater than the required pressure from Figure 57. If
				  adjustment is necessary, refer to the manufacturer's instructions.
5. After the necessary adjustment is made, repeat the
				  test.
6. Record the results of the test on the appropriate
				  form.
Action:
If forward-flow is achieved with less
				  than 69 kPa (10 psi) above the boiling point of the milk and/or milk product in
				  the holding tube, adjust the pressure setting and retest. If after adjustment
				  the pasteurization system fails this test, the pasteurization system shall not
				  be allowed to operate until the cause of this failure has been corrected and
				  compliance has been verified by the Health Officer; or in the case of HACCP
				  listed milk plants, qualified industry personnel acceptable to the Health
				  Officer in compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
For each HHST pasteurization system temperature, the milk
				  and/or milk product pressure switch setting is as follows:
Click to view
				  image
Figure 57. Pressure Switch Setting
This pressure switch setting shall be adjusted upward by the
				  difference between the routine local atmospheric pressure and the atmospheric
				  pressure at sea level.
TEST 14
SETTING THE CONTROL FOR THE DIFFERENTIAL PRESSURE
				  CONTROLLER ACROSS THE STEAM INJECTOR
Reference:
Rule
				  420-3-16-.10(18)
				  and Rule 420-3-16-.10 (21-22)
Application:
To all HTST and HHST
				  continuous-flow pasteurization systems using direct steam injection
				  heating.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever the differential pressure controller has
				  been repaired or replaced; or whenever the differential pressure controller's
				  regulatory seal has been broken.
Criteria:
The pasteurization system shall not
				  operate in forward-flow unless the milk and/or milk product pressure drop
				  across the steam injector is at least 69 kPa (10 psi).
Apparatus:
The sanitary pressure gauge and the
				  pneumatic testing device described in Test 9.1
PRESSURE SWITCHES
can be used for checking and adjusting the differential pressure
				  controller.
Method:
Adjust the differential pressure
				  controller to prevent forward-flow, unless the pressure differential across the
				  steam injector is at least 69 kPa (10 psi).
Procedure:
1.
Calibration of the Steam Injector Differential
				  Pressure Controller Sensing Elements:
a. Loosen the connection at both pressure sensing elements
				  and allow for any liquid to drain through the loose connections. While the
				  sensing elements are still in their original positions, both pointers or the
				  digital display(s) shall be within 3.5 kPa (0.5 psi) of 0 kPa (0 psi). If not,
				  adjust the pointer(s) or the digital display(s) to read 0 kPa (0 psi).
b. Remove both sensing elements and install them onto a tee
				  or connect them to the pneumatic testing device. Record any difference from the
				  zero (0 kPa [0 psi]) readings in
Procedure 1.a.
that may have
				  occurred when installing the sensing elements onto the tee. Attach the tee and
				  both sensing elements to the pneumatic testing device described in Test 9.1
PRESSURE SWITCHES
and adjust the air pressure to the operating
				  pressure used at the steam injector. Make sure that the pointer(s) or digital
				  display(s) reading separation is within 6.9 kPa (1 psi) of that observed before
				  the pressure was applied. If not, the differential pressure controller requires
				  adjustment or repair.
2. Setting of the Steam Injector Differential Pressure
				  Controller:
a. Disconnect the sanitary pressure sensing element that is
				  located after the steam injector from the pneumatic testing device and cap the
				  opening. Leave the pressure sensing element which is installed prior to the
				  steam injector on the pneumatic testing device.
b. Leave the other pressure sensing element open to the
				  atmosphere, but at the same height as the pressure sensing element connected to
				  the pneumatic testing device.
c. Wire the test light in series with the differential
				  pressure controller microswitch or use the method provided by the instrument
				  manufacturer to monitor the cut-in signal.
d. Apply air pressure to the pressure sensing element and
				  determine from the test light the pressure gauge reading at the cut-in point of
				  the differential pressure controller.
e. The differential pressure cut-in on the differential
				  pressure controller shall be at least 69 kPa (10 psi). If adjustment is
				  necessary, refer to the manufacturer's instructions.
f. After adjustment, repeat this test.
3. Record the results of the test on the appropriate
				  form.
Action:
If after adjustment the pasteurization
				  system fails this test, the pasteurization system shall not be allowed to
				  operate until the cause of this failure has been corrected and compliance has
				  been verified by the Health Officer; or in the case of HACCP listed milk
				  plants, qualified industry personnel acceptable to the Health Officer in
				  compliance with Rule
				  420-3-16-.10 (21-22); or on an
				  emergency basis, an industry temporary testing and sealing program authorized
				  by the Health Officer in compliance with Rule
				  420-3-16-.10 (21-22).
TEST 15
ELECTRO-MAGNETIC INTERFERENCE FROM HAND-HELD
				  COMMUNICATION DEVICES
Application:
To all electronic control devices
				  used to assure compliance with public health safeguards on HTST and HHST
				  continuous-flow pasteurization equipment that are installed in milk
				  plants.
Frequency:
Upon installation; at least once each
				  three (3) months thereafter; whenever any alteration of the electronic control
				  devices occur; or whenever the type or wattage of the hand-held communication
				  device(s) used in that milk plant is changed. Once a hand-held communication
				  device has been shown to cause a given electronic control device to react
				  adversely, the electronic control device shall be repaired and re-tested using
				  the same type hand-held communication device (refer to the Note below). If any
				  electronic control device is altered or there is a change in the hand-held
				  communication device(s) used, the electronic control device(s) shall be
				  tested.
Criteria:
The use of hand-held communication
				  devices shall not have any adverse effect on the electronic control device's
				  public health safeguards.
Apparatus:
One (1) hand-held communication
				  device representing each make and model used in the milk plant. The hand-held
				  communication device(s) shall be operating at maximum output and be fully
				  charged.
Method:
By observing the actual effect of the
				  hand-held communication device on an electronic control device, it can be
				  determined if that hand-held communication device can be used near that
				  equipment without compromising any of the electronic control device's public
				  health safeguards.
Procedure:
1. Position the hand-held communication device 30.5
				  centimeters (12 inches) in front of the electronic control device where the
				  public health safeguard(s) resides.
2. Place the hand-held communication device in the "send"
				  mode for five (5) seconds and observe the effect on the electronic control
				  device's public health safeguard(s). There shall not be any adverse effect with
				  the electronic control device. An adverse effect is any change that may
				  adversely affect an electronic control device's public health
				  safeguard(s).
3. If applicable, repeat the test with the operator access
				  door open.
4. Repeat the above test for each hand-held communication
				  device identified under
Apparatus
.
5. Repeat the above test for each electronic control device
				  used to regulate a pasteurization system's public health safeguard(s).
6. Record the make and model of each hand-held communication
				  device tested and the test results on the appropriate form.
Example:
For the temperature set point, operate
				  the pasteurization equipment on water in diverted-flow in the "Product" mode,
				  at a steady temperature within 3ºC (5ºF) of the lowest cut-in
				  temperature. In this example, an adverse effect is defined as the forward-flow
				  movement of the FDD or any artificial increase in temperature.
Action:
Have the milk plant check for shielding,
				  grounding, and other installation concerns with the electronic control device
				  and retest. Until a solution acceptable to the Health Officer can be found that
				  does not adversely affect the electronic control device's public health
				  safeguard(s), the hand-held communication device cannot be used in the area of
				  the electronic control device's public health safeguard(s).
Note:
Continuous "Hand-Held Communication Device
				  Free" or "Radio Free" zones, etc., are not acceptable permanent solutions to
				  hand-held communication devices which cause adverse affects to an electronic
				  control device's public health safeguards.
Author:
G. M. Gallaspy, Jr.
Statutory Authority:
Code of Ala. 1975,
					 §§
											22-2-2,
					 22-20-7.