AIB Q4 2017 Magalog

SOLUTIONS TODAY, FOR TOMORROW’'S GLOBAL FOOD INDUSTRY
Q4_2017
THE 10 STEP PATH TO DESIGNING A TOP GRADE
ENVIRONMENTAL MONITORING PROGRAM • WHAT
ABOUT SHOKUPAN• THE NEW BAKING EQUIPMENT AIB
NEEDED • BUILDING & TRAINING A QUALIFIED INTERNAL
AUDIT TEAM • BAKING BASICS WEBINAR SERIES

Foodborne illness outbreaks are in
the news more and more – often from
the result of poor hygiene practices.
Post-lethality recontamination remains
a serious concern. It’s critical to
monitor the hygienic environment
with an Environmental Monitoring
Program (EMP) used to measure the
overall effectiveness of your sanitary
design, personnel practices, and
operational methods. EMPs verify that
cleaning and sanitizing procedures
are adequate and act as an early
warning tool to assess the risks posed
by pathogens of concern. Use our 10
step path to designing an EMP that
excels.
The 10 Step Path to Designing a Top
Grade Environmental Monitoring Program
Step 1: Create an EMP Team
Bring together employees from
various areas to form your team. The
quality manager, plant microbiologist,
line supervisors, plant engineer,
and sanitation supervisors are all
great candidates. This team will be
responsible for identifying areas
where the product may be at risk of
contamination, marking the hygienic
zones, and identifying sampling sites.
Step 2: Apply the Zoning
Concept
The best way to identify sampling
points is to use the zoning
concept. Based on the sanitary
zoning concept, the operation is
divided into four zones that cover
every area from direct foodcontact
surfaces to areas remote
from product processing areas.
Step 3: Use
Indicator Bacteria/
Microorganisms
Indicator microorganisms are
optimal for the EMP because
they are high in number and
easy to enumerate. A positive
indicator means possible
contamination and a risk of
foodborne disease.
Step 4: Set Sampling
Frequencies
Swab all potential sites
within a defined period
of time (e.g., one month)
so that both food-contact
surfaces and non-food
contact surfaces are
tested at each sampling
time.
Step 5: Perfect Labeling and
Shipping Procedures
Some facilities test their swab
samples in house and others use
outside labs. To ensure accurate tests
make sure key information, such as
date, location, product size, and
date submitted to lab, is included
in your swab labeling and shipping
procedures.
Step 6: Establish a
Baseline/Target
Use historical results (e.g.,
previous year data) and
regulatory guidelines to establish
a baseline. For example, if a
site tests

What About
Shokupan?
Japanese Bread Making is Back in Portland,
Thanks to BS&T Graduate Hiro Horie
Ever since Oyatsupan Bakers opened their doors in 2016, Portland
has been craving traditional Japanese baking and their highlypopular
Shokupan and sweet rolls. Owner, Hiroyuki Horie arrived
on the baking scene in 1992 when he left Japan to attend AIB
International’s Baking Science and Technology (BS&T) resident
course. He then spent 26 years working for Pasco, starting on the
English muffin line and working his way to running the company’s
American wholesale operations in Los Angeles and then Portland.
His version of Japanese baking is a throwback to tradition and
a lot of his inspiration comes from Japanese cuisine, the Pacific
Northwest food culture, and using local farm produce. To create
his take on traditional sweet rolls, Horie tested everything in his
kitchen prior to starting the bakery. “In the beginning I was baking
everything at the bakery. I do less now, because I’m creating the
operation system for the bakery.” Horie says.
“During my time at AIB, I learned critical lessons about baking
theory and flour science.” Horie, a BS&T graduate said. “I
specifically remember a bake sale in downtown Manhattan, Kansas
where I learned a lot about the American culture of breads and
sweet goods. The bake sale was a first time experience for me while
studying abroad.”
At Oyatsupan Bakers, Horie still uses his AIB training to turn out
loaves of Shokupan – a Japanese style of white Pullman bread.
The flour science portion of BS&T is a big asset to Horie now
and fundamental to his breads, cakes, and rolls. Of course, the
Shokupan isn’t the only thing drawing the community’s attention.
Horie is bringing back traditional curry donuts, melon pan rolls
(sable cookie on top of a sweet roll), Tonkatsu sandwiches (deep
fried pork with panko), and tea sandwiches, too. Oyatsupan Bakers
is producing 50 varieties of traditional Japanese savory and sweet
goods.
“There are very few Japanese style bakeries carrying traditional
Japanese sweet rolls to savory rolls in the United States.” Horie
said. “I just want to bring a bit more variety breads and rolls to the
US, based on popular Japanese products I am familiar with.”
Enroll Now!
BS&T Spring 2018 • tiny.cc/q4p3
That’s the real challenge – managing leftover product on the
shelf, however it’s a long process. Quality of products, customer
experience, and employee satisfaction are always the main
principals for the bakery.
“It is always exciting to interact with customers at the bakery.”
Hiro said. “I rarely experienced that in the large wholesale baking
company where I used to work. It’s exciting to be creating a new
food culture in the city of Portland.”
In the last few months, Horie has started selling his baked products
wholesale at a local Japanese grocery store and at the re-designed
Portland Japanese Garden. The bread making movement across
the country is giving more opportunities for high-end gourmet to fill
the gap larger corporations can’t fill. We can only hope to one day
try these perfectly pillowy Shokupan rolls.
Hiro Horie, AIB International - 3

2017 US Seminar Calendar
Enroll today!
tiny.cc/q4p4
October November December
Foreign Supplier
Verification
Program
Philadelphia, PA
10-11
Foundations: ALL
ABOUT BAKING
Manhattan, KS
16-20
HACCP Workshop
Portland, OR
17-18
FSPCA Preventive
Controls for Human
Food
Portland, OR
24-26
HACCP Integration for
FMSA Compliance
Portland, OR
26
Specializations:
Advanced Labeling
of FDA Regulated
Foods
Chicago, IL
24-25
Calendar, AIB International - 4
Specializations: Pizza
Manhattan, KS
6-9
Food Defense Coordinator
Kansas City, MO
7-8
FSPCA Preventive Controls
for Human Food + HACCP
Integration for FSMA
Compliance for Millers
Manhattan, KS
7-9
Specializations:
Hamburger Buns
Manhattan, KS
4-7
FSPCA:
Foreign Supplier Verification Programs
October 10-11, 2017 Philadelphia, PA
January 30-31, 2018 Ontario, CA
June 5-6 , 2018 Orlando, FL
Enroll today before your preferred location fills up!

2018 US Seminar Calendar
Foundations: Bread
and Rolls
Manhattan, KS
15-19
Specializations:
Variety Breads
Manhattan, KS
22-26
Applications: Bread
Troubleshooting
Manhattan, KS
29- Feb 2
Foreign Supplier
Verification Program
Ontario, CA
30-31
January
February
Baking science and
technology
Manhattan, KS
16-week course begins Feb 1
Food Safety and
Sanitation for Food
Plants
Phoenix, AZ
6-9
FSPCA Preventive
Controls for Human
Food
Orlando, FL
13-15
HACCP Integration for
FMSA Compliance
Orlando, FL
15
Food Defense
Coordinator
Ontario, CA
27-28
Foundations: All About
Baking
Manhattan, KS
5-9
GMP/Sanitation
Workshop
Orlando, FL
6-7
FSPCA Preventive
Controls for Human
Food
Ontario, CA
13-15
HACCP Integration for
FMSA Compliance
Ontario, CA
15
March
Specializations:
Doughnuts
Manhattan, KS
19-22
HACCP Workshop
Charlotte, NC
27-28
Calendar, AIB International - 5

The New Baking
Equipment AIB
Needed
After working in the baking industry for more than 6
years, Kathy Brower knows a thing or two about bakery
equipment. And that comes from her time in the labs at
AIB as well the Riley County Health Department where
she served as a Food Service and Environmental Health
Inspector.
“I saw multiple kitchens throughout the day along with
bakery equipment so when I took a job with AIB I knew
the challenges involved with maintaining the equipment to
meet food safety standards.” Brower said. “Preparedness,
planning, communication, and adaptability are essential
functions in both roles.”
In her role as Pilot Plant Manager, Brower oversees
operations of the Pilot Plant and the staff. She also
manages ingredients and materials procurement. This
means Brower can make recommendations and work
with contributors who wish to donate or consign bakery
equipment.
“We often don’t think of bakery equipment having a
big impact on our Manhattan-based seminars, but it
really does,” Brower said. “People from all over the
world come to AIB for baking training. It’s great
for them to see equipment that shows perfectly
well the mechanics behind producing a loaf of
bread or depositing a cookie, but it’s even better
when we can expose them to new equipment that
is engineered for safety as well as automated
production.”
Our participants are interested in outfitting their own
facilities with the best equipment to meet their needs and
one of our goals is to provide insight as to what equipment
may be available to them for their applications, Brower
explained. AIB also has clients that are contracted to use
equipment for research and development projects, so
having a good variety of options is ideal for matching
them with a solution to meet their needs.
The opportunity was there and the time was right, so in
2016 AIB took a strategic business decision to invest in
new bakery equipment. The new equipment included a
724 Double Rack Revent Oven, a D-Carbonator, and two
Reed Ovens.
The first investment in bakery processing machinery was
the Revent Oven. The Revent Oven is truly a site to see
in the bread lab and a leader in energy efficiency. The
double rack oven includes a mechanical rack lift for 88%
thermal efficiency. AIB worked with Pierre Bonnet at Sasa
Demarle Inc. to exclusively build a double rack that would
fit inside the opening. As a result, the breads lab is seeing
a significantly reduced footprint and the multi-baking
opportunities are wide.
Another new addition to the lab is the D-Carbonator. This heated soak
tank cleans carbon build up off baking utensils. Carbon crust forms on
metal equipment from the constant exposure to fats, oils, and grease,
which is extremely difficult to remove.
“This is why scrubbing pots and pans is often known as one of the
worst jobs in the kitchen.” Brower said. “This cleaning procedure is
safer for our staff and easier on the environment. Scrubbing pans is a
cumbersome task that can now be done in a fraction of the time and
with far less effort.”
Dr. Gary Shifren, president at ChemxWorks, reached out to Brian
Strouts, VP of Baking and Food Technical Services at AIB, and Brower
about our interest in using this unit and showing it to our participants.
AIB is always interested in putting new equipment to the test, so Strouts
and Brower immediately jumped on Shifren’s offer. The D-Carbonator is
a perfect pan game changer, Brower explained.
Now it’s time for a new generation to use ovens that they prefer. The
Pilot Plant and maintenance team worked with the Reed Oven Company
to outfit the same footprint that our previous two revolving ovens
occupied. With the previous ovens being quite aged, it was becoming
increasingly difficult to find replacement parts, so it was time to update.
“We like the flexibility of the revolving ovens in the cake lab for baking
multiple product variations at once and having two ovens gives us the
option of using different temperatures and bake times for the same
series of lab exercises.” Brower said.
The early reviews of the new equipment from seminar attendees are full
of praise. Manhattan-based seminars give attendees the opportunity to
try the new equipment while learning a brand-new skill. Whether you’re
lucky enough to see the equipment at AIB’s global headquarters or
hearing the news via this article it’s encouraging to know that updating
bakery equipment is on the mind of AIB leader Brower.
New Baking Equjipment, AIB International - 6

BUILDING & TRAINING
A QUALIFIED INTERNAL
AUDIT TEAM
Internal audits of your food safety programs are a
necessary exercise to prevent unsafe food from reaching
the marketplace. As important as it is to build a program that
works, it’s equally important to build a team of qualified auditors
capable of ensuring your programs are thoroughly evaluated and
meeting required expectations before your certification auditor arrives.
The Cast
You want to pick your most qualified personnel to be
on the internal audit team. Your internal audit program
will have requirements established for your auditors.
There is a definite need to have documented training
for qualified auditors. For example, if you expect an
auditor to review a HACCP plan then that person would
have to receive training in those program requirements.
If auditing a laboratory, then that person should have
job experience working in a lab or knowledge of the
Good Laboratory Practices or a similar program. The
same could be said for someone auditing the sanitation
or maintenance departments for the activities they
perform. Ideally, all internal auditors should receive
training on HACCP, prerequisite programs, and the
specific industry scheme your facility is certified for.
Your auditors must have sufficient knowledge in the
activity they are auditing. If they don’t have adequate
knowledge of the process a team leader should assist
them or shadow the audit until they have developed
skills to audit independently. It takes time to develop
a qualified auditor that is fully competent to effectively
complete an audit.
As auditors gain ability and confidence in their skills
they’ll learn what you need to see to evaluate an
activity for effective implementation. There will be
conformance and non-compliance, but it is important
to keep the auditee informed when significant issues are
observed. Be prepared to note significant deficiencies
that could be a regulatory issue. If significant issues are
uncovered they should be communicated immediately
to upper level management. Internal audits can
uncover contamination such as infestation, undeclared
allergens, and unsanitary conditions. These are all
significant issues that must be corrected immediately
and properly communicated to management.
Interested in learning more about building a rock
star internal auditing team?
Our webinar – Conducting Internal Audits – is
available for free download at: tiny.cc/q4p5
Teaching Technique
There are several auditing techniques that should be used during an internal
audit to ensure that all non-conformances and potential contamination issues
are identified.
One technique that auditors use to uncover further issues in the activity
being reviewed is an audit trail. For example, if a contractor is observed not
following the GMPs during an audit of the warehouse’s receiving, storage,
and temperature control requirements, you’ll have to investigate why this
person was able to get into the warehouse unaccompanied and without
proper GMP attire. This technique is similar to root cause investigation in
that you keep asking why something occurred until you get to the end of the
line. In many cases the issues noted when doing audit trails can eventually be
traced to ineffective training of company personnel.
Asking good questions that require an explanation such as, “Can you explain
how you set up and run the CIP system to clean this filler?” helps to evaluate if
personnel understand their duties. Yes and no response questions should not
be used very often as they do not require an explanation and usually do not
convey the necessary information being audited.
Another auditing technique is to complete the audit like a flow diagram, which
is a process approach. It is sometimes referred to as a straight line audit and
is useful in the sense that you will not miss any part of the operation. It can
also be used in the reverse application where you start at shipping and work
your way backward in the process. This technique is often used when doing
milling operations that have a final packaging area and much of the process
is enclosed in equipment and pneumatic systems.
Some auditors use systematic questioning to stay on track and focus on the
activity being audited. For example, ask the auditee to explain the activity they
perform, ask them to perform the activity, and review the records they are
required to fill out. It may sound simplistic but it is important to stay focused
on the activity being reviewed.
Interviews are an excellent way to gauge if personnel truly understand the
activities they are performing. Asking them to verbally explain what they are
doing allows you to get a feel for the organization in that they understand the
importance of their job and how they accomplish it.
Observations are necessary to confirm that activities are being performed
as planned and that proper sanitary practices are in place. Internal auditor
observation skills will improve with each audit completed, allowing less
obvious deficiencies to be spotted.
Internal Audit Team, AIB International - 7

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BAKING
BASICS
WEBINAR
SERIES
Don’t let limited experience
get in the way of an effective
baking industry career.
Don’t let limited industry experience hold
you back from making a lasting impact.
Soak in expert insight about ingredients and
processes needed to make many of today’s
popular baked goods. Discover the processes
used to produce pan breads, flour tortillas,
batter cakes, sweet dough products, and
doughnuts.
DISCOVER THE WEBINARS
THAT AWAIT!
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