Food grade lubricant applicationin bakery industry
Large bakery plants which are highly automated uses conveyors , material handling equipments and conveyors . Chain drives are frequently used in bakery plants for rollers , conveyors , band drives , blowers and chain for trays , bearings for rotating equipments . These equipments are always in contact with food raw or finished . Chances are there when they can contaminate the food items with lubricant if not done properly to avoid this problem one can put food grade lubricant instead of conventional non- food grade lubricant or oil. Equipments were we can expect a food contact are mixers , molders , dividers , oven , packing machines and accessories like oil spray , milk spray ,flour sifters , screw conveyors , sugar grinders and biscuit grinders .spreading units , conches mixers , laminators , depositors and gauge rolls. Compressed air does carry lubricating oil with it . special filters are attached at the output of the compressor to trap this oil. Oil free compressor are available but a bit costlier than normal compressor. Seals and gaskets generates leaks and spillages of lubricants .
These equipments need lubrication in intervals for smooth running and proper functioning of machines .Now due new technology in lubrication and oil industry we can get food grade lubricants . Here in Indian bakery plants it still to be popular . There are some misconception about food grade lubricants .
A lubricant qualifies as food grade when, in the event of a contamination, it is present in no more than 10 mg per kg of the foodstuff in question and must not cause any physiological hazard or affect the food's odor and taste in any way. Food-grade lubricants, such Shell Cassida, are special blends of base fluids and additives, and should be approved by the US FDA and registered by NSF International in the H1 category.
All major food safety management systems recommends using food grade lubricant in food processing and packaging companies .HACCP,GMPS,BRC,ISO22000,1SO14000, SQF,IFS
Major misconception s and facts about application of food grade in bakery plants.
Legend #1: Contamination by machinery lubricants with food and beverage during manufacturing doesn't happen.
Fact #1: It happens more often than we think. Most contamination is detected before the product leaves the plant - but some aren't.
Legend #2: I am pretty sure that the lubricants I use in my plant are all food grade.
Fact #2: Food grade lubricants are made from components approved by the U.S. Food and Drug Administration (FDA) for incidental contact with food. You can verify whether the lubricant is food grade or not by asking for a declaration of the formulation from the lubricant supplier, or by checking whether the product is H1 registered with a third party certifier such as NSF International.
Food-grade lubricants are readily available in the United States and a growing number of food and beverage manufacturers are using them. Any food or beverage processor not using food-grade lubricants is courting a huge risk. The FDA has set a "zero tolerance" for contamination by non-food grade lubricants and also governs the components that are allowed to make up a food grade lubricant. The US Department of Agriculture (USDA) formerly approved lubricants as H1 ("for incidental food contact") and published the list in what was commonly known as the "White Book." The USDA ceased this activity in 1998. NSF International has since taken over the "White Book" and now registers lubricants as H1 food grade. You can verify whether the lubricants in your plant are food grade by checking the list of NSF H1 certified non-food compounds on www.nsf.org
Legend #3: Food-grade lubricant performance is inferior to traditional lubricants. The lubricants don't meet the demands of my applications.
Fact # 3: Synthetic food grade lubricants are designed to meet a wide range of applications and generally outperform traditional food grade mineral oils.
Machinery used in food and beverage processing has many moving parts requiring lubricants to maintain reliable and efficient operation. Food and beverage contamination can occur from drips off chains, hydraulic hose failure, oil leaks from seals and gearboxes, or a release of compressed air containing an oily mist. Using traditional non- food grade industrial oils and greases is inappropriate in these settings.
Food-grade synthetic lubricants, such as Shell Cassida®, are odorless, tasteless and generally outperform established mineral oil-based lubricants. They are specially engineered for high performance remaining effective in the sub-zero cold of freezers and the high heat of ovens. Their increased oxidation and thermal stability, compared to a traditional mineral or white oil-based food grade lubricant, can extend equipment life and reduce downtime, which lowers maintenance costs.
As the FDA restricts the type and concentration of additives allowed to enhance food- grade lubricant performance, the critical performance factor lies in the lubricant's base oil itself. Synthetic base oil has superior technical characteristics over traditional white mineral oils.
Synthetic food-grade lubricants are designed for use in food and beverage manufacturing applications, improving lubrication properties and performance and offering excellent water resistance. Food-grade lubricants are harmless if accidentally consumed in quantities below the maximum FDA-prescribed level of 10 ppm (10 parts per million).
Legend #4: Food-grade lubricants cost more than mineral oil products.
Fact #4: Synthetic food-grade lubricants actually cost less in the long run, because they not only reduce overall maintenance costs, but also can reduce the risk of potential liabilities from using non-food grade lubricants.
Synthetics do cost more than traditional mineral oils, but the initial cost of the synthetic brings subsequent returns, against which a food grade mineral oil-based lubricant cannot compete. Further, damages that could arise from not using H1-approved food-grade lubricants are immeasurable.
According to the Japanese Institute of Plant Maintenance (JIPM), "up to 65% of mechanical equipment failures can be attributed to some form of lubrication deficiency."2 Lubrication failures lead directly to production losses, so a robust lubrication program plays an effective part in plant management.
Lubrication quality has a significant impact on equipment life. Field experience and case studies show that food-grade synthetics have a longer product life and need to be replaced less frequently in machinery. In many instances, results demonstrate up to four times more life with synthetic oils.
Legend #5: None of my equipment actually requires food-grade lubricants for food safety.
Fact #5: Food grade lubricants should be used wherever there is a chance of incidental contact with food or beverage products during manufacturing.
Lubricants used in manufacturing facilities can make their way into the food we eat. Oil and grease droplets can seep from bearings and conveyors, can seamers, bakery ovens and other critical points of operation.
Plant quality managers and maintenance managers should identify areas of potential lubricant contamination. Companies can assist by conducting a Lubrication Contamination Control Point (LCCP) survey, which forms part of the plant Food Safety Plan. For example, a Shell LCCP Survey is based on Hazard Analysis Critical Control Point (HACCP) principles and examines where the risks are in a plant, what they are and what can be done about reducing and managing them.
Food and beverage processing plants must prevent accidental lubricant contamination, which could potentially harm consumers and damage a company's brand and reputation. Synthetic food-grade lubricants can help minimize these risks, adding a buffer against contaminating our food supply.