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Chapter 6 : Production of Powdered Infant Formulae and Microbiological Control Measures

Author: Jean-Louis Cordier1
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Affiliations: 1: Nestlé Nutrition, Avenue Reller 22, CH-1800 Vevey, Switzerland
Content Type: Monograph
Publication Year: 2008

Category: Applied and Industrial Microbiology

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Abstract:

This chapter talks about infant formulae that have been included in the Commission Directives and linked to outbreaks related to the presence of as well as of and therefore need to be manufactured according to the principles i.e., according to very stringent hygiene measures. Powdered infant formulae can be subdivided into different product categories. Milk-based formulae are based on either casein or whey as the predominant source of proteins, with some of them being based on partially hydrolyzed proteins to reduce their allergenicity. The wet-mix and combined processes can be subdivided into two very distinct parts: (i) the wet part, from the reception of raw materials and ingredients up to the drying, and (ii) the dry part, from the drying up to the filling. In the dry-mix processes, all operations performed after the drying and up to the filling are exclusively dry operations. Effective monitoring plans are based on the analysis of different types of samples, reflecting the relevant elements that have an impact on the microbiological quality of the powdered infant formulae. Recommendations made by manufacturers on the safe use of the products are related to the storage and handling conditions after reconstitution of the powders.

Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6

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Production of Powdered Infant Formulae and Microbiological Control Measures
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Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6
/content/10.1128/9781555815608.ch06.ch06fig01
Figure 1
Example illustration of a processing line with the wet-processing and the dry-processing steps. (1) Unprocessed agricultural raw materials; (2) dissolution of processed ingredients; (3) standardization tanks; (4) clarification; (5) heat treatment (direct steam injection; CCP); (6) evaporation; (7) addition of vegetable oils (dry-mix ingredient); (8) high-pressure pumping; (9) spray drying in tower; (10) drying in after-dryer; (11) addition of vitamins (dry-mix ingredients); (12) filling. This is only an example, and different layouts and processing steps are possible (e.g., mixing and intermediate storage in the dry-processing part of the process).
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Image of Figure 1
Figure 1

Example illustration of a processing line with the wet-processing and the dry-processing steps. (1) Unprocessed agricultural raw materials; (2) dissolution of processed ingredients; (3) standardization tanks; (4) clarification; (5) heat treatment (direct steam injection; CCP); (6) evaporation; (7) addition of vegetable oils (dry-mix ingredient); (8) high-pressure pumping; (9) spray drying in tower; (10) drying in after-dryer; (11) addition of vitamins (dry-mix ingredients); (12) filling. This is only an example, and different layouts and processing steps are possible (e.g., mixing and intermediate storage in the dry-processing part of the process).

Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6
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Figure 2
Impact of improved hygiene measures on the occurrence of in skim-milk powder (U.S. Department of Agriculture surveillance program data); adapted from Mettler ( ).
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Image of Figure 2
Figure 2

Impact of improved hygiene measures on the occurrence of in skim-milk powder (U.S. Department of Agriculture surveillance program data); adapted from Mettler ( ).

Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6
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Figure 3
Illustration of the fluctuations in the levels of in environmental samples from high-hygiene areas as a function of the presence of water. In case of an ingress of at very low levels (which would have occurred between days 270 and 330) remaining undetected during monitoring, the presence of water would invariably lead to an increase of the pathogen, putting the production lines and the product at risk (a hypothetical example is used for illustration).
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10.1128/9781555815608/f0166-01.gif
Image of Figure 3
Figure 3

Illustration of the fluctuations in the levels of in environmental samples from high-hygiene areas as a function of the presence of water. In case of an ingress of at very low levels (which would have occurred between days 270 and 330) remaining undetected during monitoring, the presence of water would invariably lead to an increase of the pathogen, putting the production lines and the product at risk (a hypothetical example is used for illustration).

Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6
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Figure 4
Evolution of the levels of environmental following the implementation of the stringent hygiene measures described in the text at around the fourth month. The target level is <10 CFU/g. Values of >10 CFU/g, <100 CFU/g, and >100 CFU/g automatically trigger an increase of the testing frequency of finished product for both and other . The question mark in the key at upper left indicates “>” (greater than).
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10.1128/9781555815608/f0169-01.gif
Image of Figure 4
Figure 4

Evolution of the levels of environmental following the implementation of the stringent hygiene measures described in the text at around the fourth month. The target level is <10 CFU/g. Values of >10 CFU/g, <100 CFU/g, and >100 CFU/g automatically trigger an increase of the testing frequency of finished product for both and other . The question mark in the key at upper left indicates “>” (greater than).

Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6
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Figure 5
Comparison of the mean concentrations of (EB) (90% credibility interval) in powdered infant formulae manufactured in five different factories before (2002) and after (2004) the introduction of the more stringent control measures described in the text.
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10.1128/9781555815608/f0170-01.gif
Image of Figure 5
Figure 5

Comparison of the mean concentrations of (EB) (90% credibility interval) in powdered infant formulae manufactured in five different factories before (2002) and after (2004) the introduction of the more stringent control measures described in the text.

Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6
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Figure 6
Evolution of the levels of environmental in processing environments in a factory switching from the production of powdered infant formulae to other dry dairy products with different microbiological requirements ( must be absent from 1-g samples) but equivalent requirements for . The key at upper right indicates numbers per gram.
10.1128/9781555815608/f0172-01_thmb.gif
10.1128/9781555815608/f0172-01.gif
Image of Figure 6
Figure 6

Evolution of the levels of environmental in processing environments in a factory switching from the production of powdered infant formulae to other dry dairy products with different microbiological requirements ( must be absent from 1-g samples) but equivalent requirements for . The key at upper right indicates numbers per gram.

Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6
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Tables

Production of Powdered Infant Formulae and Microbiological Control Measures
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Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6
/content/10.1128/9781555815608.ch06.ch06tab01
Table 1
Estimates of the worldwide production of infant formula
Generic image for table
Table 1

Estimates of the worldwide production of infant formula

Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6
/content/10.1128/9781555815608.ch06.ch06tab02
Table 2
Number of positive samples in three major dry-mix ingredients and illustration of the improvements over 2 to 3 years
Generic image for table
Table 2

Number of positive samples in three major dry-mix ingredients and illustration of the improvements over 2 to 3 years

Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6
/content/10.1128/9781555815608.ch06.ch06tab03
Table 3
Current situation (2007) with respect to microbiological criteria for infant formulae at Codex Alimentarius and EC levels
Generic image for table
Table 3

Current situation (2007) with respect to microbiological criteria for infant formulae at Codex Alimentarius and EC levels

Citation: Cordier J. 2008. Production of Powdered Infant Formulae and Microbiological Control Measures, p 145-185. In Farber J, Forsythe S, Doyle M (ed), . ASM Press, Washington, DC. doi: 10.1128/9781555815608.ch6

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