GUIDE TO CTCPATECHNICAL EXPERTISE

www.ctcpa.org

FOOD PRODUCT DEVELOPMENT AND FOOD TECHNOLOGY - FOOD SAFETYMICROBIOLOGY - NUTRITIONAL QUALITY - PACKAGING

ENVIRONMENT AND SUSTAINABLE DEVELOPMENT

This guide was designed to facilitate collaboration between the CTCPA, its clients and partners that offer companies expertise and know-how within the food processing sector.

The skills provided by the CTCPA, technical centre for the Preservation of Agricultural Products provides the following skills are classified:• by topic (use tabs) • by keyword (index on last page)

Your dedicated representatives are the managers of the regional areas’ managers presented on the last page.

SUPPORT WITH YOUR PROJECT ............................................................................................4

FOOD PRODUCT DEVELOPMENT & FOOD TECHNOLOGY Innovation and product formulations: from the concept to pre-production ...................................6Characterisation of present products and formula optimisation .....................................................8Development and approval of preservation processes ....................................................................9Industrialisation ..............................................................................................................................12Technical audits ..............................................................................................................................13

FOOD SAFETYReference documents and regulations ...........................................................................................15Cleaning/disinfection of equipment and lines ...............................................................................16Support with crisis management....................................................................................................17Regulatory compliance of canned products ...................................................................................17

MICROBIOLOGYManagement of microbiology risk within the food processing industry ........................................19Ecology of industrial production lines and cleaning/disinfection ...................................................19Characterisation of micro-organisms: physiology and impact of processes ...................................20Behaviour of microorganisms within foods: challenge-test ...........................................................21Details of preservation process ......................................................................................................22Specificities of pasteurised fois gras process ..................................................................................22

NUTRITIONAL QUALITYNutritional and physical-chemical characterisation of products ....................................................24Specific analytical developments ...................................................................................................24Impact and processes optimisation ................................................................................................25Nutritional labelling and regulation no. 1169/2011 INCO ..............................................................25(support and advice with communication)

PACKAGINGPhysical-chemical characterisation of materials/packaging ...........................................................27Food contact packaging ..................................................................................................................27Support with the selection/creation of packaging .........................................................................28Packaging ecodesign .......................................................................................................................29Packaging and lifespan ...................................................................................................................29Diagnosis of packaging defaults .....................................................................................................29

ENVIRONMENT AND SUSTAINABLE DEVELOPMENTCarrying out a diagnosis and defining an action plan .....................................................................32Assessing the environmental footprint ..........................................................................................32Reducing energy consumption .......................................................................................................33Reducing water consumption and optimising sewage management .............................................33Optimising waste and by-products management ...........................................................................33

GLOSSARY ...................................................................................................................................34

CONTENTS

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TECHNICAL CENTRE FOR THE PRESERVATION OF AGRICULTURAL PRODUCTS

The general interest mission of the CTCPA

The CTCPA is the industrial technical centre (CTI) of canned and dehydrated foods. In this context, it receives hypothecated tax (TFA) from foreign businesses calculated on the turnover made from canned and dehydrated products. This budget enables it to finance the projects selected by foreign companies decided by subsidiary boards. Collective activities are:• supporting and representing the profession,• collective research,• promotion, diffusion and transfer.

CTCPA trainingThe CTCPA provides inter and intra business training (271 work placements in 2015), ranging from the technical 2-day work placement to the CQP type qualifying course. The CTCPA training catalogue is available upon request.

CTCPA servicesTo satisfy the individual needs of businesses, the CTCPA offers specific services in relation with all the issues linked with food processing: processes, packaging, food safety, microbiology, nutritional details, sustainable development, trainee engineering and documentation.These activities are of different forms depending on professionals’ requirements: technical support, recommendations, research and development (process, product, packaging), tests and pre-production within our CTCPA technology halls, factory audits, analytical expertises within the laboratory.

The CTCPA in numbersThe Technical Centre for the Preservation of Agricultural Products is an Industrial Technical Centre (CTI) which holds the title of Agro-industrial technical institute (ITAI) as provided by the Ministry of Agriculture. It is a member of Actia and of the CTI network. The centre has been recognized for more than 60 years as particularly competent when it comes to canned products, specifically the establishment and validation of heat treatment scales. The centre provides support to project leaders, artisans, very small and small and medium size businesses and large groups.

In 2015, the CTCPA held 7.7 million euros of operating income, of which 2.9 million euros for research and 3.3 million euros for services, relying on:

• 8 sites• 87 employees: 39 engineers of which

10 doctors and 2 doctorates, 20 technicians• 35 collective research projects• 1100 member companies across France• 750 private clients • Regional, national (UMT,

RMT) and European partners (European Food Institutes)

• Experts involved in national commissions: Anses, Afaq-Afnor, Efsa, State managed services, Codex alimentarius ...

• Partnerships with centres of excellence: PEIFL, Agri Sud-Ouest Innovation, IAR, Valorial, Vegepolys, Plastipolis ...

• Scientific recognition from numerous research projects.

• Various funding sources: European Union, National Research Agency, Interministerial Single Fund, FranceAgriMer, Cifog, BPI France, Regions, Innovation Agencies, ARIA, COOP of France within the region, Opcalim...

• Participations in working groups and commissions. • Ability to mobilise networks to set up and coordinate collaborative projects (Mixed Research unit, Mixed theses Research unit…)

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SUPPORT WITH YOUR PROJECT

Your CTCPA representative will assemble a team able to respond to your needs/issues relying on its in-house expertise and if required, its external network.

Your contact will also help you with financing options: • Research Tax Credit (CIR): the CTCPA is automatically approved by the CIR as an industrial technical centre where projects are eligible. In this context, invoices issued as part of R&D work can be taken into account for double the amount on the CIR basis of the business. • Innovation Tax Credit (CII): some CTCPA benefits are eligible. • Capacity building Funds/ BPI France Expertises: CTCPA experts are recognized and can take part in these mechanisms. • PTR, FRAC, FRAI, ... : CTCPA support may be financed by various national and regional measures.

Regional skills available (general case): your local representative fully manages your project, bringing in, if necessary, other co-workers

Expertise: if your request necessitates a national specialist,it will be transferred to the relevant expert who will come back to you directly

Multidisciplinary project: if your request necessitates multiple expertises, it is managed by the sales team who creates and coordinates a relevant internal project

team, bringing in any necessary external experts

Your call/email

Local regional contact

First meeting to des-cribe your issue

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F O O D P R O D U C T D E V E L O P M E N T A N D F O O D T E C H N O L O G Y

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Innovation and product formulations: from the concept to pre-production

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Thanks to a group of technical experts and in-house equipment, the CTCPA will fully support you in the development of new food products. Starting from the concept and up to the commercialisation of pilot productions, you control your innovation project and gradually test the technical, commercial and financial suitability. We provide support in relation with products itended for all types of target markets: large retailers, restaurant business, individualised welcome projects.

The CTCPA has great experience with the formulation of products, identifying new trends and proposing recipes that fit your objectives. We also work on request in partnerships with chefs or master artisan caterers, butchers, bakers…

More than thirty projects completed per year (see the customer testimonials on our website).

Whether you are a business owner, very small business, a small or medium sized business or a large group, the CTCPA offers you an innovation approach suited to your situation, needs and budget. You will then gradually move forward based upon the results and the development of your project.

• Idea generation: defines the target product/market, proposes recipes, formulas according to current trends, s specification details, development plan.

• Pre-feasibility study: production of initial mock-ups in our halls, assessment of feasibility, presentation to client.

• Formulation: the CTCPA creates or improves your formula and establishes the first samples for optimal organoleptic selection.

• Optimisation and pre-production: optimisation of formulation and/or process with the pilot tool, validation by client, production of samples-tests and pre-production for the company and its clients (small and medium sized range of a few hundred products).

• Technical-economic study: the CTCPA helps you calculate investment costs based upon the desired size, the industrial cost price and the return on investment.

• Specifications: the CTCPA helps you draw up the functional specifications of materials, packaging or ingredients required for production and helps you select suppliers.

• Transfer: the CTCPA supports you with the launch of production and trains your employees.

At each stage progress will be discussed to decide how to move forwardfor the next steps.This approach applies to product, process or packaging innovations.

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• Products: cooked dishes, processed fruit and vegetables, meat, cooked meats, foie gras, preserves, fruit juices, purée, baby food, dry and soft biscuits, pastries, fish and seafood, regional specialties, sauces, ...

• Processes: fresh, fresh ready-to-use salads and vegetables, sterilisation, pasteurisation, candying, fast freezing, cooking: continuous, interrupted and aseptic processes.

• Packaging: metal box, glass box, punnet, bag, pouch, box, cups, plates.

The formula may be optimised across the following areas:

• Organoleptic: taste, texture, appearance

• Nutritional : calories, composition (salt, sugar/gluten-free, health claims…)

• Shelf life: extension of best before date, change of preservation model

• Marketing : substitution of some primary materials, clean label, vegan

• Economics : reduction of the costs of primary materials…

Main tools implemented:• tasting,• analysis of texture,• nutritional analysis: analytical including theory,• physical-chemical analysis: water content, water activity (Aw), pH,• microbiology analysis,• labelling classification.

u Protocol adapted to the issue and matrix (product/process)

Characterisation of present products and formula optimisation

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Development and approval of preservation processes

Heat treatments: pasteurisation, sterilisation

• Establishment and optimisation of sterilisation/pasteurisation scalesThe historical core activity: The CTCPA represents the reference professional centre for the establishment and approval of heat grading scales for canned products (memorandum DGAL/ SDSSA/N2011-8153).The centre is also in charge of drawing up the Subsidiary's Guide to Good Hygiene Practices (GBPH).

Control of pasteurised and sterilised product safety:Scales are developed and optimised according to product and equipment specificities on the one hand, and to the envisaged preservation conditions, on the other hand.

Some elements governing approval and optimisation of scales :• Are the sterilisation/pasteurisation target values suited to the microbial product content?• What time/temperature ratio should be applied in light of product fragility? • Does the equipment enable homogenous attainment of this temperature?

u Extend your best before date or improve the quality

• A large range of expert tools (heat probes, on-board sensors) and pilot equipment (cells, autoclaves, ovens),

• more than 50 industrial interventions per year on sterilisation/ pasteurisation scales,

• CTCPA leads numerous research programmes on heat treatments, development of tools on counter-pressure, ...

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• Mapping of heat treatment enclosures (autoclaves, cells, tunnels)

Validation of enclosures:• Thanks to a large range of suitable and calibrated measuring tools• According to protocols established in compliance and based upon international references

• Validation of heat procedures

• Heat risk mapping of enclosures• Identification of minimum heat intensity within

critical product and process conditions• Microbiology verification of process suitability

• Continuous heat treatmentsSupport with identification of continuous heat treatment scales according to installation and product specificities.

Tools: pilot apparatus enabling the measurement of potential advantages of a continuous process process when compared to an on-site discontinuous process.

• Ohmic heatingThe continuous Joule effect treatment enables the treatment of numerous fragile, viscous products, with or without fragments, by reducing the cooking effect of the heat treatment.

Products treated: • whole or cut up fruits and vegetables, purées, fruit compotes, fruits and vegetable salads, juices,• cooked dishes in sauce with pieces, made up of meat or fish products,• soups,• tomato-based sauces, emulsified sauces, white sauces,• rice and pasta in sauce,• herbs,• cheese based items...We support about ten businesses a year.

Available at CTCPA: a horizontal pilot and a vertical pilot

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• International export (FDA, others...)• Implementation of technical protocol• Completion of tests • Establishment of results• Report writing in a foreign language• Exchanges with local authorities regarding technical requests

Heat-resistant processes

• High pressure

High pressure technology enables decontamination with the application of pressure to a liquid containing products which are to undergo the treatment. It can be connected to different packaging systems according to the sought-after application: bottles, punnets, skin packages, bags,...to increase the best before date of numerous products. High pressure is suited to products sensitive to temperature and enables "cold" pasteurisation of products. This process is known to be "Listeria free" in the United States.

Treated products: • cold meats, poultry, beef, cooked dishes,• fruit juices, fruit compotes,• energy drinks,• fish,• seafood (oysters, shellfish, crustaceans),• vegetable dips such as guacamole,• rice,• foie gras products,• baby food,• pet food.

The positive feedback of Anses in 2010 with regard to these cases led to the technology being implemented across the country.

Available at CTCPA: a pilot on the HPP Atlantique platform in Nantes where the CTCPA is a partner + a laboratory pilot in Avignon

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• Pulsed light

An alternative to the physical and chemical decontamination process, bright light flashes significantly destroy food product or packaging on the surface.

• Validation of pulsed light biocide effectiveness• Composition of the process authorisation report and monitoring of report by the relevant authorities• Industrialisation: size of the machine, suitability to the site

Available at CTCPA: a ILHDE pilot (pulsed light)

Additional preservation processes

To extend the preservation life of some fresh products by a few days or weeks: • gaseous ratios within modified atmosphere (meat, fresh vegetables, ready-to-use salads and vegetables), • cooking profiles for vacuum packed products (meats, cooked dishes), • frying (vegetables)... • ready-to-use salads and vegetables and chemical decontamination.

Industrialisation

Dimensioning and industrialisation of production line and material to securean investment for:• the creation of new activities,• the development of new products,• the construction of a new production unit,• the optimisation of industrial line productivity,• the restoration of a site,• the improvement of processes and competitiveness.

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• Proposed approach:

• Creation of industrial master plan

• Establishment of technical specifications: - draw up technical specifications for each material which is included in the process, based upon the selected master plan, - consideration of process parameters and the target performance levels.

• Comparative technical-economic study of offers: - consulting multiple potential suppliers for each piece of equipment, - presentation of different options with the related costing.

• Decision support for strategy and investment choices

• Line engineer advice: - consideration of flow management (materials, personnel, fluid), - receipt of materials at the equipment manufacturer in collaboration with your new work service or engineering office.

• Support with the start set up and initiation of the line

• Validation of material performance: - heat risk mapping, - validation of continual heat treatment line sterility and aseptic packaging with the help of biotests, - validation of new economic policy.

Technical audits

In the event of a technical issue, the following actions are undertaken: • visit of installations, • review of documentation, • interview with employees, • identification of major and minor causes, • areas for improvement.

FOODSAFETY

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Reference documents and regulations

• Sanitary management plan and HACCP plan

Satisfying European regulation requirements and management of manufactured product sanitary safety.

• Implementation of recommendations and team training (integration/improvement • Management of documents: technical files right up to the HACCP plan • Management of production tools and compliance with manufacturing recommendations • Analysis of dangers and validation of measures (co-construction with entities overseeing quality) • Support with assembling the European sanitary approval file • Establishment of Sanitary Management Plan (PMS)

The CTCPA draws up Guides to Good Hygiene Practices for the profession

• IFS, BRC, ISO 22000, ISO 9001 certifications

Simple, pragmatic and progressive system adapted to each business. • Diagnosis of implemented systems according to the selected reference document and establishment of an action plan• Technical expertise: allergens, OGM, traceability, foreign bodies, food compliance, process• Mock audit• Personnel training: managers, HACCP teams, supervisory staff, relevant operators

• Regulatory dossiers: Novel Food, technology compliments

Drawing up technical-regulatory files to approve new processes, new ingredients, additives or the use of complementary technologies as part of food processes.

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• Quality reference: free website

Interactive tool developed by Actia, the CTCPA and a group of experts to make it easier for food professionals to incorporate the requirements of the different standards. This website incorporates updates of IFS 6, BRC 6 and BRC IoP 4 references and standards.

• Fraud, Food protection: prevention and management

Support with the implementation of an in-house managed security plan: • confidential audit of present situation,• intrusion test,• threat assessment,• vulnerability assessment,• implementation of security measures in compliance with crisis management and the Business Continuity Plan.

The CTCPA provides an IT tool to conduct this study

Cleaning/disinfection of equipment and lines

• Sanitary concept

The CTCPA’s support enables:• the establishment of a line sanitary concept,• the integration of sanitary concept requirements within the specifications,• the monitoring of the concept by equipment suppliers • the checking of the cleanliness of industrial installations.

• The CTCPA ensures vice-presidency of EHEDG France (French association of the European Hygienic Engineering Design Group).

• Coordinator of RMT Actia Chlean Pass which aims at gathering knowledge about the sanitary concept applied to equipment, lines and workshops.

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• Audit and expertise of cleaning/disinfection plans

• Status of places to which the cleaning is applied: method, application, cleaning of equipment and checking of cleaning and disinfection• Improvements based upon your objectives: microbiology, allergens, energy savings• Support with drawing up the specifications for On-site Cleaning certification: definition of expected functions, analysis of the technical proposals of suppliers, development proposals, audit of relative effectiveness• Microbiology audit overseeing checking the disinfection

Support with crisis management

• In the event of an emergency, one direct number to contact CTCPA (telephone number: 04 90 84 30 48). Outside of CTCPA opening times, the messaging service will allow you to explain the issue and it will be answered • The CTCPA coordinator assesses the situation with the company and defines the possible immediate actions required. • Experts will be called upon based on required expertise.

Free for CTCPA members, and also available for other businesses

Regulatory compliance of canned products

The quantitative and qualitative controls enable to analyse that the delivered lots are compliant and to recommend solutions in the event of non-compliance. This will take place in the CTCPA macroscopic laboratory or within the factories.

The CTCPA writes up the Decisions: documents approved and recognized by DGCCRF to define fair and merchantable practice to sell canned products within France

 

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MICROBIOLOGY

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• Process improvement: • management of sources of contamination and areas of proliferation on the line, • optimisation of heat treatment, preservation • extend the best before dates of fresh, pasteurised • ready-to-use salad and vegetable products.

• Identification of the causes of microbiology incidents: • rapidly provide targeted corrective actions

Field: • bacterium, mould and yeast, • flora alterations and pathogens, • spores.The tools: • knowledge of micro-organisms (physiology, • ecology), • knowledge of industrial processes, • thermobacteriology expertise, • a bacterial and fungal collection of over 2000 • industrial isolates, • a molecular biology laboratory.

Management of microbiology risk within the food processing industry

Management at every stage of the production process

Ecology of industrial production lines and cleaning/disinfection

• Identification of microbial ecology on production line and validation of the effect of decontamination of the cleaning/disinfection stages on relevant flora: • Visit to line and the production environment • Study of production and historic data • Tests and sample analysis • Identification • Typing19

Manufacturing Treatment PreservationRaw materials

• CTCPA microbiologists are familiar with the industrial processes and therefore understand the challenges.• Interventions on all product types (fresh, frozen, preserved, ...).

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• Identification of origins of microbiology defaults (preservation, alteration, pathogens) :- characterisation of microbial flora/identification, labelling- establishment of line ecology,- verification of the effectiveness of cleaning/disinfection,- adequate treatment,- optimisation of control plan.

• Definition of areas for improvement for production line hygiene corrective actions

Support from all CTCPA experts to complete diagnosis if required (packaging, technology, concept of hygiene…)

Characterisation of micro-organisms: physiology and impact of processes

• Collection of industrial environment isolated strains

• Production of spores for laboratory or pilot tests, solvent and purification of strains - yeast, - mould, - bacteria.

• Measurement of thermoresistance - with capillary action - with a thermoresistometer

• Measurement of chemical resistance - biocide - sporicide

• Measurement of heat-resistance - UV, pulsed light, ILHDE, - high pressure, - hydrogen peroxide.

• Measurement of growth (See Challenge-test)

Available at CTCPA: a thermoresistometer to simulate industrial scales within the laboratory in a quicker and cheaper way

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Behaviour of microorganisms within foods: challenge-test

• The challenge-test process Study on the development of the population of micro-organisms added to a product prior to a manufacturing process stage such as heat treatment.

• The product challenge-test Study on the growth of micro-organisms added to food at the end of manufacturing (i.e. to end product). In such a case, the development of the population is studied during preservation.

• The process-product challenge-test In such a case, the development of the population is studied during preservation following a sublethal treatment.

The CTCPA is a partner of the Sym’Previus consortium and uses the Sym’Previus software for simulations and growth probabilities.

• The CTCPA has settled a Challenge-test unit to respond to your questions and needs on microbial flora. • The CTCPA is recognised by DGAL (Direction générale de l’alimentation – Ministère de l’agriculture - General Food Management - Ministry of Agriculture) as a competent laboratory to conduct challenge-tests with Listeria monocytogenes in food in the context of application of Article 3 of EC Regulation No. 2073/2005.

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Details of preservation process

• EMaiRIT’S (Expertise within Management of Industrial Risks of Thermoresistant Form Spores) Microbiology Unit • expertise of non stable, modified preserved foods, • identification of flora responsible for alteration, • analysis of packaging: waterproofness and fastening, • effectiveness with process.

• Count and identification of spores:• NF V 08-602 standard method, • internal method specific to Thermophiles Highly Thermoresistant (THT), • internal detection and identification method using molecular biology (STQ).

• Microbiology validation of continuous heat process: • use of biotests to validate sterilisation, • use of aliginate bead inoculum to validate the scale.

Thanks to more than 20 years of research and expertise on microbiological form spore risk management within the canned food sector, the EMaiRIT’S microbiology unit has:

• in-detail knowledge of products and relative microbiology, • expertise of processes and relative microbial ecology, • great recognition of the industry and protection services as well as the scientific community.

Specificities of pasteurised fois gras process

• Characterisation of psychrotrophic/psychrophile flora• Identification: specific internal molecular biology method (SporetraQTM)• Count: internal method specifically focused on alteration psychrotoph/ psychrophile foam spore flora• Management of spoiled foies gras • Identification of source of spoilage

Available at CTCPA: an anaerobic area to grow Clostridium psychrophiles

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NUTRITIONALQUALITY

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NUTRITIONALQUALITY

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Nutritional and physical-chemical characterisation of products

• Proposed analysis: • antioxidant vitamins: A, E and C, • folates: vitamin B9, • total and/or specific polyphenols (such as anthocyanin), • total and/or specific carotenoids, • antioxidant power: ORAC and FRAP, • antioxidant enzymes: polyphenol oxydase, peroxidase and lipoxygenase, • structure enzymes: pectin methylesterase, polygalacturonase, • paracetic acid and H2O2.

• Sudied matrices: • all plant products: fruits, vegetables, plants, algae, • natural raw materials/processed products, • biological samples for clinical studies (plasma and urine).

Specific analytical developments

• Development of analytical methods on demand => With and without inclusion of protocol.• Adaptation to requirements and access to the laboratory.

Impact and processes optimisation

• Impact of storage• Impact of transformation (oxidization, washing, division, ..)• Assessment of the impact of each manufacturing stage on a product and identification of areas for optimisation (quantity of nutrients)• Comparison of technologies• Nutritional audit: characterisation of ingredients and process, latest developments, regulations, nutritional profile• Modelling and benefit-risk approach• Prediction on the future of a nutrient based upon input data (time, temperature, oxygen)• Development of new products and nutritional optimisation through formulation.

Nutritional labelling and regulation no. 1169/2011INCO (support and advice with communication)

• Establishment of nutritional information to be labelled according to the INCO regulation using calculation and/or analysis • Support with nutritional communication: allegation files, publications

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PACKAGING

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Physical-chemical characterisation of materials/packaging

• O2 permeability, water vapour, CO2,…(breathable materials with huge barrier)• Thermal properties, microstructure (DSC, DMTA, gaseous pycnometer), water sorption• Analysis of packaging structure (Identification of layers using IRTF and IRTF imaging, Determination of layer thickness)• Mechanical tests (traction, tear, rigidity, slide, peeling…)• Functionality tests (opening ; prehension, heat resistance…)• Waterproofing, performance and sealing tests

• These tests are completed as part of: • quality checks, • a comparison of material performance, • approval of suppliers, • verification of the effectiveness of packaging functionalities, • packaging optimisation projects, • validation of packaging concepts, • research on source of defaults, • resolution of issues with lines or logistics, • studies on the impact of the process on barrier, mechanical performance …

Food contact packaging

Optimise the analysis to be completed at the fairest price.

• Regulatory expertise (national, European, USA) and assembly of regulatory files: • supplier contact, assembly of regulatory file, completion of targeted analysis and regulatory extrapolation of the results achieved, • on-site training followed by monitoring of teams to increase autonomy.

• Completion of migration tests: • globally as per ISO/IEC 17025 (Cofrac No. 1-5328), • specific (phthalates, BPA, antioxidants, anti-UV, anti-static, hazardous agents, etc...).

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*

*COFRAC Essais, reference source: NF EN ISO/CEI 17025, Accreditation n°1-5328, available on www.cofrac.fr

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• Modelling of transfer phenomena • Study of compliance of specific migrations using digital tools alongside or instead of analytical tests.

• Development of regulatory strategies and analytical methods to: • assemble the substance authorisation or process file for French (ANSES) and/or European (EFSA) authorities (plastic materials treated with ionising rays, recycling files, impact of high pressure treatments on packaging, active packaging, etc..). • research on the effects of the application of legal texts such as BPA, phthalates, neoformed compounds (NIAS: Non-intentionally added substances - extraction, identification, quantification, even evaluation of associated risks. • include technical elements in view of organoleptic deviations associated with materials; subject of "off flavours".

Support with the selection/development of packaging

• Multidisciplinary expertise to cover: • innovation projects combining all food quality requirements, • the control over chemical and microbiological risks, • the reduction of the environmental impact of the packaging-product combination.

• Tools: • packaging technology monitoring and prospective analysis, • design of innovative packaging solutions, • establishment of specifications, • support with selecting materials and suppliers, • validation of packaging/product combination, • study on product/process suitability, • tests and pilot series, • studies on ageing.

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Packaging ecodesign

• Global ecodesign approach (package/product combination) or focused on minimising the packaging impact: • reduction of film thickness, • switch from glass to plastic and reduction of packaging weight, • study to explore substitution options such as biopolymers.

Packaging and lifespan

• Ageing studies (heat, heat-resistant stress oxidant*, hygrometric, under light) suited to the product/packaging combination: • anticipate sensorial and physical-chemical developments using a timeframe which is much shorter than the genuine lifespan, • check new recipes, • compare the packaging preservation performance, select an optimal packaging based on the process, • estimate or validate a lifespan.

Diagnosis of packaging defaults

• Intervention using samples in the laboratory and within manufacturing sites: • in the event of an issue with packaging: leaks with soft packaging (sealing, perforations…) or boxes (set check), • in the event of packaging defaults: - during manufacturing, processing, - during logistics.

* Unique accelerated ageing oxygen-pressurised method for long-life products in plastic packaging.

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• Proposed approach: • analysis of defective products, • research on source of default, • on-site diagnosis, • corrective action recommendations within the factory, • validation of packaging used, • personnel training...

• Innovate by optimising the 7 packaging functions: • preserve the food quality, • anticipate the microbiological risk, • preserve the physical shape of the packaging and relative content, • anticipate the chemical risk, • protect the environment, • satisfy economic requirements using suitable materials and processes, • communicate with consumers.

• Test new materials, specific formulations by implementing small scale technical prototypes (10g to 10kg) in the form of sheets, cast films: • formulations screening, blends, • biomaterial tests, • recycled materials, • non easily movable foods, • comparison of resins, • incorporation of absorbers.

These technical prototypes are compatible with the application of most analysis proposed by the laboratory.

1 * Unique accelerated ageing oxygen-pressurised method for long-life products in plastic packaging.

ENVIRONMENTAND SUSTAINABLE

DEVELOPMENT

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Carrying out a diagnosis and defining an action plan

• Assessment tool dedicated to Food Processing Industries (IAA)

It was developed to assess the company’s overall operational performance by simultaneously analysing the environmental performance, the industrial performance and the health quality: • Diagnosis within 2.5 days: global vision and identification of targeted improvements (reorganisation of line, production plan, reduction of water and energy consumption...) • Proposal for a more detailed «expert» diagnosis if needed • Action plan implementation and monitoring

• Corporate Social Responsibility assessment kit

The tool was developed by ANIA and ACTIA with the support of CTCPA to implement a pragmatic and progressive approach to social responsibility: • operational adaptation of ISO 26 000, based upon food processing business challenges and practices, • assessment charts organised per topic together with a synthesis tool: - support with establishing initial diagnosis, - implementation of an action plan.

Assessing the environmental footprint

•Life Cycle Analysis: • improving the knowledge regarding the environmental impacts generated by the product over the life cycle (raw materials, manufacturing processes, transport, end of life...), • identifying the main contributors in terms of the environmental impact, • comparing products and processes.

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The CTCPA holds user licences for the Simapro Life Cycle Assessment software and for the Bilan Carbone® software.

Reducing energy consumption

• Establishment of energy measurements and pre-diagnosis• Support with the establishment of a counting plan in order to reduce consumption of consumption

Audits of energy consumption of grain product cooking ovens conducted with Cetiat.

Reducing water consumption and optimising sewage management

• Factory audit based upon manufacturing processes (quality of water used and assessment of consumption by measuring)• Expertise in industrial hygiene: hygienic design of equipment, use of water within cleaning-disinfection procedures • Concrete recommendations for the different stages in accordance with available technical solutions: preparation of product, washing, whitening, cooling, hydraulic shipping, steaming, sewage treatment

Optimising waste and by-products management

Being involved in numerous collective research programs related with available options for the use of by-products, the CTCPA can provide you support to analyse the various ways to use and add value to your waste and by-products.

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Allegation ..................................................... 25Autoclave ........................................................... 9, 10

Best before date ............................ 8, 9, 11, 19BRC .................................................................. 15, 16

Carbon footprint .......................................... 32Challenge test ......................................................... 21Cleaning-disinfection ...................... 16, 17, 19, 20, 33Continuous heat treatment .............................. 10, 22Corporate Social Responsibility: Ania/Actia kit....... 32Crisis management ........................................... 16, 17

Ecodesign ..................................................... 29Energy ......................................................... 17, 32, 33Environment ................................... 19, 20, 28, 30, 32

Factory audit................................................. 33FDA expertise ......................................................... 11Food contact packaging .......................................... 27Food protection ...................................................... 16Food safety management ........................... 15, 16, 17

Glass box ........................................................ 8Guide to Good Hygiene Practice (GBPH) ................ 15

HACCP ........................................................... 15Heat treatment ................................. 9, 10, 13, 19, 21High pressure ............................................. 11, 20, 28Hygiene................................................... 9, 15, 20, 33

IFS ........................................................... 15, 16Industrialisation ...................................................... 12Innovation ...................................................... 6, 7, 28ISO 22000 ............................................................... 15

Laboratory ...........11, 17, 19, 20, 21, 24, 29, 30Leaks ....................................................................... 29

Mapping of heat treatment enclosures ........ 10

Metal box ................................................................. 8Microbiology ........................................ 17, 19, 20, 22

Novel Food ................................................... 15Nutrient .................................................................. 25Nutritional .................................................... 8, 24, 25Nutritional labelling ................................................ 25

Ohmic heating .............................................. 10Optimisation ........................7, 8, 9, 12, 19, 20, 25, 27

Packaging 7, 8, 11, 12, 13, 20, 22, 27, 28, 29, 30, 32Food contact packaging .......................................... 27Packaging innovation ................................................ 7Packaging optimisation........................................... 27Pasteurisation ................................................. 8, 9, 11Pasteurisation value ................................................. 9Permeability ........................................................... 27Pre-production ..................................................... 6, 7Pulsed light ....................................................... 12, 20

Reference documents ................................... 15RSE: kit Ania/Actia .................................................. 32

Sanitary concept ........................................... 16Sanitary management plan .................................... 15Scales validation ........................................... 9, 10, 20Soft packaging ........................................................ 29Sterilisation ..................................................... 8, 9, 22Sterilisation value ..................................................... 9Sustainable development ........................... 31, 32, 33Symprevius ............................................................. 21

Technology ....................................... 11, 15, 20Thermoresistance ................................................... 20Traceability ............................................................. 15

Water ...................................... 8, 22, 27, 32, 33

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