For a copy of the original document, contact the NJ Department of Public
Health
(609) 588-3123
This document was transcribed by the office of the Extension Specialist
in Food Science at Rutgers, The State University of NJ, Don Schaffner Ph.D.
(732) 932-9611x214
schaffner@aesop.rutgers.edu
A. Pre-harvest
Care of apples to be used for processing into fresh cider begins in the
orchard. Cider makers buying or harvesting apples for processing should
learn about production practices and care before accepting them.
Animal manure and bio-solids should not be used in apple orchards. No animals
should be allowed to graze in an orchard from which apples might be used
for processing into fresh apple cider. In areas with high deer populations,
fences or other devices to restrict access should be used. Make every effort
to prevent wild and domestic animals from entering or living in your orchard.
Food material from animals may contain pathogens such as E. coil 0157:H7,
Salmonella and Cryptosporidium as well as other contaminants.
If controls are not available, apples should not be picked from the ground
for use in fresh unpasteurized cider.
Pruning waste and other brush should he removed from the orchard and disposed
of or properly recycled. This practice plus adequate mowing encourages animals
to seek habitat outside of the orchard. Fruit soiled by birds can also contain
pathogenic bacteria and should not be used in unpasteurized apple juice
or uncooked apple products.
B. Harvest
Pickers should be regularly instructed to thoroughly wash their
hands with warm water and soap, or to use an anti-microbial soap or hand
sanitizer after each use of toilet facilities. Signs should be posted in
toilet areas reminding pickers to wash their hands before returning to work.
Hand washing or other hand sanitizing facilities should be available to
pickers and other help in remote orchards or remote portions of larger orchards.
The Worker Protection Standard requires that such facilities be located
within 1/4 mile of where the work is taking place . It is recommended
that growers provide mobile facilities that accompany workers to the work
site.
Apples should be picked into clean containers, free of dirt and debris.
Boxes, field bins and other containers should be used exclusively for fresh
apples, and should not be used for storing debris, garbage, or other non-food
materials.
Runners on field bins should be cleaned to prevent contaminating apples
in lower bins, if stacked. If field bins are contaminated with soil, they
should be washed in a manner to avoid splashing soil or debris onto other
containers.
If harvest controls are in place and dropped apples are used they should
be picked up daily to reduce the time in contact with the ground. Cider
makers using drops must take additional steps to reduce the potential for
fecal contamination from animal waste and soil. Such controls include, but
are not limited to double washing and double-brushing of apples before processing,
use of sanitizers in the washing/brushing process and continuous inspection
of apples being processed to remove damaged or decayed fruit.
C. Plant Construction/Facilities
- Cider processing operations must be located in an enclosed room or building
separated from other activities not related to food production.
- The processing and filling areas must be physically separated from apple
storage and other work areas.
- Floors must be of concrete or other impervious and cleanable
material and must have adequate floor drainage. Walls and ceiling in
processing, bottling areas and refrigerators must be constructed
of easily cleanable and impervious materials.
- Doors must he tight fitting and restrict insect and rodent entry. Doors
and windows that are open must be adequately screened.
- Adequate lighting must be provided in all areas of the facility. Light
fixtures must be shielded in the processing and filling areas end wherever
apples or cider are exposed.
- Hot and cold running water of sufficient volume and pressure for processing
and cleaning needs must be available in processing and filling areas. The
use of high-pressure washers or other washers using hot water or steam is
recommended.
- Water from other than municipal sources must
he tested for potability (coliform and nitrates) before beginning
seasonal pressing operations and every 3 months thereafter.
- Enclosed toilet facilities conveniently located to the
work area must be provided. A hand washing sink with hot and cold running
water, soap and disposable towels must be available in the toilet area.
Also, a sign must be placed in the toilet area
reminding employees to wash their hands after each visit to
the toilet.
The grounds surrounding the cider operation should be kept free of waste,
litter, uncut weeds and improperly stored equipment.
- All liquid waste should be properly drained into the sewer or an approved
septic system.
D. Processing Equipment
All equipment surfaces that contact apples or the cider must be food grade
smooth, non-absorbent and easy to clean. Examples of problems that should
be avoided: cardboard chutes for apples, raw and splintered wood, rusty
equipment, rough welds and cracks and corners on equipment that could not
be easily cleaned.
Brass fittings for hoses, brass filler spouts or other equipment made of
brass that comes in contact with apple cider cannot be used. Cider will
leach copper out of brass.
Galvanized buckets , pipe or sheeting should not be used.
Press Racks
Press racks must be made of food-grade plastic, steel, or if hardwood, sealed
with paraffin or other approved coatings. Keep press racks off the floor
at all times. Racks must be stored off the floor, in a well ventilated,
screened location.
Filter Cloths
Filter cloths should be specifically designed for pressing cider, made of
durable materials, and replaced as frequently as necessary. During processing,
the cloths should be handled in a sanitary manner. This includes hanging
them on a line or placing them in a clean container off the floor between
runs.
Transport Piping
All cider tubing must be approved for food use. Stainless steel piping with
sanitary couplings that can be easily disconnected and cleaned with a clean-in-place
(CIP) system is recommended. If plastic tubing is used, it must be transparent.
Plastic tubing must be protected from abrasion and breakage, and must be
easy to replace. If the plastic tubing passes through spaces that are not
easily accessible, the tubing must pass through as one piece, and it must
be easy to clean. Plastic tubing must be continuous as much as possible
with a minimal number of couplings.
Grinding/Grating
The grinder housing should be constructed of materials that are easily cleanable.
Housings constructed of wood can produce problems of splintering and are
not easily cleanable.
Pumps
The pump used for feeding apple slurry to press and those used to transport
cider to cooling tanks and fillers should be of a sanitary design for pumping
food liquids and constructed of acid resistant materials.
Cooling Equipment
Cider should be stored in either stainless steel or glass lined, insulated
storage tanks containing a refrigeration coil with a slowly rotating impeller.
Filling Equipment
Mechanical fillers and cappers of sanitary design are recommended.
Hand filling is discouraged because of the potential for contamination
by hand contact. Cider packaging containers and lids should be new unless
approved mechanical bottle washing equipment is used for returnable bottles.
E. Apple Storage
Apples must be stored so that they are protected from contamination
with manure, other fecal material, meat products and other contaminants.
Apples in field bins or other containers should not be stored in areas in
which birds roost.
Store all apples in clean containers under refrigeration as close to 32
degrees Fahrenheit but not exceeding 41 degrees Fahrenheit.
F. Apple Processing
Only firm, ripe, whole apples should be used for the production of fresh
cider. Fruit badly damaged by insects or other pests,
cuts, stem punctures, or containing decay are not suitable for processing
into fresh cider.
Apples should be carefully inspected and washed with potable (i.e. drinking
quality) water in a wet brush washer or scrubber immediately prior to processing.
Apples should be passed over an inspection table ahead of the washer and
elevator to the grinder and unsuitable fruit removed.
Wash water should be 10 degrees warmer than the fruit being processed. Scientific
studies have shown that when water temperature is colder than fruit temperature,
a temperature induced vacuum on the surface of the fruit can cause the fruit
to draw in wash water. If contaminants are present in the wash water, they
could be drawn into the flesh of the fruit. One simple way to monitor this
is to take the temperature of the wash water, make sure it is at least 10
degrees warmer than your cooler, and make sure you press only fully chilled
apples directly from the cooler.
A weak chlorine residual may be maintained in the wash water to help destroy
bacteria. The concentration should be held at 50-100 parts per million (ppm),
measured with chlorine test kit/strip. Chlorine is easily "used up,"
so it must be checked routinely. These test strips are generally available
wherever the sanitizer was purchased, including most restaurant supply houses.
The test strips can be purchased showing the appropriate range in chlorine
residuals.
Apple cider should be cooled to below 41 degrees F immediately after pressing.
For extended shelf-life, keep the temperature of the apple cider close to
32 degrees F. Fresh apple cider can be stored at 28 degrees - 30 degrees
F without the formation of ice crystals because of its high soluble solid
content. Check that the refrigerant in the cooler/chiller is fully charged;
coils do not have a dust build-up; and door gaskets form a tight seal. The
thermometer should be conspicuous and easy to read.
If preservatives such as potassium sorbate or sodium benzoate are added
to apple cider, keep records of the formula to determine the percentage,
amount of preservative and volume of cider for each batch. Sodium benzoate
cannot exceed 0.1% by weight.
Pressed pomace should be disposed of properly in either a sanitary landfill
or spread onto fields and worked into the ground. Check with local
authorities regarding disposal regulations.
Chemicals, pesticides and solvents should be stored away from the processing
or filling area to prevent accidental contamination of the equipment or
cider.
G. Employee Hygiene
All persons working in the processing area should wear clean outer garments,
maintain a high degree of personal cleanliness and conform to hygienic practices
while on duty to prevent contamination of food products.