Webinars

Culture in Hygiene: Webinar 2, Maximising the Hygiene Window

Maximising the Hygiene Window

All food businesses recognise the vital importance of the Hygiene Window to ensure cleanliness and drive compliance. But little guidance is ever offered on how to actually put this into action.

Based on the second webinar in the three-part ‘Culture in Hygiene’ series, this article addresses this issue. Following on from the previous webinar, in which three industry experts discussed hygiene team engagement and retention, this information-packed panel provides tangible advice on how to maximise the Hygiene Window.

This webinar is hosted by Alex Carlyon, a Director at Klipspringer with over 18 years of industry experience. Alex is joined by Nick Turner, a Director at FoodClean, and Andy Fletcher, a Technical Consultant with over 30 years’ experience in the food industry.

If you’re interested in a specific part of this webinar, browse the below menu to skip ahead to the section most relevant to your food safety needs:

1) Cleaning Efficiency

2) Labour Efficiency

3) Zone Segregation

Click below if you’d prefer to watch the full webinar and download the corresponding slides.

1) Cleaning Efficiency

In this section of the webinar, Nick and Andy delve into some of the biggest barriers to cleaning efficiency during the Hygiene Window. These vary from missing equipment to a lack of segregation. Nick and Andy then outline several solutions around cleaning equipment, storing tools, and protecting machinery, all of which saves costs, time, and non-conformances.

2) Labour Efficiency

Calculated in cost per minute, downtime is an expensive part of the Hygiene Window which teams must be made aware of. Nick and Andy strongly encourage bringing the hygiene team in on the journey to foster greater understanding and communication – as well as the value of ready-to-use equipment to reduce operator frustration and improve labour efficiency.

3) Zone Segregation

Thirdly, Alex draws on his extensive experience to discuss the role of zone segregation. His advice on mitigating the risks of in-process cleaning includes effective production scheduling, low pressure cleaning equipment, and mobile screening – which he provides visual examples of from a recent visit to an A.G. Barr Factory.

Watch below for more.

For more in-depth webinar content on this topics, take a look at the third episode in our ‘Culture in Hygiene’ series.

Alternatively, you can get in touch with one of our Hygiene Experts below, or by contacting us at: 01473 461 800.


    Culture in Hygiene: Webinar 1

    Hygiene Team Engagement and Retention

    Culture in food safety is one of the most crucial aspects to guaranteeing unwavering compliance. In fact, a lacklustre food safety culture plan was identified as one of the eight most common non-conformities by the BRCGS in their recently updated issue of the Global Standards of Food Safety.

    For that reason, our team at Klipspringer decided it was time to address Culture in Hygiene across a three-part webinar series.

    Hosted by Alex Carlyon, a Director at Klipspringer with over 18 years of industry experience, the first part of this series focuses on how to engage with and retain an efficient, high-functioning hygiene team. Today, Alex is joined by Phil May, Technical Support & Hygiene Manager at leading manufacturers Greencore, and Lars Turner, Food Industry Specialist at cleaning solution providers FoodClean.

    Interested in a specific part of this webinar?

    Browse the below menu to skip ahead to the section most relevant to your food safety needs:

    1) Protecting Your Team

    2) Equipment Choice

    3) Induction and Training

    4) Sustaining Good Practice

    5) Ongoing Process Refinement

    Click below if you’d prefer to watch the full webinar.

    1) Protecting Your Team

    Amid staff shortages and a smaller pool of skilled workers, ensuring that team members are safe at work is an absolute MINIMUM requirement for maintaining an effective and loyal team.

    In this section of the webinar, Lars and Phil provide several tangible examples to demonstrate the value of an operator-first approach. They discuss how labour retention is always higher among a well-protected and engaged team – and the positive economic and environmental impact this can have for food businesses.

    2) Equipment Choice

    Each year, hundreds of thousands of workers suffer from equipment-inflicted injuries. Equipment construction and maintenance was the third most common category of non-conformance identified by the BRCGS in their abovementioned Issue 9

    As explained by Phil and Lars, reduction in injury is just one facet to improving culture in hygiene. Watch below as they dissect the higher motivation and increased lifespan of equipment resulting from an ‘operator-owned’ model of workplace production.

    3) Induction and Training

    Thirdly, Alex and Phil delve into the importance of the initial onboarding process in developing an outstanding hygiene culture.

    Alex addresses the issue of high staff turnover – a common problem with many workers currently coming through recruitment agencies. Recognising that training is an ongoing process and making Critical Control Points (CCPs) highly visual is also suggested.

    4) Sustaining Good Practice

    Creating and implementing these processes is all well and good, but their long-term impact will be limited if they are not sustained. Drawing on several visual examples, Alex illustrates how to prolong and consolidate hygiene processes through adaptability.

    5) Ongoing Process Refinement

    Lastly, Lars and Phil return to offer valuable insights about ongoing process refinement.

    Contrary to popular belief, they recommend a culture which encourages workers to challenge the status quo, as the most powerful improvements often come from unexpected sources. Root Cause Analysis, cross-functional teams, and the 5-Whys are also mentioned.

    For more in-depth webinar content on this topics, take a look at the second episode in our ‘Culture in Hygiene’ series.

    Alternatively, you can get in touch with one of our Hygiene Experts below, or contact us at: 01473 461 800.


    Nine Factors to Consider When Choosing a Wireless Monitoring System

    Across the food and beverage industry, the benefits of wireless temperature monitoring are well-known. Innovative monitoring systems are proven to provide highly accurate, real-time temperature data, support food safety compliance, and cut costs of loading refrigerated food transportation. BRCGS standards also require the implementation and control of process monitoring to ensure that products are manufactured according to industry specifications.   

    These benefits have been applied across a wide range of industries, including:  

    • Food and beverage production 
    • Pharmaceutical and medical 
    • Hospitals and care 
    • Food service and hospitality 
    • Storage and logistics 
    • Laboratories and pharmacies  
    • Industry and manufacturing 
    • Food retail 

    However, there is much uncertainty around the best form of wireless monitoring system. At Klipspringer, our partner and customers frequently ask us for advice on which system to choose. Instead of simplistically recommending one of our systems, regardless of their specific temperature monitoring applications, we decided that providing all of the relevant information best enables them to make the right choice.  

    That’s why we wrote this article. Drawing on our two decades’ experience as industry leaders in modernised data logging, it is based on clips from a webinar we recently hosted in collaboration with Quorn Foods.

    The topic is nine key factors to consider before choosing a wireless monitoring system. Navigate the below menu to skip straight to the section most relevant to your needs…

    You can also watch the full webinar below:

    1) Parameters

    It’s difficult to order each factor by importance, but the parameter – or parameters – measured by the system you opt for is one of the most fundamental aspects.  

    As you begin your hunt for the perfect wireless monitoring system, one of the first questions you should ask yourself is: what exactly do I want to monitor?  

    If your answer is temperature only, most basic monitoring systems will cover your needs, even simple Wi-Fi loggers found on sites like Amazon. However, if your answer is more complex than just temperature, other options may be more suitable.  

    Do you, for example, want to measure both temperature and humidity (rH)? What about energy, concentration (ppm), or even door contact? As the number of measurables increases, so does the complexity of system required.  

    Here is a list of the most common measurable parameters: 

    • Temperature  
    • Humidity  
    • CO2 
    • Energy 
    • Pressure 
    • Concentration 
    • Door contact 
    • Data from advanced plant/engineering sensors 

    While there are countless systems that are custom-built for specific measurables, with advanced, high-end systems it is possible to measure and set up alarms for virtually any parameter.  

    2) Hardware

    Having established your required parameters, the next three factors all relate to the component setup of your system. Component setup is an essential early step in the monitoring system decision-making process, but it often gets overlooked.  

    Hardware is the first of these factors.  

    The biggest delineation in deciding your hardware is whether you require a physical base station, complete with display and sounds, or a non-physical system which operates entirely digitally.  

    Careful consideration of the working conditions your hardware will have to withstand will also be essential. For example, will your system’s sensors need to be waterproof? Does your system need to be equipped with heat-resistant casing? Or require particularly long-lasting battery life, as it needs to be placed in an inaccessible area?  

    Finally, appraising your probe options is another essential step. Will you need to measure air temperature or product temperature? If so, choose a probe that corresponds with those applications.  

    3) Data Storage Access

    Storage access is one of the most crucial, yet most misunderstood, factors to consider when choosing a wireless monitoring system. It is frequently conflated with sensor connection type – addressed below – but data storage access is its own independent category.  

    This category can be split into two options: network-based storage, and cloud-based storage. Many see network-based storage as more secure because it doesn’t rely on external servers. There are also no ongoing cloud licensing fees.  

    On the other hand, cloud-based storage offers access to data from any location, at any time. This makes it the ideal solution for those looking to implement wireless monitoring systems at multiple site locations, while accessing the data from one central location.  

    4) Sensor Connection Type

    Equally crucial is the type of sensor connector. The majority of wireless monitoring systems use one of three main types: 

    a) Wi-Fi 

    Wi-Fi-based sensor connectors are excellent, if your site has strong coverage throughout. However, in large chillers or freezers it is difficult and expensive to guarantee such Wi-Fi coverage. Because a password is required to gain access, it can result in a loss of sensor connection if this password is changed by IT. Higher battery consumption is also an issue with Wi-Fi-based systems.  

    b) Bluetooth 

    Bluetooth options require a reading device to be nearby at all times. This often constitutes a mobile phone with a downloaded data tracking app – a simple but reliable system, although battery life does drain significantly.  

    c) Radio Frequency 

    Radio frequency, or RF, is the strongest form of wireless data transfer. In most scenarios, radio systems use a frequency of 433mHz, which is used for longer-distance transmissions across large open spaces, or 868mHz, which is better suited for shorter distances with more obstructions, such as walls. When asked by customers, we are likeliest to recommend radio-based systems because of their stronger signal, lower battery consumption, and more reliable overall connectivity.  

    5) Installation

    As with any installation, the most pressing consideration is whether or not your site/s require professional support, or if you want to install the system yourself.  

    At Klipspringer, we pride ourselves on offering one of the fastest delivery turnaround times in the industry – the entire monitoring system is typically delivered within 2-3 days. For those requiring professional installation services, leading companies will send expert technicians on site. This process usually lasts between 3-4 weeks.  

    6) Alarm Type

    When looking out for the best monitoring solutions, here’s a tip: look out for the systems that issue alarms by the widest range of mediums.  

    Why? In the event of an alarm, speedy and decisive action is immediately required. This cannot happen if you are not instantly notified about the situation – hence the urgent need for alarms to be sent by phone call, SMS, email, and a variety of other methods, rather than riskily depending on just one.  

    7) Calibration

    There are three questions regarding calibration you should ask yourself before purchasing any wireless monitoring system.  

    Firstly, do you require UKAS calibration for audit requirements? If so, only UKAS accredited organisations are able to supply this service, which narrows your options to those upper-tier companies.  

    Secondly, will your system require periodic onsite recalibration? If so, take note of the costs involved in this process, how frequently your system will require recalibration, and whether your potential monitoring system supplier offers this service.  

    Thirdly, what is the location of the sensors? For example, if the sensors have to be mounted on the ceiling, this makes it altogether more difficult to access them for recalibration and servicing.  

    8) Cost

    Consult the below table for an outline of the potential costs of wireless monitoring systems, based on two generalised scenarios: 

    Factors

    Scenario 1

    Scenario 2

    Size of facility

    Small

    Large

    No. of monitoring points

    <5

    >25

    Parameters

    Temperature only (-20 to 25°C)

    Multiple parameters; mainly high temperature, some humidity (rH)

    Accessibility to sensor position

    Easy access

    Easy access

    Onsite installation and annual service/calibration

    Not required

    Professional installation and ongoing technical support

    UKAS calibration

    Not required

    Yes

    Alarming

    Basic

    Advanced

    Pricing guide

    £500

    £8,000-£10,000

    As seen above, differences in these factors can cause massive range in the price of a system. Read on to learn about the final factor to consider when choosing a wireless monitoring systems 

    9) Ongoing Support

    Last but far from least is ongoing support. In their haste to acquire the first system that crosses their path, people often overlook the vital importance of continual expert advice, long after any purchase of a wireless monitoring system has been made.  

    While sites like Amazon offer a wide range of logging systems, there is no on-site support available regarding calibration, software updates, or troubleshooting.  

    The current market is flooded with wireless monitoring systems. While many of these are perfectly acceptable, most are designed to cover multiple industries. At Klipspringer, we’ve spent years refining wireless monitoring systems to meet site requirements that are specifically focused on the food industry.  

    Listen below as Kenny Edwards, Quality Manager at Quorn Foods, outlines how wireless site monitoring provided tremendous value for him and his team.  

    Our knowledgeable, friendly team offer unequalled customer support, and our systems – such as the much-acclaimed WatchmanOne – excel at real-time monitoring across a range of parameters.  

    For any wireless monitoring system-related enquiries, feel free to contact our support team at: 01473 461 800. 


    WEBINAR: Six Strategies for Maximising Oil Life Without Compromising Quality

    On 1 June 2022, for the first time since late March, the global oil price rose about $117 per barrel (£93.47). Amid supply chain uncertainty and soaring prices, it has never been more crucial for the hospitality industry to maximise the life of cooking oil. But how can that be done without negatively impacting the safety and quality of your menu?  

    At Klipspringer, we decided to host a webinar answering exactly that. Led by a panel of oil management experts, this webinar detailed six actionable steps to ensuring that your food oil is compliant, consistent, and methodically conserved.

    Using relevant clips from the webinar, this article breaks down each step into concise, digestible chunks. It answers some of our mostly commonly asked questions, including: 

    When should I change cooking oil? 

    How do I check oil quality? 

    Does filtering help to extend oil life? 

    Navigate the menu below to be directed to the step most applicable for your food oil needs, or keep reading for a holistic insight into one of the most pressing issues the hospitality sector faces today.   

    You can also view the webinar in full below:

    Step 1 - Choosing the Right Oil

    As put by Vincent Igoe, Managing Director for Olleco Scotland: “In my 25 years in the industry, I’ve never seen markets like this”. The astronomical current price of oil is unprecedented, and is being caused by factors such as: 

    • A knock-on from the Covid-19 pandemic 
    • Extreme weather in Western Canada 
    • Increased biodiesel demand in the EU  
    • Adverse weather across South America 
    • Russia’s invasion of Ukraine  

    These circumstances have culminated in strong global demand for oil, but extraordinarily weak supply. In light of this, selecting the right type of oil has never been more crucial.  

    When choosing the best oil for frying, there are five overarching aspects to consider: 

    a) Taste 

    b) Performance 

    c) Cost 

    d) Safety 

    e) Sustainability 

    Once you’ve evaluated each of these aspects and narrowed your search down to one or two types of oil, refer to the below chart for the specific benefits of three widely used oil types.  

    Rapeseed Oil

    Vegetable Oil

    Long-Life Oil

    Non-genetically modified seed

    Produced from genetically modified soya 

    Non-genetically modified seed 

    Extended life

    Extended life

    Lasts 2x longer than extended life oils 

    Anti-foaming agent (makes it safe for use in fryers) 

    Contains anti-foaming agent 

    Lasts 2x longer than extended life oils 

    Anti-foaming agent (makes it safe for use in fryers) 

    Contains anti-foaming agent 

    Contains anti-foaming agent 

    High smoke point 

    One of the UK’s best-selling standard cooking oils 

    Certified by RSPO (Roundtable on Sustainable Palm Oil) 

    Step 2 - Choosing the Right Fryer

    Once you’ve selected the right oil type for your needs, an effective oil fryer is the next requirement. Watch the above clip for advice from Michael Eyre, Culinary Director at Jestic Ltd, on various industry staples, including:

    • Simple Fryers (£)
    • Gravity (External) Filtration Fryers (££)
    • Pumped (Internal) Filtration Fryers (££)
    • Digital Fryers with Built-In Filtration (£££)
    • Low Oil Volume Fryers (££££)

    Step 3 - Fryer Operation and Filtering

    After selecting an appropriate oil fryer, it’s important to learn how it operates. This requires thought about food types, (auto)filtering, skimming, loading, and frying temperatures. For example, does your food type contain crumbs (e.g. breaded chicken)? If so, do you have a workable particulate filtration system in place to catch solid impurities that might fall into your oil?

    Read on for a three-part process to ensure the best frying practices.

    Before Frying:

    • Don’t skip ‘melt-mode’ in your morning check-ups and clean
    • Never fill the basket over the vat
    • Respect the recommended quantity per basket (don’t overfill the basket)
    • Ensure that oil is at cooking temperature before dropping the basket in
    • Cook food items either always from frozen or always from fresh (for better consistency)

    During Frying: 

    • Ensure correct frying temperatures (frying at higher temperatures does NOT decrease frying time) 
    • Never place a basket in the oil without using a timer 
    • After placing the first basket in oil, allow 30 seconds before dropping the second basket into the same vat
    • Program an alarm to remind cooks to shake the basket during the cooking cycle  

    After Frying:  

    • Drain/shake the basket over the vat 
    • Skim the vat regularly throughout the day 
    • Top-up oil throughout the day 
    • Use ‘night’ covers (to prevent debris falling into the oil and reduce contact time with light) 
    • Test quality of oil at least once daily (after the daily filtration/clean) 
    • Proactively filter the vats during the day (the more often the better) 
    • Use the ‘idle’ feature when the fryer is not in use 
    • Change filter paper daily 
    • Polish oil daily 

    Step 4 - Monitoring Oil Quality

    As summarised by Murray Carlyon, Managing Director at Klipspringer, there are three overarching reasons to monitor oil quality.  

    Firstly, to reduce costs and wastage. An effective oil monitoring system results in significant savings, both economically (costs) and environmentally (wastage). Instead of discarding perfectly usable oil – a costly and unsustainable outcome – businesses are now using Food Oil Monitors for maximum accuracy. For a minimal upfront cost, these monitors offer a comfortable ROI, usually within just six months. Click here to read about how Whitbread’s use of a Food Oil Monitor reduced their oil consumption by up to 52% across their 1,200 different venues 

    Secondly, to maintain product consistency. Most kitchens change their oil either based on colour (when it goes dark/black, using single-use test strips and a simplistic colour chart) or schedule (twice a week – because it has always been done that way). Led by the likes of Wasabi, McDonalds, and Five Guys, hospitality businesses seeking to distinguish themselves from the crowd are standardising the use of Food Oil Monitors to guarantee such consistent menu quality  

    Thirdly, to ensure product safety. Paramount to any hospitality business is consumer welfare. As shown by the figure below, the frying process can release a variety of polar compounds (e.g. free fatty acids), which are in turn associated with acrylamide build-up. This customer-harming, cancer-causing chemical can reach dangerous levels when relying on subjective oil quality monitoring methods.  

    A percentage reading of Total Polar Compounds or Total Polar Matter (TPC% / TPM%) is reliably used in the food industry as a measure of oil degradation. High levels of TPC can negatively impact product taste, texture, and appearance, as well as causing various health disorders, both short-term (e.g. gastrointestinal disorders) and long-term (e.g. risk of heart disease).  

    A growing number of countries across Europe are legislating TPC percentages, typically around the 24-27% mark. While there is no existing legislation in the UK, leading companies are setting their own standards around a similar benchmark, using digital solutions to take the subjective guesswork out of monitoring oil quality.  

    Step 5 - Pumping and Storing Waste Oil

    Watch the above clip for advice regarding pump stations, filtration, and waste oil tanks. It addresses the following questions: 

    • How do I get oil into a fryer? 
    • How do I remove waste oil from my fryer? 
    • Where do I store waste oil? 
    • How can my waste oil get collected? 
    • How can I monitor waste oil? 

    Step 6 - Returning Used Oil

    Getting the most longevity and value out of your oil supplies is imperative for two reasons: profitability and sustainability. As one of the largest contributors to carbon footprints in commercial kitchens, oil is best suited to a circular economic system (illustrated below). Leading oil suppliers now offer the service of collecting ‘waste’ oil in the same containers it is delivered in – and they even pay for it, balancing the value of your reused oil against the costs of your fresh oil.  

    Implementing these six steps will ensure that your oil quality remains compliant, consistent, and methodically conserved. Customer satisfaction will increase, costs will decrease, and your business will be more adeptly prepared to meet any sustainability targets and initiatives.  

    Watch the below clip to hear Surendra Yejju, Executive Chef at Wagamama, outline how these six steps have helped teams across Wagamama venues nationwide.  

    Interested in learning how other leading food and hospitality companies have benefitted from food oil monitoring?  

    Click to learn how Whitbread reduced oil savings by 52%