Product Changeover Steps and Allergen Management

What Is a Changeover?

Making several products on one machine is the norm in small and mid-sized food plants. Switching from one product to another is called a "line changeover" or "die change" in the industry. Changeovers fall roughly into two types:

• Like-for-like changeover: For example, the same pork filling at a different weight specification, or the same red bean bun with a different shape. Usually only settings need changing or a few parts swapped.
• Cross-category changeover: For example, from pork to vegetarian, from a filling with peanuts to one without, or from sweet to savory. Besides changing parts, a thorough cleaning is needed to keep residue from the previous product from getting mixed in.

Which Parts to Change for a New Product

Depending on the model and product, this may involve:

• Nozzles: Changed when the wrapper-to-filling ratio or product diameter differs.
• Forming or cutting parts: Changed when the product's shape, size, or design changes.
• Molds and stamping dies: When a specific shape or imprint is needed.
• Feeding parts: When filling particle size or viscosity differs greatly, different feeding parts may be needed.
• Settings: Weight, speed, timing. Some models can store product programs; for example, Rheon USA's KN551 product page mentions that the touch panel can store data for up to 100 products and recall them with one touch.

For the parts and adjustments involved in changing products on Dong-Yih models, please call 06-257-4644.

How Long Does a Changeover Take?

There's no universal number; it depends on:

• How many parts need changing and how easy they are to remove and install.
• Whether a full cleaning is needed (cross-category changeovers usually require one).
• Operator proficiency.
• Whether parts and tools are ready.

Common ways to shorten changeover time:

1. Prepare in advance: Have the parts, tools, and raw materials for the next product ready beside the machine before the changeover.
2. Separate internal and external tasks: Do whatever can be done while the machine is still running (preparing materials and parts) instead of waiting until it stops.
3. Standardize: Write a changeover SOP, label parts, and give them fixed storage locations.
4. Time it and improve: Time each changeover, find the steps that take longest, and improve them.

How to Avoid Allergen Cross-Contact

Allergen cross-contact is the biggest risk in a changeover. The Ministry of Health and Welfare's Food Allergen Labeling Regulations (食品過敏原標示規定) took effect on July 1, 2020. Prepackaged foods sold in Taiwan that contain crustaceans, mango, peanuts, cow's or goat's milk, eggs, tree nuts, sesame, gluten-containing grains, soybeans, fish, and their products, or that use sulfites, must carry an allergen warning, for a total of 11 items; exceptions and labeling methods for each follow the Ministry's current announcements.

Article 12 of the Regulations on Good Hygiene Practice for Food (食品良好衛生規範準則) requires work areas to take measures to prevent cross-contamination; Annex 3 requires processes to include measures to prevent cross-contamination; Annex 2 requires equipment and utensils to be cleaned after use and protected from recontamination.

In practice:

1. Scheduling: Make products without allergens before products with allergens; vegetarian before meat; light-colored fillings before dark ones. This minimizes the cleaning risk at each changeover.
2. Full cleaning: For changeovers across allergens, remove and wash all food-contact parts and clean the machine body, conveyor belts, hopper, and tools completely; scraping or rinsing alone isn't enough. For cleaning methods, see Daily Cleaning: Steps for Disassembling and Washing an Encrusting Machine.
3. Separate tools and containers: Color-code scoops, buckets, and scrapers for allergen-containing products and don't share them.
4. Segregate raw materials: Store allergen-containing ingredients in a separate area with clear labels.
5. Verification: Inspect visually after cleaning, and if necessary confirm with allergen rapid test strips or protein residue tests.
6. Records: Record the changeover time, what was cleaned, who inspected, and verification results.
7. Labeling: If cross-contact can't be completely avoided, how to alert consumers on the package should follow Ministry of Health and Welfare rules and your own risk assessment.

Vegetarian products are also subject to vegetarian labeling rules; when vegetarian and meat products share equipment, changeover cleaning and records are just as important.

Checks After a Changeover

After the changeover, run the machine empty, do a small trial run, and confirm the new product's weight, shape, and appearance. Check the first batch especially carefully for any residue from the previous product (color, particles, flavor), and start full production only after it passes.

FAQ

Q: Does the whole machine have to be disassembled and washed for every product change?
A: A like-for-like changeover may only require swapping parts and settings; across allergens, between vegetarian and meat, or when flavors differ greatly, the food-contact areas must be fully disassembled and washed.

Q: How long does a changeover take?
A: It depends on the model, the number of parts, whether full cleaning is needed, and operator proficiency. Time it in practice, write an SOP, and keep improving.

Q: We make several fillings a day. How should we order them?
A: Start with products that are allergen-free, vegetarian, light-colored, and mild, then move to those with allergens, meat, dark colors, and strong flavors.

Q: How do we confirm the changeover cleaning was done properly?
A: Inspect visually, use allergen rapid tests or protein residue tests if necessary, and record the results.