Polydextrose & Resistant Dextrin Storage SOP for Food Plants

Polydextrose (powder and syrup) and resistant dextrin are highly hygroscopic soluble fibers. The following storage SOP consolidates practical receiving, packaging, warehouse control, and QA measures to protect integrity, prevent caking or contamination, and maintain shelf life. If supplier COA/SDS specifies different limits, always follow the supplier documentation.

Key points at a glance

• Shelf life: Polydextrose powder and resistant dextrin typically remain stable ≈24 months if sealed and kept dry. Polydextrose syrup (e.g., PDX‑90) is semi‑perishable and usually 3–12 months depending on grade/COA.
• Warehouse conditions: Maintain 15–25 °C; RH <55%. Prioritize humidity control for hygroscopic powders.
• Packaging: For powders, use 25 kg kraft/woven bags with multi‑layer PE liners (heat‑sealed). For bulk, use 200–250 kg drums or 1,000–1,300 kg IBCs; size desiccants for route and climate.

1. Receiving and incoming inspection

• Visual checks: Inspect pallets, seals, liner integrity, condensation, off‑odors, and tamper evidence. Reject any wet, torn, or compromised packages.
• Documentation: Verify COA, SDS, packing list; record lot/lot traceability, manufacture/expiry dates, and supplier contact details.
• Quick screening: Perform a simple moisture check (oven/IR or handheld) and take a labeled retention sample under quarantine.
• Data capture: Supplier, PO, SKU, lot, MFG/EXP, receiving temp/RH, visual pass/fail, actions taken.

2. Unpacking and repacking

• Environment: Conduct all opening and transfers in a designated low‑dust, food‑grade area with local exhaust at the opening point.
• Materials: Repack only into new food‑grade PE liners or new heat‑seal bags. Add desiccant sachets for long storage or export lanes.
• Labeling: Include product name, lot, MFG, EXP, storage instructions, and a clear “Keep Dry” symbol. Apply tamper‑evident seals after repack.
• Acceptance criteria: No contamination, correct net weight, intact seals, and matching lot IDs between outer and inner packaging.

3. Packaging for domestic and export

• Pack formats: 25 kg lined kraft/woven bags (heat‑sealed), 200–250 kg drums, or 1,000–1,300 kg IBCs/totes.
• Moisture barriers: Use multi‑layer liners; select desiccant type and loading based on container volume, route duration, and expected RH.
• Palletization: Use clean pallets, stretch‑wrap, and moisture‑proof top covers. Apply export tamper seals. Place a COA copy inside and another attached externally in a sealed pouch.

4. Warehouse storage and environmental controls

• Targets: 15–25 °C; RH <55%. Use dehumidification where ambient conditions exceed setpoints. Avoid direct sunlight and water sources.
• Pallet rules: Keep off floor ≥150 mm and ≥300 mm from walls to allow airflow and inspection. Implement FIFO/FEFO with visible shelf‑life tags.
• Monitoring: Install data loggers for continuous temp/RH recording with alarm limits; perform daily visual checks and log results.
• Excursion protocol: If limits are exceeded, quarantine the affected lots, retest moisture and microbial parameters, and consult the supplier. Consider re‑drying (as applicable and validated), relocation, or disposition.

5. QA testing, sampling, and records

• Routine tests: Moisture (oven/IR), microbial plate counts as per spec, and identity confirmation (e.g., FTIR/HPLC as required). Reconcile results against the COA.
• Retentions: Keep a retention sample per lot for the full declared shelf life plus a safety margin. Archive each lot’s COA and SDS.
• Records: Maintain incoming inspection forms, daily RH/temperature logs, and nonconformance and disposition documentation in a traceable system.

6. HSE, handling, and dust control

• Engineering controls: Local exhaust at filling and sampling points; HEPA vacuums for cleanup. Ground and add anti‑static measures on bagging equipment.
• PPE by task: For receiving, sampling, and repacking, wear an N95/P2 respirator, eye protection, and gloves. For high‑dust activities, upgrade respiratory protection per risk assessment.
• Spills: Use HEPA vacuuming. Do not use compressed air. Dispose of waste per local regulations.

7. Nonconformance, recall, and disposal

• Actions: Quarantine impacted lots, investigate root cause, and follow a defined rework/repack decision tree. Notify the supplier as needed and log all actions. Dispose of materials in accordance with local regulations.

FAQ

• What temperature and RH should we target? 15–25 °C, RH <55%, with consistent monitoring for polydextrose and resistant dextrin.
• How do shelf lives compare? Polydextrose powder and resistant dextrin are typically stable ≈24 months when sealed and dry. Polydextrose syrup is generally 3–12 months, per COA.
• Can we repack? Yes, but only in a clean, low‑dust area using food‑grade liners, heat‑seals, and desiccants. Retain original COA and maintain lot traceability.
• What PPE is required? N95/P2 respirator for dusty tasks, plus eye protection and gloves. Use local exhaust wherever powders are opened or transferred.

Get SOP templates or product support

For supplier‑specific COA/SDS and tailored storage SOP templates (incoming checklists, repack labels, alarm matrices), visit Shine Health product pages or contact our team:

• Polydextrose Powder: https://www.sdshinehealth.com/polydextrose/polydextrose-powder.html
• PDX‑90 Syrup: https://www.sdshinehealth.com/polydextrose/pdx-90-syrup.html
• Resistant Dextrin: https://www.sdshinehealth.com/resistant-dextrin/resistant.html

Contact: info@sdshinehealth.com | WhatsApp +86 13405443339 | https://www.sdshinehealth.com/

References

• Nabors, L. O. (2016). Alternative sweeteners: An overview. CRC Press. https://doi.org/10.1201/B11242-4
• Veena, N., Surendranath, B., & Arora, S. (2015). Polydextrose as a functional ingredient and its food applications: A review. Indian Journal of Dairy Science, 69(3). https://doi.org/10.5146/IJDS.V69I3.51101.G24364
• Casettari, L., Bonacucina, G., Morris, G. A., Perinelli, D. R., Lucaioli, P., Cespi, M., & Palmieri, G. F. (2015). Dextran and its potential use as tablet excipient. Powder Technology, 273, 75–90. https://doi.org/10.1016/j.powtec.2014.12.030
• Saavedra‑Leos, Z., Carrizales‑Loera, A., Lardizabal‑Gutiérrez, D., López‑Martínez, L. A., & Leyva‑Porras, C. (2024). Exploring the equilibrium state diagram of maltodextrins across diverse dextrose equivalents. Polymers, 16(14), 2014. https://doi.org/10.3390/polym16142014
• Hasjim, J., Ai, Y., & Maningat, C. C. (2013). Novel applications of amylose‑lipid complex as resistant starch type 5. In Resistant Starch: Sources, Applications and Health Benefits (pp. 67–97). Wiley. https://doi.org/10.1002/9781118528723.ch04