Treat Water like Glass Sanitation s War on Water to Reduce Pathogen Risk and Total Life Cycle Costs

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2 Treat Water like Glass Sanitation s War on Water to Reduce Pathogen Risk and Total Life Cycle Costs Karl Thorson, General Mills Rocky Olmstead, Precision Food Innovations

3 Objectives Understand the impact of sanitary design on food safety and quality. Introduce Sanitary Design Principles Understand different cleaning methods and their impact on effective and efficient sanitation. Communicate the War on Water

4 Why Clean? Allergen control Micro control Product quality Foreign material control Regulatory compliance Life cycle cost reduction Quick changeover execution Pest control Human safety Housekeeping Equipment reliability Dietary compliance/claims (Kosher, Halal, organic) GMI-FSQP08R0D3 4 This content is authorized by FSQ Corporate KD/KT

5 Changeover Efficiency Focus Minimize the impact of the cleaning method War on Water Treat Water Like Glass Cleaning Method Order of Preference Minimize the time to clean Follow QCO and sanitary design principles Minimize the frequency of cleaning Comprehensive assessment on reasons to clean Operational Safety Quality

6 Who are our sanitation partners? Who needs to be involved to have food safety success? R&D Engineering Sourcing/Suppliers Chemicals Equipment Contractors Operations Maintenance/Reliability Quality/Sanitation

7 Food Safety/Quality Formula Sanitary Design Sanitation Programs Safe/Quality Food

8 Sanitary Design The application of design techniques which allow the efficient, effective, and consistent cleaning of the entire system, facility and grounds

9 How to Build/Remodel a Kitchen? GMI-FSQP08R0D3 9 This content is authorized by FSQ Corporate KD/KT

10 Sanitation All actions dealing with cleaning or maintaining hygienic conditions of the facility. This ranges from cleaning/sanitizing specific equipment to periodic cleaning activities throughout the facility, including building, structural and grounds cleaning activities. How do we decide how often to wash?

11 SOME BASIC DEFINITIONS CLEANING: The removal of soil particles from surfaces by mechanical, manual, or chemical methods. SANITIZING: Treatment of a cleaned surface with a chemical or physical agent to destroy disease / spoilage causing organisms. Reduces total vegetative cell population to a safe level. YOU CANNOT SANITIZE A DIRTY SURFACE

12 Is your kitchen dry? Leaks Drips Condensation Pooling Stagnant

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14 Why is the WOW (War On Water) important? Leads to significant microbiological growth in our product environments Pathogens Listeria, Salmonella, etc. Spoilage Yeast, Mold, etc. Human safety hazard Chemical usage Slip hazards Equipment Reliability and Function Electrical issues FSMA Only FSIS has condensation guidance Sanitation Performance Standards Compliance Guide Environmental and Sustainability goals

15 The War on Water Contamination risk Chemical Physical Microbiological Regulatory From a microbiological standpoint Unnecessary water is like gasoline for a fire. Water should be by exception only.

16 Control Water/Moisture Necessary Water Process water Minimize/Manage Wet washing Eliminate/Reduce Unnecessary Water Condensation Fix Root Cause Leaks Fix Root Cause Ingress Fix Root Cause Internal Fix Root Cause Drains (leak or back-up) Fix Root Cause

17 Cleaning Method Order of Preference 1. No cleaning needed a. Redundant or dedicated equipment 2. Purge(next product or inert material) 3. Dry clean 4. Dry clean w/chemicals 5. CIP (Clean in Place) 6. Controlled wet clean out of place a. Automated washer 7. ACS (Assisted Cleaning System) 8. Controlled wet clean in place 9. Flood cleaning

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21 Principle 3 Accessible for Inspection & Cleaning 21

22 Principle 3 Accessible for Inspection & Cleaning 22

23 Principle 3 Accessible for Inspection & Cleaning Many tools needed for disassembly and assembly

24 What is clean? Visual Free from soil (any unwanted material) Chemical, physical, biological Analytical Chemical, physical, biological Allergens, gluten Pathogens, spoilage organisms

25 Food Safety Validation Expectations Allergens Visibly Clean & Analytical Testing Direct food contact and adjacent surfaces Micro Beyond Visibly Clean Indicator Organisms Pathogens

26 Sanitary Design Principles

27 Recall Alert: Found Listeria monocytogenes in chewy granola bars! The issue has been traced back to this conveyor. We now need to evaluate the design and put together a new cleaning protocol to address the issue. Use the Sanitary Design Checklist for Equipment and Cleaning Method Order of Preference to identify the optimal sanitation protocol and design improvements based on your cleaning method. Option 1 Full Wet Cleaning Option 2 Controlled Wet Cleaning Option 3 Dry Cleaning Considerations: This is a low water activity, ready-to-eat product that does not have a process lethality step for Listeria.

28 Group Activity Sanitary design considerations Good and bad examples related to your cleaning method Challenges with cleaning method Will cleaning be effective at eliminating Listeria? Will cleaning be efficient?

29 Conveyor Pictures

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36 Common Sanitary Machine Design Practices Minimize any use of horizontal surfaces. Use non-hollow members whenever possible. Make things accessible to clean. Use appropriate materials as well as material surface finishes in and outside of direct food contact areas. Use of fasteners and exposed threads or avoidance there of. Tool-less removal and take-down of equipment for individual cleaning of parts (especially direct food contact parts). Washdown duty components.

37 Equipment we are showing today. TroughVeyor AKA Trough Conveyor. Shown to illustrate some standard sanitary design practices that can be implemented into most equipment.

38 Minimize any use of horizontal surfaces.

39 Make things accessible to clean.

40 Make things accessible to clean.

41 Endless belt removal when possible.

42 Make parts easy to take out and reinstall

43 Wash-Down duty components Most all components (including electrical) can be acquired IP69K Example of parts: Servo and induction motors, sensors, gearboxes. IP69K Defined: The IP69K rating provides protection against ingress of dust and high temperature, high pressure water making products with this certification ideal for use in conditions where equipment must be carefully sanitized. Example of IP69K motor and gearbox Take note.stainless Steel Motors and Gearboxes run HOT! Not uncommon (and fine on motor) to run surface temps above 180 degrees F which can cause a burn if skin is exposed for even a short time. Use motorized drum drive instead. These are also available IP69K and have no hot components exposed to operators. Both Vandergraaf and Interroll have IP69K options.

44 Motorized Drum Drive option.

45 Conventional VS Motorized Roller

46 New Product: Horizontal Motion Conveyor

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48 Key Learnings Clearly define clean expectations to cross functional teams Component level of disassembly use GMA Sanitary Design Checklists Early management is key Life cycle costing must be understood Utilize the GMA checklists as a tool for risk reduction to new and heritage equipment/facilities Match design and cleaning method Control water Visual inspection is everyone's best sanitation tool! Use all your resources