Case Study: Sanitary Design. Erin Mertz

Transcription

1 Case Study: Sanitary Design Erin Mertz

2 Zone 4 Case Study Utilities Case High spoilage rates in packaging for mold Product tested low for mold Actions Check the packaging Check the sanitation Use air sampling to understand hot spots Review the design of the facility to maintain sanitary conditions

3 Zone 4 - Findings Packaging was swabbed for mold and yeast and showed <10 cfu/g consistently Sanitation review was conducted and found some opportunities Work with chemical supplier Found above average cleaning practices Utility drainage and temporary repairs were concerns Air sampling showed high Mold counts in most areas besides the main employee entrance and a slicing room with a newer HVAC unit

4 Zone 4 Key Finding Facility Sanitary Design Review Noticed musty smell when walking through adjacent corridors to the production area Found a stream of water running across the floor in a dry storage/utility area Climbed a ladder to look on the mezzanine to see boxes

5 Storage Area Design - Condensation Unjacketed cold water line - condensation dripping on air filters

6 Zone 4 Corrective Action Insulate the line Relocate the air filters Training provided to maintenance team on sanitary design and temporary repairs Air sampler purchased and periodic monitoring

7 Zone 4 Results Mold complaint reduction by 88% following a lag for shipping Internal compliance testing showed 95% reduction in average mold counts

8 Zone 3 Case Study Floor scale Case Environmental Listeria positives > 6 months / persistent No FP positives Actions Review the data Check the sanitation practices Review infrastructure and equipment sanitary design

9 Zone 3 - Findings The data showed a widespread area of positives Percent positive showed one drain was higher than others Rarely above waist level Sanitation review was conducted and found some opportunities Cleaning chemical concentrations 3-4x higher than recommended Poor traffic control during sanitation Operation traffic control was excellent Temperature control in cold storage was moderately cool

10 Zone 3 Key Finding Sanitary Design Review Floor had been patched, but in ok condition Good drain design Floor scale was difficult to clean - time Pooling water on scale harborage/vector Long hoses vector Dripping hose ran through the wall Broken conduit seal

11 Floor scale - harborage

12 Hoses and water leaks

13 Zone 3 Corrective Action Increase sanitation frequency of floor scale <9 days Replace top of scale with heavier gauge metal to prevent pooling Zoning redone to minimize traffic crosses New hose drop / repaired Conduit replaced to eliminate harborage

14 Zone 1 and 2 Case Study Case Study Environmental positives Pre-op failures micro and ATP Poor sanitary design causing challenges in sanitation and product shelf life / quality Sanitary Design training needed for sanitors, operators, maintenance, quality to help identify problems

15 Zone 1 and 2 Case Study Actions 1. Train the team - More eyes to review - Start on example conveyor that has had repeat failure on Pre-Op swabs 2. Conduct review of entire production area - Reduce environmental positives - Improve pre-op pass rates

16 Training the team hollow bodies

17 Training the team - Cleanability

18 Training the Team - Cleanability

19 Training the team Product collection Look from high and low Use checklist Work as a team Using flashlight

20 Production Line - Findings Niches that were very difficult to clean

21 Production Line - Findings Good and Bad Spacing Sandwich joint

22 Production Line - Findings Changes in installation sandwich joint

23 Production Line - Findings Changes over time harborage area

24 Production Line - Findings Cloth belt / cracked welds

25 Production Line - Findings Hard to clean - above product

26 Production Line - Findings Practices resting on insanitary surfaces

27 Zone 1 and 2 Corrective Action Significant redesign of several pieces of equipment Established a sanitary design team that conducted regular reviews Clean Out of Place utilized for parts that are removed Periodic teardown cleaning scheduled for equipment that could not be fully redesigned

28 Zone 1 and 2 Results Improvement in Environmental compliance Improved pre-operational sanitation first pass rate Improved sanitation turn around time Cost reduction in chemical spend