Sanitary Design Principles. Rudi Groppe

Transcription

1 Sanitary Design Principles Rudi Groppe

2 Hygienic Design What are the next steps? Know the Enemy Sanitary Design Guiding Principles Zone Definitions Facility Design Sanitary Methods of Manufacturing Focus: How do I ask the right questions? Rudi Groppe rudi@heinzen.com December 14-15, 2017 Yuma, AZ

3 Where can listeria hide? Laminations Bolt Connections, Sandwich joints Surface Finishes Poor welds Exposed aggregate flooring Corrosion (rusting, pitting) Control Panels Condensation, Buttons, Unmaintained gaskets Hollow Areas Tubing Product Containers (Bins/Totes) Product Utensils (Shovels, Paddles) Whether purposely penetrated or not Floors Drains Air Blowers,Cooling Evap Coils Maintenance & Sanitation Work together to voice concerns and ideas when servicing and cleaning equipment & facilities ulatoryinformation/ucm pdf

4 How does listeria move? It needs a vessel for movement. How can movement be minimized? Water Drainage, eliminate back ups and standing water Captive Footwear Properly maintained employee outerwear, Suppliers Trust but verify Aerosols In-Line Cleaning of neighboring equipment Condensation & wipe down High pressure water (NO!) Personnel directly handing product, Need for automation Vehicles (forklift, lift truck, etc.) Organized traffic flow with appropriate barriers Hand/Foot/Foaming proper concentration Pest control program Air Blow down for change-over/pre-sanitation Condensation Ducting Evaporator Units ulatoryinformation/ucm pdf

5 Sanitary Design Guiding Principles AMI, GMA, UFPA, 3A, EHEDG (developed by) (google.com) (joe stout) Method to implement sanitary design and auditing across all process zones Facility Design Guiding Principles 1. Defined Hygienic zones based on a Low Risk to High Risk definition 2. Controlled personnel, equipment, and process material flows in all zones 3. Controlled floor systems with no accumulation inside the facility 4. Room temperatures controlled based on process zones 5. Room pressures controlled based on process zone 6. Exterior of facility designed to facilitate sanitary conditions 7. Doors, Walls, Ceilings designed to facilitate sanitary conditions. 8. Planned accesses for sanitation access and maintenance access. 9. Sanitary design principles applied to all facility support equipment 10. Facility design supports the GMP master plan Equipment Design Guiding Principles 1. Cleanable to a Microbiological Level 2. Made of Compatible Materials 3. Accessible for Inspection, Maintenance, Sanitation 4. No liquid Collection 5. Hollow Areas Hermetically Sealed 6. No Niches 7. Sanitary Operation Performance 8. Hygienic Design of Maintenance Enclosures 9. Hygienic compatibility with other systems 10. Validated cleaning and sanitizing protocols

6 How do we embed the Principles of Sanitary Design into our Core Values? Develop a Vendor Qualification Program Internal teams Proactive training? Facility Contractors Equipment Suppliers Equipment Installers Heinzen Eng Team Are we armed and dangerous? Who owns it? How do we handle it?

7 Definition of Design Zones The development of Design Zones is critical for the development of the sanitation master plan, and standardized methods of sanitary design and methods of manufacturing. The Zone concept is designed to work with a Master Sanitation plan to include the testing and verification process.

8 Definitions of Design Zones Zone 1 Product Contact Surfaces These are the surfaces in direct contact with the product and are subject to regular sanitary cleaning and swabbing. Incidental Product Contact Surfaces The product and surfaces from which product, liquid or material may drip, drain, drop, diffuse or be drawn into the product or onto Product Contact Surfaces. This includes any surface through which process fluids or gases flow that are subject to environmental and sanitation concerns for a RTE food processing facility. These surfaces are subject to regular sanitary cleaning, and may present a high potential for cross contamination Zone 2 Non-Food Contact: table legs, floors, drains, aprons. Zone 3 Non Product Contact Surfaces and areas below the product line. These surfaces are subject to regular sanitary cleaning such as leg supports, drain covers, stairs, platforms, etc. and are still subject to environmental and sanitation concerns for a RTE (ready to eat) food processing facility. Zone 4 Remote: doorways, walls, drains (non-processing).

9 Defined Hygienic zones based on a Low Risk to High Risk definition RAW Incoming product storage area, pallets, wood, cardboard. RTE = Ready to Eat, zone where the product is undergoing microbial reduction. HH = High Hygienic, product is in its cleanest state, just prior to packaging. LR = Low Risk, Finished Product, Offices, Locker rooms.

10 Sanitary Plant Design Defined Hygienic zones based on a Low Risk to High Risk definition

11 Facility Design Guiding Principles Best Practices: How do we all get on the same page? Floors Floor Drains Walls Electrical and Plumbing Contractors Evaporator Units Equipment Anchoring

12 Floor Systems: What is the risk with a compromised floor system? Sloped Floors typically 1/8 inch to 1/4 inch per foot (Specify Non-Pooling) 3/16 per foot in Critical Processing areas High forklift traffic areas Floor Coatings Polyester base, Epoxy Base, Urethanes Base Urethane Floors, Set in degrees in wet cond. Retrofitting Existing Facilities Preparation is 90% of the work Urethanes cures fast in cold, now available in high build

13 FLOOR PREP FAILURE

14 URETHANE FLOOR COATINGS

15 GREAT YOUTUBE VIDEOS!

16 Lamination Control and Mobile Equipment Protection

17 What s can we improve on in this picture? Isolated Support Equipment

18 Floor Drain Systems: Short trench drains versus long trench drains Stainless Steel, design allows concrete to key to prevent de-lamination 12 x 12 Drain Box 8 x 48 Area Drains for high flow.

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20 Walls, Ceilings, How to handle Laminations and Penetrations? Ceiling Height, Raised curb system with sloped ledge and epoxy coated or Stainless Steel Base Wall systems use, 3 Urethane Insulated Metal Panel (FRP) Walk on roof system, 4 Urethane Insulated Metal Panel

21 Retrofitting Existing Walls, need creative work arounds.

22 Sub Contractors Pre Qualified Sanitary wall connections

23 Evaporators in Process Room Flush Hung to Roof Stainless Steel Coils Axial Fan vs Centrifugal Fan Types Water Wash and Flush Systems

24 Equipment Anchoring Insure grout is sealed to the edge of base plate Cap anchors to cover exposed threads Quality of grout and contractor training Equipment removal procedure to clean all connections

25 Equipment Design Guiding Principles Best Practices: How do we implement the 10 principles of sanitary design? Training Review of each principle with updated equipment checklist Examples

26 How do we Finding Discipline!

27 What does it mean? HOW DO I CLEAN IT?

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30 9. Sanitary design principles applied to all facility support equipment

31 Equipment manufactures need constant feedback on any sanitation or safety issue

32 Weld Standards - Zone one The Stack of Dimes Not Acceptable

33 Weld Standards - Zone two

34 Examples of bad welds, field repairs by unqualified welder

35 Inspect what you expect!

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38 Sheet metal - Zone 1, The importance of large radius corners 1. TIG, Butt Weld in the flat 2. Large radius Formed Corners (not welded)

39 Channelized Construction Eliminates hollow tube and threaded leg adjusters

40 Channelized Construction

41 Drop Down drain pans

42 Threadless Adjustable Footpad

43 Etched Marking

44 ROTARY VALVES WITH FLEXIBLE LIP SEALS

45 Sloping Top of Motor Control Panel

46 <<Safe Connectors Hermetically sealed push buttons <<Cable Enters Bottom of Panel

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48 Fresh Cut Facility Design Rudi Groppe December 14-15, 2017 Yuma, Az