- Protecting your Customers

Transcription

1 : ) (J) lo... -P- C: C/) Why is Sanitary Design Critial? - Proteting your Customers The three most ommon ulprits for food ontamination are Listeria, e-coli, and Salmonella. Sanitary food equipment and proessing is the main defense against ontaminated food. It is important beause sanitary onditions protet your ustomers, and protets the livelihood of your employees. Listeria Commonly found in unooked meats, unooked vegetables, unpasteurized milk, foods made from unpasteurized milk, and proessed foods. Listeria is killed by pasteurization and ooking. Salmonella Commonly found in Poultry, meats and raw eggs. Thorough ooking and washing hands after handling raw meats kills Salmonella. E-oli Commonly found in unwashed vegetables or underooked meat. Thorough ooking and washing hands after handling raw meats kills E-oli.

2 Who Sets thq Standards? There are several agenies involved in the Sanitary Design and the Sanitary Prodution of food goods. In this publiation, we will disuss the five that have the broadest impat on the Food Industry today. They have different histories, different funtions, and different levels of legal responsibility. Eah has its own publiations and websites and further information on the different organizations should be sought through those hannels. ) (f)! ) en~ Ensuring Produt Quality The Amerian Meat Institute (AMI), United States Department of Agriulture (USDA), and 3-A (an independent organization of equipment manufaturers, food proessors, and regulatory agenies) are probably the best-reognized experts in the area of good design praties for sanitary equipment appliations. Eah of the three has a slightly different approah to the task of making equipment safe for produt of Ready-To-Eat (RTE) food. RTE food is anything that the onsumer may eat without additional preparation. This inludes foods that are normally heated before serving, but ould be eaten without preparation beause of emergeny, or personal preferene. This presentation aims to take the keys points of ten different areas onsidered when evaluating a design for suitability in a RTE Food appliation, and show examples of good and better onstrution.

3 ) (f)!o (f) AMI Amerian Meat Institute At I AMERICAN MEAT INSTITUTE AMI is a national trade assoiation that represents ompanies that proess 95 perent of red meat and 7 perent of turkey in the US. Headquartered in metropolitan Washington, DC, AMI keeps its fingers on the pulse of legislation, regulation and media ativity that impats the meat and poultry industry and provides rapid updates and analyses to its members to help them stay informed. In addition, AMI onduts sientifi researh through its Amerian Meat Institute Foundation designed to help meat and poultry ompanies improve their plants and their produts. The Institute's many meetings and eduational seminars also provide exellent networking and information-sharing opportunities for members of the industry. The Amerian Meat Institute (AMI) is the nation's oldest and largest meat and poultry trade assoiation. AMI is dediated to inreasing the effiieny, profitability and safety of meat and poultry trade worldwide. AMI does not provide third-part reviews of food -pakaging equipment, but does provide exellent, urrent, review tools to assess sanitary design for food produers and equipment manufaturers. METTLER TOLEDO is an AMI member, and their Sanitary Design Cheklist was used as a framework in preparing some of the materials for this publiation. AMI does not have legal authority over food prodution, but its membership whih inludes the major meat and food manufaturers, gives it a diret and major influene on the industry. I /

4 USDA USDA United States Department of Agriulture USDA Meat & Poultry USDA Dairy The United States Department of Agriulture (USDA) is the federal government ageny that is responsible for the safe food supply for the United States. The USDA does this diretly through plant inspetion, and indiretly by providing evaluation of equipment used in the proessing and pakaging of food goods. Within USDA, there are two branhes of the department that have expertise in sanitary equipment onstrution - one for Meat and Poultry, and, the other for Dairy. : ) (/)!I.- -t- Dairy grading assists the dairy industry in marketing high-quality dairy produts by providing buyers and sellers with an impartial appraisal of produt quality and to provide the onsumer onfidene in buying. Food Safety Inspetion Servie (FSIS) USDA provides a third-party equipment evaluation servie through its Food Safety Inspetion Servies (FSIS). USDA Dairy and USDA Meat and Poultry have separate equipment grading groups, and their standards differ slightly from one another. USDA has a national responsibility for the safety of food goods in the United States, and several neighboring ountries have adopted many or all of the USDA standards as their own. The status as a federal organization with legal authority and responsibility separates the USDA bodies from other Food Safety organizations that have no legal apaity.

5 ) en ().) \,...E Cf) 3-A 3-A Sanitary Standards, In. During the 192s, the need for more stringent and uniform standards for dairy proessing equipment beame evident as the U.S. eonomy and onsumers entered the modern era. Representatives of three interest groups- proessors, regulatory sanitarians and equipment fabriators- reognized the need for ooperative ation and introdued the first industry standards for equipment. These standards beame known as '3-A' standards for the three interest groups that forged a ommon ommitment to improving equipment design and sanitation. Like other types of standards, 3-A Sanitary Standards relate to the leanability of dairy equipment. 3-A does provide a third-party evaluation for some food produing equipment, inluding some onveyors. It has no government authority like that with USDA. 3-A Sanitary Standards provide material speifiations, design riteria and. other neessary information for equipment types to satisfy publi health onerns. 3-A Sanitary Standards are available for many equipment types, from fittings to silo tanks. At this writing, standards for onveyor design are limited to use of the onveyor for dry foods and powders. I )

6 NSF NSF International NSF was founded as the National Sanitation Foundation in 1944 to standardize sanitation and food safety. NSF International is a non-profit non-government organization that provides ertifiation servies for equipment used in the proessing of meat and poultry, and Ready to Eat foods, against NSF/ANSI/3-A Standards , -2 and -3. These standards have been ited by the USDA for the evaluation of equipment used in proessing meat and poultry. NSF has no diret legal authority over food produing organizations like the USDA. The "NSF 14159" standard aligns with the European Norm (EN) NSF 14159, to advane a harmonized Sanitary Design Standard between Europe and North Ameria. NSF is more oriented towards the proess side of the business than the other agenies itted, providing training and areditation for Hazard Analysis Critial Control Points (HACCP).

7 Criteria for Sanitary Designs ') (f) '-- -+ (/) Cleanability D Design prevents mirobial growth - Smooth, regular surfaes that make sanitation easy D Surfaes are aessible for leaning and treatment - trap-free, open onstrution D Cleaning protools provided by manufaturer - means that leaning wasn't an afterthought in the design proess D Surfaes are lean visually and to touh - the eyes and fingers are your first gages of leanliness, j ' Favorable Pratie Smooth finish, free of pokets or stray material that an ollet or harbor mirobial infestation. Easily disassembled and assembled. Non-Preferred Pratie Surfaes (suh as bead-blast) that have small pokets invisible to the naked eye (USDA Dairy does not allow bead-blast beause of this trait). Surfaes with indentations that an be deteted by running your thumbnail aross the surfae.

8 Compatible Materials D Resist orrosion, non-toxi, non-absorbent - materials an't hold mirobial growth, or ontribute toxins through breakdown D 3 Series Stainless - inherently orrosion resistane, and properly handled to prevent orrosion from forming or welding D No plating or oating in food area - oatings ultimately fail and ontaminate the produt D No loth baked belts - loth wiks moisture, and harbors mirobes D No aluminum - Aluminum rumbles in typial sanitation solutions D No hemial interation between materials, or the produt - must be hemially neutral to prevent ontamination D Seals minimize produt ontat - proper use of barriers prevents ontamination of produt ontat zone from less-ontrolled area : ) U) CD ~.E C, / Cf) Favorable Pratie All stainless and food-grade plasti onstrution. Single layer plasti belt preferred over loth-baked or modular. Proper fabriation praties to prevent orrosion from weld areas. Bolted joints are properly gasketed. Non-Preferred Pratie Clothed baked belts should not be used -stray fibers wik moisture and mirobial material. Aluminum should not be used as it dissolves in harsh environments. No sealants in lieu of sanitary gaskets.

9 ) U) ' (f) No Liquid Colletion D Surfaes are designed to prevent pooling - surfae are onvex over onave D Framework is round, or turned 45 degrees - with no flat undersurfaes that are diffiult to see or lean D Surfae areas and belts do not warp or hange shape to ollet liquid - no temporary ponding from thermal bukling D No dead spaes - flat spaes are less expensive to make, but more ostly to lean, / ) Favorable Pratie Start with the produt ontat zone and ensure that everything flows down and away from there. Non-Preferred Pratie Conave surfaes, or large surfaes with tendeny to bukle. Pokets between bearings and onveyors. Frames with large upper or lower surfae areas that enourage moisture retention.

10 Sanitary Operational Performane D Buttons on ontrols are easily leaned - no buttons means the easiest leaning D Air ontating produt is dry and.3 miron filtered - an be done at the mahine, but sanitary air is ultimately dependent on plant air soure D No bearings in the produt zone- USDA Dairy 153 mm min gap, or *4"/3 mm/1 " ru le D Areas near the produt zone should be onsidered as the produt zone - onsidered "splash" areas D Produt zones prevent produt buildup - onstrution should defeat produt buildup ) U) (]) ~.E, I 1 U) Favorable Pratie Drives and bearings are we llremoved from the produt ontat zone. Proper separation of produt and non-produt ontat zones. User friendly, button-free, or buttons that are easily leaned and properly proteted. Non-Preferred Pratie Bearings in the produt zone or internal to pu lleys. User interfaes or buttons that require protetion during leaning. Use of no-sanitary guides for produt zone separation. * The " 4"/3 mm/1 " Rule" is a USDA Dairy requirement that permits a onstrution where the bearings and drive of a onveyor an be loser than standard 6" (153 mm) from the produt ontat area. It states that produt guided by sanitary guides that are 4" minimum height, no more than 3 mm from the belt surfae, and no less than 1" from the edge of the belt, permit drive omponents up to 1" from the produt ontat area.

11 ) en (])! U) Hygieni Design of Maintenane Enlosures D No drives, guards, or enlosures above the produt zone - and sloped away from the produt ontat zone D Control boxes are mounted in a sanitary manner - using the same design priniples as the mahine D Conduit and supply lines are 12" from the floor, and easily leaned -ables that are movable are easier to lean around D No onduit or able over the produt zone - ondensate with mirobes ollets and drains from the exterior D Enlosures must be able to withstand diret leaning and sanitation - no plasti shields allowed, ) ; Favorable Pratie Operator interfae on same side as the operator. Conduits and ables are freely supported. Enlosures are smooth surfaes and drain away from the produt area. Non-Preferred Pratie Operator reahes over onveyor, or Ul extends aross onveyor. Enlosures and Ul are lower IP rating than mahine omponents. Drive assemblies are part of the produt zone.

12 Aessible for Inspetion, Cleaning and Maintenane D Surfaes aessible for leaning and inspetion - easy to see and easy to lean D Inaessible parts are easily disassembled and reassembled - diffiult tasks are poorly done or ignored D CIP is preferred over COP - means the equipment designer onsidered leaning in the design D COP parts should be mounted to the mahine - or trays provided to ollet for leaning D Cath bins or pans are easily removed - rejet olletions are often overlooked as produt ontat areas D Belt is removable and tensioned without tools - more likely to be thoroughly leaned and free of threads D Produt ontat areas are 18" above the floor minimum floor learane of 12"- prevents splash and makes lean out easier D Tubing is easily removed for leaning - espeially where used to onvey food ) -- CJ) ' ) C/) I Favorable Pratie Open onstrution for leaning and visua l inspetion. Intuitive fieldassembly. Non-Preferred Pratie Field maintenane requires tools. Areas are onealed from leaning, inspetion. Narrow gaps hide areas requiring sanitation.

13 ) (/)!o....e (f) No Nihes D Produt surfae 32 IJ-in or better - for all surfaes, inluding welds D Non produt surfae 64 IJ-in or better - for areas outside produt ontat zone D 135 internal angles or with 1/8" or large radii - area between the surfaes an't be seen or leaned D No lap joints - area between the surfaes an't be seen or leaned D Welds are flush, and free of pits, olusions, and orrosion - tight orners are diffiult to lean and trap food material D No press or shrink fits - press and shrink fits have inherent gaps and are subjet to leak. Some standards allow for dissimilar materials where one material flows into the other D No fasteners in the produt zone - fasteners are harborage areas D No exposed threads - even outside the Produt Contat Zone, exposed thread is a ontamination risk D Fasteners require a positive loking method - if used in the produt ontat zone, they annot beome free D Belt support are single-part onstrution - multi-part onveyor beds require lap joints and fasteners D Bolted joints are gasketed with gasket visible - for verifiation of presene and seurity ' ) ; Favorable Pratie Brushed #4 or better. Minimum ontat between support surfaes. Smooth surfaes, and large enough radii to help leaning. Non-Preferred Pratie Pokets for produt buildup. Unsealed gaps between assemblies. Fasteners and threads in produt area.

14 Validated Cleaning and Sanitation D What needs to be leaned, how, and what materials are ompatible for leaning? D What Cleaning and Sanitation Protools are provided by the equipment supplier? D What maintenane tasks are required after leaning and sanitation? - the equipment supplier has onsidered the leaning and maintenane of the mahine at the start of the design, and not as an afterthought. ) U) ~ +- Favorable Pratie A planned sanitation protool that addresses the speifi equipment, for the ustomer to inorporate into the plant sanitation proess. Non-Preferred Pratie Sanitation instrutions that don't onsider the type of equipment, or the environment in whih the equipment will be plaed.

15 ) (f) '--.E a (/) Hermetially Sealed D Solid onstrution preferred over tube D If tube, then welded losed with dye-trae as means to trae failure D IP69K ompliant Eletronis D Monolithi preferred over parts ombinations, laminates, or fabri-reinfored D Standoffs with blind holes and gaskets where welding is not possible or pratial to attah hardware f I I ) Favorable Pratie Minimize tube or all tube losedwelded. Pulleys solid stainless or plasti, or with food dye-traer. Non-Preferred Pratie Internal bearings, soket-head or other fasteners with pokets, hollow pulleys or press-fit assemblies that foster mirobe growth.

16 Hygieni Compatibility With Other Systems Inspetion equipment generally doesn't have a "hygieni ompatibility" requirement with other systems. The equipment should identify in the graphi overview of the design: D All eletrial, mehanial, pneumati, and mounting interfaes that define how the equipment will interfae to the surroundings D All aess for maintenane, leaning and sanitation D How material will flow into and out of the equipment Favorable Pratie A definition of the speifi equipment provided along with the ustomer interfaes for all utilities and ommuniations, maintenane, produt transfers, and produt segregation. Non-Preferred Pratie A generi drawing of a mahinetype, without instrution on integration fundamentals.

17 Cited Referenes: D Wikipedia : ) U) (]) ~ -+: en D Amerian Meat Institute: D USDA: and D 3-A "Sanitary Standards, In": D NSF International : I I )