Sponsored by: Presented by: Commercial Food Sanitation, LLC Heinz General Mills, Inc. Kraft Foods Kellogg Company MOM Brands McCain Foods Limited Nestle USA & Canada Ocean Spray Cranberries, Inc. Quaker (PepsiCo) Equipment & Plant Design For Allergen/Pathogen Control in Low Moisture Foods Part 3: Sanitation Design Principles Equipment Mark Davis Sanitary design is integral to food safety. Learning Objectives • Introduction of GMA Ten Sanitary Design Principles for Equipment • Understanding Equipment Sanitary Design Principles • Review resources available Sanitary design is integral to food safety. Outline • GMA Principles for Sanitary Equipment Design • Sanitary Equipment Design Principles – Examples • Design Standard Resources • Wrap-Up Sanitary design is integral to food safety. Sanitary Design Principles For Equipment The GMA ten principles of design and the corresponding check list are tools to be used to communicate and promote understanding of design concepts which can rapidly advance equipment design. Sanitary design is integral to food safety. Sanitary Design Principles For Equipment 1. 2. 3. Cleanable Made of Compatible Materials Accessible for Inspection, Maintenance, and Cleaning/Sanitation 4. No Liquid Collection 5. Hollow Areas Hermetically Sealed 6. No Niches 7. Sanitary Operational Performance 8. Validated Cleaning and Sanitizing Protocols 9. Separate Processes Wherever Possible 10. Equipment and Personnel at Installation Meet Hygiene and Sanitation Requirements Sanitary design is integral to food safety. Outline • GMA Principles for Sanitary Equipment Design • Sanitary Equipment Design Principles – Examples • Design Standard Resources • Wrap-Up Sanitary design is integral to food safety. Principle 1 - Cleanable • Visibly clean and micro clean – Examples of issues: slide gates, conveyors Principle 1 Sanitary design is integral to food safety. Scraper Blades – Poor Sanitary Design Principle 1 Sanitary design is integral to food safety. Scraper Blades – Better Sanitary Design Principle 1 Sanitary design is integral to food safety. Fact or Fiction? Under the Food Allergen Labeling and Consumer Protection Act (FALCPA) there are only 8 major allergens and these account for 90% of all food allergies. Fact. There are many, many foods (>160) that can cause an allergic reaction, but under FALCPA only milk, egg, soy, wheat, fish, crustacean shellfish, tree nuts, and peanuts are considered “major food allergens”. Sanitary design is integral to food safety. Principle 2 – Made of Compatible Materials Principle 2 Sanitary design is integral to food safety. Solution Alternatives Bad Sanitary Design Good Sanitary Design Principle 2 Sanitary design is integral to food safety. Electrical Panel In Wet Wash Area Principle 2 Sanitary design is integral to food safety. NEMA 4X – Better Sanitary Design Principle 2 Sanitary design is integral to food safety. Principle 3 – Accessible For Inspection and Cleaning Principle 3 Sanitary design is integral to food safety. Pump Faceplate Removed Principle 3 Sanitary design is integral to food safety. Some Disassembly Required Principle 3 Sanitary design is integral to food safety. Specialized Tools Poor Sanitary Design Principle 3 Sanitary design is integral to food safety. Better Sanitary Design Principle 3 Sanitary design is integral to food safety. Quick Release Clamps Better Sanitary Design Principle 3 Sanitary design is integral to food safety. Fact or Fiction? Listeria monocytogenes can grow in your refrigerator. Fact. Listeria monocytogenes is classified as a psychotropic microorganism, which means it can grow at refrigeration temperatures, down to 31°F. Sanitary design is integral to food safety. Principle 4 – No Liquid Collection Principle 4 Sanitary design is integral to food safety. No Liquid Collection • If it’s dry… keep it dry ( no water for cleaning, no leaks, drips, condensation) • If wet… full detergent and sanitizer clean required – Examples or Issue: • Wet cleaning of DRY equipment Principle 4 Sanitary design is integral to food safety. Fitting Design Alternatives Principle 4 Sanitary design is integral to food safety. Principle 5 – Hollow Areas Hermetically Sealed Frame Penetrated Hardware improperly mounted to frame by bolting through tubing Principle 5 Sanitary design is integral to food safety. Temperature Probe Principle 5 Sanitary design is integral to food safety. Case Study: Plant Sanitation Program Failure Sanitary design is integral to food safety. Slide Gate Realities Principle 5 Sanitary design is integral to food safety. Hidden Problems Principle 5 Sanitary design is integral to food safety. Sanitary Design Principles 1-5 1. Cleanable 2. Made of Compatible Materials 3. Accessible for Inspection, Maintenance, Cleaning, and Sanitation 4. No Liquid Collection 5. Hollow Areas Eliminated or Sealed Sanitary design is integral to food safety. 32 33 Principle 6 – No Niches Principle 6 Sanitary design is integral to food safety. Principle 7.0 – Sanitary Operational Performance Principle 7 Sanitary design is integral to food safety. 7.1 – Hygienic Design of Maintenance Enclosure Principle 7 Sanitary design is integral to food safety. 7.2 – Hygienic Compatibility With Other Plant Systems Principle 7 Sanitary design is integral to food safety. Principle 8 – Validated Cleaning & Sanitizing Protocols Principle 8 Sanitary design is integral to food safety. Principle 9 – Separate Processes Wherever Possible Principle 9 Sanitary design is integral to food safety. Zoning Control Principle 9 Sanitary design is integral to food safety. Sanitary Design Principles 6-10 6. 7. No Niches Sanitary Operational Performance 8. Validate Cleaning and Sanitizing Protocols 9. Separate Processes Whenever Possible 10. Meet Personal Hygiene and Sanitation Requirements Sanitary design is integral to food safety. 42 43 Fact or Fiction? People can be a source of foodborne disease. Fact. Noroviruses readily spread from person to person via contaminated foods. Staph aureus is also another pathogen with human origins in many foodborne illness outbreaks. Sanitary design is integral to food safety. Principle 10 – Equipment and Personnel at Installation Meet Hygiene and Sanitation Requirements Principle 10 Sanitary design is integral to food safety. Outline • GMA Principles for Sanitary Equipment Design • Sanitary Equipment Design Principles – Examples • Design Standard Resources • Wrap-Up Sanitary design is integral to food safety. External Reference Materials • Sanitation by Design – Thomas Imholte – 2nd edition • American Institute of Baking – AIB • Bakery Industry Sanitation Standards Committee – BISSC • Grocery Manufacturers Association (GMA) –Equipment Checklist –Facility Checklist • 3-A Sanitary Standards, Inc. • European Hygienic Engineering & Design Group – http://www.ehedg.org/ Sanitary design is integral to food safety. Outline • GMA Principles for Sanitary Equipment Design • Sanitary Equipment Design Principles – Examples • Design Standard Resources • Wrap-Up Sanitary design is integral to food safety. Equipment Sanitary Design Summary Sanitary Design takes planning, education and communication. Should be evaluated using GMA Equipment Design Checklist principles Sanitary Design must factor in: Food Safety Personnel safety Operating costs Total cost of capital System reliability Sanitation and change-over efficiencies Sanitary design is integral to food safety. Fact or Fiction? Leftovers are always safe to eat until they smell bad. Fiction. The kinds of bacteria that cause food poisoning do not affect the look, smell, or taste of food. In fact, it is possible for spoiled food to be safer than unspoiled food. Sanitary design is integral to food safety. Thank You! Questions? Comments? Sanitary design is integral to food safety. Sanitary Design Agenda Day 1 7:00 am 8:00 am 9:00 am 9:20 am 9:40 am 10:40 am 11:00 am 12:00 am 1:00 pm 2:00 pm 2:30 pm 2:45 pm 3:15 pm 3:45 pm 4:15 pm 4:30 pm 5:00 pm Continental Breakfast / Registration 1 Hands On Demo / Intro to Controls for Pathogens & Allergens 2 Hygienic Intervention Case Study Break 3 Sanitary Design Principles – Equipment 4 Risk Remediation Case Study 5 Breakout Session #1 – Equipment Design Review Lunch 6 Sanitary Design Principles – Facility 7 Zoning Control Break 8 Sanitary Design Principles – Installation 9 Sanitary Design Principles –Maintenance 10 Life Cycle Costs & Early Management Break 11 Equipment Success Examples End Sanitary design is integral to food safety.
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