Sanitary Design
Sanitary Design
SANITARY DESIGN
John Butts
Land O’ Frost
CMC -
Toronto 2009
TOPICS TO BE COVERED
z “B
“Buy-in”
i ” – we will
ill do
d it
z Data
– Sampling data must define the pathway when improving
existing facilities and processes
– Sampling
S li data
d t can beb classified
l ifi d into
i t two
t types
t
• Control
• Verification
– Examples
• Control
– Data collected to find and control a growth niche.
• This includes investigative sampling as well as growth
niche indicator site monitoring
– Data collected to measure the effectiveness of a hurdle or
barrier to perform their respective function
• Verification
– Finished product
– Contact surfaces
The Guide for Evolutionary Change
John Butts
Land O’ Frost
CMC -
Toronto 2009
What do you mean
the sample is positive!”
“the positive!
Observe flood
sanitization Are all p
parts and
components being
Observe assembly adequately
sanitized (chemical
or heat)?
Observe Post assembly sanitizer
application
Machine Machine
Component 2
Machine
Component 3
Machine
p
Component 4
Machine
Component 5
Machine
Component 6
Machine
Component 7
JNB1
JNB1 Focus on there is more to Lm control than just eliminating the growth niches on slicers.
John N. Butts, 9/14/2008
Swat Team Sampling
z Sample during an idle period after
sanitation, before production i.e. Saturday
when no production is running
z Sample large areas using sponges or
gauze.
z Sample areas not typically sampled during
routine
ti samplingli
– We found a transient growth niche using this
method – COP basket handle
PROCESS FLOW CHART FOR DESIGN REVIEW
Manufacturer & Customer Review Equipment
Redesign
Design Agianst the Checklist Tool
YES Acceptable? NO
Acceptable? NO
OR
YES
Purchase and Install Equipment
Training and Start-up
YES
Evid ence o f
u naccep tab le
o rg anic bu ildu p?
Close Contract
If a rea is Ls p ositive th en
th e su spect area is a p ote ntia l
it is a growt h n iche
g ro wth n ich e
An Engineer’s Perspective
Compounding Opportunities
The original
design may have
been correct. As
equipment ages
it tends
t d tot collect
ll t
a “compounded
level” of difficult
to clean potential
growth niches..
AMI Equipment Design Task Force
4
4. N P
No Product
d t or Li
Liquid
id C
Collection
ll ti
Equipment shall be self-draining to assure that food product, water, or
product liquid does not accumulate, pool ,or condense on the
equipment or product zone areas.
5
5. H ll
Hollow areas H
Hermetically
ti ll S Sealed
l d
Hollow areas of equipment (e.g., frames, rollers) must be eliminated where
possible or permanently sealed (caulking not acceptable). Bolts, studs,
mounting plates, brackets, junction boxes, nameplates, end caps,
sleeves and other such items must be continuously welded to the
sleeves,
surface of the equipment and not attached via drilled and tapped holes
6. No Niches
All parts of the equipment shall be free of niches such as pits, cracks,
corrosion recesses,
corrosion, recesses open seams
seams, gaps
gaps, lap seams
seams, protruding ledges
ledges,
inside threads, bolt rivets and dead ends. All welds must be continuous
and fully penetrating.
7
7. Sanitary Operational Performance
During normal operations, the equipment must perform so it does not
contribute to unsanitary conditions or the harborage and growth of
bacteria
AMI Equipment Design Task Force
8
8. H i i D
Hygienic Design
i off M
Maintenance
i t E
Enclosures
l
Maintenance enclosures (e.g., electrical control panels, chain
guards, belt guards, gear enclosures, junction boxes,
pneumatic/hydraulic enclosures) and human machine interfaces
(
(e.g., pushbuttons,
hb tt valve
l handles,
h dl switches,
it h touchscreens)
t h ) mustt
be designed, constructed and be maintainable to ensure food
product, water, or product liquid does not penetrate into, or
accumulate in or on the enclosure and interface. The physical
design of the enclosures should be sloped or pitched to avoid
use as a storage area.
9. Hygienic Compatibility with Other Plant Systems
Design of equipment must ensure hygienic compatibility with
other equipment and systems,
systems e.g.,
e g electrical,
electrical hydraulics
hydraulics, steam,
steam
air, water.
10. Validate Cleaning and Sanitizing Protocols
The procedures prescribed for cleaning and sanitation must be clearly
written,, designed
g and proven
p to be effective and efficient. Chemicals
recommended for cleaning and sanitation must be compatible with the
equipment, as well as compatible with the manufacturing environment.
Applying the 10 Principles of Sanitary Design
Applying the 10
Principles
of Sanitary Design to
RTE Equipment
E i t
Sanitary Design
Sanitary
y Designg Processing
g
Key Criteria for Food Equipment
h)
Listeria ((0.5 µm, 19.7 µ-inch
7 µ-inch)
4 µ-inch)
Mold spo
Salt (120
MEASURES OF CLEAN
z Test for bacteria
– <11 CFU (colony forming unit) per 25
square centimeters or <1 CFU in 10 ml of
rinse water
z Acceptable RLU (relative light unit)
– as generated by an ATP reader; ATP
indicates the presence of organic material
MEASURES OF CLEAN
Measures will
M ill b
be
taken in difficult
t clean
to l areas
Applying the 10 Principles of Sanitary Design
Sterile
sponges
or
gauze
pads
Sterile gloves
Marking pen
Applying the 10 Principles of Sanitary Design
Removable belt
supports
Not
disassembled
Difficult to Easy
inspect or access to
t
sample belts
From This To This
Previous Design Sanitary Redesign
Applying the 10 Principles of Sanitary Design
5 6 7 8
1 2 3 4
Hard
Stained soft
plastic grips Non-
Non-
rubber g
grips
p
corrosive
i
Prone to materials
damage Fitted heads
Niches, for equipment
equipmen
threads longevity
t
Rust,
peeling
paint Smooth
finish Easyy to
clean &
inspect
Not original
equipment
Open
p design
g
Free standing
moisture Rounded
edges
Zone 1 – easily
missed &
unexpected
Applying the 10 Principles of Sanitary Design
Solid roller
High Low
Product
residue/buildup
Belt scraper
7. Sanitaryy Operational
p Performance
Open Design
Multiple
collection points
Minimal product
contact area
S l d cabinet
Sealed bi t
•Graphics
•Multi use document
•Training
•Reference
Reference
•Can it be use on the
floor?
•Can it withstand the
environment?
AN OVERVIEW
SANITARY FACILITY
DESIGN
55
1.7 Separate storage areas for tools and
spare parts exist to minimize
contamination for RTE/high risk and
non-RTE/lower risk zones
RTE
Raw
1.10 Separate support and storage areas
for sanitation crews exist for RTE/high
risk and non-RTE/lower risk zones
RTE
Raw
1.15 Trash collection is properly located
and locations are cleanable &
maintainable
PRINCIPLES OF SANITARY DESIGN
RTE Area
PRINCIPLE #3
WATER ACCUMULATION
CONTROLLED INSIDE FACILITY
… requires designs that facilitate free draining of
any moisture that is introduced into the facility
Ponding water environment.
P
Poor repairs
i From This To This More
CURB
COVE
SANITARY DESIGN PRINCIPLES
FOR FACILITIES
PRINCIPLE #4
OO TEMPERATURE
ROOM U U
& HUMIDITY
CONTROLLED
HOW TO CLEAN TO A MICROBIOLOGICAL LEVEL?
Outdoor make
up air inlet
Access
Bird Doors
screen
24x 72”
Exhaust return
air from RTE
Area
Intake Outlet
Air Handling System
Clean Upp Mode
Fresh Air Sanitation Processes
Intake
•Pre-Rinse
Flame sterilized – •Soap
S
Heated and Dried
•Rinse
Exhaust –
•Flood sanitize
Moist air
PRINCIPLE #5
poor design
6.1 Driveways, parking lots and pedestrian walkways
are ppaved and drained to p
prevent standing
g water
Good Design
9.2
9 2 Suspended ceilings are
smooth, cleanable, and at a
uniform height
Light
g enclosures
9.5 All vertical surface to floor junctions have
a cove and surfaces that are free of pits,
p ,
erosion and voids
Poor example
Ponding water
Pitted floor surface
No cove
9.6 Concrete surfaces are
free of pits, erosions and
voids, solid and smooth
9.16 Bases of drains are
supported to prevent
settlement
Poor examples
7.8 All voids associated with utility
… failure to fully seal void associated penetrations are fully filled with appropriate
with utility
yppenetrations materials,, then sealed. Sprinkler
p penetrations
p
insulated, sealed & heat traced
Good examples
9.21 Doors and windows are constructed to prevent
harborage, impervious, easily cleanable and resistant to
wear and corrosion
Good example
Poor example
p
• Seams From This To This More
• Damage prone
Design Sanitary Design
10.1 Horizontal piping and conduits are not
installed above exposed product or processing
Poor example – piping
above process equipment
Good example –
piping in
From This To This More interstitial space
Good example
Poor example
RTE
Cooler
Wash Room
RTE
Raw
Office and welfare areas Welfare Area
Welfare Area
RTE sewer
10.23 Where
possible, cleanouts
are installed outside
the processing areas
•Stainless traps
and drains
Other options:
•Polypropylene
•PVC, CPVC
•PVDF
PVDF
(Polyvinylidene
Fluoride)
PRINCIPLE #11
•Generally
Generally recommended as city pressure
•Low
L pressure so can’t’t move contamination
t i ti
from floor to higher surface
11.6 Adequate interventions (e.g., foot baths,
doorway foamers,
foamers boot washers) are provided at
locations as required to maintain zones of control
Sanitation hose station
Thank you