Sanitary Plant & Equipment Design for Fresh-cut Produce ... · Sanitary Plant & Equipment...

Sanitary Plant & Equipment Design Sanitary Plant & Equipment Design for for

FreshFresh--cut Produce Processingcut Produce ProcessingJim Gorny, Ph.D.Jim Gorny, Ph.D.

Executive DirectorExecutive Director

SanitaryDesign

Resources• Good • Better• Best

3-A International Association of Food Industry Suppliers

www.3-a.org

Don Graham, PresidentGraham; Sanitary Design Consulting

Jackson, MI 49203 USATel: 517.769.1733

grahamdj@prodigy.net

Sanitary design is the application of design techniques which allow for the timely and effective cleaning and sanitation of an entire food manufacturing/handling facility.

Proper Sanitary DesignReduces the potential for microbial, chemical and physical contamination & cross contamination.Difficult/impossible to clean.CorrosionReduces operating costs.

Sanitary DesignSanitary Design

Capital CostsCapital Costs

Operating CostsOperating Costs

Sanitary Design ObjectivesSanitary Design Objectives

Minimize harborages and infestationsRodents, insects, birdsMold, MildewMicroorganisms

Minimize environmental pollutants

Sanitary Design ConsiderationsSanitary Design ConsiderationsBuilding Site & GroundsFloors/DrainsWallsCeilingsProduct/Personnel FlowLightingDoors/DoorwaysHVAC SystemsRefrigeration UnitsWater Supply

PlumbingPersonnel FacilitiesHand/Boot Sanitizing StationsCompressed Air LinesPackaging AreasShipping Receiving DocksQA LabMaintenance AreaEquipment Sanitary Design

Building Site & GroundsBuilding Site & Grounds

No rodent harboragesWaste area paved, well drained, doesn’t attract pests.Minimize bird roostsGrounds, parking lot, driveways well drained. 80 cm cement or gravel buffer around buildingNo opening >0.5 cm to prevent rodent entryDoor opening equipped with air curtainsOutside lights (low UV) don’t’ shine on doors and plant openings,shielded/shatter proof.

Building Site & GroundsBuilding Site & Grounds

Isolatepedestriantrafficfromvehicular

Isolatevegetation

Isolatevegetation

50m

50m

Isolatepedestriantrafficfromvehicular

Vermin strip around building perimeter

Site DesignSite DesignVehicular CirculationVehicular CirculationVermin ProtectionVermin ProtectionVegetation IsolationVegetation Isolation

Floors & DrainsFloors & Drains

Floors and trench drains sloped (1-2% grade)Floor constructed of waterproof covering (e.g acid brick)Course non slip surface No punctures so as to prevent moisture accumulationDrains have removable covers or grates to allow cleaning.Chemical, abrasion and impact resistant.Good light reflectance.

WallsWallsSmooth, cleanable, non absorbent & bright.Fixtures, pipes, brackets mounted 1 cm to facilitate cleaning & pest control.Floor/wall joints & corners coved to facilitate cleaning.Structural seams filled/smoothed to prevent debris collection and filth/microbial harborage. Easily water cleanable and chemical resistant.

Bumper Curbs

WallsWalls

CeilingsCeilingsSmooth, cleanable, non absorbent & bright.Utility runs above the ceilingCeiling/wall joints & corners constructed to facilitate cleaning.Structural seams filled/smoothed to prevent debris collection and filth/microbial harborage. Easily water cleanable and chemical resistant. Sufficient space above ceiling for pest control/maintenance.All under ceiling structures insulated or placed so condensate will not drip on to food products or food contact surfaces.Minimize threads on pipe hangers.

Product/Personnel FlowProduct/Personnel Flow

Minimize process room entrances.Uni-directional product flow.Short, direct routes for product & personnel flow.Employees enter via break room or locker rooms.

LightingLighting

Adequate lighting for product inspection, cleaning & sanitizing activities.Process area: at least 50 foot candles illumination.Light fixtures protected with a shatter proof shield.Light fixtures located so they are easily cleanable.

Doors & DoorwaysDoors & Doorways

Solid doors and door frames.Rust resistant and sealed seamsSelf closing doors preferred.Equipped with screens or air curtains.Restroom doors should open into a hallway or anteroom, NOT the processing room.Restroom door self closing mechanism or maze entrance.

HVACHVAC

Vents should bring in sufficient filtered fresh air.Windows screened to prevent pest/insect intrusion.Positive air pressure with a gradient finished product packing area highest pressure; raw materials and shipping/receiving areas lowest air pressure.Easily cleanable filters.Filtered air intakes 95% efficient filters at 5 microns to prevent harmful pathogen intake.HEPA (99.97% at 0.3 MICRON) Microns

Bacteria: 0.4 - 5Viruses: 0.003 - 0.06Fungi: 10 - 30Yeast: 4 - 12Human Hair: 50 -100

Refrigeration Units Refrigeration Units

Drip pans piped to drain lines to remove condensate into drains not on to process room floor.Drip pans accessible to cleaning.Evaporator fins constructed for stainless steel or copper to prevent oxidation of fin metal.Air turned over at least 6 times / hour 5% filtered makeup air.

Source and distribution system should provide drinking water quality water (tested periodically).No cross connections with non-potable water.Back flow prevention devices between faucets & sinks.Retractable hose reels to prevent hoses from lying on the floor after use and to prevent back siphoning. Hot water supplied at hand wash sinks and all restroom sinks.

Water SupplyWater Supply

Drains should have an interceptor connecting to the drain or building sewer. Sufficient space around interceptor for easy cleaning.Drain lines should be constructed of corrosion resistant materials (e.g. coated concrete, PVC, stainless steel).All overhead plumbing lines should be located over an aisle or covered to prevent condensate from falling on to in-process food or food contact surfaces.

PlumbingPlumbing

Sufficient number of toilets in compliance with regulations. Sewer lines and process water sewer lines should connect outside the plant past a back flow prevention device. Restrooms should be constructed of materials that cleanable and non absorbent.Partitions, sinks and fixtures should be wall or ceiling mountedto facilitate easy cleaning under them. Restrooms should be equipped with a fan (to create negative air pressure) and actuated when the lights are turned on. An outside rack for holding smocks, gloves, etc. before employees enter the restroom. No touch actuated sink controls.Restroom doors should open into a hallway or anteroom, NOT the processing room. Restroom door self closing mechanism or maze entrance.

Personnel FacilitiesPersonnel Facilities

Hand/Boot Sanitizing StationsHand/Boot Sanitizing Stations

Sufficient number of handwashing and sanitizing stations in the processing/packaging area to assure availability, and ease of use. One handwashing station about every 100 m2

Boot sanitizing troughs, sprays or mats at all processing/packing area entrances. Hand washing stations equipped with warm water, soap, disposable paper towels and disposal containers.

Air compressors should be the oil-free type. Compressed air lines should pass through an oil filer, and dryer/cooler before entering the main air line. In-line point of use moisture traps, oil filters and air fitters where compressed air contacts product or food contact surfaces.Clean filters often.Micro test compressed air if it contacts food products.

Compressed Air LinesCompressed Air Lines

Packaging AreasPackaging Areas

Packaging supply area should cool, dry and away from the processing area. Remove packaging materials and pallets before cleanup an sanitation begins. Packaging materials should be stored in manner that prevents or provides evidence of contamination.

Shipping / Receiving DocksShipping / Receiving Docks

Elevated at least 1 mTight door seals with air curtains or quick doors. Dock leveler plates should have brush seals to keep rodents out.Dock canopies should prevent/reduce likelihood of bird nesting. Produce containers should be stored on clean pallets 15 cm off the floor.45 cm buffer between walls and product to permit cleaning and pest inspection.

Quality Assurance LabQuality Assurance Lab

Dedicated lab or room for QA activities.Walls, ceilings and counter tops constructed of acid resistant impervious materials. Adequate lighting (100 foot candles)Hot and cold water with a sink.Segregated from processing plant especially if you are doing any microbiological testing.

Maintenance AreaMaintenance Area

Physically segregated from the processing area.Sufficient access for machinery to be brought into the shop. Appropriate number/type of drop clothes, shields and plastic sheets available to contain possible contamination in the work area during on line repairs. Facilities for good housekeeping in the maintenance area.Facilities to clean and sanitize equipment after repairs.

Equipment Sanitary DesignEquipment Sanitary Design

Constructed to prevent product build up whereby build up falls back into the product flow.Easy disassembly for cleaning and sanitizing during the sanitation shift.If possible no special tools should be required.Food contact surfaces:

non-toxicnon reactive with foodsnon contaminatingnon corrosivecan be easily cleaned & sanitized

Equipment Sanitary DesignEquipment Sanitary DesignConsider use of product color contrasting materials.Equipment supports accessible to cleaning/sanitizing.Keep equipment 45 cm from other pieces of non attached equipment and 80 cm from walls.Keep equipment at least 20 cm off the floor.Use only non toxic food grade lubricantsMotors and drives mounted outside the food contact zones with drip pan to catch any leaking lubricant.Motors fully enclosed and sealed to prevent moisture ingress.Do not use PVC piping due to porosity and microbial harborage potential.

Cleaning & SanitizingCleaning & Sanitizing

Physical Debris RemovalPhysical Debris Removal

RinseRinse

DetergentDetergent

PostPost--rinserinse

SanitizeSanitize

Total Plate Count: < 200 Total Plate Count: < 200 cfucfu / 25 cm/ 25 cm22

Yeast & Mold: < 50 Yeast & Mold: < 50 cfucfu / 25 cm/ 25 cm22

Pseudomonas: < 50 Pseudomonas: < 50 cfucfu / 25 cm/ 25 cm22

ColiformsColiforms: < 10 : < 10 cfucfu / 25 cm/ 25 cm22

What Does Clean & Sanitary Mean?What Does Clean & Sanitary Mean?

Cleanable Surface?

Replicate Organism Direct Agar Replicate Organism Direct Agar (RODAC)(RODAC)Contact Plates Petri Contact PlatesContact Plates Petri Contact PlatesSurface SwabbingSurface SwabbingSurface Rinse Method Surface Rinse Method BioluminescenceBioluminescence

Inspection and Microbial Monitoring Inspection and Microbial Monitoring

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Lot Number

Log

(CFU

/g)

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4

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0 5 10 15 20

Lot Number

Log

(CFU

/g)

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Microbial Monitoring: Trend Analysis Microbial Monitoring: Trend Analysis

Good Agricultural PracticesGood Agricultural PracticesGood Manufacturing Practices Good Manufacturing Practices Personnel Policy ManualPersonnel Policy ManualStandard Operating Procedures Standard Operating Procedures Sanitary Standard Operating ProceduresSanitary Standard Operating ProceduresMaintenance Schedule, Preventative Maintenance, LogsMaintenance Schedule, Preventative Maintenance, LogsMaster Sanitation ScheduleMaster Sanitation ScheduleEnvironmental Micro Monitoring Environmental Micro Monitoring HACCPHACCP

Food Safety Program Component ProgramsFood Safety Program Component Programs

GAPsGAPs

GMPsGMPs

SSOPsSSOPs

HACCPHACCP

Master Sanitation ScheduleMaster Sanitation Schedule

Area SanitationMethod

Tool CleaningMaterials

Frequency

Walls Foam,Brush,Rinse

SoftNylonBrush

Chlorine-quat

basedcleaner

Once /Month

Floor Wash,Rinse

HardBristleBroom,Hose

Chlorine-quat

basedcleaner

Daily

Sanitary Standard Operating ProceduresSanitary Standard Operating Procedures

What: Identifies Task

Why: Purpose of Task

Who: Responsible Person

How: Steps for completing the task

Sanitary Design: A Case StudySanitary Design: A Case StudyFebruary 2007, ConAgra Peter Pan Brand and some Great Value (Wal-Mart's store brand) peanut butters were linked to 425 cases of Salmonella across the USA.44 States71 hospitalizations 0 deathsIllness onset: August 1, 2006 - February 16, 2007 most (67%) after December 1st.ConAgra traced the source of the Salmonella contamination to a leaky roof and sprinkler in its Georgia plant.

Sanitary Design: A Case StudySanitary Design: A Case Study

What criteria is used and when do you decide to stop production due to a facility or equipment sanitary design issue?Who makes the decision?

quality assuranceproductionplant managerowner

What food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Baling wire Duct Tape

Fiberglass Panel

In Good Repair?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Sanitary Design: Cases StudiesSanitary Design: Cases StudiesWhat food safety component program(s) should address the issue?How does one fix the problem short-term?How does one fix the problem long-term?

Summary

Sanitary facility and equipment design are critical in assuring product safety. Sanitary design capital costs can be recouped by reducing recurring costs.Have food safety programs in place that evaluate and constantly address implementation of facility and equipment sanitary design and use. Have a plan to know when to stop production due to an unsanitary facility or equipment condition..

Jim Gorny, Ph.D.Executive Director

University of CaliforniaDepartment of Plant Sciences MS2

3045 Wickson Hall1 Shields Ave

Davis, CA 95616

Tel: 530.754.9270Email: jrgorny@ucdavis.edu

http://postharvest.ucdavis.edu/