Food SafetySite Evaluations

1.) Learn what the customer does2.) Specific areas of concern3.) Current treatment technologies4.) What are their food safety goals5.) Conduct a plant tour, start at the beginning6.) Identify possible treatment points7.) Recommend solutions

The Process

Pet FoodManufacturer

Materials Cook Cyclone Dryer

EnroberCoolerConveyors

Process Flow

Topical

Packaging

Dry Topical Room

Challenges

1.) Two pneumatic systems moving dry additives to further process areaIntake points pulling in plant air through wall.Need CFM rating.

2.) Area is to be walled off from raw materials section within 2 months and they will be installing a new 25,000cfm air handler to cool room.

Dry Topical Room

Dry Topical Room

Solutions

1.) Two Custom fabricated PHI systems utilizing BOS-HOX units to connect at intake points

 2.) One PHI Rack System for new air handler

Cooking Rooms

Challenges

1.) Two rooms with two cookers each. Material is put through extruders and cooked with water and steam so product is hot and moist. This is the only “kill” point in the plant. It goes directly through a cutting die where it takes on the final shape and then is taken vertical through an air lift system. The positive pressure air comes from 4 blowers in adjacent room, each has a HEPA filter. Customer to provide CFM rating of air lift, positive and negative.

 2.) Each cooking room is fed by (3) 50,000cfm air handlers for cooling. .

Cooking Rooms

Cooking Rooms

Solutions

1.) PHI Rack System for each cookers air lift system

 2.) Two PHI Rack Systems for each air handler

Cyclones

Challenges

1.) Four cyclones to remove loose particles from productVery turbulentProduct only inside for a short period of timeInside is never cleaned

Cyclones

Cyclones

Solutions

1.) Not a feasible treatment point.Residual PHI will be present from previous treatment as no venting occurs.

Dryers

Challenges

1.) 160 to 270 degrees F product enters on serpentine style conveyor belts through four drying units.

 Makeup air - 2 dryers are fed by plant air and 2 from outside air. Exhaust rate is 20,000 to 25,000cfm and makeup air is 15,000cfm.

 Each dryer has recirculation blowers. Would be a good place to put treatment units but there is no access and could not see where they could be installed. Drawings are not available.

Dryers

DryersSolutions

1.) PHI Rack System on each dryer makeup air.

Customer will fabricate a plenum for plant air intakes to attach to the side of the dryers where the makeup air enters and PHI Rack will be installed there.

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Enrobers

Challenges

1.) Hot grease and additives from topical area enter at this point. Product is hot and steamy. Lids are supposed to be closed but they leave them open to prevent mold from growing inside.

 2.) Exiting the Enrober the product is transferred to the cooling units using an

auger system

Enrobers

EnrobersSolutions

1.) Not a feasible treatment point.Too hot and product is not present long enough for effective treatment .

2.) Three UVAO panels over auger sections.

 

Coolers

Challenges

1.) Four Coolers with two different styles.

The first type has a bed and the air is pulled in around open bottom and is pulled up through the bed.  The second is a conveyor style. Air is supposed to pull in from bottom and go up through perforated conveyor but is plugged so most of the cooling air is going in at entry point of product on conveyor, which is very small.Need cfm ratings of blowers

Coolers

CoolersSolutions

1.) Two BOS units for each cooler on floor with hoses going up to be attached at bottom openings.

2. ) No treatment proposed for conveyor style coolers as there is no evident means of introducing PHI gases into the unit. Customer to evaluate

modifying cooler.

Packaging Conveyors

Challenges

1.) Some conveyors vibrate very strong so the panels would need to be floor mounted and movable. Other panels would be attached to top structure.Need product travel speed for all conveyorsWill need detailed drawings to size panels as it was not possible to access areas to take measurements.

Packaging Conveyors

Packaging Conveyors

Solutions

2.) Numerous custom UVAO panels over conveyors.

 

QUESTIONS?