Production Fryer Case Study - IOSH

Production Fryer Case StudyJackie Wooldridge – Group H&S Adviser

profiting together through performance

Agenda

• Company overview

• Case study background

• Causes of fryer fires

• Controls

Interlocked fryer hoods


What we do

3 year objective is to sustain steady top and bottom line growth’

Our simple strategy:1. Focus on attractive market segments 2. Partner with customers looking for quality and

performance3. Deliver through a low cost/high performance

business model

Northern Foods makes great tasting food. We produce

outstanding branded and retailer own label ready meals,

sandwiches and salads, pizza, biscuits and puddings. With

revenues of nearly £1 billion, we employ around 10,000 people at sites across the UK and Ireland.


Agenda




• Controls


A typical production fryer

• In line

• Typically heated by thermal oil, electric or occasionally gas fired

• Extract ducts to remove fume

• Automatic or manual hoist to raise lid

• Contain several thousand litres of oil


Background

• 2005/6 – increase in no. of fryer fires

• No significant losses

• Manufacturing Director challenge

• Decided to audit sites with fryers – 2 days including cleaning

• Identified an external expert

• Defined standards

• Continue this process today ‘in house’


Agenda




• Controls


Typical causes of fryer fires• Overheating

- Fryer temperature control failure- Welding on ‘contactors’- Temperature control failure of thermal oil boiler- Temp alarm failure- Temp probe failure- Extract fan failure

• Low oil level- Failure of float controls- Build up of sediment in float chamber- Human failure

• Sediment build up- Failure to empty crumb trays- Sediment removal belt failure- Sediment removal auger failure- Poor cleaning regime

• Fryer extract duct- Lack of inspection hatches- Failure to clean extract ducts- Poor filter selection

• Change managementFully within our controlPartially within our controlInherent risk

Likelihood ConsequenceRisk

Controls •Basic standards‐½ hourly emptying of crumb tray‐40 hourly clean‐Constant supervision‐Metal storage bins etc…

•Designing risk out‐Two sets of contactors on electric fryers ‐Motion detectors on sediment removal belts‐Hoods interlocked so won’t lift above 1400C etc

•Risk assessment‐Regular audit & review

High risk processes

Combustible construction ‐ Put in non combustible box

x=

Protection•Local suppression‐Provided primary water mist suppression ‐Secondary wet chemical system

•Watermist/sprinklers‐At Carlisle

•Compartmentation‐ Put in non combustible box

Insurance

Business Continuity Management


Agenda




• Controls


Fryer:Critical controls

10. Change management

9. Other hazards

8. Training & procedures

7. Suppression

6. Compartmentation

5. Extract duct standards

4. Fryer controls

3. Cleaning standard

2. Maintenance & inspection procedures

1. Operating procedures

Critical controls


1. Operating procedures

Volumes, product specifications Product flow rates, machine operating hours, ingredients and oilsSafe systems of workTemperature checksSediment removal bin checks

Recorded checks every 30 mins

Metal trays

Stored under water


1. Operating proceduresCooking oils

Type of cooking oil Flash point (0C) Ignition temperature (0C)

Canola Oil 232 330

Corn Oil 254 393Cotton seed oil 252 343

Palm oil 162 316

Peanut oil 282 445

Soybean (Soya) oil 282 445

Sunflower Seed oil 288 Unknown

Commonly used cooking oils including their flash point and ignition temperatures

* Extract from FM Global Property Loss Prevention Data sheet 7-20 ‘Oil Cookers’ – Sept 2007


2. Maintenance & inspection procedures

• Checks on over temperature cut outs

• Checks on alarms

• Planned maintenance

• Annual calibration of temperature probes

• Suppression maintenance system

• Extract duct maintenance

• Contactors – visual checks and replacement policy


3. Cleaning standardsPre cleaning


3. Cleaning standardsPost cleaning


3. Cleaning standards

x


3. Cleaning standards: Critical control pointse.g. float chamber

x


3. Cleaning standardsProcedures

• Documented

• Scheduled

• Gross debris/full deep clean

• Photographic standards

• Visible

• Zero tolerance


4. Fryer controls

• Independent over temperature

• Independent level control

• Interlocked fryer hoods

• Sediment removal belt – motion detector

•Alarms- Over temperature- Sediment removal- Low/high oil level- Sediment bin

• Labels

Mechanical fryer hood interlock


Fryer specification:Critical controls

PRODUCTION FRYERS – SUMMARY OF SAFETY CRITICAL CONTROLS & SUPPRESSION SITE: DATE: CONTROLS Control Set point Audible Alarm Visual alarm Fryer heating Oil fill pump Rec. Actual Rec. Actual Rec. Actual Rec. Actual Rec. Actual Fryer oil over temperature 2100C Yes Yes Shutdown N/A

Low oil level control Fitted Yes Yes Shutdown Shutdown

Bottom scraper belt motion detector Fitted Yes Yes Shutdown N/A

High oil level control Fitted Yes Yes Normal Shutdown

Fryer hood interlocks 1400C Yes Yes Shutdown N/A

Sediment bin alarm Every 30 mins. Yes N/A N/A N/A

Sediment auger motion detector Fitted Yes Yes Shutdown N/A

SUPPRESSION Control Set point Audible Alarm Visual alarm Fryer heating Fire alarm Fire shutters Propellant leak

detection Rec. Actual Rec. Actual Rec. Actual Rec. Actual Rec. Actual Rec. Actual Rec Actual Water mist suppression 2600C Yes N/A Shutdown Activate Activate Yes

Wet chem. suppression 2600C Yes Yes Shutdown Activate Activate Yes

Key In place No further recs. Not in place Further action required Partially in place Upgrade required Not applicable Not applicable


5. Extract duct specification

• As vertical as possible

• Avoid 900 bends

• Easily removable sections

• Filters at base to reduce contamination

• Inspection hatches

• Dampers

• Fans interlocked with fryer heating

• 150mm gap from any combustible construction


6. Compartmentation

• 1 hour compartment

• Protect openings with shutters

• Alarms outside compartment


7. Suppression• Watermist – 10 min discharge

• All key areas including- Sediment removal tray- Outfeed- Infeed- Extract ducts

• Wet chemical back up

•Shut off fryer heating

• Turn off fryer extract duct fans

• Automatic - 2600C

• Manual back up

• Alarmed

• Linked to fire shutters and detection

• Interlocked with fryer heating

• Commissioning


8. Training & procedures

Documented procedures including:

• How to start up and shut down the fryer equipment.

•How to clean, operate and maintain the fryer

•How to empty, fill, and change fryer oils.

•How to identify when the equipment is operating outside its design parameters.

•How to monitor and record regular inspections of float controls, crumb build up, and equipment performance when in operation.

Dalepak Foods Plc Form: FCP 09 Hygiene Training Procedure Issue No. 5 Page 1 of 4 Date: 12.09.06

Title: VEG FRYER ( DEEP CLEAN ) Equipment involved: FRYER

HEALTH & SAFETY You should not carry out this cleaning operation if you have not received the correct training by your Training Officer, Team Leader or Line Manager. You should not deviate from the procedure laid down in the following instruction. Any deviations from these procedures could create a hazard or an unsafe practice. Wear PPE when handling chemicals (chemical gloves, goggles, chemical suit and safety wellingtons). The chemicals used for this cleaning procedure are highly corrosive and should be handled with extreme care, whilst wearing chemical gloves. MIP FT IS ADDED TO COLD WATER. Use correct lifting and handling practices when moving the chemical drums. Ensure the safety of others at all t imes. During the initial pre-clean the floors will become wet and slippery and care should be taken accordingly, ensuring signage is present at all times. During the cook out and whilst the C.I.P. is turned on, the caustic solution will overflow from the fryer slightly, and cover the surrounding floor areas. It is essential that operat ives carrying out the cleaning and any others in the area are aware of this and act appropriately and safely. Ensure that any part drums of chemical are returned to the chemical store with their lids secure. Empty drums should be rinsed out and removed to the appropriate storage facility. N.B. THIS HYGIENE TASK SHOULD ONLY BE CARRIED OUT IF THERE ARE 2 PEOPLE WORKING IN THE AREA, NEVER BY ANYONE ON THEIR OWN. INSTRUCTION FREQUENCY: As required. EQUIPMENT: Metal Scoop, Dolly of Cold Water. OPERATION PRE-CLEAN Before cleaning the fryer it is necessary to empty it. The Oil Holding Tank should have been ‘run down’ during production to enable this. When oil is cool enough (Below 140 ºC), raise the fryer hood, insert the fryer hood retaining pins. Then empty the oil into the holding tank. The sediment drive chain must also be in operation. When sufficiently empty stop sediment chain and remove sediment f ilter, then re-start sediment chain to allow remaining oil to be pumped into holding tank. When the fryer is empty stop the sediment chain and with a flat purpose built scoop remove any remaining oil / fryer debris from the fryer and place this in a suitable waste container. On completion open drain valves at the front and rear of the fryer. The fryer is now ready to be rinsed and refilled with cold water. CHEMICAL DOSING Two drums of MIP FT should now be carefully added to the cold water in the fryer from the accessible (front) end. INSERTING THE HOOD RETAINING PINS ADDING THE CAUSTIC TO FRYER

Signed: Date:

ADDING MIP FT TO THE FRYER


9. Other hazards

• Manual handling e.g. hoods

• Struck by e.g. hood

• Hot oil

• Machinery e.g. nip points

• Chemicals e.g. caustic boil out


Change management

• Consider all changes includingProduct changesProduction increasesMaintenance changesMissed cleansFryer oil changesOperative changes – sickness, holiday

Consider formal change management process

Regular inspections and audits to identify potential issues

Make sure the leadership are aware of the potential risks – give fryers the right priority


Further guidance

FM Global Property Loss Prevention Data sheet 7-20 ‘Oil Cookers’ –Sept 2007

RC 26 recommendations for Organic Thermal Fluid heating systems -FPA


Any questions?

28

Documents

Production Fryer Case Study - IOSH