Sanitary Equipment Design and Installation Practices suitable for the

Sanitary Equipment Design and
Installation Practices
suitable for the Biscuit Industry
Biscuit & Cracker
Manufacturers’ Association
Manufacturers
Technical Conference
April 27 – 30,
30 2014
Nashville, Tennessee
1
Guidelines for Sanitary Design
• GMA Principles of Equipment Design for
Low
moisture Foods
Low-moisture
– Developed by the Grocery Manufacturers Association’s
Sanitary Design Working Group which consists of sanitation
professionals from the top food companies
– Aim is to improve food safety through equipment design
enhancements by working with equipment manufacturers
to develop
d
l
equipment
i
with
i h the
h best
b
possible
ibl designs
d i
in
i
accordance with the 10 principles
• ANSI
– Z50.2 Baking Industry Sanitary Standard
2
GMA Principles of Sanitary Design
• Cleanable to GMP, product hazard (microbiological,
chemical, physical), and quality levels
• Made of compatible materials
• Accessible for inspection, maintenance,
and
d cleaning/sanitation
l
i /
it ti
• No liquid collection
• Hollow areas hermetically sealed
• No niches
• Sanitary operational performance
– Hygienic design of maintenance enclosures
– Hygienic compatibility with other systems
• Validated
V lid t d cleaning
l
i
and
d sanitizing
iti i
protocols
t
l
• Separate processes wherever possible
• Equipment and personnel at installation meet
hygiene and sanitation requirements
3
“Clean-ability”
• Minimize cleaning requirements
– Flat Surfaces
– Ledges
– Crevices
• Make it easy to clean
–
–
–
–
–
Access
Disassembly/Reassembly
Time
M t i l off C
t
ti
Materials
Construction
Ergonomic Design
• Install
I t ll it so that
th t it is
i easy to
t clean
l
– Clearances
4
“Afford-ability”
• Customized Equipment Designs vs.
Standard Equipment
– Past practices of specifying in detail equipment
requirements from individual equipment manufacturers
l d to
led
t customization
t
i ti
off th
their
i standard
t d d equipment
i
t which
hi h
invariably increased cost
– By
y making
g equipment
q p
manufacturers aware of the
cleaning issues by showing specific examples has lead
the manufacturers to upgrade their standard equipment
in most cases without increasing
g their cost
5
“Afford-ability”
• Industry Conferences and Workshops
between Food Processors and Equipment
Manufacturers
– To address the issues about major
j recalls in recent
times the concerns of our industry were shared with
equipment manufacturers
– Since recalls effect the entire industry,
industry and since
product protection is not and should note be a
competitive advantage, the GMA Work Group and
others have shared the concerns at equipment
manufacturers meetings such as the FPSA and BEMA
conferences
– Addressing
Add essing the need for
fo sanitary
sanita design improvements
imp o ements
as a joint food industry group with joint equipment
manufacturing groups has also already yielded
significant
i ifi
t equipment
i
t enhancements
h
t
6
7
Man Dies From Salmonella Traced To Bakery
March 30, 2011
PROVIDENCE, R.I. (AP) — A man who tested positive for salmonella in an outbreak that may be linked
to a Rhode Island bakery has died.
State health department spokeswoman Annemarie Beardsworth said Tuesday the man died March 23
23.
The man was in his 80s and lived in Providence County. He tested positive for the strain of the bacteria
that has now sickened 39 people.
Beardsworth says 24 of those people have been hospitalized.
Officials say many of the people ate doughnut-like pastries called zeppoles (ZAY'-puh-luhz) made by
DeFusco's Bakery in Johnston. The pastries also were sold at other stores around the state and have
been recalled. The bakery has voluntarily shut down until further notice.
Beardsworth says officials are investigating whether the man who died ate one of the pastries.
8
Equipment
Design Features
9
Minimize Flat Surfaces
Motor Mounts
10
Minimize Flat Surfaces/Chain Drives
and Guards
G a ds
Shaft Mounts & Pulley Drives
11
Hopper Design
Eliminate Square Corners
Provide Round Hoppers or
Corners with 50 mm minimum Radius
12
Eliminate Crevices
Very difficult and time consuming to clean
13
Provide Spacers
Create Gap between Frame and Panel Box
14
Conveyor attached with Spacers
15
Holes and Penetrated Frames
Unnecessary Openings require
additional time
time-consuming
consuming cleaning
16
Ledges
Eliminate Dirt Traps
17
Ledges
Roof Joists with Dirt Traps
18
Extruded Aluminum Frames
Extremely difficult to clean – Avoid them
19
Extruded Aluminum Frames
Acceptable with good covers
20
Cross Braces
Gussets would eliminate need for Braces
21
Panel Legs
Provide Sanitary Legs – not Enclosed Bases
22
Panel Legs
Angle Iron Legs have Crevices
that are very difficult to clean
23
Air Handler Support Frame
Eliminate Cross Braces – very difficult to clean
24
Air Handler Support Frame
Before
After
25
Basic Belt Conveyors
All Components need to be
designed for good Sanitation
Major Components:
• Drive
• Take-up
• Infeed & Discharge Nosers
• Rollers
• Belt Trackers
• Belt
l Scrapers
S
• Belts
26
Maintenance and Sanitary
Conside ations
Considerations
• Belt conveyors must be easy to maintain and clean.
Provide
both
P
id b
h visual
i
l and
d physical
h i l access to all
ll components.
If you can’t see or access components they will be neglected.
Conveyors fabricated from a combination of welded SS tubular
frames and SS or aluminum plates usually provide the best
balance of strength and access for sanitation and long term
maintenance
• All rollers
ll
iin contact
t t with
ith th
the product
d t side
id off the
th belt
b lt
are to be easily accessible or removable without the use
of tools for cleaning purposes. This allows for quick removal
sanitation Also,
Also rollers can be replaced more quickly.
quickly
and sanitation.
This design requires the use of ER type bearings – the roller
rotates on a fixed shaft
• T
Teflon
fl
sleeves
l
for
f
rollers
ll
will
ill eliminate
li i t product
d t buildup
b ild
in
i
most cases. The sleeve should be 6 mm thick hard virgin
Teflon. Do not use standard thin Teflon coating as it will wear
and can lead to product contamination
27
Conveyor Design
Basic Components for Sanitary Design
28
Conveyor Drive Section
Single-roll Drive – No Tandem Drives
29
Lift-Out Rollers
Belt Support Rollers in contact with the
Product Side of the Belt should be easily
accessible for Cleaning or removable without Tools
30
Product Contact Roller on
E tendable Con
Extendable
Conveyor
e o
Not removable without
complete Disassembly
Lift out Rollers
Lift-out
without Tools
31
Teflon Coated Rollers
Do not use Teflon Coating on Rollers that are in contact with
the Product Side of Belts
32
Belt Scraper Detail
Good Design is essential
33
Belt Scrapers
Lack of Scrapers will result in
dirty Belts and Build-up on the Rollers
34
Belt Scraper
Even with considerable
Product Build-up Rollers are kept clean
35
Roller Condition
Without and with good Belt Scrapers
36
Roller Build-up
Without good Scrapers all Rollers build up
and create Belt Tracking Problems
37
Disc Support Rollers
Much easier to clean and cost less
38
Conveyor Legs
Unsanitary
Sanitary
39
Conveyor Legs
Sanitary Leg but
Tripod Base would be better
Good sanitary Leg
without exposed Threads
40
Conveyor Legs
Sturdy with
good
d Access
A
Good but Tripod
without
i h
Brace
B
is
i better
b
41
Conveyor Legs
Ideal Sanitary Design
42
Conveyor Side Guides
Tilt-up Guides for easy Cleaning
43
Product Guides
Guiderail Assembly can be lifted from
both sides for easy Cleaning Access
44
Conveyor Belting
The Strings can end up in the Product
Reinforced Edge
Frayed Edge
45
Conveyor Crossovers
Provide 100 mm high Kickplates
to avoid Product Contamination
46
Platforms
Must have Kickplates that are a minimum
of 100 mm high without any Gaps
between the Kickplate and Floor
47
Platform Design
Poor Design – difficult to clean,
Gap can lead to Product Contamination
S
Square
C
Corner
G
Gap
48
Good Platform Design
Handrails
mounted outside
Overhang and
rounded Corners
49
Platform Design
Good Design with Rounded Corners
50
Good Platform and Steps
Easy to clean
51
Stair Design
Poor – difficult to clean
Better – easier to clean
52
Poor Stair Design
Closed Risers – difficult to clean
53
Stair Tread Design
Square Corners and Crevices –
difficult to clean
54
Good Stair Design
Open Risers – easy to clean
55
Stair Tread Design
Gap between Tread Plate and Frame –
easy to clean
56
Covers
Ingredient Cart
Mixer Shield
57
Improved Door Design
Before
After
Ledge - higher Cost
No Ledge - lower Cost
58
Wire-cut Machine
Before
After
Closed Design
with bolted Covers
Wide open Design
with hinged Covers
59
Rotary Molder
Before
After
Closed Design with bolted
Covers - difficult Access
Open Design with hinged
Covers - easy Access
60
Rotary Molder
Stand-offs
with
ith easy Access
A
Panels and Guards are
sloped
l
d for
f
easy Drainage
D i
61
Open Design
Outboard Drives leaves lower
A
Area
open ffor easy A
Access
Opens completely
with
ith easy Access
A
62
Installation
Practices
63
“Installation Practices”
Clea ances
Clearances
150 mm Clearance
but poor for cleaning
Wide open –
easy to clean
64
Clearances
Clearance meets
Requirements
…but higher mounting of Pipe
would make it easier to clean
65
Poor Clearance and Wiring
Poor
Worst... Dirt Catcher
66
Pump Mounts
Good
Poor
67
Pump Mounts
Good
Poor
68
Pump Mounts
Good Clearance
Better Clearance
69
Insufficient Clearances
Very difficult to clean
70
Clearances
Good Access for Cleaning
71
Pump Base
Legs are too short – nearly impossible to clean
72
Excellent Clearance
Very easy to clean
73
Trapped Area
Very difficult to clean
74
Condensate Pump Mount
Poor Frame
with open Ends
Trapped Area
75
Floor Mounted Condensate
Tank Wiring
Tank,
Wi ing and Piping
Totally unacceptable
76
Unistrut
- Not to be used in Food Production Areas
- Angle Iron Brackets are preferred
77
Unistrut in Production Area
Impossible to clean
78
Hanger Rods
Allthread Rods not to be used –
Rods are to be threaded
only
100
l about
b
00 mm at each
h End
d
79
Covers over Allthread Rods
Not to be used –
they provide an Insect Harborage Area
80
Panel Installations
Unistrut and
Insufficient Clearance
Insufficient Clearance
81
Wall Mounted Panels
Brackets with sufficient Clearance
for Cleaning Access is preferred
Sealed
S
l d–
when Stand-offs not possible
Unsealed –
Insect Harborage
82
Poor and Good Panel Installation
Poor Clearance
and Legs
Good Clearance, Legs
and gabled Top
83
Panel Mount
Solid Bases are good Alternative
84
Pipe and Wireway Mounting
Provide Clearances
Debris accumulates
Insect Harborage Area
85
Wall Mounted Conduit and Pipe
Leave Clearance to avoid Dirt Accumulation
Good
Bad and Good
86
Pipe Mounting
Space between Wall is good –
Unistrut is wrong
87
Wiring
Very difficult to clean, use Conduit
88
Cable Racks
Not to be used in dusty Areas
89
Cable Racks
Poorly installed Cables
When Flour Dust is present it
is nearly impossible to clean
90
Cable Mounting
Acceptable in Packaging Areas that are not dusty
Better – with removable Cover
Poor
91
Cable Trays and Cable Racks
Not to be used in dusty Areas
Cable Trays not to
be used at all
Most difficult to clean
Cable Racks are acceptable
but must be mounted with
Access for Cleaning
92
Cable Rack
Nearly impossible to clean
93
Cable Racks
Must be mounted vertically
to provide Access for Cleaning
Not to b
be used
dusty Areas
d iin d
94
Cable Racks
With easy Access for Cleaning
95
Cable Racks
Clearance between Wall and Rack
for easy Cleaning Access
96
Cable Entry into Panels
Good
Poor
97
Cable Entry into Panels
Poor – not to be used
when
h
Fl
Flour D
Dustt iis presentt
Good
98
Panel Entry
Conduit with Sealtight – Ideal Solution
99
Conduit and Sealtight
Ideal for dusty Areas
100
Gasketed Wireways and Conduits
To be used in all dusty Areas
101
Lower Cost Wireway
102
Wiring in Machine Frames
Very clean – Code Issues in some Countries
103
Cables in Machine Frames
Unsealed Openings are totally unacceptable
104
Ideal Sanitary Installation
Good Conduit Mounting,
Wireway and Conveyor Legs
105
Support Brackets
Considering “Clean-ability” and “Afford-ability”
what should have been done differently?
106
Sanitary Equipment Design and
Installation Practices
suitable for the Biscuit Industry
Biscuit & Cracker
Manufacturers’ Association
Manufacturers
Technical Conference
April 27 – 30,
30 2014
Nashville, Tennessee
107