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BCMABCMAFood IndustryFood Industry

Ten Sanitary DesignTen Sanitary DesignPrinciplesPrinciples

Hygienic RestorationHygienic Restoration

Gary Goessel R.S.Gary Goessel R.S.

99--2121--20092009


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Sanitary Design Principles for EquipmentSanitary Design Principles for Equipment

1.1. CleanableCleanable

2.2. Made of Compatible MaterialsMade of Compatible Materials

3.3. Accessible for Inspection, Maintenance, Cleaning andAccessible for Inspection, Maintenance, Cleaning and

SanitationSanitation4.4. No Liquid CollectionNo Liquid Collection

5.5. Hollow Areas Eliminated or SealedHollow Areas Eliminated or Sealed

6.6. No NichesNo Niches

7.7. Sanitary Operational PerformanceSanitary Operational Performance

8.8. Validate Cleaning and Sanitizing ProtocolsValidate Cleaning and Sanitizing Protocols

9.9. Separate Processes Wherever PossibleSeparate Processes Wherever Possible

10.10. Meet Personnel Hygiene and Sanitation RequirementsMeet Personnel Hygiene and Sanitation Requirements

Adapted from American Meat Institute (AMI, 2002)


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Sanitary Design Principles for EquipmentSanitary Design Principles for Equipment

During Hygienic RestorationDuring Hygienic Restoration

CleanableCleanable

Accessible for Inspection, Maintenance,Accessible for Inspection, Maintenance,

Cleaning and SanitationCleaning and Sanitation Validate Cleaning and Sanitizing ProtocolsValidate Cleaning and Sanitizing Protocols

Separate Processes Wherever PossibleSeparate Processes Wherever Possible

Meet Personnel Hygiene and SanitationMeet Personnel Hygiene and SanitationRequirementsRequirements


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o e age | earch ite | -Z Index | ontact

Recall -- Firm Press Release

eanut roduct ecalls:Salmonella yphi uriu


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SanitationSanitation


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Hygienic RestorationHygienic Restoration -- SanitationSanitation

Establishing A Clean BreakEstablishing A Clean Break TransportationTransportation

Peanut Paste Storage and Distribution SystemsPeanut Paste Storage and Distribution Systems Peanut Butter Processing and PackagingPeanut Butter Processing and Packaging

Equipment.Equipment.


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Scope of Plant Hygienic Restoration SanitationScope of Plant Hygienic Restoration SanitationActivityActivity

All Building StructuresAll Building Structures

CeilingsCeilings

WallsWallsFloorsFloors

All Equipment SurfacesAll Equipment Surfaces

Multiple Production LinesMultiple Production Lines

Peanut Paste Delivery and Peanut Butter StoragePeanut Paste Delivery and Peanut Butter Storage

Peanut Butter Mixing, Peanut Butter deliveryPeanut Butter Mixing, Peanut Butter delivery


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Sanitation StrategySanitation Strategy1.1. Determine level of clean.Determine level of clean.

2.2. Assess facilities and infrastructure in place to performAssess facilities and infrastructure in place to performsanitation tasks.sanitation tasks.

3.3. Assess manpower requirements to get work done inAssess manpower requirements to get work done inexpedited fashion.expedited fashion.

4.4. Review existing cleaning SSOPs and enhance orReview existing cleaning SSOPs and enhance ordevelop additional.develop additional.

5.5. Determine necessary level of disassembly to attainDetermine necessary level of disassembly to attain

targeted level of clean.targeted level of clean.

6.6. Obtain vendor support for supplies and equipment andObtain vendor support for supplies and equipment andcontracted services.contracted services.

7.7. Establish sanitation verification and validation.Establish sanitation verification and validation.


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Determine level of clean Principle # 1Determine level of clean Principle # 1

Criteria for specific target Level ofCleanCriteria for specific target Level ofClean

Microbiologically CleanMicrobiologically Clean

Clean to a level that completely removes residualClean to a level that completely removes residualfood from the product zone and rendersfood from the product zone and renders

surfaces free from harmful and/or excessivesurfaces free from harmful and/or excessive

microorganisms. Generally considered inmicroorganisms. Generally considered in

situations where there are potentialsituations where there are potentialmicrobiologically sensitive ingredients, productsmicrobiologically sensitive ingredients, products

and/or processes.and/or processes.


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Considerations for a microbiological mitigationConsiderations for a microbiological mitigation

Maintenance and EngineeringMaintenance and Engineering

Vendors and SuppliersVendors and Suppliers

Verification procedures and documentationVerification procedures and documentation

Validation protocol.Validation protocol.

Documentation of all activityDocumentation of all activity


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GMPsGMPs

Monitored 24/7Monitored 24/7


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RTU Alcohol Surface SanitizerRTU Alcohol Surface SanitizerProduct Description:Product Description: A readyA ready--toto--use sanitizing and disinfecting solutionuse sanitizing and disinfecting solution

for use on hard, nonfor use on hard, non--porous food contact surfaces.porous food contact surfaces.

Convenient and Easy to UseConvenient and Easy to Use

Ideal for sanitizing areas where water use isIdeal for sanitizing areas where water use is

limited.limited.

Dries quickly to help protect waterDries quickly to help protect water--sensitivesensitive

equipment.equipment.

Application:Application:

Any person entering the plant (employee,Any person entering the plant (employee,

contractor, etc.) must spray boots with RTUcontractor, etc.) must spray boots with RTUSanitizer then walk through mat filled with SaniSanitizer then walk through mat filled with Sani--StepStep

prior to entry into all isolated areas and upon exiting.prior to entry into all isolated areas and upon exiting.

Use as a final sanitize step on production equipmentUse as a final sanitize step on production equipment


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Temporary Isolation


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SaniSani--StepStepProduct Description:Product Description:

A water activated, timeA water activated, time--released, EPAreleased, EPA--registeredregistered

solid floor sanitizer designed to help improvesolid floor sanitizer designed to help improve

environmental sanitation on processing floorsenvironmental sanitation on processing floors

during production where wet conditions favorduring production where wet conditions favor

microorganism growth.microorganism growth.


Any person entering the plant (employee,Any person entering the plant (employee,

contractor, etc.) must spray boots with RTUcontractor, etc.) must spray boots with RTU

Sanitizer then walk through mat filled with SaniSanitizer then walk through mat filled with Sani--Step prior to entry into all isolated areas and uponStep prior to entry into all isolated areas and upon

exiting.exiting.


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How was this Accomplished?How was this Accomplished?A Call For ResourcesA Call For Resources

InternalInternal

ExternalExternal Implementing Available TechnologiesImplementing Available Technologies


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Ancillary Cleaning / Sanitizing SolutionsAncillary Cleaning / Sanitizing Solutions

Ameri Vap Steam CleanerAmeri Vap Steam Cleaner

Must follow with RTUMust follow with RTU

SanitizerSanitizer

Alcohol Sanitizer / BioAlcohol Sanitizer / Bio--mist Systemmist System

CO2 Propellant for RTUCO2 Propellant for RTU

SanitizerSanitizer

Must PreMust Pre--Clean, Rinse and Post Sanitize after EVERY use!Clean, Rinse and Post Sanitize after EVERY use!


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HAFCO Pneumatic powered drum

vacuums with high efficiency filters

Tornado electric powered wet

vacuums


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COP TanksCOP Tanks


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Ancillary Cleaning / Sanitizing SolutionsAncillary Cleaning / Sanitizing Solutions

Ameri Vap Steam CleanerAmeri Vap Steam Cleaner

Must follow with RTUMust follow with RTU

SanitizerSanitizer

Alcohol Sanitizer / BioAlcohol Sanitizer / Bio--mist Systemmist System

CO2 Propellant for RTUCO2 Propellant for RTU

SanitizerSanitizer

Must PreMust Pre--Clean, Rinse and Post Sanitize after EVERY use!Clean, Rinse and Post Sanitize after EVERY use!


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Dry Steam SanitationDry Steam Sanitation


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EcoEco--Wipe FCSWipe FCSProduct Description:Product Description:

EcoEco--Wipe FCS is an EPA registered, preWipe FCS is an EPA registered, pre--moistened, single use sanitizing wipe for use onmoistened, single use sanitizing wipe for use onhard, nonhard, non--porous food contact surfaces.porous food contact surfaces.

175 ppm Quaternary Ammonium Compounds175 ppm Quaternary Ammonium Compounds

5.48% alcohol5.48% alcohol

100 Pre100 Pre--measured, Premeasured, Pre--moistened Wipes permoistened Wipes percanistercanister


Remove any gross soils with mechanical actionRemove any gross soils with mechanical actionusing one wipeusing one wipe

Once visually clean, follow with another wipe as aOnce visually clean, follow with another wipe as asanitize stepsanitize step

All tools wiped at least once/shift and at entry andAll tools wiped at least once/shift and at entry andexit of isolated areas.exit of isolated areas.


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Principle #3 Validate Cleaning andPrinciple #3 Validate Cleaning and

Sanitizing ProtocolsSanitizing Protocols

Sanitation Verification Using ATPSanitation Verification Using ATP

Provides rapid realProvides rapid real--time resultstime results Make DecisionsMake Decisions Take Proper Corrective ActionTake Proper Corrective Action

Provides OnProvides On--line or nearline or near--linelinetestingtesting

Testing should be done onceTesting should be done once

visibly cleanvisibly clean


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Shelf-Stable(Up to 12 months at room temp)


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The ScopeThe Scope

The Scope ofCleaning VerificationThe Scope ofCleaning Verification

Visibly CleanVisibly Clean

ATP Testing of food contact surfacesATP Testing of food contact surfaces Random Microbiological TestingRandom Microbiological Testing

On All Equipment and Building SurfacesOn All Equipment and Building Surfaces


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Peanut Paste SystemPeanut Paste System

Establishing A Sanitation BreakEstablishing A Sanitation Break

TransportationTransportation

Peanut Paste Storage and DistributionPeanut Paste Storage and Distribution Thermal SanitizationThermal Sanitization

Visual InspectionVisual Inspection


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The ScopeThe Scope


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TransportationTransportation


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Heat TraceHeat Trace


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Commissioning ProceduresCommissioning Procedures

DisDis--Assembly CompleteAssembly Complete

Cleaning and Sanitization CompleteCleaning and Sanitization Complete

Area SecuredArea Secured

Inspection and Environmental SamplingInspection and Environmental Sampling ReRe--Assembly Complete.Assembly Complete.

Sanitization during reassembly.Sanitization during reassembly.

Sign Off of Visibly CleanSign Off of Visibly Clean

Final Cleaning and SanitizationFinal Cleaning and Sanitization

Secure Area for:Secure Area for:

Environmental SamplesEnvironmental Samples

Test Shots Finished ProductTest Shots Finished Product


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Questions ?Questions ?

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