NSF International A Global Leader in Public Health and Safety Food safety Considerations for Hygienic Design of Manufacturing and Processing Equipment Mona Malhotra and Navin Sharma NSF International 3 rd Dec. 2014
Principles of Sanitary Equipment Design
Principles of Sanitary Equipment Design Cleanable to a microbiological level: • designed as to prevent bacterial ingress, survival, growth and reproduction on both product and non-product contact surfaces of the equipment. Made of compatible materials: • with the product, environment, cleaning and sanitizing chemicals and the methods of cleaning and sanitation.
Principles of Sanitary Equipment Design Accessible for inspection, maintenance, cleaning and sanitation: • inspection, maintenance, cleaning and sanitation without the use of tools. No product or liquid collection: • self-draining to assure that liquid, which can harbor and promote the growth of bacteria, does not accumulate, pool or condense on the equipment. :
Principles of Sanitary Equipment Design Hollow areas should be hermetically sealed • such as frames and rollers must be eliminated wherever possible or permanently sealed • Bolts, studs, mounting plates, brackets, junction boxes, nameplates, end caps, sleeves and other such items must be continuously welded to the surface not attached via drilled and tapped holes. No niches: • such as pits, cracks, corrosion, recesses, open seams, gaps, lap seams, protruding ledges, inside threads, bolt rivets and dead ends.
Principles of Sanitary Equipment Design Sanitary operational performance: • does not contribute to unsanitary conditions or the harborage and growth of bacteria. Hygienic design of maintenance enclosures: • such as push buttons, valve handles, switches and touchscreens, must be designed, to ensure food product, water or product liquid does not penetrate or accumulate in and on the enclosure or interface. • physical design of the enclosures should be sloped or pitched to avoid use as storage area.
Principles of Sanitary Equipment Design Hygienic compatibility with other plant systems • such as electrical, hydraulics, steam, air and water. Validated cleaning and sanitizing protocols: • Clearly written, designed and proven effective and efficient • Cleaning and sanitation chemicals must be compatible with the equipment and the manufacturing environment.
Examples of Sanitary Equipment Design Congested Design Open Design Solid Rollers Hollow Rollers
Examples of Sanitary Equipment Design Continuous Welds Gasket Non-Functioning Openings Continuous welding of parts also prevents bacteria from harboring and growing in niches.
BENEFITS Optimizing the design and performance criteria for equipment and related systems as well as establishing industry-wide specifications benefit the entire industry by promoting one standard design that will help reduce contamination and associated recalls.
Food Equipment Certification
22 Food Equipment Standards • NSF/ANSI 2: Food Equipment • NSF/ANSI 3: Commercial Warewashing Equipment • NSF/ANSI 4: Cooking and Hot Food Holding Equipment • NSF/ANSI 5: Water Heaters • NSF/ANSI 6: Dispensing Freezers • NSF/ANSI 7: Commercial Refrigerators and Freezers • NSF/ANSI 8: Commercial Powered Food Preparation Equipment • NSF/ANSI 12: Automatic Ice Making Equipment • NSF/ANSI 13: Refuse Processors • NSF/ANSI 18: Manual Food and Beverage Dispensing Equipment • NSF/ANSI 20: Commercial Bulk Milk Dispensing Equipment • NSF/ANSI 21: Thermoplastic Refuse Containers • NSF/ANSI 25: Vending Machines for Food and Beverages • NSF/ANSI 29: Detergent and Chemical Feeders for dishwashing machines • NSF/ANSI 35: High Pressure Decorative Laminates • NSF/ANSI 36: Dinnerware • NSF/ANSI 37: Air curtains for entranceways in food establishments • NSF/ANSI 51: Food Equipment Materials • NSF/ANSI 52: Supplemental Flooring • NSF/ANSI 59: Mobile Food Carts • NSF/ANSI 169: Special Purpose Food Equipment and Devices • NSF/ANSI 170: Glossary of Food Equipment Terminology
Minimum Requirements for Certification • Physical Evaluation: NSF evaluates the design and construction of the equipment to make sure that it is easily cleanable. We look at things such as joints, seams, fastening methods, radius’ etc. • Material Review: We will review all materials that are in contact with food or have the potential to be in contact with food to make sure that they don’t impose any taste, odor, or harmful effects onto the food. Materials will be evaluated against FDA guidelines (21 CFR). • Performance Testing: Includes tests such as: Temperature maintenance, in place cleaning test, coating tests, thermometer accuracy test. • Compliance Audit : An audit is conducted for initial Certification at each production facility, and on an annual basis thereafter, for continued Certification.
Zones • Food Zone – Direct food contact – Surfaces where food can drain or drip back on to food • Splash Zone – Surfaces subject to splash or spills • Nonfood Zone – Surfaces exposed to dirt and debris but not exposed to food or splash • Unexposed Nonfood Zone – Surfaces that are not exposed Material and Design Requirements vary by Zone…
Food Zone Direct Contact Examples Food pans Cutting board Food preparation surface
Food Zone Non-Direct Contact Examples Interior of Underside of top refrigerator cover
Splash Zone Examples Interior of cabinet and exposed exterior surfaces Exposed shelving
Nonfood Zone Examples Underside of Underside of wall shelf equipment
1. Wrong Materials – Wood or Bamboo Needs to be Replaced Critical Issues of material, design and construction Potential Food safety hazards
2. Inadequate Materials – Quality of Plastic or Steel not fit for purpose Minor issues of material, design, performance and construction Potential Food safety hazards
3. Inadequate Cleaning – Improved Cleaning Procedures Needed Potential Food safety hazards from harborage of bacteria
4. Improper Use – Continual Improvement Needed Potential Food safety hazards from use of equipment Training needs
5. Improper Design or Construction – Need to Change Equipment Minor issues of material, design and construction Replaced with approved equipment
6. Rust from Inadequate Material Specification Material specification not suitable for intended use Cleaning chemicals and processes may be a factor
7. Continual Improvement on site Replacement equipment to be certified Use and cleaning of equipment to be controlled
Overview of Material Requirements Requirement Food Zone Splash Zone Nonfood Zone Nontoxic Required No Requirement No Requirement Smooth Yes Yes Yes Easily Cleanable Yes Yes Yes Corrosion Yes Yes Yes Resistant
Overview of Design Requirements Requirement Food Zone Splash Zone Nonfood Zone Accessibility Without Tools With Tools With Tools Radius Required Not Required Not Required Easily Fasteners Not Permitted Easily Cleanable Cleanable Exposed Not Permitted Not Permitted Limited Threads Seams Sealed Sealed Closed
Examples of Performance Testing Required • Temperature maintenance – Verify equipment can maintain food at safe temperatures • In place cleaning test – Confirm manufacturers cleaning & sanitizing instructions remove harmful bacteria • Organic coating tests – Confirm food contact materials meet regulations • Thermometer accuracy test – Validate accuracy of readings over a range of temperatures • Corrosion resistance testing for shelving – Verify surfaces remain smooth and easily cleanable
NSF Certification Process Providing all clients with: Quote and Application A dedicated point of contact • Physical Evaluation Access to NSF/ANSI standards • Ongoing technical support • Testing / Material Review Unmatched food safety expertise • (if Applicable) 65+ years of certification excellence • Documentation Report Issued Certification, Listing and Authorization to use NSF Mark Facility Audit to Verify Ongoing Compliance
Water is an important part of Food and Food Chain
Safe Water – Delivery has many Mechanical Elements Pipes / Pipe fittings • Miscellaneous components • Plastics • Pumps • UV systems (municipal) • Water meters • Membranes • Filters • Tanks • Valves • Faucets • And more •
Safe Water – Delivery has many Chemical Elements Coagulation Chemicals • Corrosion Inhibitors • Disinfectants • RO Antiscalants • Miscellaneous • treatment chemicals And more! •
How do NSF standards Work? • Evaluation of any contaminants (metal and non-metal) that migrate into drinking water. • Evaluation of weighted average lead content for products that contain brass or bronze. • Evaluation of claims by the manufacturers (cyst removal, TDS removal, other contaminant removal, etc.) • Evaluation of the Performance claims
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