HYGIENIC DESIGN REQUIREMENTS FOR FOOD PROCESSING MACHINERY Emma Maguire Food Manufacturing Technologies Department Campden BRI
INTRODUCTION Over view of Campden BRI Hygienic design Regulations Examples Other considerations Summary
CAMPDEN BRI Membership based: 2,400 members Independent, Non-profit distributing International clients in 75 countries Turnover: c. 21 m Staff: 390 Industry and Government Clients Member involvement and influence - Governance - Scientific & Technical Strategy - Project development & selection Largest in the world
VISION To be the partner of choice for the development and application of technical knowledge and commercially relevant solutions for the food and drink supply chain MISSION The practical application of technical excellence for the food and drink supply chain
HYGIENIC DESIGN IN FOOD PRODUCTION: Quality The art of producing a product without (unintentionally) changing it - good hygienic design maintains product in the main product flow Safety The art of producing a product without adding anything to it - good hygienic design prevents the transfer of hazards Efficiency The ability to (dismantle) access all product contact areas to facilitate cleaning in an economic time frame
I have to clean this for the next 20 years?!! What were they thinking? LIFE CYCLE FOR EQUIPMENT IN A FOOD PRODUCTION PLANT During the 20 year life cycle we 2014 will: Proactively we will need to: Redesign to improve effectiveness Educate management on 2034 risks Spend capital to reduce risks Redesign to improve cleaning Redevelop cleaning procedures Produce 2 billion meals Train 250 employees on how to clean Introduce and train 80 production supervisors Spend up to 33,000 hours cleaning it Spend 2500 hours doing pre-op inspections Waste up to 295 Million lbs. of food Generate 15 million gallons of effluent + BOD Generate 78 million lbs of rework Generate 17 million lbs. of inedible waste
Early recognition Product hold-up causes product deterioration
SCHEMATIC FOOD FACTORY Hazard analysis Specified raw materials Hygienic design HACCP Process development Prerequisites ISO 9000 Hygienic practices Process control ISO/TS 22002-1:2009 ISO 22000 Safe, wholesome Food
HYGIENIC DESIGN Hazard analysis Buildings Site Fabric Segregation Size Flows Services Equipment Lines Equipment Utensils Bins Robots People Medical screening Labs and toilet location
Housekeeping Sanitation Waste control Pest control Maintenance GHP Audit Buildings Sanitation Maintenance Audit Personal hygiene Return-to-work Training Equipment People Hazard analysis Hygienic practices
REGULATIONS AND STANDARDS
Reg. (EC) no 178/2002 European Food Law
Food hygiene: EU Regulation 852/2004 Requires companies to implement a quality control system and proposes the Hazard Analysis and Critical Control Points (HACCP) system most appropriate. Surfaces and equipment should be: Easy to clean and disinfect. Smooth, washable, corrosion-resistant and nontoxic materials are desired. kept in good order, repair and condition, so as to minimise any risk of contamination Installed so as to allow ample cleaning of the equipment and the surrounding area.
Food contact EU Regulation 10/2011 plastic materials and articles intended to come into contact with food EU Regulation 1935/2004 on materials and articles intended to come into contact with food EU Regulation 2023/2006 on good manufacturing practice for materials and articles intended to come into contact with food
MACHINERY EC Directive 2006/42/EC, or the Machinery Directive. EN 1672-2 (2009), Food processing machinery - Basic concepts - Part 2: Hygiene requirements BS EN ISO 14159:2008 Safety of machinery. Hygiene requirements for the design of machinery Doc 8, 10 and 13 of the EHEDG.
EC DIRECTIVE 2006/42/EC, or the MACHINERY DIRECTIVE. Annex 2.1: Machinery intended for use with foodstuffs or with cosmetics or pharmaceutical products must be designed and constructed in such a way as to avoid any risk of infection, sickness or contagion
EN 1672-2 (2009), Food processing machinery - Basic concepts - Part 2: Hygiene requirements Materials of construction Surface finish Joints Fasteners Drainage Internal angle and corners Dead spaces Bearings and shaft entry points Instrumentation Panels, covers and doors Covers
European Hygienic Engineering & Design Group Best practice guidance on hygienic engineering and design for food equipment manufactured in or imported into Europe Knowledge on the design, installation and cleanability of components Best practices for hygienic operations, supply and maintenance
PREVENTING BARRIERS TO TRADE - EUROPE EHEDG 1989 www.ehedg.org Directive 2006/42/EC on machinery machinery directive CEN/TC 153 - Machinery intended for use with foodstuffs and feed BS EN 1672-2:2005+A1:2009 -Food processing machinery. Basic concepts. Hygiene requirements
PREVENTING BARRIERS TO TRADE - USA 3-A Sanitary Standard- 1920 International Association of Food industry Suppliers (IAFIS) International Association for Food Protection (IAFP) Milk Industry Foundation (MIF) National Sanitation Foundation NSF -1944 NSF International Standard for Food Equipment NSF/ANSI 2-2007 ANSI/NSF/3-A 14159-1999 Safety of Machinery NSF 3A 14159-1-2010- Hygiene Requirements for the Design of Meat and Poultry Processing Equipment
HYGIENE PRINCIPLES/RULES
HYGIENE RULES 1. Relevant materials in contact rules. Machinery designed such that these materials can be clean before use. Where this is not possible, disposable parts must be used 2. All surfaces, including their joints, must be smooth, and must have neither ridges nor crevices which could harbour organic materials 3. Projections, edges and recesses must be minimised,
2. Surface finish (RA) and cleanability RA = 0.5 RA = 1.0 RA = 3.0
2. Staphylococcus aureus
3. Projections, edges and recesses must be minimised!!
HYGIENE RULES CONTINUED... 4. All surfaces in contact with food must be easily cleaned and disinfected, where possible after removing easily dismantled parts. Inside surfaces curves must be reduced to facilitate cleaning 5. Liquids, gases and aerosols derived from foodstuffs... and cleaning should be completely discharged (if possible, in a cleaning position) - Drainable 6. Design and construction should prevent the entry of liquids or animals and prevent accumulation of soil in areas that cannot be cleaned No Niches 7. Design and construction such that no ancillary substances (e.g. lubricants) can come into contact with foodstuffs... Compliance should be able to be checked
4. Inside surfaces curves must be reduced to facilitate cleaning
5. Drainable
6. No niches or dead spaces
Listeria in sliced meats (2001)
7. Design and construction such that no ancillary substances (e.g. lubricants) can come into contact with foodstuffs
OTHER CONSIDERATIONS
Siting of equipment
HYGIENIC DESIGN VALIDATION 2/3 dimensional drawings Computer aided CFD modelling Equipment visualization and inspection Third party approvals EN 1672, ISO 14159, EHEDG, 3-A Cleanability tests (primarily for closed equipment) Microbiological tests, organic tests, commissioning tests Specific tests Pasteurizability, sterilizability, bacterial ingress EHEDG Certification
CERTIFICATION CRITERIA Hygienic design to meet the requirements of EHEDG Guideline No. 8 Hygienic Equipment Design Criteria If appropriate, cleanability assessment is required to meet the requirements of EHEDG Guideline No. 2 A method for the in-place cleanability of food processing equipment In all cases, the requirements of the machinery directive 2006/42/EC, via EN 1672-2 should be met
RETAILER REQUIREMENTS Product contact surfaces, including those not in direct contact with food, must be constructed of materials that will not contribute a food safety risk SQF (Annex 1: Guidance-premises and equipment construction and design) All materials used for maintenance and repair shall be fit for the intended use IFS, Version 5, 2007 Certificates of conformity or other evidence shall be available for equipment in direct contact with food to confirm its suitability for use, e.g. Conveyor belts BRC,
FINAL CONSIDERATIONS
HYGIENIC DESIGN?
BUT SAFETY?
SUMMARY: Hygienic design in food production: Quality The art of producing a product without (unintentionally) changing it - good hygienic design maintains product in the main product flow Safety The art of producing a product without adding anything to it - good hygienic design prevents the transfer of hazards Efficiency The ability to (dismantle) access all product contact areas to facilitate cleaning in an economic time frame
Campden BRI The partner of choice for the development and application of technical knowledge and commercially relevant solutions for the food and drink supply chain Questions Emma Maguire Contact details: 01386842038 Emma.Maguire@campdenbri.co.uk no. 1079 no. 1207
SANITARY PRINCIPLES 1. Cleanable to a Microbiological Level 2. Made of Compatible Materials 3. Accessible for Inspection, Maintenance, Cleaning and Sanitation 4. No Product or Liquid Collection 5. Hollow Areas Should be Hermetically Sealed 6. No Niches 7. Sanitary Operational Performance 8. Hygienic Design of Maintenance Enclosures 9. Hygienic Compatibility With Other Plant Systems 10. Validated Cleaning and Sanitizing Protocols