Sanitary Design Industries, LLC

Transcription

1 Sanitary Design Industries, LLC Providing Innovative solutions for the food processing industry Food Safety in Small Dairy Operations Prepared for the Dairy Practices Council Nov 5 th 2015

2 Planning The correct floor plan to support your GMP s Write a specification for every space, build to a specification Understand Building Materials Have the correct air flow all the time Pos & Neg Understand the role of equipment Pros and Cons Budgets their role in Food Safety

3 Competency of the Planners Issues: Lack of experience Attitude Still an opportunity for the Rebel operator Conflicted regulatory environment Frequently required to encourage industry development and then regulate the same industry

4 No Room a Corridor There must be clear and easy access to all rooms in the facility with a few exceptions: A raw room with pasteurizers A receiving bay attached to the raw pasteurizer room There are exceptions, but as a general principle, don t turn rooms into corridors

5 Example Gouda AP.ing 55ef 65'J'o R l l Ave Age G l""'ths. :i;:eeejejejej EJEJEJ ] 1rlf9rJEJEJ Aging Room1 [)4..t. RH O<'F I 1 I I 'Y'ng Room ss 0 r 70}0 RIt I I c=::j - Productior Bline Room 4!')"F A.o, P, r.a oiinvji.n;lt Room A 75 -SC"F RH?? [ Brine Ier1110 A>< ] - 08<...<I'...,,"_ Produc:lion WK I KB/\& Flll l Statton RAW A-- 3.5CO g:il J 3:),0001! l wrey I Fvlu111 I '---,,,,. I I G>,,_,. / --,ci C(lrridor // < \ " L-----J.u...l..---,-r LI,'_",. -=1:--T--"""'1 /--... l - - I Corrido 1 A- Corridor2. Fa,q Flle1 l 1JOOOlt \'at -Cl D I RAW -...,; A gel () 30.00J> Mk I 3'" - (Zr') I Fu!"'" l.'1::+c1'tab0 I I

6 ) "":'.,,..._ :J..':>UU Q!'!I L,.!,.. J_..!i..,.i,..._ I 1 I eal nr "---l I { I 3 0.ooJ# \_,. Milk ===--r.,---...j Une \ ' htst c 27- l J_,! ;;; 11 r I I

7 n " -- " D SDI

8 Controlled Entry Point

9 A Separate Entrance For: Employees Customers Raw milk Processing materials, chemicals * Does not permit access to the controlled area. Separate shipping dock Direct access to the mechanical room Does not permit access to the controlled area.

10 Construction When I approach any Food Processing Plant: Low dust area surrounding the facility, not always possible * Positive Filtered Air just became a priority (HRV makes this simple) Rodent zone around the perimeter, 18 to 36 with no grass or foliage growing near the building. Concrete or Rip Rap A generally tidy appearance

11 Rodent Zones should be part of all planning and construction. Concrete is best Riprap works but will require constant maintenance

12 Recirculated Air Food Grade Approach i. Commercial building air systems are not designed for food grade applications ii. Coils are remote and frequently not designed to be cleaned iii. Window air conditioners are not Food Grade iv. Mini-splits are not Food Grade

13 This is not Food Grade Air

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15 This is not Food Grade Air

16 This is not Food Grade Air

17 This is not Food Grade Air

18 Food Grade Air Floor Mounted Air Handler with Fabric Duct

19 SDI Answer to Sanitary Air

20 Making your Own Positive Air System

21 11 years

22 General requirements for all rooms: Failure to put thermal breaks beneath cooler walls adjacent to corridors has in effect created a Listeria creation zone: Cool Damp Impossible to clean

23 Rodent Zones should be part of all planning and construction. Concrete is best Riprap works but will require constant maintenance

24 7 Years

25 Full Panel Structure

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27 Galvalume 8 years

28 Galvalume doesn t stand up to wet condtions

29 SDI

30 Budget Approach

31 Air Handlers Ceiling mounted units running on refrigerant or chilled liquids will frequently have encasements that are below the dew point to achieve the cooling function in the room. All condensate drains to be vented and trapped before water is removed from the room a. Condensate must not be allowed back onto the floor, it is not potable water

32 Sanitary Air Handlers Ceiling Mount Value Series - Stainless Housing Construction - Multiple Layer Condensate Pan - Wide Fin Spacing for Easy Cleaning - ECM Fan Motors for Energy Efficiency - Chilled Water or Refrigerant

33 Air Handlers a.when cleaning is being conducted it is better to remove product from the room Which begs the question, who is going to do this? Floor mounted Vertical Air Handlers remove the condensate drains from above product a.fully washable while product is in the room Rooms need good sealing doors with no thresholds Air changes in these rooms, small vents, low volumes, large vents create problems

34 Vertical Floor Mount Series Sanitary Air Handlers - All Stainless Housing Construction - Wide Fin Spacing for Easy Cleaning - Coated coil to endure harsh environments - Wash down motor - VFD Fan Motors for Energy Efficiency - Easy access for sanitary maintenance - Chilled Water or Refrigerant - Combined with Fabric Ducts

35 Fabric Duct System Combines with vertical air handler to create uniform conditions throughout the room Easy to install Easy to clean and change Flexible design Does not transmit noise

36 Writing a Building Specification State the function of the items so the specification can match Write the Specification before you talk budget When you have to do it twice it is no longer cheap

37 Floor Specification Floors: * Wet areas 2% slope * Corridors less critical areas 1% slope * Where necessary suitable coatings to protect the concrete. Does not include thin epoxy coatings with poor impact and thermal ratings * Insert thermal breaks beneath walls where needed * Drains

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39 Whats wrong Not flat floors with drains cut in FRP over moisture resistant Sheet Rock, no sealed coves, water is running to the walls reported as 2 deep in one room against one wall, runs to all 4 walls in another, three rooms that require constant squeege activity This facility received its States approval to operate?

40 Wall Specification Walls: Monolithic Smooth Impervious Correctly placed vapor barriers Over thermal breaks where needed No penetrations All pass-throughs to be sealed and flashed

41 Steel Door Frames Rusted Out

42 The addition of Wooden Frames on Doors to Mount Strip Curtains

43 Ceiling Specification The Ceiling must protect the product from above It is not there just to look shiny and white? That means it must have the ability to stop what ever falls on the top from coming down into the production space. * Vapor barrier on the appropriate side

44 SDI

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47 Drains The purpose of a drain is to conduct liquids off the floor and prevent solids from going down the drain? Should seal tightly against the substrate Shall not block during the production shift

48 Plastic Trench Drains Plastic Drains expand when hot liquids a run into them. The sides of the drains pull away from the substrate. No amount of caulk will solve the problem

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50 Questions