Yearbook 2013/2014 - ehedg

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The importance of hygienic design: A process facility case study and checklist 23 • resistant to mechanical tensions; • absent of protective fragile coverings or coatings that easy deteriorate; and • of an ideal cleanliness capacity, which translates to a high degree of elimination of microorganisms. g. Hygienic design principle 4: Smooth and accessible surfaces. Considerations include: • Roughness of the material (i.e., 0.8 mm for product contact surfaces and 3 mm for non-product contact surfaces). • Smooth and continuous welding. • Equipment accessibility for cleaning effectiveness check (e.g., spray balls and agitators). • Cleanability of the space around the equipment. h. Hygienic design principle 5: Self draining. The following actions should be taken: • Minimise horizontal surfaces. • Process and CIP piping should be sloped to allow drainage (20 mm per meter). • Equipment/installation is self-draining (Figure 8). Figure 9. Examples of hygienic design issues identified in FAT. In this specific case during the FAT of the filling machine, niches in the frame and exposed treats were found that could promote dirtiness harbourage 2. Start with the construction of the line. The first step to be taken prior to construction is to determine the traffic patterns. The production and personnel traffic patterns are established in order to minimise the risks and prevent product contamination. ▬► Entrances for people to the manufacturing line Figure 10. The traffic patterns of personnel through the production area can have a big impact on the hygiene of the plant. In the case of the cream cheese production facility, a new entrance for construction workers was established, isolating the area under construction from the production area (Figure 10). Figure 8. Self-draining installation. During the CIP cleaning the direction of the flow is opposite to the one shown in the figure 8 (pink arrows). At the end of the last step of the cleaning the pump changes the rotation direction thus ensuring the complete drainage of the pipe. Once the installation of the equipment begins it is important to perform a regular review of the installation to ensure all hygienic design principles and goals are and continue to be implemented and met (Figure 11). Phase 3. Project Execution: Building In Phase 3, the building and execution step, there are a few important tasks to be done. These include: 1. Perform a factory acceptance test (FAT) at all suppliers’ sites in order to: • Confirm that all of the hygienic design principles are met. • Identify potential needs that were not considered in the previous project development phases (Figure 9). Figure 11: Equipment hygienic design issues. Both pictures show hygienic design issues, the first one a syphon that promotes water stagnation and the second one the presence of a screw that could drop into the product.
24 The importance of hygienic design: A process facility case study and checklist Phase 4. Project Commission: Accept and installation This is the last phase of the project. Once this phase is completed, the installation will be approved by all of the functions involved and production can begin. The commissioning, under a sanitation point of view, consists of: • An entire review of the hygienic design of the installation once it is completely built. • Validation of the effectiveness of the cleaning (e.g., visual inspection + swabbing, enzyme-linked immunosorbent assay [ELISA]) during the start-up phase. • Training of the operators on how to clean the new installation. After the line has been running for a certain period of time, the site acceptance test (SAT) will take place to approve the final handover of the installation to the plant. During the SAT, a complete tear-down of the line will be carried out by the sanitation team to confirm the absence of product residues, biofilms, allergen residues, and other potential contaminants. This verification will be performed using the same tools used in the start-up phase. Conclusion • In addition to the takeaway messages that can be gleaned from this example of the application of hygienic design principles to the design and construction of a cream cheese manufacturing facility, there are some that are worth reiterating: • Allocate the proper amount of time/resources for the feasibility and pre-engineering phases. The more the work is developed during these phases, the higher the likelihood of successful implementation of the project. • Sanitary design expertise has to be present in the FAT in order to identify potential sanitary design issues that equipment suppliers should modify before bringing the systems on site. • During the execution phase it is really important to perform a frequent (i.e., daily) assessment of the building and processing areas to identify potential design “issues” that can still be fixed at this stage but not in further stages in the process. • Unexpected “surprises” may arise during the execution and commissioning phase. Be ready to proactively look for feasible alternatives that can be implemented without significant impact to the efficiency of the line.
Page 1 and 2: EHEDG Yearbook 2013/2014 European H
Page 3 and 4: European Hygienic Engineering & Des
Page 5 and 6: 4 Contents EHEDG Guidelines 154 EHE
Page 13 and 14: 12 EHEDG Company and Institute memb
Page 15 and 16: 14 EHEDG Company and Institute memb
Page 19 and 20: 18 Legal requirements for hygienic
Page 23: 22 The importance of hygienic desig
Page 33 and 34: 32 Particle and VOC emissions, chem
Page 45 and 46: 44 Hygienic design of floor drainag
Page 47 and 48: 46 Hygienic design of floor drainag
Page 49 and 50: 48 Hygienic design of high performa
Page 53 and 54: 52 Performance testing of air filte
Page 57 and 58: 56 Spray cleaning systems in food p
Page 59 and 60: 58 Spray cleaning systems in food p
Page 63 and 64: 62 Environmentally friendly water b
Page 65 and 66: 64 Environmentally friendly water b
Page 69 and 70: 68 Flow behaviour of liquid jets im
Page 73 and 74: 72 Optimisation of tank cleaning Th
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74 Optimisation of tank cleaning Re
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European Hygienic Engineering & Des
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78 Effective tank and vessel cleani
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84 Practical considerations for cle
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86 Integrated hygienic tamper-free
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88 Damage scenarios for valves: Ide
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90 Damage scenarios for valves: Ide
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Material and design optimisation ca
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Improved hygienic design and perfor
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Smart hygienic solutions for the fo
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A cleaner, healthier future. Cleani
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Examination of food allergen remova
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Hygienic automation technology in f
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Cleanability test of a hygienic des
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Aspects of compounding rubber mater
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New developments for upgrading stai
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New developments for upgrading stai
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International Hygienic Study Award
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EHEDG Regional Sections 131 MEXICO
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EHEDG Regional Sections 133 In Octo
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EHEDG Regional Sections 135 EHEDG D
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EHEDG Regional Sections 137 EHEDG G
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EHEDG Regional Sections 139 Members
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EHEDG Regional Sections 141 EHEDG L
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EHEDG Regional Sections 143 Beside
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EHEDG Regional Sections 145 To prom
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EHEDG Regional Sections 147 EHEDG R
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EHEDG Regional Sections 149 and adv
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EHEDG Regional Sections 151 Transla
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EHEDG Regional Sections 153 EHEDG U
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EHEDG Guidelines 155 Doc. 7. A meth
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EHEDG Guidelines 157 Doc. 18. Passi
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EHEDG Guidelines 159 Doc. 28. Safe
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EHEDG Guidelines 161 Doc. 37. Hygie
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EHEDG Subgroups 165 design, selecti
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EHEDG Subgroups 167 Given a clean s
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EHEDG Subgroups 169 • Doc. 26 Hyg
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EHEDG Subgroups 171 It will address
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EHEDG Subgroups 173 EHEDG Subgroup
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EHEDG Subgroups 175 Chairman: Andy
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EHEDG Subgroups 177 EHEDG Subgroup
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EHEDG Secretariat Lyoner Strasse 18
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