NSF International A Global Leader in Public Health and Safety Food - - PowerPoint PPT Presentation

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 3rd 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

Hollow Rollers Solid Rollers Congested Design Open Design

Examples of Sanitary Equipment Design

Continuous welding of parts also prevents bacteria from harboring and growing in niches. Gasket Continuous Welds Non-Functioning Openings

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

Cutting board Food pans Food preparation surface

Food Zone Non-Direct Contact Examples

Underside of top cover Interior of refrigerator

Splash Zone Examples

Exposed shelving Interior of cabinet and exposed exterior surfaces

Nonfood Zone Examples

Underside of equipment Underside of wall shelf

• 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

Use and cleaning of equipment to be controlled Replacement equipment to be certified

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 Resistant Yes Yes Yes

Overview of Design Requirements

Requirement Food Zone Splash Zone Nonfood Zone Accessibility Without Tools With Tools With Tools Radius Required Not Required Not Required Fasteners Not Permitted Easily Cleanable Easily Cleanable Exposed Threads Not Permitted Not Permitted Limited 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

Quote and Application Physical Evaluation Testing / Material Review (if Applicable) Documentation Report Issued Certification, Listing and Authorization to use NSF Mark Facility Audit to Verify Ongoing Compliance

• A dedicated point of contact
• Access to NSF/ANSI standards
• Ongoing technical support
• Unmatched food safety expertise
• 65+ years of certification excellence

Providing all clients with:

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!

• 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

How do NSF standards Work?

Various NSF Standards

Applicable Standards :

• NSF/ANSI 60 Drinking Water Treatment Chemicals
• NSF/ANSI 61 Drinking Water Treatment Components

(Public Health only)

• NSF/ANSI 14

Plastic Pipes/Pipe fittings (Public Health and Performance)

• NSF/ANSI 42 and/or 53 Filtration, Active Media
• NSF/ANSI 44

Ion Exchange Softener

• NSF/ANSI 55

Ultraviolet Systems

• NSF/ANSI 58

POU Reverse Osmosis

• NSF/ANSI 177

Shower Filtration

• NSF/ANSI 372

Low Lead Compliance

• NSF/ANSI 50

Shower Filtration