Sanitary Equipment Design and

Installation Practices
suitable for the Biscuit Industry

Biscuit & Cracker

Manufacturers’ Association
Manufacturers
Technical Conference
April 27 – 30,
30 2014
Nashville, Tennessee

1
Guidelines for Sanitary Design

• GMA Principles of Equipment Design for

Low moisture Foods
Low-moisture
– Developed by the Grocery Manufacturers Association’s
Sanitary Design Working Group which consists of sanitation
professionals from the top food companies
– Aim is to improve food safety through equipment design
enhancements by working with equipment manufacturers
to develop
d l equipment
i with
i h the
h best
b possible
ibl designs
d i in
i
accordance with the 10 principles
• ANSI
– Z50.2 Baking Industry Sanitary Standard

2
GMA Principles of Sanitary Design

• Cleanable to GMP, product hazard (microbiological,

chemical, physical), and quality levels
• Made of compatible materials
• Accessible for inspection, maintenance,
and
d cleaning/sanitation
l i / it ti
• No liquid collection
• Hollow areas hermetically sealed
• No niches
• Sanitary operational performance
– Hygienic design of maintenance enclosures
– Hygienic compatibility with other systems
• Validated
V lid t d cleaning
l i and
d sanitizing
iti i protocols
t l
• Separate processes wherever possible
• Equipment and personnel at installation meet
hygiene and sanitation requirements

3
“Clean-ability”

• Minimize cleaning requirements

– Flat Surfaces
– Ledges
– Crevices

• Make it easy to clean

– Access
– Disassembly/Reassembly
– Time
– M t i l off C
Materials t ti
Construction
– Ergonomic Design

• Install
I t ll it so that
th t it is
i easy to
t clean
l
– Clearances

4
“Afford-ability”

• Customized Equipment Designs vs.

Standard Equipment
– Past practices of specifying in detail equipment
requirements from individual equipment manufacturers
l d to
led t customization
t i ti off th
their
i standard
t d d equipment
i t which
hi h
invariably increased cost
– Byy makingg equipment
q p manufacturers aware of the
cleaning issues by showing specific examples has lead
the manufacturers to upgrade their standard equipment
in most cases without increasing g their cost

5
“Afford-ability”

• Industry Conferences and Workshops

between Food Processors and Equipment
Manufacturers
– To address the issues about major j recalls in recent
times the concerns of our industry were shared with
equipment manufacturers
– Since recalls effect the entire industry,
industry and since
product protection is not and should note be a
competitive advantage, the GMA Work Group and
others have shared the concerns at equipment
manufacturers meetings such as the FPSA and BEMA
conferences
– Addressing
Add essing the need forfo sanitary
sanita design improvements
imp o ements
as a joint food industry group with joint equipment
manufacturing groups has also already yielded
significant
i ifi t equipment
i t enhancements
h t

6
7
Man Dies From Salmonella Traced To Bakery
March 30, 2011
PROVIDENCE, R.I. (AP) — A man who tested positive for salmonella in an outbreak that may be linked
to a Rhode Island bakery has died.
State health department spokeswoman Annemarie Beardsworth said Tuesday the man died March 23
23.
The man was in his 80s and lived in Providence County. He tested positive for the strain of the bacteria
that has now sickened 39 people.
Beardsworth says 24 of those people have been hospitalized.
Officials say many of the people ate doughnut-like pastries called zeppoles (ZAY'-puh-luhz) made by
DeFusco's Bakery in Johnston. The pastries also were sold at other stores around the state and have
been recalled. The bakery has voluntarily shut down until further notice.
Beardsworth says officials are investigating whether the man who died ate one of the pastries.

8
 Equipment
Design Features

9
Minimize Flat Surfaces

Motor Mounts

10
Minimize Flat Surfaces/Chain Drives
and Guards
G a ds
Shaft Mounts & Pulley Drives

11
Hopper Design
Eliminate Square Corners
Provide Round Hoppers or
Corners with 50 mm minimum Radius

12
Eliminate Crevices

Very difficult and time consuming to clean

13
Provide Spacers

Create Gap between Frame and Panel Box

14
Conveyor attached with Spacers

15
Holes and Penetrated Frames

Unnecessary Openings require

additional time
time-consuming
consuming cleaning

16
Ledges

Eliminate Dirt Traps

17
Ledges

Roof Joists with Dirt Traps

18
Extruded Aluminum Frames

Extremely difficult to clean – Avoid them

19
Extruded Aluminum Frames

Acceptable with good covers

20
Cross Braces

Gussets would eliminate need for Braces

21
Panel Legs

Provide Sanitary Legs – not Enclosed Bases

22
Panel Legs
Angle Iron Legs have Crevices
that are very difficult to clean

23
Air Handler Support Frame

Eliminate Cross Braces – very difficult to clean

24
Air Handler Support Frame

Before After

25
Basic Belt Conveyors
All Components need to be
designed for good Sanitation

Major Components:
• Drive
• Take-up
• Infeed & Discharge Nosers
• Rollers
• Belt Trackers
• Belt
l Scrapers
S
• Belts

26
Maintenance and Sanitary
Conside ations
Considerations
• Belt conveyors must be easy to maintain and clean.
Provide
P both
id b h visual
i l and
d physical
h i l access to all
ll components.
If you can’t see or access components they will be neglected.
Conveyors fabricated from a combination of welded SS tubular
frames and SS or aluminum plates usually provide the best
balance of strength and access for sanitation and long term
maintenance
• All rollers
ll iin contact
t t with
ith th
the product
d t side
id off the
th belt
b lt
are to be easily accessible or removable without the use
of tools for cleaning purposes. This allows for quick removal
sanitation Also,
and sanitation. Also rollers can be replaced more quickly.
quickly
This design requires the use of ER type bearings – the roller
rotates on a fixed shaft
• T
Teflon
fl sleeves
l for
f rollers
ll will
ill eliminate
li i t product
d t buildup
b ild in
i
most cases. The sleeve should be 6 mm thick hard virgin
Teflon. Do not use standard thin Teflon coating as it will wear
and can lead to product contamination

27
Conveyor Design

Basic Components for Sanitary Design

28
Conveyor Drive Section

Single-roll Drive – No Tandem Drives

29
Lift-Out Rollers
Belt Support Rollers in contact with the
Product Side of the Belt should be easily
accessible for Cleaning or removable without Tools

30
Product Contact Roller on
E tendable Con
Extendable Conveyor
e o
Not removable without Lift out Rollers
Lift-out
complete Disassembly without Tools

31
Teflon Coated Rollers
Do not use Teflon Coating on Rollers that are in contact with
the Product Side of Belts

32
Belt Scraper Detail

Good Design is essential

33
Belt Scrapers
Lack of Scrapers will result in
dirty Belts and Build-up on the Rollers

34
Belt Scraper
Even with considerable
Product Build-up Rollers are kept clean

35
Roller Condition

Without and with good Belt Scrapers

36
Roller Build-up
Without good Scrapers all Rollers build up
and create Belt Tracking Problems

37
Disc Support Rollers

Much easier to clean and cost less

38
Conveyor Legs

Unsanitary
Sanitary

39
Conveyor Legs

Sanitary Leg but Good sanitary Leg

Tripod Base would be better without exposed Threads

40
Conveyor Legs

Sturdy with Good but Tripod

good
d Access
A without
i h Brace
B is
i better
b

41
Conveyor Legs

Ideal Sanitary Design

42
Conveyor Side Guides

Tilt-up Guides for easy Cleaning

43
Product Guides
Guiderail Assembly can be lifted from
both sides for easy Cleaning Access

44
Conveyor Belting

The Strings can end up in the Product

Reinforced Edge Frayed Edge

45
Conveyor Crossovers
Provide 100 mm high Kickplates
to avoid Product Contamination

46
Platforms
Must have Kickplates that are a minimum
of 100 mm high without any Gaps
between the Kickplate and Floor

47
Platform Design
Poor Design – difficult to clean,
Gap can lead to Product Contamination

S
Square C
Corner G
Gap

48
Good Platform Design

Handrails Overhang and

mounted outside rounded Corners

49
Platform Design

Good Design with Rounded Corners

50
Good Platform and Steps

Easy to clean

51
Stair Design

Poor – difficult to clean Better – easier to clean

52
Poor Stair Design

Closed Risers – difficult to clean

53
Stair Tread Design

Square Corners and Crevices –

difficult to clean

54
Good Stair Design

Open Risers – easy to clean

55
Stair Tread Design

Gap between Tread Plate and Frame –

easy to clean

56
Covers

Ingredient Cart Mixer Shield

57
Improved Door Design
Before After
Ledge - higher Cost No Ledge - lower Cost

58
Wire-cut Machine
Before After
Closed Design Wide open Design
with bolted Covers with hinged Covers

59
Rotary Molder

Before After
Closed Design with bolted Open Design with hinged
Covers - difficult Access Covers - easy Access

60
Rotary Molder

Stand-offs Panels and Guards are

with
ith easy Access
A sloped
l d for
f easy Drainage
D i

61
Open Design

Outboard Drives leaves lower Opens completely

A
Area open ffor easy A
Access with
ith easy Access
A

62
Installation
Practices

63
“Installation Practices”
Clea ances
Clearances

150 mm Clearance Wide open –

but poor for cleaning easy to clean

64
Clearances

Clearance meets …but higher mounting of Pipe

Requirements would make it easier to clean

65
Poor Clearance and Wiring

Poor Worst... Dirt Catcher

66
Pump Mounts

Good Poor

67
Pump Mounts

Good Poor

68
Pump Mounts

Good Clearance Better Clearance

69
Insufficient Clearances

Very difficult to clean

70
Clearances

Good Access for Cleaning

71
Pump Base

Legs are too short – nearly impossible to clean

72
Excellent Clearance

Very easy to clean

73
Trapped Area

Very difficult to clean

74
Condensate Pump Mount

Poor Frame Trapped Area

with open Ends

75
Floor Mounted Condensate
Tank Wiring
Tank, Wi ing and Piping
Totally unacceptable

76
Unistrut

- Not to be used in Food Production Areas

- Angle Iron Brackets are preferred

77
Unistrut in Production Area

Impossible to clean

78
Hanger Rods
Allthread Rods not to be used –
Rods are to be threaded
only
l about
b 100
00 mm at each h End
d

79
Covers over Allthread Rods
Not to be used –
they provide an Insect Harborage Area

80
Panel Installations

Unistrut and Insufficient Clearance

Insufficient Clearance

81
Wall Mounted Panels
Brackets with sufficient Clearance
for Cleaning Access is preferred

Sealed
S l d– Unsealed –
when Stand-offs not possible Insect Harborage
82
Poor and Good Panel Installation
Poor Clearance Good Clearance, Legs
and Legs and gabled Top

83
Panel Mount
Solid Bases are good Alternative

84
Pipe and Wireway Mounting
Provide Clearances

Debris accumulates Insect Harborage Area

85
Wall Mounted Conduit and Pipe

Leave Clearance to avoid Dirt Accumulation

Good Bad and Good

86
Pipe Mounting

Space between Wall is good –

Unistrut is wrong

87
Wiring
Very difficult to clean, use Conduit

88
Cable Racks
Not to be used in dusty Areas

89
Cable Racks

When Flour Dust is present it

Poorly installed Cables is nearly impossible to clean

90
Cable Mounting
Acceptable in Packaging Areas that are not dusty

Better – with removable Cover

Poor

91
Cable Trays and Cable Racks
Not to be used in dusty Areas

Cable Trays not to Cable Racks are acceptable

be used at all but must be mounted with
Most difficult to clean Access for Cleaning

92
Cable Rack
Nearly impossible to clean

93
Cable Racks
Must be mounted vertically
to provide Access for Cleaning
Not to b
be used
d iin d
dusty Areas

94
Cable Racks
With easy Access for Cleaning

95
Cable Racks
Clearance between Wall and Rack
for easy Cleaning Access

96
Cable Entry into Panels

Good Poor

97
Cable Entry into Panels

Poor – not to be used Good

when
h Fl
Flour D
Dustt iis presentt

98
Panel Entry
Conduit with Sealtight – Ideal Solution

99
Conduit and Sealtight
Ideal for dusty Areas

100
Gasketed Wireways and Conduits
To be used in all dusty Areas

101
Lower Cost Wireway

102
Wiring in Machine Frames
Very clean – Code Issues in some Countries

103
Cables in Machine Frames
Unsealed Openings are totally unacceptable

104
Ideal Sanitary Installation
Good Conduit Mounting,
Wireway and Conveyor Legs

105
Support Brackets
Considering “Clean-ability” and “Afford-ability”
what should have been done differently?

106
Sanitary Equipment Design and
Installation Practices
suitable for the Biscuit Industry

Biscuit & Cracker

Manufacturers’ Association
Manufacturers
Technical Conference
April 27 – 30,
30 2014
Nashville, Tennessee

107