Gen SanitationRom

8/17/2019 Gen SanitationRom

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HACCP Consulting 1

Sanitation Requirements forMeat, Poultry, and

Other Food Processing

Plants

(CFR 416 Sanitation!



HACCP Consulting 2

"eneral Rules ## "oal$ach %lant must &e constructed,

maintained and o%erated in a

sanitary manner sufficient to ensure

that %roduct is safe ' not

adulterated



HACCP Consulting 3

Plant "rounds

"rounds and Pest Control

"rounds must &e maintained to %re)entconditions that could lead to insanitary

conditions

Pest Control must ha)e a Pest Management

Program (to &e co)ered in more detail later!



HACCP Consulting 4

Plant Construction

Construction "eneral Requirement

$sta&lishment &uildings must &e of soundconstruction and &e *e%t in good re%air+

alls, floors, ceilings must &e &uilt of dura&le

materials im%er)ious to moisture and &e cleanedand saniti-ed as necessary


http://slidepdf.com/reader/full/gen-sanitationrom 5/117 HACCP Consulting 5

Plant Construction # continued

Construction

alls, floors, ceilings, doors, .indo.s must &e

constructed and maintained to %re)ent entry of

)ermin, etc

Rooms or com%artments in .hich edi&le %roduct is

%rocessed must &e se%arate from rooms in .hich

inedi&le %roduct is handled or stored to the e/tent

necessary to %re)ent adulteration+


http://slidepdf.com/reader/full/gen-sanitationrom 6/117 HACCP Consulting 6

Plant 0ighting

0ighting of good quality and

sufficient intensity to ensure thatsanitary conditions are maintained

0ighting at ins%ection locations should

&e 243 0u/ (23 foot candles!



HACCP Consulting 7

Plant entilation

5dequate )entilation is required to

control odors, )a%ors, and condensationto the e/tent necessary to %re)ent

adulteration of %roduct and the creation

of insanitary conditions



HACCP Consulting 8

Plum&ing

Must &e installed and maintained to• Carry sufficient quantities of .ater to required

locations in %lant

• Pro%erly con)ey se.age and liquid dis%osal

.aste from the %lant



HACCP Consulting 9

Plum&ing # continued

Must &e installed and maintained to• Pre)ent adulteration of %roduct, .ater su%%lies,

equi%ment, and utensils

• Pre)ent &ac*#flo. conditions

• Pre)ent &ac*u% of se.er gases

• Pre)ent 7dead s%aces8



HACCP Consulting 10

Plum&ing Se.age 9is%osal

Se.age must &e dis%osed into a system

se%arate from all other drainage linesPri)ate se.age dis%osal systems must &e

a%%ro)ed &y a go)ernmental health

authority



HACCP Consulting 11

ater ' :ce Su%%ly

;he .ater su%%ly must &e %ota&le and com%ly.ith a %rescri&ed go)ernment standard (ie the

<ational Primary 9rin*ing ater regulations43 CFR Part 141!

:ce that .ill contact %roduct or &e used as aningredient in %roduct must &e made from

%ota&le .ater ' &e %rotected fromcontamination



HACCP Consulting 12

ater, :ce, and Solution Reuseater, ice and solutions may &e reused for the

same %ur%ose %ro)ided they are maintained free of

%athogenic organisms and other %hysical and

chemical contaminates+



HACCP Consulting 13

Reuse of ater, :ce and

Solutions

ater Su%%ly and ater, :ce, and

solution reuseReconditioned .ater that has ne)er contained

human .aste and that has &een treated &y an

onsite ad)anced .aste.ater treatment facility may

&e used on ra. %roduct++



HACCP Consulting 14

Reuse of ater, :ce and

Solutions

ater, :ce, and Solution reuse5ny .ater that has ne)er contained human .asteand that is free of %athogenic organisms may &eused in edi&le and inedi&le %roduct areas, %ro)idedit does not contact edi&le %roduct

ater that does not meet the use conditions may

not &e used in areas .here edi&le %roduct ishandled+



HACCP Consulting 15

9ressing Rooms, 0a)atories,

' ;oilets

9ressing Rooms, 0a)atories, and ;oilets

9ressing rooms, toilet rooms, and urinals must &e

in sufficient num&ers, am%le in si-e, con)eniently

located, and maintained in a sanitary condition and

in good re%air to ensure cleanliness of all %ersons

handling any %roduct



HACCP Consulting 16

9ressing Rooms, 0a)atories,

' ;oilets, continued

9ressing Rooms, 0a)atories, and ;oilets

0a)atories .ith hot and cold .ater (dis%ensed

.ithout use of hands!, soa%, and to.els, must &e

%laced in or near toilet and urinal rooms++

Refuse rece%tacles must &e constructed and

maintained in a manner that %rotects against the

creation of insanitary conditions



HACCP Consulting 17

$qui%ment ' =tensils

Sanitation "oals$qui%ment and utensils must &e maintained insanitary condition so as not to adulterate %roduct

$qui%ment and utensils must &e constructed, located,or o%erated in a manner that ena&les :ns%ectors '%lant em%loyees to conduct sanitation ins%ections

Rece%tacles for inedi&le or condemned %roduct mustnot &e used for storing any edi&le %roduct and must&ear cons%icuous and distincti)e mar*ing to identify%ermitted use



HACCP Consulting 18

Equipment: Prior Evaluation

Prevention of Problems

Clenbilit!

"it#stn$ Pro$u%tion Con$itions

&inimi'e H'r$s to Pro$u%t

&(imi'e "or)er *fet!



HACCP Consulting 19


5cce%ta&le Materials

+onto(i% n$ %#emi%ll! %%eptble

"ill not $eteriorte t#roug# norml useor $uring %lening , sniti'ing

*moot#- %orrosion n$ brsion resistnt

*#tterproof

+onbsorbent n$ .ill not stin ormigrte to t#e pro$u%t



HACCP Consulting 20


=nacce%ta&le Materials

G/A** voi$ if possible lig#t

bulbstubes must be prote%te$ .it#s#tterproof plsti%

+A&A/"A- PC/A+ or P

C &A/* su%# s le$ :in%lu$ing*ol$er;- %$mium- mer%ur!- ntimon!



HACCP Consulting 21


=nacce%ta&le Materials ::

/AH or <A=C* $ue to porous nture:fe. e(%eptions fbri% in %ertin ft or ir

>lters;"? is porous .ill bsorb moisture llo.s mi%robil gro.t# ver! $i@%ult to %lenn$or sniti'e

PA+ s#oul$ be voi$e$ ? + B* on orner pro$u%t %ont%t surf%es



HACCP Consulting 22

Equipment

Sanitary Design & ConstructionPrimr! be%tiveD o f%ilitte %leningn$ Prevent Pro$u%t Contmintion

*moot# *urf%es free fromD pitsE %r%)sE%revi%esE et%

nternl Corners , Angles %ontinuous ,smoot# r$ius of F 065%m

"el$ing %ontinuous- smoot#- even- ,reltivel! us# .it# $%ent surf%es +spot .el$ingI



HACCP Consulting 23

Sanitary Design & Construction II

"el$e$ Joints must be resistnt to t#e stressof norml use

&ust =e *elf?rining or ot#er.ise ble to be

%ompletel! ev%ute$&otori'e$ Prts , =erings s#oul$ belo%te$ outsi$e t#e pro$u%t 'one if t#is isnot possible- t#en %t%# pnI or some ot#er

$evise must be instlle$ to prevent possiblelubri%nt le)ge into pro$u%t res



HACCP Consulting 24

Design & Construction III

Kuipment s#oul$ be s *impleConstru%tion s possible .it# t#e fe.estnumber of prts pr%ti%l

ime , se of ?isssembl! importnt ools reKuire$ for $ismntling s#oul$ bevilble

Conve!or Gui$es- *pls# Gur$s et% must

be esil! remove$ to permit %lening n$inspe%tion



HACCP Consulting 25

Design & Construction IV

Hori'ontl /e$ges or <rme &embers outsi$e of pro$u%t 'one minimi'e n$ useroun$e$ or tubulr %onstru%tion .#enever

possible?esign- %onstru%tion- n$ instlltions#oul$ llo. s! A%%ess for snitr! ,me%#ni%l mintenn%e



HACCP Consulting 26

Design & Construction V

Pro$u%t Lone free of re%esses-opensems- gps- protru$ing le$ges- insi$et#re$s- insi$e s#oul$ers- bolts- rivets- n$

$e$ en$s

/rge Kuipment pproprite %lenout ,inspe%tion openings- %t.l)s- l$$ers- or

ot#er provisions to ensure t#t ll prts %nbe %lene$ n$ inspe%te$



HACCP Consulting 27

Design & Construction VI

C#utes- Pumps , Pipelines %onve!ingpro$u%t

Mmust be es! to $ismntle for %lening ,inspe%tion

M&ust not #ve $e$ sp%e .#ere pro$u%t m!stgnte

M nstll snitr! Kui%)$is%onne%ts t ll %#ngesof $ire%tion



HACCP Consulting 28

Design & Construction VII

*A< $esigne$- %onstru%te$ n$instlle$ to gur$ ginst inur! topersonnel

Consi$erDM*#rp e$ges

M&oving prts

Mle%tri%l s#o%)

M(%essive noise

Mt#er #'r$s

MProte%tive Gur$s



HACCP Consulting 29

Clean-in-Place (CIP) Systems

CP *!stems A$vntges

Controlle$ more esil! n$ %losel!

/ess $epen$ent on #umn involvement t#us less sus%eptible to error

?esign , perting Pln %riti%l for

su%%ess



HACCP Consulting 30

Clean-in-Place (CIP) Systems II

Clening , sniti'ing solutions n$rinse .ter must %ont%t ll interiorsurf%es

&ust be self$rining .it# no lo. orsgging res

Pipe interiors must be #ig#l! polis#e$

:120180 grit; stinless steel



HACCP Consulting 31

Clean-in-Place (CIP) Systems III

lbo.s esil! removble At e%# %#nge of $ire%tion *#ort enoug# for interior inspe%tion

An! prt outsi$e of CP s!stem must be$ismntle$ n$ %lene$ mnull!

Abilit! to sfel! inspe%t ll prts

Ne%tiveness evlute$ b! perio$i%$ismntling , inspe%ting



HACCP Consulting 32

Equipment u!ricants

Bse foo$ gr$eI lubri%nts

Avoi$ (%essive Bse

)e mesures to prevent%ontmintion of pro$u%t



HACCP Consulting 34

Equipment Installation II

Oent *t%)s from Hoo$s

&gneti% rps n$ &etl ?ete%tors

"ter on "or) ble :23%m lip;Air /ines <ilter on ir int)e

Clen n$ free of oil n$ moisture



HACCP Consulting 35

Equipment Installation III

"s# *in)s

Hn$ "s# *in) Pro$u%t "s# *in)

KuipmentBtensil "s# *in)s

Kuipment "s#rooms



HACCP Consulting 36

Equipment "aintenance

outinel! inspe%te$ n$ mintine$

epir or repl%e prt =< pro$u%t

is %ontminte$?o nor overlo$ eKuipment

?evelop Preventive &intenn%eProgrm



HACCP Consulting 37

&ust not be%ome p#!si%l-

mi%robiologi%l- or %#emi%l#'r$

&ust be mintine$ in goo$

%on$ition

ooden Pallets



HACCP Consulting 38

ooden Pallets ::

&ust not #ve n! %ont%t .it#

e(pose$ pro$u%t&ust not be use$ or store$ inres .#ere e(pose$ or

ot#er sensitive pro$u%ts repro%esse$ or #n$le$



HACCP Consulting 39

ften e(pose$ to mn! )in$s of

%ontmintion n$ busee$il! splinter or bre) nils-stples or .oo$ splinters m!

$ulterte pro$u%t

ooden Pallets

Potential Pro&lems



HACCP Consulting 40

&! bsorb %ontminnts su%#

sD oil- grese- met ui%es-niml fe%es- %#emi%ls- et%

"s#ingsniti'ing $i@%ult

pllets re slo. to $r!

ooden Pallets

Potential Pro&lems ::



HACCP Consulting 41

Plastic ;rays

Commonl! Bse$ in &n! Plnts. pro$u%t :e(pose$ n$ p%)ge$; mulsionsCoo)e$ Pro$u%ts :e(pose$ n$ p%)ge$; Pro$u%ts :e(pose$ n$ p%)ge$; nplnt Bse n$ s *#ipping Continers ne$ibleCon$emne$ Pro$u%ts

&n! P=/&*



HACCP Consulting 42

Plastic ;rays ::

Automte$ .s#ing s!stem

emove $mge$ tr!s

Color %o$ing

*pe%i>% %olor for oorpllet %ont%t

*uggest inplnt use onl!

*uggest pol! liners

Clerl! i$entif! tr!s use$ forine$ible%on$emne$ :*pe%i>% %olor;



HACCP Consulting 43

Cleaners & Saniti#ers - De$initions

Acid Cleaner pH belo. 7 %#emi%ls.#i%# relese #!$rogen ions :H; in solution #ese #!$rogen ions re %#emi%ll! ver!

%tive

#e! re prti%ulrl! eNe%tive for removingminerl $eposits su%# s %l%ium n$

mgnesium pre%ipittes from eKuipment



HACCP Consulting 44

Cleaning De$initions (%)

Alkaline Cleaners pH bove 7 Cuse$b! %#emi%ls .#i%# relese #!$ro(!l ions:H; in solution #e #!$ro(!l ion is

reltivel! %tive

?iNerentite$ s .e) or strong $epen$ingon t#eir $egree of l)linit! Al)lies re

use$ to remove fts n$ ot#er orgni%mterils from eKuipment surf%es



HACCP Consulting 45

Cleaning De$initions (io$ilm)

Bioflm Compose$ of %losel! p%)e$%olonies of b%teri t#t $#ere to surf%e :in%lu$ing stinless steel;

Att%# t#emselves to t#e surf%e b!pro$u%ing %omple( %rbo#!$rte or

pol!s%%#ri$e substn%e



HACCP Consulting 46

Cleaning De$initions (io$ilm-%)

<irml! $#eres to t#e surf%e n$ trpsnutrients- ot#er mi%roorgnisms-viruses- ft- proteins- n$ ot#er $ebris

#is >lm %ontinues to buil$ in l!ers

t is not esil! remove$ b! or$inr!%lening mesures n$ resists t#e

penetrtion of sniti'ers



HACCP Consulting 47

Cleaning De$initions (')

Buer A substn%e %pble ofmintining t#e pH of solution t somefirl! %onstnt vlue

Chelation C#emi%l formtion of QringQ roun$ metlli% ion %reting

stble soluble %ompoun$ t#us llo.ingits removl



HACCP Consulting 48

Cleaning De$initions ()

Disinect ?estro!ing 100R of t#e trgete$pt#ogeni% vegettive %ells of b%teri*ome $isinfe%tnts .ill $estro! or $mge

some spores

Sanitize <or snittion purposes- sniti'emens t#e pro%ess of re$u%ing t#e totl

mi%robil popultion :Het or %#emi%l;



HACCP Consulting 49

Cleaning De$initions ()

Suractant Compoun$ t#t lo.ers t#esurf%e tension of t#e solution Also )no.ns .etting gents

Suspension A%tion .#i%# )eeps insolubleprti%les of soli$s uniforml! $istribute$ in solution- preventing t#em from settling n$forming $eposits &)es it esier to us#

t#em .! from surf%es being %lene$



HACCP Consulting 50

Cleaning De$initions (*)

Water hardness efers to .ter%ontining %#emi%ls- su%# s vriousminerls or $issolve$ slts

Common .ter softeners e(%#nge t#e%l%ium ions in t#e .ter .it# so$ium

ions from slt



HACCP Consulting 52

+ater Supply (Pu!lic or +ell)

+ot %#emi%ll! pure

Bsull! %ontins vriet! of $issolve$minerls n$ orgni% %#emi%ls

f not remove$- t#e eNe%tiveness of%lening %ompoun$s .ill be re$u%e$

n$or result in Q.ter spottingQ on %lensurf%es



HACCP Consulting 53

.ar/ +ater 0se/ in Cleaning

en$s to interfere .it# t#elt#ering %tion of sops n$$etergents

eKuires t#e use of more of t#e%lening %ompoun$s



HACCP Consulting 54

.ar/ +ater 0se/ in Cleaning , (%)

n%reses t#e lo$ on t#e.ste .ter tretment s!stem

=est to use .ter t#t is ssoft s pr%ti%l n$ nerneutrl in pH



HACCP Consulting 55

1rea or ocation to !e Cleane/

#e lest mount of foreignmteril .ill be t#e esiest to %len

#e t!pe of opertion in t#e re#s mor inuen%e on t#e

sele%tion of %lening pro%ess



HACCP Consulting 56

Special Cleaning

?r! *usge pro%essing res often#ve nturl mi%robiologi%lpopultion ne%essr! to fermenttion

Comptible nturl or en#n%es$r!ing , fermenttion

An$ often re ble to #ol$ un$esirble

orgnisms in %#e%)



HACCP Consulting 57

Special Cleaning (%)

o $estro! t#is or %oul$ %use filures infermenttion- n$ %rete n environmentfvoring #'r$ous orgnism :ie

*tp#!lo%o%%us ureus; +ot n rgument ginst %lening n$sniti'ing su%# rooms- but

mp#si'es t#e importn%e of pproprite

te%#niKues for e%# spe%i>% re



HACCP Consulting 58

"ec2anical Cleaning

<irst step in t#e %lening pro%ess

&! be %%omplis#e$ .it#out t#e useof %lening %ompoun$s

P#!si%ll! removing gross $ebris b!brus#ing- s.eeping- v%uuming-rinsing- or ot#er mens



HACCP Consulting 59

Cleaning 3emperatures

emperture of .ter prerinsesE%lening %ompoun$sE n$ sniti'ers-importnt for eNe%tiveness

Prerinse s#oul$ use .rm or %ol$ .ter

Hot .ter .ill %ogulting proteins n$QsetQ t#em on surf%es



HACCP Consulting 60

Cleaning 3emperatures (%)

n%e proteins re set on surf%es it ismore $i@%ult to remove t#em

Clening n$ sniti'ing preprtions

#ve optiml use tempertures

mportnt to use t t#e re%ommen$e$tempertures



HACCP Consulting 61

Saniti#ers

#e use of %#emi%l sniti'ers is nosubstitute for eNe%tive %lening

=si% %tegories of ut#ori'e$ %#emi%ls

use$ to sniti'e eKuipment in%lu$e

C#lorineE io$ine n$ io$op#orsEKuternr! mmonium %ompoun$sE n$

%i$nioni% surf%tnts



HACCP Consulting 62

C2lorine

C#lorine usull! so$ium#!po%#lorite

200 ppm of vilble %#lorine

ne(pensive

Corrosive

rrigting to s)in , e!es

n%tivte$ b! orgni% mtter

pi$ $issiption



HACCP Consulting 63

C2lorine - +14I45

WARNING Chlorine !as is e"tremel#to"ic$

Should ne%er &e com&ined 'ith acidsor ammonia compounds &ecause

hazardous !ases and(or %iolent anddan!erous reactions ma# result)



HACCP Consulting 64

C2lorine , +14I45 (%)

I acid cleaners are used* make surethere is no a%aila&le chlorine present'hen the cleaners are applied)

Should onl# &e applied ollo'in! thecomplete remo%al o acid cleaners &#thorou!h rinsin!)

Because the &actericidal action is %er#rapid* chlorine sanitizers oten are

preerred on e+uipment a&out to &eused)



HACCP Consulting 65

o$op#ors io$ine

%omple(esSimilar to chlorine in their effectiveness

Maximum limit of available iodine is 25 ppm

Only slightly corrosive

Highly unstable in hot solutions above 151°F

!!°"#

Should be used $ithin a narro$ pH range

%&5 to 5&5#&



HACCP Consulting 66

Suternr! Ammonium

Compoun$sCommonl! )no.n s KutsI

<reKuentl! use$ s sniti'ers

*ele%tivel! eNe%tive ginst grmpositive n$ grmnegtive b%teri

+ot eNe%tive ginst b%teril

spores



HACCP Consulting 67

67uats8

'ot corrosive to the e(uipment

'ot irritating to the s)in

Stable in hot solutions above 151°F!!°"#

*eave an active residue



HACCP Consulting 68

‘ 7uats8 (%)

*ome re Ne%te$ b! #r$.ter- ot#ers re not

Suts re in%omptible .it#nioni% .etting gents- sops-.oo$- %lot#- %ellulose- n$

n!lon



HACCP Consulting 69

A%i$nioni% *niti'ers

Bse$ in t#e >nl rinse of utomte$%lening s!stems

P#osp#ori% %i$ is %ommon in t#e

formultion"ell suite$ to sniti'ing stinless steelsurf%es

Cn prevent minerl $eposits from%%umulting



HACCP Consulting 70

A%i$nioni% *niti'ers :2;

&(imum ntimi%robil eNe%tiveness oft#ese pro$u%ts is t pH of belo. 30

Al)line .ters $e%rese t#eireNe%tiveness

A%tivit! of %i$nioni% sniti'ersginst b%teri is repi$



HACCP Consulting 71

estrictions on C2emical 0se

+emove food products and pac)aging materials

prior to cleaning a processing area

,hose $ith odors-fragrances $hen diluted for use .

may interfere $ith sanitary inspection and must notbe used on food contact surfaces

,hose containing abrasive materials silica/

pumice/ etc&#/ 00 may be used F all residues are

removed $ith potable $ater&



HACCP Consulting 72

estrictions on C2emical 0se (%)

All cleanin! compounds used inedi&le product processin! areas must

&e ollo'ed &# a pota&le 'ater rinse)

,his includes so called -spra# and'ipe- cleaners or other similarcompounds



HACCP Consulting 73

estrictions on C2emical 0se (9)

Some sanitizers are appro%ed or use'ithout a pota&le 'ater rinse.

// 0ust &e used accordin! to la&eldirections

// Suraces are drained thorou!hl#

// An# puddlin! or collection o li+uid isremo%ed &eore contact 'ith oodproducts)

R1AD ,21 3AB13



HACCP Consulting 74

Costs o$ Cleaning

F 90R lbor

T 35R %lening %#emi%ls , supplies

Competent supervisor vitl

Proper trining , te%#niKues essentil

e.r$sD <oo$ *fet!E Kulit!E , s#elf

life



HACCP Consulting 75

3ec2nical 1ssistance

C#emi%l mnuf%turers

*uppl! %ompnies

&n! universities



HACCP Consulting 76

Con/ensation

A ver! %ommon problem

ften %riti%l >n$ing in u$its

Plnts #ve ll t#e elements nee$e$

"rm moist ir

pertions .it# #uge temperturevritions from %oo)ing to free'ing

Poorl! $esigne$ iro. ptterns



HACCP Consulting 77

Con/ensation (%) , Post Clean-up

Generte$ b! t#e %lening pro%ess

ften $ire%tl! over pro$u%t %ont%tsurf%es

&B* be remove$ prior to t#e strt ofopertions



HACCP Consulting 78

Con/ensation , De$inition

Con$enste is t#e free moisture forme$on surf%e or in t#e ir .#en t#ere is toomu%# .ter vpor for t#e ir to #ol$

Con$enstion is t#e pro%ess b! .#i%#%on$enste is %rete$

Con$enste is forme$ onl! .#en t#etemperture of t#e ir or surf%e is belo.t#e $e. point of t#e surroun$ingtmosp#ere



HACCP Consulting 79

Con/ensation (sli/e ;)

"#en %on$enste forms in ir- itbe%omes fog or rin

"#en %on$enste forms on surf%e- it

.ets itf t#e %on$ition persists- t#e moisture%%umultes be$s into $rops n$

flls

C / i ( li/ )



HACCP Consulting 80

Con/ensation (sli/e ')

ater is a solvent for some materials

3ecomes a vehicle for carrying solubles and

particulate matter&

"ondensate tends to ta)e on the character of

its environment& including its microbes#

C / i ( li/ )



HACCP Consulting 81

Con/ensation (sli/e )

=e$e$ n$ flling moisture mostl!from .ter vpor %on$ense$ on rils-pipes- %eilings- or stru%turl members is

%ommon problem in met n$ poultr!plnts

n re$ met plnts m! be most severein t#e #ot %r%ss %ooler

C / i ( li/ )



HACCP Consulting 82

Con/ensation (sli/e )

Hot- moist %r%sses from t#e slug#ter$eprtment entering %ol$ environment

Cool ir psses %ross t#e %r%sses

Pi%)s up t#e vilble #et n$or moistureeturns to t#e %ooling unit to give up t#t#et n$or moisture n$ repet t#e %!%le

C / ti ( li/ *)



HACCP Consulting 83

Con/ensation (sli/e *)

*igni>%ntl! $iNerent ir %#r%teristi%sfrom pl%etopl%e .it#in t#e %ooler

Con$enste generll! forms in onl!some res rt#er t#n t#e entire

%ooler

C / ti t l i l



HACCP Consulting 84

Con/ensation , controls in cooler

"rm up t#e Cooler fter $esire$ %#illbut before more #ot %r%sses

urn oN refrigertion )eep fns on

empering perio$ for eKuilibrtion emperture eKuli'es bet.een rils- .lls-%eiling n$ %r%sses

e$u%es opportunit! for %on$enstion

C / ti t l (%)



HACCP Consulting 85

Con/ensation , controls (%)

Bse of <ns *trtegi%ll! lo%te$

eliminte stti% po%)ets of moist ir

in%rese ir %ir%ultion in t#e room

n .rong lo%tion %n ggrvte%on$enstion problem

+ t C il $ i ti



HACCP Consulting 86

+et Coil e$rigeration

nl! use$ .#en room temperture isbove free'ing

Coils operte$ belo. free'ing in #umi$

environment- Kui%)l! buil$ frost<rost in#ibits ir o. #et trnsfer isre$u%e$ e@%ien%! is impire$

+et Coil e$rigeration (%)



HACCP Consulting 87

+et Coil e$rigeration (%)

Fro4en condensate refrigeration loss

ater to ice re(uires 1%% 3,6s of

refrigeration-pound 728 3,6-)g#

3,6s not available for product

1 3,6 185%&75 9oules 251&::5; "alories#

<nergy to heat 1 pound $ater 1°F

+et Coil e$rigeration (9)



HACCP Consulting 88

+et Coil e$rigeration (9)

Gives m(imum %ontinuous #ettrnsfer

?oes not $epre%ite in eNe%tiveness

+o $efrost %!%le

Continuous ir %ir%ultion

De$rosting



HACCP Consulting 89

De$rosting

et coil may not be used if insufficient coil

surface

=efrost by air flo$ 0 return the 3,6s from

frost to useful refrigeration3y raising suction pressure for 15028 minutes

to 58 psi 7&!% )g-cm2# or 7%°F 1°"# $ith

fans operating&

<eep Coils Clean



HACCP Consulting 90

<eep Coils Clean

Coils not %lene$ often enoug#- if ever

<ilm of ft n$or lint $e%rese

e@%ien%!

*igni>%ntl! re$u%e ir %p%it! of fns

<t is goo$ insultor even if not felt

m! impir performn%e

Con/ensation Summary



HACCP Consulting 91

Con/ensation - Summary

=ig problem

+o es! solution

=est to prevent s mu%# s possible

emove prior to opertion

?uring opertions %refull! removebefore it $rips

Sanitary O%erations



HACCP Consulting 92

Sanitary O%erations

5ll food#contact surfaces+ Must &e

cleaned and saniti-ed as frequently as

necessary++<on#food#contact surfaces must &e

cleaned and saniti-ed as frequently as

necessary +++

Sanitary O%erations Continued



HACCP Consulting 93

Sanitary O%erations Continued

Cleaning com%ounds, saniti-ing agents,

%rocessing aids+must &e safe and

effecti)e under the conditions of use+Product must &e %rotected from

adulteration during %rocessing, handling,

storage, loading and unloading+

Section 416 2 $m%loyee >ygiene



HACCP Consulting 94


Cleanliness

5ll %ersons must adhere to hygienic %ractices .hile on duty

to %re)ent adulteration of %roduct

Clothing

5%rons, froc*s, and other outer clothing .orn &y %ersons

.ho handle %roduct must &e of material that is dura&le and

readily cleaned Clean garments must &e .orn at the start

of each .or*ing day++




HACCP Consulting 95

Section 4162 $m%loyee >ygiene

9isease Control

5ny %erson .ho has or a%%ears to ha)e an

infectious disease, o%en lesion, including &oils,

sores, or infected .ounds+ must &e e/cluded from

any o%erations .hich could result in %roduct

adulteration

Section 416 ;agging :nsanitary



HACCP Consulting 96

gg g y

$qui%ment, =tensils, Rooms, orCom%artments

hen an FS:S %rogram em%loyee finds thatany equi%ment, utensil, room, or com%artment

is insanitary or that its use could cause the

adulteration of %roduct, he?she .ill attach to it

a @=S ReAected @ tag

Section 416 ;agging :nsanitary



HACCP Consulting 97

gg g y

$qui%ment, =tensils, Rooms, orCom%artments

$qui%ment++ so tagged cannot &e used untilmade acce%ta&le

Only an :ns%ection %rogram em%loyee may

remo)e an official @ReAectB tag

Pest Control



HACCP Consulting 98

Pest Control

Gol &intin Pest <ree <%ilit!

"ritten Progrm

Ueep e%or$s

utsi$e Contr%tor m! be bestppro%#

Pest Control



HACCP Consulting 99

Facility SanitationAvoi$ *itutions t#t Attr%t*upport Pests emovl of *our%es of <oo$ n$ "ter

emovl of rs#

Cutting "ee$s

emove Bnuse$ Kuipment , mterils

Clen /o%)ers , "elfre <%ilities

Coopertion from A$%ent Propert! .ners

Pest Control Plant Maintenance



HACCP Consulting 100

Pest Control Plant Maintenance

Crete =rriers to ntr! of Pests Kuipment , <%ilities epir or epl%e

<loors- "lls- Ceilings *uitble ig#t <itting&terils

=ro)en Ares- Cr%)s , *eprtions *el Possible A%%ess Corre%t mme$itel!

<loor ?rin Covers n Pl%e

penings- ?oors- "in$o.s *%reene$- ig#t

<itting

Pest Control Storage 5reas




Pest Control Storage 5reas

liminte o$ents in *torge Ares Oerif! t lest .ee)l!

%)s F 30%m N t#e <loor

*tore F 45%m <rom An! "llotte Pllets

Pest Control ritten Program




Pest Control ritten Program

Progrm *#oul$ n%lu$e&pC#rt .it# /o%tion of =it =o(es- rps- et%

/ist of &terils Bse$ n$ Ares rete$:n%lu$e %opies of pprove$ lbels;

$entif! Commer%il (termintor if use$

Pest Control ritten ::




?es%ription of ControlsD "#ere- "#en =it =o(es rps

*ti%)! =or$snformtion on =it =o(es *eKuentill! +umbere$+me!pe of Poison .or$s Vo$ent =itW

+meP#oneX of (termintor

:nsect Control # ritten




?es%ribe Controls "#ere n$ "#en le%troni% nse%t trps

*ti%)! =or$s*trips

?es%ribe nse%ti%i$es Bse$ "#ere-"#en- Ho.+onesi$uls

esi$uls

Pest Control erification




outine Au$its

$entif! n$ ?o%ument All ?e>%ien%ies

Pest Control <ile to Contin"ritten Progrm"ee)l! , ?il! eports

Commer%il (termintorIs eports

&ps n$ C#rts

Pest 5cti)ity <on#Product 5reas




y

?o%ument

+otif! @%ils

*urve! of Premises

?etermine if Commer%il (termintor+ee$e$

Pest 5cti)ity Product 5reas




y

=efore pertions?etermine *our%e n$ (tent

i$ Are of Pests

Clen n$ *niti'e Are mplement Corre%tivePreventive A%tions

?o%ument

Pest 5cti)ity Product 5reas ::




y

?uring pertions *top pertions

Prote%t Pro$u%t

liminte Pests?etermine *our%e

)e Corre%tive A%tion

?o%ument

Sanitation Program




Goo$ *nittion $oes not

V#ppenW t must be$esigne$ into t#e s!stem

Plant Responsibility




t is t#e responsibilit! of Plnt &ngementto %#ieve t#e proper level of snittionD

?esign- Constru%tion , &intenn%e of t#e plnt

Bse proper %lening pro%e$ures n$ freKuen%ies

&onitor to ssure t#t stn$r$s re %onsistentl!met on $il! bsis

Inspector Responsibility




&)e sure t#t t#e plnt meets itsresponsibilit!

Sanitation Priorities




?ire%t Pro$u%t Contmintion most%riti%l :**Ps;

n$ire%t or Possible Pro$u%t

ContmintionPotentil Pro$u%t Contmintion

emote Potentil for Contmintion

Sanitation Standard Operating

Procedures (SSOPs)




Procedures (SSOPs)

*!stem use$ b! t#e B* Plnts toprevent Pro$u%t ContmintionD

"ritten Progrm t#t n%lu$es bot# Pre

opertionl n$ pertionl Components

?il! e%or$s of <in$ings $es%ribes$evition n$ %orre%tive %tion t)en:n%lu$ing Preventive &esures;

<in$ings re use$ to improve progrm

Pre-op Typical Sequence




Plnt mplo!ees or utsi$e CleningCre. %omplete t#eir ob %#e%)e$ b!t#eir supervisor

?esignte$ Plnt mplo!ee %on$u%ts preopertionl inspe%tion- re%or$s results-reKuests %orre%tive %tion s nee$e$

GovIt nspe%tor Hs pportunit! toCon$u%t nspe%tion



Operational SSOPs




tems t#t re %#e%)e$ $uring plntopertions :some e(mples;D

mplo!ee pr%ti%es #n$ .s#ing et%

Prote%tive %lot#ing #ir nets- gloves et% e%on$itioning Pro$u%t

Con$enstion Control

*nitr! ?ressing Pro%e$ures




>uestions?

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