Professional Documents
Culture Documents
Summary: The following is a guide to supplying equipment to meet current Kraft sanitary design standards for USDA Pizza and Meat Projects.
Resource: Rory Redemann, Sr Program Leader USDA Sanitation & USDA Sanitary Design , Madison 608-285-4129
The American Meat Institute has written the Sanitary Design Checklist to identify ten principles of sanitary design for food processing equipment.
Using this tool will assist designers in identifying problem areas and typical design flaws that limit the effectiveness of cleaning and sanitizing
processes.
Three classifications are used in the checklist: Satisfactory, Marginal, and Unacceptable.
Due to the stringent micro testing and zero tolerance placed on meat products, these guidelines are being provided to aid in identification of design criteria needed to
improve the cleanability of processing equipment.
Continue by selecting the AMI Checklist tab, when the checklist is completed, select the Summary tab to review.
Effective: March 8, 2010
Supersedes: February 23, 2009
Checklist Utilized Buildings & Grounds YES NO Equipment Checklist YES NO If the project scope does nodt justify the
(Project SD Team Checklist AMI or GMA completion of the checklist apture action items
Determines) below
Required Required Off site 8 Hours Dry Comments:
YES or Alternate method approved Time (Date)
Passivation NO
by CSC. Attach approval
(wet clean product contact) Internal
and Passivation Records.
Written Instructions YES NO Projected time & labor Projected time & labor Total projected annual sani cost
Provided, If no define routine sani/annualized for PEC /annualized
Cleaning Method CA in action register
Sanitation Cost
COMMENTS / NOTES
# Follow Up / Action Status Owner Completed
1
2
3
4
5
6
7
8
9
SANITARY DESIGN AUDIT
To complete this checklist, place an "X" in the appropriate box; Revised: February 23, 2009
S = Satisfactory Supersedes: August 13, 2008
M = Marginal Originated: October 9, 2003
U = Unsatisfactory
The total score will automatically calculate and can be viewed on the Summary page
100
100 /100
PRINCIPIO #2 - HECHO DE MATERIALES COMPATIBLES
S M U NA Deficiency
2.1 Las superficies de contacto con el producto deben estar hechas con NSF 4.1, 4.2
materiales resistentes a la corrosión, no tóxicos y no absorbentes, 10
según lo aprobado en NSF/ANSI/3A 14159-1.
-
2.2 En general, el acero inoxidable debe ser de la serie AISI 300 o superior. NSF 4.2.1
Kraft requiere la pasivación de superficies de acero inoxidable en
10
contacto con el producto limpiado en húmedo. ¿Se ha completado o
programado la pasivación? -
2.3 Los compuestos y plásticos permanecen intactos sin cambios en la AMI
forma, estructura y función a través de los protocolos de limpieza y
10
saneamiento
-
2.4 Las superficies chapadas, pintadas y recubiertas no se utilizan para AMI
superficies en contacto con alimentos o para superficies por encima de
10
las áreas de la zona del producto.
-
2.5 Los recubrimientos y el revestimiento deben permanecer intactos. NSF 5.1.8
10
-
2.6 No se utilizan cinturones traseros de tela. NSF 5.3.3
10
-
2.7 Los materiales no utilizados incluyen madera, esmalte, aluminio sin NSF 4.1.1,
recubrimiento, aluminio anodizado sin recubrimiento, etc. según 4.2.1.2, 4.3
10
NSF/ANSI/3A 14159-1.
-
738769934.xls
S = Satisfactory, M = Marginal, U = Unsatisfactory, NA = Not Applicable Rev:(12/7/98)
4
SANITARY DESIGN AUDIT
738769934.xls
S = Satisfactory, M = Marginal, U = Unsatisfactory, NA = Not Applicable Rev:(12/7/98)
5
SANITARY DESIGN AUDIT
4.5 La humedad no gotea, drena ni atrae las áreas de la zona del producto. AMI
15
-
4.6 La tensión de la correa es adecuada durante todas las operaciones para AMI
evitar que el agua se acumule en las correas. 15
-
4.7 Los espacios muertos se eliminan en el diseño NSF 5.1.6,
B.3 15
-
4.8 Los materiales utilizados no serán absorbentes NSF 4.2, 4.3
15
-
4.9 Las tuberías de proceso y las tuberías CIP tienen una pendiente de 1/4" Kraft Aug
por pie para un drenaje adecuado 2008
100 /100 100
PRINCIPIO # 5 - ÁREAS HUECAS SELLADAS HERMÉTICAMENTE
S M U NA Deficiency
5.1 Todos los miembros giratorios, como las ruedas dentadas de AMI
transmisión o las poleas de correa, deben ser sólidos o rellenos de tinte
y completamente sellados con soldaduras continuas. 30
-
5.2 Toda la construcción estacionaria de tubos huecos, como los miembros NSF 5.2.1
del bastidor o los espaciadores de las cuchillas, está completamente
sellada con soldaduras continuas para evitar la contaminación interior. 30
-
5.3 No hay penetraciones de sujetadores en la construcción de tubos AMI
huecos.
30
-
5.4 Los ajustes de las patas roscadas son internos y no penetran en los NSF 5.2.4
miembros del bastidor del tubo.
30
-
5.5 Las placas de identificación y las etiquetas se minimizan. Cuando se AMI
unen, las placas y etiquetas se sueldan continuamente. Los remaches o
las placas atornilladas (a menudo selladas con masilla) están ausentes. 30
-
6.2 La textura de la superficie de una superficie que no esté en contacto AMI
con el producto no debe exceder las 125 μ-pulgadas. 10
-
6.3 Las esquinas y ángulos internos deben tener un radio suave y continuo NSF 5.1.9
de al menos 1/8 de pulgada (ángulos de menos de 135º) 10
-
6.4 No hay juntas traslapadas. Algunos ejemplos son el hecho de separarse NSF 7.1.7,
de los rodamientos con brida frente al montaje directo en el lateral de B.4
un transportador. 10
-
6.5 Los espaciadores herméticamente sellados se utilizan para dejar espacio AMI
entre dos piezas contiguas para permitir la acción mecánica durante la 10
limpieza. -
6.6 No se utiliza calafateo. AMI
10
-
6.7 Todas las juntas y soldaduras están al ras y libres de picaduras, grietas AMI, NSF
y corrosión. 5.1.7 10
-
6.8 Todas las soldaduras son continuas, lisas y pulidas NSF 5.1.1
10
-
6.9 Los conjuntos con manguito (por ejemplo, bujes, ruedas dentadas, AMI
cojinetes) no miden más de 1-1/2 pulgadas o se pueden desmontar 10
para su limpieza. -
738769934.xls
S = Satisfactory, M = Marginal, U = Unsatisfactory, NA = Not Applicable Rev:(12/7/98)
6
SANITARY DESIGN AUDIT
738769934.xls
S = Satisfactory, M = Marginal, U = Unsatisfactory, NA = Not Applicable Rev:(12/7/98)
7
SANITARY DESIGN AUDIT
8.8 El agua de refrigeración, las líneas de drenaje, las bandejas de goteo Kraft Nov
KFT (elementos con agua que fluye constantemente) deben canalizarse y / o 2013
dirigirse a un desagüe.
8.9 Los conductos y otras líneas de suministro de servicios públicos no se Kraft Nov
KFT enrutan por encima de las áreas de contacto con el producto 2013 50
50 / 50 50
738769934.xls
S = Satisfactory, M = Marginal, U = Unsatisfactory, NA = Not Applicable Rev:(12/7/98)
8
SANITATION AUDIT SUMMARY
PRINCIPIO #2 - HECHO DE MATERIALES COMPATIBLES 100.0 /100 Less than 1000 needs improvement
PRINCIPIO #8 - DISEÑO HIGIÉNICO DE LOS RECINTOS DE MANTENIMIENTO 0.0 0 Unsatisfactory = zero points
# #
1 2
3 4
5 6
7 8
9 10
11 12
13
Cleanability Acceptance Protocol
In accordance with the specifications provided, Company will assist Kraft in jointly developing(this is an exception - the long term
requirement is to have the vendor provide the cleaning protocols) cleaning protocols that effectively and efficiently deliver microbio
clean surfaces for the Equipment. Cleaning protocols will detail the level of disassembly required for normal sanitation, how to per
the task, and recommended cleaning aides (clean out of place tanks or clean in place systems) needed. The protocol will also spe
periodic cleaning tasks, the details for dismantling, and the recommended frequencies. KRAFT shall be responsible for following al
cleaning protocols.
In order to test the effectiveness of the jointly developed cleaning protocol(s), KRAFT will monitor swab results taken after the san
process and prior to production start up. This data will be trended over a period of 45 days, which will begin as soon as Equ
is running at full production shifts and, to the extent possible correspond with the Final Acceptance test. Acceptable results for
swab results will be <100 colony forming unit (CFU) for aerobic plate count.
Targeted sampling areas shall cover 40 square inches and will be mutually agreed upon by KRAFT and Company prior to the begin
the test. The # of samples sites may very depending on the design. As a general guideline 10 sample sights for direct pro
contact surface locations and 10 sample sights for indirect/non product contact surface locations should be identif
Indirect/non product contact surfaces will include sights directly adjacent to product contact and upper framework.
KRAFT will collect the samples, perform the analysis, and share the results with Company on a regular basis during
test. To pass the test each site must show a 98% cleaning effectiveness rate over the 45-day test period. When te
results are outside the requirements of this test, KRAFT and Company will investigate the causes for the results and determine cor
actions. Corrective actions can include, but are not limited to, improving efficiency of personnel performing cleaning protocol, sani
design changes and / or cleaning protocol changes. Corrective actions shall be implemented as soon as possible and monitored fo
improvement during the remainder of the test period. Any corrective action to be taken and the responsibility for the cost of reme
be mutually agreed upon between KRAFT and Company. Company shall only be responsible for any corrective action pertaining t
machine improvements so that the Equipment can achieve a 98% cleaning effectiveness rate when mutually agreed upon protocol
followed. Company shall not be responsible for any of KRAFT’s costs related to wash-down or sanitation such as additional labor c
additional sanitation costs or any direct or indirect costs related to lost profits.
In the event that the 98% cleaning effectiveness rate can not be obtained when mutually agreed upon cleaning protocols are follo
and if mutual agreement regarding corrective action and cost of remedy cannot be reached then KRAFT, as its only remedies, and
notwithstanding any rights or remedies otherwise provided herein: 1) shall have the right to return the Equipment and receive a re
the purchase price of the Equipment or, 2) upon mutual agreement, may accept the equipment as is and receive a financial settlem
exceeding three (3) percent of the value of the machine (limited to the particular machine which does not meet the specified hygie
acceptance criteria). Any sample site that does not pass will continue to be tested, after corrective actions have been
implemented, until 12 consecutive results for that site yield a 98% cleaning effectiveness rate.
Definition of 98% cleaning effectiveness rate:
1. No consecutive out of spec results per swab site location.
2. In spec percentage equal > 98% of swabs tested.
3. Out of spec results directly attributable to KRAFT failing to follow the company defined protocol will not be used in calculatin
cleaning effectiveness rate.
Sampling Guidelines:
Swabs: Use pre-sterilized swabs and sterilized buffers, pre-sterilized swab kits with swabs and pre-made buffers or
internally prepared and sterilized swabs and buffers. Examples of commercially available pre-sterilized swabs and bu
include 3M Quick swabs and Redi-swabs. Pre-sterilized sponges containing sterile buffers may also be used for samp
collection. An example of this type of sponge is the Hydrasponge available from International Bioproducts.
Media: For total plate count estimations it is recommended laboratories use Plate Count Agar, APT agar containing
and Brom Cresol Purple or 3M Petrifilm. If using Petrifilm, be sure to follow the manufacturers instructions and avoid
buffer containing citrate or sodium thiosulfate.
Action limits: Total plate count < 100 CFU per area swabbed. Target to sample 40 square inches.
Edits / Changes
1 Added signature line for individual completing the review.
2 Added reference on 1.2 to cleanability languaged used in performance agreements.
Added reference worksheet titled Cleanability Test Protocol & updated protocol document
3 based on the most recent performance agreements (Proj Blondie)
4 Added statement on the summary worksheet explaining the purpose of the # rating.
Added question to 2.2 requesting confirmation that equipment meets A3 policy
5 requirements on passivation.
6 Added 4 Gate sign-off worksheet to track project review progression
Date Changed
6/23/2005
6/23/2005
6/23/2005
6/23/2005
6/23/2005
2/23/2009