Hygienic design_nadeles PDF

DEPARTMENT OF FOOD TECHNOLOGY, FOOD SAFETY AND HEALTH INSTRUMENTELE PROCES- EN KWALITEITSCONTROLE (I700181A) HYGIENISCH ONTWERP Prof. Dr. MSc. Ing. Imca Sampers INTRODUCTION 2 FOOD SAFETY: CHAIN APPROACH Picture: LinkedIN by Hasanuzzaman Hasan...

DEPARTMENT OF FOOD TECHNOLOGY, FOOD SAFETY AND HEALTH INSTRUMENTELE PROCES- EN KWALITEITSCONTROLE (I700181A) HYGIENISCH ONTWERP Prof. Dr. MSc. Ing. Imca Sampers INTRODUCTION 2 FOOD SAFETY: CHAIN APPROACH Picture: LinkedIN by Hasanuzzaman Hasan Hygienic design 3 FOOD SAFETY: SOURCES Food hazards via humans, raw material/products, the environment and machines Hygienic design 4 FOOD SAFETY: DANGERS ̶ Biological ̶ Parasites, pests, microorganisms, natural biological toxins Hygienic design 5 BIOFILM FORMATION – Biofilm is formed – On contact surfaces – To liquid-air interfaces https://www.the-scientist.com/infographics/infographic-stages-of-biofilm-formation-71140 EPS laag wordt gevormd Hygienic design 6 BIOFILM A biofilm is a 3-dimensional organized, dynamic structure/community of one or more species of microorganisms, surrounded by an organic polymer matrix, which is irreversibly adhered to the surface. Water EPS (extracellular polymeric substances: polysaccharides, glycoproteins,...) Bacteria Hygienic design 7 BIOFILM: WHERE? MO in water zijn makkelijk te verwijderen maar eens ze gehecht zijn aan de matrix is het onmogelijk ze nog weg te krijgen ̶ On food and ingredients Shigella boydii op een blad van peterselie (Annous et al., 2009) Niet-pathogene microflora aan de oppervlakte van een vrucht (Y, B, F) Pseudomonas biofilm op de huidmondjes van slabladeren Hygienic design 8 (PIHM) BIOFILM: WHERE? ̶ On the processing lines Vleesindustrie: koude kamer Viskwekerij: oppervlakte van een vijver stockeerruimte (L. monocytogenes) (Yersinia ruckeri) Hygienic design 9  SURFACE CONTAMINATION ̶ On the processing lines ̶ => Spash zones: aerosol formation ‒ Walls, Floors ‒ Ventilation, air conditioning, ventilation systems (HVAC) Hygienic design 10 als je naast die lijn nog een andere productielijn hebt die reeds gereinigd is, dan wordt deze gecontamineerd door de reiniging van de andere lijn SURFACE CONTAMINATION Biofilm formation: Where? In closed systems that are not regularly or inadequate, e.g. pipes (especially bends), heat exchangers,... Yang H, Xu Z, Xu Z, Li Y. Mini-Review of Biofilm Interactions with Surface Materials in Industrial Piping System. Membranes. 2023; 13(2):125. https://doi.org/10.3390/membranes13020125 Hard-to-reach places such as cracks, seams (joint), rubber seals, conveyor belt and cooling equipment (fan) e.g. the persistence of L. monocytogenes in drains is usually due to biofilm formation On surfaces that come into contact with food/ingredient: - biofilm formation of B. cereus on surfaces in contact with starch, potatoes, bakery products,... For example, kettles for rice, pasta,... - surfaces in contact with proteins and fats: if insufficiently cleaned (rinsing water of too low a T), proteins and fat residues will remain and lead to growth and biofilm formation of bacteria, incl. L. monocytogenes flexibel dus kan overal gebruikt worden maar moet wel regelmatig gecontroleerd worden Hygienic design 11 SURFACE CONTAMINATION Caitlin R. Proctor, Mauro Reimann, Bas Vriens, Frederik Hammes, Biofilms in shower hoses, Water Research, Volume 131, 2018, Pages 274-286, Hygienic design 12 SURFACE CONTAMINATION techniekers kunnen ook bron zijn van contaminatie, afvalkarren die buiten gestockeerd worden,…. wheeled dumpsters or other carts going in and out: accumulation of residues that allow growth of L. monocytogenes Foot bath: organic material from shoes can inactivate disinfection and lead to niche formation, contamination further spread through feet potentiele bron want ze controleren nooit het vat dus ipv desinfectie is het je ziet spatten aan de kant gaan dus contaminatie dan Hygienic design nooit in de productieruimte maar in een 13 lokaal voor de productie BUT, ALSO… ̶ But also in dishcloths, sponges… ̶ 109 bacteria in a single drop from a sponge/cloth Sponges op tijd vervangen! Pathogens may survive for weeks (Kusumaningrum, 2002) reinigingsmateriaal ook reinigen ̶ Restaurants: Tables are sometimes 45 times more contaminated after cleaning with a cloth than before (for E. coli, contamination x19) Dish towels 3 10 bacteria of which 13 Salmonella (14%) S. aureus (20%) Coliformen (31%) Enterobacter (50%) Hygienic design 14 15 PERSISTENCE? als je jaren lang hetzelfde product maakt L. monocytogenes has been found to be persistent in food-processing plants Ice cream 7 years Not in raw material Cheese plant 7 years Now part of domestic flora Chilled pizza, pasta Longer even possible! RTE Up to 8 years Cold-smoked salmon 4 years RTE smoked fish 2 years Hygienic design 16 Møretrø and Langsrud (2004) Definition for persistence of mo 17  DEFINITION als je meerdere malen dezelfde stam vindt op een opp mag je gaan nadenken over persistentie —> je moet ook kijken naar het genoom!! het moet altijd hetzelfde zijn anders geen persistentie Examples of some of the many definitions Recovered on successive occasions from the same environments over a sampling period; minimum 12 months, maximum 4 years (Nilsson, 2011) L. monocytogenes strains were considered persistent when they were found repeatedly (three times or more) in the environment or on equipment over a minimum of a 3-month period. Strains that were isolated sporadically (fewer than three times) or within a shorter time period ( 3 months) were considered non- persistent (Keto-Timonen, 2007) Strains were considered persistent if they were isolated on two occasions at least six months apart and were genetically indistinguishable through ribotyping (Rodríguez-Campos, 2019) Persistence can be defined as the repeated isolation of organisms of a specific molecular subtype from the same processing environment despite the frequent and correct application of C&D procedures (Overney et al., 2017) als je na goede reiniging nog steeds dezelfde stam vindt —> GROOT PROBLEEM! Hygienic design 18 DEFINITION Aspects of persistence found in definitions: Period (precise or imprecise) Amount of sampling Specific molecular subtype Location Frequent and adequate C&D Hygienic design 19 PERSISTENCE  INFRASTRUCTURE Problem = harbourage sites  “Places that are inadequately cleaned and disinfected due to ignorance or inaccessibility” How do these “persistent” microorganisms reach these places? ‘’Accidental’’ e.g. C&D insufficient, abnormally high number of cells entering harbourage site Through purchase of contaminated second-hand equipment + wear of own equipment Through raw ingredients Through cross-contamination from other contaminated places inside the facility (e.g. trolley wheels, personnel shoes, aerosols…) 20 Hygienic design 2de hands toestellen goed controleren ! BIOFILM ̶ Biofilm arises because bacteria choose to multiply on surfaces instead of in liquid phase (advantage: protection against external influences); in a matrix, favorable conditions for growth and survival are common (eg. biofilm-MO: increased resistance to disinfectants) All bacteria can in principle form biofilm. ̶ Cell density in a biofilm = 104 TO 108 cfu/cm2 ̶ Thickness of a biofilm = from a few micrometres to several cm Hygienic design 21 BIOFILM: ISSUES Microbially induced corrosion ̶ Biofilm of L. monocytogenes at 20°C on stainless steel https://doi.org/10.1111/1751-7915.13690 Other disadvantages besides persistence include mechanical blockage, impedance of heat transfer, corrosion to metal surfaces, hamper filtration - MO kan leiden tot corrosie - Lysteria is schadelijk —> gezondheidsproblemen Hygienic design 22 FOOD SAFETY: DANGERS ̶ Biological ̶ Parasites, pests, microorganisms, natural biological toxins ̶ Chemical ̶ Pesticides, herbicides, fungicides, fertilizers, pharmaceuticals ̶ Contaminants due to processing: nitrosamines, fat oxidation, migration product kan in contact komen met transportband (bevat smeermiddelen) dus ̶ Environmental contaminants: allergens, heavy metals die hulpstof mag niet op het product terecht komen ̶ Lubricants, cleaners and disinfectants, paints ̶ Physical ̶ Foreign material specific to raw material: last batch, seeds ̶ Glass, wood, stones, hair, waste (product) ̶ Rust, paint particles ̶ fabric, paper Hygienic design 23 een aantal vliegen kan nog maar als er plots meerdere binnenkomen —> kijken hoe als er gaten zijn waar een balpen door kan dan ook ratten WHAT COULD HAPPEN TO YOUR BUSINESS? – Health of consumer – Reputation damage – Legal consequences – Financial damage – Loss of certificates and accreditations – Increased control and audits – Longterm impact on the supply chain Hygienic design 24 FOOD SAFETY: HACCP https://simplerqms.com/capa/ https://www.thema-med.com/en/2018/05/02/corrective-preventive-actions-causes-investigation/ Hygienic design 25 SOLUTIONS ̶ Secondary processes such as cooling, cleaning and disinfection ensure e.g. an acceptable microbial count. Cooling Heating Raw materials Production Transport Consumption Cleaning and desinfection Hygienic design 26  CLEANING AND DISINFECTION machine wordt ouder dus veranderd ook wat 71 SUMMARY ̶ Food safety is a matter of the entire food supply chain ̶ hazards arising from humans and the environment and also from machines ̶ Secondary processes such as cleaning have an impact on the shelf life of products, if buildings and machinery are of poor design – cleaning will be difficult and time consuming. ̶ Hygiene is the essential basis for the quality of a food product. ̶ Product quality also depends on the design and quality of the machines used. Hygienic design 72 SUMMARY ̶ operational safety requirements conflict with hygiene requirements in many cases ̶ interpretation of regulations and standards should always be done in relation to the local situation (specific product and process requirements, available equipment and personnel, environment) ̶ guidelines (knowledge, experiences and sometimes simple solutions) are available Hygienic design 73 HYGIENIC DESIGN OF MACHINES / FACILITIES ̶ Definition: ̶ Design of machines and layout of facilities in line with hygiene-oriented standards that allow good cleanability and avoid dead spaces and corners that are difficult or impossible to reach where food residues can be trapped. ̶ "If you can't see it and you can't reach it, you can't clean it or take samples." belangrijk!!! Hygienic design 74  je hebt een ontwerp voor de doos (gebouw) maar ook voor de machines HYGIENIC DESIGN OF MACHINES / FACILITIES ̶ Principle: ̶ Generally Accepted Principles of Equipment Design: ‒ Cleanability ‒ Accessibility ‒ no niches ‒ No liquid collection (disposability) ‒ Maintenance Enclosures ‒ Food Grade Building Materials ̶ Generally Accepted Principles of Hygienic Facility Design: ‒ Zoning ‒ Appropriate layout ‒ Pest Prevention ‒ Hygienic building materials ‒ Plumbing Pipe Insulation ‒ Chemical and wear-resistant floors Hygienic design 75 HYGIENIC DESIGN x ̶ Part of food safety ̶ Ease and level of cleaning of machines and production facilities are directly related to possible cross-contamination (e.g. micro-organisms or allergens) and other undesirable safety and quality effects on food. ̶ Regulations, industry standards and best practices require machines and facilities to be hygienically designed for easy and thorough cleaning. Taking care of a good cleaning and sanitation makes safe food processing possible! http://www.foodsafetymagazine.com Hygienic design 76 HYGIENIC DESIGN ̶ Machines and facilities that are difficult to clean require more chemicals, water and labor, resulting in reduced life expectancy, increased maintenance and thus higher operating costs. ̶ Using hygienic design principles in production can result in the following additional benefits: ̶ Less rejected product ̶ Less product is put on hold ̶ Less reworked product ̶ Less product destroyed ̶ Fewer consumer complaints ̶ Fewer quality checks ̶ Less research costs for cotton swabs ̶ Less wastewater and biochemical oxygen demand ̶ Less pre-operational test costs ̶ Less chemical products and cleaning time ̶ Less chance of a recall of contaminated product https://www.foodengineeringmag.com/ext/resources/WhitePapers/Kollmorg en---Hygienic-Design-and-Food-Safety.pdf Hygienic design 77  ventilatoren zuiveren maar lucht verplaatst zich dus kan zo ook MO vervoeren! (van vuile naar propere zone —> werken met sas/overdruk HYGIENIC DESIGN ̶ CONSTRUCTION DESIGN ̶ Factory related aspects ̶ Layout related aspects ̶ Air-related aspects ̶ Water-related aspects ̶ Zoning ‒ Air flow: from higher to lower hygienic zone and from lower to higher dust loaded areas. ‒ Air pressure (positive; 2-5 Pa) ‒ Air lock systems —> flow personeel afval mag nooit in de buurt zitten ‒ Avoid open windows and doors Hygienic design 78 ONTWERP GEBOUW Fabriekgerelateerde aspecten Hygienic design 79 ONTWERP GEBOUW Fabriekgerelateerde aspecten ̶ Beperkte toegang: ̶ Controle betreffende toegang van dieren. ̶ Controle betreffende ongeautoriseerde mensen. ̶ Duid dit aan door hekken te plaatsen and zichtbare signalisatie. Hygienic design 80 ONTWERP GEBOUW Fabriekgerelateerde aspecten Bomen en struiken rondom de voedselproductie zien er misschien leuk uit, maar herbergen ongedierte. Gebieden binnen een omtrek van 3- 5 m van de fabriek moeten vrij worden gehouden van vegetatie. Voldoende drainage om hardnekkige plassen te voorkomen wordt aanbevolen. Regelmatige verwijdering van afval is cruciaal om de prevalentie van ongedierte te verminderen. Hygienic design 81 ONTWERP GEBOUW Fabriekgerelateerde aspecten Daken, muren en fundering beschermen tegen elementen en ongedierte. Daken moeten zo worden ontworpen en gebouwd dat ze kunnen worden geïnspecteerd en geen water en bladeren verzamelen. Gladde oppervlakken bereiken dit het beste. Mogelijke bronnen van vervuiling zijn ventilatieopeningen. Alle functies die vuil kunnen verzamelen, moeten worden vermeden. Dicht af op punten waar afvoeren, leidingen enz. door muren gaan. vensterltabletten niet want dat kan rustplaats zijn voor dieren liefst hoek van 45 ° dan! Hygienic design 82 ONTWERP GEBOUW Fabriekgerelateerde aspecten Plafonds moeten goed worden afgedicht. Muren moeten van goede kwaliteit zijn, zonder gaten of gaten, en gemaakt zijn van gemakkelijk te reinigen materiaal. Schilfers van verf of ander materiaal moeten worden verwijderd. Ongedierte verstopt zich en vuil hoopt zich op achter beschermende schermen. Bouw solide constructies zonder openingen (zie afgeronde vloerhoeken in figuur) en installeer alleen beschermingsschermen als dit om technische / veiligheidsdoeleinden absoluut vereist is. Hygienic design 83 ONTWERP GEBOUW Fabriekgerelateerde aspecten Als de opening leidt tot een gebied met een hoge hygiëne of naar de buitenkant van het gebouw, vul en dicht de opening dan zodanig af dat er geen ongedierte kan binnendringen. Als gat van het ene productiegebied naar het andere van hetzelfde niveau van hygiëne repareer wand om afbrokkelen te voorkomen, inspecteer dan regelmatig en houd schoon. Hygienic design 84 ONTWERP GEBOUW geen hoeken maar afrondingen met radius met minstens 3 cm —> je kan daar niet kuisen Lay-out gerelateerde aspecten vloer mag niet vlak zijn moet helling hebben van 3° —> anders ophoping water —> biofilm ̶ Plaatsing van fysisch gescheiden ruimtes (zonering): aparte droge en natte ruimtes, korte product route zonder kruisingen ̶ Binnen moeten de oppervlakken van bouwelementen niet-elektrostatisch, glad en ronde hoeken zijn en een goede bereikbaarheid hebben voor reiniging ̶ Geen metalen panelen ‒ hoge warmteoverdracht -> condensatie - > uitzetting -> afdichtingen Hygienic design 85 ONTWERP GEBOUW Lay-out gerelateerde aspecten ̶ Materialen ̶ moeten bestand zijn tegen voedselcomponenten, reinigingsmiddelen en ontsmettingsmiddelen ̶ Geen hout en standaard glas in open bewerkingsruimten, maar polymeermateriaal zoals polycarbonaat of versterkt glas (standaard glas met beschermfolie) ̶ Roestige apparatuur kan leiden tot fysische, chemische en microbiologische gevaren. ̶ Roest geeft aan dat het materiaal niet voedselcontactveilig is. Metaaldeeltjes kunnen in voedsel terechtkomen en een beschadigd oppervlak bevordert de groei van micro-organismen. ̶ ROESTVRIJ STAAL hoe lager de nummer —> hoe geodkoper ̶ AISI 304 Normaal van toepassing, indien nee: geen chloriden; anders risico op putcorrosie ̶ AISI316 Beter bestand tegen chloriden, maar > 60 ° C: spanningscorrosie ̶ AISI410 beter bestand tegen spanningscorrosie ̶ Alternatieven: AISI 409; AISI 329 en Incolony 825 zijn de desinfectiemiddelden foodgrade en zijn ze wel geschikt voor de materialen? Hygienic design 86 ONTWERP GEBOUW Lay-out gerelateerde aspecten afvoer of goot —> NOOIT ONDER MACHINE —> biofilm ̶ Afvoer buizen moeten ook hellend zijn —> NOOIT WATERPAS ̶ Niet in droge zones ̶ Zo ver mogelijk van verwerkende machines ̶ Voldoende hellend ̶ Met de mogelijkheid om af te sluiten tijdens de productie ̶ Waterslot moet intact zijn zorgt dat iets vanuit de goot de fabriek niet meer kan binnenkomen Hygienic design 87 ONTWERP GEBOUW Lay-out gerelateerde aspecten ̶ Frame: open profielen, gemonteerd met strakke pasvorm, geen holle lichamen en horizontaal oppervlakken, ingesloten in beton ̶ Platforms en loopbruggen: zou moeten geminimaliseerd zijn, niet boven open processen Hygienic design 88 ONTWERP GEBOUW Lay-out gerelateerde aspecten alle bouten moeten afgerond zijn, geen groeven geen sterretjes Hygienic design 89 ONTWERP GEBOUW Lay-out gerelateerde aspecten ̶ vermijd vals / verlaagd plafond constructies (controlekamers) ̶ Ramen: niet te openen of horren (gemakkelijk toegankelijk, reinigbaar of vervangbaar), ̶ geen of 45 ° hellende dorpels en richels Hygienic design 90 ONTWERP GEBOUW Lay-out gerelateerde aspecten ̶ Bekabeling en Leidingen goed maar buizen moeten hellend zijn niet goed Hygienic design 91 ONTWERP GEBOUW Lay-out gerelateerde aspecten ̶ Kabel montage: geschikte ensembles die veel stof verzamelen, moeten worden ingesloten in een droge ruimte. Verwarde kabelconstructies zijn broedplaatsen voor ongedierte en bemoeilijken inspectie en passende reiniging Kabels kunnen worden beschermd tegen stofophoping en beschadiging door ze in hermetisch gesloten kabelbehuizingen in te kapselen, zoals roestvrijstalen buizen, vooral in de buurt van voedselcontact en spatgebied Hygienic design 92 ONTWERP GEBOUW Lay-out gerelateerde aspecten ̶ Kabel montage: Het wordt aanbevolen om de kabels gescheiden te leggen over een afstand van niet minder dan 25 mm om vuilophoping te voorkomen en om het schoonmaken te vergemakkelijken: (a) kabelscheider om in draadgoten te installeren, (b) om te installeren in de buurt van apparatuur. Hygienic design 93 ONTWERP GEBOUW Lay-out gerelateerde aspecten ̶ Kabel montage: rooster of plaat, één laag, schuin of verticaal Het gebruik van horizontale rekken voor elektrische bekabeling moet tot een minimum worden beperkt, vooral die dicht bij het plafond, aangezien er ontoegankelijke stoflagen ontstaan die hygiënische risico's opleveren. Waar mogelijk moeten verticale kabelgoten worden gebruikt, omdat deze beter toegankelijk en gemakkelijk te reinigen zijn Hygienic design 94 niet goed niet goed ONTWERP GEBOUW Lay-out gerelateerde aspecten ̶ Lasnaden: Hygienic design 95 ONTWERP GEBOUW Lay-out gerelateerde aspecten ̶ vermijd besmetting ̶ niet dicht bij deuren (insecten) ̶ niet boven open processen (vreemde lichamen) ̶ vermijd stof en condensatie (waterdicht) lampen geen horizontale vlakken Hygienic design 96 ONTWERP GEBOUW Water gerelateerde aspecten ̶ Vloeren moeten gemaakt zijn van duurzaam materiaal dat bestand is tegen reinigingsprocessen (d.w.z. heet water en chemicaliën), het gewicht van machines en fysieke slijtage (d.w.z. bewegende vorkheftrucks) kan dragen. ̶ Vloeren moeten hellend zijn om ervoor te zorgen dat het water (bijv. Tijdens het reinigen) naar de afvoeren stroomt. Voorkom dat zich stilstaande poelen vormen. ̶ Regel de productiestroom om te voorkomen dat verontreinigd water gebieden binnendringt waar onbeschermde voedselproducten worden verwerkt. Hygienic design 97 HYGIENIC DESIGN ̶ CONSTRUCTION DESIGN ̶ Factory related aspects ̶ Layout related aspects ̶ Air related aspects ̶ Water-related aspects ̶ Zoning ̶ MACHINE DESIGN ̶ INSTALLATION AND INTEGRATION OF MACHINERY Hygienic design 98 DESIGN MACHINE je moet achter, boven en onder een machine kunnen All equipment used must be designed to comply with food safety standards: access must be easy ̶ for visual checks of cleanliness ̶ for easy cleaning, and ̶ for easy process control. Hygienic design 99 DESIGN MACHINE Hygienic design 100 DESIGN MACHINE Product contact surfaces 3A definition of product contact surfaces: “All surfaces which are exposed to the product and surfaces from which splashed product, liquids, or material may drain, drop, diffuse {where applicable}, or be drawn into the product or onto product contact surfaces.” EHEDG definition of product contact surfaces: “All surfaces of the machine that intentionally or unintentionally come in contact with the product, or from which product or condensate may drain, drop, or be drawn into the product or container, including surfaces (e.g. unsterilized packs) that may indirectly cross-contaminate product contact surfaces or containers.” NOTE: Product Contact Surfaces may contribute to cross-contamination, and must therefore be included in the hazard analysis (HACCP). zijkant van goot is wel productcontactopp dat van de wasbak niet —> kritische zone (want condens, …) goot mag nooit op die plaats zitten Hygienic design 101 DESIGN MACHINE Product contact surfaces must comply with European Union and United States (FDA) regulations. Food contact surfaces are: non-reactive with the product, cleaning agents (migration, absorption) non-contaminating to the product non-corrosive non-toxic does not absorb any liquid mechanically stable cleanable to prevent biofilm formation and Ra contain micro-organisms, allergen-containing residues or other chemical contaminants. Surfaces must be finished with a sufficiently smooth surface roughness so that they can be easily cleaned and disinfected. The surface finish must be such that there are no cracks, pits or voids where water or dirt could remain and give rise to possible contamination. The surface finish (roughness Ra ≤ 0.8 μm) must not be affected under the conditions of use (cold rolled steel has 0.2 Ra ≤ 0.5 μm and does not need to be polished). Hygienic design 102 DESIGN MACHINE x Food processing equipment should be ̶ intended for food production, ̶ obtained from a reputable supplier who will be able to provide the correct replacement parts for the life of the machine, ̶ easy to clean (beware of hidden spaces behind sealing gaskets!), ̶ easy to maintain. When buying new or used equipment, first test it for functionality and hygienic properties. Disinfect before first use! Hygienic design 103 DESIGN MACHINE ̶ Following properties regarding the machine materials used: ̶ Composition ̶ Topography ̶ Physicochemistry ̶ Surface finish affect hygiene. Hygienic design 104 DESIGN MACHINE verschil in groei van MO qua opp maar ook qua stam ̶ Composition: Formation of biofilm L. monocytogenes biofilm - 24 hours Stainless steel / PVC (Borucki et al., 2003) ≠ amounts of adherent bacteria ≠ biofilm structures What is the role of surface physico-chemistry on disinfectant resistance? Lm M39503A Lm M35584 Hygienic design 105 DESIGN MACHINE ClO2 + acid QAC ̶ Composition: ClO2 Acid QAC L. monocytogenes Neutral QAC Mixed halogen biofilm - 24 hours; Peracetic acid resistance to Fatty acid Acid anionoc disinfectants Iodophor Chlorine Polyester/Polyurethane Polyester Control Stainless steel 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 (Krysinski et al., 1992) What is the role of surface physico-chemistry on disinfectant resistance? Hygienic design 106 DESIGN MACHINE ̶ Composition: The type of food product has an influence on the presence/amount of biofilm. Listeria monocytogenes biofilms Bacillus biofilms (Krysinski et al., 1992) Hygienic design 107 DESIGN MACHINE ̶ Composition: Temperature: Plays a role in attachment and formation of biofilm High T° => ↑ adhesion of Bacillus spores High T° => amount of biofilm of L. monocytogenes [4°C (a), 12°C (b), 22°C (c), 37°C (d)]. (Krysinski et al., Hygienic design 1992) 108 DESIGN MACHINE ̶ Composition: Oxygen has an influence on the formation of biofilm. Absence of O2 => Sometimes inhibition of biofilm formation Campylobacter biofilm (strain dependent) No pronounced biofilm. (Krysinski et al., Hygienic design 1992) 109 DESIGN MACHINE ̶ Topography: kijken of een opp glad is of niet ̶ penetration depth in micro-slits Hygienic design 110  DESIGN MACHINE ̶ Topography: https://www.pfonline.com/articles/mastering-sanitary-stainless-steel-finishes Criteria for defining the surface roughness: a Ra, b Rz, Rt according to ISO 4287 What is the role of surface defects in bacteria entrapment and resistance to cleaning (release?) Hygienic design 111 DESIGN MACHINE ̶ Topography: What is the role of surface defects in bacteria entrapment and resistance to cleaning (release?) Hygienic design 112 DESIGN MACHINE ̶ Topography: Hygienic design 113 DESIGN MACHINE ̶ Topography: Hygienic design 114 DESIGN MACHINE ̶ Topography: ̶ arithmetic mean of roughness = mean of the absolute values of the differences between the profile and an average line of this profile. ̶ Surfaces with very different profiles can have the same Ra value, no information about the shape of unevenness. ̶ Ra does not provide any information about "hygienic character". Hygienic design 115 DESIGN MACHINE ̶ Topography: ̶ Rz = maximum profile height = distance between the projection line and the line of the valleys ̶ No information on the shape of the irregularities ̶ Rz does not provide information about "hygienic character". Hygienic design 116 DESIGN MACHINE ̶ Topography: ̶ Parameters derived from the Abbot-Firestone curve (lift) ̶ Rpk (Reduced Peak Height) ̶ Rvk (Reduced Valley Depth) ̶ Mr1, Mr2... => Better description of the topography (shape of peaks and valleys) => More relevant parameters Hygienic design 117 DESIGN MACHINE ̶ Physico-chemical properties: ̶ Roll on the cleaning resistance of adherent spores/biofilms ̶ Stronger spore/material interactions on hydrophobic materials ̶ Structure of the biofilm influenced by physico-chemistry => role on detachment? Many inconsistent results in the literature Different parameters work together? Role of biofilm structure / surface heterogeneity? C. freundii op SS (links) en Téflon (rechts) Hygienic design 118 DESIGN MACHINE ̶ Finishing: ̶ Food and Detergents - Hygienic Roll ̶ Modification of physicochemical properties – Stabilisation after 15-20 fouling cycli ̶ Consequences for the hygienic condition (adhesion of spores) Stainless steel treated with milk and alkaline detergent (RBS) Hygienic design 119 => Importance of the industrial sector + hygiene procedures DESIGN MACHINE ̶ Interface air-liquid : ̶ Presence on the surface of tanks, containers, reservoirs, wash tanks... – In the medical world – In the food industry Hygienic design 120 DESIGN MACHINE ̶ Interface air-liquid : ̶ Presence in case of drainage problems – Tanks – Low-point – Low-point leidingen, reducties pipes, reductions – Dead arms Hygienic design 121 DESIGN MACHINE ̶ Interface air-liquid : ̶ Avoids accumulation of water/product ̶ Self-draining (without dismantling) Hygienic design 122 DESIGN MACHINE ̶ Interface air-liquid : ̶ Effect of flow on dead spaces Hygienic design 123  DESIGN MACHINE ̶ Interface air-liquid : ̶ Experimental demonstration of the role of interfaces on surface contamination – Bacillus – On PVC & stainless steel – Salmonella enteritidis on stainless steel, 20°C  Coupon with half submerged  Coupon fully submerged Hygienic design 124 DESIGN MACHINE ̶ Interface air-liquid : Preferred area for biofilm formation – Interface: dense biofilm, large dense cell clusters – submerged surface: alternating zones of low contamination and biofilms – Splash zone (above the interface): isolated cells, small clusters Hygienic design 125 DESIGN MACHINE ̶ Interface air-liquid: ̶ Removing biofilms (rinsing = mechanical) ̶ Biofilms at the interface: one of the most resistant biofilms to mechanical detachment Hygienic design 126 DESIGN MACHINE ̶ Splashes and aerosols : ̶ During production ̶ Washing salads (air injection) ̶ Ventilation systems and evaporators  Example: contamination of poultry carcasses in evisceration farms. Using HEPA-filtered air =>Infection rate (total aerobic) decreased by 68-fold on surfaces (Burfoot et al., 2007) ̶ Production during cleaning ̶ High pressure cleaning  Example: cleaning siphons ̶ Boot Washer... Hygienic design 127 DESIGN MACHINE ̶ Splashes and aerosols : ̶ The role of the material on ease of cleaning ̶ Resistance to rinsing => Highly resistant deposits (detachment) on all materials. ̶ Resistance to cleaning => very resistant deposits, except on glass, hydrophilic Detachment of dried droplets strongly influenced by physicochemical properties Hygienic design 128 DESIGN MACHINE ̶ Splashes and aerosols: ̶ The role of drying time on ease of cleaning ̶ Spores/material interaction force (1 hour / 24 hours drying time) 24 hours >> 1 hour An extension of the drying time enhances the interactions between traces and materials. Hygienic design 129 DESIGN MACHINE ̶ Avoid accumulation of dust / water (condensate) / product ̶ No horizontal surfaces ̶ No ledges ̶ No empty spaces ̶ No dead spaces Dead space Hygienic design 130 DESIGN MACHINE ̶ Avoid accumulation of dust / water (condensate) / product ̶ No dead spaces Hygienic design 131 DESIGN MACHINE ̶ Avoid accumulation of dust / water (condensate) / product ̶ No splits Food Safety Magazine ̶ No metal/metal Hygienic design 132 DESIGN MACHINE ̶ Avoid accumulation of dust / water (condensate) / product 3-a,org Hygienic design 133 DESIGN MACHINE ̶ Avoid accumulation of dust / water (condensate) / product ̶ No splits ̶ Sharp angles ̶ Dead spaces Food Safety Magazine Hygienic design 134 DESIGN MACHINE ̶ Avoid accumulation of dust / water (condensate) / product 3-a,org Hygienic design 135 DESIGN MACHINE ̶ Avoid accumulation of dust / water (condensate) / product ̶ Install hygienically designed agitators, free from voids, sharp corners, crevices, threads, etc Hygienic design 136 DESIGN MACHINE ̶ Castor wheels Hygienic design 137 DESIGN MACHINE ̶ Control buttons ̶ Avoid dead spaces Hygienic risk Hygienic design 138 INSTALLATION AND INTEGRATION ̶ Avoid corners and misalignment Hygienic design 139 INSTALLATION AND INTEGRATION ̶ Avoid corners and misalignment Hygienic design 140 INSTALLATION AND INTEGRATION ̶ Avoid corners and misalignment Hygienic design 141 INSTALLATION AND INTEGRATION ̶ Space around the process equipment must be sufficient for proper cleaning. ̶ Also avoid creating hidden spaces for insects and rodents ̶ Unless mounted such that dust and other foreign matter cannot enter, overhead utilities (lighting, piping and ducts) should be avoided. ̶ Machines should not be positioned over drains if, in doing so, access for inspection and cleaning of the drains is restricted. ̶ Services such as air (gases), water, electricity need to be connected ensuring hygiene of the equipment and area ̶ The exterior of non-product contact surfaces should be arranged to prevent harbouring of contamination in, and on, the equipment itself! Hygienic design 142 INSTALLATION AND INTEGRATION ̶ supporting structures must be applied without any holes to the floor / wall / ceiling https://doi.org/10.1016/B978-0-12-820013-1.00014-0 Hygienic design 143 INSTALLATION AND INTEGRATION ̶ Installation of sensors ̶ Avoid dead spaces Hygienic design 144 DESIGN MACHINE ̶ Conveyor belts ̶ All surfaces must be accessible for cleaning. ̶ Avoids cross-contamination https://www.behabelt.com/en/conveyor_belts/ Hygienic design 145 DESIGN MACHINE ̶ General rules when designing a machine : ̶ The equipment must be designed for easy cleaning and must be free from crevices, grooves, uneven or rough surfaces and similar obstructions in areas where cleaning is difficult or impossible. ̶ Hinges must be removable for cleaning and inspection ̶ The structure should be designed with no hidden areas or blind spots where water, detergents or dirt can collect and accumulate ̶ All horizontal surfaces must be kept to an absolute minimum and must have a slope of five degrees to allow water to drain off ̶ The equipment should be as open as possible. Hygienic design 146 DESIGN MACHINE ̶ General rules when designing a machine such as conveyor belts : ̶ Building materials apply to the European regulations on materials in contact with food (EC 1935/2004) and to the national regulations. Therefore, the materials used in conveying systems must be non-toxic and non-absorbent. They should not adulterate the food by adding harmful substances to it, nor affect its organoleptic properties. It is clear that food contact materials should not contain lead, arsenic, cadmium or mercury which could leach into the food. Hygienic design 147 DESIGN MACHINE ̶ General rules when designing a machine such as conveyor belts : ̶ Stainless steel generally offers excellent corrosion resistance and is therefore widely used in the food industry. The range of stainless steels available is extensive, but the choice of the most suitable grade depends on the conditions of the intended use, the stresses to which the steel will be exposed and the limitations of machinability, formability, weldability, hardness and cost. ̶ Aluminum is generally not sufficiently resistant to corrosion and should be avoided in contact with foodstuffs, especially in wet cleaning procedures. Likewise, galvanized substrates are not recommended. If nickel-plated or chrome-plated equipment is used, the plating must be reliably manufactured and its integrity checked regularly to ensure that it does not flake and contaminate the product. ̶ Plastic materials can be used to avoid metal-to-metal contact (e.g. for bearing surfaces), as guides and covers, or for hoses because of their flexibility and corrosion resistance, but it should be noted that some plastics are porous and can absorb product components and harbor micro-organisms. ̶ Rubber materials and other elastomers commonly used for gaskets, seals and scrapers can be damaged by excessive mechanical or thermal compression or by severe deformation, and this can affect their cleanability. ̶ The use of many traditional materials (such as wood) in conveyor belts should be limited and in all cases considered a hygiene risk. Hygienic design 148 DESIGN MACHINE ̶ General rules when designing a machine such as conveyor belts : ̶ The EHEDG guideline states on the construction of fabric conveyor belts: ‒ Fabric conveyor belts usually have one or two fabric inserts with a variety of thermoplastic or rubber covers on both sides ‒ The belt material must be 'food approved' according to local legislation ‒ The most common colors available are blue and white. Blue is preferred in the food industry today as it does not occur naturally in foods and can be easily detected as contaminant ‒ For hygienic reasons it is important to keep the fabric embedded and not to expose it to dirt. Edge fraying should be avoided by sealing the edges or by using specially designed 'non-fraying' or knitted conveyor belts ‒ Fabric conveyor belts can be made endless by welding or mechanical joining methods. The latter allows for easier disassembly, but can be a trap for germs and bacteria ‒ Fabric conveyor accessories, such as cleats, are usually extruded and welded/glued to the belt surface. This must be done without creating crevices ‒ To track the belt, one (often the drive pulley) or several tapered or crowned pulleys are used. Alternatively, belt traction can be done with a fitted guide strip welded to the belt tread ‒ In order to properly follow curved conveyors, the belts of the conveyor belts are provided with guides such as welded profiles at the rear. Hygienic design 149 DESIGN MACHINE ̶ General rules when designing a machine such as conveyor belts: ̶ The EHEDG guideline states on the cleanability of fabric conveyor belts: ‒ Cleaning can be done manually or by Cleaning-In-Place. In general, the surface is homogeneous and smooth and therefore easy to clean. To exclude porosity, the tire must have sealed and tight surfaces ‒ Any damage to the belt (e.g. fraying of the edges, cuts in the surface) can prevent proper cleaning, resulting in poor hygiene. To avoid belt damage due to chemical degradation, the chemical resistance of the respective synthetic belt materials should be taken into account ‒ To clean the bottomside of the belt, the design of the conveyor belt must allow the initial belt tension to be released so that the belt can be removed or lifted ‒ In cases where the belt is supported by a flat plate, full accessibility for cleaning the underside requires an easy method to remove the belt ‒ Since mechanical connections can become a trap for microorganisms, they must be fully opened and thoroughly cleaned. Hygienic design 150 DESIGN MACHINE ̶ General rules when designing a machine such as conveyor belts: ̶ About the service and maintenance of fabric conveyor belts is stated in the EHEDG guideline: ‒ All belt surfaces should be checked regularly for damage - for example, worn top coating, frayed edges, cuts and crevices and dirt build-up. Particular care is required in complex structures with welded flights, guides and sidewalls ‒ The belts, the conveyor frame and the sliding bed should be checked regularly for accumulated dirt and damage ‒ Correct belt tension must be applied to avoid slipping on the drive drum during operation. To this end, the tensioning device must be intact and fully functional ‒ All rotating conveyor components (drive, tension, head and tail sheaves, idlers, carrier rollers, etc.) should be checked regularly to ensure they are clean and proper working. Hygienic design 151 CHECK THESE VIDEOS!!! Hygienic design 152 153 https://www.youtube.com/watch?v=DHeh2cmtFSY 154 REFERENCES ̶ ASIFOOD; Asian Institute of Technology, Thailand ̶ Burggraaf & Partners ̶ www.EHEDG.org (Doc 29 & 46) ̶ Moerman, F. and Kastelein, J. (2014) Chapter 26 – Hygienic Design and Maintenance of Equipment, Food Safety Management, A practical Guide for the Food Industry, 673-739. ̶ Moerman, F. (2011) 19 – Hygienic supply of electricity in food factories, Hygienic Design of Food factories, Woodhead Publishing Series in Food Science, Technology and Nutrition, 369-411. ̶ Moerman, F. (2011) – Hygienic design of lighting in food factories, Hygienic Design of Food factories, Woodhead Publishing Series in Food Science, Technology and Nutrition, 412-470. ̶ PhD Tessa Tuytschaever (i.f.v. Interreg FWVl VEG-i-TEC) ̶ Hamed et al. (2019) Milling parameters of Al-Cu and Al-Si cast alloys. The International Journal of Advanced Manufacturing Technology, (104) 3731-3743. ̶ Christine Faille, INRAe ̶ FAO, Design and Facilities, 2016. ̶ Davies, S., Sykes, T., Philips, M., Hannock, J. (2015) Chapter 10 Hygienic design and Cleaning-In-Place (CIP) systems in breweries. Brewing Microbiology, Managing Microbes, Ensuring Quality and Valorising Waste, Woodhead Publishing Series in Food Science, Technology and Nutrition ̶ Lelieveld, Mostert & Curiel (2014) 4- Hygienic design of food processing equipment; Hygiene in Food Processing, Principles and Practice, Woodhead Pulbishing Series in Food Science, Technology and Nutrition; P91-141. ̶ Schmidt, R.H., Piotter, H.M. (2020). The Hygienic/Sanitary Design of Food and Beverage Processing Equipment. In: Demirci, A., Feng, H., Krishnamurthy, K. (eds) Food Safety Engineering. Food Engineering Series. Springer, Cham. https://doi.org/10.1007/978-3-030-42660-6_12 Hygienic design 155