graintec · hygienic design & sanitary guidelines graintec ... the construction layout should...
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Hygienic Design & Sanitary Guidelines
GRAINTEC
GRAINTEC
GRAINTEC
What is cross contamination?Cross contamination occurs when feed becomes contaminated during processing by an unwanted bacteria, animal bi-product, medicine, allergens or similar. This happens either by direct or indirect contact with another feed/food, which is already contaminated.
What are the sources of cross contamination? - Residual feed from incomplete emptying of bins and hoppers including bridging and hang-ups - Residual feed in feed mixers: Ribbon mixer with liquid addition represents the biggest risk- Residual feed in bucket elevator foots- Leaking mixer gates and other gates and outlet slides- Delayed return of dust to production line (central dust aspiration filters, hammer mill filters etc.)- Various dust emissions including dust adhesions inside conveying equipment, bins and hoppers
A zone-division of the facility is the first move in making a plant design hygienic.
In order to minimize the risk of bringing contaminated matter from unclean zones (raw material zones) to the clean zones (finished product zones) precautions must be made.
Contaminated matter can be airborne, but also carried by machinery and personnel!
ExtrusionMash meal
handling
Raw Material Receiving
GrindingPackagingStorage
ProductStorageDryingAirlock AirlockCooling
Air flow from clean to unclean
How to keep clean zones clean: - Optimize production flow- Focus on zoning- Ensure correct airflow- Traffic flow
What to do?
Ensure feed safety throughout the factory layout
Focus on the areas of the plant where hygienic design and sanitary measures are crucial
Have a close look at the current factory design
EncobingCoating
GRAINTECAll machines must be manufactured with special consideration for feed production, which often is regulated by law or directives. It is important to be able to trust that the machines do not hold residues from the production, which can be transferred to the food or feed.
Silo mass flow is necessary to ensure the principle in silo filling and emptying ”first in – first out”. The principle guarantees the storage time of theraw material to be identical and limit the risk of bacterial growth in remaining old residues of raw material stuck inside the silo. The conveying systems shall be able to be completely empty to prevent cross contamination between transportation of different raw material – also to avoid accumulation of remaining material. Liquids, which generally are added after heat treatments, entail special focus to the hygienic design to ensure bacteria free finished products.
Construction details in your design
- Design of floors, walls, ceilings- Sanitary design of drain and sewage systems- Design against intrusion from birds, rats, or other vermins
The construction layout should complement the zoning of the facility with special focus on the clean zones. Choice of material is crucial in order for easy cleaning.
GRAINTEC has knowledge on bacteria growth hazards – including the encouraging conditions for salmonella, whose prospects can be reduced significantly already in the design layout and the choice of technology.
Focus on process equipment details:
- Machine construction details- Silo design- Conveying equipment- Liquid systems
Which conditions encourage the growth of salmonella?
In dry ingredients:-Moisture between 20 – 30 %-Temperature between +7 to 46 °C// +44.6 to 114.8 °F -PH value above 4
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Carry-over and cross contamination -Mixer residues Adjust ribbons or paddles Install plastic “wipers” on ribbons Install air sweep jets for cleaning - remodel discharge for more complete cleanout Ad additives when mixer is 1/2 to 3/4 full
-Bin and conveyor residues Adjust for more complete cleanout Remodel bin or discharge hoopers
-Elevator residues Adjust bucket clearance in boot (if possible) Install air sweep jets Remodel boot for more complete cleanout
-Dust controlSelect the appropriate bins, conveyers, elevators and mixers. Equipment that ensures a minimum escape of dust
The equipment must be carefully chosen to avoid the risk of carry-over and cross contamination.
GRAINTEC - more than a standard EPC company GRAINTEC is an engineering company with more than 30 years of experience, and solemnly dedicated to the aqua feed and pet food industry. Our main expertise is engineering, contracting and project management (EPC). We plan, design and manage the building of production facilities. We are your partner when it comes to energy recovery and environmental improvement and we innovate hygienic design.
GRAINTEC is a knowledge-based company providing each facility the appropriate, tailored solution. We are not an equipment manufacturer and are therefore independent from machine suppliers, but maintain a close cooperation with these in order to ensure the right technology for each distinct solution.
Our knowledge of hygienic and sanitary design enables us to be your competent partner when meeting the increasing demand for feed and food producing factories to comply with strict hygiene regulations.
Europe Graintec A/S40 EnghavevejDK-7100 Vejle, DenmarkPhone: +45 76 436 910Telefax: +45 76 436 943Mail: [email protected]
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GRAINTEC
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Latin America Graintec Chile Ltda.Lincoyan 282 Piso 6.Concepción, ChilePhone: +56 412 910 515Telefax: +56 412 910 512Mail: [email protected]
North America Graintec, IncOne Main Plaza4435 Main Street, Suite 504Kansas City, MO 64111United StatesPhone: (+1) 816-621-3000Mail: [email protected]
Asia Graintec China Ltd.Room 402, Tower BMing Gu Technology Park, Minhand DistrictShanghai 201101, ChinaPhone: +86 139 18 52 42 39Mail: [email protected]
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