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Wisconsin Association for Food ProtectionJune 11, 2014

Food Safety Practices for HVAC and Refrigeration Systems

Gregg Galbreath Industry Technical Consultant, HVAC Performance ServicesNalco, an Ecolab Company

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Wisconsin Association for Food ProtectionJune 11, 2014

PURPOSE

Define Areas of ImpactChallenges & Root CauseBest Practice SolutionImpact in Your OperationQuestions

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Wisconsin Association for Food ProtectionJune 11, 2014

Critical Parameters for Food Protection in HVAC & Refrigeration

Temperature

Relative Humidity

Airborne contamination

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Wisconsin Association for Food ProtectionJune 11, 2014

Facilities

Food processing facilities

Food storage & distribution facilities

Retail facilities

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Wisconsin Association for Food ProtectionJune 11, 2014

AREAS IMPACTEDFood Processing

Roof Top Unit

Hanging Evaporator

Freezers

Ductwork

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Wisconsin Association for Food ProtectionJune 11, 2014

CHALLENGESFood Processing

Temperature control Different set point in each area Process areas Packaging areas Warehouse areas Shipping areas

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Wisconsin Association for Food ProtectionJune 11, 2014

CHALLENGESFood Processing

Humidity Control Condensate dripping onto product

Increases microbiological growth

Interferes with productiono Labelingo Dry product processingo Product mobility system

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Wisconsin Association for Food ProtectionJune 11, 2014

CHALLENGESFood Processing

Airborne contamination Microbiological contamination

o Ductworko Facility surfaces

Particle contaminationo Microbiological food sourceo Heat transfer contaminant

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Wisconsin Association for Food ProtectionJune 11, 2014

AREAS IMPACTEDFood Storage & Distribution

Freezers

Roof Top Unit

Hanging Evaporator

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Wisconsin Association for Food ProtectionJune 11, 2014

CHALLENGESFood Storage & Distribution

Temperature control Different set point in each area Warehouse areas Shipping areas

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Wisconsin Association for Food ProtectionJune 11, 2014

CHALLENGESFood Storage & Distribution

Humidity Control Condensate dripping onto product

Damaging cardboard boxes

Safety from wet floors

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Wisconsin Association for Food ProtectionJune 11, 2014

CHALLENGESFood Storage & Distribution

Airborne contamination Particle contamination

o Heat transfer contaminant

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Wisconsin Association for Food ProtectionJune 11, 2014

AREAS IMPACTEDRetail

Freezers

Coolers

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Wisconsin Association for Food ProtectionJune 11, 2014

CHALLENGESRetail

Temperature control Maintaining set point in each area

Energy use increases

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Wisconsin Association for Food ProtectionJune 11, 2014

ROOT CAUSESProcessing, Warehousing, Distribution, Retail

Insufficient coil maintenance program Cleaning practices Cleaning frequencies

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Wisconsin Association for Food ProtectionJune 11, 2014

ROOT CAUSESCleaning Practices & Frequencies:

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Wisconsin Association for Food ProtectionJune 11, 2014

ROOT CAUSESCleaning Practices & Frequencies:

Current cleaning practices are not sufficient to keep the evaporators clean

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Wisconsin Association for Food ProtectionJune 11, 2014

ROOT CAUSESProcessing, Warehousing, Distribution, Retail

Inadequate air filtration program Filter efficiency Change-out frequency

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Wisconsin Association for Food ProtectionJune 11, 2014

ROOT CAUSESProcessing, Warehousing, Distribution, Retail

By-pass

MERV 8 & 3 month life

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Wisconsin Association for Food ProtectionJune 11, 2014

ROOT CAUSESProcessing, Warehousing, Distribution, Retail

Inadequate air filtration program Manpower

requirements

Increased costs

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Wisconsin Association for Food ProtectionJune 11, 2014

ROOT CAUSESProcessing, Warehousing, Distribution

Deficient duct cleaning program Poor cleaning process Frequency

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Wisconsin Association for Food ProtectionJune 11, 2014

BEST PRACTICE SOLUTION

Design a program that Meets the indoor environment standards Supports the maintenance needs of the facility Optimizes efficiency, saving energy

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Wisconsin Association for Food ProtectionJune 11, 2014

BEST PRACTICE APPROACH TO HVAC/REFRIGERATION EFFICIENCY

Restore efficiency of coils

Keep coils clean to promote safe food environment and maintain efficiency

Measure improvement gains

Deep clean coils with effective cleaning process

Use state-of-the art air filtration

Benchmark and manage safety and performance protocols

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Wisconsin Association for Food ProtectionJune 11, 2014

PROGRAM DESIGN

Coil cleaning process

Air filtration

Duct cleaning program

Monitoring improvements

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Wisconsin Association for Food ProtectionJune 11, 2014

DEEP CLEANING PROCESSRecover Coil Heat Transfer Performance

Complete Penetration

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Wisconsin Association for Food ProtectionJune 11, 2014

FIND A CLEANING PROCESS Fully penetrates coil & removes soils

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Wisconsin Association for Food ProtectionJune 11, 2014

RESULTS

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Wisconsin Association for Food ProtectionJune 11, 2014

BEST PRACTICE FILTRATION APPROACH

Step 3:Engineer a

filter solution

Step 2:Identify end users improvement goals

Step 1: Understand- Customers system requirements- Mechanics of Refrigeration system- Operation of Refrigeration system- Performance of Refrigeration system

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Wisconsin Association for Food ProtectionJune 11, 2014

ENERGY REDUCTION& MANPOWER UTILIZATION

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Wisconsin Association for Food ProtectionJune 11, 2014

DUCT CLEANING PROGRAM

National Air Duct Cleaning Association (NADCA) cleaning standards National standard Methodical process to insure proper cleaning

NADCA certified crewsDesign program to meetyour specific need

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Wisconsin Association for Food ProtectionJune 11, 2014

MONITORING GOALSMeasure and document system improvements Coil cleaning and efficiency improvement impact Filter upgrade impact Duct cleaning impact

Manage food safety & performance life cycle with on-going monitoring

Predict optimum time to change filters, clean coils and clean ducts to protect food process

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Wisconsin Association for Food ProtectionJune 11, 2014

ENERGY MONITORING

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Wisconsin Association for Food ProtectionJune 11, 2014

BEST PRACTICE PROGRAM DELIVERS

Food Safety Prevents food contamination (from evaporators & ducts) Prevent condensate drips onto food Easier control of room temperatures

Total Cost of Operation Reduction Energy reduction Material reduction Asset reliability and preservation Manpower utilization Waste reduction

Sustainable Savings (on-going savings)

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Wisconsin Association for Food ProtectionJune 11, 2014

Questions?