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0/APV APV Baker

Hygienic Design Handbook

APV Baker World Engineering Standards

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Disclaimer The purpose of this handbook is to provide statements of principle and generic guidelines which may be of assistance in the design of hygienic and easily-cleaned equipment. It has been produced primarily for use by experienced engineers within APV Baker. While APV Baker trusts that this handbook may be of general application and assistance, it is neither intended nor designed to replace detailed engineering advice in any specific case. APV Baker would be happy to agree terms upon which such engineering advice could be provided. The reader should be aware that, while every effort has been made to ensure that it is so, this handbook may not be complete or accurate. The handbook may not be appropriate in all instances and may be subject to a number of differing interpretations. Any use which any reader makes of the information set out in this handbook is undertaken solely at the reader's risk and the reader may make no reliance upon APV Baker in so doing. All and any liability which APV Baker may have as a result of any act or omission undertaken based upon the information set out in this handbook is hereby expressly excluded, to the fullest extent permitted by law.

0/APV APV Baker - WES Hygienic Design Handbook - Second Edition - Revised Jan. 2001

Contents Disclaimer Introduction Acknowledgements Hygiene for profit Design specification Key principles for hygienic design Materials of construction Surface finish Support and frame structures Fabrication Mechanical fixings Covers and guards Transparent covers Conveyors Electrical installation Control panels Hinges Hardware - handles, knobs, latches and handwheels Ventilation Feet Castors Instruction and identity plates Motors, gearboxes and transmissions Seals and gaskets Platforms, ladders and handrails Tanks and containers Pipework installation Equipment siting Food scrap

0/APV APV Baker - WES Hygienic Design Handbook - Second Edition - Revised Jan. 2001

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Introduction Improved standards of hygiene are being demanded by food producers, retailers and legislation. This handbook gives practical guidance for the design of hygienic and easily cleaned equipment. It deals primarily with open processing where cleaning methods vary from dry wipe to high pressure washing. The principles are developed from: Research with APV Baker customers. APV Baker experience in a variety of food industry sectors. Food producers' hygiene specifications. Research establishment recommendations. Current legislation. The contents form part of APV Baker World Engineering Standards and wherever possible should be adhered to by APV Baker designers and external suppliers including sub-contractors.

Contributions are welcome and design advice is available from: Industrial Design APV Baker Manor Drive Paston Parkway Peterborough England PE4 7AP Tel. +44 (0)1733 283000 Fax. +44 (0)1733 283001

Second Edition - May 1996 - Revised January 2001 Copyright - APV Baker

0/APV APV Baker - WES Hygienic Design Handbook - Second Edition - Revised Jan. 2001

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Acknowledgements APV Baker Industrial Design would like to thank the following companies who contributed to the research for this handbook: Allied Bakeries British Bakeries Burtons Biscuits Cadbury Ltd Cadbury Schweppes Plc Cereal Partners UK Ltd Consolidated Biscuit Company De Vau Gesundkostwerk GmbH Elkes Biscuits Frito-Lay Inc Interbake Foods Jacobs The Kellogg's Company of Great Britain Ltd Leaf UK Ltd Mars UK M & M, Mars USA McVities Mrs Bairds Bakery Nabisco Biscuit Company Nestle Rowntree Northern Foods Pepperidge Farm Thorntons Plc Warburtons

0/APV APV Baker - WES Hygienic Design Handbook - Second Edition - Revised Jan. 2001

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Hygiene for profit Research confirms that hygiene is an increasingly important consideration in the design of equipment. This is because: Retailers are demanding improved quality from food producers. Food producers must be confident that their products will not be contaminated microbiologically, chemically or by foreign materials. Cleaning is expensive in terms of both plant downtime and labour. Operator empowerment and clean-as-you-go policies are gaining popularity.

Difficulties in cleaning are often encountered and hygiene policies compromised because: Access is inadequate. Materials of construction and finishes are incompatible with actual cleaning methods. Electrical equipment and services are inadequately considered. Plant and equipment design lacks detail thought. Methods of cleaning vary widely. Dry machines are often washed down.

Ultimately, our customers stand to lose production and market position through inadequate consideration of hygienic design.

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Design specification Hygienic design must eliminate all microbiological, chemical and foreign material hazards. Hygiene is not an optional extra nor an add-on feature. It can only be designed in. Hygienic design and cleaning must be considered throughout the design process, particularly during concept and detail stages. The proposed and likely methods and frequency of cleaning should be understood. Design must meet relevant hygiene standards including, BS EN 1672-2 "Food Processing Machinery; Hygiene Requirements". Also industry specific standards, both European and American eg. standards compiled by the 'Baking Industry Sanitation Standards Committee' of America - (BISSC). If FDA approval is required, seek further guidance. The Food Area The 'food area' can be defined as any area that touches, is near to, is above or below the path of food as it passes through the machine. The 'food area' may also be referred to as the 'product zone' or 'food zone'. The differing requirements of the 'food area' and the 'non-food area' should be considered.

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Key principles for hygienic design 1

Consider changing or refining the food process to make it as clean as possible.

2

Ensure containment of the food process within the designated food area.

3

Ensure any potential contamination is visible and accessible for cleaning.

Generally Provide adequate access for cleaning in and around equipment. Avoid dead spaces, crevices, joins and horizontal surfaces which may trap food, prevent effective cleaning and harbour contamination. Select materials and finishes to resist corrosion. Minimise obstructions to cleaning. Eliminate cleaning hazards eg. sharp corners, edges and protrusions. Insulation materials must be accessible for cleaning or sealed to prevent infestation or contamination. Be aware of relevant safety standards eg. BS EN 292-1 & 2 - Safety of Machinery; OSHA 1910.613 ANSI Z50.1 Safety and noise requirements are often in conflict with hygiene. Try to achieve a balanced solution.

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In the food area Construction materials should be inert to food and cleaning agents. Surfaces should be smooth and non-porous. Surfaces should be readily visible or easily dismantled for inspection. Surfaces should be accessible for manual cleaning, or clean-in-place techniques should give equivalent results. All surfaces should be self-draining or self-emptying in washdown situations. Food should be protected from external contamination.

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Materials of construction Many countries have codes of practice covering the composition of materials in contact with food. Ensure that materials are permitted under existing or pending legislation. Select materials to resist wear and corrosion. Select materials to avoid electrolytic or galvanic corrosion. Many materials are permitted but not suitable for all foods eg. aluminium, brass, bronze and copper. Generally stainless steel grades 304, 316 and 316L offer sufficient corrosion protection. 316 is preferred for food contact, due to improved corrosion resistance. Aluminium rubs-off-black and should be avoided, unless a protective coating is used. Cadmium, zinc, lead, antimony, bismuth, mercury and alloys containing these must not be used. Vitreous enamel, nickel plating and electro-chromium plating should not be used. Plastics and plastic coatings containing free phenol formaldehyde or plasticisers should not be used. Wood must not be used. Glass must not be used. Be aware that some clean-in-place solutions promote corrosion. Be aware that salt may be present in the process.

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Surface finish Self -finish surfaces are preferred wherever possible. Do not use paint on surfaces in or above the food area. All surfaces must be smooth to touch. Appearance quality, cost effectiveness and customer preference should be considered. Consistency of finish on unit machine components and throughout a plant should be considered. Blackodising or Parkerising should not be used. Surface measurement techniques are unreliable methods of determining cleanability. Stainless steel finishes Brushed or super satin (Opti-sheen)

Ideal for large surface areas as material is pre-finished. Difficult to blend and refinish after welding.

Bead blast

Ideal for small and intricate components. Can be used on larger components and fabrications but care is needed to avoid sheet metal distortion.

Orbital sand (DA-Dual Action)

Ideal for large sheet metal fabrications, especially in washdown situations as appearance is maintained, even after repeated cleaning.

Mild steel finishes Electroless Nickel Plate Generally used to finish components in or above the food area. Can be used on side frames, size permitting and is resistant to cleaning with scrapers. Paint

Use in non-food area where damage from cleaning and maintenance will not occur.

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Support and frame structures Maximise access for cleaning, in and around equipment. Minimise the number of legs, especially when considering total plant - can adjacent equipment share legs? Minimise overall plan area. Minimise the area in contact with the floor. Minimise frame support structure. Ground clearance should be no less than 200mm or equipment should be sealed to the floor. Seal hollow sections by welding. Plastic plugs should not be used. Do not penetrate tubular sections eg. with fasteners. When fastening to hollow sections give preference to welded plugs. Welded studs and tapping plates are not recommended. Rectangular hollow section and fabricated sections should be angled at 45o to eliminate horizontal surfaces in washdown situations or where they are likely to be contaminated or for visibility. Recommended stretcher options for washdown situations 45

o

Welded or bolted from behind

Angled

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3 Minimise frame support structure 2 Minimise number of legs 1 Maximise ground clearance

4 Minimise plan area 5 Minimise floor contact

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Fabrication Weld rather than bolt wherever possible. Welded joints in the food area must have the same characteristics as the surrounding materials ie. surface finish, appearance, quality, etc. Weld fillets in the food area should have a minimum radius of 6mm. If the material is less than 4mm thick the minimum radius should be 3mm. Internal corners should have a minimum radius of 6mm. All welds should be continuous or filled.

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Welded

Bolted

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Mechanical fixings Where possible eliminate mechanical fixings. Allow sufficient space around fixings for cleaning (minimum 25mm). Use stainless steel or dull-nickel plated fixings as specified in the fixings and fastenings handbook. Use blind holes in preference to through holes. Do not use plastic fixings where there is a risk of contamination, as they cannot be identified by metal detectors. Do not use socket head screws in the food area or in frequently cleaned areas. Avoid split pins, self-tapping screws, spring tension pins and pop-rivets. Use spring washers only where necessary. Avoid exposed thread and knurling. Avoid fixings smaller than M6. Avoid counterbores. Avoid slotted and countersunk screws with pockets that are difficult to clean. Be aware of customer preference.

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Not recom mended

Alternatives - Weld - Bond - Stud mount - Combine components

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Covers and guards Ensure gaps between covers are adequate for cleaning and that safety is not compromised. The recommended gap is 25mm. Avoid panel joins in horizontal surfaces and provide overlap where possible. Avoid surfaces which allow liquid to stand. Minimum draining angle should be 5o Avoid covers and guards which must be totally removed for cleaning. They will be damaged or not replaced. Sliding covers are non-preferred. Avoid internal trays which are difficult to clean. Eliminate upturned flanges particularly on doors.

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Back 25mm

5 o Minimum

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Transparent covers Select appropriate material for the task. Consider impact strength and rigidity for shatter resistance. Acrylic (eg. Perspex) should be at least 12mm thick and Polycarbonate (eg. Makrolon and Lexan) should be at least 5mm thick. Ensure compatibility with cleaning agents. If clear material is required, ensure clarity is maintained over the life of the machine. Follow manufacturers guidelines for manufacture and assembly. Polycarbonate is especially prone to cracking, allow for high expansion rate. Avoid using clear plastic covers where flour or oil are present. Avoid using clear plastic covers if frequent removal is required. Avoid using Expamet and woven weld mesh, except for the underside of machines and perimeter guarding. Be aware of safety legislation, especially BS EN 294 Safety of Machinery - Safety distances to prevent danger zones being reached by the upper limbs. Be aware of customer preference. Each guarding application must be judged on its own merits seek Industrial Design advice.

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Clear guard materials Bar hinge

Bonded 3M VHB doublesided adhesive tape

Frame

Space and mount from one surface only

Open designs Bar guards

Punched

Weld mesh

40/50% open area - max

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Conveyors Minimise the number of rollers (especially those in contact with food surfaces). Rollers should have flush sealed ends. Conveyor belts should be readily slackened allowing them to be raised for cleaning. Belts should be a food approved material, non-toxic and non-absorbent. Cantilevered rollers allow belts to be removed quickly and easily. Return side of conveyor belts should not be allowed to run through or over contaminated material build up. Component removal for cleaning may be necessary, preferably without tools. Avoid webbed or spoked pulleys. Bearings should be outside the food area and should be sealed or self-lubricating. Use food approved lubricants in the food area.

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Access for cleaning Cantilevered rollers for easy and fast belt removal

Lift -out rollers

Belt too close to structure

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Electrical installation Consider electrical installation early in the design process - aim to design-in trunking, connection boxes, etc. Electrical boxes should be spaced away from mounting surfaces larger boxes require greater clearance. Position trunking away from surfaces. Mount trunking with lids on the side. Services should enter equipment at high level, preferably on a vertical face. Use of structural hollow section for wiring normally reduces component count and improves cleanability but must have internal conduit and effective sealing. Avoid using sealant. Avoid using ribbed flexible conduit. Trailing conduit in contact with the floor must be avoided. Light bulbs, lamps and tubes must be shatter resistant or protected. Be aware of IP ratings and NEMA standards. Be aware of customer preference. Be aware of EMC requirements.

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High level entry on vertical face

Adequate space for cleaning

Spaced

Lids on side Smooth

Ribbed

Sealed

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Control panels Position away from the food area. Position so that the operator does not have to lean over the food area. Use membrane panels when possible as they are inherently clean. If a push button panel is necessary, select easily cleaned components. Arrange components with space for easy cleaning. Position any running adjustments, so that operators do not have to touch food contact surfaces. Be aware of ergonomic requirements. Be aware of IP ratings and NEMA standards. Be aware of customer preference.

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Panel on operator side

Membrane panel

Push button panel

Adequate space

Clean detail

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Hinges Use as few hinges as possible. Use hinges with the least number of parts. Internal hinges are preferred for an easily cleanable exterior. Hinges should have removable hinge pins or be lift-off. Do not use continuous (piano) hinges.

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Concealed - with or without Emka seal

Emka hinge part no.1031-U2 S/Steel Emka seal part no.1011-15

+ Machine looks clean + Stainless steel + Removeable door + Cheap + Worldwide availability - Limited opening

Block

Pin

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Hardware - handles, knobs, latches and handwheels Ensure all components are durable and will not corrode. Ensure that moulded parts, especially handles and handwheels, have no hidden crevices. Be aware of ergonomic requirements. The components illustrated represent the best currently available. Please inform Industrial Design of alternatives.

Recommended components Preference should be given to silver finished components. Natural aluminum should have a protective finish. Handles

Berger U-handle GN 565 100/160mm

Elesa/Ganter - lever handle GN 300 & 300.1

BL - bright tumble finish

Black epoxy resin coated. Grey available on request for sufficient quantities

Elesa VC.192 & 192p VC.192s & 192s-p

Elesa/Ganter GN 5336

Black Duroplast plastic

Natural aluminum

Knobs

Latches

Southco International vise action

Mechanical Electrical Knob style T -Handle with -hexagonal -triangular or without keylock All available in satin silver polyester powder coated finish except for the knob style

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Back Handwheels

Selection criteria - Diameter appropriate to the force required - Integral spinner for several revolutions/foldaway - Preference for female fitting - Material, finish and quality appropriate to machine and market - Worldwide availability

Non-indicator type

Elesa VRTP & VDS without handle VRTP+I & VDS+I with handle VRTP+IR & VDS+IR foldaway handle

Elesa/Ganter GN321 -solid GN322 -spoked with or without handle/fixed or foldaway

Matt black plastic

Aluminum

Clayton/Elesa - digital position indicators for use with non-indicator type handwheels

Indicator type

Clayton/Elesa VRTP, VAD & VDC without handle VRTP+I, VAD+I & VDC+I with handle

Siko HK, HKL, HS &HSL

Matt black plastic and black oxide steel

Aluminum

When small diameter indicator handwheels are appropriate for fewer revolutions, consider the use of Elesa VHT (black) and Siko HST and HST7 (silver/aluminum finish)

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Ventilation Slots are the preferred solution when a filter is not required. When a filter is required, Rittal is the preferred supplier. Ventilation should be in a vertical or near vertical surface. A baffle may be required to prevent tool access and deflect water away from internal components. Be aware of IP ratings and NEMA standards.

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Baffle

Cleaning space

Rittal filter

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Feet Ensure feet do not create dirt traps. Ensure feet are self -draining. Threads should not be exposed. Feet should be corrosion resistant. Provide feet with fixing holes only if fastening to the floor is necessary. Provide an adequate range of adjustment. Be aware of industry standards and customer preference eg. ball foot is a dairy standard.

The components illustrated represent the best currently available. Please inform Industrial Design of alternatives.

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Robo by Marbett International BV UK distributor, Oadby Plastics Current dry food standard

Ball foot Wet industry standard

Acceptable only if grouted in

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Castors Castors should not be used in the food area. All materials should be corrosion resistant, self -finish or dull-nickel plated. Paint must not be used. Axle bolt ends should be flush and should not extend more than two-and-a-half exposed threads beyond the retaining nut. Washers should not be used between the horn and the axle retaining nut. Cotter pins and castellated nuts should not be used on the axle. The wheels should have minimum clearance of 6mm all round. Plate mountings and forks should be flat and free from crevices. Wheels should have solid and flat webs. The included angles between all surfaces should have a minimum radius of 6mm. Brakes and locking devices should comply with the requirements above. Be aware of BISSC standard.

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6mm all round clearance

Flat plate mountings

Solid flat webs

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Instruction and identity plates If possible apply the graphic directly to the component, eliminating the need for a separate plate. If direct application is not possible, bond plate to component to avoid mechanical fastening. Graphic should be smooth eg. screen printed, engraved and filled flush or 'metalphoto'. Plates should have corner radii. Do not use laminated engraved plastic eg. Trafolite. Self-adhesive decals are appropriate for large graphics eg. APV logotypes. Ensure material specification is 3M Scotchcal or equivalent. Be aware of the need for good graphic design and legibility. Consult Industrial Design.

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Motors, gearboxes and transmissions Select easily cleanable motors. Direct drive, flange or shaft mounted units are preferred. Slide rails and screw adjusters are inherently difficult to clean. Position motors, gearboxes and transmissions outside the food area. Do not mount directly above or below the food area. Ensure food is not contaminated by chain or timing belt wear, etc. Avoid using chains whenever possible. Cover where necessary. A minimum of 50mm clearance should be provided. Provide good access to gearbox drain and fill plugs. Ensure drip trays are visible, accessible, cleanable, drainable and large enough.

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Flange mounted with timing belt drive

Slide mounted with chain drive

Open

Cover, leaving access for maintenance and cleaning

Mount drives externally away from the food area

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Seals and gaskets Avoid using seals, gaskets and O-rings. When seals, gaskets or O-rings have to be used they should be impregnated for metal detection and non-toxic. Design and position gaskets, seals and O-rings so they do not create crevices. Be aware of industry standards when using O-rings. Exposed gasket edges must be minimised, trimmed and smooth. Do not use liquid sealant, mastic or caulking in the food area. Do not use liquid sealant on external surfaces. If liquid sealant is necessary it must be food approved. Ensure foam seals are closed cell. Be aware of customer preference.

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Door seals

Preferred Emka seal/IP 65 rating

Rubber or closed cellular foams

Window retaining seals

3M VHB double sided adhesive tape

Not recommended

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Platforms, ladders and handrails Provide handrails. Ladder rungs should not be used as handholds. Handrailing systems should have smooth junctions. Handrails should be stainless steel. Minimise the floor contact area. Provide generous radii in corners of kickplates. Ensure non-slip surfaces on platforms and stairs. Prevent debris from falling onto food or equipment. Do not use open grating for platforms and stairs. Be aware of ergonomic requirements and safety legislation.

Non-slip surfaces Step profiles

Minimal floor contact

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200 mm

Safety cage may be required depending on height of ladder

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Tanks and containers Ensure tank base design allows free draining of contents and cleaning solution. Arrange tank inlets to minimise splashing and foaming. Ensure tank lids, hinges, handles, etc. are cleanable. Internal tank corners should have generous radii. Ensure tanks, pumps and motors have adequate ground clearance. Position pumps and motors away from tanks. Dead ends should be avoided. Be aware of industry standards.

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Tank flanges

Not recommended

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Pipework installation Position pipes away from surfaces by at least their flange diameter. Allow space between pipes at least equal to the pipe or flange diameter, which ever the larger, but never less than 25mm. Pipes should hang rather than be supported above horizontal surfaces. Allow 2500mm headroom to underside of pipe runs. Allow 300mm between pipe runs and ceiling. Pipes and hangers should have the minimum of exposed thread. Liquid ingredient pipes, valves and fittings should be take-apart type, unless designed for clean-in-place. All pipes and equipment should be self -draining to avoid liquid retention ie. pitch pipework and provide drain valves, etc. Pipework which may produce condensation, should not be positioned above the food area nor above equipment.

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100mm 300mm

50mm

2500mm 100mm 100mm

100mm

100mm

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Equipment siting Site equipment so that it can be easily cleaned. Allow free access of at least 1000mm all round. Be aware of site limitations - building constraints, existing plant, etc. Avoid soil trapping ledges over the food area. Be aware of BISSC installation guidelines.

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1000mm. minimum

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Food scrap Minimise scrap production. Design to allow scrap to drop through the machine onto the floor and/or into trays. Ensure scrap trays are visible. Ensure scrap trays are adequately sized bearing in mind frequency of emptying and weight to be carried when full. Consider the use of dual scrap trays for containment of scrap by one tray whilst emptying the other. Ensure safety is not compromised when scrap trays are removed. Be aware of customer preference.

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On machine

Floor tray

Wheeled tubs

0/APV APV Baker - WES Hygienic Design Handbook - Second Edition - Revised Jan. 2001

0/APV APV Baker World Engineering Standards