Every food processor has their own unique food safety challenges. Here is one
process room scenario where attention to process layout, equipment modifications and
training can significantly reduce foreign material contamination.
- Operator Training High-volume automation brings a
high degree of risk for machinery fatigue and vibration. Over time, nuts and bolts will
loosen and moving components that become misaligned can produce loose metal. In addition,
the equipment operator must completely understand how every facet of the equipment works,
including the symptoms when it isn’t running properly.
- Seal Maintenance Many causes of downstream food
contamination are the result of a broken seal, improper packing or a grooved or broken shaft. COP
(clean-out-of-place) split seals should be checked for wear and sanitized daily. Seals
should be part of the preventative maintenance program and included in your parts
- Pallet Retention System (PRS) The PRS
is integrated into the loading base of select pallet dumper equipment. It is engineered to
securely remove the pallet away from the dump zone so that wood, nails, and other impurities
are prevented from entering the product stream.
- Liner Hold Down Another option on pallet dumper
equipment is the liner hold-down mechanism which is engineered to hold back the liner during
the dumping process. The liner hold-down prevents the plastic from entering the food zone
and prevents the operators from having to lean or reach over the food zone to control the
- Electropolished Food Contact
Finishes Processors often choose electropolished food contact surfaces on equipment which
provide the smoothest surfaces for ease of sanitation, and provide the highest level of
corrosion resistance, including the performance of weldments.
- Open-frame Construction Open-design framework with
butt weld type, ground to a smooth finish provides superior sanitation performance. Bolt
and thread designs should be hygienically designed with enclosed threads.
- Metal Detection In this example, the metal detector
is placed near the beginning of the grind-blend line to detect and circumvent tramp metal
from entering the grinder and downstream equipment.
- Drop-Conveyor Inspection The drop belt conveyor shown
in the layout allows trim meat to be flipped during conveyance and allows for visual
inspection of foreign material before the product is transported downstream.
- Grinder Maintenance Foreign material can include
metal shavings and shards from grinders. Keep the grinder finely tuned and in proper
alignment; keep the pins, bushings, heads and knives in well maintained
- Sanitation Training Confirm that the sanitation crew
completely understands the proper disassembly and reassembly of all COP (clean-out-of-place)
components. Improper installation may create wear points on machinery which can lead to