aGENDA

Hygienic by design means designing or modifying facilities, equipment and systems to minimize the risk of contamination in all phases of food production. It involves considering hygiene and sanitation at every stage of facility design, construction, and operation. This includes selecting materials, equipment, and surfaces that are easy to clean and maintain, creating layouts that minimize cross-contamination, and implementing effective cleaning and disinfection procedures. The goal is to create a hygienic environment that supports food safety and reduces the risk of foodborne illness.

In general, a facility that manufactures, processes, packs, or holds food for consumption in the United States and must register with FDA is subject to the Current Good Manufacturing Practice, Hazard Analysis, and Risk-Based Preventive Controls for Human Food rule (CGMP & PC rule). The CGMP & PC rule requires a facility to conduct a hazard analysis and establish preventive controls when there is a hazard identified that requires a preventive control for food safety. To ensure the effectiveness of preventive controls, the CGMP & PC rule further requires that preventive control management components (i.e., monitoring, verification, and corrective actions) be established, taking into account the nature of the preventive controls and their role in the facility's food safety system. Likewise, food safety controls for FDA-regulated food that is also subject to other rules (i.e., infant formula) require appropriate verification and corrective action activities. This presentation will review certain verification and corrective action practices and how they relate to selected recent food safety events, such as recalls and/or foodborne illness outbreaks.

Perspectives from three experienced and respected industry experts.
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Mr. Erickson has been traveling the world evaluating dairy equipment and dairy plant and packaging operations outside of the US for almost 20 years and will share his experience and the perspectives of specific dairy equipment hygienic design failures including the “whys”, “hows” and lessons to be learned.
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Drawing upon years of experience as a state dairy farm and plant processing specialist and food safety and regulatory manager in the US dairy industry, Ms. Piotter will share her experiences on specific processing equipment hygienic design failures, its impact on dairy facility operations, products and lessons learned including tips of what to look for when evaluating dairy processing equipment.
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As both a 3-A Certified Conformance Evaluator(CCE) and USDA AMS Meat and Poultry Equipment Review program evaluator, Mr. Glick will illustrate the key differences between hygienic design requirements for the dairy equipment inspection program and the USDA AMS meat equipment evaluation and certification program.  In addition, he will share specific experiences in evaluating meat equipment, common shortcomings and why meat equipment meeting the USDA AMS “Guidelines for the Evaluation and Certification of the Sanitary Design and Fabrication of Meat and Poultry Processing Equipment - February 2009” still require periodic “deep cleaning”.

Hygienic design challenges exist across the food industry, and the produce industry is not immune to these challenges. Design challenges begin in the field and continue through the process at the plant. This presentation will focus on the current state of design in the process and how to increase food safety with improvements in design. Discussion will include thinking holistically about design and applying hygienic design principles to equipment, infrastructure and plant layout. With this approach the produce industry has the opportunity to maximize the benefits of hygienic design, resulting in wins in food safety and productivity.

How does smart hygienic design add up to a positive return on the investment?   This will give you an expert view to quantify your return through water, energy and comprehensive operating cost savings while enabling you to achieve both business and sustainability goals - without tradeoffs.

Product Recovery or ‘pigging’ systems have been in use since the early days of US oil exploration. The use of pigs has expanded in the proceeding century to include hygienic process plants. Pigging systems have multiple benefits, both direct and secondary, that touch on CIP systems, waste, yields, product purity, and environmental impact. With some limitations, the benefits range broadly from cost reduction to revenue increase to lowered environmental impact. Product recovery/pigging systems should be part of every new plant and existing plants should be trying to retrofit to accommodate one.

In today’s complex and ever-changing marketplace, uptime in manufacturing can be a make or break for processors, especially when looking at slim margin products.  From the process automation and engineering side the same slim margins exist along with the ever-shrinking experienced labor pool.  This presentation will cover the basics of making the right choices in vendors, how to ask the right questions and how to cross check that the work that is being completed matches the master scope of work and design criteria and that all of the project documentation is completed to the final ‘as built’ status prior to final close out.  It is so easy for companies to ‘copy’ and ‘paste’ to save time but does that help or hinder you?

Food Safety is the overarching goal of food production. As such, it must be built into the design and construction of new and remodeled food factories.  In order to comply with regulations and ensure that customers will be safe, such design must look at all the aspects of the food supply chain, including warehousing, transportation, preparation, processing and final distribution.  This presentation will discuss a practical engineering approach to design food safety into your factory using Process Systems Engineering, and Data-mining techniques to improve safety and overall operational or supply chain efficiencies.