| Equipment Component |
I Have: |
What's the risk? |
| Drive Components |
Belt/Chain Driven
Comments:Traditionally chain driven drives are of mild steel construction with a cover. Belts are usually constructed of rubber and require special cleaning chemicals.
Options:
1.
Remove guard and chain or belt for PEC. As they are removed, inspect for wear. There may be rubber fragments on the guard that indicate wear in the belt.
Pros:Can be added into any maintenance and sanitation program with proper procedures and training.
Cons:Will take time and resources each time this is taken apart and reassembled.
2.
Potential shaft-driven modification - Discuss with manufacturer. Conversion from belt or chain driven, can modified with a new motor and shaft-mounted gear box.
Pros:If an easy modification, the old drive design could be eliminated.
Cons:Could be expensive and a new design may be required.
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Corrosion, PEC cleaning requirement, can be difficult to clean. |
Hollow Rollers
Comments:Rollers will expand and contract, not always showing the accumulation. End caps will wear and create openings for access to the hollow rollers.
Options:
1.
Inspect, monitor and replace when penetrations/damage is seen.
Pros:Easy to replace with rotation schedules for some or all of the rollers at a PM. If one roller has failed, most are probably failing and replacing all might be beneficial.
Cons:Not all penetrations/damage may be visually caught and contamination could still occur.
2.
Replace with solid rollers - Discuss with manufacturer.
Pros:Could be a direct replacement.
Cons:May not be a direct replacement and may require equipment modification.
3.
Replace the conveyor for a more sanitary design.
Pros:A new conveyor could mean additional sanitary changes.
Cons:Expensive.
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Liquid accumulation and/or food debris. |
Hydraulics
Comments:Elimination of oil and surface area of hoses decreases sanitation needs. Heat associated with hydraulics raises the temperature in this area, creating a different concern for growth.
Options:
1.
Purge system to replace with Food Grade Oil.
Pros:Relatively quick and easy and can be completed by in-house personnel.
Cons:Oil and hoses are still present in the processing environment. Heat is still produced within the hydraulic location. Standard detergents may not help remove oil spills, requiring a special degreaser.
2.
Convert equipment to electric.
Pros:No concerns of oil, hoses, or micro-climate.
Cons:Can be expensive and could require design change.
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Non-food grade oil, Hoses, "Micro-Climate" created with Temperature of Oil. |
| Gauges |
Pressure/ Temperature Gauges made from Glass or a Shattering material.
Comments:Glass sight gauges have been used for many years in and out of the food industry. The location of these gauges can vary and are used to measure temperature, pressure, fill, etc.
Options:
1.
Add a shatterproof material to the gauge face, such as a clear window tint, making the face shatterproof.
Pros:Relatively quick and easy, addressing in house with little resources.
Cons:May peel over time (and lead to harborage) if shatterproof material is applied and does not address hollow area between the face plate and the face of the gauge.
2.
Replace the gauge with a shatterproof material.
Pros:Shatterproof from installation, with less inspections required.
Cons:May take time and may be more expensive.
3.
Replace the gauge with a wash-down transducer.
Pros:Limits can be programmed which are wired into the control system.
Cons:More expensive, and electronic controls will need to be updated.
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Foreign material contamination in a breakage. |
| Belting |
Fraying/ Damaged Belts
Comments:With all belting issues, ensure proper tracking. If belting is going to be replaced, be sure to check the lacing as some may require special tooling for installation.
Options:
1.
Cut the sides of the belt and melt - Depending on the belt type.
Pros:Quick and easy to do in-house.
Cons:This is only a temporary fix and the belt may not track properly.
2.
Replace.
Pros:If belting is in stock, replace.
Cons:Might not be the right belt for that particular application.
3.
Replace with a new design - Check with the manufacturer to determine availability and compatibility.
Pros:Could be better fitting application.
Cons:Could be expensive and will take some time to get belting in, tested, and installed.
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Harborage in the fraying edges. |
Cap Strip
Comments:Cap strip was used in the slider bed of many older conveyors. When addressing cap strip, it is beneficial to remove the belt first, making easier access to the interior.
Options:
1.
Remove the plastic bolt and UHMW on a periodic basis for cleaning.
Pros:Cleaning can be completed in house.
Cons:May be time consuming and plastic bolts may need to be replaced due to stripping.
2.
Check with the manufacturer for replacement options.
Pros:Could be a direct sanitary replacement.
Cons:May require equipment modification, cost may vary.
3.
Replace the equipment.
Pros:Additional Sanitary Design aspects may be included on this design vs. the old.
Cons:Could be expensive. Weigh out the time to clean and maintain; a new piece of equipment may not be as expensive as you think when all consumable and labor costs are spelled out.
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A water collection channel that is a potential bacterial harborage point. |
| Component Fasteners |
Zip Ties
Comments:Typically used for routing cables to equipment from control panels or outlets.
Options:
1.
Replace with metal detectable zip ties.
Pros:Quick and easy.
Cons:May not provide sanitary access to all surfaces of the cables and wires.
2.
Install a sanitary method, such as wire looms, to the equipment to run cables through.
Pros:Could provide a clean and easy to remove application.
Cons:May be time consuming and would require a qualified sanitary welder for install.
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Bundled cables and wires leading to inaccessible cleaning surfaces. |
| Hinges |
Piano Hinges
Comments:Piano hinges could be commonly seen on electrical control panels for equipment. They are difficult to clean and pulling the pin on the piano hinge, creates difficulty when reinstalling. With any modification, check for potential for water intrusion and integrity of the weather stripping/gasket. With any option below, be sure to disconnect the electrical for personnel safety.
Options:
1.
Remove and modify to a bolt-pivot hinge. Check with the manufacturer.
Pros:Could be done house with a qualified fabricator or custom manufacturer.
Cons:Could lead to leakage or water intrusion if not done properly.
2.
Replace the panel or other equipment.
Pros:Guarantee of no piano hinges and of sanitary construction.
Cons:Could be expensive and would require an electrician for installation.
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Lots of surface area and niche points for cleaning. If the piano hinges are bolted on, check for lamination between flanges. |
| Fabricated Weldments |
Tube Construction
Comments:Is the structure worth modifications?
Options:
1.
Inspect for penetrations, drain at base (if possible) and plug weld.
Pros:Relatively cheap and easy and can be completed in house with a qualified welder.
Cons:Moisture can remain in the tubes and will need inspection to ensure tubes are not penetrated in the future.
2.
Cut & remove, replace with open frame.
Pros:Easy to clean with little maintenance.
Cons:Expensive. Will require engineering to ensure proper support structure.
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Liquid accumulation. |
Inappropriate welding - Skip, messy
Comments:Do not just immediately grind or reweld, the repair will depend on the location of the weld! Evaluate area to ensure structure integrity is maintained so that cracking will not occur. Be sure the metal is clean prior to any repair.
Options:
1.
TIG-wash the weld.
Pros:Quick and easy if there is a good welder in house.
Cons:Could negatively impact the structure of the weld. May provide a temporary benefit leading to a long-term loss.
2.
Cut out the heat-affected zone and replace with a continuous weld or move the weld location.
Pros:A cleaner weld will be easier to clean and maintain.
Cons:Surface may warp, causing uneven surfaces that could lead to water/product pooling.
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Improper penetration, bacterial harborage. |
Bolted Flanges
Comments:Bolted flanges were commonly found on flume tanks, especially if the facility moved. If flanges are to be addressed, be sure there is room to take the section of equipment out in order to clean and/or weld.
Options:
1.
Unbolt, clean, and apply Food-Grade caulking on the lamination.
Pros:Could be completed in house, however, having adequate room to move the equipment in and out can present a challenge.
Cons:Will eventually peel and will require additional maintenance.
2.
Unbolt, clean, and install a food contact approved gasket.
Pros:Could be completed in house, however, having adequate room to move the equipment in and out can present a challenge.
Cons:Increases laminations and will require inspections for wear.
3.
Cut off flanges and weld together.
Pros:With a solid and smooth weld, harborage points are eliminated.
Cons:Could be the more expensive route and is not ideal for plants that move
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Lamination = bacteria harborage. |
Bolted Laminations
Comments:Bolted laminations, like that of the bolted flanges, were commonly seen when equipment moved, or was frequently moved in a facility. Bolts make movement relatively quick and easy as compared to cutting and welding.
Options:
1.
Unbolt and clean periodically, applying Food Grade Anti-Seize on the threads.
Pros:Relatively quick and easy although spacing between laminations of equipment may present repair challenges.
Cons:May not be done as frequently as desired. Hardware gets lost and could lead to galling.
2.
Add standoffs to allow for cleaning between the sheet metal.
Pros:Cleaning can be completed with adequate spacing between the plates.
Cons:Dimensions may not allow for adequate length of standoffs.
3.
Determine if laminations can be welded 100% or if additional modifications will be necessary. Consult manufacturer for information.
Pros:Could provide a hermetic seal.
Cons:Expensive, and could cause warping.
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Lamination = bacteria harborage. |
Painted Equipment
Comments:Not approved for food contact. If equipment is very old, evaluate for potential use of lead-based paint and ensure proper removal or disposal.
Options:
1.
Can be stripped and repainted.
Pros:Easy to do with a limited amount of time.
Cons:Will peel again, and depending on the location, corrosion will continue.
2.
Can be stripped and powder coated - Contact Manufacturer for recommendations.
Pros:Can be done within a couple of weeks depending on location and contractor availability.
Cons:Could chip, and depending on the location, corrosion could continue.
3.
Replace with Stainless Steel - Contact Manufacturer for recommendations.
Pros:No need for recoating.
Cons:Will be expensive and will take some time to get equipment built and installed.
|
Peeling, harborage underneath. |
All-Thread Footings
Comments:All-thread footings are used on equipment for ease of height adjustment. They are threaded into square hollow tubing, make a risk for slight accumulation in the tube as they equipment height is adjusted.
Options:
1.
Remove regularly for sanitation and ensure drainage of tube.
Pros:Can be done in house.
Cons:Would require resources to disassemble, inspect, clean and reassemble.
2.
Modify the leg adjustment by welding, replacing with round bar, etc. Contact the manufacturer.
Pros:No future concern of threaded footings
Cons:Could be expensive for footing and leg modification.
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Deep threads create harborage areas that are difficult to clean. |
Rusty Scratches on Stainless Steel surfaces
Comments:Can be seen on the insides of hoppers, especially after bin dumpers as rock, nails, and other items may damage the surface at dumping. These types of objects can have a high iron content which contaminates the surface of the Stainless Steel, impregnating the surface with these impurities.
Options:
1.
Treatment of surface with an approved pickling paste or other passivation treatment followed by proper sanitation procedures.
Pros:Quick and relatively easy.
Cons:If it happened once, it could happen again. Need monitoring to ensure it is addressed accordingly.
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Corrosion on that surface leading to a harborage point. |
| Equipment Marking |
Decals / Stickers / Cut-Outs
Comments:Do not just remove! Decals/stickers are present for a reason.
Options:
1.
Replace sticker.
Pros:Cheap and easy.
Cons:Will have peeling issues again.
2.
Plaque with stand-offs.
Pros:More permanent, can be cleaned, ensure spacing is adequate.
Cons:Might not be cleaned like it should.
3.
Remove and etch into SS.
Pros:No lamination.
Cons:Can potentially be removed by cleaning.
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Peeling, harborage in and underneath. |
| Process Piping |
Underground Piping
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Comments:Underground (or overhead) piping can be typical from wash systems to chillers which are located either in another room or outside of the facility.
Options:
1.
Ensure verified and validated cleaning procedure.
Pros:Sounds easy to do. Inexpensive line cameras can be used to inspect piping. It is recommended a minimum flow of detergent solution is utilized at 5 feet per second.
Cons:Verification of cleaning is difficult as what is out of sight, may be out of mind.
2.
Replace an exterior chiller with an in-line chiller such as a glycol chiller. Contact manufacturer for options.
Pros:All water is contained close to the tank. All piping could be designed to be dismantled and inspected.
Cons:Could be more expensive, with engineering, fabrication, and installation required.
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Cleaning and verification difficulty. |
| Compressed Air & Pneumatics |
Air used for Equipment Blow-Down
Comments:At times, air may be used for equipment cleaning, although not recommended due to the potential transfer of material from one line to the next. Point of use filters can be common on air lines used on or near the product zone, however, there are other air lines that may be needed to run equipment.
Options:
1.
Test the air on periodic basis to ensure purity.
Pros:Testing can help determine the risk (and purity) of air usage in a particular area.
Cons:Does not address the potential for cross-contamination or cross-contact with usage due to handling.
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Unfiltered or unmaintained air blowing on or around product contact surfaces. |
Air Cylinders used for Equipment Movement
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Comments:Air cylinder integrity is maintained by pressure inside of the cylinder that allows proper function. If the gasket was leaking, the cylinder would not properly function.
Options:
1.
Test and monitor pneumatic air cylinders.
Pros:Testing can help determine the risk (and purity) of air usage in a particular area.
Cons:If a pneumatic fails, a long term replacement may be difficult. Cylinders can be easily replaced, however, a long term solution may lead to equipment replacement.
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Accumulation inside of the air cylinder. |
| Motor Controls and Electrical |
Strain Relief
Comments:Strain relief typically comes with a braiding on the cable that connects to the motor. This strain relief acts as a uni-directional support for the cable into the motor, box or panel.
Options:
1.
Lock-Out, un-wire the motor, remove (trim or unscrew) the strain relief, and reinstall cord grip.
Pros:Can be completed in-house with qualified electrician and maintenance.
Cons:If not removed properly, could lead to a personnel safety concern.
2.
Replace the cord grip with one that does not have a braided strain relief.
Pros:No need for future modification.
Cons:Could be more expensive.
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Difficult to clean areas between the braiding and the cord. |
Rubber Grommets
Comments:In older equipment, it is commonly seen that the rubber insert has been removed. Check for potential damage of wires and cables.
Options:
1.
Remove the rubber insert.
Pros:Quick and easy, could be cut to allow the cable to slide in and out for sanitation.
Cons:Could lead to cable or wire damage.
2.
Replace with a more sanitary method for removal of cords such as Heinzen Sanitary Wire Looms.
Pros:Wire looms are designed for this application and will not damage the cables or wires.
Cons:Could be more expensive and a qualified welder may be required.
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Foreign material from the rubber falling into the product and harborage points where the rubber attaches to the grommet. |
Fan-Cooled Motor
Comments:These fans are commonly seen in motors greater than 1hp. In legacy equipment, fan-cooled motors were more common than the non-ventilated motors we see today. Some of the larger motors, even today, are not available without these visible fans so a PEC will still be necessary.
Options:
1.
Remove fan guard at PEC intervals following appropriate LOTO procedures.
Pros:Can be completed by in-house maintenance and sanitation.
Cons:Will require maintenance and sanitation communication
2.
Consult with manufacturer for availability of non-ventilated motors.
Pros:Concern eliminated with replacement.
Cons:May be unable to locate a NV motors and will have to be special ordered, then installed.
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The fan that is inside of the guard can be difficult to access and clean. |
Motors with open drain ports
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Comments:Drains and T-drains are provided with the motor but may not be installed. If an open port is seen, a cap or drain should be installed in proper locations. It is best to ensure motors are of IP69K for full washdown. Bagging (and unbagging) of motors takes time.
Options:
1.
Clean area as best as possible to ensure any debris is removed. Install the T-vent, drain, or cap to prevent future debris collection.
Pros:If the motor is new, there should not be any water or debris in this port, and installing a new vent should be relatively easy.
Cons:If the motor is older, than it may be very difficult to ensure that installing a vent may not trap material inside. Evaluate the risk based on location, price of a new motor, etc.
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Product / debris collection. |
| Clamps |
Non-Tool less Clamps
Comments:T-Bolt Clamps,V-Band Clamps etc.
Options:
1.
A handle can be added as a modification.
Pros:Short term fix and can be completed by in-house maintenance.
Cons:May not be done in a sanitary manner for long-term.
2.
Ferrule set-up required and installed by certified individual.
Pros:Done right, tool-less disassembly.
Cons:Can be expensive.
|
Not easy disassembly for frequent sanitation. |
| Support Structures |
Aluminum Platforms
Comments:Inspect for penetrations and water inside of the tube. Drill a small hole at the bottom of the beam. In all cases, remove build-up that may be on the decking/support prior to modifications.
Options:
1.
Drill out rivets, inspect for water intrusion, plug weld if SS tubing. If you want to continue use of the existing structure, the deck can be reinstalled utilizing bolts into non-hollow structure such as welded external mounting tabs.
Pros:Can be completed with in-house maintenance and sanitation personnel. Existing deck can be utilized as a cost-savings.
Cons:Welding may not be complete and warpage may occur which may lead to water pooling on the deck.
2.
Aluminized or other caulking can be used between the platform and the tube.
Pros:Can be completed with in-house maintenance and sanitation personnel. Existing deck can be utilized as a cost-savings.
Cons:Additional maintenance and inspection may be required as caulking is known to eventually peel.
3.
SS decking is preferred and can be welded to the SS support.
Pros:Cleanest and least long-term management.
Cons:Expensive and will require time for welding at install by a qualified fabricator, ensure warpage is minimized.
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Hollow tubing secured with rivets. |
| Isolation |
Rubber Isolators
Comments:Discuss with the manufacturer for alternatives based on the durometer.
Options:
1.
Replace with a more sanitary version such as urethane. Discuss with the manufacturer.
Pros:Enhanced cleanability.
Cons:May not be a direct replacement and may require equipment modification.
2.
Keep in place with additional environmental monitoring.
Pros:No equipment modification needed.
Cons:Additional resources may be required to effectively clean these isolators.
|
Damaged, harborage points. |
All-Thread Shaker Support
Comments:All-Thread naturally has deep areas that are hard to clean, and in the area of a scale feed shaker, access can be limited.
Options:
1.
Replace with round bar, custom threaded on each end. Seal to the ceiling with Pipetite.
Pros:Elimination of excessive all-thread .
Cons:Will take time to install.
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Difficult to clean areas threads. |
| Lubricants |
Non-Food Grade Lubricants
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Comments:Inspect to ensure units are not over greased and the seal is still in tact. Can be potentially switched out at a PM service.
Options:
1.
Find comparable Food Grade Lubricants and solvents to replace in the unit.
Pros:Cheap and easy.
Cons:May not be fully flushed to allow 100% of NFG lubricant removal. Ensure FG lubricants are used moving forward.
2.
Communicate with the manufacturer on alternatives, or replace unit with a Food Grade filled unit.
Pros:Guarantee that the unit is packed with FG lubricant.
Cons:Depending on the unit, may be more expensive. Ensure FG lubricants are used moving forward.
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Potential product contamination. |
| Infrastructure |
Ceiling Tiles
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Comments:Ceiling tiles were used in areas which were typically not designed for a wash-down environment. These tiles do not lend themselves for ease of cleaning and direct water can be problematic.
Options:
1.
Remove the ceiling tiles at a defined frequency for wipe down.
Pros:Removal and disassembly can be easily written into a sanitation and maintenance schedule.
Cons:Resources can be expensive. Weigh out the cost of cleaning versus a wash-down ceiling or utilization of another room.
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When cleaning, they lift, making it difficult to efficiently clean and water intrusion can occur. |
Non-Wash Down Lights
Comments:Can be seen on the ceilings and underneath decks. Ensure it is shatterproof!
Options:
1.
Cover during sanitation.
Pros:Can be easily written into a procedure and can be executed relatively quickly.
Cons:May not be adequately covered and does not address water that may already be in the light cover.
2.
Replace with wash-down version.
Pros:Done once, done right.
Cons:Can be expensive and may require an electrician for install.
|
Water intrusion and inaccessibility for cleaning. |
Lined Drains
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Comments:Typically seen in older drains and are usually a blue or other color.
Options:
1.
Cut back the lining to keep water pooling at a minimum.
Pros:Relatively quick and easy.
Cons:May not address all of the harborage points and may expose aggregate flooring.
2.
Replace with a more sanitary version such as Stainless Steel trench or area drains.
Pros:Done once, done right.
Cons:Will be expensive and may require downtime in the facility for installation.
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Peeling of inner liner causing a harborage point. |
Cast Iron Drain Grates
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Comments:Old style drain grates are typically seen in trench drains. These are heavy and awkward to move which can lead to damage of floors when moved frequently for sanitation. There can also be compatibility issues with most cleaning detergents and some sanitizers.
Options:
1.
Powder-Coat Grates.
Pros:Cheapest route to go although will require a qualified company to ensure coating is applied correctly.
Cons:Material will eventually chip and lead to corrosion. These grates will have to be treated with care in order to ensure chipping and corrosion is kept to a minimum. Not recommended for forklift traffic.
2.
Replace with SS grates. Be sure there are proper cut-outs in the grates to allow for ease in lifting and placing back on the trench.
Pros:The grates themselves can be cut of SS plate to the desired size of the old grates. Fairly easy replacement.
Cons:Heavier. Eventually, spot contamination from the iron trench to the stainless can occur. Proper wash-down with acid is recommended to keep the corrosion at a minimum. If the trench is still made of cast iron, there is still the potential for harborage in the drain material.
3.
Replace the grates and drain itself for a cleanable material such as SS. Be sure there are proper cut-outs in the grates to allow for ease in lifting and placing back on the trench.
Pros:Drain and grates are made of a cleanable material and can be washed down regularly with no concern of corrosion.
Cons:Heavier and most expensive route requiring construction by qualified fabricators in the facility.
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Corrosive material in a fresh-cut processing environment, leading to harborage points. |
Evaporators
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Comments:Always make sure to provide floor space around evaporators accompanied with adequate Lock-Out Tag-Out procedures. Watch out for fire sprinklers, electrical, and ammonia lines when accessing, cleaning and maintaining. Never use high pressure water as coils can bend, reducing airflow. Discuss options with your refrigeration technician in terms of cleaning, maintenance, and defrost cycles. Defrost cycles can possibly be modified to reduce the risk of any residual moisture blowing onto unwanted surfaces.
Options:
1.
If condensate is noticed on the bottom of the unit, inspect the plumbing to ensure drains aren't plugged. If the unit is of mild steel construction, there may be small rust particles along with dust that can cause the drain to plug.
Pros:Ensuring the drain is clear and clean could be completed in house and added to any PEC program.
Cons:If small metal particles and dust are clogging the drain, this may be indication of more conditional issues with the evaporator. It is best to call in the manufacturer or discuss with your refrigeration technician.
2.
If the evap is deemed uncleanable, evaluate with your refrigeration tech to see if it can be shut off permanently to eventually remove. If it cannot be shut off, the drip pan and fans will need to be unbolted for inspection and cleaning. Always put back together prior to production!
Pros:Shutting off the evap can be a short term fix, although stagnant equipment is not ideal in any production facility. Disassembling the evap can be added to any in-house PEC.
Cons:Unbolting and reassembling equipment takes time and resources for cleaning and maintenance. Non-wash down components, such as motors, can take time to not only properly clean, but to bag and unbag during required sanitation.
3.
Add a stainless drip pan and an air diverter to prevent condensate drip and air blowing directly on the food zone.
Pros:This can be completed by contacting an OEM to properly design and install for your application. Proper drainage and airflow requirements need to be taken into consideration for proper functionality of your system
Cons:The cost can add up when adding additional material to any equipment. That equipment will now need to be cleaned periodically as part of a Sanitation Program. Weigh out cost of time and material versus a newer cleanable system and potential ROI.
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Placement and condition of Evaps in the production facility may not allow for cleaning in addition to lack of sanitary design. |
