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6. Equipment

• Scope
• 6.1 Outcome
• 6.2 General Principles
  • 6.2.1 Equipment approval
  • 6.2.2 Good sanitary design
    • 6.2.2.1
    • 6.2.2.2
    • 6.2.2.3
  • 6.2.3
  • 6.2.4 Cleanability
    • 6.2.4.1
    • 6.2.4.2
    • 6.2.4.3
  • 6.2.5Clean-in-place (CIP) systems
    • 6.2.5.1
    • 6.2.5.2
    • 6.2.5.3
    • 6.2.5.4
    • 6.2.5.5
  • 6.2.6Durability
    • 6.2.6. 1
    • 6.2.6. 2
    • 6.2.6. 3
    • 6.2.6. 4
    • 6.2.6. 5
  • 6.2.7Corrosion resistance
  • 6.2.8Inertness
  • 6.2.9Impact resistance
  • 6.2.10Thermal properties
  • 6.2.11Operational characteristics
    • 6.2.11.1
    • 6.2.11.2
    • 6.2.11.3
    • 6.2.11.4
    • 6.2.11.5
    • 6.2.11.6
  • 6.2.12Adulteration of food
    • 6.2.12.1
    • 6.2.12.2
  • 6.2.13Non-food contact surfaces
  • 6.2.14Resistance to discolouration
  • 6.2.15Ease of repair and maintenance
  • 6.2.16Materials of construction
    • 6.2.16.1
    • 6.2.16.2
    • 6.2.16.3
    • 6.2.16.4
• 6.3Hygiene Equipment
  • 6.3.1Personnel wash units and sterilisers
    • 6.3.1.1
    • 6.3.1.2Suitability for use
    • 6.3.1.3Waste water containment
    • 6.3.1.4Operation
    • 6.3.1.5Warm water and soap
    • 6.3.1.6Hand drying
    • 6.3.1.7Steriliser temperature
    • 6.3.1.8Aerosols and vapour
    • 6.3.1.9Supply valves
    • 6.3.1.10Combination hand wash / knife steriliser units
  • 6.3.2Hoses
    • 6.3.2.1
    • 6.3.2.2
    • 6.3.2.3
• 6.4Monitoring Equipment
  • 6.4.1General
  • 6.4.2Alarm systems
  • 6.4.3Accuracy
  • 6.4.4Temperature indicators
    • 6.4.4.1Equipment sterilisers
  • 6.4.5Calibrated automatic temperature recorders (CATRs)
  • 6.4.6Water treatment systems
    • 6.4.6.1
    • 6.4.6.2
  • 6.4.7Electrical stunning equipment
• 6.5Chutes
  • • 6.5.1
    • 6.5.2
    • 6.5.3
• 6.6Conveying Systems
• 6.7Receptacles
  • 6.7.1Differentiation between food and byproducts containers
  • 6.7.2Receptacles to convey food in byproducts areas
  • 6.7.3Byproducts from the slaughterfloor
• 6.8Motors, Drives and Pumps
• 6.9Dry Cleaning Equipment
  • 6.9.1
  • 6.9.2
  • 6.9.3
  • 6.9.4
  • 6.9.5Vacuum Systems
    • 6.9.5.1
    • 6.9.5.2
    • 6.9.5.3
    • 6.9.5.4
    • 6.9.5.5
    • 6.9.6

6. Equipment

Scope

This section applies to the design, construction, installation, use and maintenance of equipment in any food area and food support area for any of the following categories of premises:

AB, ME, PH, DSP, GIP, PPH, APH, RSH

Section 6.3: Hygiene Equipment also applies to Section 14: Custom Killing Premises and Rural Slaughter Houses.

Section 6.5.3: Chutes conveying byproducts and Section 6.7: Receptacles also applies to Section 16: Byproducts Facilities.

6.1 Outcome

Equipment shall be designed, constructed and installed to provide for ease of cleaning, maintenance and inspection. Parts of the equipment that come into contact with food shall be capable of being easily cleaned and, if necessary, sterilised. Equipment shall protect the food from contamination, shall not be a source of contamination and shall perform the function for which it is designed.

6.2 General Principles

6.2.1 Equipment approval

Equipment complying with the requirements of this section can be used in premises licensed in terms of the Meat Act 1981 and approved premises. In addition, a current list of equipment that have been validated as meeting the requirements of this section and has been approved by MAF RA (M&S) for use in licensed and approved premises can be found in Manual 15: Approvals, "Building Materials and Equipment".

6.2.2 Good sanitary design

The sanitary design of the equipment shall ensure:

6.2.2.1	efficient performance of the intended task, where applicable (this includes monitoring, control and recording of its function or performance);
6.2.2.2	no additional contamination of the food, chemically, physically or microbiologically;
6.2.2.3	maximum protection of the food from external contamination and minimum contamination by the food of other equipment and plant structures.
6.2.3	General principles of sanitary design for equipment are described in the following Sections 6.2.4-6.2.16.

6.2.4 Cleanability

Equipment shall be:

6.2.4.1	able to be adequately cleaned by normal procedures (for that area of the premises) without damage to the material’s surface;
6.2.4.2	smooth and non-porous and free from cracks, crevices, recesses, dead-ends and gaps, so as to eliminate contaminant collection areas;
6.2.4.3	readily accessible for inspection except where it can be shown that cleaning procedures eliminate the possibility of contamination.

6.2.5 Clean-in-place (CIP) systems

Sanitation procedures for CIP systems shall be as effective as those for cleaning and sanitising disassembled equipment. Only equipment which meets the following criteria may be cleaned in place:

6.2.5.1	Cleaning solutions, sanitising solutions, and rinse water shall come in contact with all interior surfaces of the equipment in the CIP system.
6.2.5.2	All internal surfaces shall be either designed for self draining or physically disassembled for draining after rinsing.
6.2.5.3	Pipe interiors shall be highly polished stainless steel or some other acceptable, smooth-surfaced material. All interiors shall be easy to inspect.
6.2.5.4	Easily removable elbows with quick disconnect mechanisms shall be placed at each change of direction.
6.2.5.5	All sections of the system shall be capable of being completely disassembled for periodic inspection of all internal surfaces.
	Any equipment or portions of equipment not meeting these requirements shall be disassembled for daily cleaning and inspection.

6.2.6 Durability

Equipment shall be:

6.2.6. 1	resistant to chipping, flaking or delamination;
6.2.6. 2	able to withstand exposure to heat and/or water under normal operating conditions;
6.2.6. 3	resistant to abrasion;
6.2.6. 4	able to withstand machinery vibration;
6.2.6. 5	able to withstand regular cleaning and sanitising programmes.

6.2.7 Corrosion resistance

Equipment shall be corrosion resistant under the prolonged influence of the corrosive agents encountered during normal conditions of use, including water vapour, food ingredients and chemicals.

6.2.8 Inertness

All surfaces in direct contact with food shall be inert to food, cleaning materials and methods of sterilisation which may be employed under normal conditions of use.

6.2.9 Impact resistance

Equipment shall be resistant to or be protected from an impact of the magnitude likely to be encountered during normal conditions of use.

6.2.10 Thermal properties

Equipment shall be capable of maintaining its original properties when subjected to temperature changes that may occur during normal conditions of use.

6.2.11 Operational characteristics

The equipment shall:

6.2.11.1	be installed and operated in accordance with the manufacturers’ specifications (alternative uses of the equipment that may jeopardise the hygienic safety of food shall be avoided);
6.2.11.2	be designed to eliminate excessive build-up of food components, waste components and waste water for the normal period of operation;
6.2.11.3	where appropriate, have interior surfaces which come in contact with food arranged so that the equipment is self-emptying, self-draining or designed to be easily evacuated of water;
6.2.11.4	where appropriate, have internal corners or angles with a continuous smooth radius of at least 7 mm (a lesser radius may be used where necessary for proper functioning of parts or to facilitate drainage, provided that such areas can be readily cleaned);
6.2.11.5	be installed and operated so as to protect the food from external contamination while in use;
6.2.11.6	be arranged to ensure an orderly flow and hygienic handling of the food components.

6.2.12 Adulteration of food

6.2.12.1	The design, construction, installation, use and maintenance of equipment shall preclude the adulteration of the food. Adulteration may involve the use of lubrication oils causing toxic effects or odour, colour and flavour taints, abnormal use of equipment causing incidental heating of the food, incidental inclusion of metal or paint flakes, contaminated water and other sources of contamination, etc.
6.2.12.2	A current list of authorised chemical compounds and details of the types of chemical compounds which require specific evaluation and authorisation is available in Manual 15: Approvals "Chemicals".

6.2.13 Non-food contact surfaces

Exterior surfaces and non-food contact surfaces shall be arranged to prevent the harbouring of contaminants in and on the equipment, including their contact with other equipment, floors, walls or hanging supports.

6.2.14 Resistance to discolouration

Equipment should not stain when splashed with food components handled in the premises, acids or alkaline solutions, or other chemicals normally found in the premises.

6.2.15 Ease of repair and maintenance

Equipment shall remain fit for purpose following repair and maintenance.

Equipment should be easy to maintain and repair without damage to surface areas or integrity of the equipment. All welding within the food zone should be continuous, smooth, even and relatively flush with adjacent surfaces.

6.2.16 Materials of construction

6.2.16.1	Plastic and synthetic materials and resinous coatings used as food contact materials shall meet the appropriate requirements specified in the current US Code of Federal Regulations Title 21 Parts 170-199.
6.2.16.2	The responsibility for compliance with the specifications for composition of any food contact material rests with the manufacturer or supplier. The Licensee shall obtain a written guarantee from the manufacturer or supplier that the material complies with the above requirements. The guarantee shall contain the following information:

(a) the identity of material, i.e. the distinguishing brand name or code designation appearing on or with the material;

(b) the specific part(s) of Title 21 that are applicable to the material;

(c) the specific conditions of use, such as temperature limits or any other pertinent limits, particularly those which are stipulated by the US regulation;

(d) the signature of an authorised agent for the manufacturer or the supplier;

(e) whether the guarantee is limited to a specific shipment of an article, in which case it may be part of or attached to the invoice covering such a shipment; or

(f) whether the guarantee is generic and continuing; in which case, in its application to an article or other shipment of an article, the guarantee shall be considered to have been given at the date such article was shipped by the person who gives the guarantee.

6.2.16.3

It should be noted that the guarantee provides approval for the composition only of the food contact material, and is not an approval for any constructed piece of equipment. All equipment shall be designed, constructed and installed in accordance with the outcome and all the general principles in IS 2: Section 6.

 

The most satisfactory material for direct food contact is stainless steel (300 series or better). Aluminium used as a food contact surface, while acceptable, is not desirable. It has a marked tendency to warp, and is susceptible to oxidation. The oxide tends to discolour foods, and the soft nature of the metal leaves it susceptible to pitting and scratching. Aluminium is also prone to corrosion. Galvanising is acceptable for non-food contact surfaces but the finish should be of a high quality commercial hot dip or the equivalent.

6.2.16.4

The following materials shall not be used in any equipment that can possibly come into contact with food:

(a) metals such as cadmium, copper, lead and their alloys;

(b) dissimilar metals, if their contact with liquid or other substances may create harmful chemical and electrolytic action;

(c) sponge rubber, stone slab, leather fabrics and any other porous materials;

(d) wood;

(e) galvanised metal, except where used for processing equipment in accordance with the following requirements:

(i) galvanising to the standard of high quality, smooth-finished commercial hot dip, and;

(ii) limited to use for processing of skin-on animals, and;

(iii) limited to equipment which occurs up to, and including, the point of dehairing and/or the associated scraping table.

6.3 Hygiene Equipment

6.3.1 Personnel wash units and sterilisers

6.3.1.1

There shall be sufficient numbers of conveniently located personnel wash and/or equipment sterilising facilities to enable hygiene functions to be carried out in accordance with specified requirements, and enable regular use by the operators as appropriate to the nature of the process.

6.3.1.2 Suitability for use

Wash facilities shall be designed, constructed and located to suit the operator, the protective clothing that is worn and the equipment that is used.

6.3.1.3 Waste water containment

All waste water shall be contained and ducted to a drain.

6.3.1.4 Operation

Unless the premises is solely packing or storing protected product, the personnel wash facilities shall be operated by foot, knee or another approved method for hand

wash, apron wash and implement sterilising units used in food areas, and for hand wash units used in food support areas.

6.3.1.5 Warm water and soap

Hand wash units shall be provided with warm potable water and liquid soap dispensers.

The recommended mixed warm water temperature range is 38-44 0C at the point of use.

6.3.1.6 Hand drying

Single use towels or other hand drying facilities that do not contaminate washed hands or the surrounding area shall be provided adjacent to hand wash units unless the nature of the processing exempts the requirement (for example, some slaughtering operations.)

Where single use hand drying towels are used, facilities shall be provided for their disposal.

6.3.1.7Steriliser temperature

Sterilising units shall be provided with potable water at a minimum temperature of 82 ⁰C.

6.3.1.8 Aerosols and vapour

Aerosols or vapour emanating from hygiene equipment shall be minimised where it may come in contact with and/or contaminate exposed food.

6.3.1.9 Supply valves

Water supply control valves for continuously operating hygiene equipment shall be either out of easy reach from the work station or operable by hand tools only.

6.3.1.10 Combination hand wash / knife steriliser units

(a) The design and/or operation shall preclude the mixing of hand wash waste water and steriliser water where there is the potential to cool the steriliser water temperature to an unacceptable temperature.

All waste water from the hand wash section should be contained within that section of the combination unit and ducted directly to waste, not via the steriliser section to its waste outlet.

(b) The flow of hand wash waste water over the knife, while in the steriliser section, shall not shield the knife from sterilising water.

(c) The volume, pressure and temperature of wash and steriliser water shall be adequate to achieve hygienic requirements.

6.3.2Hoses

6.3.2.1	Where required, premises shall be equipped with an adequate number of hose connection points to enable effective cleaning.
6.3.2.2	Appropriate facilities shall be provided for the storage of hoses to ensure nozzles are free from contact with the floor.
6.3.2.3	The fabric of the hose shall not jeopardise the safety of food. Hose materials shall be able to be adequately cleaned and maintained under the normal conditions of use.

6.4Monitoring Equipment

6.4.1General

Monitoring equipment shall accurately reflect the process being controlled and be suitable for the purpose of use.

6.4.2Alarm systems

Visual and/or audible alarm systems required in conjunction with monitoring equipment shall be located to ensure immediate corrective action can be taken in the event of failure of the monitoring equipment.

6.4.3Accuracy

The accuracy of every monitoring or measuring device shall be calibrated against a reference standard. Refer also to Manual 8.

6.4.4Temperature indicators

Temperature indicators are required at the point of use in all circumstances where a specified temperature shall be achieved.

6.4.4.1Equipment sterilisers

Permanent temperature indicators for equipment sterilisers are not required if a manual measurement can be taken. Alternatively, the thermometer may be remote from the point of use if it can be proven that temperature loss does not occur, and

that the line between the point of use and the thermometer is free from taps or any other variable flow regulating device.

6.4.5Calibrated automatic temperature recorders (CATRs)

Calibrated automatic temperature recording equipment shall be provided to monitor the temperature of temperature controlled rooms where required. Refer also to IS 2: Section 10.

6.4.6Water treatment systems

6.4.6.1	Automatic water chlorination systems shall be fitted with alarm devices that indicate when they have ceased to function correctly.
6.4.6.2	Ultra-violet light water disinfection systems shall be fitted with monitoring and alarm systems to automatically shut down the water supply to the uv water treatment unit in the event of:

(a) power failure to the treatment unit;

(b) lamp failure of the treatment unit;

(c) excessive water turbidity.

6.4.7 Electrical stunning equipment

Monitoring equipment shall be provided that indicates electrical stunning equipment is functioning correctly.

6.5 Chutes

6.5.1	Chutes shall be clearly identified and provided with suitably located inspection ports.
6.5.2	Inspection ports shall be sealed to minimise leakage.
6.5.3	Chutes conveying byproducts shall not have any inspection ports or openings in areas producing food, and conversely chutes conveying food shall not have any ports or openings in byproducts areas.

6.6 Conveying Systems

Conveyors, rails, and other food transport systems shall be designed and constructed to minimise contact of food with non-food contact surfaces. Refer also to Manual 3.

6.7 Receptacles

6.7.1 Differentiation between food and byproducts containers

Byproduct containers shall be clearly labelled, except where there is a permanent approved and documented system of differentiating food and byproducts containers which is consistent within all areas of the premises and which has been effectively communicated to all premises personnel.

6.7.2 Receptacles to convey food in byproducts areas

Receptacles used to hold or convey food through byproducts areas, or byproducts through food areas and food support areas, shall be identified, leak-proof and covered to prevent contamination of food.

6.7.3 Byproducts from the slaughterfloor

Receptacles (for example, buckets and wheel barrows) used to collect byproducts from the slaughter floor shall be identified and leak-proof to prevent contamination of product. Receptacles may be required to be covered if the means of conveyance through the slaughter floor will jeopardise the safety or hygienic processing of product.

6.8 Motors, Drives and Pumps

Motors, drives and pumps, including vacuum pumps, shall be enclosed and suitably maintained so that lubricants and smoke do not cause contamination of the food or process. Alternatively, they should be located outside the food area.

6.9 Dry Cleaning Equipment

6.9.1	All equipment used in dry cleaning, such as brushes, scrapers, vacuum systems and pressurised air, shall be designed, constructed, installed and operated in accordance with good sanitary design principles.
6.9.2	In order to reduce airborne dust levels, it may be necessary to install suitable dust extraction systems.
6.9.3	Filters and air handling systems shall be well maintained to prevent them becoming a source of contamination.
6.9.4	Compressed air in direct contact with food contact surfaces shall be filtered or treated in such a manner to remove contaminants. Refer also to IS 2: Section 5.9.

6.9.5 Vacuum Systems

6.9.5.1	Vacuum systems shall be designed, installed and operated in accordance with good sanitary design principles and shall be fit for purpose.

Vacuum systems should be chosen on the recommendation of a supplier of vacuum systems that are specifically designed for the purpose of dry cleaning. Consideration should be given to the desired effectiveness, intended use and the ease of maintenance and cleaning, including accessories, exterior design, dust collector, filters, apparatus surfaces, etc. The cleaning and maintenance programme of the system should include the instructions and recommendations of the supplier.

6.9.5.2	The vacuum system shall be well maintained to prevent it becoming a source of contamination.
6.9.5.3	Vacuum systems shall be equipped with a filter system for outgoing air leaving the system.

The filter system should consist of a coarse filter to trap large dust particles and fine micro-filters upstream from the coarse filter to retain fine particles, including bacteria, yeasts and moulds. Outgoing air from the vacuum system into food processing areas should be filtered through air filters that comply with at least the standard set out in Class EU5, DIN 24-185 Part 2.

6.9.5.4	Cross contamination shall be avoided by providing two different sets of attachments and tubes, one for food contact surfaces, the other for floors and room surfaces.
6.9.5.5	Vacuum systems and attachments shall be stored in a dry state, free from moisture and food residues.
6.9.6	Refer also to Manual 3.