Slide 1: Welcome to our 3rd Capability Session of the Year: Utilities
WELCOME TO OUR 3 CAPABILITY RD SESSION OF THE YEAR UTILITIES
Slide 2: About Today's Session
ABOUT TODAY’S SESSION 1 This webinar is being recorded and will be available at supplier central website 2 Send any questions you have throughout today’s session using the Q&A panel 3 Questions will be addressed at the end of the webinar 4 If your questions are not answered, please contact us throug
Slide 3: Moderators and Presenter for Today's Training
Moderators For Today’s Training Nathalia Galliano Supplier Quality Manager Mondelēz Global Supplier Quality São Paulo, Brazil Today’s Presenter Dimitri Tavernarakis Global Hygienic Desing Excellence Lead Mondelēz Global Food Safety Wroclaw, Poland Mondelez International Public
Slide 4: Tavernarakis - Intro
TAVERNARAKIS - INTRO Education: BSc in Mechanical\Industrial Engineering, Mediterranean University of Crete, GR MSc in Industrial automations and robotics, Mediterranean University of Crete, GR Professional background Over 20 years of experience in new equipment development, production lines design
Slide 5: Before We Start...
BEFORE WE START... Keep your eyes open everytime you see a red baloon next to a topic. NC It means that MDLZ is frequently finding NC connected with it. Mondelez International Public
Slide 6: Hygienic Design Requirements for Utilities
HYGIENIC DESIGN REQUIREMENTS FOR UTILITIES • Air Under Pressure - Compressed Air • Pneumatic Conveying Systems - Low Pressure Air • Environmental Air • Steam
Slide 7: Air Under Pressure - Compressed Air
AIR UNDER PRESSURE - COMPRESSED AIR
Slide 8: Compressed Air and Its Application
COMPRESSED AIR AND IT’S APPLICATION Compressed air is air kept under a pressure that is greater than atmospheric pressure APPLICATION Non – product contact: • Belt tensioning Air Blower and Fans Compressed Air • Machine movement Low Pressure / High Volume High Pressure / Low Volume • Driving pistons
Slide 9: Applicable Standards for Compressed Air
APPLICABLE STANDARDS FOR COMPRESSED AIR
Slide 10: MDLZ Design Considerations for Compressed Air System
MDLZ DESIGN CONSIDERATIONS FOR COMPRESSED AIR SYSTEM General requirements for the fabrication of the compressed air system shall be followed: • For new installations compressors shall be of oil- free technology • Air contact surfaces shall be smooth, continuously welded and external surfaces of pipi
Slide 11: Air Intake
AIR INTAKE Compressors - Intake Air Filters (input of the compressing equipment): • Inlet filtration shall be in accordance with the suppliers' requirements for reliable operation, based on site conditions specified at the time of the contract agreement with the minimum following condition – the air
Slide 12: Compressor Location
COMPRESOR LOCATION • Air supply shall be taken from a clean space – e.g., away from sources of steam, vapor, engine exhaust , dust or any other contaminants. • Discharge from the compressor into the local atmosphere must be avoided • Compressor located outdoors should require weatherproofing Locatio
Slide 13: MDLZ Standards for Purity of Compressed Air
MDLZ STANDARDS FOR PURITY OF COMPRESSED AIR • Compressed air used in product or product contact areas shall be dry, oil free and filtered. • Compressed air used in the product and product contact areas shall meet at minimum purity class 1.4.1 according to ISO 8573-1:2010 • Higher purity grades may b
Slide 14: ISO8573-1 Standard: 1.4.1
ISO8573-1 STANDARD : 1 . 4. 1 MDLZ Standard description for Product Contact In each cubic meter of compressed air, the particulate count should not exceed 20,000 particles in the 0.1 - 0.5-micron size range, 400 Solid particulates = Class 1 1 . 4. 1 Oil Content = Class 1 particles in the 0.5 - 1 mic
Slide 15: Compressed Air System Example
EXAMPLE MIST ELIMINATOR OR VERY FINE STAINLESS OF KEY STEEL MESH FILTER ELEMENTS OF (OPTIONAL), NICE TO COMPRESSED AIR HAVE FOR OIL FLOODED SYSTEMS SYSTEM Distribution pipes Filter Point of Use Water Receiver Wet Receiver / Compresor Dry Receiver Air Reciever / (1) Filter Filter Filter Intake Air Co
Slide 16: Possible Sources of Contamination in Compressed Air
POSSIBLE SOURCES OF CONTAMINATION IN COMPRESSED AIR Environment Compression Valves & Receivers & Improper Filter fittings Pipework Maintenance • In addition to • Contamination • Rust, pipe scale and • High pressure dust, pollen and can not only • Oil- deposits can build up humidity, oil, occur lubri
Slide 17: Compressed Air System
COMPRESSED AIR SYSTEM • Key Terminology • Associated Hazards and Sources • Key Elements & Their Working Principle
Slide 18: Oil Injected Compressors / Condensate Fallout
OIL INJECTED COMPRESSORS NC • Only food grade oils (H1 lubricants) shall be used. • Oil (including vapor and odor filters) & dust filtration shall be placed at the compressor's outlet (Dust & Oil => Class 1 in new • NOTE: Though oil-free installations; for existing installations, use current Oil & D
Slide 19: Filtration at POU - General Purpose
FILTRATION AT POU – GENERAL PURPOSE TYPCALL INSTALLED BY OEM –AIR REGULATOR & COALESCING FILTER COMBO Filtration for the Filtration for foreseeable general purpose non food contact shall be (e.g., Valve/piston at the point of use together operation) with a coalescing filter 0.3 µm and active carbon
Slide 20: Filtration at POU - Food Contact Application
FILTRATION AT POU – FOOD CONTACT APPLICATION COALESCING + MICRO + CARBON, Filtration for the Filtration for foreseeable general purpose food contact shall be at the (e.g., Valve/piston point of use coalescing operation) filter 0.3 µm, micro filter 0.01 and active carbon filter. Mondelez Internationa
Slide 21: Compressed Air Filtration - General Requirements
COMPRESSED AIR FILTRATION – GENERAL REQUIREMENTS The final filter shall All filters shall be Filter be coalescing of a accessible for inspection, elements high efficiency oil cleaning and replacing the shall be removal type filter and/or the filter designed and media and all filter changes built to
Slide 22: Other Processes Uses Air
OTHER PROCESSES USES AIR • Low Pressure Air
Slide 23: MDLZ Design Considerations: Fans, Blowers & Ducting
MDLZ DESIGN CONSIDERATIONS : FANS, BLOWERS & DUCTING • Blowers & fans shall be of oil-free design, shall be hygienically constructed so that they are smooth & cleanable • Fans shall be located before the final filter and there shall be no motors exposed to the air after the final filter. • Air Distr
Slide 24: MDLZ Design Considerations: Air Filtration Requirements
MDLZ DESIGN CONSIDERATIONS NC Air Filtration Requirements Frequency of filters replacement depends on many parameters as to dirt load build up, type, quality, operating conditions and shall be part of the preventive maintenance program of the facility Mondelez International Public
Slide 25: Hygienic Design Requirements - Environmental Air
HYGIENIC DESIGN REQUIREMENTS- ENVIRONMENTAL AIR
Slide 26: Room Air Quality Overview
ROOM AIR QUALITY NC overview Temperature, humidity, relative room pressures and filtration efficiencies shall be implemented & maintained to minimize the potential for microbial cross contamination- refer to HACCP & zoning QPs. Control of Moisture & Temperature PREVENT MICROBIAL Proper Air GROWTH Mo
Slide 27: Environmental Air Filter Standards
ENVIRONMENTAL AIR FILTER STANDARDS
Slide 28: Air Quality
AIR QUALITY NC Air quality requirements linked to zoning (Table 3.2.1) . The filter sizes given in this table shall be converted to the new applicable ISO 16890:2016 NC standard. Recommended Air Changes Raw zone/Limited Processing Zone Controlled Zone High Controlled Zone Minimum air changes/hour --
Slide 29: Air Quality
AIR QUALITY NC Air quality requirements Where hygienic zoning programs require positive/negative air pressure, differentials shall be maintained. Air for processed product zones shall not be sourced from unprocessed [raw] product zones. If more than one type of process is used in a common area, the
Slide 30: Air Quality
AIR QUALITY Exemption to requirements Bakery Oven rooms are exempted from the requirements detailed in Table 3.2.1 as long as proper air balancing is in place and unprocessed air doesn’t flow towards the finished goods area All openings for air intake are protected with a screen of minimum 18 mesh (
Slide 31: Air Quality
AIR QUALITY outside storage venting Air used for venting outside storage tanks or silos, which are not located inside the facility building, shall be filtered to prevent airborne contamination. Filter classifications shall meet the criteria given in Table 3.2.1 as well as the Guidance document Air c
Slide 32: Hygienic Design Requirements: Air Intake
HYGIENIC DESIGN REQUIREMENTS AIR INTAKE All plant exterior air intake ports shall be visually examined for physical integrity at regular intervals at least annually & shall be included in preventive maintenance plans. Outside air shall be clean, dry, free from odors / particulates / birds / animals
Slide 33: Hygienic Design Requirements
HYGIENIC DESIGN REQUIREMENTS Example of porous material Material of construction of air contact surfaces shall be chosen for their intended use & shall be inert, non- toxic, and non- porous. Suitable access for inspection, maintenance and cleaning of all parts of the system. Air contact surfaces sha
Slide 34: Hygienic Design Requirements
HYGIENIC DESIGN REQUIREMENTS Fans, grills or louvers shall be fitted with 18 mesh (1 mm/0.04 inches) screen as a minimum to prevent the entry of extraneous materials or pests. HVAC units shall be provided with suitable access doors for cleaning & inspection Cladding (e.g. stainless steel, aluminum,
Slide 35: Hygienic Design Requirements
HYGIENIC DESIGN REQUIREMENTS Unit heaters contact surfaces shall be accessible for cleaning and inspection. In steam heated units, condensate shall be piped to a condensate return system or to an open hub drain. Piping to an open floor drain is not acceptable. Unit coolers shall be easy to inspect a
Slide 36: Special Gases (N2, CO2 and Other Gases)
SPECIAL GASES (N2 , CO2 AND OTHER GASES) Carbon dioxide, nitrogen and other gas systems used in manufacturing and/or filling shall be constructed and maintained so as to prevent product contamination. NC Gases intended for direct or incidental product contact shall be of food grade quality of 1.4.1(
Slide 37: AHU Design
AHU DESIGN Air handling unit (ahu) with key elements process steps Mondelez International Public
Slide 38: Hygienic Design Requirements - Culinary Steam
HYGIENIC DESIGN REQUIREMENTS- CULINARY STEAM
Slide 39: Steam Grades
STEAM GRADES Pure Steam Quality Steam Refers to the amount of water in the steam. Clean Steam Steam Purity STEAM PURITY Quantitative measure of the dissolved solids, volatiles or other Culinary Steam particles. Steam shall be of the correct quality and purity to meet process and usage needs. Process
Slide 40: Steam Generations
STEAM GENERATIONS Schematic block diagram Process Culinary Steam Steam Conditioned Feed tank Boiler Filtration Water • Softened water • De-alkalization • Reverse Osmosis Water Treatment Chemicals Mondelez International Public
Slide 41: Boiler Water Treatment Chemicals
BOILER WATER TREATMENT CHEMICALS Added to reduce scale, corrosion and chemcial attack within the steam generation and supply system. • The quality of boiler water shall meet the requirements laid down by the MDLZ requirement or local/national regulations, whichever are more stringent. • Boiler feed
Slide 42: Process Steam: Need to Know
PROCESS STEAM NEED TO kNOw… • May be used where steam will not be in contact with product or product contact surfaces, like heat exchangers, hot water preparation (CIP), etc. • Quality/purity will be determined by quality of feed water, water teatment, correct boiler operation, cross contamniation f
Slide 43: Culinary Steam Hygienic Design Considerations
CULINARY STEAM Hygienic design considerations • Materials of Construction (downstream of the culinary steam filter) Definition : – AISI 300 series stainless steel grades or equally corrosion-resistant metal. Filtered steam that is – Polymers (rubbers of plastics) compatible for the application in or
Slide 44: Culinary Steam Hygienic Design Considerations
CULINARY STEAM Hygienic design considerations • Fabrication, cont’d – Product contact surfaces not designed to be mechanically cleaned and shall be readily accessible for cleaning and inspection. – Smooth product contact surfaces (Ra of 0.4 - 0.8 µm / 32 μ inches), free of imperfections (pits, folds
Slide 45: Culinary Steam Filtration, Typical Configuration
CULINARY STEAM Filtration, typical configuration Process Steam Culinary Steam 1 Separator 7 Safety valve 2 Ball valve 8 Culinary Steam Filter, 5μ 3 Strainer 9 Pressure gauge 4 Pressure gauge 10 Check valve (figure courtesy of Spirax-Sarco Limited) 5 Pressure Reducing Valve 11 Ball valve 6 Pressure G
Slide 46: Verification: Steam Condensate Testing
VERIFICATION Steam condensate testing • Culinary Steam condensate shall be evaluated for turbidity and particulates (visually), plus off flavours (aroma), at minimum every six months. • Process Steam condensate shall be evaluated at minimum annually against the same criteria. • Document of the resul
Slide 47: Thank You
THANK YOU Mondelez International Public
Slide 48: Hey! Don't Forget the Survey
HEY! DON’T FORGET THE SURVEY ☺ https://forms.office.com/r/qD9ACc8Ab4 Mondelez International Public