July 31, 2012
by Meat&Poultry Staff
Joe Stout, founder and CEO of Commercial Food Sanitation LLC, Libertyville, Ill., has more than 35 years of experience in quality and sanitation, including nearly 30 years at Kraft Foods, where he spent his final 10 years as global director of product protection, sanitation and hygienic design. Stout is committed to the improving quality, food safety and operational effectiveness by providing ongoing support and leadership in sanitation.
Stout discusses the importance of the entire organization committing to food safety.
Meat&Poultry: How can companies prepare for the level of perfection expected from their customers and consumers?
Joe Stout: They need to step back; take a holistic look at their processes, facilities, equipment, employees and procedures; and honestly appraise where they need to improve. Once shortfalls are identified, they need to work on a continuous improvement basis to repair any shortfall. As an industry, we need to evaluate our processes, and instead of routinely doing things the same way, we should conscientiously evaluate where we can do better and practice continuously until we get it perfect and then keep practicing.
If we try this, I guarantee we will surpass our own expectations. The problem today is we are just keeping up with activity, and we don’t have or take the time to work on continuous improvement. We need to be honest with ourselves and get going if we are going to improve to the degree needed.
M&P: What equipment design changes over the past few years would you consider the most critical to improving food safety and why?
JS: I consider accessibility to be most important to effective cleaning. There is the old saying, “If you can’t see it, you cannot reach it, clean it or sample it.” It is key to conceptualize the right equipment design.
M&P: How is the process for dealing with allergens different from that of avoiding pathogen contamination? In what ways do the two processes overlap?
JS: In many ways, they would share common preventive controls such as separation (raw from RTE and allergen from non-allergen) and effective cleaning techniques that would remove each from being a contaminant. I think the real difference is that we have sanitizers that will kill pathogens on contact, while we have no such magic bullet to eliminate allergens.
M&P: When purchasing equipment, what should a plant seek in sanitary design?
JS: Most important, as a plant starts to think of a redesign, is to be linked to engineering, quality, operations, sanitation and procurement. The best sanitary project development processes are generated by cross-functional teams. They all had input into the design and ownership of the finished product. Sanitation must clean it, quality needs to monitor it, operations must run it and procurement must buy it. To get the best design for food safety, productivity, quality, cleanability and price, they must agree on what is most important and work together strategically to get it.
M&P: What is the best advice you have ever given or heard about improving food safety?
JS: Perhaps it would be to take a different approach to how we think about contact surfaces. We need to revere and respect product contact surfaces. Contact surfaces are more than a length of belt or a piece of stainless steel; they are, in fact, an intersect point that transfers our food to the dinner plates of our consumers. If we treat these surfaces with the respect due them and our consumers, we will be on our way to perfection in food safety. Consumers deserve it.
Joe Stout is the owner of Commercial Food Sanitation LLC, a consulting business providing sanitation and hygienic design consulting for the food industry. He can be reached at firstname.lastname@example.org.
Principles of Sanitary Design
The American Meat Institute developed its “10 Principles of Sanitary Design” a decade ago to help both processors and equipment manufacturers understand how they can help control pathogens. AMI has always insisted that sanitation be a shared responsibility between equipment manufacturers and plant engineers.
Joseph Bove, vice president of design for Stellar, was part of AMI’s task force for food safety that developed the principles of sanitary design. “Our objective was to develop best practices the entire industry could benefit from,” Bove says. The checklist is now a commonly used tool when designing and building new facilities and equipment, as well as renovating existing plants, he added.
The 10 principles are:
- Cleanable to a microbiological level
- Made of compatible materials
- Accessible for inspection, maintenance, cleaning and sanitation
- No product or liquid collection
- Hollow areas should be hermetically sealed
- No niches
- Sanitary operational performance
- Hygienic design of maintenance enclosures (push buttons, switches and touchscreens)
- Hygienic compatibility with other plant systems
- Validated cleaning and sanitizing protocols
Bove says the most important aspect to sanitary equipment and plant design is incorporating enough space – it’s essential to have enough space around the equipment in order to effectively clean the equipment. Bove explanined, “If maintenance and sanitation are difficult to accomplish, then they won’t happen.”