US20100206181A1 - Clean room food processing systems, methods and structures - Google Patents

Abstract

Some food pathogens are not well controlled by lethality treatments followed by refrigeration. A food processing facility according to this invention reduces the likelihood that food pathogens will be able to enter the food processing facility, or spread should they be able to enter. The food processing facility is divided into a plurality of area, with different areas having different allowed actions that can be taken on the food product, different rules and/or procedures for persons who are allowed entry, and/or different levels of cleanliness. The hod processing facility includes a plurality of separate rooms for processing the food product, each including separate food processing machines, air handling systems, drain systems and/or often-used supplies and tools. Different air pressures within different areas limit the possible movement of airborne food pathogens. Sanitizing stations are placed between various ones of the different areas.

Description

PRIORITY
• This application is a continuation application of pending U.S. application Ser. No. 10/818,944 filed Apr. 6, 2004, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• This invention is directed to systems, methods and structures for reducing the likelihood of contamination of processed foods by bacteria, other microorganisms, or other pathogens.
• 2. Related Art
• As food quality, sanitation and refrigeration practices have become better, the presence in processed foods of most common bacteria that affect food safety has been substantially reduced. While this has improved food safety overall, it presents the opportunity for more marginalized, less common bacteria and other food pathogens, which are otherwise unable to compete with such more common bacteria, to proliferate and colonize food product(s) as they are processed. For example,Listeriamonocytogenes (hereafter “LM” or “Listeria”), which is inhibited by competition from more common bacteria, and thus naturally prevented from reaching fatal concentrations, is sometimes able to colonize food product(s) as they are being processed. BecauseListeria, unlike more common bacteria and other food pathogens, is able to grow well in refrigerated conditions, and because most, if not all, competing bacteria have been eliminated from the food product(s) being processed, there is little or no competition to theListeriabacteria to keep it from growing to fatal concentrations whenListeriacontaminates food.
• At the same time, the U.S. government has instituted numerous programs and testing regimes to ensure that food products are pathogen-free, i.e., are not adulterated. For example, the presence of a food pathogen on a ready-to-eat meat product renders the meat product adulterated under the provisions of the Meat Inspection Act and/or the Poultry Inspection Act. If adulterated, the ready-to-eat meat product cannot be shipped. Additionally, if the ready-to-eat meat product has already been shipped, it must be recalled. Moreover, in most, if not all, conventional food processing facilities, even if the source of adulteration of a particular lot of food product can be traced to a single processing element, such as a food slicer, in that food processing facility, it is difficult, if not impossible, to determine which particular food items may have come in contact with that source of adulteration. As a result, the typical recall involves all products passing through a food processing facility during the time of potential adulteration to ensure that no adulterated food product remains available for sale to the ultimate consumer.
• The U.S. Department of Agriculture (USDA) has determined, for example, thatListeriais a hazard reasonably likely to occur in a slicing operation. Slicing operations are relatively high risk because pathogenicListeriamonocytogenes is ubiquitous and grows at refrigerated temperatures. Thus, becauseListeriais ubiquitous, it is very difficult to preventListeriafrom colonizing processed food product(s) at points between an upstream lethality treatment and a downstream packaging operation, such as at a slicing operation. Furthermore, because sliced meats are “ready-to-eat”, they are typically removed from packaging and consumed without any consumer-applied lethality treatment, such as cooking.
SUMMARY OF THE DISCLOSURE
• Bacteria and other food pathogens that are not well controlled by the current regimes of lethality treatment followed by refrigeration, such asListeria, provide significant challenges in preparing and packaging processed food product(s) so they do not become adulterated. For example, common industry practice is to have multiple food processing devices, such as slicers, and multiple downstream packaging machines in the single food processing room of the food processing facility. However, this provides a chance for contamination by bacteria or other food pathogens spreading from machine to machine by migration across wet floors, through the air for microorganisms, such asListeria, that are able to aerosol and float around on water droplets in the air, by food processing and supervisory personnel moving from one machine to another in the single processing room, by food processing personnel moving freely from one food processing room to another, and/or by maintenance personnel working on multiple similar and dissimilar machines within a single food processing area or freely moving between separate food processing areas.
• This invention provides food processing facilities, systems and methods that reduce the ability of bacteria and other food pathogens to spread from outside of the facilities into and through the facilities to contaminate food processing machinery and food being processed within the facility.
• This invention separately provides food processing facilities, systems and methods which place one or more food processing machines and one or more associated packaging machines forming a single set of food processing devices in a separate food processing room.
• This invention separately provides food processing facilities, systems and methods that reduce the ability of food pathogens to migrate from a contaminated location or machine and/or from outside of the facility to an uncontaminated location or machine by controlling the movement of persons between unsecure, semi-secure and secure portions of the food processing facility.
• This invention separately provides food processing facilities, systems and methods that reduce the ability of food pathogens to migrate from a contaminated location or machine and/or from outside of the facility to an uncontaminated location or machine by limiting food processing personnel to working in a single food processing rooms containing a single set of food processing devices.
• This invention separately provides food processing facilities, systems and methods that reduce the ability of contamination to migrate from an adulterated location or machine and/or from outside of the facility to an unadulterated location or machine by limiting the movement of food processing personnel between food processing rooms containing a single set of food processing devices.
• This invention separately provides food processing facilities, systems and methods that reduce the ability of contamination to migrate from an adulterated location or machine and/or from outside of the facility to an unadulterated location or machine by controlling the movement of maintenance personnel between food processing rooms.
• This invention separately provides food processing facilities, systems and methods that reduce the ability of contamination to migrate from an adulterated location or machine and/or from outside of the facility to an unadulterated location or machine by separately providing at least commonly-used maintenance materials in each separate food processing room.
• This invention separately provides food processing facilities, systems and methods that reduce the ability of contamination to migrate from an adulterated location or machine and/or from outside of the facility to an unadulterated location or machine by placing each set of one or more food processing devices and one or more associated packaging devices in a separate high-pressure area such that air flows from the high-pressure areas into areas adjacent to the high pressure areas.
• This invention separately provides food processing facilities, systems and methods that reduce the ability of contamination to migrate from an adulterated location or machine and/or from outside of the facility to an unadulterated location or machine by providing separate food processing rooms, each having separate, dedicated ventilating and/or air conditioning (VAC) systems.
• This invention separately provides food processing facilities, systems and methods that reduce the ability of contamination to migrate from an adulterated location or machine and/or from outside of the facility to an unadulterated location or machine by drawing all initial and make-up air supplied to a particular VAC system from outside the food processing facility containing the individual food processing rooms.
• This invention separately provides food processing facilities, systems and methods that use a first conveyor system to convey unpackaged lethality-treated food product(s) into a food processing room to be further processed in that room and a separate packaged food output conveyor system that conveys food product packaged in that food processing room to a downstream handling system.
• This invention separately provides food processing facilities, systems and methods that provide higher air pressure regions in the food processing rooms and lower air pressure regions around input and output conveyor systems such that air flows from the food processing room into the conveyor areas.
• This invention separately provides food processing facilities, systems and methods where each food processing room has a sloped floor leading to a dedicated floor drain and line that continues uninterruptedly from the food processing room to a point where the drain line can be plugged independently of any of the other drain lines.
• This invention separately provides food processing facilities, systems and methods for plugging the drain and filling the drain line and the lower portions of the associated food processing room with a disinfectant or the like which sanitizes the plugged portion of the drain, the room floor and the lower portions of the structures in the food processing room.
• This invention separately provides food processing facilities, systems and methods in which air is circulated into the food processing rooms at a sufficiently high velocity to dry and maintain dry the floor and any equipment services within a particular food processing room between sanitizing cleaning procedures.
• This invention separately provides food processing facilities, systems and methods where the joints between walls, walls and ceiling, and/or walls and floor are specially designed and treated to inhibit movement of water or moisture between individual floor, ceiling or wall panels, and into or between separate food processing rooms.
• This invention separately provides food processing facilities, systems and methods that use special floor-wall joint structures to inhibit moisture transfer between food processing rooms and between food processing rooms and food delivery areas, food boxing areas, and other food processing areas and from occurring beneath the walls dividing each separate food processing room from other food processing rooms and from common areas.
• This invention separately provides food processing facilities, systems and methods that include footwear sanitizing stations within the food processing facility at interfaces between different food processing and/or common areas.
• This invention separately provides food processing facilities, systems and methods for receiving food product(s) to be processed in the food processing facility and for sanitizing the exterior surfaces of the food product(s) to be processed at the food processing facility before delivering the food product(s) to be processed to the separate food processing rooms.
• In various exemplary embodiments of food processing facilities, methods and systems according to this invention, any persons entering secure and semi-secure areas of the food processing facility must wear specialized footwear, which must be sanitized upon entering and exiting semi-secure and secure areas of the food processing facility. Persons moving between various ones of the semi-secure and secure areas of the food processing facility must also pass through footwear sanitizers as they move between the different sub-portions of the food processing facility. Employees entering a secure area, where the food product is exposed, must wear a clean “secure area” uniform. All other persons entering the semi-secure areas of the food processing facility must wear designated clothing and are prevented from entering the secure areas of the food processing facility. In various exemplary embodiments, upon a person exiting the secure areas to a semi-secure or unsecure area, the current secure area uniform worn by that person must be discarded and a new sanitized secure area uniform must be worn and footwear appropriately sanitized before re-entering any secure area. Any equipment, such as tools, that are to be taken into one of the food processing rooms is desirably flushed with alcohol or otherwise sterilized before that equipment can be taken into that food processing room.
• In various exemplary embodiments of food processing facilities, systems and methods according to this invention, food product(s) to be processed entering even the semi-secure areas of the food processing facility must be pre-cooked and/or must have been otherwise subjected to appropriate protective and lethality treatments to ensure that the food product(s) are essentially free of adulterating pathogens when they enter the food processing facility. In various exemplary embodiments, the food product(s) must be received in casings, other sealing material or the like, which are also essentially free of adulterating pathogens. After being received at the food processing facility, and before any processing of the received food product(s), the casing, sealing material or the like are sanitized and the food product(s) are next removed from the casing, sealing material or the like and one or more further lethality treatments are applied to kill any pathogens that might somehow have reached the surface of the food product(s).
• After the one or more lethality treatments, the received food product(s) are transported, for example, by conveyor through a food produce delivery area, to each of the separate food processing rooms for further food processing. In general, the food product(s) delivery areas through which the food product(s) pass between the final lethality treatments and the food processing rooms are also treated as secure or sterile regions such that any source of contamination is excluded from such regions. In various exemplary embodiments, the food product(s) pass from the delivery area, which is at a first pressure, through a delivery opening into a particular food processing room, which is maintained at a higher air pressure, such that air moves unidirectionally through the delivery opening in the direction opposite that of the food product(s) as they enter that food processing room.
• In various exemplary embodiments of food processing facilities, systems and methods according to this invention, once in a given food processing room, the food product(s) is processed and immediately packaged for transport out of the food processing facility while in that food processing room. The packaged food product(s) is then transported, for example, by conveyor, out of the higher air pressure food processing room into a second common area. Because the food processing room is also at a higher pressure than this second common area, air constantly moves unidirectionally through the exit opening in the direction of movement of the packaged food product(s). The packaged food product(s) from the various food processing rooms are then inspected for package integrity, further packaged, held under refrigerated conditions and prepared for transport to a customer for sale to the ultimate consumer. Any inspected package which lacks integrity is rerouted for another lethality treatment before repackaging in the food processing room from which it came.
• In various exemplary embodiments of food processing facilities, systems and methods according to this invention, should one of the isolated food processing rooms become contaminated, that room can be shut down and sterilized without affecting the operation of other food processing rooms. Furthermore, because all of the food product processed in that food processing room were separately packaged and identified while in that food processing room, the food product from that food processing room is inherently distinguishable from the food products processed in the other food processing rooms, and thus can be separately recalled or otherwise destroyed. If contaminated, that food processing room can then be sterilized using a combination of one or both of heat and chemical sanitizers. In addition, the drain for that room can be separately plugged and flushed for sanitizing reasons without affecting the operation of the drain lines of the other food processing rooms.
• In various exemplary embodiments of food processing facilities, systems and methods according to this invention, when repair or maintenance of the machinery in a given food processing room is required, maintenance personnel entering that food processing room must also be wearing secure area uniforms and go through the same sanitary procedures as the operators working in that food processing room. In various exemplary embodiments, if the maintenance personnel are coming from another food processing room, those maintenance personnel desirably don new, sanitary food processing uniforms.
• In various exemplary embodiments of food processing facilities, systems and methods according to this invention, each of the food processing rooms contains all of the supplies and tools necessary to perform common maintenance procedures and to repair the food processing equipment due to common or expected faults. Accordingly, for simple or common repairs or maintenance, the maintenance personnel do not need to carry any tools or supplies into that food processing room. If more unusual repairs or maintenance needs to be made, any parts, supplies or tools that must be carried into that food processing room by the maintenance personnel are desirably first subjected to an alcohol wash or other appropriate cleaning and/or sterilizing procedure before those parts, supplies and/or tools are carried by the maintenance personnel into that food processing room.
• These and other individual features and advantages which may be separately incorporated in various exemplary embodiments of systems and methods according to this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of the systems, methods and facilities for processing food according to this invention.
BRIEF DESCRIPTION OF DRAWINGS
• Various exemplary embodiments of the systems, methods and food processing facilities of this invention will be described in detail, with reference to the following figures, wherein:
• FIG. 1 is a schematic top plan view of a first exemplary embodiment of a food processing facility and food processing systems according to this invention;
• FIG. 2 is a schematic top plan view illustrating one exemplary embodiment of a drain system usable with the first exemplary embodiment of the food processing facility and related systems according to this invention shown inFIG. 1;
• FIG. 3 is a schematic top plan view of a second exemplary embodiment of a food processing facility and related systems according to this invention;
• FIG. 4 is a cross-sectional view of second and third exemplary embodiments of curb structures according to this invention;
• FIGS. 5 and 6 are schematic top and side views, respectively, of a first exemplary embodiment of a ventilating and air conditioning system for a food processing room according to this invention;
• FIGS. 7 and 8 are a flowchart outlining one exemplary embodiment of a method for processing a food product according to this invention;
• FIGS. 9 and 10 are a flowchart outlining one exemplary embodiment of a method for controlling movement of personnel within a food processing facility according to this invention; and
• FIG. 11 is a flowchart outlining one exemplary embodiment of a method for providing heating, ventilation and air conditioning to a given food processing room according to this invention.
DETAILED DESCRIPTION OF DISCLOSED EMBODIMENTS
• As developed countries, such as the United States, consume ever larger percentages of processed food products, the safety of such processed food products has become of paramount importance. As a result, various governmental agencies in such developed countries have promulgated various rules and regulations which have improved food quality and safety and have substantially eliminated contamination or adulteration of such processed food products by most common food-born pathogens.
• However, this has opened up the possibility of contamination or adulteration by more marginalized food pathogens. That is, the most common food pathogens are those that grow most readily and rapidly on food products at room temperatures in standard environments, and can be controlled or lethally treated by refrigeration and heat treatment. However, in the absence of such pathogens controlled or eliminated by conventional refrigeration and heat treatment, other pathogens have shown the ability to grow and prosper under refrigerated conditions.
• For example,Listeriamonocytogenes (“LM” or “Listeria”) is one such bacteria that is better able to tolerate colder temperatures than more common bacterial species. As a result,Listeriais able to successfully colonize and multiply at refrigeration temperatures that control the growth of more common bacteria. In fact,Listeriacolonies can grow to concentrations in refrigerated processed food products that can cause fatal side affects in humans when such processed food products are consumed. As a result, current food safety standards generally require that contamination or adulteration of processed food products byListeriabe, ideally, completely avoided.
• The following detailed description of various exemplary embodiments of food processing facilities, systems and methods according to this invention are described relative to controlling the risk ofListeriamonocytogenes adulteration of processed meat products. However, it should be appreciated that the food processing facilities, systems and methods illustrated by the exemplary embodiments described herein are equally applicable to other types of processed food products, such as dairy products, fruit and vegetable products, and the like. Moreover, it is likely that other bacteria and other pathogenic microorganisms, in addition toListeria, such asSalmonella, are or will become of concern in the future. It should be appreciated that the food processing facilities, systems and methods according to this invention illustrated by the following exemplary embodiments are equally useful in reducing the ability of other pathogenic microorganisms to adulterate processed food products, such as meat products, dairy products, fruit and/or vegetable products, or the like. However, for ease of understanding and simplicity of discussion, the following detailed descriptions will disclose food processing facilities, systems and methods for reducing contamination or adulteration of processed meat products with particular reference toListeria.
• FIG. 1 is a schematic top plan view of a first exemplary embodiment of afood processing facility100 according to this invention that employs “single-line” food processing rooms and clean room-like procedures to both reduce the ability ofListeriamonocytogenes or other pathogens to initially contaminate a single-line food processing room or other area of thefood processing facility100 from outside of thefood processing facility100, and, if a single-line food processing room or other area of thefood processing facility100 should become contaminated, reduce the likelihood that the contamination will spread to other single-line food processing rooms or other areas of thefood processing facility100. In particular, thefood processing facility100 shown inFIG. 1 is a meat and cheese slicing facility. However, it should be appreciated that various ones of the different structures of thefood processing facility100 described herein can be applied to food processing plants designed for processing other types of food products and other types of food processing operations.
• As shown inFIG. 1, previously-processed meat products are received at a receivingarea118 of thefood processing facility100 and stored in a foodproduct storage cooler110 until such time as a particular portion of the received food product is ready for further processing in thefood processing facility100. It should be appreciated that, in various exemplary embodiments, to reduce the likelihood that the food product to be processed in the food processing facility is not contaminated when it is received at thefood processing facility100, only previously processed food products, such as previously cooked meat products, are received and processed by thefood processing facility100. In various exemplary embodiments, to reduce this risk as much as possible, any raw or untreated food products are denied entry into thefood processing facility100. In various exemplary embodiments, the received processed meat product is a relatively long tubular cooked meat product which will be subsequently sliced at thefood processing facility100. Such long tubular cooked meat products are commonly referred to as “logs”. In various exemplary embodiments, theselogs114 have been encased in a sealed plastic casing after cooking and prior to arrival at thefacility100.
• In various exemplary embodiments according to this invention, the received food products, such as the encased logs, as received, are stored in specialized stainless steel containers, racks, or any other appropriate device that can be used to transfer the received food product to the food processing facility. Thecontainers116 allow different lots of the processed meat product or other received food product to be kept separately from other lots to avoid cross-contamination while the received food products are being transported and/or while the received food products are awaiting further processing. In various exemplary embodiments, the received ready-to-eat food products to be processed in thefood processing facility100 are transported to thefood processing facility100 on a “just-in-time” schedule. However, even in this case, it is often necessary to temporarily store thecontainers116 in thestorage cooler110. By using thecontainers116, only limited amounts of the processed food product need to be exposed when removing thelogs114 from thecontainers116 for transport into the secure areas of thefood processing facility100. It should be understood that, in various exemplary embodiments, conventional enclosures (not shown) are used between the trailer of the delivery truck and the doorway to the receivingarea118 of thefood processing facility100 to minimize the possibility of contamination of the food product while moving thecontainers116 from the trailer to the receivingarea118 of thefood processing facility100.
• The receivingarea118 where thecontainers116 of received food product enter thefood processing facility100 and thestorage cooler110 are two portions of asemi-secure region104, which also includes abuffer zone115, that lies between generally unsecured areas where little or no effort is made to ensure that food pathogens are not present, and secure areas of thefood processing facility100, where extensive efforts are made to prevent food pathogens from entering such areas and to inhibit the spread of food pathogens should any be present in the secure areas. It should be appreciated that the terms “secure” and “semi-secure” refer to the efforts to exclude food pathogens and other microorganisms, and not to efforts directed to preventing theft, unauthorized access, terrorism or the like.
• In various exemplary embodiments, when a food log114 (or any other processed food product) is to be removed from thestorage cooler110 for further processing, thecontainer116 containing thatlog114 is typically removed from thestorage cooler110 and placed adjacent to aconveyor112. Thelog114 is removed from itscontainer116 and placed onto theconveyor112, which conveys thelog114 into atreatment room120. Thetreatment room120 is used to reduce the presence of, and ideally completely remove, any bacteria or other pathogenic microorganisms, which may have opportunistically colonized the processed food products, before the processed food product is transported into thefood processing facility100.
• For example, for processed ready-to-eatmeat logs114, as previously indicated, the meat logs114 are typically sealed in plastic casings when received from the upstream food processing facility that formed the processed meat logs114. In various exemplary embodiments, the plastic-encasedmeat logs114 are transported in thecontainers116 from thestorage cooler110, removed from thecontainers116 and placed onto theconveyor112, which conveys thelogs114 through a sanitizingwasher111 to remove any pathogens which may be present on the exterior of the casing, and into thetreatment room120, where the cleansed plastic casing is removed from around the processedmeat log114 and discarded. The exterior surface of the processedmeat log114 is then subjected to a post-lethality treatment to reduce, and ideally eliminate, any bacteria or other pathogenic microorganisms that may have colonized the surface of the processedmeat log114.
• In various exemplary embodiments, the term “post-lethality treatment” means a treatment that is applied to the processed meat log114 (or other food product to be processed in the food processing facility100) after it was subjected to cooking or another upstream lethality treatment at the upstream food processing facility before being packaged for transport to thefood processing facility100. In various exemplary embodiments of thefood processing facility100, the post-lethality treatment applied in thetreatment room120 comprises running the meat log through atreatment device122 and/or an infrared tunnel125 (shown in the area130) that heats the entire surface of the processedmeat log114 to a sufficiently high temperature that any pathogenic bacteria or other microorganisms which may be present on the surface of themeat log114 are expected to be killed. Thetreatment device122 can be a hot liquid bath, such as a hot oil bath or hot water bath, or a steam treatment device, or another appropriate device that obtains a product surface temperature that results in a 2 log reduction in the pathogen. In another exemplary embodiment, the meat log may be run through a conventional chemical sanitizer (not shown) employing, for example, a sanitizing solution comprising chlorine or peracedic acid. The treated meat log114 (or other processed food product) is then transported on aconveyor124 from thetreatment device122 and/or125 that is within thetreatment room120 into adelivery area130. In various exemplary embodiments, theconveyor124 may deliver the treatedmeat log114 to acruster128, such as a Vertical Rapid Cluster manufactured by Unitherm Food Systems of Bristow, Okla., which creates a uniform frozen crust in the surface of themeat log114 to improve the sliceability of themeat log114. From thecruster128, theconveyor124 delivers the crustedmeat log114 to adistribution conveyor132 located in thedelivery area130. Thedistribution conveyor132 is used to convey aparticular meat log114 or other treated food product to a desired one of a plurality of single-linefood processing rooms140.
• It should be appreciated that, in various exemplary embodiments, thetreatment room120 is another portion of thesemi-secure region104. In such exemplary embodiments, while the food product is unsealed and exposed in thetreatment room120, because of the treatment applied in thetreatment room120, thetreatment room120 does not need to be part of thesecure area106. However, if desired, thetreatment room120 can be made part of thesecure area106. It should also be appreciated that, in various exemplary embodiments, thetreatment room120 is equipped with anexhaust system121 for maintaining a slightly negative atmospheric pressure in thetreatment room120. Thus, air will be pulled out of the delivery-area130 into thetreatment room120, and then, together with any fumes from thefryer122, is exhausted out of thefacility100 to the outdoors by the exhaust system.
• Alternatively, one or moreinfrared tunnels125 may be located in thedelivery area130, as shown inFIG. 1. Accordingly, in various other exemplary embodiments, while a lethality treatment is applied to aparticular log114 or other processed food product, that log114 or other processed food product does not go through thetreatment room120. In this case, a dedicated lethality treatment or device may be provided for one or more sets of one or more suchfood processing rooms140 that process such a log or other processed food product. For example, if the treatment applied in thetreatment room120 is applied using a heated oil bath, but the customer does not want the processed food product to go through such a process, or the food product cannot withstand such a treatment, that food product will skip thetreatment room120. In this case, the food product can be removed from itscontainer116 and the outside of the casing sanitized. The sanitized food product is then delivered to thedelivery area130, the casing removed, and the uncasedfood product114 transported to the appropriatefood processing room140. At some point between having the casing removed and being transported into the appropriatefood processing room140, the lethality treatment, such as passing through aninfrared tunnel125 shown inFIG. 1, or the like, is applied to the uncasedfood product114 while in the delivery area.
• The various single-linefood processing rooms140 are the only locations within thefood processing facility100 where the food product to be processed, such as the meat logs114, is actually processed, other than receiving lethality treatments, such as those described above. It should be appreciated that only a single line of food processing devices may be provided in each of the various “single-line”food processing rooms140. This remains the case even if the single line of food processing devices in a givenfood processing room140 is divided into two separate food processing paths or sets, as there is a single food product inlet from thefood delivery130 to a single-linefood processing room140 and a single outlet from a single-linefood processing room140 to a packagedfood receiving area150. The food processing devices in that single-linefood processing room140 are independent of the food processing devices in any other single-line food processing room. In any case, the product packaged in any such single-linefood processing room140 will receive an unique identity code, printed on the package, which will enable the operators to trace every package produced in thefood processing facility100 back to the individualfood processing room140 in which it was processed and packaged.
• In various exemplary embodiments, each set or line of devices in a single-linefood processing room140 includes two or more serially-connected food processing elements. For example, in various exemplary embodiments of thefood processing facility100, each of the single-linefood processing rooms140 is a slicing room where the meat logs114 are converted into sliced meat product. In some exemplary embodiments of such slicing rooms, the output of an upstream food processing device is directed to a single downstream food processing device and only one such line is present in any given single-linefood processing room140. For slicing operations, a single-linefood processing room140 will typically include a slicingmachine142 and apackaging machine146.
• It should also be appreciated that, in various exemplary embodiments according to this invention, any food product leaving a single-linefood processing room140 will be packaged before it leaves that single-linefood processing room140. It should be appreciated that “packaged” generally encompasses providing a sealed barrier between the processed food product and its ambient environment, such that any pathogens in the ambient environments that the processed food product experiences after leaving the single-linefood processing room140 and until the opening of the package, either by the end consumer or within another downstream food processing facility, are unable to penetrate the barrier and contaminate or adulterate the processed food product.
• As shown inFIG. 1, atransfer conveyor134 receives the meat logs114 or other processed food product from thedistribution conveyor132 and conveys the meat logs114 or other processed food product from thedelivery area130, through a passage or opening in a wall separating that single-linefood processing room140 from thedelivery area130, and into the interior of the single-linefood processing room140. It should be appreciated that the processed food product can go directly from thetreatment room120 to one of the single-linefood processing rooms140. In various other exemplary embodiments, the treated food product is chilled, for example, by using thecruster128 described above, before being delivered to the single-linefood processing room140. Using thecruster128 both reduces the surface temperature of thelog114, and arrests any bacterial activity that could otherwise occur on the surface of thatlog114 after passing through the oil bath or infrared tunnel, and also beneficially makes thelog114 easier to slice. Thechilled log114 or other food product is then transported to the appropriatefood processing room140 as described above.
• It should be appreciated that, in various exemplary embodiments, the passage or opening for theconveyor134 through the wall separating the single-linefood processing room140 from thedelivery area130 is desirably sized on the order of themeat log114 or other processed food product being conveyed by thetransfer conveyor134. It should also be appreciated that the single-linefood processing room140 is desirably kept at a higher internal pressure and a colder temperature than the pressure and temperature within thedelivery area130. As a result, there is a positive or increasing pressure gradient along the direction of travel of thetransfer conveyor134 such that there is an unidirectional air flow out of the single-linefood processing room140 into thedelivery area130. This ensures that any pathogens which may be present in the atmosphere in thedelivery area130, however unlikely, cannot travel by aerosol action or air flow from thedelivery area130 into a particular single-linefood processing room140.
• Once in a given single-linefood processing room140, each meat log114 or other processed food product received from thedelivery area130 passes generally (i.e., more or less) serially through the various food processing and/or packaging machines that form the single food processing line contained within that single-linefood processing room140. As shown inFIG. 1, themeat log114 or other processed food product transported by thetransfer conveyor134 travels to afeeder station142, where themeat log114 or other processed food product is fed to a slicingmachine143 and sliced into a plurality of separate slices of a desired thickness. A number of slices are gathered into a portion and the plurality of slices of the sliced food product forming a portion are then conveyed together by asecond transfer conveyor144 to, and packaged by, apackaging machine146. In various exemplary embodiments, the sliced meat or other processed food product is packaged into thermoformed plastic cavities, which are then flushed with a gas as a plastic sheet is heat sealed to the cavity rim to form a hermetic or other impervious seal. In contrast, in various other exemplary embodiments, the sliced meat or other processed food product portion is vacuum packaged and sealed while in the single-linefood processing room140.
• It should be appreciated that, in various other exemplary embodiments, different types of food processing equipment will be contained within the single-linefood processing room140. In some exemplary embodiments, regardless of the types and numbers of food processing devices contained within the single-linefood processing room140, the various food processing devices will be organized such that a single line or series of food processing devices, through which all of the receivedmeat logs114 or other processed food products pass, is formed. That is, in such exemplary embodiments, the various food processing devices contained within the single-linefood processing room140 are not organized into two separate, effectively parallel lines or the like. By having only a single line of series-connected food processing devices in each single-linefood processing room140, each single-linefood processing room140 becomes essentially a separate food processing facility.
• Thus, if any one of the food processing devices in a single one of the single-linefood processing rooms140 becomes contaminated, only the processed food product which passed through that single-linefood processing room140 could be contaminated. Should a particular lot of processed food product which passed through that single-linefood processing room140 need to be recalled and/or destroyed before shipping, that processed food product lot can be dealt with in the knowledge that none of the other processed food products produced by the other single-linefood processing rooms140 in thefood processing facility100 need to be recalled the contamination present only within that first single-linefood processing room140. Likewise, should a particular device within the single-linefood processing room140 become contaminated, there will be a concern that all of the processed food product passing through that single-linefood processing room140 during the contamination period may have come into contact with that particular contaminated food processing device and thus, may need to be recalled and/or destroyed or otherwise rehabilitated.
• However, it should be appreciated that, in less rigorous exemplary embodiments, a particular “single-line”food processing room140 could contain more than one of a particular type of food processing equipment that is fed by a set of one or more input conveyor(s) and discharged to a set of one or more output conveyor(s). However, in this case, while the risk of cross-contamination between food processing lines in differentfood processing rooms140 has been reduced, the ability ofListeriaor other pathogenic microorganisms to cross contaminate parallel machines within a single-linefood processing room140 is not inhibited.
• The packaged food product is then output from thepackaging device146 on to athird transfer conveyor148. Thethird transfer conveyor148 transports the packaged food product into the receivingarea150. In particular, thethird transfer conveyor148 passes through a passage or opening in a wall that separates the single-linefood processing room140 containing thattransfer conveyor148 from the receivingarea150. In various exemplary embodiments, the passage or opening is desirably sized on the order of the size of the packaged food product being transferred out of that single-linefood processing room140.
• In various exemplary embodiments, as the packaged food product enters the receivingarea150 on thethird conveyor148, the packaged food product is inspected. If the inspection reveals that a particular packaged food product needs to be re-packaged, that packaged food product is placed on a return conveyor (not shown) that conveys that packaged food product back into thefood processing room140 that it came from. The returned packaged food product's package is sanitized before or as it enters that single-linefood processing room140. Once in thatfood processing room140, the returned food product package is opened and disposed of and the returned food product is placed into a new package and resealed.
• In contrast, in some exemplary embodiments, thethird transfer conveyor148 deposits the packaged processed food product from that single-linefood processing room140 onto acollection conveyor152 that collects various processed and packaged food products from the various single-linefood processing rooms140. Once on thecollection conveyor152, the packaged processed food product can be inspected, boxed, collected and/or palletized for shipping to a finished product cooler, a warehouse, or the ultimate consumer.
• It should also be appreciated that, like thedelivery area130, the receivingarea150 is at a lower atmospheric pressure and temperature than the single-linefood processing rooms140, although the receivingarea150 does not need to be at either the same pressure or the same temperature as thedelivery area130. As a result, there is a decreasing, or negative, pressure gradient along the direction of travel of thethird transfer conveyor148 as it passes through the opening in the wall separating the single-linefood processing room140 from the receivingarea150. As a result, there is a unidirectional air flow from the single-linefood processing rooms140 into the receivingarea150, effectively preventing the migration of any pathogens present in the receivingarea150 into the single-linefood processing rooms140 through the limited openings in the walls separating the single-linefood processing rooms140 from the receivingarea150. Likewise, there will be a similar unidirectional air flow from the single-linefood processing rooms140 to the receivingarea150 surrounding the return conveyors (not shown) and the packages being returned to the single-linefood processing rooms140 for repackaging.
• To further reduce the ability ofListeriaand other pathogenic microorganisms from migrating from place to place within thefood processing facility100, thefood processing facility100 is divided into thefirst region102, thesecond region104 and thethird region106. In general, thefirst region102, which corresponds to the unsecured area, includes such facilities as locker rooms where the personnel employed in thefood processing facility100 can change their clothes, lunch and/or break rooms where the personnel can take their breaks and/or eat breakfast, lunch or dinner, restrooms, offices for the management personnel for thefood processing facility100 and the like. Thefirst region102 can also include conference and meeting rooms, visitor reception areas and the like. Because these areas are in thefirst region102, rather than in thesecond region104, it is likely that the personnel employed by thefood processing facility100 will make multiple trips between thefirst region102 and the second orthird regions104 or106 during the typical work shift. Thesecond region104, which corresponds to the semi-secure area, includes aclean uniform storage117 in thebuffer zone115, thestorage cooler110, the receivingarea118, thetreatment room120, and the receivingarea150. Thethird region106, which corresponds to the secure areas, includes thedelivery area130 and the various single-linefood processing rooms140.
• In general, movement within thefirst region102 and access to thefirst region102 from outside thefood processing facility100 by authorized personnel is generally not restricted. Accordingly, employees and other authorized personnel can freely enter thefirst region102 from thesecond region104 and from outside thefood processing facility100. Thus, thefirst region102 can be referred to as an “unsecure area”. In contrast, access to the various rooms and areas forming thesecond region104 and movement between those regions and thefirst region102 is strictly controlled. In particular, movement between thefirst region102 and thesecond region104 requires passing through a sanitizingstation160, such as the sanitizingstation161 located between thefirst area102 and thebuffer zone115. In addition, in various exemplary embodiments, movement from thefirst region102 into thesecond region104 requires that special clothing or uniforms be donned prior to or immediately after passing through the sanitizingstation161. Similarly, moving from thesecond region104 into thefirst region102 requires passing through the sanitizingstation161 and removal of the special clothing or uniform.
• In various exemplary embodiments, the required clothing includes rubber boots or other appropriate footwear that is generally impervious to liquids and from whichListeriaand other pathogenic microorganisms can be relatively easily removed. In such exemplary embodiments, the sanitizingstation161 includes footwear scrubbing and/or sanitizing devices that use both mechanical devices and chemical applications to remove and/or kill any bacteria that may be present on the rubber boots. When personnel pass between the first andsecond regions102 and104, they are required to pass through the sanitizingstation161 to ensure that noListeriaor other pathogenic microorganisms that may be present on the employees' footwear survives the sanitizing station, such that such microorganisms are not transported between the first andsecond regions102 and104.
• In various other embodiments, in addition to or instead of the rubber footwear, the specialized clothing can include head coverings, smocks and other over-clothing, and even can include specialized clean room-type sanitized suits or uniforms. Additionally, in various exemplary embodiments, personnel leaving thesecond region104 and entering thefirst region102, before or after passing through the sanitizingstation161, are required to remove the specialized clothing and recycle it for sanitizing.
• Because reasonably strict procedures, including that cooked-only food product be stored and processed in thesecond region104, the type of food processing not permitted in thesecond region104, and the movement of food processing personnel between thefirst region102 and thesecond region104, are designed to reduce the likelihood thatListeriaor other pathogenic microorganisms are able to enter or migrate into theregion104, theregion104 can be referred to as a semi-secure area. Additionally, in various exemplary embodiments, in addition to controlling how the food processing personnel move between thefirst region102 and thesecond region104, the types of personnel that are permitted to move between thefirst region102 and thesecond region104 can also be controlled. In various exemplary embodiments, access to thesecond region104 can be limited to food processing personnel and visitors having designated certifications, such as having completed food safety specialist training and certification.
• Once in thesecond region104, access to thedelivery area130, the receivingarea150, and the single-linefood processing rooms140 can be further controlled by requiring food processing personnel to pass through further sanitizingstations160 between thesecond region104 and thedelivery area130, the receivingarea150 and the single-linefood processing rooms140. Thus, in such exemplary embodiments, the food processing personnel pass through additional sanitizingstations160 to enter thedelivery area130, the single-linefood processing rooms140, or thereceiving room150 from thebuffer zone115, and when passing back into thebuffer zone115 from the single-linefood processing rooms140, thedistribution area130, or the receivingarea150.
• In various exemplary embodiments, while access to thebuffer zone115 may be permitted, access to thethird region106, i.e., at least thedelivery area130 and the single-linefood processing rooms140, can be limited to food processing personnel having completed food safety specialist training and certification and having specific duties within such areas. Furthermore, in various exemplary embodiments, access to the single-linefood processing rooms140 is further limited only to operators of the machines forming the single-line food processing system in the single-linefood processing room140, to supervisors and quality control/assurance personnel, and to maintenance personnel who require entry into a particular single-linefood processing room140 in order to maintain and/or repair the equipment in that single-linefood processing room140. In various exemplary embodiments, any food processing personnel entering such a single-linefood processing room140 must wear a clean room-style protective suit or other appropriate full-body covering, in addition to the prescribed footwear. Similarly, in various exemplary embodiments, any food processing personnel entering thedelivery area130 are also required to wear such a clean room-style protective suit or other appropriate full-body covering. In various exemplary embodiments, if a food processing employee moves from thethird region106 back out into any portion of thesecond region104, that person must remove the protective suit or other full body covering and don a new such protective suit or full-body covering before re-entering thethird region106.
• Thus, the likelihood is reduced that anyListeriaor other pathogenic microorganisms that have been able to migrate into the second orthird regions104 or106 will be able to migrate further into thethird region106, i.e., into thedelivery area130, or even further into the single-linefood processing rooms140. Likewise, the likelihood that anyListeriaor other pathogenic microorganisms which may be present in a particular single-linefood processing room140 will migrate out of that single-linefood processing room140 into either the other areas of thesecond region104 or another single-linefood processing room140 is reduced. Because of the additional controls on movement of personnel between thethird region106, i.e., the single-linefood processing rooms140 and thedelivery area130, and the other portions of thesecond region104, thedelivery area130 and the single-linefood processing rooms140 can also be referred to as the “secure areas”.
• FIG. 2 illustrates a first exemplary embodiment of a drain system usable in thefood processing facility100 according to this invention. Conventional drains are a potential source of environmental contamination. This drain system forms another aspect of thefood processing facility100 that is usable to reduce the likelihood thatListeriaor other pathogenic microorganisms will migrate from the other portions of thethird region106 or thesecond region104 into the single-linefood processing rooms140, or vice versa, or between individual single-linefood processing rooms140. As shown inFIG. 2, each single-linefood processing room140 has its own dedicated drain line180-187. As shown inFIG. 2, each drain line180-187 extends directly from a particular single-linefood processing room140 to one of a number of collection manholes or catchbasins170, such as the manholes or catchbasins171,172, and173.
• In particular, as shown inFIG. 2, the various drain lines180-187 do not intersect each other prior to reaching theparticular catch basin170 to which they are connected. Additionally, the outlet of each of the drain lines180-187 connects to and preferably discharges by gravity into thecorresponding catch basis170 at a location that is spaced apart from the outlets of the other drains180-187 both circumferentially, as can be seen inFIG. 2, and/or axially. That is, the outlet for each drain180-187 into the correspondingcatch basin170 is spaced apart from the other outlets both along the circumference of thecatch basin170 and along the axis of thecatch basin170 that extends into and out of the drawing ofFIG. 2. Accordingly, any waste materials flushed down a particular one of the drains180-187 from a particular single-linefood processing room140 into the correspondingcatch basin170 generally will not splash into, be directed into, or otherwise contaminate any of the other ones of the drains180-187 that are connected to thatcatch basin170. WhileFIG. 2 shows only food processing room drains180-187, it should be understood that thefacility100 will have as many such drains as there are such single-linefood processing rooms140.
• Furthermore, thecommon drain lines190, such as thedrain lines191 and192, which are designed to receive waste materials from, for example, thedistribution room130 and/or thereceiving room150, respectively, are also connected to thecatch basins170 at locations that are spaced apart from the drain lines180-187 both circumferentially and/or axially, so that waste from the various single-linefood processing rooms140 does not contaminate thedrain lines190 or vice versa. In various exemplary embodiments, the drain lines180-187 are designed with minimum bends or elbows, such that there are minimal locations in the drain lines180-189 where waste material can collect within those drain lines180-187.
• In various exemplary embodiments, each of the drain lines180-187 can be fitted with an end cap, damper orvalve188 or other appropriate device that allows that drain line180-187 to be sealed, such that it can be backfilled for its entire length from the corresponding single-linefood processing room140 with a cleaning and/or sanitizing agent or the like. In various exemplary embodiments, this would allow that drain line180-187, if it were to become contaminated withListeriaor other pathogenic microorganisms, to be cleaned and/or sterilized to remove such contamination. In various exemplary embodiments, such caps, valves or other appropriate structures are located at the outlet ends of the drain lines180-187 at the catch basins.170. In various exemplary embodiments, thecatch basins170 are connected to a waste disposal system, such as a sewer system, a waste water treatment system, or the like. In various exemplary embodiments, thecatch basins170 are located outside of the walls of thefood processing facility100.
• In various exemplary embodiments, the floors of the single-linefood processing rooms140 are sloped toward thedrain fixtures194 at the upper ends of the drain lines180-187, such that any liquids, including cleaning and flushing liquids which may drop or be directed onto the sloped floors, are directed into thedrain fixtures194 and the drain lines180-187, regardless of where in the single-linefood processing room140 the liquid may contact the floor. In various exemplary embodiments, thedrain fixtures194 may be constructed of anti-microbial stainless steel, such as are supplied by Unitherm Food Systems of Bristow, Okla.
• FIG. 3 illustrates a second exemplary embodiment of afood processing facility200 according to this invention. It should be appreciated that the structures shown inFIG. 3 generally correspond to similar structures shown inFIG. 1 and/orFIG. 2, including door openings and doors between the various rooms and areas as shown inFIGS. 1 and 2, and otherwise as may be necessary or convenient.FIG. 3 additionally shows a number of exemplary curb structures used within thestorage cooler210, thetreatment room220, thedelivery area230, the various single-linefood processing rooms240, the receivingarea250 and the other regions which form the various portions of thesecond region104. These curbs are located at the base of the walls of the various portions of thefood processing facility200 used to divide the space within thesecond region104 into the various rooms discussed above. These curbs may include three different types of curbs, which have increasing abilities to slow down or prevent the migration ofListeriaor other pathogenic microorganisms along or under the walls within theregions104 and106.
• As shown inFIG. 3, these curbs include a first type ofcurb202, which is used to line the interior surfaces of walls of those spaces where the processed food product that is processed within thefood processing facility200 is not expected to be present. This first type ofcurb202 can also be used to line those walls where the processed food product is present in only a packaged state. Such regions includehallway areas262,maintenance areas264, drysupply storage area260, the receivingarea250, ashipping dock area270 and the like.
• The second type ofcurb204 is used to line those walls where it is likely that the processed food product to be processed in thefood processing facility200 will be present, either in a sealed casing or in an unpackaged state but is not being processed. Such regions include thestorage cooler area210, thebuffer zone215, thetreatment room220, thedelivery area230 and adjacent areas. A third type ofcurb206 is used to line the interior walls of the single-linefood processing rooms240.
• In general, the first type ofcurb202 provides relatively lesser protection against the migration ofListeriaand other pathogenic microorganisms. The second type ofcurb204 provides an intermediate level of protection against migration ofListeriaand other pathogenic microorganisms. The third type ofcurb206 provides relatively greater protection against the migration ofListeriaand other pathogenic microorganisms. In general, the curbs202-206 protect against migration of such pathogenic microorganisms along and under the walls separating the various spaces within theregions104 and106 of thefood processing facility200. In particular, the curbs202-206 generally prevent water and other liquids from moving from the enclosed spaces within theregions104 and106 to spaces under the walls, either along the walls or to the other sides of the walls, becauseListeriaand other pathogenic microorganisms can be carried by movements of water and other liquids under the walls and into other spaces within theregions104 and106 of thefood processing facility200 unless measures are taken to prevent such intrusions and movements.
• FIG. 3 also shows one exemplary embodiment of a cooling and air circulation system for thestorage cooler210, thedelivery area230, the receivingarea250, theshipping dock area270 and thefinished product cooler280, which includes a plurality of evaporatorcooler fans196 mounted in the upper portions of the identified areas. The evaporator coolers may be positioned parallel to one or more walls of an enclosed space, as shown in thestorage cooler210, theshipping dock area270 and thefinished product cooler280, or perpendicular to a wall as shown in back-to-back relation in the elongated spaces of thedelivery area230 and the receivingarea250, or in any other position which will result in a vigorous circulation of cold air sufficient to provide constant air movement over surfaces of and/or within the identified areas and their contents to prevent the condensation or accumulation of moisture on any such surfaces. The maintenance of dry surfaces within thefacility200 by the circulation of cold air minimize the opportunities forListeriaor other pathogens to colonize on, and subsequentially spread from such surfaces within such areas to elsewhere within thefacility200.
• FIG. 4 shows one exemplary embodiment of a wall andfloor structure300 and various exemplary embodiments ofcurb structures400 and500 usable infood processing facilities100 or200 according to this invention. As shown inFIG. 4, the wall andfloor structure300 comprises afloor310 against or into which awall340 is set. In general, thefloor310 is formed of concrete or other hard and generally impervious substance and may be coated with a lithium-based sealant or other appropriate protective coating. In various exemplary embodiments, thewalls340, as well as the ceilings, are constructed of 4″thick freezer panels344 with urethane foam insulation or the like having an insulating value of R43.5. Typically, all joints between wall andceiling panels340 are dovetailed to provide foam-to-foam interfaces and are caulked to prevent any movement of water between or along the panels. Thewalls340 may include galvanizedsteel skins342 placed on both sides of thefoam panels344. In various exemplary embodiments, water-impervious polymer coatings are formed over the steel skins342.
• It should be appreciated that, in various exemplary embodiments, thecurbs202 are formed of concrete as shown inFIG. 4 coated similarly to thefloor310. In contrast, in various exemplary embodiments, thecurbs204 and206 are keyed stainless steel curbs such as that shown inFIG. 4. In various exemplary embodiments, thecurbs206 use anti-microbial stainless steel curbs manufactured by Unitherm Food Systems. Thecurbs204 are standard stainless steel.
• As shown inFIG. 4, a simpleconcrete curb400 includes aconcrete mass420 that contains reinforcing iron bars410. Theiron rebar410 also attaches theconcrete curb400 to thefloor310. Caulking or other sealants are provided at the joints between theconcrete curb400 and thefloor310, and the concrete400 and the galvanizedsteel skin342 on awall340.
• As further shown inFIG. 4, a second type ofcurb500 includes agroove510 cut into thefloor310, as well as reinforcingiron bars520 that extend into thefloor310. Aconcrete mass530 extends around the reinforcingiron rebar520. Astainless steel cover540 extends around theconcrete mass530 and into thegroove510. The top of thestainless steel curb540 is connected to the stainless steel skin of thewall340. An epoxy or polyurethane or thelike seal550 is placed in and/or around thegroove510 to seal thestainless steel curb540 into thegroove510 to form an impervious barrier to liquids that may be present on thewall340 and/or thefloor310. It should be appreciated that thecurb structure500 is particularly useful as thecurbs204 and206 described above. Other curb designs which provide a liquid impervious barrier between the floor and the walls under expected conditions, and which also provide physical protection to the bases of the walls to reduce physical damage to the walls from impacts from lift trucks, pallets, equipment or the like, and/or which further inhibit the presence or growth of microorganisms are also acceptable for thecurbs202,204 and206.
• FIGS. 5 and 6 are top and side plan views of the ventilating and air conditioning (VAC) system for each of the plurality of single-linefood processing rooms140 and240 described above. That is, in various exemplary embodiments, each of the single-linefood processing rooms140 and240 has its own separate VAC system, for whichFIGS. 5 and 6 illustrate one exemplary embodiment. Eachseparate VAC system600 is mounted on the outer surface of theceiling209 for the corresponding single-linefood processing room140 to which thatVAC system600 is connected.
• As shown inFIGS. 5 and 6, eachseparate VAC system600 includes anair inlet610 in which a high efficiencyparticulate filter612, such as a high-efficiency particulate air (HEPA) filter, is fitted. TheVAC system600 also includes a “doghouse”620 in which a ventilation andair conditioning unit624 is mounted. Theair inlet610 connects the corresponding single-linefood processing room140 or240 to aspace650 above the single-linefood processing rooms140 or240, while anair inlet622 connects that single-linefood processing room140 or240 to the interior of thedoghouse620. Accordingly, the ventilation andair conditioning unit624 draws air from the single-linefood processing room140 or240 through theinlet622, possibly conditions the withdrawn air, and returns the withdrawn air to that single-linefood processing room140 or240 through aduct630 and areturn inlet632.
• It should be appreciated that all initial and make-up air that is supplied to theseparate VAC systems600 and has been drawn from outside thefood processing facility100 or200 first passes through anoutside air intake670, as shown inFIG. 1, and into thespace650 above the single-linefood processing rooms140 or240. In various exemplary embodiments, theoutside air intake670 also includes aHEPA filter672 or the like. Because eachinlet610 also includes anintake HEPA filter612, all air drawn from outside thefood processing facility100 or200 passes through two HEPA filters or the like before entering into the individual single-linefood processing rooms140 or240.
• TheVAC system600 for this particular single-linefood processing room140 or240 circulates the air into that single-linefood processing room140 or240 through the duct orair plenum630 at near freezing-level temperatures and relatively high speeds to create a positive air pressure within that single-linefood processing room140 or240. That is, a pressure greater than ambient atmospheric pressure is created in each single-linefood processing room140 or240 by theVAC system600. Accordingly, no ambient air will be able to flow from the rest of thefood processing facility100 or200 into any of the single-linefood processing rooms140 or240. Rather, during food processing operations, room air will flow out of each of the single-linefood processing rooms140 or240 through the openings through which the incoming and outgoing transport conveyors pass between thedelivery area130 or230 and the receivingarea150 or250.
• If any air needs to be exhausted from the single-linefood processing room140 or240, such as after a cleaning operation, anair outlet642 in theceiling209 allows air to pass from the single-linefood processing room140 or240 into anexhaust duct640, controlled by a damper andcontrol644, which guides exhaust air through aroof660 of thefacility100 or200 and thus entirely out of thefood processing facility100 or200, while directing that exhaust air away from theair inlet670. In various exemplary embodiments, all exhaust air from any portion of the facilities is exhausted entirely out of the facilities to the outdoors.
• It should be appreciated that, in various exemplary embodiments, the air is introduced into the particular single-linefood processing rooms140 or240 by theVAC system600 at a substantial velocity of for example, 22 miles per hour, to quickly dry and maintain dry the floor and any equipment surfaces to avoid wet surfaces whereListeriaor other pathogenic microorganisms could grow or prosper. In various exemplary examples, this air is exhausted through theexhaust duct640 to the outside during and after the introduction of water or other liquids into the corresponding single-linefood processing room140 or240, such as by daily cleaning, backfilling of a room drain and floor area with a disinfectant, or the like.
• It should also be appreciated that, in various exemplary embodiments, any piping of any kind entering the single-linefood processing rooms140 or240, or any other areas of the plant, is preferentially orienting vertically down from the utility space above and through theceiling209, such that horizontal pipe runs extending within the single-linefood processing rooms140 or240 and other plant areas are eliminated or minimized, as horizontal pipe can provide surfaces where moisture can condense and collect.
• It should also be appreciated that, in various exemplary embodiments, a selected single-linefood processing room140 or240 and all of the contents of that single-linefood processing room140 or240, may be heated to a temperature and for a time that should be sufficient to be lethal to anyListeriabacteria or other pathogenic microorganisms that might be found on, or suspected to be present on, the devices forming the single-line food processing system, including the food processing devices, the packaging equipment or any other locations within that single-linefood processing room140 or240. Thus, in such exemplary embodiments, it would not be necessary to completely remove the equipment or physically reach every pathogen on the equipment in that single-linefood processing room140 or240 in order to sanitize the equipment in that single-linefood processing room140 or240.
• It should be appreciated that, in such exemplary embodiments, the walls208 and theceiling209 used to separate each of the single-linefood processing rooms140 or240 from each other and from the areas within theregion104 of thefood processing plant200 should be designed to be able to withstand experiencing such elevated temperatures for sufficiently long periods of time to allow the food processing equipment in that single-linefood processing room140 or240 to be heat sterilized. It should also be appreciated that it may be desirable, depending on the construction of the walls208 and/or theceiling209, to warm up one or more adjacent ones of the normally refrigerated single-line food processing rooms surrounding the single-linefood processing room140 or240 to be sterilized, or to heat one or more adjacent single-linefood processing rooms140 or240 having a common-pour floor section with the single-linefood processing room140 or240 to be sterilized, to avoid creating too large a temperature differential between the single-linefood processing room140 or240 being sterilized and the surrounding single-linefood processing rooms140 or240. It should also be appreciated that the temperature of the room or rooms to be heated could be raised and lowered slowly between normal operating temperature and heat sterilization temperature to avoid structural damage.
• FIGS. 7 and 8 are a flowchart outlining one exemplary embodiment of a method for handling processed food product(s) within a food processing facility according to this invention. As shown inFIGS. 7 and 8, the method begins in step S100 and continues to step S105, where an initially-processed food product is received and possibly stored in a designated area of the food processing facility. As outlined above, in various exemplary embodiments, this designated area can be a short-term storage cooler or the like. Next, in step S110, a portion of the received food product is selected for processing by the food processing facility. In various exemplary embodiments, as outlined above, the selected portion can be a meat log or the like. Next, in step S115, the selected portion of the food product is transferred from the designed area to a treatment area or the like. Operation then continues to step S120.
• In step S120, at least one post-processing lethality treatment is applied to the selected portion of the food product. As outlined above, this is done to reduce the likelihood that an opportunistic adulterant, such asListeriaor other adulterating microorganism, has colonized the surface of the selected portion of the food product to be processed. Next, in step S125, the selected portion of the food product is transferred from the treatment area or the like to a near-sterile food product delivery area. In general, the selected portion is transferred using any desirable appropriate devices which reduce the likelihood that the surface of the food product will be recolonized withListeriaor other pathogenic microorganisms as it is transferred from the treatment area or the like through the food product delivery area to the particular single-linefood processing room140 in which that food product will be further processed. It should be appreciated that steps S120 and S125 can be reversed, in that the food product can be treated after it is in the delivery area rather than before it enters the delivery area. Then, in step S130, the treated selected portion of the food product is transferred from the food product delivery area to a single-line food processing room through an opening in the wall separating the food product delivery area from the single-line food processing room. It should be appreciated that, in various exemplary embodiments, a positive pressure gradient, as outlined above, is applied to this opening to create a pressure differential across that opening. By forming a positive pressure gradient from the interior of the single-line food processing room to the food product delivery area, air moves through the opening toward the food product delivery area from the single-line food processing room. This tends to prevent air-borne microorganisms, such asListeria, from entering the single-line food processing room. Operation then continues to step S135.
• In step S135, the received portion of the food product is processed in the single-line food processing room using a set of one or more food processing devices. Then, in step S140, the processed food product is transferred within the single-line food processing room from the one or more food processing devices to one or more food packaging devices. Next, in step S145, the processed food product is packaged within the single-line food processing room. Operation then continues to step S150.
• In step S150, the packaged food product is transferred from the single-line food processing room to a receiving area through an opening in the wall separating the single-line food processing room from the receiving area. In various exemplary embodiments, a pressure gradient is created across that opening from the single-line food processing room to the receiving area to generate a unidirectional flow of air from the single-line food processing from into the receiving area. Next, in step S155, the packages of packaged food product are inspected for leakage or other faults with the packaging such thatListeriaor other pathogenic microorganisms could migrate into that packaging. Next, in step S160, any leaking or defective food product packages are returned to the single-linefood processing room140 from which they came for re-sterilization and repackaging in the single-line food processing room, are discarded or otherwise appropriately dealt with. Operation then continues to step S165.
• In step S165, a determination is made whether the food product was packaged on a Friday or other designated day. It should be appreciated that Friday is used to allow the food product packaged on that day to be extensively inspected, sampled and tested for the presence of pathogens, while being held a sufficient time to receive the testing results from the lab before the product is shipped. Thus, it should be appreciated that any particular day of the week or any particular shift could be used in place of Friday in step S165, so long as sufficient time is allowed to pass before step S170 is carried out relative to such packaged food products. In particular, if the food was packaged on Friday or other designated time for such tests, operation continues to step S170. Otherwise, operation jumps to step S180.
• In step S170, the packaged food product(s) are stored until Monday, or for some other necessary or desired interval, while awaiting receipt of the test results showing that the food processing product is acceptable. Next, in step S175, if no contamination is found, the packaged food product(s) are prepared for shipping from the food processing facility. Otherwise, if contamination is found in any of the packaged food product(s) tested, appropriate steps may be taken to identify the single-line food processing room(s) within which the contaminated product was processed, to segregate all product from that room(s), and to take appropriate remedies or action to identify the source of the contamination and to properly dispose of or subject to additional lethality treatment the contaminated product and facilities. Operation then jumps to step S185.
• In contrast, in step S180, the uninspected packaged food product(s) are prepared for immediate shipping from the food processing facility. Then, in step S185, the packaged food product(s) are shipped from the food processing facility to either a downstream food processing facility, a downstream warehouse or other storage location, a retailer or the like. Operation then continues to step S190, where operation of the method ends.
• FIGS. 9 and 10 are a flowchart outlining one exemplary embodiment of a method for controlling movement of personnel within a food processing facility according to this invention. As shown inFIGS. 9 and 10, operation of the method begins in step S200, and continues to step S205, where a person wishing to enter the semi-secure or secure areas of the food processing facility dons appropriate footwear, such as, for example, rubber boots. Then, in step S210, the person proceeds through a sanitizing station to enter a buffer area. In the buffer area the person will be able to don an appropriate uniform. Next, in step S215, a determination is made which areas of the food processing facility the person wishes to enter. Operation then proceeds to step S220.
• In step S220, a determination is made whether the person wishes to enter the food delivery or food processing areas, i.e., the secure areas of the food processing facility. If so, operation continues to step S225. Otherwise, operation jumps to step S240. In step S225, a determination is made whether the person has completed appropriate food safety training. If not, operation continues to step S230. Otherwise, operation jumps to step S235. In step S230, because the person has not completed the appropriate food safety training to enter the food delivery or food processing areas, the person is denied access to these areas. Operation then returns to step S220. In contrast, in step S235, the person, having completed the appropriate food safety training, and thus being authorized to enter the food delivery or food processing areas, dons a full-body or other secure area uniform. Operation then jumps to step S245. In further contrast, in step S240, because the person does not wish to enter the food delivery or food processing areas, the person puts on a food transfer-type, or semi-secure area-type, uniform. Operation then proceeds to step S245.
• In step S245, the person proceeds from the buffer area to the authorized area(s) of the food processing facility the person, assuming the proper uniform is being worn, wishes to visit. Next, in step S250, a determination is made whether the person wishes to enter the packaged food receiving area, the food delivery area, or the food processing areas. If so, operation continues to step S255. Otherwise, operation jumps to step S260. In step S255, the person proceeds to a second boot sanitizing station to enter the desired area of the food processing facility. Operation then proceeds to step S260.
• In step S260, a determination is made whether the person wishes to exit the food processing facility completely or whether the person wishes to change to a different area of the food processing facility. If not, operation returns to step S260. Otherwise, if the person wishes to change which area of the food processing facility the person is in, operation continues to step S265. Else, if the person wishes to exit the secure and semi-secure areas, operation jumps to step S280. In step S265, a determination is made whether the person wishes to re-enter the food delivery or food processing areas from the buffer area or one of the other semi-secure areas of the food processing facility, such as the treatment room, the receiving area, the packaged food receiving area, the cold storage area or the like. If so, operation continues to step S270. Otherwise, operation jumps to step S275. In step S270, the person puts on a new full-body uniform and recycles the old full-body uniform for sanitation. Then, in step S275, the person proceeds to the appropriate boot sanitizing station. For example, if the person is leaving the food delivery or food processing areas into one of the semi-secure areas, the person will proceed through a footwear sanitizing station. Likewise, if the person is proceeding from the packaged food receiving area to another one of the semi-secure areas, the person will proceed through the appropriate footwear sanitizing station. Operation then returns to step S260.
• In contrast, in step S280, the person proceeds through the footwear sanitizing stations necessary to reach the unsecured areas of the food processing facility. Then, in step S285, the person recycles for sanitation whatever uniform the person is currently wearing. Next, in step S290, a determination is made whether the person wishes to re-enter the food processing area. This will occur when the person is returning from a visit to the restroom or from lunch or some other break. If so, operation returns to step S210. Otherwise, operation continues to step S295, where operation of the method stops.
• FIG. 11 is a flowchart outlining one exemplary embodiment of a method for cooling and ventilating a single-line food processing room according to this invention. As shown inFIG. 11 beginning in step S300, operation of the method continues to step S305, where air is drawn from outside of the food processing facility through an air inlet, through a bacterial grade filter, such as a HEPPA air filter or other appropriate filter device and into a plenum that supplies at least the food processing rooms. Then, in step S310, the filtered outside air is allowed to pass through a second filter into the associated single-line food processing room to provide twice filtered make-up air as needed. Next, in step S315, air is withdrawn from the associated single-line food processing room into a dedicated ventilating and air conditioning (VAC) enclosure. Operation then continues to step S320.
• In step S320, the temperature and humidity of the withdrawn air are reduced to near or below freezer-range temperature and humidity. Next, in step S325, the withdrawn and cooled air is returned to the single-line food processing room at high velocity to create higher than ambient air pressure in the single-line food processing room and maintain room temperature near freezing. Then, in step S330, due to the higher than ambient air pressure in the single-line food processing room, high pressure air is unidirectionally exhausted from the single-line food processing room through the openings in the walls that lead to the delivery and receiving areas. Operation then continues to step S335.
• In step S335, a determination is made whether the air in the single-line food processing room needs to be vented rather than recirculated. If not, operation returns to step S315. Otherwise, operation continues to step S340, where the high pressure air is exhausted from the single-line food processing room to outside of the food processing facility via one or more damper controlled ducts that direct the exhausted air away from the air inlet that is used to draw air from outside of the food processing facility into the bacterial grade filter. Operation then returns to step S310.
• It should be understood that the order of the steps of each of the foregoing methods is not limited to the order described and illustrated, but in exemplary embodiments can include any such step in any appropriate order which does not preclude or compromise other steps of the method.
• The above-outlined various exemplary embodiments of various structures, systems and techniques are each useful in reducing the ability ofListeriaor other pathogenic microorganisms to enter food processing facilities, or migrate between, or cross contaminate, different food processing devices or food processing device lines. Thus, each of the various structures, systems and methods described herein are separately useful. When such structures, systems and methods are combined into various combinations, the ability ofListeriaand other pathogenic microorganisms to invade or migrate between different food processing devices and/or lines is even further reduced. Thus, it should be appreciated that food processing facilities, systems and methods according to this invention do not need to use all or even a plurality of the various structures, systems and techniques disclosed herein.
• While this invention has been described in conjunction with the exemplary embodiments outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.

Claims (2)

1. A food processing facility, comprising:

a plurality of single-line food processing rooms, each food processing room comprising a secure area having a single line of series-connected food processing elements including at least one food processing device and at least one food packaging device, each food processing room at a first substantially sterile level of cleanliness which substantially prevents the presence and growth of pathogenic microorganisms includingListeria, the plurality of secure area single-line food processing rooms each being individually atmospherically and structurally isolated from each other to effectively prevent any contamination occurring in any one such food processing room or series-connected food processing element therein from contaminating food products processed in any other of such plurality of food processing rooms and series-connected food processing elements therein;

at least one semi-secure delivery area, each delivery area adjacent to at least some of the food processing rooms, each delivery area at a second level of substantial cleanliness that can be below the first level of cleanliness but will substantially prevent contamination of previously processed food products after at least one selected post-lethality treatment of the food products;

at least one semi-secure packaged food receiving area, each receiving area adjacent to at least some of the food processing rooms, each receiving area at a third level of substantial cleanliness that can be below the first level of cleanliness but will substantially prevent contamination of hermetically sealed food packages within the semi-secure receiving area;

at least some of the plurality of the secure food processing rooms having a first passage to the semi-secure delivery area, and having a second passage to the semi-secure packaged food receiving area;

at least one semi-secure buffer area adjacent to at least one of at least one receiving area or at least one delivery area, each buffer area at a fourth level of cleanliness that can be below the second level of cleanliness but will substantially prevent contamination of previously processed food products after at least one selected post-lethality treatment of the food products within the semi-secure buffer area, and of personnel, clean uniforms, cleaning supplies and equipment located within and passing through such semi-secure buffer area;

at least one common unsecure area adjacent to at least one buffer area, each common area at a fifth level of cleanliness that can be below the fourth level of cleanliness, wherein the fifth level of cleanliness is appropriate for management staff and personnel support activities;

a plurality of sanitizing stations, at least one sanitizing station located between a common area and an adjacent buffer area and at least one sanitizing station located between a buffer area and an adjacent receiving or delivery area.

2. A food processing facility usable to process a food product in an environment having low risk for contamination, comprising:

a plurality of single-line food processing rooms, each food processing room comprising a single line of series-connected food processing elements including at least one food processing device and at least one food packaging device, said plurality of single-line food processing rooms each being atmospherically and structurally isolated from each other to effectively prevent any contamination occurring in any one such single-line food processing room or series-connected food processing element therein from contaminating food products processed in any other of such single-line food processing rooms or series-connected food processing elements therein

a first area, at least some of the plurality of food processing rooms having a first passage to the first area;

a second area that includes at least some of a holding area, a treatment area, a buffer area and a packaged food receiving area, at least some of the plurality of food processing rooms having at least a second passage to the packaged food receiving area; and

a third area that includes at least some of a break room, restrooms, a locker room, at least one office and a reception area;

wherein:

the first area and the plurality of single-line food processing rooms comprise a secure area and are each at least at a first sanitary level of cleanliness, at least some of the single-line food processing rooms each at a substantially sterile condition which substantially prevents the presence and growth of pathogenic microorganisms, includingListeria;

the second area comprises a semi-secure area and is at a second level of substantial cleanliness that may be less than the first level of cleanliness but will substantially prevent contamination of previously processed food products after at least one elected post-lethality treatment of the food products within the semi-secure second area, and of hermetically sealed food packages conveyed and handled within the second area, and of personnel, clean uniforms, cleaning supplies and equipment located within and passing through such second area; and

the third area is an unsecure area which has a third level of cleanliness that can be less than the second level of cleanliness.

Images