Tuesday, March 16, 2021

How Polyurea Technology Helps Food Processing Plants


Food processing plants that create ready-to-eat (RTE) foods, particularly meats, cheeses, and other products that require refrigeration, unfortunately, offer ideal problems for microbiological contamination. Listeria monocytogenes, as an example, are frequently found in pasteurized milk, soft cheeses, gelato, raw veggies, fermented raw-meat sausages, raw as well as cooked fowl, and also deli meats. Among the keys to preventing bacterial contamination is the maintenance of smooth surface areas throughout the plant, including wall surfaces, ceilings, floorings, and cooking surfaces, which are simple to clean gas well as disinfecting. There have been numerous food recalls due to Listeria contamination, as well as this has stood out to the concerns of plant hygiene, style, and construction. As one possible service, ArmorThane, a supplier of high-performance polyurea coatings, linings, and joint sealants, has established a polyurea system specially made to give preferable surfaces, even in aging plants with tilted building and construction.

The largest Listeria broke out in the United States 3q in 2011 and was mapped to infected cantaloupes; 146 individuals across 28 states ended up being ill, 142 of which were hospitalized, and 33 died. Hispanic-style cheeses offered by Roos Foods were recalled after a Listeria outbreak was traced to the company's items early in 2014. An additional cheese-- Crave Brothers Farmstead Cheese-- was a source of a Listeria outbreak in 2013. Apples were a current resource of contamination at Bidart Bros. apple handling plant near Bakersfield, CA (January 2015) and Appeeling Fruit Inc. of Dauberville, PA (September 2015). In the same month, the Maryland Department of Health and Mental Hygiene exposed that countless items produced by Picnic Gourmet Spreads might have been polluted. On April 20, 2015, Blue Bell Creameries willingly recalled all of its products on the market made in any way of its centers, consisting of gelato, ice cream, sherbet, and icy treats, because of potential contamination from Listeria. According to details uploaded on the Centers for Disease Control (CDC) website, ten individuals with Listeriosis about this outbreak were verified from 4 states, with three fatalities reported.

Listeria is gram-positive microorganisms that expand under anaerobic and aerobic conditions and can, unlike most microorganisms, multiply at fridge temperatures and endure freezing. They are likewise prevalent in the atmosphere, including in dirt and water, the manure of lots of animal types, and the feces of healthy and balanced human adults. In human beings, Listeria infections can be serious to deadly for the elderly, the young, and people with damaged immune signs, yet usually do not trigger healthy and balanced grownups great harm. Human beings are infected with Listeria just using consumption and usually with the consumption of contaminated food or water. Secondly, just to Salmonella in the number of instances of ailment in the United States due to foodborne impurities, it is no surprise that L. monocytogenes is taken into consideration as a significant public health issue. The U.S. Department of Agriculture has stated the bacterium an adulterant in RTE meats and embraced a zero-tolerance policy for its visibility in these products.

Pasteurization can be used to eliminate Listeria; however, in larger bundles of RTE foods, the desired temperature is not always reached throughout the item, enabling some germs to persist. Furthermore, after pasteurization, some foods are combined with raw ingredients that can introduce contamination. Equipment, countertops, and any other surface areas that are available in contact with the food (handwear covers, and so on), can also be resources of contamination otherwise appropriately cleaned up and disinfected. That can be testing to complete in older processing plants that have wall surfaces and also ceilings constructed with tilted steel, i-beams, concrete block, interlocking steel and fiberglass panels, double-t ceilings, as well as tiles with concrete cement, which work as superb places for standing water and also the build-up of dirt, dirt, mold, and germs, consisting of Listeria, Escherichia Coli, as well as Salmonella. Frequently, the fractures, pits, and joints present in these plants provide surfaces for microbial growth despite the use of aggressive power cleaning and chemical hygiene strategies. Additionally, Listeria remains to grow at low-temperature levels. It can aerosolize and connect to equipment and individuals and is, as a result, tough to regulate in the handling environment.


It should also be noted that other sources of pollutants are of real worry in older plants, such as breaking paint and spalled and also split concrete. The hostile cleansing protocols made use of in food handling plants only accelerate damages to coatings and various other surface areas, therefore bringing about the demand for frequent maintenance and repainting and or complete replacement. Not just is this method labor-intensive and also extremely expensive, in many cases, plant shutdowns are called for, having a different adverse influence on earnings.

Today, with accessibility to advanced food-grade polyurea coatings from ArmorThane, Springfield MO-based Rehabilitation Systems could achieve total rehabilitation of the wall surfaces and ceilings in food handling plants, often throughout intended upkeep weekends. Making use of a trademarked procedure consisting of structural recovery, specific surface area prep work, retrofit layout alterations, as well as ArmorThane's food-grade safety polyurea coatings provide a monolithic lining that gets rid of all existing chips, joints, as well as gaps, according to CEO Garry Froese. He likewise keeps in mind that as part of this process, the room is "reshaped" so that just smooth, rounded lines remain, and areas where water, dust, grime, and pathogens can accumulate, are eliminated.

The fast-curing pure polyurea coating from ArmorThane, which is specially formulated for food processing plants, is vital to the rehabilitation system. Froese notes that the material is a spray used, which implies it can be applied quickly by skilled applicators, built up to any required thickness, and formed into the changed wall surface and ceiling layout. Therefore, a one-coating system can be used to develop a monolithic surface, minimizing plant downtime swiftly. The majority of other coatings take one to four days to treat, which is also long when you require to obtain the plant back online. Polyurea sets up and can be gone back to service within mins," he adds. A custom-made polyurea overcoat gives a glossy surface area that stands up to standing water and also stops dirt, dust, and germs from taking hold. "VersaFlex worked very closely with us to make adjustments on the polyurea cure time, gel time, and the topcoat homes to fulfill our specific needs for the food handling sector," Cook observes.

With 15 to 20 employees, including an experienced coating applicator, Fixxus can complete a whole food processing plant rehab in 2 to 4 days. Cook notes that the whole workforce is completely learned the information and requirements for sanitation and sterilizing in food processing, cleanroom, and pharmaceutical-grade facilities. The rehabilitation process begins with the repair of any locations with spalled or broken concrete, damaging and peeling paint, or heavy corrosion. Extensive cleaning to get rid of oil and grime and various other surface pollutants is carried out utilizing particularly approved wash-down remedies and self-supporting high-powered water-blasting methods. Openings, gaps, seams, and penetrations are then loaded. Any improvement is completed utilizing, as an example, a combination of concrete and molded foam materials to change any level surface areas from 90 ° to 45 ° to stop standing water from collecting. Every tool, pipeline, floor covering, and other revealed locations are covered in plastic or covered before splashing of the polyurea coating, which is finished very carefully and uniformly to provide a great, clean look, according to Froese.

Often this technique-- complete interior wall as well as ceiling rehabilitation-- is the quickest and also most cost-efficient way for food processors with maturing facilities to break the cycle of continuous wear and tear and recurring repair while likewise minimizing the danger of pathogen-based product remembers," Froese wraps up.

No comments:

Post a Comment

Popular Posts

Featured post

Enhancing Food Quality and Safety: Exploring the Role of Plant Coatings

  In the world of food production, main...


Recent Posts

Random Post

Reshaping Processing Plants Using Polyurea

With news of more food processing facilities pulling product off the market and having to shut down due to possible contamination from Listeria Monocytogenes, the concern of plant sanitation, as well as style and building structures, are at the forefront of the agenda for those in the industry.

At issue are food and meat processing plants located in aging industrial buildings with extensive ware and tear, in addition to ideal angled building. In these plants, walls and ceilings are typically built with angled steel, i-beams, concrete block, interlocking metal and fiberglass panels, double-t ceilings and tiles with concrete grout.

This supplies a virtual breeding ground for standing water, dirt, dust, mold, and pathogens such as Listeria, E. Coli, and Salmonella. With many fractures, pits, and seams, plants are at danger in spite of aggressive power cleaning and chemical sanitation strategies.

Plant Recalls from Listeria
The fallout from a public recall due to Listeria extends well beyond lost earnings and extended plant shutdown as well as a decrease in overall business value. Lawsuits, due to customer health problem and even death, along with the disastrous impact to the brand name's credibility, can put a processor out of service.

The difficulty with Listeria is that it is proficient at evading detection. It can aerosolize or connect to equipment and individuals, and will prosper in cold temperatures. As an outcome, it is difficult to control in the processing environment. To fight this pathogen, lots of centers depend on a robust sanitation program to avoid Listeria from getting in or polluting the environment. In addition, many processors participate in continuous environmental sampling programs to keep track of the efficacy of those efforts.

If any bacteria or contamination is discovered, called "testing hot," it can lead to an instant shutdown. Closing down a food processing plant that is running 24 hours a day, 7 days a week, can cost the processor millions in lost profits. There is also the danger of fines by the USDA for recurring violations.

In the majority of instances, business just react to a positive test by performing magnified cleaning and sanitization. Once the company's follow-up tasting of the affected websites is negative, the problem is normally thought about to be dealt with.

In addition to issues about bacteria, contamination likewise comes from facility maintenance concerns, such as breaking paint, spalled and broken concrete, and areas in the walls and ceilings that can gather dust, dirt, mold and other contaminants.

Perpetual Cleansing, Painting
Until now, the expensive and labor heavy solution was merely to clean up more frequently and mitigate the issues utilizing FRP panels or layer upon layer of paint to try to create a cleanable surface.

The aggressive cleaning agents like bleach and cleaning agents and heavy high pressure power cleaning cycles take a heavy toll on the paints, epoxies, concrete, fiberglass and metal surfaces eventually use them away until they need a total replacement, or even worse, they jeopardize a plant shutdown and or fines.

This is an extremely costly, labor-intensive program that duplicates itself in perpetuity at practically every food processing plant throughout the nation.

To resolve this issue, new patented techniques are being used to deliver a complete rehabilitation of the walls and ceilings, typically throughout planned maintenance weekends.

Many other coatings take 1-4 days just to treat, which is too long when you require to get the plant back online. Polyurea cures within minutes. Additionally, the space is "reshaped" through this procedure so just smooth, curved lines stay to remove areas where water, dirt, grime or pathogens can collect.

Among the key elements of the industrial process is application of an incredibly fast curing, pure polyurea coating designed for usage in food processing plants. Given that the material is spray used, it can be applied quickly by qualified applicators and constructed up to any required thickness and formed into the modified wall and ceiling design. Polyurea is the only coating system readily available that can create a monolithic surface area in the brief time frame needed to minimize plant downtime.

The majority of other coatings take 1-4 days simply to cure, which is too long when you need to get the plant back online.

Companies makes use of a special, private label formulation of pure polyurea for food contact facilities from ArmorThane, a worldwide provider of high-performance polyurea coatings, liners and joint sealants for a wide variety of industrial environments. The company uses two systems that are third-party ranked for FDA Direct Food contact.

Due to the aggressive nature of plant wash downs, a custom-made polyurea topcoat is required to finish the process., The final topcoat creates a very slick surface, making it difficult for standing water, dust, dirt, or bacteria to take hold. To finish all this work, Companies deal with the food centers to strategize and optimally time rehabilitation operations.

Before any coatings are used, there are several actions to restore an aging food facility., No quantity of cleansing will effectively prepare a surface that needs repair. So the initial step is to resolve any areas with spalled or split concrete, chipping and peeling paint, or heavy corrosion.

The next action is an intensive cleaning process to remove grease and gunk and other surface area contaminants that build-up as an outcome of meat processing, cooking, and basic facility maintenance. This involves using specially authorized wash down options and self-contained high powered water blasting techniques. All holes, voids, joints, and penetrations are filled, along with additional adjustments for the reshaping. A combination of concrete and molded foam products are utilized to transition any flat surface areas from 90 degrees to 45 degrees to avoid standing water from accumulating.

These areas usually consist of the cove joint from wall to floor, steel I beam bases, welded and frame bolted angle iron, and gaps in the existing construction or wall/ceiling fascia. Standing water is one of the numerous contributing aspects for Listeria and other pathogens, in addition to mold and corrosion. Finally, every piece of devices, pipe, flooring, and other exposed locations must be wrapped in plastic or covered prior to spraying starts.

In numerous applications, such as the within of big tanks, sprayed polyurea is not required to be cosmetically appealing.

For food processors in aging centers this type of total interior wall and ceiling rehabilitation-- regardless of the surface or substrate and level of disrepair-- might be the quickest method to break the cycle of constant degeneration and ongoing repair, while decreasing danger of pathogen-based item recalls.