Exploring the Role of the Floor

in a HACCP Food Safety Plan

Presented by Mike Dzialo

Welcome to Flowcrete Group Ltd

•  World leader in specialty polymer flooring since 1982

•  Wide range of resin floor chemistries

•  8 plants, 20 distribution centers & sales reps in 32 countries

•  Sales into 77 countries worldwide

•  Backed by RPM International Inc.

•  HACCP International certified flooring manufacturer

Presentation Summary

•  What is HACCP?

•  What Does HACCP Say About Floors?

•  HACCP-Based Floor Specification Considerations

•  HACCP International Certified Flooring Solutions

•  Questions & Answers

What is HACCP?

•  Hazard Analysis / Critical Control Points

•  Developed by NASA in the USA

•  Proactively seeks to prevent any hazards that can result in unsafe food products

•  Reduces the reliance on end-testing of products

•  Identifies potential hazards through risk assessment

•  Implements measures to ensure hazard avoidance

HACCP & the FDA/USDA

•  HACCP is legally mandated by the USDA & FDA for meat & poultry, seafood and juice processing brands

•  FDA requires a Food Safety Plan for all food processing businesses (Food Safety Modernization Act)

•  FDA is urging food retail and food service sectors to apply HACCP

principles

•  State County Inspectors publicize brands that are shut down for food safety infringements

What Hazards are Assessed?

Microbiological Chemical Physical Allergenic

Food Safety: A Serious Business

•  Contamination can kill a food manufacturing business

•  Microbiological - 2011, C, L. monocytogenes US outbreak in

cantaloupes kills 33, sickens 146

•  Physical - 2012, Kellogg’s recalls cereal boxes due to possible presence of metal mesh

•  Chemical – 2012, FDA detains shipments of orange juice from Brazil and Canada containing illegal fungicide, Carbendazim

Hazards from Equipment, Fittings & Finishes

Equipment

Drains

Doors

Lighting

Coving

Walls

Floor Coatings

What Does HACCP Say About Flooring?

•  Walls, floors & ceilings must be built of durable materials, impervious to moisture and be cleaned and sanitized (AS 4674-20)

•  Specification considerations –  Porosity

–  Finish (Seamless vs. Tile)

–  Make-Up (Toxicity)

–  Thermal Shock Resistance

–  Chemical Resistance

–  Surface Drainage

–  Coving

Porosity

•  Porosity – the extent to which the floor absorbs liquid

•  Highly absorbent floors will encourage the growth of

microorganisms & discoloration

•  Non-porous floors should be used in food prep areas

•  Porous floors; unglazed tile, grout, stone, VCT, wood, brick & concrete

•  Non-porous floors; glazed tile, quarry tiles, terrazzo & resin

Finish (Seamless vs. Tile / Brick)

•  Seamless floors are free from grout lines – prime areas for moisture ingress and the growth of microorganisms

•  Easy sweeping, squeezing, mopping, vacuuming or steam cleaning - without struggling with debris in the grout of the floor

Make-Up (Toxicity)

•  Many flooring options, including vinyl, contain toxic phthalates and plasticizers

•  These toxic chemicals are banned by the U.S. Consumer Products Safety Commission for use in children’s toys

•  These toxic chemicals are banned in the make-up of flooring by the

European Union

•  Look out for phthalate-free floor coatings and finishes

Thermal Shock / Cycling Resistance

•  Exposure to hot liquids or steam cleaning can result in thermal shock

•  Processes taking the room above or below ambient temperature can result in thermal cycling

•  Flooring without sufficient resistant and which expand / contract at a different rate to the concrete slab

can crack or delaminate

•  This damage will penetrate the clean barrier risking food safety hazards

Chemical Resistance

•  Food processing environments are subject to a wide range of chemicals

•  Pesticides, fertilizers, additives, lubricants, cleaners, sanitizers etc.

•  These can contaminate food products and also corrode floor coatings

•  Penetrating the clean barrier and risking food safety hazards

Surface Drainage & Coving

•  A food safe floor also has appropriate gradients, drainage systems, seals, joints and coving

•  Hygienic design of drainage prevents water pooling and minimizes bacteria traps

•  Coving must be a curved, sealed edge between the floor and wall – eliminating sharp corners

•  Hygienic resin wall coatings envelope the entire area

What Would Flowcrete Recommend?

•  Flowfresh cementitious urethane flooring systems

–  Seamless

–  Non-porous

–  Non-tainting

–  Phthalate free

–  Adjustable slip resistance

–  High chemical resistance

–  Temperature resistant to 250°F

–  Moisture vapor resistance

–  Includes a coving mortar

–  Decorative options available

–  Silver-ion antimicrobial additive

–  HACCP International certified

Innovations in Flooring - Polygiene®

•  Silver-ion (natural) antimicrobial additive within the resin matrix

•  Protects the surface from degradation caused by microbial

growth

•  Polygiene® offers protection against:

–  E-coli

–  Listeria

–  Salmonella

–  MRSA

–  Salmonella Typhi

–  Campila Bacta

The silver ions are homogenously distributed throughout the floor.

Silver ions migrate to the surface.

They protect the surface from degradation caused by microbial growth.

1

2

3

1

2

3

How Does Polygiene® Work?

What is HACCP International?

•  An independent organization dedicated to Food Safety

•  Third party certification for non-food services, products and

chemicals

•  Certification is offered to suppliers of equipment or materials that make a contribution to food safety

•  Certification personnel are tertiary degree qualified food technologists

•  USA, Australia, Hong Kong, UK

HACCP International Floor Hazard Analysis

Client: Big Food Company Product: Flowfresh HF

Technician: Mr. D McNeece Line: Premises fit-out, fixtures & fittings

Date & Sign Off: September 30, 2015 Category: HACCP International: 8.3 Floor Surfaces

C P M Hazard Sev. Lik. Sig. Control Measures Ref.

ü   x x Toxicity H M Y Toxicity of components assessed. Curing process. Appropriate food safety risk.

2, 5

ü  

ü  

ü  

Ease of cleaning H M Y

Usage instructions, type of flooring surface, non absorbent, coving, durability

5, 6, 7

ü  

ü  

ü  

Direct food safety contribution

H L Y Product durability and fit for purpose assessed 2, 5

Flowfresh HACCP International Certification

•  Trusted mark of “food safety & fitness for purpose”

•  Meets the need of specifiers in mitigating food safety risk from

materials

•  Supports “premium product” placement in support of food safety

•  Reaches to a wider audience in keeping with growing food safety concerns, standards and legislation worldwide

Flowfresh Global Client Network

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@flowcreteamer slideshare.net/flowcrete

“Flowcrete Group Ltd” americas@flowcrete.com

Thank You & Questions