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New Door Cleans Up in Food Manufacturing Plants
Few plant operations function at the same high standards of quality as the food manufacturing industry. In addition to the maintenance headaches inherent in any manufacturing operation, food manufacturers must comply with a litany of federal, state and municipal regulations affecting every phase of the manufacturing process. Yet, in spite of regulatory burdens, production schedules must be kept. In response to the unique demands of the food manufacturing industry, the Rytec Corporation, a Jackson, Wisconsin-based manufacturer of high-speed rolling and folding doors, has developed a high performance roll-up door designed specifically for use in the food manufacturing environment. Called he Rytec Clean-Roll Door, this new entry into the high-speed door market not only satisfies the expectations of increased productivity and reduced maintenance costs, but also meets compliance standards set forth by the Hazardous Analysis Critical Control Points (HACCP) and other food safety programs. The Clean-Roll is the first door to combine the requirements for a hygienic/clean room door with the benefits of a high-speed door. The Clean-Roll fulfills the Good Manufacturing Practices (GMP) as defined under the Food, Drug and Cosmetic Act, which dictates that equipment and utensils in food production areas must be chosen and designed to prevent disease and adulteration. The code prescribes that they must be easily cleaned and sanitized and all material must be non-toxic. The Clean-Roll's special features include removable stainless steel side frames and a stainless steel roll drum. The door's non-porous USDA/FDA approved fabric is completely extended when the door is closed, preventing microorganisms and debris from being able to collect around the drum. "A tremendous amount of thought went into this door," stated Scott Blue, Rytec's marketing director. "The Clean-Roll design allows for easy and thorough cleaning. Equally significant, the door's high speed opening at 32 inches per second helps minimize the spread of airborne pathogens." There has been significant research on critical control points (CCP), the areas identified in the food processing chain where contaminations may occur. Yet, only recently have microbiologists looked into the role that airborne microorganisms play in the adulteration of food products. Airborne microorganisms that infiltrate plant processing areas represent a serious threat to product quality and safety. According to a study commissioned by the American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) and conducted by Dr. A. J. Heber, of Purdue University's Department of Agriculture and Biological Engineering, these bioaerosal emissions may be carried throughout a processing plant via airflow caused by openings such as doorways. "Doorways are for the convenience of workers and vehicle traffic. However, the effect that open doorways have on air transference of bacterial pathogens and spoilage microorganisms is not usually considered. The speed at which a door operates definitely could affect dispersion or movement of bioaerosal emissions to clean rooms in a food processing operation," stated Dr. Heber. Hygienic benefits aside, the primary function of the Clean-Roll Door is to improve plant efficiency. In addition to external doors needed for shipments and deliveries, almost every manufacturing facility has internal doorways connecting rooms to block out noise, dust, odors or vapors, or maintain proper temperatures. Slow operating doors compromise this role with increased migration of dust, fumes, and noise between areas, and they reduce control over desired temperatures. The faster a door operates, the more effective its performance as a barrier. Slow moving doors also exact a cost in lost production time. Many doors are opened hundreds of times each day. Assuming that a door opens at the rate 8 inches per second, it takes 15 seconds for a ten-foot high door to fully open. If a forklift operator transports material through 25 times each hour, he collectively spends 50 minutes per each 8 hour shift waiting for a door to open. Its also been shown that slow doors contribute to accidents resulting from impatient forklift drivers waiting for a door to open. It is common for slower doors to be struck by harried forklift operators. At 32 inches per second, Rytec's Clean-Roll speed of operation alone reduces such accidents. Regardless of their speed and durability, doors will occasionally get hit. Repairs sometimes disrupt the flow of ingredients and products to the production and shipping areas. Anticipating that the occasional accident will occur even with a high speed door, Rytec equips its roll-up doors with a patented Break-awayTM bottom bar that releases in either direction without sustaining any damage upon impact. The bottom bar can be easily reset in minutes without tools, allowing traffic to continue virtually uninterrupted. Rytec's doors are actuated by a variety of methods ranging from photoelectric cells to hand-held radio controls. Some operations can be combined and are programmed through a wall-mounted controller. The most effective actuating system consists of an induction loop embedded in the floor that senses metallic objects passing over it which then activates the door. An induction loop can be installed in existing floors as well as new construction and positioned at any preferred distance that provides optimal efficiency. The Rytec Corporation is no stranger to the food industry. In 1988, Rytec became the first American company to apply high-speed door technology to coolers and freezers. Today, Rytec's Fast-Fold Freezer Door is the leading cold storage door on the market. Opening at 7 feet per second, the Fast-Fold's speed of operation conserves energy and reduces warm air infiltration. Rytec offers three different defrost systems that keep the doors transparent 3/8" Puralon panels clear and frost-free. The Fast-Fold is designed to withstand temperatures to -20 degrees Fahrenheit. For more information on the selection and specifications of high-speed doors from Rytec and other manufacturers, request Rytec's free manual, The Authoritative Guide to High Speed Doors. Call 888-467-9832. |
