STANDARD OPERATING PROCEDURE – Building Shutdown and Monitoring Procedure
INTRODUCTION
Prior to any prolonged shutdown the processing plant and its equipment need to be inspected to assure that it is left in a safe condition. And throughout a shutdown the processing plant should be inspected periodically to make certain that the dairy products and ingredients stored in the freezers and coolers are being maintained at proper temperatures.
Building security is another concern. Exterior and interior doors in the processing plant,
Creamery Store, Creamery office and the Food Science department should be checked to ensure they are locked before a shutdown and that they remain locked throughout the shutdown.
PROCEDURE
1. Fill out a Building Checklist (a copy is attached) immediately prior to a prolonged shutdown and during every inspection. Note the conditions found, including any equipment failures or unusual temperatures that would affect the safety and quality of stored products or ingredients. If anything is out of order contact Thomas Palchak at 777-7892 and Penn State’s Office of Physical Plant at 865-4731.
2. Walk through and observe the condition of each room in the dairy processing area and retail store.
a. The agitators on all of the tanks should be turned off.
b. Most equipment should be turned off. However some pieces of equipment must be kept
on at all times.
c. There should be no unusual noises
d. There should be no unusual odors, including the distinct odor of ammonia.
e. There should be no unusual air or fluid leaks. A small amount of water on the floor in the
CIP room (106) is normal.
f. All chemicals should be stored safely.
g. There should not be any alarms (ammonia, carbon monoxide, etc.)
3. Access the dairy equipment monitoring software.
a. Turn on the computer located on the west wall desk in the Creamery manager’s office.
b. Double click on the “Q-talk” icon
c. When the “Com Set-up” window appears on the screen, press OK.
d. When the “Available Devices” window appears, scroll down the list to “7 – Evaporator”.
Record the current temperature at all monitoring locations on the Building Checklist.
e. Look at the remaining devices (compressor / condenser) and note any alarm conditions
on the Building Checklist.
f. Turn off the computer.
4. Observe and record the temperature of all refrigerators and freezers.
a. In the dairy processing plant compare the thermometer readings to the recommended
temperature ranges listed below. At locations not monitored by the Q-talk software
program, record the thermometer readings on the Building Checklist.
Room 102B cheddar cheese cooler 43 to 48°F
Room 103 sample refrigerator 0 to 4°C
Room 103 shelf-life refrigerator 3 to 6°C
Room 103 culture freezer -83 to -77°C
Room 103 sample freezer -20 to -15°C
Room 108 raw milk refrigerator 0 to 4°C
Room 111 ingredient freezer -25 to -15°F
Room 112 ingredient cooler 34 to 40°F
Room 114 blast freezer -30 to -22°F
Room 116 cold dock 34 to 40°F
Room 117 storage freezer -25 to -15°F
Room 117A tempering freezer 3 to 10°F
Room 118 milk and cheese cooler 34 to 40°F
b. At other critical locations throughout the building, record the temperatures in the freezers and refrigerators on the Building Checklist. The recommended temperatures are listed below.
Room 127 retail sales cooler 38°F
Room 127A retail sales freezer -15°F
Room 134A dry pilot plant cooler 38°F
Room 135A wet pilot plant cooler 38°F
Room 135B wet pilot plant freezer 0°F
Room 415 pathogen pilot plant cooler 38°F
Room 415 pathogen pilot plant freezer 0°F
5. Check that the building is secure.
a. Notify campus police (863-1111) if you find any unauthorized people in the building.
b. All exterior and interior doors should be locked. The two roll-down doors in the
processing area should be lowered. Note on the Building Checklist the condition of the
following doors.
Room 101 processing plant door leading to the front lobby
Room 106 door between receiving bay and tank hall
Room 108 receiving bay truck doors and walk-thru doors
Room 109 Creamery corridor doors
Room 119 doors from Creamery office to salesroom and retail sales preparation area
Room 120 vault
Room 122 salesroom supervisor’s office
Room 129 all salesroom exterior and interior doors
Room 134 dry pilot plant
Room 135 wet pilot plant
Room 136 room between wet and dry pilot plants
Room 202 main door to the Food Science Department administrative suite
Room M233 ammonia compressor room door
Room 236 front and rear doors to the bottle preparation room
c. Also verify that the small safe located in the retail sales preparation area (room 124) is
locked.
RECORDKEEPING
1. Building Checklists should be filled out, signed and dated each time an inspection of the building
is performed.
2. All completed Building Checklists shall be retained for at least three months.
REFERENCES
1. Penn State College of Agricultural Sciences building floor plans can be accessed at
http://www.cas.psu.edu/construction/FoodSci/2.html
2. Attachment: Building Checklist
Add Comment