Equipment maintenance for food-safe packaging printing

hace 3 meses

Continuing our series on navigating ink-related food safety standards

We’ve started a blog series that focuses on meeting the requirements of the Global Food Safety Initiative (GFSI). In our first post, we introduced the three main food safety management schemes for packaging printers and summarized eleven food safety standards related to ink.

Over eleven blogs, we explore these standards and their specific ink-related requirements in more detail. We’ll also explain how our ink management solutions can assist you in meeting these requirements.

This is a blog about the fourth standard, equipment maintenance. In previous blogs, we have explored hazard analysis and risk management, record keeping and traceability.

For printers active in the food industry, it is crucial to have a pro-active and well-documented maintenance approach to prevent contamination risks and ensure equipment reliability.

In this blog, you will learn the relevant requirements of the GFSI-recognized schemes (BRCGS, SQF, and FSSC 22000) and our documents and services that help you to comply.

Requirements related to equipment maintenance in the three food safety management schemes

The criteria regarding equipment maintenance can be found in:

Section 4.7 of the BRC Global Standard (BRCGS) for Packaging Materials
Sections 2.5 of FSSC 22000 (Food Safety System Certification)
Section 13.2.1 and 13.2.2 of Safe Quality Food (SQF).

Below we summarize the requirements of these three schemes.

Maintenance program

Converters must implement and document a maintenance program to prevent contamination and reduce equipment breakdowns. A documented schedule for routine maintenance of all plant and processing equipment is required, with equipment failures and repairs recorded and incorporated into the schedule. The maintenance and site supervisors must be notified if any repairs or maintenance pose a potential food safety risk from foreign objects or contaminants. Additionally, requirements for new equipment should be clearly defined.

Manufacturer instructions

The manufacturer’s guidelines for installing, using, cleaning, disinfecting, verifying, calibrating, and maintaining equipment that could impact food safety must be followed.

Maintenance staff and contractors

Contractors involved in maintenance or repair must be monitored by a responsible staff member. Both maintenance staff and contractors must follow the site’s personnel hygiene requirements. Contractors working on-site must be trained in the site’s food safety and hygiene procedures or be escorted until their work is completed.

Inspections

Equipment at risk of causing product contamination due to failure or damage must be inspected at set intervals, with results documented and corrective actions taken. Equipment crucial to food safety must be regularly evaluated by an industry-recognized professional or authority.

Clear working environment

Maintenance work must not compromise product safety or quality. After maintenance, a documented clearance procedure must confirm that contamination hazards have been removed and equipment is ready for production.

Tools and equipment must be cleared and stored properly after use. Engineering workshops should be controlled to prevent debris from entering production or storage areas.

Maintenance staff and contractors must remove all tools, parts, and debris after repairs, and notify the supervisor so that hygiene actions and a pre-operational inspection can be completed before resuming operations.

Colorsat Switch ink dispensing system, well-maintained since its installation in 2016

Food grade lubricants and paints

Lubricants that may contact water or food must be approved for food-contact use, and equipment above raw materials, packaging, or conveyors must use food-grade lubricants to prevent contamination.

Additionally, paint used in food sector packaging areas and product contact zones must be suitable, intact, chip-free, and not applied to any food-contact surfaces.

Repairs

Temporary repairs must not pose a food safety risk and should be included in routine inspections and cleaning programs. A plan must ensure these repairs don’t become permanent. Temporary fixes using materials like tape or cardboard are only allowed in emergencies when there’s no risk of product contamination, and their deployment must be time-limited, documented, and scheduled for proper correction.

GSE’s services to comply with maintenance-related requirements

GSE offers a range of solutions to meet maintenance-related GFSI requirements.

With each installation, GSE provides a user manual with a plan and instructions for maintenance. We advise following these instructions to ensure optimal performance, safety, and longevity of the equipment. These instructions are tailored to the specific design and function of the machine, providing guidelines on how to clean and maintain it properly, prevent breakdowns, and avoid costly repairs.

In general, our machines are designed for low maintenance, featuring minimal moving parts and easy-to-clean stainless steel components that can become soiled by ink. Most maintenance work involves limited cleaning and component inspections. For instance, the cleaning solution in the dosing head’s cleaning unit needs to be refreshed daily. Replacing parts is only necessary when malfunctions occur. For various operations, such as cleaning and replacing valves, GSE provides standard operating procedures (SOPs).

Our standard machines have no parts that require lubrication. However, optional components, such as some parts of the roller conveyor for ink bucket transport, or the shaft of a mixer, sometimes need to be lubricated with a dry lube that leaves no residue.
If you need on-site assistance for inspection, calibration, or servicing of your ink dispensing system, we can schedule a visit from one of our trained technicians. Our technicians are certified in risk assessment and safe work practices and typically undergo food safety and hygiene training before accessing your site. This service may be included in a support and service contract. The advantage of having a visit as part of this contract is that you will receive a comprehensive inspection report. Additionally, there are no extra charges for any scale calibration reports.

GSE’s commitment to effective maintenance and support not only ensures your equipment remains in optimal condition with minimal downtime but also upholds the highest standards of food safety and compliance.