4  SPECIFIC PRINCIPLES TO COVER EXCEPTIONS AND ADDITIONS TO THE DESIGN, CONSTRUCTION AND CLEANING OF ALL BAKERY EQUIPMENT, AS DEFINED IN SECTION 3.

4.11  DESIGN REQUIREMENTS FOR INGREDIENT WATER COOLERS AND ICE MAKERS (ATMOSPHERIC-TYPE)

4.11.1 Definitions

4.11.1.1 The product zone shall include all surfaces of the cooling and ice making equipment with which the ingredient water has contact before, during or after cooling or freezing.

4.11.2 Specific Design Requirements

4.11.2.1 All product zone surfaces shall be enclosed, but shall be readily accessible either in an assembled position or removed.

4.11.2.2 Adjacent product zone surfaces shall not be less than 4 inches (100mm) apart, or shall be readily removable. Where two or more such surfaces are so spaced, they shall not extend more than 36 inches (900mm) from open side. Where cooler surfaces are submerged, they shall have a minimum clearance of 4 inches (100mm) from tank bottom and sides.

4.11.2.3 Pipe coils or plates shall be so designed and located within the tank as to permit the cleaning of all sections, joints and fittings, as well as adjacent tank surfaces.

4.11.2.4 Scrapers, ice breakers, drums or other harvest devices on ice machines shall be readily removable, or shall be equipped with a specifically designed system for effective in-place cleaning. If surfaces are intended for in-place cleaning, tubing, pipe fittings and valves shall be so arranged that cleaning solutions can be circulated throughout the fixed system. Such systems must be completely drainable. Systems designed for cleaning in place (CIP) must have removable section for inspection.

4.11.2.5 A drain pipe at least one pipe size larger than the inlet, but not less than 1½ inches (40mm), shall be provided and the tank or storage reservoir sloped thereto so as to permit complete drainage.

4.11.2.6 In all tanks, excluding ice storage bins, an overflow pipe at least one pipe size larger than inlet shall be provided to prevent flooding. The discharge of this pipe from the tank shall be provided with a readily removable, corrosion-resistant screen of 30 mesh.

4.11.2.7 The discharge opening of the water inlet shall be located at least 1 inch (25mm), or twice the diameter of the inlet pipe, whichever is greater, above the flood level rim.

4.11.2.8 If ball float valves are used, the ball and arm assembly shall be of corrosion-resistant material, seamless and smooth. The valve body and mechanism shall be located above the flood level rim.

4.11.2.9 Distributing troughs shall be readily removable.

4.11.2.10 A corrosion-resistant enclosure shall house the cooler surfaces and shall have lift-off cover plates providing access to the sides of the cooler surfaces. Such cover shall prevent water from passing in or out around the edges.

4.11.2.11 Complete drainage shall be provided for all points where water (condensate and drip) may collect.

4.11.2.12 All surfaces of insulation, unless enclosed and sealed, shall be impervious to moisture, and shall be accessible for cleaning.

4.11.2.13 Tank covers shall be provided, and shall be of the overlapping type, and if they are in two or more parts, they shall be tight-fitting in closed position, and shall be so constructed to prevent foreign material on the cover from falling or draining into the product zone when cover is opened or closed. Hinged covers shall pivot outboard. No horizontal stationary surfaces shall be used where such surfaces exceed 36 inches (900mm) from outside of machine. If surface exceeds 36 inches (900mm), surface must be capable of reach from both sides.

4.11.2.14 Stationary portions of the tank cover shall be sealed around the edges, and around pipes and fittings passing through them.

4.11.2.15 Refrigerant piping or compartments must be designed to permit possible leak sources, such as seals, flexible connections and bushings on rotating drums, from contacting the product zone. These points must be kept in non-product zone.

4.11.2.16 All refrigerant piping shall have shut-off valves on either side of evaporator to allow shutdown in case of leaks.

4.11.2.17 Refrigeration coils or plates exposed within the product zone shall be smooth. Fin-type coils or plates shall not be permitted.

4.11.2.18 Ventilation louvers for openings shall be effectively screened with 30-mesh screen or equivalent. Screens shall be removable for easy cleaning. Compressor compartments are exempt from this requirement provided the area inside is accessible. All louvers shall be of drip-proof construction.

4.11.2.19 Protective devices such as strainers, filters, check valves and pressure control valves shall be accessible for cleaning.

4.11.2.20 The product zone valves, exclusive of water supply inlet valves, shall conform to the material and design provisions of Section 3.1, and shall be accessible for cleaning.

4.11.2.21 Temperature sensor connections of 2 inches (50mm) or smaller in diameter shall be welded into place and ground flush on the interior, and shall contain no internal threads or inaccessible recesses in the product zone. Threadless flange connections shall be used at openings larger than 2 inches (50mm), and shall be welded in place and ground flush on the interior.

4.11.2.22 Meters shall conform to the requirements of Section 4.26.

4.11.2.23 Lubrication points shall not be located directly above a product zone.