Food Engineering logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • TOPICS
  • EXCLUSIVES
  • MEDIA
  • FOOD MASTER
  • EVENTS
  • RESOURCES
  • EMAGAZINE
  • SIGN UP!
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest Headlines
  • Manufacturing News
  • People & Industry News
  • Plant Openings
  • Recalls
  • Regulatory Watch
  • Supplier News
  • PRODUCTS
  • New Plant Products
  • New Retail Products
  • TOPICS
  • Alternative Protein
  • Automation
  • Cannabis
  • Cleaning | Sanitation
  • Fabulous Food Plants
  • Food Safety
  • Maintenance Strategies
  • OEE
  • Packaging
  • Sustainability
  • More
  • EXCLUSIVES
  • Plant Construction Survey
  • Plant of the Year
  • Sustainable Plant of the Year
  • State of Food Manufacturing
  • Top 100 Food & Beverage Companies
  • MEDIA
  • Podcasts
  • Videos
  • Webinars
  • White Papers
  • EVENTS
  • Food Automation & Manufacturing Symposium and Expo
  • Industry Events
  • RESOURCES
  • eNewsletter
  • Custom Content & Marketing Services
  • FE Store
  • Government Links
  • Industry Associations
  • Market Research
  • Classified Ads
  • EMAGAZINE
  • eMagazine
  • Archive Issue
  • Advertise
Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!
Food Safety

Food Safety: Time to check the plumbing

By Richard F. Stier
column
September 10, 2012
Processors must understand not only what materials are being moved through their plumbing systems but how these lines are designed and laid out. 
 
Do you ever think about how your plant is plumbed? Most plants have lines for wastewater, sewage, fresh water, recycled water and steam. If these systems are properly designed, they include backflow devices, air gaps, steam traps and sample ports. Depending on what the facility processes, there also may be product lines, CIP system lines, holding tanks and chemical waste to deal with. To ensure the integrity of their products, processors must understand not only what materials are being moved through their plumbing systems but how these lines are designed and laid out. 
 
Here are some basic guidelines to ensure food safety and quality:
  • An up-to-date plumbing diagram—The plumbing diagram should clearly delineate each of the items mentioned in the first paragraph, as well as  the direction of flow, type of line, location of backflow devices and absence of cross-connections between lines. Whenever changes are made to any system, the diagram must be revised and then dated and signed by the plant engineer indicating the diagram is accurate.
  • Cross-connections—The plumbing system must have no cross-connections between lines. However, when a beverage or sauce plant uses CIP, there will be one or more cross-connections between the product side and the chemical system. Therefore, the system design and controls must ensure no chance for leakage between the two systems.
  • Dead ends or legs—Product and water lines should have no dead ends or dead legs. These are areas that cannot be adequately cleaned or flushed. For instance, emergency eye wash stations are often left unattended for months, even though many are connected to the main plumbing system and are a serious source for dead end contamination. When conducting a spoilage incident at a tomato processor, our team identified a large number of dead legs. Lengths of pipes went nowhere, yet branched off the main processing lines. When we cracked the valves at the end of these, they were loaded with spoiled paste. However, dead legs are not always associated with piping. My colleague was asked to help a beverage processor troubleshoot a problem with off-flavors. He deduced there was probably a dead spot within the water lines and recommended breaking through the floor to examine them. Under the floor, he found a reservoir of stale water that had adversely affected the product’s flavor. He also found the reservoir had cracked, allowing groundwater to enter and contaminate the process water.
  • Backflow devices—All water lines should have backflow devices that are highlighted on the plumbing diagram. They can be one-way valves or air gaps. The water main or mains coming into the facility must also have a backflow device. Many states mandate backflow devices on water mains be inspected and tested by a certified plumber at least once a year. These documents must be kept on file.
  • Floors and drains—If a food plant has wet processing operations, floors must be designed with an adequate slope or falls to properly carry waste water to the drains. Locating drains directly beneath outlets can minimize the need for cleaning. It also is important to know which drains are most likely cross-connected and to take steps to prevent the drain “P” traps from becoming a source for airborne contamination. Drains may be designed with vapor traps or screens. Sanitizer blocks in drains minimize the potential for microbial growth. Quat rings and quat socks help ensure the drain system below the floor will continually be bathed with an antimicrobial solution.  
 
All food processors must have a program to monitor water quality since water is a primary ingredient or used to mix ingredients. It also is certainly used for rinse downs on equipment that has direct food contact. 
 
The sampling program varies with the water source. Processors using well water should test their water at least once a quarter. These operations should also test water from various locations within the plant. Processors drawing from a city water source should test water from various locations within the plant at least once a year. It is also a good idea to ask the local water district for its test results annually. 
 
Of course, testing without established specifications is a waste of time. The testing program must describe the corrective actions required if the sampling results indicate the water is out of specification, as well as what to do about  any product that was affected by the water. 
KEYWORDS: CIP/COP wastewater water

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Richard stier 200px
Richard Stier is a consulting food scientist who has helped food processors develop safety, quality and sanitation programs. He believes in emphasizing the importance of how these programs can help companies increase profits. Stier holds degrees in food science from Rutgers University and the University of California at Davis. He is a Contributing Editor for Food Engineering. Email: rickstier4@aol.com

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • Global Organic Food & Beverage Market to Grow

    Global Organic Food & Beverage Market to Grow

    With a CAGR of 12.07%, Bonafide Research estimates this...
    People & Industry News
  • skilled MEP worker

    Predicting Food and Beverage Manufacturing Trends for 2024

    The two words that should be kept in mind are labor and...
    Automation
    By: Derrick Teal
  • cleaning and sanitation

    The basics of cleaning and sanitation in food plants

    Sanitation maintains or restores a state of cleanliness...
    Food Safety
    By: Richard F. Stier
Subscribe For Free!
  • eMagazine
  • eNewsletter
  • Online Registration
  • Manage My Preferences
  • Customer Service

Food Plant Openings and Expansions May 2025

Food Plant Openings and Expansions May 2025

OT Cybersecurity Vulnerabilities in Food Manufacturing Facilities

OT Cybersecurity Vulnerabilities in Food Manufacturing Facilities

Understanding Impacts of OT Cybersecurity Events in Food Manufacturing

Understanding Impacts of OT Cybersecurity Events in Food Manufacturing

Food Plant Openings and Expansions April 2025

Food Plant Openings and Expansions April 2025

More Videos

Popular Stories

FMTE Formed by Four Food Manufacturing Companies

Coalition Unites Europe’s Food Manufacturing Technologies and Equipment Sector

Kraft Heinz DeKalb Distribution Center Rendering

Kraft Heinz Upgrades U.S. Manufacturing Facilities

Sanitation worker spraying water

Fighting the Foodborne Bacteria War with Cleaning and Sanitation

CHECK OUT OUR NEW ESSENTIAL TOPICS

Alternative ProteinAutomationCleaning/SanitationFabulous Food Plants

Food SafetyMaintenance StrategiesOEE

PackagingSustainability

Events

June 17, 2025

Refrigerated & Frozen Foods’ State of the Cold Chain

Kelley Rodriguez, Editor in Chief of Refrigerated & Frozen Foods, will be joined in this 60-minute webinar by industry experts to help unpack the latest research.

January 1, 2030

Webinar Sponsorship Information

For webinar sponsorship information, visit www.bnpevents.com/webinars or email webinars@bnpmedia.com.

View All Submit An Event

Products

Recent Advances in Ready-to-Eat Food Technology

Recent Advances in Ready-to-Eat Food Technology

See More Products

Plant of the Year

Related Articles

  • Food Safety: California's Proposition 65--It's time to end the hypocrisy

    See More
  • Antimicrobial activity of soy sauce

    Take the time to do food safety right

    See More
  • Food Safety: Ode to the pallet

    See More

Related Products

See More Products
  • food crime.jpg

    Food Crime: An Introduction to Deviance in the Food Industry

  • small-occ.jpg

    Occupational Health and Safety in the Food and Beverage Industry

  • The-Food-Business-Toolkit-Cover.jpg

    The Food Business Toolkit for Entrepreneurs (ebook)

See More Products

Events

View AllSubmit An Event
  • November 12, 2015

    Plumbing System Design for Food Safety

    On Demand Plumbing System Design for Food Safety, a Food Plant of the Future webinar presented by Hixson and co-sponsored by Food Engineering magazine, will cover plumbing design strategies that help facilities keep food safety at the forefront, maximize plumbing systems for expansion and change and provide the necessary durability for the future.
View AllSubmit An Event
×

Elevate your expertise in food engineering with unparalleled insights and connections.

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Food Master
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing

Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!