KS-1 KNIFE SANITIZER
Description
The KS-1 knife sanitizer is a dip-style thermal knife sanitizer with intermittent overflow. Its internal boiler produces the 180F/82C water used to sanitize knives, and its controls precisely manage temperature and minimize the amount of water used in the process. The 180F/82C water in the sanitizing well refreshes roughly every four minutes, using approximately sixteen ounces of water, with overflow going into the drain.
Current Situation
Knives are used at various steps in the meat slaughtering process. The USDA-FSIS and the EU Meat Hygiene directives require disinfection of hand-held tools (knives, hooks, etc.) during production, with water maintained at 180F/82C or higher. Disinfection of knives is considered a component of overall hygiene control.
Water at a temperature above 180F/82C provides a high antimicrobial effect, reducing microorganisms by 4 Log or 99.99% to a level that is not harmful to human health or the quality of food produced. Removing organic material from the knife blade before sanitizing is recommended to achieve this high antimicrobial effect, as protein coagulates at 180F/82C. Using two knives alternately at each station is recommended to ensure proper disinfection dwell time.
North American meat harvest facilities overwhelmingly use dip-style knife sanitizers with continuous overflow. These knife sanitizers provide a constant stream of 180F/82C water that overflows into a drain. Systemic 180F hot water from a facility’s boiler system feeds the knife sanitizers. Each knife sanitizer uses one to two gallons of water per minute.
This leads to…
• Excessive water and energy usage.
• High operating costs, including acquiring, heating, distributing, treating, and disposing of water.
• Unfavorable working conditions with the scalding heat generated at the operation site.
• The constant release of steam leads to surface condensation, which can foster the growth of microorganisms and compromise food safety.
A large harvest facility will have more than fifty dip-style knife sanitizers. Some facilities have over one hundred sanitizers operating eighteen hours per day, seven days per week, and fifty weeks per year. This translates into tens of millions of gallons of water, thousands of MMBtus of energy, and millions of dollars in operating costs annually per facility.
Why KS-1
Most meat processing companies have the same goal: reduce water and energy usage and reduce costs.
The KS-1 uses less than four ounces of water per minute, reducing annual water and energy usage by 95-99% compared to dip-style knife sanitizers with continuous overflow.
By replacing fifty or more dip-style knife sanitizers, the annual usage reduction will be in the millions of gallons of water and thousands of MMBtus of energy. In turn, cost savings will be in the millions of dollars. Additionally, the return on investment for each unit replaced is less than six months.
The KS-1 is a significant and quantifiable way to reduce water and energy usage and reduce costs!
Food Safety
The USDA-FSIS and the EU Meat Hygiene directives require disinfection of hand-held tools (knives, hooks, etc.) during production, with water maintained at 180F/82C or higher. Disinfection of knives is considered a component of overall hygiene control. In addition, water at a temperature higher than 140 degrees Fahrenheit liquefies fat, and it does not require a knife cleaning step or freshwater rinse after sanitizing.
Operator Safety
Working conditions at the operation site are improved because the boiler and basin are insulated, eliminating heat in the enclosure. The outer skins of the enclosure are at ambient temperature. The knife sanitizing well is covered, limiting access and protecting operators from scalding water. Furthermore, steam release is minimal due to the sanitizing well’s small surface area and the sanitizing well cover.
Extreme Environment Protection
The KS-1 enclosure has a NEMA 4X rating and features a removable, cleanable double door seal, as well as condensation prevention, ensuring long-term survival in harsh environments.
Easy to Clean
The knife block and sanitizing well cover can be removed for cleaning without requiring any tools. Both are made of HDPE, which ensures no knife-to-metal contact. Both can be easily customized based on customer requirements to accommodate scabbards, hooks, and other similar objects. Additionally, the standard knife block can hold up to four boning knives.
Small Footprint
You can mount the equipment on existing square tubing or the floor, and the KS-1 new 11 x 11.25-inch footprint ensures it fits into the tightest spaces.
Use cost-benefit analysis to determine cost savings and ROI. This includes savings for acquiring, heating, distributing, treating, and disposing of water.
Technical Information
Voltage | 120 VAC Standard, 208, 240, and 277 VAC available on request |
FLC | 7 to 13.5 A, dependent on Voltage |
Phase | Single, Neutral is required |
Frequency | 60 Hz |
Sanitizing Temperature Set Point | 180 deg F |
Water Connection | 1/2-inch NPT |
Water Pressure | 30 to 100 psi |
Water Supply Flow Rate (minimum) | 1.0 gal/min |
Water Use | Approximately four ounces per minute |
NEMA Type | 4X Extreme Duty |
The USDA-FSIS requires sanitization of equipment using hot water at a minimum of 180F to address microbiological and pathological contaminants.
The North American meat industry overwhelmingly uses dip-style hot pot sanitizers, providing 180F water with continuous overflow. These sanitizers utilize systemic hot water from the facility boiler system.
Is 180 degree F water required for sanitizing equipment and utensils used during livestock carcass dressing procedures?
Establishments are required to maintain equipment and utensils in a sanitary condition so as not to adulterate product, 9 CFR 416.3, and to clean and sanitize that equipment and utensils as frequently as necessary to prevent adulteration, 9 CFR 416.4(a).
When dressing livestock carcasses that are affected by any disease condition mentioned in 9 CFR 311.16, 9 CFR 311.16(b) requires sanitization of equipment using hot water at a minimum of 180° F.
Chemical sanitizers may be used in lieu of 180° F water if the requirements of 9 CFR 416.4(c) are met and the chemical sanitizer used provides an equivalent sanitizing effect.
Stop pouring water and energy down the drain!
