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3035 Denmark Ave - MN Dept. of Agriculture Plan Review Sam's Club #4738p July 28, 2009 Jolynda Cooper PB2 Architecture and Engineering 710 W. Roselawn Drive Rogers, AR 72756 Dear Ms. Cooper: General Comments MINNESOTA DEPARTMENT OF ( AGRICULTURE D p © W rs' FROM THE FARM TO YOUR FAMILY v v Dakota County JUL 3 1 2009 License # 20070549 This office has completed a preliminary plan review for the Sam's Club #4738 store located at 3035 Denmark Avenue in Eagan, Minnesota. The plan review was conducted as required by Minnesota Statute Chapter 28A and the Minnesota Food Code Chapter 4626. The Minnesota food code is the primary governing document for this review and may be found on line at www.l eg.state.mn.us /leg/statutes.asp by requesting Minnesota Rule Chapter 4626. All appropriate permits from the local authorities shall be applied for and issued prior to starting, any work on the site. Failure to comply with this may result in a delay or this office not issuing your retail Food Handlers license until the proper permits are issued. In addition if your water is supplied from a well you will be required to provide a current proof of water potability. Our inspector will verify that the permits have been obtained. The Minnesota Department of Agriculture grants preliminary plan approval to the plans for this proposed food establishment. Upon this agency certifying that all items in this review have been addressed, final plan approval will be granted. This preliminary plan approval is based upon the supposition that construction and equipment plans submitted to this office do not change. Any deviation from the approved plans and specifications must have prior approval from this agency. Preliminary approval of the plans and specifications does not constitute endorsement or acceptance of the completed establishment. Periodic on -site inspections may be made during construction. A final inspection of the completed establishment, with equipment installed, must be conducted to determine if it complies with the requirements of the Minnesota Food Code. Contact Food Inspector Martha Steinhart at 651- 283 -0040 to arrange for a final inspection. You are listed as the contact for this project at479- 878 -3515. This review was for major remodeling in a 136,532 square foot store with groceries, deli, bakery, produce and meat departments. The existing snack bar will be demolished and replaced with a new snack bar. Some refrigerated cases will be replaced with new cases. Room finishes will be removed and replaced with new room finishes to include in, but not limited to the following areas: rotisserie display area, produce prep and bakery. The existing Demo room will be demolished and a new relocated Demo room built. The janitor closets and restrooms will be remodeled. Some refrigerated cases will be refurbished. The meat, bakery and produce walk-in coolers and bakery walk -in freezer will be remodeled. A proofer will be removed from the bakery prep area. The plans indicate the following will be added: 88' Tyler single -deck meat cases, 116' Tyler multi -deck deli cases, 48' Hill Phoenix produce cases and 28' Tyler rear load produce cases. A Hardt Zone 8 hot food case will replace the existing hot food case in the deli. A new three compartment utensil washing sink and hand washing sink will be installed in deli prep. A new produce prep area will be constructed. A new one compartment produce prep sink will be installed in the produce prep area. The plans indicate the produce prep sink in the produce prep area will be used only for rinsing and sorting raw produce and shall not be used for any other purpose, including slicing produce and warewashing. At this time, a HACCP plan has not been submitted for review. In addition, I have found nothing within the plans or application to indicate a HACCP plan review is necessary. Licensing of your firm is dependent upon proper installation of an approved water supply, plumbing and waste system. Our inspector will review your approval letters from the appropriate authorities to insure these requirements are met. Pursuant to MS 31.175 a license shall not be issued or renewed without approved plumbing, water and waste systems. (4626.0980, 4626.1030) (5- 101.11, 5- 401.11) Also our inspector will review approvals from building and fire officials before granting final approval. Please provide copies of approvals for review at the final inspection. 625 Robert Street North • St. Paul, MN 55155 -2538 • 651 - 201 -6000 • 1- 800 - 967 -2474 • www.mda.state.mn.us An Equal Opportunity Employer And Provider • TTY: 1- 800 - 627 -3529 Page 2 Minnesota requires that all equipment be Certified to the National Sanitation Foundation Standards for clean abilit durabilit and s erformance. New or used e i ui s ment not meetin • these standards is • rohibited. An equipment installed that does not meet these standards may be ordered removed. As submitted, the following food equipment appears to be listed as meeting the applicable NSF standard: Lancer 4500 series ice - beverage dispenser, Scotsman CME -806 ice maker, True TPP -67 pizza prep table, Metro wire shelving, Holman 214HX pretzel oven, Wisco 850 pretzel warmer, Profit Master syrup rack, Lincoln 1162 -080 -A conve or izza oven Hatco GR2SDH -48T izza dis la Dou hPro DP -1100 dou h i ress Crown -Verit CV -3WHS Barker steamer Stoeltin F131 frozen 0 ur dis True TUC -27 under counter refri erator enser electric hot do BDPF self service refrigerated deli merchandiser, Tyler NMGHP fresh meat case, Tyler N6DHPM deli refrigerated case T ler NP i roduce case K sor/Warren B3 refri erated cake case K sor/Warren I D6 refri erated multi deck cake case and Hardt Zone 8 hot food case. The walk -in cooler and freezer in the snack bar are manufactured by NSF fabricator Kvsor Panel. The prep sink, three compartment utensil washing sink,.prep tables, pizza cutting table, condiment counter and beverage counter were indicated to be manufactured by Win -holt, an NSF fabricator. The plans indicate a Captive Aire 5424ND -2 Type I hood with an Ansul chemical fire suppression system will be installed over the Lincoln 1162 -080 -A conveyor oven in the Snack Bar. The Snack Bar floor plan shows two conveniently located hand washing sinks, a one compartment food prep sink, a three compartment utensil washing sink and a mop sink. The new Demo room will have a three compartment utensil washing sink and a hand washing sink. As submitted on the room finish schedule, the following room finishes appear to be acceptable. The Snack Bar and Snack Bar utili room will have a resinous seamless e s ox floorin s stem and 4" e ' ox base fiber lass reinforced Mastic panel covered walls and vinyl covered ceiling tile. The remodeled bakery and rotisserie display area will have a new resinous epoxy flooring system and 4" epoxy base. The walls will be covered with new fiberglass reinforced lastic s anels in the remodeled bake rotisserie dis • la area demo room 'anitor room and s roduce s re s areas. Vinyl covered ceiling tiles will be installed in the demo room. The bakery and rotisserie display areas will have painted ceilings. The remodeled restrooms will receive a ceramic tile floor and base, ceramic tile walls and painted ceilings. The plans indicate a stainless steel backsplash wall covering will be installed under the hood for the Lincoln conveyor oven. The stainless steel backsplash under the hood behind and on the side of the rotisserie oven in the deli will be extended, if necessary to more completely cover the wall. Concerns: 1) Please provide information to verify the Icee BL -A slushie machine, Hill Phoenix UP produce case and the Air Systems WMSSTB60 table are listed as meeting the applicable NSF standard. This could not be determined with the information provided. Hill Phoenix is a NSF fabricator, but information could not be found for the model UP produce case. Food Inspector Steinhart will verify the food equipment is marked to indicate it meets the applicable NSF standard. 2) The plans submitted indicate the general scope of work includes the reskin of the self - service cake case and ice cream cases. The refurbishing of these cases must be done only by the original equipment manufacturer or any parts replaced must be replaced with parts meeting the original manufacturer specifications. Per Mr. Chris Bosshart of NSF International, NSF would no longer consider the food equipment listed as meeting NSF standards, if its been modified by any person other than the original manufacturer. The remodel of existing walk -in coolers and freezers must be completed by the original manufacturer or a firm approved by the original manufacturer to do this work. 3) The plans show an insect control device in the snack bar utility room. This device must not be located within three feet horizontally of any food preparation area, utensil washing area or unpackaged food or single service article storage area. 4) Sealed concrete is not an approved floor for the remodeled produce cooler, remodeled bakery freezer, remodeled meat cooler, remodeled bakery cooler or the new Snack Bar walk -in cooler and walk -in freezer. The plans submitted indicated the floor in the produce cooler, bakery cooler and bakery freezer is existing and will remain, but did not indicate the type of flooring which is existing. The seamless resinous epoxy flooring system is an example of an approved floor for the walk -in coolers and freezers. If the epoxy flooring system is used in walk -in freezers, the flooring specifications must indicate it is approved for freezer temperatures. The plans indicate the floor in the Snack Bar walk -in freezer is a self contained floor, but did not specify the floor material. Stainless steel or aluminum are approved freezer floor materials. The floor must be rust - resistant. Page 3 5) The room finish schedule indicates the floor in the proposed produce prep area is existing and will remain. Sealed concrete flooring will not be allowed in this area. The epoxy resinous flooring system with resinous base is acceptable in the produce prep area. 6) The room finish schedule did not indicate the type of ceiling in the produce prep area. The ceiling must be washable. 7) Sealed concrete flooring is not approved under full service cases. The epoxy resinous flooring is approved for under full service cases. Room Finish Schedule note #12 appears to indicate the epoxy flooring will run only 12 inches beyond the approximate line of the back edge of the case. Deficiencies: 1) Sealed concrete is not an approved floor for the Demo room and the walk -in produce cooler. The seamless resinous epoxy flooring system is an example of an approved floor for the Demo room and walk -in produce cooler. 2) Walk -in coolers and freezers must have approved base coving at the floor -wall junctures inside the walk -in coolers and freezers. Examples of approved base coving include the epoxy base coving, stainless steel or aluminum. The plans indicate the interior bases of cooler /freezer boxes with sealed concrete floors will be installed with a continuous silicone caulk bead with finger cove where wall panels meet the concrete slab. Caulking the floor -wall junctures inside walk -in coolers and freezers is not satisfactory without adding approved base coving. 3) The floor plan did not show a hand washing sink in the produce prep area, only a produce prep sink. A hand washing sink must be conveniently located in the produce prep area. 4) The specifications provided for the epoxy resinous flooring system did not clearly indicate if the flooring will meet the minimum thickness requirements specified below under Polymer Flooring Systems. In the Project Specifications manual under System Description, the floor thickness is indicated to be a nominal 1/8" thick, but under Installation, it is indicated the flooring thickness provided must be a minimum 1/8" thick. For polymer flooring systems installed in snack bars and sandwich preparation areas the minimum floor thickness required will be 1/8 ". In areas with ovens, fryers, etc. where heavy kitchen operations take place, the polymer flooring system must be a minimum of 3/16" thick containing a round aggregate to refusal. 5) The deli prep area does not show a food prep sink. If raw fruits and vegetables will be processed in the deli prep area, a food prep sink will be required. Equipment Food equipment shall meet the applicable National Sanitation Foundation (NSF) International food service standards. The equipment shall be determined by NSF International or an American National Standards Institute (ANSI) Z34.1 accredited independent entity, including Underwriters Laboratory or the Edison Testing Laboratory, to be equivalent to the NSF International Standard. The use of equipment, which does not meet the applicable NSF standard, is prohibited. Bakery equipment must comply with the Bakery Industry Sanitation Standards Committee (BISSC). (4626.0505)(4- 201.11) Custom fabricated or modified equipment must be constructed by a contractor listed by NSF International. The name and address of the fabricator for custom fabricated equipment must be identified. (4626.0505)(4- 201.11) All service counters and other millwork surfaces shall be protected with stainless steel, plastic laminate, or equivalent, covering all exposed wood. In areas where food equipment involves heat or moisture, or where food comes in contact with the surface, a stainless steel finish or approved equivalent material is required. Solid surfaces for food contact, such Corian or Gibraltor shall be constructed by a fabricator listed by an approved third -party testing agency. They are required to be installed on six -inch legs or a solid base. All areas of the custom fabricated counters shall meet the requirements of NSF International Standard No. 35. All hard grain decor wood (e.g. oak) shall be properly sealed with a polyurethane or varnish -like material. (4626.0505)(4- 201.11) Used equipment meeting NSF International, NAMA, or BISSC standards, specified at the time of installation is permitted if it: met the NSF International, NAMA, or BISSC standards, in effect at the time it was manufactured, remains in good repair, is capable of being maintained in a sanitary condition, and is approved by the regulatory authority. Your inspector will evaluate any used equipment to determine if it is acceptable. (4626.0505) (4- 201.11) Page 4 Provide multi -use equipment, utensils, and food storage containers that are smooth, easily cleanable, and resistant to pitting, chipping, or scratching. All food equipment in a retail food store must be designed as to be easily cleanable, durable and be adequate for its intended use. Household utensils or equipment is prohibited. The use of commercial equipment not meeting the NSF standards must be evaluated and approved prior to installation. (4626.0505)(4- 201.11) Retail shelving and refrigeration and freezer display cases shall be designed and constructed to be durable and to retain their characteristic qualities under normal use. (4626.0505)(4- 201.11) Provide sufficient refrigeration to hold all readily perishable food products at 41°F or less. Provide sufficient ventilation (e.g. louvers, etc.) for the compressor unit to evacuate any buildup of heat at the underside of the cold pans in and about the compressor area. (4626.0675.) (4- 301.11) If an ice machine or bulk water unit is to be installed, the waste drain must be properly plumbed and divert to an indirect waste (air break) floor drain. *(4626.1045 A.) (5- 201.11) Food Protection Provide a food thermometer for checking the internal temperatures of potentially hazardous foods. Thermometers must be provided in all coolers, freezers, and hot holding units where potentially hazardous food is stored, and must be located in an area that is representative of the true air temperature. (4626.0 705) (4- 302.12) The internal temperature of potentially hazardous food must be maintained at 41°F or below, or 140 °F or above, except during preparation. *(4626.0395(3 - 501.16) All freezer units shall hold food frozen. (4626.03 70)(3-501.11) Food on display must be protected from potential contamination from coughs, sneezes and improper handling by installing properly constructed food shields, the use of packaged food items or other effective means of protection. (4626.0320)(3- 306.11) Provide tongs, ladles, spatulas, scoops, single- service papers, etc., to avoid unnecessary manual handling of dispensed food items. (4626.0330 A.) or * (4626.0330 B.) (3- 306.13) Utensils must be stored in an appropriate manner between uses. (4626.0275) (3- 304.12) Installations Seal (caulk) all annular openings around pipes and other conduits, where they pass through walls and floors. Seal all junctures between the wall surface and the edges of attached equipment with approved caulk/sealing compound. (4626.1395 A. (1) (6- 202.15) If conduit pipes are provided for beverage lines they must extend at least three to four inches above the finished floor elevation at both ends. The annular opening between the beverage lines and the conduit pipe must be sealed with a hard material and provide a cleanable fmish. (4626.1395 A. (1))(6- 202.15) All doors to the outside of the establishment must be self - closing and vermin proof. (4626.1395 A. (3.))(6- 202.15) Lighting Provide at least 10 -foot candles (110 LUX) of light intensity, at a distance of 30 inches from the floor, in the walk -in refrigeration units, dry food storage areas, and during periods of cleaning. Provide at least 20 -foot candles (220 LUX) of light intensity, at a distance of 30 inches from the floor, for areas where food is provided for consumer self - service, including buffets and salad bars, or where fresh produce or packaged foods are sold or offered for consumption, inside equipment including reach -in and under counter refrigerators, in utensil storage areas, in areas behind a bar used for ware washing, and in toilet rooms. (4626.1470)(6 - 303.11) Provide at least 50 -foot candles (540 LUX) of light intensity for areas where food employees are working with utensils and equipment where safety is a factor and areas used for ware washing. (4626.1470)(6- 303.11) Install effective shielding or shatter - resistant bulbs for all light fixtures over exposed food storage, food preparation, food display facilities, clean equipment, utensils and linens, and unwrapped single- service or single -use articles. (4626.1375)(6- 303.11) Page 5 Plum bing At least one toilet facility and not fewer than the number required by law shall be provided. *(4626.1075)(5 203.110) These facilities must be conveniently located and accessible to employees at all times. * (4626.1095)(5 204.11) Toilet rooms must be provided with adequate ventilation, hand cleanser, single -use towels or hand drying devices, tissue paper and waste paper receptacles. Toilet rooms shall have at least one covered waste receptacle for sanitary napkins, paper towels or diapers. (4626.1260)(5 - 501.17) Plumbing plans must be submitted to the Minnesota Department Labor and Industry, Engineering Unit, or delegated authority for review and approval prior to installation. All plumbing must be installed according to the Minnesota Plumbing Code, including current amendments. *(4626.1045) (5 202.11) Equipment connected to the potable water supply shall be protected from back - siphoning and back flow. Equipment with submerged inlet lines (dish machine, garbage disposal, steam table, urinal, etc.) shall be equipped with an approved backflow preventor, this includes all threaded hose bib connections. *(4626.1085) (5 203.14) If a post -mix beverage system is provided, an approved pressure -type, back -flow preventor upstream from the control valve on the carbonator (water line to the carbonator) is required. (Toilets shall be equipped with an anti - siphonage ball cock assembly. The water line serving a dipper well shall be permanently installed with an air gap on the water line entering the fixture. * (4626.1055) (5 202.13) Please contact a licensed plumber or refer to the Minnesota plumbing code: Install a hot water heater in accordance with NSF Standard #5. (4626.0505) (4 201.11) It must be of adequate size and recovery rate to provide hot water to all taps during peak water usage. Lack of hot water will require the installation of additional hot water capacity. (4626.1025) (5 101.13) If a grease interceptor or grease trap is required by the city building official, it shall be located to be easily accessible for cleaning and maintenance. The lid shall be water -tight and securely fastened in place. A grease removal device should be installed flush with the floor. (4626.1195)(5 402.13) If soap and chemical dispensing devices are installed on potable water lines, they shall be listed to ASSE plumbing standard 1055. (4526.1260) (5- 501.17) Sinks Install hand washing sinks in all food preparation, food dispensing, toilet rooms and utensil washing areas. Generally this is within 20 feet as a person walks. *(4626. 1095) (5 204.11) Provide hand cleanser, single - use towels, and a fingernail brush at the hand -wash sink located in the food preparation, and ware washing areas. Install a NSF three compartment, utensil - washing sink (4626.0680) (4 301.12) with integral drain boards, racks or tables, (4626.0685) (4 301.13) for the proper cleaning and sanitizing of all multi -use equipment and utensils. The size of the sink compartment must be large enough to accommodate the largest utensil/equipment, which is to be cleaned and sanitized. Provide and use an appropriate chemical test kit to determine the strength of the sanitizing agent in the final rinse water of the three- compartment sink. ( 4626.0715) (4 302.14) Install a separate food preparation sink if raw food will be cut or combined with other ingredients, or otherwise processed. (4626.0780) Install at least one service sink or curbed unit with a floor drain for disposal of mop water and similar liquid waste. (4626.1080)(5 203.13) Provide hooks or hang -up brackets at the utility sink for storage of mops and brooms. Utensil washing and hand washing sinks are designed and approved only for their intended use. Storage Provide adequate shelving covering the food operation to ensure that food products, utensils or single - service articles are stored at least six inches off the floor. (4626.0730 A.) Food storage shelving used in walk -in refrigerators must be in conformance with NSF standard #2. Chrome or zinc- plated shelving without an approved factory applied hard -baked protective coating is not approved for this purpose. (4626.0505 B) Retail shelving shall be designed and constructed to be durable and to retain their characteristic qualities under normal use conditions. (4626.0505A.) Page 6 Provide an area for storage of employee's personal belongings that is separate from food, clean equipment, and single service supplies. (4626.1560) Provide an approved area for storage of chemicals, which is separate from food, food equipment, and single service articles. (4626.1600) Room Finishes The floors, floor coverings, walls, wall coverings, and ceiling surfaces shall be designed, constructed, and installed so they are: a) smooth, durable and easily cleanable where food operations are conducted; b) nonabsorbent, for food preparation areas, walk -in refrigerators, ware washing areas, toilet rooms, janitorial areas, laundry areas, interior garbage, refuse storage rooms, and areas subject to flushing or spray - cleaning methods, or other areas subject to moisture. (4626.1325) Polymer flooring systems: If polymer flooring such as an epoxy or urethane systems are installed they must be 1/8 inch minimum in thickness in snack bars and sandwich preparation areas and 3/16 inch minimum in thickness in areas where ovens, fryers and other heavy kitchen operations take place and contains a ground aggregate to refusal The finish coat must render the floor surface smooth to the extent that it can be cleaned with available cleaning equipment. A test area should be provided so that our inspector can verify the flooring thickness. Concrete, sealed or unsealed, is prohibited: a) where food product packages, containers, or cases in those areas are opened. b) Under equipment in food preparation and service areas including under service cases. c) in walk -in refrigerators or freezers, ware washing areas, toilet rooms, mobile food establishment servicing areas, hand wash areas, janitorial, laundry areas, interior garbage and refuse storage rooms, areas subject to flushing or spray - cleaning methods and areas subject to moisture. (4626.1335 D.) Unsealed concrete is permitted: For use where outside garbage and refuse containers are placed, including compactors stored on a smooth and nonabsorbent surface. (4626.1230) Vinyl flooring is prohibited: In a walk -in cooler or freezer. (4626.1335 C.) Vinyl flooring is not allowed in kitchens, deli areas, behind fast food or service counter areas unless the manufacturer recommends it for this use. It is allowed in storage rooms and retail areas including under food and beverage counters. Proof of recommended use will be required in the form of sales material or a letter from the manufacturer specifically showing the recommended use before approval of this flooring will be granted. Floor and wall junctures: Shall be coved and closed to no larger than one millimeter (1/32 inch) when cleaning methods other than water flushing are used for cleaning floors. At the floor wall juncture where the fiberglass panel meets the floor an acceptable base coving such as stainless, quarry or other pre- approved materials must be installed. (4626.1345A.) Where water flushing is used coving shall be sealed. (4626.1345B.) Glued rubber coving may not be acceptable on fiberglass panels, as it may not bond to the fiberglass material. Floor surfaces: Shall in the food preparation, food storage, and utensil washing areas be constructed of smooth, durable, nonabsorbent, easily cleanable materials, which resist the wear, and abuse to which they are subjected. The walls and ceiling in the food preparation, utensil washing and toilet room areas shall be smooth, non - absorbent, and easily cleanable. (4626.1335A) Ceilings: Perforated or fissured drop lay -in ceiling panels are prohibited in food preparation, food service, and utensil washing or toilet room areas. (4626.1360B.) Ventilation All heating appliances which generate either excessive heat, vapors, condensation, greases, odors or fumes, must be properly situated beneath a mechanical exhaust canopy. The canopy and hood construction must meet the applicable standards of the NSF. (4626.0505) In addition, the requirements of the 2001 Uniform Mechanical Code and the 2001 amended Minnesota Building Code covering commercial kitchen ventilation systems must be met. Additionally vent less systems requiring alternative methods shall meet standards UL 710B, (incorporating EPA 202, UL 197), NFPA 96 chapter 13 and have the local building and fire official's approval. (4626.1380) (4626.1475) Page 7 In accordance with the Minnesota Clean Indoor Air Act, this establishment shall be posted as NO SMOKING ALLOWED. Post signs at all public entrances. This facility may not be constructed, remodeled or converted, except in accordance with the plans and specifications as approved by this department. Please contact me for approval of any proposed changes or additions. (4626.1720) Thank you for your cooperation in addressing the items outlined in this letter. I shall remain available for consultation and review of your facility's construction progress. Should you encounter any problems through the course of your construction or equipment installation activities, please call me at 651- 201 -6214. Sincerely, Rick Bruecker Food Standards Compliance Officer Dairy and Food Inspection Division RPB:dg C: Martha Steinhart, Food Inspector Lorna Girard, Supervisor City Building Official Heather Edmiston Miscellaneous