Ensuring food contact equipment meets sanitary design requirements is essential for food safety. FOODS.EDU.VN provides detailed guidelines to help you select and maintain equipment that minimizes contamination risks and promotes a safe food processing environment. Equip yourself with the knowledge to uphold the highest food safety standards, covering everything from surface materials to cleaning protocols, promoting safety and hygiene.
1. What Key Qualities Must Food Contact Equipment Possess?
Food contact equipment must be functional, efficient, economical, and easily cleaned and sanitized. Beyond mere functionality, modern food processing demands equipment that meets stringent hygiene standards to prevent contamination and ensure food safety.
1.1 Prioritizing Sanitary Design
Sanitary design is no longer an afterthought but a fundamental requirement. Previously, functionality, efficiency, and economy were the primary considerations in equipment design. However, with the advent of Hazard Analysis and Critical Control Point (HACCP) programs, sanitary design has become crucial. The U.S. Department of Agriculture (USDA) was one of the first major organizations to enforce the use of easily cleanable equipment, requiring approval for equipment used in meat, poultry, and egg processing facilities.
1.2 The Role of HACCP
The implementation of mandatory HACCP programs by the USDA has elevated the importance of sanitary equipment design. Processing companies now recognize that equipment must not only perform its intended function but also be designed to prevent microbial contamination. As a result, many equipment companies claim their products have sanitary designs. However, it’s crucial for processing companies to establish their own sanitary design criteria tailored to their specific operations.
1.3 AMI’s Sanitary Design Checklist
The American Meat Institute (AMI) has developed a comprehensive sanitary design checklist for the meat and poultry processing industry. This checklist provides valuable guidance applicable to a wide range of food processing equipment. By using such resources, processing companies can make informed decisions when selecting equipment that meets the highest sanitary standards.
2. What Should You Consider When Selecting New or Used Equipment?
When selecting new or used equipment, cleaning and sanitizing capabilities should be central to your decision-making process. Prioritizing ease of cleaning can save time and resources while enhancing overall hygiene.
2.1 Ease of Cleaning and Sanitizing
When evaluating new or used equipment, always consider the design and operational features that facilitate cleaning and sanitizing. Equipment that is easy to disassemble, clean, and sanitize reduces the risk of microbial growth and ensures compliance with food safety regulations. Look for features that minimize harborage points for bacteria and allow for thorough cleaning.
2.2 FDA Requirements for Food Contact Surfaces
According to FDA requirements, food contact surfaces on equipment must be non-toxic, non-absorbent, non-reactive, non-corrosive, and cleanable. These regulations are specific to food contact surfaces in or on food processing equipment. The materials used must not corrode when exposed to food products or cleaning and sanitizing chemicals. For instance, wood is not an approved food contact surface because it can absorb moisture and harbor microbes, leading to contamination.
2.3 Prohibited Materials
The use of cadmium, antimony, and other toxic metals is strictly prohibited in food contact surfaces. Soft metals, in general, are unsuitable for food contact because they can corrode or react with food. Specifically, 21 CFR, Part 110.40 states that “Food contact surfaces shall be corrosion-resistant when in contact with food” and must be maintained to protect food from contamination.
3. Why Are Welds Important in Food Contact Equipment?
All joined food contact surfaces must be butt-welded and free of overlap welds. Proper welding techniques are crucial for preventing microbial contamination.
3.1 Avoiding Overlap Welds
Joined food-contact surfaces that are overlap-welded create metal-to-metal contact points, which can flex, crack, and provide hidden niches for microbial growth. These niches are virtually impossible to clean, making them a significant source of contamination.
3.2 Eliminating Stitch or Spot Welds
Processing equipment, particularly in the food contact zone, should be free of stitch or spot welds. These types of welds leave voids that can harbor microbes. Microbes are extremely small, and many can fit into the voids created by stitch/spot welds.
3.3 Sealing and Finishing Welds
If stitch welding is necessary, the voids between the welds should be sealed with silver solder or by rewelding to fill in the gaps. The surface should then be ground and polished to create a smooth, cleanable surface. Caulk is not recommended because it can mold, harden, and fall out of the voids. All welds must be continuous, smooth, and polished in food contact surfaces, free of pits, cracks, and corrosion.
4. Should Food Processing Equipment Be Painted?
All equipment and component surfaces should be paint-free to prevent contamination and corrosion. Paint can chip and peel, leading to contamination and corrosion.
4.1 Risks of Paint
The harsh chemicals and high-pressure water used during sanitation can quickly strip paint off equipment surfaces. Once the paint is removed, the base metal is exposed to corrosion, and the loosened paint can contaminate the food being processed. This poses a significant food safety risk.
4.2 Alternative Coatings
Instead of paint, consider using materials like stainless steel or food-grade plastics that are durable, corrosion-resistant, and easy to clean. These materials can withstand the rigors of food processing environments without posing a contamination risk.
5. What Are the Best Designs for Equipment Legs and Bracing?
Open, inverted angle supports are best for equipment legs and bracing to ensure easy cleaning. Proper support structures prevent the accumulation of dirt and moisture.
5.1 Open Support Structures
Open supports, mounted with the internal angle facing downward or out to the side, eliminate hard-to-reach areas for cleaning. This design ensures that sanitation crews can easily access and clean all surfaces, preventing the buildup of dirt and debris.
5.2 Solid Legs and Bracing
If solid legs or bracing are used, they should be round or square but turned 45 degrees to create a diamond shape. This design provides sloped sides that prevent the accumulation of dust, dirt, and moisture. Any solid legs or bracing must be free of open holes, ends, or cracked welds.
6. How Should Fasteners Be Designed on Food Contact Equipment?
Food contact surfaces should not have any recessed fasteners to avoid potential contamination. The design of fasteners can impact the ease of cleaning and the risk of contamination.
6.1 Avoiding Recessed Fasteners
Recessed fasteners, such as Allen heads and Phillips screw heads, should be avoided on food contact surfaces. The product zone should be free of bolts, nuts, or other fasteners that could loosen and become a foreign-object hazard. All nuts should be mounted on the outside of the equipment, and exposed threads in product zones should be covered with sealed cap nuts.
6.2 Secure Mounting of Fasteners
Ensure all fasteners are securely mounted to prevent them from loosening during operation. Regularly inspect fasteners to ensure they remain tight and in good condition. This proactive approach helps minimize the risk of foreign-object contamination.
7. What Design Should Rolled Edges on Equipment Have?
Rolled edges on equipment, including work tables, should not be rolled more than 180 degrees to avoid creating hard-to-clean flat areas. Proper edge design is crucial for maintaining hygiene.
7.1 Optimal Edge Design
Edges rolled more than 180 degrees create flat areas that are extremely difficult to access and clean. The ideal design allows for easy access from the exterior for cleaning. Edges should be shaped to prevent the accumulation of dirt and grease.
7.2 Inspecting Equipment Edges
When purchasing equipment, always inspect the edges to determine their shape and accessibility for cleaning. Edges that are not easily cleanable can become breeding grounds for bacteria, posing a significant food safety risk.
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8. How Should Equipment Legs Be Designed for Cleanliness?
Equipment legs should be easy to clean around, with no niches, cracks, or exposed threads where dirt and debris can collect. Proper leg design facilitates thorough cleaning.
8.1 Design Considerations
Legs should be designed to support the equipment off the floor, with a minimum clearance of 12 inches (depending on the buyer’s requirements), to facilitate cleaning underneath. This clearance allows sanitation crews to easily access and clean the floor around the equipment, preventing the buildup of dirt and debris.
8.2 Material and Construction
The legs should be made of a material that is easy to clean and resistant to corrosion. Avoid legs with niches, cracks, or exposed threads where dirt and debris can accumulate. Smooth, seamless designs are best for maintaining hygiene.
9. What Materials Are Best for Faceplates on Gauges and Sensors?
Faceplates on gauges, sensors, sight glasses, and other surfaces should be made of shatterproof, easily cleanable materials like polycarbonate. Selecting appropriate materials is vital for durability and hygiene.
9.1 Material Properties
Shatterproof materials like polycarbonate are ideal for faceplates because they are durable and resistant to damage. These materials are also easy to clean, ensuring that they can be properly sanitized to prevent contamination.
9.2 Removable Enclosures
Enclosures for gauges and sensors should be easily removable from the mounting surface for cleaning. This design allows sanitation crews to thoroughly clean all surfaces, reducing the risk of microbial growth.
10. How Should Control Boxes Be Designed and Mounted?
Control boxes should have sloped, cleanable tops and doors without piano hinges. Proper design and mounting prevent contamination and facilitate cleaning.
10.1 Design Features
Control boxes should have sloped tops to prevent the accumulation of dust and moisture. Doors should be free of piano hinges, which can be difficult to clean. These boxes should be constructed to withstand the water pressure used during sanitation.
10.2 Mounting Requirements
Control boxes should be mounted on support posts, frameworks, or standoffs, with a minimum clearance of one and one-half inches from the nearest surface to provide adequate cleaning behind the boxes. This clearance allows sanitation crews to easily access and clean all surfaces, preventing the buildup of dirt and debris.
11. Where Should Bearings Be Located on Equipment?
All bearings on the equipment should be outside the product zone to prevent lubricant contamination. If they must be in the product zone, they should be sealed.
11.1 Bearing Placement
Placing bearings outside the product zone minimizes the risk of lubricant leakage into the product. If bearings must be located in the product zone, they should be sealed or capped to prevent leakage.
11.2 Material Compatibility
All bearings must be able to withstand cleaning and sanitizing procedures with the selected chemicals and water pressure levels used by the plant. This ensures that the bearings remain in good condition and do not become a source of contamination.
12. What Are the Best Practices for Equipment Belts and Conveyors?
Belts should have quick releases for cleaning, and belting material should be easily cleanable, preferably without cloth backing. Proper design ensures hygiene and ease of maintenance.
12.1 Belt Design
Belts should be equipped with quick releases or other access points to enable cleaning around belt pulleys. The belting material should be easily cleanable and sanitizable, preferably without cloth backing, which can harbor bacteria.
12.2 Conveyor Design
No hollow rollers should be used on conveyors. All conveyors should be equipped with solid rollers, slides, or friction strips to prevent the accumulation of dirt and debris.
13. Should Equipment Be Easy to Dismantle for Cleaning?
Equipment requiring dismantling for cleaning, sanitizing, or maintenance should be constructed so that it can be dismantled without special tools. Ease of disassembly is crucial for thorough cleaning.
13.1 Tool Requirements
If dismantling the equipment requires tools, they should be no more complicated than a screwdriver or crescent wrench. This ensures that sanitation crews can quickly and easily disassemble the equipment for cleaning.
13.2 Training and Procedures
Provide training to sanitation and maintenance personnel on the proper procedures for dismantling, cleaning, and reassembling equipment. This ensures that equipment is properly cleaned and maintained, reducing the risk of contamination.
14. What Assurance Should You Seek From Equipment Manufacturers?
Obtain assurance from the equipment manufacturer that cleaning and sanitizing were considered in the overall design and manufacturing of the equipment. Seek validated cleaning protocols.
14.1 Manufacturer’s Role
Equipment manufacturers should provide documentation and validation of the sanitary design of their equipment. This includes providing cleaning protocols that have been third-party validated to ensure their effectiveness.
14.2 Training and Documentation
These protocols should be included in a training manual and be easily read and followed by sanitation and maintenance personnel. Ideally, the manufacturer would provide a representative to lead the sanitation crew through the sanitation procedures during the commissioning of the equipment.
15. What Cleaning Protocols Are Recommended For Food Contact Equipment?
Effective cleaning protocols involve several key steps to ensure thorough sanitation and prevent contamination. Proper procedures protect consumers and maintain regulatory compliance.
15.1 Pre-Cleaning
Begin by removing any visible debris, food particles, and residue from the equipment surfaces. This step is crucial for preparing the equipment for the subsequent cleaning and sanitizing processes.
15.2 Washing
Use a suitable cleaning agent to wash all surfaces thoroughly. The cleaning agent should be compatible with the equipment materials and effective in removing grease, oil, and other contaminants. Follow the manufacturer’s instructions for dilution and application.
15.3 Rinsing
After washing, rinse all surfaces with potable water to remove any remaining cleaning agent and loosened debris. Ensure that all traces of the cleaning agent are completely removed to prevent any potential chemical contamination of food products.
15.4 Sanitizing
Apply a sanitizing solution to all cleaned surfaces to kill any remaining bacteria and microorganisms. The sanitizing solution should be appropriate for the equipment and comply with relevant regulations. Follow the manufacturer’s instructions for concentration and contact time.
15.5 Drying
Allow the sanitized surfaces to air dry completely before resuming food processing operations. Proper drying prevents the growth of bacteria and ensures that the equipment remains sanitary.
15.6 Verification
Regularly verify the effectiveness of the cleaning and sanitizing procedures using methods such as ATP testing or microbial swabbing. This step helps ensure that the equipment is consistently cleaned to the required standards.
| Step | Description |
|---|---|
| Pre-Cleaning | Remove visible debris, food particles, and residue. |
| Washing | Use a suitable cleaning agent to wash all surfaces thoroughly. |
| Rinsing | Rinse with potable water to remove cleaning agent and loosened debris. |
| Sanitizing | Apply a sanitizing solution to kill remaining bacteria and microorganisms. |
| Drying | Allow surfaces to air dry completely. |
| Verification | Regularly verify the effectiveness of cleaning procedures. |
16. How Can You Ensure Ongoing Compliance and Training?
Maintaining sanitary standards requires ongoing training, regular inspections, and adherence to best practices. By fostering a culture of food safety, facilities can minimize risks and protect consumers.
16.1 Regular Inspections
Conduct frequent inspections of all food contact equipment to identify any signs of wear, damage, or contamination. Address any issues promptly to prevent potential food safety hazards.
16.2 Staff Training
Provide ongoing training to all staff members on proper cleaning and sanitizing procedures, as well as the importance of maintaining sanitary conditions. Ensure that staff are aware of the latest guidelines and best practices.
16.3 Documentation
Maintain accurate records of all cleaning and sanitizing activities, including dates, times, procedures used, and any issues encountered. This documentation can help demonstrate compliance with regulatory requirements and identify areas for improvement.
16.4 Continuous Improvement
Continuously evaluate and improve cleaning and sanitizing protocols based on feedback from staff, inspection findings, and the latest scientific research. Stay informed about new technologies and methods that can enhance food safety.
17. What Are The Key Considerations For Equipment Design And Maintenance?
Prioritize sanitary design, choose non-toxic materials, and ensure easy access for cleaning. Regular maintenance is essential to prevent contamination and ensure food safety.
17.1 Sanitary Design
Sanitary design should be the foremost consideration when selecting or designing food processing equipment. Equipment should be designed to minimize harborage points for bacteria and allow for thorough cleaning and sanitizing.
17.2 Material Selection
Choose materials that are non-toxic, non-absorbent, non-reactive, and corrosion-resistant. Stainless steel is a popular choice due to its durability and ease of cleaning. Avoid materials that can leach chemicals into food products or harbor bacteria.
17.3 Accessibility
Ensure that all parts of the equipment are easily accessible for cleaning and maintenance. Design equipment so that it can be quickly disassembled and reassembled without special tools. This facilitates thorough cleaning and reduces the risk of contamination.
17.4 Maintenance
Implement a regular maintenance schedule to inspect and repair equipment. Replace worn or damaged parts promptly to prevent breakdowns and ensure optimal performance. Proper maintenance can extend the lifespan of equipment and minimize the risk of food safety hazards.
17.5 Cleaning and Sanitizing
Establish and follow effective cleaning and sanitizing protocols. Use appropriate cleaning agents and sanitizers that are compatible with the equipment materials and effective against common foodborne pathogens. Regularly verify the effectiveness of cleaning procedures.
| Consideration | Description |
|---|---|
| Sanitary Design | Equipment should be designed to minimize harborage points for bacteria and allow for thorough cleaning and sanitizing. |
| Material Selection | Choose non-toxic, non-absorbent, non-reactive, and corrosion-resistant materials. Stainless steel is a popular choice. |
| Accessibility | Ensure that all parts of the equipment are easily accessible for cleaning and maintenance. Equipment should be designed for quick disassembly and reassembly without special tools. |
| Maintenance | Implement a regular maintenance schedule to inspect and repair equipment. Replace worn or damaged parts promptly. |
| Cleaning | Establish and follow effective cleaning and sanitizing protocols. Use appropriate cleaning agents and sanitizers. Regularly verify the effectiveness of cleaning procedures. |
18. What Are The Current Trends In Food Safety And Equipment Design?
Innovations in materials, coatings, and cleaning technologies are driving improvements in food safety and equipment design. Staying current with these trends can help facilities optimize their processes and reduce contamination risks.
18.1 Advanced Materials
The use of advanced materials, such as antimicrobial coatings and self-cleaning surfaces, is becoming increasingly common in food processing equipment. These materials can help inhibit the growth of bacteria and reduce the need for frequent cleaning.
18.2 Hygienic Design Principles
Hygienic design principles, such as minimizing dead spaces, using rounded corners, and sloping surfaces, are now standard in many new equipment designs. These features make it easier to clean and sanitize equipment, reducing the risk of contamination.
18.3 Automation
Automated cleaning and sanitizing systems are also gaining popularity. These systems can reduce the need for manual labor and ensure consistent cleaning results. Automation can also provide real-time monitoring of cleaning effectiveness, allowing for quick corrective action if needed.
18.4 Data Analytics
Data analytics are being used to track cleaning and maintenance activities, identify potential food safety hazards, and optimize cleaning protocols. By analyzing data on cleaning frequency, chemical usage, and microbial test results, facilities can make informed decisions about how to improve their food safety practices.
18.5 Sustainability
Sustainability is also a growing concern in the food processing industry. Equipment manufacturers are developing more energy-efficient and water-efficient equipment to reduce the environmental impact of food production.
| Trend | Description |
|---|---|
| Advanced Materials | Use of antimicrobial coatings and self-cleaning surfaces to inhibit bacterial growth and reduce the need for frequent cleaning. |
| Hygienic Design | Implementation of hygienic design principles, such as minimizing dead spaces, using rounded corners, and sloping surfaces, to make equipment easier to clean and sanitize. |
| Automation | Use of automated cleaning and sanitizing systems to reduce manual labor and ensure consistent cleaning results. |
| Data Analytics | Use of data analytics to track cleaning and maintenance activities, identify potential food safety hazards, and optimize cleaning protocols. |
| Sustainability | Development of more energy-efficient and water-efficient equipment to reduce the environmental impact of food production. |
19. What Regulatory Standards Govern Food Contact Equipment?
Several regulatory standards govern the design, construction, and use of food contact equipment. Compliance with these standards is essential for ensuring food safety and avoiding legal issues.
19.1 FDA Regulations
The U.S. Food and Drug Administration (FDA) has specific regulations for food contact surfaces, as outlined in 21 CFR Part 110. These regulations require that food contact surfaces be non-toxic, non-absorbent, non-reactive, and corrosion-resistant.
19.2 USDA Guidelines
The U.S. Department of Agriculture (USDA) also has guidelines for equipment used in meat, poultry, and egg processing facilities. These guidelines emphasize the importance of sanitary design and easy cleaning.
19.3 NSF International Standards
NSF International develops standards for food service equipment, including requirements for materials, design, and construction. Equipment that meets NSF standards is certified to be safe for food contact.
19.4 European Union Regulations
The European Union (EU) has regulations for food contact materials and articles, as outlined in Regulation (EC) No 1935/2004. These regulations ensure that food contact materials do not transfer harmful substances to food.
19.5 Global Food Safety Initiative (GFSI)
The Global Food Safety Initiative (GFSI) is a private organization that sets standards for food safety. GFSI-recognized certification schemes, such as BRC, SQF, and FSSC 22000, include requirements for food contact equipment.
| Regulation | Description |
|---|---|
| FDA Regulations (21 CFR Part 110) | Requires food contact surfaces to be non-toxic, non-absorbent, non-reactive, and corrosion-resistant. |
| USDA Guidelines | Emphasizes the importance of sanitary design and easy cleaning for equipment used in meat, poultry, and egg processing facilities. |
| NSF International Standards | Develops standards for food service equipment, including requirements for materials, design, and construction. |
| EU Regulations (Regulation (EC) No 1935/2004) | Ensures that food contact materials do not transfer harmful substances to food. |
| GFSI Standards | Sets standards for food safety through GFSI-recognized certification schemes, including requirements for food contact equipment. |
20. How Can Small Food Businesses Ensure Sanitary Equipment?
Small food businesses can ensure sanitary equipment by prioritizing design, maintenance, and staff training. These steps are crucial for compliance and food safety.
20.1 Selecting Equipment
When selecting equipment, prioritize sanitary design features, such as smooth surfaces, rounded corners, and easy-to-clean materials. Choose equipment that is certified by recognized organizations like NSF International.
20.2 Cleaning and Sanitizing
Implement a regular cleaning and sanitizing schedule. Use appropriate cleaning agents and sanitizers, and train staff on proper cleaning procedures. Regularly verify the effectiveness of cleaning procedures using methods like ATP testing.
20.3 Maintenance
Perform regular maintenance on equipment to prevent breakdowns and ensure optimal performance. Replace worn or damaged parts promptly. Keep accurate records of all maintenance activities.
20.4 Staff Training
Provide comprehensive training to staff on food safety practices, including proper cleaning and sanitizing procedures. Ensure that staff understand the importance of maintaining sanitary conditions.
20.5 Consultation
Consult with food safety experts or equipment manufacturers to get advice on selecting, using, and maintaining sanitary equipment. These experts can provide valuable insights and help small businesses comply with regulations.
| Action | Description |
|---|---|
| Selecting Equipment | Prioritize sanitary design features, choose certified equipment, and consult with experts. |
| Cleaning | Implement a regular cleaning schedule, use appropriate cleaning agents, train staff, and verify cleaning effectiveness. |
| Maintenance | Perform regular maintenance, replace worn parts promptly, and keep accurate records. |
| Staff Training | Provide comprehensive training on food safety practices and the importance of sanitary conditions. |
| Consultation | Consult with food safety experts or equipment manufacturers for advice on selecting, using, and maintaining sanitary equipment. |
FAQ Section
1. What does “food contact equipment” refer to?
Food contact equipment refers to any machinery, tools, or utensils that come into direct contact with food during processing, preparation, or storage. This includes items like conveyor belts, cutting surfaces, mixing bowls, and storage containers.
2. Why is sanitary design important for food contact equipment?
Sanitary design is crucial because it minimizes the risk of bacterial contamination, ensures food safety, and complies with regulatory standards. Properly designed equipment prevents the accumulation of dirt and bacteria, making it easier to clean and sanitize effectively.
3. What materials are best for food contact surfaces?
The best materials for food contact surfaces are those that are non-toxic, non-absorbent, non-reactive, and corrosion-resistant. Stainless steel is a commonly used material due to its durability, ease of cleaning, and resistance to corrosion.
4. How often should food contact equipment be cleaned and sanitized?
Food contact equipment should be cleaned and sanitized regularly, ideally after each use or at least once per day. The frequency depends on the type of food being processed and the potential for contamination.
5. What are some common cleaning agents used for food contact equipment?
Common cleaning agents include alkaline detergents, chlorinated cleaners, and acid cleaners. The choice of cleaning agent depends on the type of soil and the equipment material. Always follow the manufacturer’s instructions for dilution and application.
6. What is the role of HACCP in ensuring sanitary equipment design?
HACCP (Hazard Analysis and Critical Control Points) programs emphasize the importance of identifying and controlling potential food safety hazards. Sanitary equipment design is a critical component of HACCP, as it helps to minimize the risk of contamination.
7. How can equipment manufacturers contribute to food safety?
Equipment manufacturers can contribute by designing equipment that meets sanitary design principles, providing detailed cleaning instructions, and offering training to food processing facilities.
8. What is the significance of NSF certification for food equipment?
NSF (National Sanitation Foundation) certification indicates that a piece of equipment has been tested and certified to meet specific standards for food safety and sanitation. NSF-certified equipment is designed to be easy to clean and sanitize, reducing the risk of contamination.
9. Are there specific regulations for used food contact equipment?
Yes, used food contact equipment must meet the same regulatory standards as new equipment. It should be thoroughly inspected, cleaned, and sanitized before being used in a food processing facility. Any worn or damaged parts should be replaced.
10. How can small food businesses afford sanitary equipment?
Small food businesses can afford sanitary equipment by prioritizing essential items, considering used equipment from reputable sources, and seeking financing or grants specifically for food safety improvements.
Adhering to these guidelines is essential for maintaining food safety and regulatory compliance. FOODS.EDU.VN offers a wealth of information to help you navigate the complexities of food safety, from detailed equipment guides to expert advice on cleaning protocols. To learn more, visit foods.edu.vn or contact us at 1946 Campus Dr, Hyde Park, NY 12538, United States, Whatsapp: +1 845-452-9600.
