hygienic design of food manufacturing premises holah... · hygienic food factory design provides: -...
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Hygienic Design of Food
Manufacturing Premises
Dr. John Holah
Technical Director
IFTS Hygienic Design Conference 25th February 2016
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Guideline No. 44
2
• Largest Working Group
• Largest Document
• Suggested established best
practice
• Novel solutions
• Published late 2014 –
currently final review due
to EHEDG restructuring
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Hygienic food factory design
provides:-
• Defence against external factory hazards
• Defence against internal factory hazards - no
harbourage sites and ease of cleaning
• Internal flows of people, product, packaging, air
and wastes to prevent cross-contamination
• Security against deliberate contamination
• The maintenance of hygienic conditions via
structure rigidity – appropriate foundations, steelwork, floor slabs
• The Maintenance of hygienic conditions via material
durability
• Compliance with customer/GFSI best practice
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• Hazard management – segregation, zoning and external/internal barriers
• Personnel entrances and hygiene sequences
• Cleaning and disinfection rooms
• Walls and floor interfaces
• Drains and flooring integration
• Structural rigidity/flexibility
• Services – electrical, compressed air
New concepts
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• People (petty crime, journalist, fraud, bioterrorists)
• Pests – rodents, insects, birds, reptiles
• Microorganisms – farm operations, animal activities, refuse/waste disposal, sewage works
• Industrial activities - Chemicals/odours, particulates
• Water – pests, rain, flood,
• Ground movement – effect on foundations and structures
Hazard management – external hazards
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10m 12m 14m 16m
P
r
e
v
a
i
l
i
n
g
w
i
n
d
Elevation
Poultry waste spreading
Salmonella risk Agricultural
land
Effluent
treatment
River
Rodent
and
insect
risk
Industrial
zone
Particulate risk Chemical risk
Car
park
Ingredients
Finished
product
R
o
a
d
Waste
Dust and microbial risk
particularly during
harvest
Domestic
area
Noise and
odour risk
(from
factory) Traffic fume
risk
Security fence
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Challenge
Barriers
Factory zoning
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• Site barrier (1)
• Non-food production areas
• Factory barrier (2)
• Basic hygiene area
Soiled raw materials, packed ingredients/finished products
• Medium hygiene area
Ingredient preparation
General processing
• High hygiene barrier (3)
• High hygiene area
Microbiologically decontaminated products, design risk assessed
• Aseptic barrier (4) – may be medium or high hygiene
Zoning and barriers
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Site
Soil/dust/water Air Air Air
Raw materials Packaging
People
Product
Air Air
Services
Supplies
Drains
High
hygiene Medium hygiene
Outer packaging
Prevent entry of pathogens
Basic
hygiene
Basic
hygiene
Non Food Production area
Laboratory Toilets
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• Degree of preservation/susceptibility to microbial growth
• Shelf-life and storage conditions
• Consumer type
• Size of company/market - strength of brand name
(Barrier 1) - Raw produce in the field
Barrier 2 - Processed foods/GMP in the factory
Barrier 3 – Ready-to-eat products – ready meals, fresh-cut produce, infant formula, chocolate, cereals, peanuts?
BRC High care, High risk Ambient high care
Aseptic – true aseptic, ultra-clean, some RTE products
Category of food product:- Degree of protection required
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Barrier 1: Site Barrier
• Environment
– wind direction, surface run-off
– Landscaping
Supply air
Factory building
Prevalent wind direction Exhaust air
Factory entrance
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Factory barrier
Hygienic receiving
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Pests:- Preventing entry
principle
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Pests - control them
externally! • Sealed surface entry points in the
external factory structure
• Covered waste collection units and
frequent removal
• 4mm door gaps
• Limit surface water
Hygienic trees and
shrubbery!
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• Ventilation devices that discharge food particles
onto the roof should be avoided (they can attract
birds, infestation - Salmonella)
• Roofs shall be pitched to the external walls, self
draining and roof drains should be external to the
building wherever possible.
• All openings to the roof should be curbed and
flashed to a height of 0.3m (12 inches)or more (snow
levels?)
Roofs: water leakage
and Salmonella
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Site
Security
• Perimeter fence/security guards/CCTV/no dogs
• No raw materials/finished products outside barrier 2
• Silos, water tanks locked off (super chlorination?)
• Bulk loading equipment – factory pumps/pipework should beused
• Parking areas not close to factory entrance
• Lighting at night
• National guidance e.g. Defending food and drink PAS 96:2008 British Standards
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G
Goods
in
Goods
out
Wet
store
Dry
store Despatch
store
Administration
and amenities
Site
Medium hygiene High hygine
Prim
ary
pa
cka
gin
g P
rod
uct d
eco
nta
min
ation
Process line
Perimeter fence
Drivers
rest room Drivers
rest room
Changing
rooms
Changing
rooms
Engineering Lobby Cleaning
room
Single operative and goods entrance
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• Microorganisms
• Allergens (milk, gluten, peanuts, strawberries)
• Foreign bodies:- glass, plastic, metal, wood, water
• Religion (Halal, Kosher)
• Personal choice (vegetarian, organic, GMO)
• Legal (meat speciation), DNA
• Bioterrorism
• Fraud
Barrier 2:- hazard management internal Barrier 2:
Internal Hazards
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• Allergens (milk, gluten, peanuts, strawberries)
• Religion (Halal, Kosher)
• Personal choice (vegetarian, organic, GMO)
• Legal (meat speciation), DNA
• Separate factories – not likely
• Separate areas (goods in, transport, utensils, cleaning equipment, clothing etc.)
• Separate times (verified cleaning, labelling, rework?)
Internal hazards/brand protection
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Horizontal segregation across
zones
20
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• Foreign bodies
• Pests
• Glass/plastic – covered lighting, breakage policies
• Glass – no windows – what about the cows?
• Wood policy – limit of pallet movement
• Maintenance policy
• Metal/foreign body – metal/x-ray detection
• Pest control
Internal hazards/brand protection
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• Microorganisms
• 5 point pathogen control plan
Internal hazards/brand protection
Prevent
entry
Restrict
harbourage
and growth
Reduce cross-
contamination
vectors
Control
Kill or
remove
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Amenities
Tray
wash
Wet
DRY
?
Microbial growth requirements
•Temperature
•Nutrients
•Oxygen
•Water
Water supply
Drain
Internal hazards/brand protection
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Proces
s flow
24
Traffic routes
Waste flows
Process line
Product ingredient flow
Pedestrian routes
Air flows
Packaging flows
Cross contamination
No back tracking
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Foundations to prevent structural movement but above all else,
consideration of the sub-floor and its movement
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Good drain design
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Drain/floor
interfaces
Need to
integrate drain
and flooring
contactors
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28
Doors
To be effective barriers
• Tight fitting (no gaps)
• Threshold
• Solid or closed cell foam
• Self closing (man doors)
• Actuator closing (trucking)
• Horizontal rather than vertical roller shutter doors
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Electrical
installations
• Minimum wire ways and cable routing
• No conduits.
• Cables clips should be avoided.
• Control boxes sealed, not over product,
sited to facilitate cleaning and bottom
cable entry
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Bioterrori
sm/fraud
• Key processes:
mixing/even
distribution
• Mixers, bulk
storage, grinders
• Collective responsibility
Store
Prep
Chill
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Barrier 3: High hygiene
• Product (pasteurisation
or decontamination)
• Utensils etc.
• Packaging
• People
• Air
• Solid and liquid waste
• Risk assess required
barriers
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Boxes within boxes
Easy to manage?
•Manufacturing
flexibility
•Infection
control
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Wall-to-floor
Junctions?
Low risk
Medium risk
High risk
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Personnel - High hygiene entry
sequence • Remove outer/low
risk clothing
• Put on hair net
• Remove footwear
• Step over barrier -
Wash hands -
psychology
• Put on high risk boots
• Step over barrier -
Wash hands
• Put on factory
clothing
• Alcohol rub on entry
Lock
ers
Male Female
Food processing area
Corridor
Hair nets
and mirror
Sh
oe
lock
ers
in w
all
Boot
rack
PPE waste
Lock
ers
Hand wash and dry
Boot wash room
Washing
machine
Laundry hatch Cleaning
store
PPE waste
Ha
nd
wa
sh a
nd
dry
Clean PPE
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Packaging and
airlocks
• Double bagged
• Who owns it – high or
low
• Who cleans it – high or
low
• Can we effectively over
pressure it
High Low
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Air movements between high and low
hygiene
10oC 20oC
High risk Low risk Low risk High risk
Positive pressure is required, typically 2-5 Pascals /air velocity>3m/s
Low risk High risk
Natural Induced Forced
Intake Extract
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Design for cleaning and
decontamination
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Wait Washing area
Dry
Local ventilation
Air lock
Chemical supply
Food Production Area
Factory exterior
Drain
Ring main Wash room
Decontamination
room