Layout and facilities of food processing plant according to FSSAI regulations and Codex Alimentarius.

1. FOOD PROCESSING PLANT DESIGNE
Dr. FASLU RAHMAN CK
Division of LPT
ICAR-IVRI

2. FOOD PROCESSING PLANT
• Food processing
 transformation of agricultural products into food
 one form of food into other forms.
• Food plant
 Enclosed area into which food materials are brought and
modified in various ways to manufacture an end product.

3. FACTORY SITE
• Permission from both national and local governments.
• Comply with legislations.
• Facilities for discharge of waste materials.
• Determination of possible hygienic hazards.
• Basic arrangements for workers.
• Close to market

4. SITE
Water
Quality
labour
Area -
expansion
Road
Electricity
Resource

5. GENERAL DESIGN PRINCIPLES
• Various services
o heating
o lighting
o ventilation
o waste disposal
• Should operate efficiently.
• Fire resistant.
• Sound transmission and vibration should be minimized.
• Should resist various stresses and strains.
• Must conform to high standard of hygiene

6. LAYOUT AND DESIGN OF PLANT
• Good Manufacturing Practices (GMP)
• Bio-security
• Black zone and White zone
• No cross movement of labours/ products/ equipment
• White zone - Exit of finished product only
• Black zone – Unhygienic
• Always a forward movement of the products

8. ROOFING AND LIGHTING
• Flat or slightly pitched.
• Height - critical factor.
• Roof - source of natural light.
• Lighting is from two sides: illumination is more uniform
shadowing is restricted.
• Direct sunlight - glare problems and temperature
increases

9. ROOFING AND LIGHTING
• Single glazed windows = heat loss restrict 10% of the
roof area.
• Wall window - glazed area of at least 30% -
• Opening windows are not recommended.
• Artificial lighting - Advantageous.
• Shadows and glare to be avoided.
• Intensity – adequate & should spread uniformly
Lux meter – intensity of light

10. CEILINGS, WALLS AND FLOORS
• Junctions between ceiling and walls should be rounded
and sealed against dust and water
Obviate condensation
Paint flakes
Mould growth
MATERIAL

11. ROOFING AND LIGHTING
• Smooth and free from cracks and crevices
• Resistant to chemical and biological agents.
• Impervious to grease and water.
• All wall angles, corners and junctions - sealed and rounded
• Coving of the wall floor junctions to a height of approx. 15 cm

12. FLOORS AND DRAINS
• Material should be impervious, Durable and impact
resistant.
• Resistant to grease, cleaning agents including hot water or
steam and to biochemical and microbial attack.
• Should be free from cracks, crevices
• Surface should be non-slippery.
Non-slippery floor- surface additives such as carborundum

13. FLOORS AND DRAINS
 Floor - easy to clean and disinfect.
 Slope – 1:40 to 1:60 towards drains.
 Distance between drains:- restricted to 5 m
 Washing fluids should pass from cleaner to dirtier areas

14. FLOORS- materials
• Prone to dust,
• little resistance to acids or to
biochemical attack and
• liable to wear
• unevenly forming pits.
• resistance to impact,
chemicals and microbial
attack
• Durable and easy to clean
• Good non slippery surfaces
• Temperature
sensitiveness 70-
800C.
• smoothness
• Popular,
• very durable,
• moisture and stain resistant.
But expensive

15. DRAINAGE SYSTEM
• Totally covered drains - avoided.
• Should have smooth, vertical sides with a rounded base
and be slopped to allow for adequate water velocity.
• Depth should be sufficient - prevent over flow.
• Should be sited adjacent to but not directly against walls.

16. VENTILATION AND AIR CONDITIONING
• Hygienic food processing and/or comfort of personnel.
• For overcoming condensation
• To minimize the build up of offensive fumes and odors.
• Optimum environment temperature
• 21-22°C (for sedentary occupation)
• 13-14°C (for heavy manual work)

17. VENTILATION AND AIR CONDITIONING
• Humidity: 30-70%
• Rate of Air Change:
 Cooking areas 20 changes / hour
 Stores and Office 1/2 changes / hour
• Air flow - in the opposite direction to the process flow
• Fresh air - heavy manual work.
• Air entering factory - filtered or treated
• Excess pressure with in factory relative to the outside is
recommended.

18. FACTORY LAYOUT
a. Reception area
• easy access for transport.
• Efficient unloading to avoid deterioration in the
incoming raw material.
Liquid – may require pumps
Dry – may require mechanical means

19. FACTORY LAYOUT
Storage area
• Site- efficient flow to processing line.
• Room should be clean, adequate space for inspection and
cleaning, good air circulation and correct temperature and
humidity.
• Protection from dust, insects, rodents
• Food material should not be placed directly on the floor.
• Cold stores -cuboid in shape
• Efficient air circulation- reduces temp. Fluctuations.

20. PROCESSING AREA
processed food material from one operation to the next should
be with the absolute minimum delay.
FLOW CONCEPT
1. Straight line flow (I-flow)
• Process layout is literally straight
• Separate receiving and shipping area
• Minimize the chances of recontamination

21. PROCESSING AREA
FLOW CONCEPT (continued.)
2. L-Flow
• when straight line flow chart is to be accommodated Process
layout is literally straight.
3. U-Flow
• very popular as a combination of receiving and dispatch
4. S-Flow
• when the production line is long and zigzagging on the
production floor is required.

22. PROCESSING AREA
small factories
Equipment and
utensils may be
used in more than
one process – In
such cases
equipment must
be cleaned
between one
operation and the
next.

23. FINISHED PRODUCT STORAGE
(i) Constant environment
 Correct temperature
 Correct humidity
 Correct good air circulation
 Adequate space
 Durable construction materials.
(ii) Clean environment: Protection from Dust, air, insects, birds and
other pets.
(iii) Careful handling.
(iv) Efficient stock rotation.
(v) Sited at distance from warm processing area.

24. EMPLOYEE SERVICE & WELFARE AREA
• Principal amenities for employees.
• Toilets – with in 50 m distance
1 per 15 female employees
1 per 25 male
• Hand washing – in food handling areas
1 basin/ 10-12 employees
• Hot (440C) + cold water tapes – knee/foot operated

25. EMPLOYEE SERVICE & WELFARE AREA
Health
facilities
Canteens
Cloak
rooms
Office
Laboratory

26. Modern food
processing
plants…
“Let your food be your
medicine, and your
medicine be your food.”
-Hippocrates

27. Safe food…!
Healthy population.

28. Dr. Faslu Rahman CK
M-6059
Division of LPT
ICAR-IVRI, Izatnagar, UP