The document outlines key considerations for designing a food processing plant, including the transformation of agricultural products, the importance of hygiene, and compliance with regulations. It details requirements for facilities, such as effective ventilation, appropriate flooring and drainage systems, and designated zones for clean and unhygienic areas to ensure food safety. Additionally, employee welfare amenities and efficient layout designs are emphasized to maintain a productive and safe working environment.

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