This document outlines food safety guidelines for plant layout, design, and hygiene. It recommends: 1. Separating production areas into "black zones" for raw materials and "white zones" for finished goods to prevent cross-contamination. Workflows should move from dirty to clean areas. 2. Using smooth, impervious materials for floors, walls, and ceilings that are resistant to chemicals and moisture. Junctions should be sealed to prevent accumulation of dirt and bacteria. 3. Maintaining proper ventilation, air filtration, temperature, and humidity controls to minimize odors and ensure an optimum environment for personnel and food processing. Drainage systems should be covered and sloped to remove water efficiently.

1. Food Safety Hygiene and Sanitation
A. Poshadri
Scientist -Food Technology
PJTSAU
Email: achinna.fst@gmail.com
Cell No: +919492828965

3. 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

4. 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

5. 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

6. CEILINGS, WALLS AND FLOORS
• Junctions between ceiling and walls should be rounded and
sealed against dust and water

7. 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
• Junctions between ceiling and walls should be rounded
and sealed against dust and water

8. 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

9. 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

10. FLOORS AND MATERIALS
Prone to dust,
little resistance to acids or to
biochemical attack and
liable to wear unevenly
forming pits.

11. 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

12. 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)

13. 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.

14. 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.

15. 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 (44°C) + cold water tapes – knee/foot operated

16. EMPLOYEE SERVICE & WELFARE AREA

18. QC Log
sheets

22. Operational
SOP’s

40. Cleaning check list @
Stores