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Sanitary design and construction for food processing
- 1. Sanitary Design and Construction forFood Processing 1 Prof. Aarti Vyas Dept. of Food Microbiology and Safety Dr. Ulhas Patil College of Food Technology, Jalgaon
- 2. Introduction • A foodestablishment should follow a sanitary design strategy to ensure that the facility can be cleaned to protect against spoilage and pathogenic microorganisms. • The major sources of contamination from the facility. • Facility and equipment design enhances cleaning effectiveness and avoids microbial growth niches. • Hygienically designed facilities enhance the wholesomeness of all foods and improve the effectiveness and efficiency of a sanitation program. 2
- 3. Sanitary Design andConstruction for Food Processing • Site selection • Site preparation • Building construction considerations • Processing design considerations • Pest control design 3
- 4.
- 5. I. Site selection Location(site) shall ideally be away from- 1. environmentally polluted area. 2. industrial activities that produce disagreeable odour, wastes, chemical or biological emissions etc. 3. areas which are prone to infestations of pests. 4. areas where industrial wastes cannot be removed effectively. 5. residential area. 6. trees should not be planted close to buildings. In case there are hazards of other environment polluting industry located nearby, 1. Take appropriate measures to protect the manufacturing area from any potential contamination. 2. The site should be graded to prevent standing water, which provides breeding sites for insects. 5
- 6. Location, Layout &Facilities Dirty passage being used as Food Storage Urinal without doors Food Preparation area Poor Civic Sense cause airborne bacteria6
- 7. Location, Layout &Facilities Garbage lying open – Source of Flies, Insects, Rodents Open and unattended Garbage Bins 7
- 8.
- 9. II. Site preparation •The site should be graded to prevent standing water, which provides breeding sites for insects (especially mosquitoes). • Toxic materials be removed, if present at the site, to prevent potential contamination. • shrubbery should be at least 10 m from buildings to eliminate protection for pests such as birds, rodents, and insects. • Grass should not be present within 1 m of building walls. 9
- 10. Location, Layout &Facilities 10
- 11. Building construction considerations Thedesigning of premises shall be such that - - no cross contamination in food preparation area occur from pre and post manufacturing operations - one direction material movement (no backward flow) should be followed 1. Walls – • must be made of impervious material, easily cleaned, and constructed to prevent rodent entry. • maintained in a sound condition to minimize accumulation of dirt, condensation & growth of moulds • should be smooth and easy to clean with no flaking paint or plaster. • Epoxy paints over a compatible sealer provide additional protection. 11
- 12. 12 Surfaces of walls,partitions and floors should have smooth and impervious surface. Cracks on walls can harbour germs and dirt that can contaminate food. They do not allow walls/floors to be cleaned appropriately. Cracks, peeling paint, toxic material on walls/floors are hazards. Fungal growth (moss) on walls can release toxic spores and contaminate food.
- 13. Location, Layout &Facilities Cleanable, durable, impervious to moisture Cracks allow bacteria and molds to accumulate Floors, ceilings and walls - 13
- 14. 2. Loading Dock- • Loading docks and platforms should be constructed at least 1 m above the ground. • The underside of the dock opening should be lined with a smooth, impervious material, such as plastic or galvanized metal, to prevent rodents from climbing into the building. • Pest entry is discouraged through truck door seals and air curtains. • The truck dock area should be equipped with dock seals. • Dock seals can replace overhead canopies that require constant monitoring to prevent pest entry, especially birds. 14
- 15. 3. Roof construction- • A logical roof type for precast concrete wall panels is a precast double tee. This design is attractive and hygienic. • smooth membrane- type roofs because they can be swept, hosed, and kept clean more effectively than other roofs. • Roof openings for air handling or other uses should be screened, flashed, or sealed to prevent the entry of contaminants such as insects, water, and dust. 4. Ceilings - • Ceiling construction should be a smooth concrete slab of exposed double tees with caulked joints. 15
- 16. Location, Layout &Facilities Good Repairs & Clean walls Floors, ceilings and walls - Ceiling made of impervious material 16
- 17. LAYOUT AND DESIGNOF FOOD ESTABLISHMENT PREMISES 5. Floor – - shall have adequate and proper drainage with appropriate slope and easy to clean and where necessary disinfect - the drainage shall flow in a direction opposite to the direction of food preparation area. - Floors in food facilities should be impervious to water, free of cracks and crevices, and resistant to chemicals. 6. Drains – - should be covered to prevent insects and rodents from entering the processing area 17
- 18. Location, Layout &Facilities Repaired Floor 18
- 19. Location, Layout &Facilities Floor with drainage of appropriate slope 19
- 20. Location, Layout &Facilities Drains should be covered to prevent insects and rodents Floor with proper drainage 20
- 21. Location, Layout &Facilities 7. Windows, & all other openings to outside environment – - shall be well screened with wire-mesh or insect- proof screen to protect the premise from pests - the doors be fitted with automatic closing springs - mesh should be easy to remove & clean 8. Doors – - shall be made of smooth and non-absorbent surfaces - A double-door entry reduces airborne and pest contamination. - The exterior of the doors should be equipped with air curtains. 9. Food Preparation Areas – - shall have no smoke nuisance - install a chimney having appropriate suction prior to start of business. - food if contaminated from any privy, urinal, sullage, drain or place of storage of foul and waste matter, shall not be manufactured, stored or expose for sale. 21
- 22. Location, Layout &Facilities Doors made of smooth and non-absorbent surfaces 22 Well screened windows
- 23. Location, Layout &Facilities Food Preparation Areas shall have a installed chimney 23
- 24. Location, Layout &Facilities Food Preparation Areas shall have no smoke nuisance 24
- 25. Location, Layout &Facilities 25
- 26. • Appropriate facilitydesign incorporates a product flow that permits finished items from making contact with raw materials or unprocessed products. • The ideal flow provides for raw materials and adjuncts to enter the process near the receiving dock, flowing sequentially into the preparation area, process area, packaging area, and to the storage. • design flow, permits proper air pressure conditions to the overall plant efficiency. • Some personnel doors support this concept because they are designed so that workers must pass from a “clean” to “less clean” area. • Return to the cleaner area may require a uniform change and a sanitizing step, followed by entrance through an air lock or pressurized vestibule. 26
- 27. • Processing equipmentshould have 1 m of clear space around it to facilitate maintenance and cleaning. • A minimum of 0.5 m of clearance over each piece of equipment should be provided to permit effective cleaning. • Floor-mounted equipment should be either sealed directly to the floor or mounted at least 15 cm from the floor. • The processing layout should permit the location of equipment for accessibility to maintenance, sanitation, and inspection. • Areas that are difficult to reach and clean are less likely to be cleaned frequently and thoroughly. 27
- 28. • Equipment openingsand covers should be designed to protect stored or prepared food from contaminants and foreign matter that may fall into the food. • Failure to provide parts that extend into the food-contact areas with a watertight joint at the point of entry into the food-contact area make cause liquids to contaminate the food by adhering to shafts or other parts and running or dripping into the food. • If the apron is not properly designed and installed, condensation, drips, and dust may gain access to the food. • Equipment containing bearings and gears that require lubricants should be designed and constructed to prevent lubricant leaks, drips, or entry into food or onto food-contact surfaces. • Condenser units that are an integral component of equipment should be separated from the food and food-storage space by a dust-proof barrier. • A dust-proof barrier between the condenser and food storage areas of equipment protects food and food contact areas from dust contamination that is accumulated and blown about during the condenser’s operation. 28
- 29. • Stainless steelis the preferred material for food contact surfaces. This inert material resists corrosion, abrasion, and thermal shock; is cleaned easily; and is resistant to sanitizers. • The high chromium content (12% or more of the steel) provides corrosion resistance. • The most commonly used stainless steel is type 304 of the 300 series. 29
- 30. • effectively andefficiently cleaned. • Construction materials must be completely compatible with the product, environment, cleaning and sanitizing compounds and methods. • Equipment construction materials must be inert, corrosion resistant, nonporous, and nonabsorbent. • All parts of the equipment shall be accessible for inspection, maintenance, cleaning, and/or sanitation. Disassembly and assembly should be facilitated by equipment. • Hollow areas of equipment (e.g., frames and rollers) must be eliminated if possible or permanently sealed. • All parts of the equipment must be free of niches such as pits, cracks, corrosion, recesses, open seams, gaps, lap seams, protruding ledges, inside threads, bolt rivets, and dead ends. All welds must be continuous and fully penetrating. 30
- 31. • Maintenance enclosuresand human machine interfaces must be designed, constructed, and maintainable to ensure that the product, water, or product liquid does not penetrate into, or accumulate in or on the enclosure and interface. • Equipment with bearings and gears that require lubricants should be designed and constructed so that the lubricant cannot leak, drip, or be forced into food or onto food contact surfaces. • Design of equipment must ensure hygienic compatibility with other equipment and systems. • Procedures for cleaning and sanitizing must be written clearly and validated. • Compounds recommended for cleaning and sanitizing must be compatible with equipment and the manufacturing environment. 31
- 32. • Principle 1:Identify Distinct Hygienic Zones Established in a Facility. • Principle 2: Control Personnel and Material Flow to Reduce Hazards. • Principle 3: Control Water Accumulation. • Principle 4: Control Temperature and Humidity. • Principle 5: Control Air Quality and Flow. • Principle 6: Provide Site Accommodations. • Principle 7: Provide Building Envelope for Sanitary Conditions. • Principle 8: Provide Interior Spatial Design Conducive to Rigid Sanitation. • Principle 9: Incorporate “Sanitation Friendly” Construction Materials and Utility Systems. • Principle 10: Incorporation of an Integrated Sanitation System. 32
- 33. Location, Layout &Facilities Cooking containers with lids Equipments made of corrosion free material 33
- 34. Location, Layout &Facilities Storage containers with lids 34
- 35. Location, Layout &Facilities Storage containers in the kitchen with lids 35
- 36. EQUIPMENT & CONTAINERS Cleaning& Disinfectant system - - facilities for the cleaning and disinfecting of equipment and instruments shall be available - wherever possible, cleaning in place (CIP) system shall be adopted. - If required, a waste water disposal system / effluent treatment plant shall be put in place. 36
- 37. Location, Layout &Facilities Cleaning of equipments 37
- 38. Location, Layout &Facilities Sanitizing of equipment 38
- 39. PEST CONTROL DESIGN •Conduct pest control regularly. • Take all-round action for pest control. 39
- 40. • A rodentlip installed 60 cm down on the foundation and extending out 30 cm prevents rats from burrowing under the slab and entering the plant by chewing through felt expansion joints or through drains inside the building. • Cavities within walls should be avoided. • Ventilation stacks should be equipped with adequate screening to prevent pest entry. • Locker tops should contain a 60°slope to avoid debris accumulation. • Vents, drains, and windows should be covered with screens. 40
- 41. Location, Layout &Facilities 41
- 42. Location, Layout &Facilities FACILITIES 1. Water supply - - only potable water in processing and cooking, food handling, washing shall be used. (Explanatory Note – Potable water shall be tested according to IS:10500) - storage tanks shall be cleaned periodically & records shall be maintained. - non potable water can be used for cleaning of equipment not coming in contact with - Food - Food steam production - Fire Fighting - Refrigeration equipment - non potable water pipes shall prevent the use of this water for contamination of food material. - non potable water pipes shall be clearly distinguished from those in use for potable water. 42
- 43. Location, Layout &Facilities FACILITIES 2. For Cleaning Utensils / Equipment – - adequate facilities for cleaning, disinfecting shall be provided - hot and cold water facility shall be provided if required 3. Washing of Raw materials – - sinks with a draining board, detergent and hot water shall be provided - these facilities must be kept clean and, where necessary, disinfected - separate sinks shall be used for washing raw foods & washing utensils or any other purposes. 4. Ice and Steam – - potable water shall be used. - should be handled hygienically to avoid cross contamination. 43
- 44. Location, Layout &Facilities FACILITIES 5. Personnel facilities and toilets i. Hand washing facilities shall be provided Requirements of a Hand washing and drying system – Porcelain/Stainless Steel Wash-hand basins, preferably knee operated Germicidal liquid Soap Sanitizer Supply of hot and /or cold water Wet hands drying system Clean and dry towels, preferably paper towel/rolls Covered Trash Bin, preferably pedal operated with plastic lining ii. separate adequate number of hygienic lavatories shall be provided iii. changing facilities for personnel shall be provided iv. restroom and refreshments rooms shall be separate from food process and service areas v. display hygiene requirements for the workers at a prominent place in English or in local language 44
- 45. Location, Layout &Facilities FACILITIES 6. Air quality and ventilation – - ventilation systems shall be designed and constructed so that air does not flow from contaminated areas to clean areas. 7. Lighting – - sufficient lighting system shall be provided to the food establishment - lighting fixtures should be covered to prevent breakages of electrical fittings to contaminate food. 45
- 46. Location, Layout &Facilities Colour coding of water pipes to avoid contamination 46
- 47. Location, Layout &Facilities Cleaning of water storage tanks 47
- 48. Location, Layout &Facilities Cleaning of utensils 48
- 49. Location, Layout &Facilities Cleaning of utensils 49
- 50. Location, Layout &Facilities Cleaning of utensils 50
- 51. Location, Layout &Facilities Cleaning of utensils 51
- 52. Location, Layout &Facilities Washing of Raw materials Vegetable washing machine 52
- 53. Location, Layout &Facilities Handling Ice Machine 53 Clean & hygienic Ice Machine Dirty Ice Machine
- 54. Location, Layout &Facilities Hand washing facilities 54
- 55. Location, Layout &Facilities Hand washing facilities 55
- 56. Separate lockers formen and women for changing work clothes Food shall be consumed in Refreshment Room and not in Rest Room 56
- 57. Location, Layout &Facilities Air quality and ventilation Illustrative 57
- 58. Location, Layout &Facilities Lighting Proper lighting facility in the work area Lights shall be covered 58
Editor's Notes
- #5 Site selection plays an important role in the development of a hygienic operation.
- #6 Food facilities should not be constructed near chemical plants that emit noxious odors, or near salvage or water disposal operations. Food products that are relatively high in fat will readily pick up bad odors and flavors, and pathogenic microorganisms can be picked up by the wind and blown on the manufactured products
- #12 Properly designed and constructed food premises minimize the likelihood of food contamination arising from unnecessary movement of food and personnel within the premises, or likelihood of operations being in close proximity to sanitary operations. Floors- Non-absorbent materials prevent absorption of water and grease. Suitable sloping enables excess water to be drained away to avoid ponding Properly constructed floor surfaces are easier to clean and sanitise All the above minimise risk of food contamination from environmental sources. Light coloured walls and ceilings enable easy detection of dirt for prompt removal. Durable, impervious and easily cleaned surfaces facilitate cleaning work Accumulation of food waste, dirt, grease etc. provide food for pests and enable microbial growth. These dirt and waste may come from food spills, food handlers’ shoes, linen and food packaging etc.Liquid on floors provides water source for pests and causes microbial Contamination. Cracks, crevices etc. on walls , floors or ceiling harbour pests. Effective, frequent and regular, cleaning, sanitizing and maintenance Of floors, walls, ceilings and equipment are necessary for removal of food contaminants and prevention of microbial proliferation
- #16 Pitch and gravel roofs should not be installed over food processing or preparation areas, as they are difficult to clean. Low-moisture materials, such as grain, starch, and flour, can be carried out through vents and will attract birds and insects and encourage the growth of weeds, bacteria, molds, and yeasts.
- #18 Accumulation of waste water on the floor of food premises increases the risk of food contamination. Properly designed and constructed floor drains can eliminate water accumulation and prevent entry of pests to food premises
- #19 Monolithic floors are gaining in popularity because they are seamless, easier to apply, and less expensive than brick or tile. Acid brick floors deserve consideration because of their durability and ease of replacement in case of breakage and their reduced moisture accumulation under cracks and holes.
- #22 Adequate space for food preparation is essential to effective and hygienic food preparation having regard to the number of customers to be served. Too small a kitchen or food room may cause congestion and insanitary food operation that increases the risk of food contamination. All the above should be completely separated from and should not open directly on to food handling areas
- #26 Food Contact surfaces be maintained clean and sanitary. Cleaning and Sanitisation of equipment and utensils used for raw and cooked food between the uses prevents cross-contamination. Chipped or cracked Eating or drinking utensils harbour dirt and bacteria and cannot be effectively cleaned and sanitised and may cause infectious diseases. They may also contaminate food By broken / chipped pieces.
- #37 Similar to food contact surfaces, non-food contact surfaces should also be kept clean and in good repair to help minimise the possibility of food contamination Single-use items are not manufactured to permit cleaning and sanitising. Re-use of these can contaminate food. Use of the same gloves for handling raw and ready-to-eat food easily leads to cross-contamination
- #42 Water from public mains or from an approved source ensures Clean & safe water to drink and avoid contamination of food or equipment. Adequate supply ensures effective and safe processing. Adequate water supply is necessary to ensure effective cleaning and Safe food production. Water used for food preparation, Cleaning and Scullery purposes should be of safe quality to avoid contamination of food or food equipment
- #43 Water from public mains or from an approved source ensures Clean & safe water to drink and avoid contamination of food or equipment. Adequate supply ensures effective and safe processing. Adequate water supply is necessary to ensure effective cleaning and Safe food production. Water used for food preparation, Cleaning and Scullery purposes should be of safe quality to avoid contamination of food or food equipment
- #44 Food contact surfaces should not introduce into food any substance which may be harmful to health of consumers, such as migration of copper or lead to acidic food or beverages. Properly designed food contact surfaces can facilitate effective cleaning and sanitising. Food deposits on food contact surfaces for long get contaminated Dirty sinks or drip boards can be a source of contamination of food And equipment. A well functioned steriliser or mechanical dish washer can effectively destroy microorganism on the surface of the equipment and utensil
- #45 Provision of well-equipped and properly located changing and toilet facilities prevents equipment and food from faecal contamination that may be carried by insects, hands or clothing. A properly maintained changing and toilet facility can reduce the likelihood of spread of foodborne diseases Improper handwashing is a major contributing factor to outbreak of foodborne illnesses. Provision of proper and adequate handwashing facilities is essential to minimising food contamination and maintaining personal hygiene. Handwashing with hot water can help remove oil /grease from hands Provision of scullery facilities is crucial to minimising the risk of contamination of food by removing the debris, soil and bactirial film from utensils and crockery that may come into contact with food. Provision of hot water helps in removing oil / grease from utensils Hand washing is important to maintenance of personal cleanliness and hygiene, especially for food handlers who are likely to transmit bacteria or harmful microbes onto food, food contact surfaces, or equipment if their hands are contaminated. Provision of adequate hand washing Facilities is crucial to the prevention of food contamination and spread of foodborne diseases. Properly maintained toilet facilities, apart from maintaining personal Hygiene, can protect, utensils and food from faecal contamination that may be carried by pests, food handlers and customers, so that the opportunities for spread of foodborne diseases can be minimised
- #46 Adequate,clean and quality fresh air prevents contamination of food and equipment and is good for employees and customer health. Unclean air, dust, odours condensation and grease cause harmful effect to health of employees and customers and is also a fire hazard. Adequate lighting facilitates easy identification of dirt, helps maintain the hygienic condition of food premises and promotes safe food production. Protection of lights by shields is important for preventing contamination of food by glass fragments. Excessive fumes, smoke, grease or vapour pose potential hazards to health of workers and fire safety, and are potential sources of food contamination. Dripping grease or condensation can contaminate food or food contact surfaces. Provision of adequate natural and mechanical ventilation can Keep the air clean and healthy by removal of excessive fumes or vapour, and introduction of fresh air. Air supplied to food premises should be of sufficient quality and quantity to replace contaminated air for health of workers and customers