Food Safety Hygienic Plant Designs for the Food and Beverage Industry

Frank Nyegaard

frny@alectia.com

+45 5121 7992

www.alectia.com

Independent engineering and advising company

100 years. Founded in 1912 as Birch & Krogboe

Rapid growth through acquisitions and employment since 2005

Name changed to ALECTIA in 2008 to reflect diversification and growth

Owned by the ALECTIA Foundation

650 employees in Denmark and abroad

Wide global presence with

main office in Denmark

ALECTIAFacts

ALECTIASkills

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BuildingBuilding ProcessProcess

Leadership, Health and

safety

Leadership, Health and

safety

Environment, Energy and

Water

Environment, Energy and

Water

Our strength is in our ability to combine our competences and hereby make a significant positive difference for our clients

Vision: Masterminding Sustainable Progress

ALECTIAFour Divisions with cross-disciplinary collaboration

ProcessProcess

• 140 employees

• A leading consultant within process engineering

• In-depth industry knowledge

ClientsA small selection..

Pharmaceutical BrewingDairy Food

ALECTIAProcess Division

ALECTIA FoodPlanning & Design and analyses

Productions audits

Structural analysis

Financial analysis

Project Plans

Master plans

Conceptual design

Value Engineering

Basic Design report

Requirements specification

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Architecture and Site LogisticsConnection between hygiene zones, flow and plant layout in relation to the production process

Flow – materiale and persons

Hygiene zones –division and classification

ALECTIA FoodHygiene and Food Safety

Hygiene Analyses

Hygienic Design

EU Regulations

USDA Regulations

Customer Demands

Own Control, HACCP

What can affect the quality?Lack of hygienic production facilities

What can affect the quality?Lack of the right Cooling and ventilation

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What can affect the quality?Cross contamination

Cross contamination in a production facility

Cross contamination in a production facility

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Corrections to avoid cross contamination

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ALECTIA FoodFacility assessment

The main outcome of the factory survey will be:

1. Overview of the current state (as-is situation)

2. Overview of current capacity/capability and efficiency

3. Hygiene and quality issues analysed and highlighted

4. Assessment of the current service and maintenance level

5. Overview and review of current planned investments

6. Major risks analysed and highlighted

7. Health & safety issues analysed and highlighted

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Clean up and keep order

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Keep the rooms dry

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Selected references

Stourton InglaterraPlanta de leche fresca año 2009-2010

Colun DairyLa Union, Chile. Nueva planta de yogurt 2012-2013

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Colun DairyLa Union, Chile. Nueva planta de yogurt 2012-2013

Master Plan for the development of the production of sausages in a new greenfield factory in Ecuador, capacity 85 ton/day

Pronaca, Ecuador, New Greenfield Sausage Factory, Year 2012-2013

ALECTIA services:

• Proposal for implementation of new technologies

• Proposal for layout of new factory and all supporting installations

• Plan for hygiene zones and flow of product and staff to secure compliance with EU Food standards

• Logistic plan for new site

• Time schedule and investment budget

• Conceptual design for the new factory

• Tender specifications for equipment

Arla Alimentos lacteos TaulovLa planta más grande queso amarillo del Norte Europa 1997-2013

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New 76.000 m² highly automated pig slaughterhouse with a capacity of 1.200 pigs/hour. Nearly all slaughter and main cutting processes are fully or highly automated.

DANISH CROWN, DenmarkPig slaughterhouse, Year 2001-2004

ALECTIA services :

• General slaughter-technical advising

• Layout and hygienic planning

• Process equipment and installations

• Refrigeration and ventilation plant

• Electrical installations

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