HYGIENE MANAGEMENT

HYGIENIC DESIGN OF MACHINERY AND ESTABLISHMENT

June 2002

AIMS:

• KNOW THE IMPORTANCE OF A GOOD DESIGN OF BUILDINGS FACILITIES AND MACHINERY • KNOW THE ASPECTS TO HAVE IN ACCOUNT

• KNOW ALTERNATIVES OF DESIGN AND HYGIENIC MATERIALS

Hygienic design

Attention to good hygienic design and construction, appropriate location, and the provision of

adequate facilities, is necessary to enable hazards to be effectively

contolled

Index:

# Plant site and location

# Design and layout

#Condition of floor

#Condition of walls, doors and windows

#Condition of ceiling and lights

#Condition of drainage

#Condition of other elements

#Sanitary facilities

#Equipment and utensils

Plant site and location• The establishments shall be free from any hazards for the safety of the products. It should be located in areas which are free from objectionable odours, smoke, dust or other contaminants

• The grounds and surrounding areas shall be tidy and free from improperly stored equipment, garbage, refuse, scrap metal (to avoid pest hiding and breeding)

• Perimeter roadways and yard areas should have a pave, suitable for wheeled traffic. Dust development shall be prevented.

• Adequate drainage and sewage disposal systems shall function at all times. Drains must be covered adequately

• Waste collection and storage areas must be paved, cleaneble and equipped with drains

Establishments should normally be located away from:

• environmentally polluted areas and industrial activities which pose a serious threat of contaminating food

• areas subject to flooding unless sufficient safeguards are provided

• areas prone to infestations of pests

• areas where wastes, either solid or liquid, cannot be removed effectively

Plant site and location

Design and layout:

The internal design and layout of food establishments should permit good foodhygiene practices, including protection against cross-contamination between and during operations by foodstuffs

•Layout must be in a logical sense, straight line, but U is acceptable

• areas with conflicting functional purpose which could potenctially affect product must be clearly segregated though partition, location or other effective means (ZONING)

Condition of floor

• Floors should be designed to withstand the rigours of the production processes that are being conducted

•Floors must be made of impervious, non toxic materials, washabel, non absorbent, and be free from cracks and open joints

• The floor surface must be impervious to moisture and grease, resistant to chemicals and food materials to which it may be exposed and safe to walk on when wet, dry or greasy.

• Floor must be kept clean and free from the accumulation of water or other spillage’s, specially in corners and areas hidden by equipments, material, etc.

•Sufficient sloping of floors to drains and trapped outlets exist where appropriate.

• Coved wall and floor junctions should facilitate cleaning.

• Demaged flooring must be reparaired as quicly as possible with materials compatible with the original flooring and in a permanent fashion.

Condition of floor

Condition of walls, doors and windows

WALLS

• All interior walls in rooms where open food is stored or processed must be in good condition and finished with a hygienic, easy to clean surface, which does not pose a foreign hazard e.g. Walls should be finished with a continous, bonded surface and protected from damage. Corners, joints between cladding sheets or ceramic tiles must be sealed with a suitable impervios sealant.

• Walls and wall surface should be free from shelves and other protruding attachments wherever possible. The design must me such as to avoid any horizontal surface, which could act as a dust trap, or impromptu shelf space,

WALLS

•All wall-wall and wall-floor junctions should be coved. Wall ceiling junctions and other juctions should be coved or sealed to facilitate cleaning

• Walls are be white or light coulored

• All signs of deterioration and damage should be dealt with immediately and the repairs should be compatible with the original finish.

•Services must be sealed into any wall through they pass (electrical fittings, plumbing..)

Condition of walls, doors and windows

Condition of walls, doors and windows

DOORS

• All external opening doors must be kept closed. Where frequent use makes this impractical then either automatic doors, rubber swing doors, plastic strip curtaining or air curtain should be provide to prevent bird and insect ingress

• All doors to production areas should be self-closing to mantain the necessary atmospheric conditions. They should be close fitting on all sides and the doorframes and corners must be given protection against damage.

Condition of walls, doors and windows

WINDOWS

• All windows should be kept closed. Those required to be opened to provide additional ventilation, should have the total opening area screened with a mesh small enough to exclude flying insects. These insect-proof screens can be easily removed for cleaning

• All exterior windows must be clear, complete and properly fixed. Their frames must be of sound fitting and completely sealed to prevent insect ingress

Condition of walls, doors and windows

WINDOWS

•Broken or cracked windows must be replaced imediately before production recommences. Approved shatterproof materials must used.

• Windowsills and ledges should be sloping to prevent tools and other articles being placed on them

Condition of ceiling and lightsCEILING

• In any room where open food is stored or processed, the condition of the ceiling must be smooth, easily cleaned and kept in good repair. It must not pose a foreign body hazard to the area below, The finishing material must be selected to prevent the shedding of particles (i.e. Paint flakes, rusty particles, etc.) and mould development.

• Ceilings may be underdrawn or suspended, however, access must be provided to the void above to enable adequate cleaning and pest control inspections. Adequate walkways must be provided for this purpose and also for access to services

Condition of ceiling and lights

CEILING

• All junctions between walls and ceilings should be sealed and impermeable to facilitate cleaning. Additionaly eves and ridges must be sealed to prevent access to birds, insects, and rodents.

• Where painted suface are unavoidable, both these and underlying surfaces must be sound and free from flaking, and repainted as necessary with a paint approved for use in food preparation areas.

Condition of ceiling and lights

LIGHTS

• Light bulbs/fluorescent tubes and fixtures, including elecrical UV-light insect control units suspended in food handling areas in any stage of production, must be of safety type and protected to prevent contamination of food in case of breakage.

• All light units must be kept clean, and bulb replacement or any other maintenance carried out when the department is not in production.

• The capacitiy of the drains must be sufficiente to cope wih the maximum process requirementes placed on them.

• Drains must be non-corrodable, trapped, easy to clean and durable

• The flow of drains shall be from high to low risk to avoid contamination of the clean environment.(1% slope)

• The drains and gullies covered with removable easily grids are recommended

Condition of drainage

Other elements• Any stairsways to or from mezzanine floors or gangways over production lines must be sealed and include side walls to prevent product contamination

• Shelves and racks in storage areas must be of hygienic contruction and of non corrodable material

• Pipelines, fixtures, light fittings, cable chanels, ventilation points and other everhead structures and services in manufacturing areas, must be installed such that sagging and any connections, surface, joints, etc.. Which are difficult to clean and inspect , are avoided,

• Pipelines should be clearly identified to show direction and contents

Sanitary facilities

• They should be hygienic in design, easy to clean, prevent the acumulation of dirt and dust, kept in clean and hygienic condition and well maintained.

•Appropriate and adequate facilites for hand washing and drying shall be provided in sufficient number and conveniently located in processing area

The hand-washing facilities must include hot and cold water, preferably from mixing taps of a non han operable type. Liquid soap and, where appropiate, facilities for hand disinfection should be provided

Disposable paper or re-washable, one-use roller dispensed textile towels shall be used for hand drying.

Air-dryers are not recommended

Where paper towels are used, a sufficient number of dispensers and appropriate waste receptacles shall be provided adjacent to each washing facility

• Toilets shall be provided in a sufficient number in all establishments.

They shall be easily accessible and not open directly into food handling areas.

Sanitary facilities

Toilets shall be well lit and ventilated and easy to clean and sanitise

•Cloakrooms shall be well lit, ventilated and provide enough space for users

•Sufficient and adequate lockers (one per person) should be provide as well as adequate storage facilities for shoes and boots

Lockers should facilitate clear segregation between working and civilian clothing

Sanitary facilities

•A lockable room or facility to store cleaning and disinfection agents shall be provide as well as a segregated facility to dry an store cleaning tools.

Sanitary facilities

Equipment and utensils

•Equipment and utensils must be designed, contructed and installed or used to suit the specified purpose, to prevent any product contamination, to allow for esasy inspection, to prevent pest breddin and to enable easy dismanting, cleaning and disinfection.

• Wood and glass should be avoided, unless such use can be justified

• Equipment and utensils must be dedicated clearly for food or non food use and be identified and use accordingly.

•Utensils or tools, used in food production or coming into contact with food or food processing equipment shall be clearly differentiated in colour from any other tools and utensils (cleaning tools)

•All utensils must be stored adequately

• Equipment should be located so that it: permits adequate maintenance and cleaning; functions in accodance with its inteded use; and facilitates good hygiene practices, including monitoring.

• Equipment must be positioned at least 50 cm Away from the wall and off the floor

Equipment and utensils

• Equipment design

Must be designed for the tpe of product (haccp)

Must allow for sampling and monitoring (where required)

Position of motors and pumps (not over product)

Must easy clean (CIP or easy to take apart for manual cleaning)

Must be easy to mantain

Must have product contact surfaces compatible with product

Corners must be rounded

exterior surface must be easy to clean

Equipment and utensils

ZOONINGZOONING

ZONINGZONINGA CRITICAL ELEMENTOF ALL PREVENTION

PLANS

• Zoning is an integral part of manufacturing plans, control procedures and GMP.

•Is a part of a factory´s total plan for prevention, never to be considered in isolation, must to be supported by many other preventive measures such correct cleaning and good equipment installation.

•Zoning is successful only if all personnel and visitors to the factory understand them.

ZONING AND LAYOUT FOR PREVENTION

Keeping out and keeping away unwanted items, animals and people from the product contact points is a major step towards prevention of food hygiene problems.

ZONING FOR PREVENTIONWhat is zoning ?• Zoning suggests divisions and limitation (barriers)• Zoning is equivalent to dividing into areas, each having a

well-defined use• Zoning is part of a total concept to prevent product

contamination• Zoning implies a knowledge of product, process and

preventive measures

..but most important zoning will be ineffective without coaching and correct attitudes.

ZONING FOR PREVENTION

Zoning is closely related to:

Needs for Product safety and Safety of the consumer

But zoning must remain realistic an affordable

Within the local limits and those of manufacturing

ZONING FOR PREVENTION

Zoning a new factory is relatively easy

But zoning an existing factory can be a very costly and time consuming exercise

...Compromises or justification of investments may be essential as long as food safety

is never put at risk

ZONING FOR PREVENTIONHow to proceed sensibly and systematically.How to proceed sensibly and systematically.

• Form a multidisciplinary team• Establish required level of product protection; use HACCP

and other information• Discuss with all concerned• In existing factories, study all circulations• For projects make preliminary circulation plan• Establish all details of hygienic design for barriers and

installations• Plan associated routines and organise training

BRAINSTORMING for APPROPRIATE ZONING. • What is the product/consumer concern?

• Is this related to food safety?• Are there local concerns related to this issue?• What are the product specifications?• What are the sampling plans and inducators?• What are the contamination sources of concerns?• What is the microbiological history of the facility?• What cleaning procedures are used for equipment?• What cleaning procedures are used for the environment?• What services are necessary?• What are the incoming goods?

ZONING FOR PREVENTIONHints and words of warningHints and words of warning• Keep zoning logical in accordance with required product and

consumer protection• Barriers must apply to everyone and everything• Never use zoning just for psychological reasons• Zoning must remain acceptable and practical for all

concerned• Details of line layout and equipment installation must

complement zoning• Training for all concerned is essential

ZONING and LAYOUT FOR PREVENTION

• Industrial services• Drainage and floor slopes• Drainage and equipment

positions• CIP circuits• Fire protection• Conveyors

• Waste collection• Rework handling• Off-line labs.• Stores for spare parts,

maintenance tools and cleaning equipment

• Air conditioning• Personnel and material

routes

When planning do not forget elements associated with layout:

THE DIAGRAM OF THE FACTORY WITH CRITICAL CIRCULATIONS:

• Personnel Production Entries/ ExitsEngineers Cross-oversVisitors Between zones• ProductsRaw materials/packaging Between zonesSemi-finished products WarehousingFinished products and zonesReworkEquipment and cleaning items

THE DIAGRAM OF THE FACTORY WITH CRITICAL CIRCULATIONS:

• WasteFilled bags/bins Collection, exitProduct residues and re-entry• WaterHot and cold Circuits/drainageTreatments entry and exit• AirFiltered Directions andNot filtered circuits

SOME CONCLUDING COMMENTSZoning is a useful tool but must not be abused:It would be wrong to:

• Put all products into one hygiene (risk) level with one class of zoning and similar preventive measures

• Arrive at such a point - "Point of no return" - with too many/too expensive measures being used for no specific reason but with fear of impact if barriers are then reduced.

• By example, set impossible standards• Loose focus on the product and factory having direct

influence on its safety