Sanitary design and construction for food processing

Sanitary Design and
Construction
for Food Processing
1
Prof. Aarti Vyas
Dept. of Food Microbiology and Safety
Dr. Ulhas Patil College of Food Technology, Jalgaon

Introduction
• A food establishment 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

Sanitary Design and Construction
for Food Processing
• Site selection
• Site preparation
• Building construction considerations
• Processing design considerations
• Pest control design
3

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

Location, Layout & Facilities
Dirty passage being used as Food Storage
Urinal without doors
Food Preparation area
Poor Civic Sense cause airborne bacteria6

Garbage lying open – Source of Flies, Insects, Rodents
Open and unattended Garbage Bins
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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.
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Building construction considerations
The designing 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.
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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.

Cleanable, durable,
impervious to moisture
Cracks allow bacteria
and molds to accumulate
Floors, ceilings and walls -
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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.
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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

Good Repairs & Clean walls
Floors, ceilings and walls -
Ceiling made of impervious material
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LAYOUT AND DESIGN OF 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
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Repaired Floor
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Floor with drainage of appropriate slope
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Drains should be covered to
prevent insects and rodents
Floor with proper drainage
20

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

Doors made of smooth and
non-absorbent surfaces
22
Well screened windows

Food Preparation Areas shall have a installed chimney
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Food Preparation Areas shall have no smoke nuisance
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• Appropriate facility design 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

• Processing equipment should 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

• Equipment openings and 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

• Stainless steel is 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

• effectively and efficiently 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.
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• Maintenance enclosures and 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.
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• 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.
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Cooking containers with lids
Equipments made of corrosion free material
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Storage containers with lids
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Storage containers in the kitchen with lids
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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.
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Cleaning of equipments
37

Sanitizing of equipment
38

PEST CONTROL DESIGN
• Conduct pest control regularly.
• Take all-round action for pest control.
39

• A rodent lip 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.
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41

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

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

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
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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.
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Colour coding of water pipes
to avoid contamination
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Cleaning of water storage tanks
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Cleaning of utensils
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Washing of Raw materials
Vegetable washing machine
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Handling Ice Machine
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Clean & hygienic Ice Machine Dirty Ice Machine

Hand washing facilities
54

Hand washing facilities
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Separate lockers for men and women for changing work clothes
Food shall be consumed in Refreshment Room and not in Rest Room
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Air quality and ventilation
Illustrative
57

Lighting
Proper lighting facility in the work area
Lights shall be covered
58

Sanitary design and construction for food processing

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