Hygienic Design of Food Factories

Prof. Dr. John Holah is an applied microbiologist focused on the prevention of microbial, chemical, and foreign body contamination of food during manufacture and retail distribution. He is currently Technical Director of Holchem Laboratories (UK), a major supplier of cleaning chemicals, disinfectants and hygiene services. He is a Visiting Professor in Food Safety at Cardiff Metropolitan University and was previously Head of Food Hygiene at Campden BRI. He has been a member of the EHEDG (the European Hygienic Engineering and Design Group) since 1989 and has also chaired ISO Working Groups producing standards on hygienic design and lubricants and chaired the GFSI Working Group on the hygienic design of food facilities and equipment. He is a co-editor in the other two Elseveir books. He has published and presented hundreds of scientific papers, technical articles and presentations in food safety and hygienic design. Prof. Dr. h.c. H.L.M. (Huub) Lelieveld is President of the Global Harmonization Initiative and Fellow of the International Academy of Food Science and Technology, and was formerly at Unilever in Vlaardingen, The Netherlands. He editor or co-editor of numerous books, including several on hygiene and food safety management; novel food processing technologies and harmonization of food safety regulations. He produced chapters for many books and encyclopaedia, hundreds of scientific articles and articles for magazines and presented hundreds of papers, globally. He has been awarded doctor honoris causa at the National University of Food Technologies in Kiev, Ukraine.

"This book encompasses all the relevant and important topics regarding food facility design, construction and renovation." --Croatian Journal of Food Science and Technology"This book is an essential source of all relevant information on food facility design…I warmly recommend this book." --Croatian Journal of Food Science and Technology"The comprehensive coverage of the subject in this book makes it an important addition to the literature on food factory hygienic design. This book is likely to become the standard industry reference for this highly important aspect of safe food provision." --International Journal of Dairy Technology

• Contributor contact detailsWoodhead Publishing Series in Food Science, Technology and NutritionDedicationPrefaceChapter 1: Business case assessment and design essentials for food factory building projectsAbstract:1.1 Introduction1.2 The need for a new or refurbished food factory1.3 A new product: generation, approval, specification and business plan1.4 Determine process and mass flow1.5 ConclusionChapter 2: Determining equipment and process needs and how these affect food factory designAbstract:2.1 Introduction2.2 Brownfield projects: processes and equipment2.3 Greenfield projects: processes and equipment2.4 Future trendsPart I: Regulatory issues and retailer requirementsChapter 3: EU food hygiene law and implications for food factory designAbstract:3.1 The relevance of EU food hygiene law for the design of food factories3.2 The objectives of EU food hygiene law3.3 The EU General Food Law (GFL)3.4 EU food hygiene law3.5 Four types of EU food hygiene law3.6 The combination of EU food hygiene law and other law on the design of food factories3.7 ConclusionsChapter 4: Regulations on the hygienic design of food processing factories in the United StatesAbstract:4.1 Introduction4.2 Regulatory requirements in the United States4.3 Guidance documents4.4 Other agencies and considerations4.5 Case study: a milk processing plant4.6 ConclusionChapter 5: Regulation relevant to the design and construction of food factories in JapanAbstract:5.1 Introduction5.2 Contents of regulatory requirements5.3 Legal regulations concerning the Food Sanitation Act5.4 Legal regulations other than those concerning the Food Sanitation Act5.5 Industrial Safety and Health Act5.6 Legal regulations concerning the environment5.7 Case study5.8 Future trendsChapter 6: Regulation and non-regulatory guidance in Australia and New Zealand with implications for food factory designAbstract:6.1 Introduction6.2 Food regulatory requirements in Australia and New Zealand6.3 Trade regulations and requirements6.4 Building requirements6.5 Case study: food safety in meat processing6.6 Future trends6.7 Conclusion6.9 Appendix 1: Australasian standards for building and construction6.10 Appendix 2: Relevant food acts and regulationsChapter 7: Regulatory requirements for food factory buildings in South Africa and other Southern African countriesAbstract:7.1 Introduction7.2 South African regulations and standards7.3 Regulations and standards in other Southern African Development Community (SADC) countries7.4 Future trends7.5 Sources of further informationChapter 8: Retailer requirements for hygienic design of food factory buildingsAbstract:8.1 Introduction: private labels and retailers’ responsibility8.2 Background to the British Retail Consortium (BRC Food) and the International Food Standard (IFS Food)8.3 Global Food Safety Initiative8.4 Retailers’ requirements8.5 Future trends8.6 Sources of further information and adviceChapter 9: Food factory design to prevent deliberate product contaminationAbstract:9.1 Introduction9.2 Historical incidences of intentional food contamination9.3 Food fraud versus intentional contamination9.4 Prevention of intentional contamination9.5 Future trends9.6 ConclusionsChapter 10: Minimum hygienic design requirements for food processing factoriesAbstract:10.1 Introduction10.2 Site10.3 Building design10.4 Internal divisions10.5 Building fabric10.6 Services10.7 Sources of further information and advicePart II: Site selection and factory layoutChapter 11: Aspects to be considered when selecting a site for a food factoryAbstract:11.1 Introduction11.2 Product11.3 Utilities11.4 Sources of contamination11.5 Regulations11.6 Protection of the environment11.7 Industrial zoning11.8 Financial aspects11.9 Personnel11.10 Security11.11 Access11.12 Climate11.13 Research and Development11.14 Conclusions11.15 Sources of further information and adviceChapter 12: The impact of factory layout on hygiene in food factoriesAbstract:12.1 Introduction12.2 Layout of plant grounds and outer perimeter12.3 Layout of the outer plant building12.4 General interior building layout requirements12.5 Manufacturing layout12.6 Future trendsChapter 13: Hazard control by segregation in food factoriesAbstract:13.1 Introduction13.2 Barrier 1: site13.3 Barrier 2: factory building13.4 Barrier 3: high care/risk areas13.5 Barrier 4: product enclosure13.6 Future trendsChapter 14: Managing airflow and air filtration to improve hygiene in food factoriesAbstract:14.1 Introduction14.2 Airflow14.3 Air handling equipment14.4 Air filtration14.5 Air handling system monitoring and maintenance14.6 Future trends14.7 Sources of further information and advicePart III: Hygienic design of walls, ceilings and floorsChapter 15: Hygienic wall finishes for food processing factoriesAbstract:15.1 Introduction15.2 High performance paint coatings15.3 Thermoplastic wall cladding systems15.4 Stainless steel cladding15.5 Reinforced resin laminates15.6 Insulated panel walls and ceilings15.7 Wall tiling15.8 Future trendsChapter 16: Hygienic design of ceilings for food factoriesAbstract:16.1 Introduction16.2 Hygiene levels in food processing factories16.3 Other factors affecting the type of ceiling system used in a food factory16.4 Types of hygienic suspended ceiling systems16.5 Walk-on type ceiling consisting of sandwich panels16.6 Selection of the type and make of sandwich panels16.7 Non-walk-on acoustical lay-in hygienic tiling systems16.8 Hygienic coatings for production facilities without suspended ceilings16.9 Hygienic coatings16.10 Lighting16.11 Heating, ventilation and air conditioning (HVAC)Chapter 17: Hygienic floor finishes for food processing areasAbstract:17.1 Introduction17.2 Establishing requirements for floor finishes in food processing factories17.3 Selection of floor finish materials17.4 Substrate requirements17.5 Detailing within the design17.6 Hygiene control during the renovation of existing floor finishes17.7 Cleaning and maintenance17.8 Future trends17.9 Sources of further information and adviceChapter 18: Hygienic design of floor drains in food processing areasAbstract:18.1 Introduction18.2 Channel and gully system functional overview18.3 Floor drains as a point of contamination18.4 Material choice for floor drainage18.5 Modelling flow in drainage channels18.6 Incorporating hygienic design principles in drain design18.7 Layout and zoning areas18.8 Load capacity18.9 Slip resistance18.10 Fire preventionPart IV: Hygienic design of selected fixtures, utility systems and process support systemsChapter 19: Hygienic supply of electricity in food factoriesAbstract:19.1 Introduction19.2 Standards and regulations with which electrical equipment has to comply19.3 Use of electrical equipment in the food industry19.4 Materials of construction19.5 Hygienic supply of electricity19.6 Electrical cabinets and field boxes19.7 Hygienic design and installation of electrical equipment19.8 Data/telecommunication and control systemsChapter 20: Hygienic design of lighting in food factoriesAbstract:20.1 Introduction20.2 Electric lighting standards20.3 Use of daylight20.4 Light intensity and uniformity of illumination20.5 Functional lighting20.6 Application of the appropriate lighting in warehouses20.7 Lamps20.8 Selection of armatures20.9 Cleaning and maintenance of lamps and armatures20.10 Innovative energy-saving lighting technologies and strategies20.11 Hygienic recommendations with respect to electric lighting20.12 Special duty lightingChapter 21: Hygienic design of piping for food processing support systems in food factoriesAbstract:21.1 Introduction21.2 Location of support systems and building services within the food factory21.3 General hygienic requirements for food processing support piping within the factory21.4 Specific hygienic design requirements for food processing support piping in rooms of different hygienic classChapter 22: Hygienic design of exhaust and dust control systems in food factoriesAbstract:22.1 Introduction22.2 Mechanical ventilation22.3 Hygienic design of exhaust systems for the removal of steam, heat, odours and grease–contaminated vapour outside the food factory22.4 Hygienic design of specific exhaust systems used to handle effluents produced during the processing of food by means of heat22.5 Installation of exhaust systems within the food factory22.6 Cleaning of exhaust systems22.7 Inspection and maintenance of exhaust systems22.8 Hygienic design of exhaust facilities applied to extract heat, aerosols, bio-burden, odours and toxic vapours out of process rooms and technical areas22.9 Hygienic design of dust control systems22.10 Influence of the exhaust system on the air flow and air qualityChapter 23: Managing steam quality in food and beverage processingAbstract:23.1 Introduction23.2 Steam grade definitions23.3 Plant steam23.4 Filtered steam23.5 Clean steam23.6 Pure steam23.7 Installation, operation and maintenance23.8 Boiler installation23.9 Steam pipe insulation23.11 Appendix 1: Typical applications where steam is used in direct contact with the product/process23.12 Appendix 2: Typical chemicals, which are generally added to the feedwater as part of a water treatment programme23.13 Appendix 3: Chemicals that are approved by the Food and Drink Administration (FDA) in the USA for use with food and beverage products with acceptable concentration for each chemicalChapter 24: Hygienic design of walkways, stairways and other installations in food factoriesAbstract:24.1 Introduction24.2 Determining the equipment needs24.3 Future trends24.4 Sources of further information and advice24.5 AcknowledgementPart V: Hygienic design of specific factory areasChapter 25: Hygienic design of entries, exits, other openings in the building envelope and dry warehousing areas in food factoriesAbstract:25.1 Hygienic design of foundations, support structures, external walls and roofs25.2 Hygienic design of entry, exit and storage points25.3 Entry doors – visitors and employees25.4 Truck docks (loading, unloading)25.5 Storage – dry warehousing25.6 Cold storage (including freezer storage)25.7 Sanitary design of openings in the building envelope25.8 Future trendsChapter 26: Effluents from the food industryAbstract:26.1 Introduction26.2 Effluent characterisation26.3 Sequence of processes and operations26.4 Microbiological hazards for the food factory26.5 Sources of further informationChapter 27: Design of food storage facilitiesAbstract:27.1 Introduction and definitions27.2 General design requirements27.3 Storage facilities for dry products and dry cleaning requirements27.4 Wet cleaning of storage facilities and storage of liquid products27.5 Future trendsChapter 28: Design, installation and operation of cleaning and disinfectant chemical storage, distribution and application systems in food factoriesAbstract:28.1 Introduction28.2 Storage of industrial detergents, disinfectants and associated products28.3 Hygiene chemical distribution and point of use location within production areas28.4 Dose, control and application of hygiene chemicals28.5 Dry cleaning and goods area28.6 Cleaning rooms and utensil washing28.7 Maintenance and cleaning of the cleaning systems28.8 Requirements for transition to operation28.9 Future trendsChapter 29: Design of food factory changing roomsAbstract:29.1 Introduction29.2 Legislation29.3 Facilities design29.4 Low risk/high risk barriers29.5 Cross-contamination risks29.6 Future trendsPart VI: Managing building work and additional factory design considerationsChapter 30: Managing a factory building project: from development of a construction brief to commissioning and handoverAbstract:30.1 Introduction30.2 Business case justification30.3 Project definition30.4 Construction brief30.5 Contractual arrangements30.6 Model contracts30.7 Selecting a contractor30.8 Overview30.9 Managing construction30.10 Equipment procurement, testing and installation30.11 Commissioning and handover30.12 Future trends30.13 Sources for further information and adviceChapter 31: Inspecting hygienic design, hygiene practices and process safety when commissioning a food factoryAbstract:31.1 Inspecting for commissioning of manufacturing sites for hygienic design and practice31.2 A site that has been newly designed and built for food manufacture31.3 An existing manufacturing site that is being acquired by another company31.4 An existing site that has no history of food production is to be adapted for food purposes31.5 Preparing the team31.6 ConclusionChapter 32: An insurance industry perspective on property protection and liability issues in food factory designAbstract:32.1 Introduction32.2 Hazard analysis32.3 Requirements for property insurance (fire, natural hazards, business interruption)32.4 Requirements for liability insurance (occupational safety, third party, product and environmental liability)32.5 Prevention and protection32.6 Future trends32.7 Checklist for easy reference32.8 Sources of further information and adviceIndex