GMP Requirements in Design, Construction
and Installation of Food Processing Industry
In the previous article (second in the series), "Common Sense in Good Manufacturing Practices" it was discussed how we can use our diversified learning to improve our business operations. In this article, I will discuss some of the design errors, commonly visible in many of the food factories, which are facing quality management problems. It is important to note that it is very difficult to ensure food safety and quality in badly designed food factories. It is also observed that, the maintenance and operation cost of badly designed food factories is very high.
This means, such companies are losing on both fronts i.e. their production costs goes up and the manufactured products are also of inferior quality.
This all happens when the architects and the consultants involved in designing food factories gives more importance to external beauty of the building and other comforts for managers than the functional need of the food factories which are essential features of Good Manufacturing Practices.
While designing a food factory or processing unit the two basic features should be given top most priority:
In order to ensure cleanliness, without compromising on safety of workers and food safety in the factory, following points, which are vital, should be considered.
Floors, Walls, and Ceilings
The floors, floor coverings, walls, wall coverings, and ceilings in food processing factories can be source of contamination therefore they should be designed, constructed, and installed in such a manner that they are smooth and easily cleanable. There are various construction materials available now-a-days but selection criteria should consider the requirements of the process like hot water, acid, alkali, cleaning materials, spillage, etc.
At the same time precautions should be taken to ensure anti-slip floor coverings may be used for safety reasons in work areas.
Utility Lines
Common utilities for any food factories are like tap water, hot water, compressed air, steam, electricity, etc.
Utility service lines and other pipes may not be unnecessarily exposed because these can be ideal place for accumulation of dirt and dust and breeding ground for contamination. At the same time, exposed utility service lines and pipes should be installed in such a way so that they do not obstruct or prevent cleaning of the floors, walls, or ceilings or movement of goods and people when required.
Exposed horizontal utility service lines and pipes should not be installed on the floor to avoid smooth movement of goods and people when required.
Floor and Wall Junctures
Floor and Wall Junctures are critical points. In food establishments in which cleaning methods other than water flushing are used for cleaning floors, the floor and wall junctures should be covered and closed to no larger than 1 mm. The floors in food establishments in which water flush cleaning methods are used should be provided with drains and be graded to drain, and the floor and wall junctures should be covered and properly sealed.
Floor Carpeting and Attachments
All floor coverings such as carpeting or similar material may not be installed as a floor covering in food preparation areas where the floor is subject to moisture, flushing, or spray cleaning methods like walk-in cold-storage, ware-washing areas, toilet room areas, refuse storage rooms, or other areas
If carpeting is installed as a floor covering in areas other than those specified above, it should be:
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Securely attached to the floor, by using a stretch and tack method, or by another method; and |
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Installed tightly against the wall under the covering or installed away from the wall with a space between the carpet and the wall and with the edges of the carpet secured by metal stripping or some other means. |
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Temporary coverings like mats should be designed to be removable and easily cleanable. At the same time, Wall and ceiling covering materials should be attached so that they are easily cleanable. |
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Areas used for dry storage only, concrete, porous blocks, or bricks used for indoor wall construction should be finished and sealed to provide a smooth, non-absorbent, easily cleanable surface. |
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Not only Walls and Ceilings but also attachments to walls and ceilings such as light fixtures, mechanical room ventilation system components, vent covers, wall mounted fans, decorative items, and other attachments should be easily cleanable. |
Functionality of Factory Design is very important, otherwise the cost of rectification of quality problems and maintenance of factory will be very expensive.
Light Bulbs with Protective Shielding
Light bulbs should be shielded, coated, or otherwise shatter-resistant in areas where there is exposed food; clean equipment, utensils, and linens; or unwrapped single-service and single-use articles. An infrared or other heat lamp should be protected against breakage by a shield surrounding and extending beyond the bulb so that only the face of the bulb is exposed.
Heating, Ventilating, Air Conditioning System Vents and Ducts
Heating, ventilating, and air conditioning systems should be designed and installed in such a manner that make-up air intake and exhaust vents do not cause contamination of food, food-contact surfaces, equipment, or utensils.
Proper air filters and air cleaning system should be followed and properly maintained. Selection of air filters will depend upon the flow rates and quality of air required.
Design and Installation of Insect Control Devices
Insect control devices that are used to electrocute or stun flying insects should be designed to retain the insect within the device.
Insect control devices should be installed so that the devices are not located over a food preparation area; and dead insects and insect fragments are prevented from being impelled onto or falling on exposed food; clean equipment, utensils, and linens; and unwrapped single-service and single-use articles.
At the same time devices are installed in such a manner that it should not become obstruction to the smooth movement of man and material and should not cause any harm to the employees due to prolonged exposure.
Toilet Rooms
The toilet rooms located in the premises should be completely enclosed and provided with a tight-fitting and self-closing door. This requirement does not apply to the toilet room that is located outside the food establishments and does not open directly into the food establishment areas for e.g. toilet room that is provided by the management in the administrative area away from the food production area.
Outer Openings like windows and doors
Outer openings, like windows and doors of a food establishment should be protected against the entry of insects and rodents by filling or closing holes and other gaps and sloops along floors, walls and ceilings; also by closed, tight-fitting windows; and Solid self-closing and tight-fitting doors.
If the windows or doors of a food establishment, or of a larger structure within which a food establishment is located, are kept open for ventilation or other purposes it should be protected against the entry of insects and rodents. Combinations of insect resistant screen; properly designed and installed air curtains; or other effective means can achieve the purpose.
Exterior Walls and Roofs and Gardens
Perimeter walls and roofs of a food establishment should effectively protect the establishment from the weather and the entry of insects, rodents, and other animals. Very often the gardens and trees around the food factories act as a breeding ground for insects and rodents and is an ideal place for birds nesting.
Outdoor Walking and Driving Surfaces
Exterior walking and driving surfaces should be graded to drain to avoid water logging. Exterior walking and driving surfaces should be made of easily cleanable material and should not act as a source of contamination.
Outdoor Refuse Areas
Outdoor refuse areas should be constructed in accordance with provisions of law and should be curbed and graded to drain, to collect and to dispose of liquid waste that results from the refuse.
Change Rooms
Change rooms provided for lodging and rest of workers should be separated from rooms and areas used for food establishment operations by complete partitioning and solid self-closing doors.
All washrooms, lunchrooms and change rooms should be separate from the food processing areas and should be properly ventilated and maintained. Washrooms should be equipped with a sufficient number of properly installed sinks and plumbed with hot and cold potable water.
Processing areas and areas where employees are in direct contact with microbiologically sensitive product should contain conveniently located hand-washing stations controlled by foot, knee or a timer with sensors.
Clear signs should be posted in these areas, in appropriate languages, requiring employees to wash their hands.
Outdoor food handling areas
Storage area, despatch and other food handling areas should be provided with proper overhead protection. Areas used only for the loading of water or the discharge of sewage and other liquid waste, through the use of a closed system of hoses, need not be provided with overhead protection.
The above article discussed few important dimensions of the food factory designing and constructions. The next article will discuss various other dimensions of food safety, quality and application of Good Manufacturing Practices in food industries.
The views outlined above are some of the more important ones. It is definitely not easy to talk about common sense. To quote an Old Spanish proverb, "Common Sense is the least common of the senses."
