Hygienic Design, Construction and Layout of Food Processing Factories

INTRODUCTION Hygienic design philosophy The primary concern of food manufacturers is to produce a product that is both wholesome, and safe, i.e. free from pathogenic microorganisms and chemical and foreign body contamination. The schematic diagram shown in Figure 0. , which is typical for all food factories, shows that the production of safe, wholesome foods stems from a thorough ris! analysis. "ndeed, this is now a legal re#uirement. The diagram also shows that, gi$en specified raw materials, there are four ma%or &building bloc!s& that go$ern the way the factory is operated to ensure that the safe, wholesome food goal is realised. Hygiene considerations dictate the design of the production facility and e#uipment, whilst process e$aluation enables the design of safe, $alidated processes. Hygienic practices and process control subse#uently ensure the respecti$e integrity of these two dependables. Figure 0.1 Schema ic s ages re!uired o ensure sa"e# $holesome "ood produc s H'CCP (pecified raw material))* Hygienic design +* Hygienic practices (afe, wholesome food ,))Process de$elopment ,))Process control -is! analysis encompasses indentifying the ha.ards that may affect the #uality or safety of the food product and controlling them at all stages of the process such that product /contamination is minimised. "n the food industry this is commonly referred to as critical Control Point 0H'CCP1. Such ha%ards are usually descri&ed as'
2 CCF-' 3004

5Type te6t7 . 8iological, e.g. bacteria, yeasts, moulds . Chemical, e.g. cleaning chemicals, lubricating fluids . Physical, e.g. glass, insects, pests, metal, dust ' ha.ard analysis should be underta!en at the earliest opportunity in the process of food production and, if possible, before the design and construction of the processing facility. This allows the design of the production facility to play a ma%or role in ha.ard elimination or ris! reduction. To restrict the potential of food contamination, a ha.ard analysis should also be underta!en if construction wor! is to be underta!en whilst the factory is in production. 9f the : building bloc!s illustrated in Figure 0. , this ;uideline document deals with those aspects of hygienic design concerned with the factory building, including building siting and construction, the segregation of wor! areas to control ha.ards, the flow of raw materials and product, and the mo$ement and control of people. The document addresses the design and construction of factories from first principles and adopts a systematic approach as illustrated by Figure 0.3. The human resources that ma$ be re#uired to underta!e this approach, from both the fn . a sources that may be indicated in Figure 0.4. The approach ta!en in fig. 3 is not necesarly se#uintal and some of the stages can run in parallel, particularly those from after defining the product to the !ey decision phase ) to build or not to build. 9ther CCF-' guidelines are a$ailable that specifically loo! at factory drains,floors,walls,ceilings, ser$ices and air supplies 08rown, <<=> Timperley, 3003,30041. 8efore underta!ing design and construction wor! food manufactures should consult H(? information on the CD@ -egulations <<: 0H(C, 300 1. Figure 0.( Ne$ "ood "ac ory decision ree
Define product and business plan (ite location assessment and ris! management philosophy Determine process and mass flow Determine the re#uired le$el of segregation 0site, factory, high hygiene, product enclosure1 Determine e#uipment and factory layout ?stimate the si.e of factory re#uired and consider new build

5Type te6t7

5Type te6t7
or refurbishment alternati$es. 'd$ise cost and pro%ect timetable DecisionA) To build or not to build 'ppoint Planning (uper$isor De$elop construction brief ?stablish type of contract and select main contractor0s1 Bnderta!e building wor! Bnderta!e e#uipment installation Pro%ect completion

5Type te6t7

5Type te6t7

5Type te6t7

5Type te6t7

5Type te6t7

5Type te6t7
1. D)FIN) *RODUCT +ND ,USIN)SS *-+N Cew product de$elopment is a comple6 sub%ect in its own right and this section co$ers the essentials that relate to building design. For more detailed information in this area, readers are referred to Product de$elopment guide for the food industry 0(haw <<=1. "t is also recognised that there may be a new building re#uirement if it is wished to increase the output of e6isting products or if the e6isting processing en$ironmentDe#uipment is outdated or does not meet currentDfuture legislation. 1.1 Resource The de$elopment of new products is normally underta!en in)house and should encompass as many people as possible becauseA) ?$erybody, not %ust the product de$elopment department, are capable of generating good ideas 'll departments within the factory will play some role in the de$elopment of new products, whether it be the sourcing of new raw materials, sourcing new !it, planning factory trials, e$aluating shelf life, e$aluating microbiological safety, calculating production costs, or selling the product etc. Product de$elopment costs money and gets in the way of day)to)day acti$ities such as manufacture and sales. Eithout the support from senior management downwards, new product de$elopment will not ha$e the necessary support to ensure that the ideas generated at the earliest stage end up as products on retail display Cot all food and drin! companies conduct their creati$e design and mar!eting wor! in) house. Consultancies are a$ailable that can offer ad$ice and support in both creati$e desi ad$ertisement and mar!eting, and consumer studiesDmar!et research. 1.( The need "or ne$ produc s Cew products are designed to increase business profits stemming from increased sales $olume andDor increased profit margin on products sold. Cew products may also be necessary forA) Defensi$e action ) a competitor may introduce a new product range that needs to be matched or impro$ed on (trategyDcorporate prestige) the company may identify a need to buy its way into a new mar!et sector or to enhance its image with a new range of products "mpro$e #ualityDreduce costs by adopting a new range of products

For &commodity& type products it may be possible to either e6pand sales $olume by e6panding the mar!et or e6pand mar!et share by de$eloping new products in those part the sector which are growing 0or de$elop new mar!ets1. @any food manufacturers are mo$ing into &added $alue& products, which may be characterised as beingA) 5Type te6t7

5Type te6t7 Convenient Attractive New/novel/unique Different from competition Interesting/unusual/exciting High in consumer appeal Price difficult to compare High margin 9nce a decision has been made to de$elop one or more new products, product de$elopment is underta!en in three !ey stepsA) . "dea generation 3. "dea acceptance 4. ;eneration of a product specification brief and business plan
1.3 Idea genera ion dea generation can be internalDe6ternal or a combination of both. "nternally, competiti$eness in food mar!ets has led many companies to ta!e positi$e action to stimulate the creati$e process. &"deas generation& or &8rainstorm& sessions are a common means of achie$ing this. ?6ternally, a lot of new product de$elopment acti$ity is inspired by watchingA what is happening in the mar!et place and as!ing #uestions such asA) Ehat are our competitors doingF Ehat new launches are occurring in other sectors which suggest new general mar!et trends 0e.g. children&s snac!s, &healthier foods&, ethnic cuisine, new forms of pac!aging1F Ehat is happening in other world mar!etsF

1.. Ne$ produc appro/al 't some point, e$ery idea for a new product must be assessed and a decision made about its $iability. Guestions which will ha$e to be addressed include A) "s there a mar!et for the productF Ehat is the mar!et si.e in terms of salesF . Can we actually ma!e itF . 're raw materials a$ailableF ) Can we produce the recipe at a production le$elF ) "s it microbiologically safeF ) Eill the shelf life be long enoughF . Ehat is the result of consumer trials ) do people li!e itF "f so ) how much will they pay for itF Can we ma!e it for what people would payF ) Ehat are the raw materialDrecipe costsF ) Ehat are the processing costsF ) Ehat are the pac!aging costsF ) Ehat margin do we wish to addF . "s there the need for long term technical de$elopment to bring the pro%ect to fruition/ 5Type te6t7

5Type te6t7 . "s capital e6penditure re#uired and, if so, what is the paybac! timeF . Has the company a suitable sales and distribution networ! for the product typeF 1.0 Ne$ produc speci"ica ion and &usiness plan "f a new product is appro$ed for further de$elopment, it normally progresses from small bench scaleDtest !itchen wor! through pilot plant studies to production scale factory trials. The purpose of these studies is to deri$e the breadth of information necessary for the product to first be manufactured and then be distributed and sold, both in the short and long term. (uch information, which can be used to formulate a business plan for the new product, encompassesA) Product details Product description ) what the product is> any reference to e6isting products> whether it falls within e6isting legally)recognised categories> consider the need for "P- protection, e)g. of trade mar!s, copyright, patents, design rights. -aw materials)commerciall$ a$ailable to a set specification> satisfy any labeling claims> thenically the most appropriate and cost effecti$e> > must be permitted in foodstuffs0i1 of the proposed type and 0ii1 and in the mar!ets where the product will be sold> define any Health and (afet$ re#uirements for their safe handling -ecipe ) properly documented> any labelling claims which must be met by the formulation ) e.g. dietary, &free from& claims, use of specific ingredients> any legal re#uirements in the mar!ets where the product will be sold 0compositional standards for some products e6ist1 Process details ) all process parameters 0timesDtemperaturesDpressures etc.1 should be detailed> assess potential processing product losses Process flow chart ) all stages of the proposed process should be detailed on a flow chart to facilitate H'CCP and #uality analyses H'CCP study ) using the C9D?H approach as detailed in, for e6ample, H'CCPA ' Practical ;uide 0;a.e, 30041, determine all potential ha.ards to the consumer, how they can be eliminated or controlled by factoryDprocess design and any Critical Control Points which must be controlled to ensure product safety Product specification ) detail all #uality and sensory parameters which must be measured, together with target $alues and limits 'nalytical standards ) detail analyticalDcompositional specifications and methods of testing @icrobiological standards ) what are the microbiological ris!sF> detail microbiological specifications 0are these being met during production trialsF1 and re%ection criteria> what type of in)production testing is re#uiredF Cleaning ) define a potential cleaning programme either in)house, based on similar products or with the help of a cleaning ser$ice supplier> define cleaning and 5Type te6t7

5Type te6t7 en$ironmental testing specifications including microbiological standards as appropriate. Pac!aging specification ) define the pac!aging specification> define the pac!aging design labelling information, declarations 0including e6port considerations1 and customerDconsumer instructions (helf life ) must be established either by real time storage trials or prediction 0including microbiological models1 based upon similarDrelated products> manufacturing and distribution time and temperature limitations Finished product weightsD$olumesDsi.esDshapes ) detail any statutory re#uirements and tolerances ,usiness plan Pro%ected unit cost Pro%ected wholesale andDor retail price Pro%ect write down costs and estimated paybac! Target customers ) what is the li!ely consumer age and potential ris! categor Predicted first year product sales $olumes Predicted ne6t I years product sales $olumes Decide whether the new product re#uires a new manufacturing technology Decide whether the new product re#uires new manufacturing e#uipment Decide whether the new product re#uires additionalDrefurbished manufacturing space 0for an e6isting manufacturing site1 or a new food manufacturing facility Consult with source of financial bac!ing and obtain agreemeni in principle to proceed. (. SIT) -OC+TION +SS)SS1)NT +ND RIS2 1+N+3)1)NT *HI-OSO*H4 'ssuming that a building pro%ect is re#uired, this section ta!es the designed product to the ne6t stage and as!s some basic #uestions to determine whether the building of a factory in a gi$en area is feasible. "t also considers the management of the potential ris!s to the business. (.1 Resource eam Food companies range in their building design capabilities from large multinationals with in) house facilities to design new factories 0often with preferred building consultantsD contractors1 to small companies with either no time or e6perience to consider building pro%ects. 'll food companies need help from the new product de$elopment stage to bring the manufacture of such products to fruition, though the degree of such support will $ary tremendously, depending on the in)house capabilities of the food company and the nature of the building pro%ect. For e6ample, many food companies would attempt to underta!e the first J sections of this document themsel$es for a small area of the factory that they wanted to refurbish, but would not attempt the design of a new factory. The traditional way to design and construct a food factory is to engage an architectDdesigner, whose role is to interpret the clientKs re#uirements into a specific design and specification. The builder would then be appointed to carry out the wor!, to the instructions of the designer. To accomplish this, the architect would probably bring together a design team for the pro%ect consisting of an 'rchitect, Pro%ect @anager, Guantity (ur$eyor, (er$ices ?ngineer, (tructural ?ngineer, Ci$il 5Type te6t7

5Type te6t7 ?ngineer, ?n$ironmentalist and Planning (uper$isor 0see (ection L.41. The design team then considers statutory design and Health and (afety re#uirements, assesses cost limits and time scale, and prepares s!etch plans for appro$al. Then contract drawings and bills of #uantities are prepared and tenders applied for from !nown building contractors. The architect chec!s tenders, accepts one, then holds a pre)contract meeting, prepares and obtain signatures for a contract and to agree a programme, and super$ises the pro%ect using a Cler! of Eor!s. Ehilst there is a wide choice of help in realising the building construction and the manufacture of the product, one thing remains clear ) the final design is only as good as the design team. Food manufacturers should ensure, therefore, that potential design consultants are familiar with the general concepts of food factory design and for more specific food manufacturing operations 0e.g. chilled foods1, e6perience in that particular food commodity. "nformation on the performance of contractors can be obtained from other food manufacturers, by contacting contractorsK pre$ious clients, or from trade organisations. The following websites pro$ide useful contacts in the BMA) N -oyal "nstitute of 8ritish 'rchitects N ?ngineering Construction "ndustry 'ssociation N @echanical and ?lectrical Consulting ?ngineers N Cational Cetwor! of Chartered (ur$eyors and Oaluers Si e plan For refurbishments or e6tensions, the first consideration is ) do you really need to build at allF "s it possible that you can get by using different production methodsDtimes etcF "f this is not possible, or if it is a new build pro%ect, the ne6t consideration is to decide on a geographical area for the construction site. ' suitable geographical area should ideallyA) N 8e close to raw material sources. N 8e close to the finished product consumer. N Ha$e easy access to a suitable transport distribution networ! to ease the supply of other ingredients and to facilitate transport of finished product to the customer. N Ha$e a readily a$ailable source of trained operati$es N Ha$e undergone a flood ris! assessment 9nce a suitable geographical area has been found, a specific site needs to be chosen. "n addition to new build pro%ects, the attributes of a suitable site may also need to be considered for refurbishments and e6tensions. Considerations includeA) N 9wnership of the land 0freehold, leasehold1 and any legal responsibilities that arise from leasing. N Possibilities for obtaining outline planning permission 0if the site does not already ha$e planning permission for industrial use ) 8l, 83 or 8L1, including any constraints on building styleDheight etc. 'lso any constraints on noise le$els, traffic mo$ements and odour issues. N 'n assessment of ground contamination and any necessary remediation issues. N N 'n assessment of any surrounding ha.ards that may affect site access. Possibilities for obtaining grants that could reduce business costs.

5Type te6t7

5Type te6t7 N (ufficient space a$ailability to incorporate initial and predicted future needs. N (ufficient energy supplies to ser$ice power and process heatingDcooling needs. N (ources of potential ha.ards from surrounding operations, e.g. sewage wor!s, landfill, farming, particle emitting processes. N ?ase of remo$al of solid wastes N Li!elihood of obtaining discharge consent for li#uid wastes 't this concept stage, appropriate members of the design team should consider !nown facts, building costs, plus problems uni#ue to the proposed site which could include the land 0e.g. pre$ious useDcontamination issues, access and ad%acent property issues and en$ironmental issues1. 'll current and future legislation and liabilities impacting on the proposed site from the intended business should be carefully considered. 't the time of writing. "ntegrated Pollution Pre$ention and Control 0"PPC1, a system following the ?uropean Community Directi$e 0<=D< 1, is being implemented and will introduce a more integrated approach to controlling pollution from industrial sources, across ?ngland and Eales. Further details on this and other legislation can be found atA) httpADDwww.defra.go$.u!Den$ironmentDppcDinde6.htm. For pro%ects in which e6isting operati$es will be used, but the new product range has a higher le$el of ris!, e.g. companies mo$ing into chilled foods, the fle6ibility of staff is important. -esources and time should be allowed for managing the cultural change needed to re)educate staff to the re#uirements for higher hygiene standards. 3.3 Ris5 managemen 't a fundamental le$el, the management of any food processing facilities must ta!e proacti$e steps in order to ensure that their business remains in e6istence to do precisely what it was established to do> i.e. to trade at a profit. -is! management is the effecti$e management of ris! e6posures by the company in order to eliminate or minimise their effect and thus ensure the e6istence of the company. -is!s to the success of the food business, for e6ample, can focus on the followingA) N The staff employed N The sourcing of raw materials N -aw material #uality N The factory buildings in which the food is processed N Hygienic design and manufacturing N The pro$ision of utilities N The performance of the food processing machinery N (torage, dispatch and transport of finished product N Pre$ention of product adulteration This document is primarily concerned with the ris!s associated with the temporary or permanent loss of the buildings, primarily due to fire, and how this can be managed. Clearly the buildings are a significant proportion of company assets, and are fundamental to allowing the company to manufacture food. "nsurance companies can pro$ide e6cellent ris! management e6pertise in relation to food industry ris!s. 't the time of writing, the food industry has special consideration in terms of insurance ris!, primarily because of the numbers and se$erity of fires, many lin!ed to polystyrene cored composite panels. 9ne ma%or insurer estimates that claims made for the food industry are 3.I times the premium. Fires in$ol$ing such panels, and the way they are tac!led by fire fighters 0see Firefighting options for fires involving sandwich panels at www.homeoffice.go$.u!1, typically result in both the total loss of the 5Type te6t7

5Type te6t7 building and of the product 0through destruction or potential smo!e damage or tainting1. 's far as the food industry is concerned, insurance is currently a PhardK mar!et> that is to say insurance pro$ision will only be considered if the food manufacturer underta!es specific ris! management strategies. The food industry is thus seen by insurance companies as high ris!, with conse#uent high losses, and as such, both premiums and the le$el of e6cess are rising significantly. Eith respect to fire, good ris! management is designed toA) N -educe the ris!s of fires starting N Control fires and other ris!s by restricting their impact to particular areas N Pro$ide an early warning of impending disaster N Pro$ide an immediate means of controlling that disaster when it has ta!en place prior to the arri$al of fire fighting assistance -is! management uses both passi$e and acti$e tools. Passi$e ris! management tools for fire include the use of incombustible building materials, the pro$ision of fire detection systems, and the segregation of $arious sections of the whole site, particularly storage and process areas, into distinct fire ris!s, by compartmentation using incombustible fire walls. Bse of non)combustible panels for both building construction and insulation is also recommended. The fire alarm should be installed fully up to the highest life safety standard, L", or preferably the higher property standard, P" 0where all rooms and significant $oids are protected1 set out in 8(IL4<A Part A 3003 ) code of practice for system design, installation, commissioning and maintenance 0'non 30031. "t should be a fully addressable system, configured across the site and recei$ing signals from automatic smo!e, heat, rate of rise etc. detectors, the Fire Panel being fitted, ideally, in a permanently manned location on site. The fire signal should then be transmitted to a remote 'ppro$ed 'larm -ecei$ing Centre, $ia a 8T -edCare 0monitored1 line, with procedures in place for initial in$estigation by the (ecurity personnel or whoe$er on duty is trained to perform this tas!. 'cti$e ris! management tools for fire include sprin!lers, gas flooding systems and e6tinguishers. There may be particular high ris!s, such as deep fat frying, where special Class F wet chemical fire e6tinguishers are needed or where automatic gas flooding is re#uired in the coo!ing area and flue arrangements. "deally such high ris! areas should ha$e one hour fire resistance construction, in terms of insulation and integrity, around them ) this can be reduced to a 40 minutes fire resistance if the premises are sprin!ler protected. 9ther high fire ris! areas include those for bul! storage of oils and fats, and these should be !ept separate. Ehere thermal fluid heating systems are installed, the LPC -ecommendations -C3= rganic !hermal Fluid Heating "#stems gi$e e6cellent guidance. @uch of the food industry has been reluctant to fit sprin!lers, with concerns o$er hygiene 0potential lea!s of microbially contaminated water and difficult to clean o$erhead constructions1 and inad$ertent use leading to loss of product through water damage. Howe$er, it should be remembered that in cool and cold en$ironments the sprin!ler system should be a Qdry pipeR system ha$ing only air from the main $al$es to the sprin!ler head ) it is only when there is an acti$ation of a sprin!ler head that the system will fill with water. @any insurers strongly recommend the fitting of sprin!lers in large factories and warehouses, and they should be consulted. ;eneral information on fire protection of buildings can be found in the Loss Pre$ention Council document !he $PC Design %uide for the Fire Protection of &uildings '((() in particular Part J.3, details a$ailable atA httpADDwww.thefpa.co.u!DPagesDPublications 'd$ice on suitable building materials is contained in $ist of Approved Fire and "ecurit#* Products and 5Type te6t7

5Type te6t7 "ervices 0The LPC8 &-ed 8oo!K, Oolume 1 Fully -e$ised ?dition, and is a$ailable atA httpADDwww.brecertification.co.u!DlpcbDredboo!.html Eith respect to sandwich panels from a fire protection $iewpoint, fillings should ideally be made of LPC8 ;rade ' appro$ed materials, that include rigid Polyisocyanurate 0P"-1, or better still mineralDglass wool ha$ing at least =0 minutes fire resistance and fire insulation properties. Polystyrene will produce copious amounts of smo!e, whereas polyurethane and polyisocyanurate foam produce less> modified phenolic foam produces e$en less smo!e, and both glass and mineral wool produce least. The relati$e properties of different types of cores, such as smo!e production, fire load, ease of ignition, fire spread and fire resistance, can be found in the Loss Pre$ention Council boo!let QCode of Practice for Fire Protection in the Food and Drin+ Industr#R "(8C 0 <03 =J 3<):. There is also a possible issue of moisture ingress at low temperatures that can lead to delaminating of the surface panel from the different types of core, thus e6posing the core to a fire, as well as the creation of a microbiological ha.ard. "mpact damage to the panels can also e6pose the core directly to a fire. (ometimes holes are punched through the panels for ser$ice pipes and electrical cables, and without suitable grommets and seals such areas ha$e been !nown to be the seat of fires within the panels. These panels can also #uic!ly delaminate in a fire situation, in any e$ent, with e6posure causing a serious increase in fire load and rapid fire spread. Soint detailing is of paramount importance. (andwich panels should meet the re#uirements of ,equirements and tests for wall and ceiling products and composite cladding products- LP( L A "ssue 4 <<<, Fire performance requirements for metal.faced fire.resisting insulated panels LP( 30LA "ssue <<I and thus 8( :J= Part 33A <LJ. Full details can be found at httpADDwww.bre.co.u!DfrsDinde6.html. @aterials that ha$e passed this test are also listed on the abo$e QbrecertificationR website. Currently, LPC8 Qappro$edR panel construction is either P"- or mineral wool, although it should be recognised that the testing procedure is somewhat limited in scope and may not fully reflect the ha.ards in$ol$ed in using P"-. ' new $ersion of LP( L is planned to be published in 3004. The re#uirement for segregation and compartmentation of specific heat processes, e.g. o$ens and fryers, has long been recognised in the food industry, and the special protections re#uired are generally well understood. There is a new recognition, howe$er, that the creation of large open spaces abo$e processing areas by the use of false, and structured, ceilings, can create problems as fires can spread rapidly o$er a large area in these roof spaces, some of which can become QtemporaryR storage areas to some e6tent. Compartmentation of this roof space is strongly recommended. "n addition strict controls on any maintenance and hot wor! processes in the $icinity of the panels is of paramount importance. Eith arson forming a significant part of total fire claims, it is important that wooden pallet storage is not a$ailable for use by arsonists, near either the buildings or boundary fences. (torage of such pallets should be !ept to a minimum and should also not be allowed to form a Qfire bridgeR between buildings. "n conclusion, when designing an e6tension or a new site, it is strongly recommended that insurers are consulted about building and insulation materials, fire protection and ris! management strategies. 6.D)T)R1IN) *ROC)SS +ND 1+SS F-O7 Following the de$elopment of a product, the selection of a site and an assessment of the businessKs ris!s, the preliminary design of the factory can commence. The #uality of the building design, the suitability of the process and how well a factory or process layout flows, are the !ey to ensuring that 5Type te6t7

5Type te6t7 the food manufacturer starts with a technically correct and efficient operation. To achie$e the abo$e, emphasis is placed on regular client meetings to de$elop the more detailed design for agreed stage appro$als. To design the optimum food factory, the design team re#uires the information listed below, some of which is li!ely to be a$ailable from the product de$elopment briefDbusiness plan. "f not readily to hand, some information can be found by obser$ing and recording current operations of e6isting products. "n the absence of !ey information, estimates can be made to #uic!ly build up a general plan. This section concentrates on determining process and mass flow whilst further details of factory segregation and e#uipment and layout design are dealt with in (ections : and I respecti$ely. "n practice, all these acti$ities are de$eloped in parallel. ,aw materials Define the raw materials to be used, in terms of type and #uantity. How much storage space is re#uired and how is ingredient storage to be segregated 0e.g. $egetables from meat1F How much storage is re#uired for final pac!agingF "s there the re#uirement for a separate dry goods storeF Ehat are the ingredients to be stored in 0bag, bo6, tray, bins, silo etc.1 and at what temperatureF How much room is re#uired for initial de)bo6ingF Ehat is the number of days storage re#uired per ingredientF "s a P%ust)in)timeK operation en$isaged or will deli$eries be once per wee!Dmonth etcF Ehat is the ideal Pgoods inK arrangementF Eill deli$eries be by $an or large lorryF "s there a need for temperature controlled doc!ingF How will ingredients be transferred to a 0preferred1 recei$ing doc! ) is there a need for for!lift truc! storageDrechargingF Ehere and how will incoming ingredient pallet separation be controlledF Eill internal plasticDaluminium etc. be usedF Ehere will they be storedF Figure 6.1 Schema ic diagram o" a &asic lasagne process "lo$ line

5Type te6t7

5Type te6t7

Process For each intended product, define the processes re#uired through preparation, processing, portioning and pac!aging. Ehat are the unit operationsK masses and the component yieldsF Ehat are the estimated, future unit operationsK massesF Ehere is there li!ely to be the re#uirement to store wor! in progressF Ehat is the re#uired storage temperature and tolerancesF 're specific processes re#uired, e.g. coo!ing, steaming, ba!ing, frying, chilling, free.ingF Ehat are the coo!ing and cooling throughput per product and the coo!Dcool residence timesF Ehat is the general process plant type and location 0see (ection I1F How many product flow streams are re#uired, i.e. how can process lines be optimised to accept the ma6imum number of intended products with the fewest linesF Ehat are the re#uirements for for!liftDhand pallet mo$ement T charging 0if re#uired1. 8y the time raw materials and the process has been considered, it is possible to construct product flow diagrams. Figure 4. gi$es an e6ample of a basic lasagne flow and helps $isualise the re#uirements for other factors, e.g. people, wastes, cleaning and ser$ices. Finished goods N Ehat are the final product pac!aging dimensions and print re#uirementsF N Ehat are the re#uirements for final product storage and the number per crateDpalletF 5Type te6t7

5Type te6t7 N Ehat are the final product pac! si.e, dimensions and weightF "torage and distri/ution N Define the final product storage temperature and tolerances. N Define the number of intended days of storage prior to distribution. N Consider the optimum design of the despatch area. "s there the need for temperature controlled doc!ingF N Eill traysDbins etc. be returned that need cleaning before re)pac!ingF N Eill the transport $ehicles be company owned or contractedF "s there the re#uirement for $ehicle garagingDser$icingF 0nvironment N For each storage and processing area, define the re#uired room temperatures and tolerances. N Eill there be the re#uirement to remo$e condensation or dust particlesF N Ehat are the re#uired le$els of air filtration, air changesDhour and air pressures 0see (ection :1F N "s there a re#uirement for controlled relati$e humidity air control 0see (ection :1F N Has the runoff of fire fighting water been consideredF N 're there any special re#uirements for chimneys or $entsF People N How many people are re#uired, administration, laboratory 0if re#uired1, engineers and food operati$es 0including nightshiftDcleaners1, to staff the operationF N Ehat is the li!ely mi6 of males to femalesF This will help si.e changing areas. N Ehat shift patterns are en$isaged and what is the number per shift, i.e. what is the ma6imum number of people on site at any one timeF N 're separate entrances re#uired for food operati$es, office staff, $isitorsF N "s there the need for High Care D Low -is! entrance barriers 0see (ection :1F N Eill the company supply catering ser$ices or pro$ide a canteenDrestroom areaF N Define the company smo!ing policy, including the pro$ision of any smo!ing areas N Eill the company pro$ide a medical roomF N Ehat is the re#uirement for disabled access in all processing areasF N Ehat are the management and administration re#uirementsF 1astes N How will ingredient pac!aging waste be handledF N How will solid process waste be handledF N How will pac!aging waste be handledF N Eill wastes be stored outside in co$ered containers or within the buildingsF N Eill li#uid wastes re#uire screening within the factory 0e.g. drain bas!ets1 or e6ternallyF N Eill li#uid wastes be discharged directly to the municipal sewer or be first treated on siteF Cleaning N Eill cleaning be underta!en in)house or contracted outF N Eill chemicals be sourced locally or from a cleaning ser$ice pro$iderF "f a cleaning ser$ice pro$ider, contact should be made at the earliest possible stage to enable them to ha$e design input. 5Type te6t7

5Type te6t7 N How many purpose built cleaning rooms will be re#uired, including e#uipment dirty storage and cleaned and drying storage areasF N Ehere will cleaning e#uipment and chemicals be storedF N How will cleaning chemicals be deli$ered and in what $olumes ) 3I litre drums or larger transport tan!sF N How will cleaning fluids be distributed around the processing areas ) manually or $ia cleaning ring mainsF N "s there a need for a $acuum ring mainF "en*ices N Ehat is the re#uirement for power 0H.O. and ;as1 consumptionF "s a bac!)up electricity supply necessaryF N Ehat is the re#uirement for waterF 's far as possible the main cold water feed to the factory should be installed underground and not within the building, as this would cause the water temperature to go up and increase the chance of $egionella bacteria occurring. N Ehat is the re#uirement for compressed airF N Ehat is the re#uirement for hot waterF N Ehat is the re#uirement for steamF N Does the company ha$e a refrigeration policyF N Ehat is the re#uirement for storm water controlF N "s there a re#uirement for effluent treatment on siteF N Define the drainage layout including segregation of any low and high ris! drains N Ehat building management systems will be re#uiredF N Define the re#uirements for "T, telephones, fibre optics and burglar alarms N Ehat is the re#uirement for fire control 0sprin!ler systems, fire alarms, fire hydrants1F N Ehat is the re#uirement for engineering stores and wor!shopsF N Define the need for on)line or off)line analyses of raw materials, process intermediates and final products. D)T)R1IN) TH) R)8UIR)D -)9)- OF S)3R)3+TION N 3eneral considera ions N Le$els of hygienic design To pro$ide protection from general contamination 0physical, chemical and biological ha.ards1 during manufacture, food is protected by a barrier system, made up of up to : barriers 0Figure :. 1. These encompass the site 0 1, the factory building 031, a high ris! or high hygiene .one 041 and a product enclosure .one 0:1. "n this system, the degree of control of the production en$ironment increases such that finally, fully processed products are manipulated in controlled en$ironments in which contaminants are acti$ely e6cluded. Figure ..1 Schema ic diagram o" he . le/els o" hygiene &arrier po en ially "ound in "ood "ac ories The produc and i s hygiene ris5s Eith respect to factory design, foods and drin!s can be broadly di$ided into low and high ris! products, depending on their stability or whether they will be further processed by the food manufacturer or the final consumer. 5Type te6t7

5Type te6t7 Low ris! products, typically either raw materials or ambient shelf stable products, include eggs, raw meat and fish, fruit, $egetables, dried goods, canned foods, ba!ery and ba!ed products, confectionery, snac!s, brea!fast cereals, oils and fats, food additi$esDingredients and be$erages. High)ris! products, typically short shelf life ready)to)eat foods, include coo!ed and smo!ed meat and fish, prepared $egetables, prepared fruit, mil!, cream, cheese, yoghurt, ice cream, sandwiches and ready meals. The number of factory barriers re#uired will be dependent on the nature of the food product and the nature of the ha.ard, and will be established from the H'CCP study. For low ris! products, the first two barriers only are re#uired. For some high ris! products, e.g. sandwiches, in which some of the components are decontaminated 0e.g. washing salad ingredients in chlorinated water1 rather than heat pasteuri.ed, the use of the third barrier is re#uired for microbiological control. For fully coo!ed ready) to)eat products, microbiological shelf)life may be e6tended by underta!ing all processing manipulations, from coo!ing to pac!ing, in an enclosed atmosphere. There is some confusion o$er terminology related to the third, Phigh hygieneK barrier .one, with the terms high care and high ris! area often used. To help clear up this confusion, the Chilled Foods 'ssociation in the BM 0'non, <<Ja1 established guidelines to describe the hygiene status of chilled foods 0based upon microbiological criteria1 and indicate the area status of where they should be processed after any heat treatment. Three le$els were describedA high ris! area 0H-'1, high care area 0HC'1 and good manufacturing practice 0;@P1 area. Their definitions wereA) H-' 'n area to process components, +H of which ha$e been heat treated to *<0UC for 0 min 0for psychrotrophic Clostridium /otulinum spores1 or *J0UC for 3 min 0for $egetati$e pathogens1, and in which there is a ris! of contamination between heat treatment and pac! sealing that may present a food safety ha.ard. HC' 'n area to process components, Some of which ha$e been heat treated to *J0UC for 3 min, and in which there is a ris! of contamination between heat treatment and pac! sealing that may present a food safety ha.ard. ;@P 'n area to process components, None of which ha$e been heat treated to *J0UC for 3 min, and in which there is a ris! of contamination prior to pac! sealing that may present a food safety ha.ard. "n practice, the definition of HC' has been e6tended to include an area to further process components that ha$e undergone a decontamination treatment, e.g. fruit and $egetables after washing in chlorinated water, or fish after low temperature smo!ing and salting. @uch of the re#uirements for the design of H-' and HC' operations are the same, with the emphasis on pre/en ing contamination in H-' and minimising contamination in HC' operations, respecti$ely 0'non, <<Ja1. "n considering whether a high ris! or high care area is re#uired and therefore what specifications should be met, chilled food manufacturers need to carefully consider their e6isting and future product ranges, the ha.ards and ris!s associated with them and possible de$elopments in the near future. "f budgets allow, it is always more economic to build to the highest standards from the onset of construction rather than try to retrofit or refurbish at a later stage. The re#uirements for high careDris! segregation for appropriate foodstuffs is now recognised by the ma%or food retailers and is a re#uirement in the !echnical "tandard and Protocol for Companies "uppl#ing ,etailer &randed Food Products 0'non 30001. N (egregation 9ther than for microbiological reasons, it may be necessary to segregate areas for the processing of different product ingredients. This is to pre$ent the possibility of contamination ofA organic foods with 5Type te6t7

5Type te6t7 non)organic components> non);@9 with ;@9 deri$ed foods> $egetarian foods with non $egetarian components> religious based foods 0e.g. Mosher or Halal1 with foods that do not conform with these criteria> and non)allergenic foods> with allergenic components 0e.g. nuts1. "deally, manufacturers who manufacture organic, $egetarian, ;@9 free, PreligiousK or allergenic products should do so on separate sites such that there is no chance of crosscontamination from different ingredients. "f this is not possible, production of organicDnon) organic etc. foods can be processed on the same site pro$iding the whole process, from goods in through raw material storage and processing to primary pac!aging, is segregated. (ome manufacturers ha$e segregated processes by time, e.g. by manufacturing non)nut containing products first and then manufacturing nut)containing products last. Thorough cleaning and disinfection is then underta!en before the manufacture of non)nut containing products is then re)commenced. "f segregation by time is to be considered, a thorough H'CCP study should be underta!en to consider all aspects of how the ha.ard 0e.g. nuts1 is to be stored, transported, processed and pac!ed etc. (egregation is also now considered as a method of increasing manufacturing fle6ibility. For e6ample, by splitting down large processing areas into smaller sub)units 0e.g. a single 3 line meat slicing hall into 4 fully segregated sub)units of : slicing lines1, cross)contamination between lines can be eliminated when some lines need to be shutdown for cleaning or maintenance whilst the others need to remain in production. "n many factories it is necessary to segregate areas to !eep product dry, e.g. special areas for the handling of dry ingredients or con$ersely specific areas for wet cleaning or traywashing. "n addition it may be necessary to segregate particularly noisy pieces of e#uipment> see ,educing noise exposure in the food and drin+ industries) Food "nformation (heet Co. 43, httpADDwww.hseboo!s.co.u! N ,arrier 1' Si e 'ttention to the design, construction and maintenance of the site, from the outer fence and the area up to the factory wall, pro$ides an opportunity to set up the first of a series of barriers to protect production operations from contamination. This le$el pro$ides barriers against en$ironmental conditions, e.g. pre$ailing wind and surface water run)off, and a$oidance of pest harbourage areas. 't the site le$el, a number of steps can be ta!en includingA) 3.4 The site should be well fenced to pre$ent unauthorised public access and the entrance of domestic animals etc. 3.: Eell)planned and properly maintained landscaping of the grounds can assist in the control of rodents, insects and birds by reducing food supplies and breeding and harbourage sites. "n addition, good landscaping of sites can reduce the amount of dust blown into the factory. 3.I The factory building may often be placed on the highest point of the site to reduce the chance of ground le$el contamination from flooding. 3.= 'n area of at least 4m immediately ad%acent to buildings should be !ept $egetation free and co$ered with a deep layer of gra$el, stones, pa$ing or roadway etc. This practice helps maintain control of the fabric of the factory building. 3.J To help pre$ent flying insects from entering buildings, install security lighting away from factory openings so that insects are attracted away from them. 3.L Processes li!ely to create microbial or dust aerosols, e.g. effluent treatment plants, waste disposal units or any preliminary cleaning operations, should be sited such that pre$ailing winds do not blow them directly into manufacturing areas. N ,arrier (' Fac ory &uilding 5Type te6t7

5Type te6t7 The building structure is the second and a ma%or barrier, pro$iding protection for raw materials, processing facilities and manufactured products from e6ternal contamination or deterioration. Ehilst it is ob$ious that the factory cannot be a sealed bo6, openings to the structure must be controlled and the following concepts applyA) 3.< Ehere possible, buildings should be single story or with $arying headroom featuring me..anine floors to allow gra$ity flow of materials, where this is necessary. This pre$ents any mo$ement of wastes or lea!ing product mo$ing between floors. 3. 0 "t is worth considering $ery early in the design stage of the building to ha$e all the structural steelwor! positioned e6ternally, therefore ha$ing no ledges internally. (imilarly, the inclusion of -H( steelwor! as purlins instead of proprietary purlins will again alle$iate a ledge. 3. "deally, the factory buildings should be designed and constructed to suit the operations carried out in them and should not place constraints on the process or the e#uipment layout. 3. 3 The layout should also consider that pro$ision is made for the space necessary to underta!e the process and associated #uality control functions, both immediately the factory is commissioned and in the foreseeable future. 3. 4 The floor of the factory should ideally be at a different le$el to the ground outside and openings should be designed to be pest proof when not in use 3. : 9penings should be !ept to a minimum and e6terior doors should not open directly into production areas. Plastic stripsDcurtains are acceptable in interior situations only, as they are easily affected by weather. Ehere necessary, internal or e6ternal porches can be pro$ided, with one door, usually the e6ternal door on an e6ternal porch, being solid and the internal door being a flyscreen door> on an internal porch it would be the opposite configuration. 3. I Doors should be constructed of metal, glass reinforced plastic 0;-P1 or plastic, self) closing, designed to withstand the intended use and misuse and be suitably protected from $ehicular damage where applicable. 3. = For many food manufacturers and retailers, glass is seen as the second ma%or food ha.ard after pathogenic microorganisms. For this reason, glass should be a$oided as a construction material 0windows, inspection mirrors, instrument and cloc! faces etc.1.

Ehere the use of glo$ebo6es is impractical, partial enclosure of the product can be achie$ed by the use of localised airflow, with the ob%ecti$es ofA)

V Pro$iding highly filtered 0H" ) 31, chilled air directly o$er or surrounding product, whilst maintaining
ambient air temperatures in e6cess of 4UC.

V Pro$iding a degree of product isolation ranging from partial enclosure in tunnels to chilled con$eyor wells,
where the flow of the air pro$ides a barrier that resists the penetration of aerosol particles, some of which would contain $iable microorganisms. 'n e6ample of such a technology, which at the time of writing is state of the art, is shown m t Figure :.3 and shows a schematic diagram of a con$eyor that has chilled, filtered air directei o$er it, sufficient to maintain the low temperature of the product. Ehen a microbial aerosol was generated around the operational con$eyor, microbiological air sampling demonstrated/ )3 log reduction of microorganisms within the protected .one. This wor! has been report in 8urfoot et ai, 3000.

5Type te6t7

5Type te6t7 3. J Eindows should be gla.ed with either polycarbonate or laminated. @etal or plastic frames with internal sills sloped 030U):0U1 to pre$ent their use as PtemporaryK storage places and with e6ternal sills sloped at =0U to pre$ent bird roosting, should be used. ' glass register, detailing all types of glass used in the factory, and their location, should be maintained. N Ehere opening windows are specifically used for $entilation 0particularly in tropical areas1 they must be screened and the screens be designed to withstand misuse or attempts to remo$e them. Flyscreens should be constructed of stainless steel mesh and be remo$able for cleaning. (pecific design features of floors, drains, walls, ceilings and ser$ices are detailed in the companion CCF-' documentsA) ;uideline Co. :0, %uidelines for the design and construction of floors for food production areas and ;uideline Co. : , %uidelines for the design and construction of walls) ceilings and sen*ices for food production areas 0see -eferences1. 3.3 ,arrier 6' High care:ris5 areas The building structure, facilities and practices associated with the high careDris! 0referred to as simply high ris! in the following te6t1 production and assembly areas pro$ide the third barrier. Together with the building structure, this barrier is built up by the use of combinations of a number of separate components or sub)barriers, to control contamination that could enter high ris! areas. These includeA) N Product entering high ris! $ia a heat process N Product entering high ris! $ia a decontamination process. N 9ther product transfer into high ris! N Pac!aging materials entering high ris! N Li#uid and solid waste materials entering high ris! N Food operati$es, maintenance and cleaning personnel etc. entering high ris! N The air e6iting high ris! N Btensils, which may ha$e to be passed between low and high ris! "tructure The design of the high ris! food processing area must allow for the accommodation of fi$e basic re#uirements, namelyA N Processed materials and some ingredients N Processing e#uipment N (taff concerned with the operation of such e#uipment N Pac!aging materials N Finished products There is a philosophy which has considerable support, that states that all other re#uirements should be considered as secondary to these fi$e basic re#uirements and, where$er possible, must be !ept out of the high ris! processing area. These secondary re#uirements includeA) N (tructural steel framewor! of the factory. N (er$ice pipewor! for water, steam and compressed air> electrical conduits and trun!ing> artificial lighting units> and $entilation ducts. N Compressors, refrigeration units and pumps. N @aintenance personnel associated with any of these secondary re#uirements. Heat treated product Ehere a product heat treatment forms the barrier between low and high ris! 0e.g. an o$en, fryer or microwa$e tunnel1, the heating de$ice must be designed such that as far as is possible, the de$ice forms a solid, physical barrier between low and high ris!. Ehere it is not physically possible to form a solid barrier, air spaces around the heating e#uipment should be minimised and the lowDhigh ris! floor 5Type te6t7

5Type te6t7 %unction should be fully sealed to the highest possible height. 9ther points of particular concern for heating de$ices includeA) N Heating de$ices should be designed to load product on the low ris! side and unload in high ris!. N ;ood seals are re#uired between the heating de$ice surfaces, which cycle through e6pansion and contraction phases, and the barrier structure that has a different thermal e6pansion. N 9$ens should not ha$e e6posed sumps that can spread contamination into high ris! during cleaning N 'ny $entilation system in the coo!ing area should be designed so that the area is $entilated from low ris!> $entilation from high ris! can draw into high ris! large #uantities of low ris! air. N Mettles should be installed within low ris! and transfer product 0by pumping, gra$ity, $acuum etc.1 through into high ris! $ia a pipe in the di$iding wall. The !ettles need to be positioned in low ris! at a height such that the transfer into high ris! is well abo$e ground le$el. Product decontamination Fresh produce and the outer pac!aging of $arious ingredients may need to be decontaminated on entry into high ris!. Decontamination is underta!en wet, using a washing process incorporating a disinfectant 0usually a #uaternary ammonium compound1, or dry, using BO light. 's with heat barriers, decontamination systems need to be installed within the lowDhigh ris! barrier to minimise the free space around them. 's a minimum, the gap around the decontamination system should be smaller than the product to be decontaminated. This ensures that all ingredients in high ris! must ha$e passed through the decontamination system and thus must ha$e been decontaminated ther product transfer 'll ingredients and product pac!aging must be de)bo6ed and transferred into high ris! in a way that minimises the ris! of cross)contamination into high ris!. (ome ingredients, such as bul! li#uids that ha$e been heat)treated or are inherently stable 0e.g. oils or pasteurised dair* products1, can be pumped across the lowDhigh ris! barrier directly to the point of use. Dry. stable bul! ingredients 0e.g. sugar1 can also be transferred into high ris! $ia sealed con$eyors. For non)bul! #uantities, it is possible to open ingredients at the lowDhigh ris! barrier and decant them through into high ris! $ia a suitable transfer system 0e.g. a simple funnel set into the wall1 into a recei$ing container. Transfer systems should, preferably, be closeable when not in use and should be designed to be cleaned and disinfected, from the high ris! side, prior to use as appropriate. Pac+aging Pac!aging materials 0film reels, cartons, containers, trays etc.1 are best supplied to site Pdouble baggedK. Ehen called for in high ris!, the pac!aging material is brought to the lowDhigh ris! barrier, the outer plastic bag remo$ed and the inner bag and pac!aging enters high ris! through a suitable hatch. The hatch, as with all openings in the lowDhigh ris! barrier, should be as small as possible and should be closeable when not on use. This is to reduce airflow through the hatch and thus reduce the airflow re#uirements for the air handling systems to maintain high ris! positi$e pressure. For some pac!aging materials, especially hea$y film reels, it may be re#uired to use a con$eyor system for mo$ing materials through the hatch. 'n opening door or preferably, double door airloc! should only be used if the use of a hatch is not technically possible and suitable precautions must be ta!en to decontaminate the airloc! after use. $iquid and solid wastes 5Type te6t7

5Type te6t7 9n no account should li#uid or solid wastes from the low ris! area0s1 be remo$ed from the factory $ia high ris!, and attention is re#uired to the procedures for remo$ing high ris! wastes. The handling of li#uid wastes from low and high ris! is described in CCF-' ;uideline Co. :0 0see -eferences1. (olid wastes in bags should lea$e high ris! in such a way that they minimise any potential cross) contamination with processed product and should, preferably, be routed in the re$erse direction to the product. For small #uantities of bagged waste, e6isting hatches should be used, e.g. the wrapped product e6it hatches or the pac!aging materials entrance hatch, as additional hatches increase the ris! of e6ternal contamination and put e6tra demands on the air handling system. For waste collected in bins, it may be necessary to decant the waste through purpose built, easily cleanable 0from high ris!1, waste chutes that deposit directly into waste s!ips. Personnel The high ris! changing room pro$ides the only entry and e6it point for personnel wor!ing in or $isiting the area and is designed and built to both house the necessary acti$ities for personnel hygiene practices and minimise contamination from low ris!. "n practice, there are some $ariations in the layout of facilities of high ris! changing rooms. This is influenced by, for e6ample, space a$ailability, product throughput and type of products, which will affect the number of personnel to be accommodated and whether the changing room is a barrier between low and high ris! operati$es or between operati$es arri$ing from outside the factory and high ris!. ;enerally higher construction standards are re#uired for lowDhigh ris! barriers than outsideDhigh ris! barriers because the le$el of potential contamination in low ris!, both on the operati$esK hands and in the en$ironment, is li!ely to be higher 0Taylor and Holah, 30001. ' generic layout for a changing room should accommodate the following re#uirements. N 'n area at the entrance to store outside or low ris! clothing. Loc!ers should ha$e sloping tops. N ' barrier to di$ide low and high ris! floors. This is a physical barrier such as a small wall 0appro6imately =0cm high1, that allows floors to be cleaned on either side of the barrier without contamination by splashing etc. between the two. N 9pen loc!ers at the barrier to store low ris! footwear. N ' stand on which capti$e, high ris! footwear is displayedDdried. 8oot baths and boot washers are not recommended as a means of decontaminating footwear between low and high ris! areas as they are not an effecti$e means of microbial control. The use of bootwashers in high ris! should only be used to help control the ris! of operati$es slipping 0if the floors are particularly slippery1 by controlling food debris build)up in the soles of the boots. N 'n area designed with suitable drainage for bootwashing operations. -esearch has shown 0Taylor et ai) 30001 that manual cleaning 0preferably during the cleaning shift1 and industrial washing machines are satisfactory bootwashing methods N Hand wash basins to ser$ice a single, hand wash. Handwash basins should ha$e automatic or !neeDfoot operated water supplies, water supplied at a suitable temperature 0that encourages hand washing1 and a waste e6traction system piped directly to drain. "t has been shown that hand wash basins positioned at the entrance to high ris!, which was the original high ris! design concept to allow $isual monitoring of hand wash compliance, gi$es rise to substantial aerosols of staphylococcal strains that can potentially contaminate the product. N (uitable hand drying e#uipment, e.g. paper towel dispensers or hot air dryers and, for paper towels, suitable towel disposal containers. 5Type te6t7

5Type te6t7 N 'ccess for clean factory clothing and storage of soiled clothing. For larger operations this may be $ia an ad%oining laundry room with interconnecting hatches. N 'lcoholic hand rub dispensers immediately inside the high ris! production area. The air is a potential source of pathogens and air inta!e into the high ris! area, and lea!age from it, has to be controlled. 'ir can enter high ris! $ia a purpose built air handling system or can enter into the area from e6ternal uncontrolled sources 0e.g. low ris! production, pac!ing, outside1. For high ris! areas, the goal of the air handling system is to supply suitably filtered fresh air, at the correct temperature and humidity, at a slight o$erpressure to pre$ent the ingress of e6ternal air sources. 'ir #uality standards for the food industry were first re$iewed by 8rown 0 <<=1 and the design of the air handling system should now consider the following issuesA) N Filtration of air is a comple6 matter and re#uires a thorough understanding of filter types and installations. For high care applications, a series of filters is re#uired to pro$ide air to the desired standard and is usually made up of a ;:DFI panel or poc!et filter followed by an FJ)< rigid cell filter. For some high ris! operations an H 0 or Hll final filter may be desirable. N The pressure differential between low and high ris! should be between I) I Pascals or be .ImDsec or greater through openings. The desired pressure differential will increase as both the number and si.e of openings and also the temperature differentials between low and high ris! increases. 's a general rule, openings into high ris! areas should be as small and as few as possible. ;enerally I)3I air changes per hour are sufficient to remo$e the heat load imposed by the processing en$ironment 0processes and people1 and pro$ide operati$es with fresh air, though in a high ris! area with large hatchesDdoors that are fre#uently opened, up to :0 air changes per hour may be re#uired. N The re#uirements for positi$e pressure in high care processing areas are less stringent and ceiling mounted chillers together with additional air ma!e)up may be acceptable. N 's well as recirculating temperature controlled air, the system may need to be designed to dump air directly to waste during cleaning operations and to recirculate ambient or heated air after cleaning operations to increase en$ironmental drying. Eith respect to drafts, the ma6imum air speed close to wor!ers to minimise discomfort through Pwind) chillK should be 0.4m s& . This is typically achie$ed with airsoc!s, positioned directly o$er the product lines N Soint BM go$ernment sponsored wor! at CCF-' and the (ilsoe -esearch "nstitute has in$estigated the measurement of both air flows and airborne microbiological le$els in actual food factories, from which computational fluid dynamics 0CFD1 models ha$e been de$eloped to predict air and particle 0including microorganism1 mo$ements 0'non, 300 1. This has allowed the design of air handling systems that pro$ide directional air that mo$es particles away from the source of contamination 0washrooms, hatches, doors, people etc.1, in a direction that does not compromise product safety. N -elati$e humidity should be typically =0)J0W to restrict microbial growth in the en$ironment, increase the rate of e#uipment and en$ironment drying after cleaning operations and pro$ide operati$e comfort. Low humidities can cause drying of the product with associated weight and #uality loss, whilst higher humidities maintain product #uality but may gi$e rise to drying and condensation problems that increase the opportunity for microbial sur$i$al and growth. N "n the BM, !he 1or+place 2Health) "afet# and 1elfare3 ,egulations 0'non, <<3a1 re#uire that the Qtemperature in all wor!places inside buildings shall be reasonableR, which, in the supporting Approved Code of Practice 0'non <<3b1, is normally ta!en to
' generic layout for a changing room should accommodate the following re#uirements.

5Type te6t7

5Type te6t7 V 'n area at the entrance to store outside or low ris! clothing. Loc!ers should ha$e sloping tops. V ' barrier to di$ide low and high ris! floors. This is a physical barrier such as a smal wall 0appro6imately
=0cm high1, that allows floors to be cleaned on either side of the barrier without contamination by splashing etc. between the two.

V 9pen loc!ers at the barrier to store low ris! footwear. V ' stand on which capti$e, high ris! footwear is displayedDdried. 8oot baths and boo washers are not
recommended as a means of decontaminating footwear between low high ris! areas as they are not an effecti$e means of microbial control. The use of bootwashers in high ris! should only be used to help control the ris! of operati$es slipping 0if the floors are particularly slippery1 by controlling food debris build)up ii soles of the boots.

V 'n area designed with suitable drainage for bootwashing operations. -esearch has shown 0Taylor et a l )
30001 that manual cleaning 0preferably during the cleaning shi and industrial washing machines are satisfactory bootwashing methods

V Hand wash basins to ser$ice a single, hand wash. Handwash basins should ha$e automatic or !neeDfoot
operated water supplies, water supplied at a suitable tempen 0that encourages hand washing1 and a waste e6traction system piped directly to draA has been shown that hand wash basins positioned at the entrance to high ris!, whicl the original high ris! design concept to allow $isual monitoring of hand wash compliance, gi$es rise to substantial aerosols of staphylococcal strains that can potentially contaminate the product.

V (uitable hand drying e#uipment, e.g. paper towel dispensers or hot air dryers and.
towel disposal containers.

paper towels, suitable

V 'ccess for clean factory clothing and storage of soiled clothing. For larger operati this may be $ia an
ad%oining laundry room with interconnecting hatches.

V 'lcoholic hand rub dispensers immediately inside the high ris! production area.

Air The air is a potential source of pathogens and air inta!e into the high ris! area, and le from it, has to be controlled. 'ir can enter high ris! $ia a purpose built air handling X or can enter into the area from e6ternal uncontrolled sources 0e.g. low ris! productior pac!ing, outside1. For high ris! areas, the goal of the air handling system is to suppl> suitably filtered fresh air, at the correct temperature and humidity, at a slight o$erpreF pre$ent the ingress of e6ternal air sources.

'ir #uality standards for the food industry were first re$iewed by 8rown 0 <<=1 and the design of the air handling system should now consider the following issuesA) N Filtration of air is a comple6 matter and re#uires a thorough understanding of filter types and installations. For high care applications, a series of filters is re#uired to pro$ide air to the desired standard and is usually made up of a ;:DFI panel or poc!et filter followed by an FJ)< rigid cell filter. For some high ris! operations an H 0 or H" final filter may be desirable. 5Type te6t7

5Type te6t7 N The pressure differential between low and high ris! should be between I) I Pascals or be .ImDsec or greater through openings. The desired pressure differential will increase as both the number and si.e of openings and also the temperature differentials between low and high ris! increases. 's a general rule, openings into high ris! areas should be as small and as few as possible. ;enerally I)3I air changes per hour are sufficient to remo$e the heat load imposed by the processing en$ironment 0processes and people1 and pro$ide operati$es with fresh air, though in a high ris! area with large hatchesDdoors that are fre#uently opened, up to :0 air changes per hour may be re#uired. N The re#uirements for positi$e pressure in high care processing areas are less stringent and ceiling mounted chillers together with additional air ma!e)up may be acceptable. N 's well as recirculating temperature controlled air, the system may need to be designed to dump air directly to waste during cleaning operations and to recirculate ambient or heated air after cleaning operations to increase en$ironmental drying. Eith respect to drafts, the ma6imum air speed close to wor!ers to minimise discomfort through &wind)chill& should be 0.4m sY . This is typically achie$ed with airsoc!s, positioned directly o$er the product lines N Soint BM go$ernment sponsored wor! at CCF-' and the (ilsoe -esearch "nstitute has in$estigated the measurement of both air flows and airborne microbiological le$els in actual food factories, from which computational fluid dynamics 0CFD1 models ha$e been de$eloped to predict air and particle 0including microorganism1 mo$ements 0'non, 300 1. This has allowed the design of air handling systems that pro$ide directional air that mo$es particles away from the source of contamination 0washrooms, hatches, doors, people etc.1, in a direction that does not compromise product safety. N -elati$e humidity should be typically =0)J0W to restrict microbial growth in the en$ironment, increase the rate of e#uipment and en$ironment drying after cleaning operations and pro$ide operati$e comfort. Low humidities can cause drying of the product with associated weight and #uality loss, whilst higher humidities maintain product #uality but may gi$e rise to drying and condensation problems that increase the opportunity for microbial sur$i$al and growth.
N "n the BM, !he 1or+place 2Health) "afet# and 1elfare3 ,egulations 0'non, <<3a1 re#uire that the Ytemperature in all wor!places inside buildings shall be reasonableY, which, in the supporting Approved Code of Practice 0'non <<3b1, is normally ta!en to at least =UC or at least 4UC where much of the wor! in$ol$es serious
physical effort. "n many areas of the chilled food industry, howe$er, room temperatures of 0UC or less are sought to control en$ironmental microbial growth and product shelf life and to ensure compliance with the Food "afet# 2!emperature Control3 ,egulations 4556 0'non, <<I1 as well as those imposed by their retail customers. To help sol$e this conflict, a document entitled %uidance on achieving reasona/le wor+ing temperatures and conditions during production of chilled foods 08rown, 30001, which e6tends the information pro$ided in H(? Food (heet Co.4 0-e$1 1or+room temperatures in places where food is handled 0'non, <<<1 has been produced. The guidance document 08rown, 30001 states that employers will first need to consider alternati$e ways of controlling product temperatures rather than simply adopting lower wor!room temperatures. "f the alternati$e measures are not practical then it may be %ustified for hygiene reasons for wor!rooms to be maintained at temperatures lower than =UC 0or 4UC1. Ehere such lower temperatures are adopted, employers should be able to demonstrate that they ha$e ta!en appropriate measures to ensure the thermal comfort of employees. N 'ir handling systems should be installed such that they can be easily ser$iced and cleaned.

7tensils Ehere$er possible, any e#uipment, utensils and tools etc. used routinely within high ris! should remain in high ris!. This

5Type te6t7

5Type te6t7
may mean that re#uirements are made for the pro$ision of storage areas or areas in which utensils can be maintained or cleaned. Typical e6amples includeA) N The re#uirement for ingredient or product transfer containers 0trays, bins etc1 should be minimised but where these are una$oidable they should remain within high ris! and be cleaned and disinfected in a separate wash room area. N (imilarly, any utensils 0e.g. stirrers, spoons, ladles1 or other non)fi6ed e#uipment 0e.g. depositors or hoppers1 used for the processing of the product should remain in high ris! and be cleaned and disinfected in a separate wash room area. N ' separate wash room area should be created in which all within)production wet cleai operations can be underta!en. The room should preferably be sited on an outside wall that facilitates air e6traction and air ma!e)up. 'n outside wall also allows e6ternal bul! storage of cleaning chemicals that can be directly dosed through the wall into the ring main system. The room should ha$e its own drainage system that, in $ery wet operations, may include barrier drains at the entrance and e6it to pre$ent water spread from the area. The wash area should consist of a holding area for e#uipment etc. awaiting cleaning, a cleaning area for manual or automatic cleaning 0e.g. traywash1 as appropriate, and a holdingDdrying area where e#uipment can be stored prior to use. These areas should as segregated as possible. N 'll cleaning e#uipment, including hand tools 0brushes, s#ueegees, sho$els etc1 and larger e#uipment 0pressure washers, floor scrubbers and automats etc.1 should remain in high ris! and be colour coded to differentiate between high and low ris! e#uipment if necessary. (pecial pro$ision should be made for the storage of such e#uipment when not in use. N Cleaning chemicals should preferably be piped into high ris! $ia a ring main 0which should be separate from the low ris! ring main1. "f this is not possible, cleaning chemicals should be stored in a purpose built area. N The most commonly used e#uipment ser$ice items and spares etc., together with the necessary hand tools to underta!e the ser$ice, should be stored in high ris!. For certain operations, e.g. blade sharpening for meat slicers, specific engineering rooms may need to be constructed. N Pro$ision should be made in high ris! for the storage of utensils that are used on an irregular basis, but that are too large to pass through the lowDhigh ris! barrier, e.g. stepladders for changing the air distribution soc!s. :.I 8arrier :A Product enclosure The high ris! air handling system pro$ides control of airborne contamination e6ternal to high ris!, but pro$ides only partial control of aerosols, generated from personnel, production and cleaning acti$ities, in high ris!. 't best, it is possible to design an air handling system ihat minimises the spread of contamination generated within high ris! directly o$er product. ?conomically, it is also $ery e6pensi$e to cool the whole of the high ris! area down to simply maintain low product temperatures. ' %oint CCF-'D(ilsoeDLeatherhead Food -esearch 'ssociation, BM ;o$ernment sponsored pro%ect has e6amined the use of systems designed to fully or partially enclose products further processed in high ris! areas. ;lo$ebo6es offer the potential to fully enclose product with the ability to operate to aseptic conditions. They wor! best if the product is deli$ered to them in a pasteurised condition, is pac!ed within the bo6 and in$ol$es little manual manipulation. The more complicated the product manipulation, the more ingredients to be added, the faster the production line or the shorter the product run, the less fle6ible glo$ebo6es become. 9perating on a batch basis, pre)disinfected glo$ebo6es gi$e the potential for a temperature controlled en$ironment with a modified atmosphere if re#uired " e.g. high C93, low 93 or $ery high 93 concentrations1, that can be disinfected on)line by gaseous chemicals 0e.g. o.one1 or BO light.

Ehere the use of glo$ebo6es is impractical, partial enclosure of the product can be achie$ed by the use of localised airflow, with the ob%ecti$es ofA)

V Pro$iding highly filtered 0H" ) 31, chilled air directly o$er or surrounding product, whilst maintaining
ambient air temperatures in e6cess of 4UC.

V Pro$iding a degree of product isolation ranging from partial enclosure in tunnels to chilled con$eyor wells,
where the flow of the air pro$ides a barrier that resists the penetration of aerosol particles, some of which would contain $iable microorganisms. 'n e6ample of such a technology, which at the time of writing is state of the art, is shown m t Figure :.3 and shows a schematic diagram of a con$eyor that has chilled, filtered air directei o$er it, sufficient to maintain the low temperature of the product. Ehen a microbial aerosol was generated around the operational con$eyor,

5Type te6t7

5Type te6t7
microbiological air sampling demonstrated/ )3 log reduction of microorganisms within the protected .one. This wor! has been report in 8urfoot et ai, 3000.

Figure ..( Chilled air is supplied "rom air duc s on ei her side o" a produc con/eyoc The chilled air main ains he produc empera ure $hils i s mo/emen # spilling o/er he duc sur"aces# pro/ides a &arrier o microorganism pene ra ion.

-ocalised air deli/ery ; roughs (olid or fabric air supply ducts Food product

0. D)T)R1IN) )8UI*1)NT +ND F+CTOR4 -+4OUT

Following an assessment of the process and mass flow, suitable e#uipment can be selected to @anufacture the intended product in its re#uired #uantities. 'fter the e#uipment has been Miected and its space and ser$ice re#uirements determined, the layout of the factory can begin in which the e#uipment, process lines and supporting ser$ices can be planned and a basic factory plan established 0(ection =1.

5Type te6t7

5Type te6t7

0.1 )!uipmen choice Production e#uipment and process lines can either be transferred from e6isting operations or can be purchased 0new or secondhand1. Ehate$er the source of the e#uipment, the following are !ey points for considerationA)

V (ince <<I, all machinery used in the ?B must carry the C? @ar! and thus show compliance with the
Council Directi$e relating to machinery 0L<D4<3D??C1, subse#uently updated by <LD4JD?C 0'non <<La1. This ensures that the machinery is safe to the machine operati$e and the consumer of the product produced. This legislation also co$ers the lin!ed assembly line.

V "n addition, e#uipment can be chec!ed for conformity with the hygiene re#uirements of ?C =J3)3 0'non
<<Jb1 or the hygienic design guidelines of the ?uropean Hygienic ?ngineering Design ;roup on open 0'non <<41 and closed 0'non <<I1 process e#uipment.

V ' suitable means of entry to processing areas must be pro$ided for all large pieces of e#uipment, both at the
point of factory construction and subse#uently for ser$iceDmaintenance. This may re#uire the design of wallsDdoorways that are closed whilst in normal operation but can be opened without too much effortDdisruption if re#uired for e#uipment access.

V "n the BM, all e#uipment must meet the Pro$ision and Bse of Eor! ?#uipment -egulations 0PBE?-1 0'non
<<L1. The performance of e6isting e#uipment will be !nown, both its ability to produce a product of the re#uired functional design and #uality and its throughput. For purchased processing e#uipment 0new or secondhand1, food manufacturers need to assure themsel$es of the ability of the machinery to produce the intended product, in sufficient $olume and at the right price. Purchase considerations shouldA)

D CCF-' 300 4

V "dentify as many suppliers or new and secondhand !it as possible V Try to obtain e6amples of the !it on loan for product trials to ensure that the intended products can be
de$eloped to the re#uired #uality.

V "f this is not possible, can product trials be underta!en on pilot plant at the !it manufacturer&s premises or
somewhere else, e.g. CCF-'F

V "dentify which model si.e offers the potential for efficient initial and predicted manufacturing $olumes 5Type te6t7

5Type te6t7 V "dentify which !it offers the most fle6ibility to produce different products in the future V "dentify which !it is the easiest to clean 0small differences in cleaning time per day can mount up to
significant differences in cleaning costs o$er the lifetime of the machine1

V "dentify which !it is most easily ser$iced V Consider total lifecycle costs and calculate the benefits of purchasing new or secondhand

0.( )!uipmen needs @any new build factories are designed and built around the most efficient production line configuration. "t is essential, therefore, that the following information is readily a$ailableA) The dimensions, shape and weight of all of the !ey items in the production line. The total assemblyDfillingDpac!aging throughputs per product. The re#uired control philosophy for indi$idual machines and the process lines. List of ser$ices re#uired per machine and their consumption rates. Local e#uipment $entilationDe6traction re#uirements. 'ny other Health T (afety re#uirements. ?#uipment waste 0solid and li#uid1 disposal re#uirements. Degree of space re#uired around the line to facilitate operation, maintenance and cleaning. 0.6 Fac ory layou The factory layout should start with a list of all of the roomDspace re#uirements re#uired for all of the acti$ities needed to facilitate the production of the product. "t is impossible to list all such areas here but a list could includeA)

V V V V V V V V V V V V V

goods in raw material storage> chilled, ambient, fro.en, dry etc pac!aging storage water storage for!lift truc! storage and maintenance preparation areas processing areas high ris! areas in)process product storage final product storage wash)up facilities waste disposal area plantroom

5Type te6t7

5Type te6t7 V V V V V V V V V V V V V V V V V
engineering wor!shop cleaning stores microbiology, chemistry and GC laboratories and test !itchens pilot plant area changing facilities restrooms canteens medical rooms area for $isiting inspectors obser$ation areasD$iewing galleries finished goods dispatch warehousing office space reception board room security room "TDser$ers etc.

9nce the re#uired spaces are identified, the potential layout that best suits the processes& current and future re#uirements can be considered. The factory layout should be such that processing operations are as direct as possible as this minimises the possibility of

5Type te6t7

Hygienic Design. Construction and Layout of Food Processing Factories

contamination of processed or semi)processed product by unprocessed or raw materials and is more efficient in terms of handling. "t is also easier to segregate clean and dirty process operations and restrict mo$ement of personnel from dirty to clean areas.

V Ehilst, ideally, the process line should be straight, this is rarely possible, but there should be no
bac!trac!ing and, where there are changes in the direction of process flow, there must be ade#uate physical barriers.

V -aw materials and ingredients should mo$e from &dirty& to &clean& areas as they are incorporated
into food products.

V (ufficient space should also be allowed for the mo$ement of materials and personnel to (er$ice
the process lines.

V The flow of air and drainage should be away from &clean& areas towards &dirty& ones. V The flow of discarded outer pac!aging materials should nbt cross, or run counter to, the flow of
either unwrapped ingredients or finished products.

V The flow of food product wastes ideally should run in the opposite direction to product flow. V 9perati$es should ha$e direct access to processing areas without ha$ing to cross areas o"
contamination 0internally or e6ternally1.

V (eparate access is re#uired to each hygiene .one in the factory. V 9n a site scale, optimum staff tra$el distances should be considered between staff entrances,
changing areas and production and between production and canteen areas.

V 9n a process line scale, optimum staff tra$el distances should be considered 0e.g. wal!ways
acrossDunder the line1 to allow operati$es to access all necessary wor!Dcontrol areas.

V There should be sufficient height to allow ade#uate access for inspection, cleaning and
maintenance of the e#uipment and for the cleaning of floors.

V 'll parts of the e#uipment should be installed at a sufficient distance from walls, ceilings and
ad%acent e#uipment to allow easy access for inspection, cleaning and maintenance, especially if lifting is in$ol$ed.

V 'ncillary e#uipment, control systems and ser$ices connected to the process e#uipment should be
located so as to allow access for maintenance and cleaning. "n addition to internal factory layout, pro$ision should be made for e6ternal site re#uirements. (uch re#uirements includeA)

V (ufficient space for goods)in and despatch access. V (ufficient space for carD$anDtruc!Dlorry par!ing and manoeu$ering. V The need for e6ternally sited water storage, cooling towers, effluent treatment plant, additional
storage space etc

V The need for the site to be landscaped to limit its appearanceDpotential nuisance to the community. V The need for site security 0security fencing, gatehouse, traffic barriers, CCTO, burglar alarms1.

2 CCF-' 3004

Hygienic Design. Construction and Layout of Food Processing Factories

<. )STI1+T) TH) SI=) OF F+CTOR4 R)8UIR)D +ND CONSID)R N)7 ,UI-D OR R)FUR,ISH1)NT +-T)RN+TI9)S

This section is concerned with gathering all the information from (ections )I, considering whether refurbishment or new build is the preferred route and de$eloping a factory plan. The purpose of the plan is to pro$ide sufficient information for all concerned to ma!e sensible decisions about !ey aspects of the factory. These could includeA)

V To allow potential customersDretailers to $iew the pro%ect and ma!e comment. V To allow potential third party auditors 0e.g. to the 8-C standard1 to $iew the pro%ect and ma!e
comment.

V To allow the responsible 'uthority ?H9&s to $iew the pro%ect and ma!e comment. V To allow Fire 9fficers to $iew the pro%ect and ma!e comment. V To allow informal consultation with Town Planners. V To pro$ide the 8oard with all the information they need to underta!e any necessary neZ build,
refurbishment or pro%ect acceptance decisions.

V To pro$ide architectsDconstruction companies with sufficient details to facilitate construction

plans

<.1 Re"ur&ishmen :ne$ &uild Mey to the decision ma!ing process is whether new build or refurbishment should be considered. "n this conte6t, new build is defined as being constructed on an ad%acent or ne[ site such that there is no disruption to the e6isting production operation 0other than management time1. -efurbishment is repairs, e6tensions or new build pro%ects on the e6isting site which will be disrupti$e to the current manufacturing operation. (ome of the ad$antages and disad$antages of the options are listed below. Financial benefits or drawbac!s are easy to recognise and are clear to all. 9ther benefitsDdrawbac!s are of a moi intangible nature, howe$er, and are more difficult to ran!, e.g. the opportunity for a new company culture in a new site as against the potential loss of company e6pertise from staff unwilling to mo$e to the new site. Refurbishment - advantages

V Li!ely to be cheaper in the short term V 8uilding and hence e6penditure can be phased. V 8uilding can be geared to sales and upta!e of the new product range. V The e6isting infrastructure and ser$ices are retained. V ?6isting staff and s!ills are retained. V ?6isting raw material and ingredient suppliers are retained. V ?6isting ser$ice pro$iders are retained.

Refurbishment - disadvantages

V Fitting new process lines in e6isting buildings may lead to too many hygieneDproduction restraints
andDor compromises leading to increased operational costs.

V Continual, phased e6penditure is li!ely to cost more in the long term. V 9ld personnel habits are retained. V "t is unli!ely that company image will go through a ma%or step change 0if this is re#uired1. V (pace for new buildings and related operations may be limited. V (er$ices for new buildings may be limited. V 'dditional si.eDwor! forceDnoiseDeffluentsDtransport etc. may ha$e an unacceptable effect on the
surrounding community.

) CCF-' (006

Hygienic Design. Construction and Layout of Food Processing Factories

V The e6isting buildings may not lend themsel$es to the pro$ision of ade#uate, new hygiene
standards.

V -efurbishment is li!ely to close the site 0howe$er temporarily1 and additional costs may be
re#uired to facilitate contract pac!ing.

V 8usiness to e6isting customers may be lost during this period. V Potential unforeseen ha.ards can increase costs and timescales once building wor! has
commenced, e.g. asbestos, contaminated land, underground ser$ices.

New build - advantages

V Cheaper in the long term. V ' purpose designed and built factory will be achie$ed. V The pro%ect may be self financing from the sale of the old site. V There may be an opportunity for possible off)balance sheet funding V 'll industry current best hygienic design and manufacturing practices can potentially be adopted. V Cew staff are li!ely to be employed, leading to the opportunity to de$elop a new company
culture.

V The new site could facilitate a change in company image with customersDretailers. V Co disruption to e6isting business. V Potentially easier to meet new product launch deadlines.

New build - disadvantages

V ' new, suitable site has to be found. V @ore e6pensi$e in the short term. V There is a danger that the building may be designed for production o$ercapacity if initia sales
targets are not met.

V (taff redundancy costs for staff choosing not to mo$e. V ?6isting site saleDwrite downDwrite off costs. V Potential loss of e6isting !ey staffDs!ills and staff culture. V @ay need to find new raw materialDingredientDser$ice pro$iders.
Eith new build sites, it is also necessary to consider freehold or leasehold ownership. Leasehold has the ad$antage that building cost 0rent1 is low compared to capital in$estment and the landlord ta!es responsibility for building maintenance and the ris! of building con$ersion to the company&s design 0if the design is not successful1. The disad$antages arc that the landlord may put unacceptable constraints on the building designDuse and the rent H li!ely to rise in an uncontrolled fashion. Freehold purchase may initially tie up capital that could be used to de$elop the business, but in the long term offers the company control, fle6ibility and !nown o$erheads.

<.( Si e plan 'n e6ample of a site plan for the production of a lasagne product, the flow of which was shown in Figure 4. , is shown in Figure =. . The layout of e#uipment and internal walls may not be finalised, as comments will be elicited from customersD?H9&sDFire 9fficersDconsultants. There is sufficient detail present, howe$er, on which in)depth considerations can be made and a final plan de$eloped.

) CCF-' (006

Figure <.1 ,asic "ac ory plan "or he produc ion o" lasagne. The plan gi/es su""icien in"orma ion on >lie layou o" he "ac ory $i hou going in o oo much de ail on he ins alla ion o" process lines and ser/ices

Hygienic Design, Construction and Layout of Food Processing Factories

?.

D)CISION'; TO ,UI-D OR NOT TO ,UI-D

't this stage in the potential construction wor! programme, the following will ha$e been underta!en A)

V ' basic business plan will ha$e been completed. V "f a greenfield site is in$ol$ed, a potential site will ha$e been located and outline planning
permission agreed.

V ' food product process will ha$e been determined, rele$ant food processing e#uipment
selected and predicted product $olumes will ha$e been calculated.

V The potential health ris!s of the product to the final consumer will ha$e been considered and
the necessary degree of product segregation re#uired during processing will ha$e been designed into the factory layout.

V From this information the si.e and layout of the factory will ha$e been calculated and plans
for the intended construction will ha$e been drawn.

V Comments on the design will ha$e been recei$ed from interested parties, e.g. customer)
insurance bro!ers, ?n$ironmental Health 9fficers, CCF-'. This information can then be used to gather further facts about the associated costs of the pro%ect and construction timetables. The following can then be consideredA)

V Potential capital costs V -e#uired cash flows V Capital e6penditure appro$al procedures V Loan a$ailability from the ban! V Timescales for the construction phase V "ntended launch date of the new product V Time to shelf ) when will income be earnedF V -eturn on controllable capital e6penditure 0-9CC?1
2 CCF-' 3004

Hygienic Design, Construction and Layout of Food Processing Factories

9nce this information is a$ailable, a case for a construction pro%ect can be presented to the company board for a decision on whether to proceed with the pro%ect 0with or without modifications1 or not. 't this stage it is also worth noting two !ey pointsA)

V Feasibility design wor! must be completed by this stage. 'ny changes to the proposed pro%ect
plan from this stage forward will incur cost and time penalties.

2 CCF-' 3004

aenic Design. Construction and Layout of Food Processing Factories

The final costs will be affected by un!nown costing such as un!nown en$ironmental issues, some of which will only be apparent from reports, e.g. when trial holes ha$e been dug and e6amined.
the decision is to proceed with the pro%ect, (ections < to 4 of this guideline should be csulted.
't the

appropriate stage, an application for detailed planning should be made. "t should be noted that this process can ta!e eight wee!s or more.

DCFR+ (006

Hygienic Design. Construction and Layout of Food Processing Factories

@. CONSTRUCTION AD)SI3N +ND 1+N+3)1)NTB R)3U-+TIONS 1CC.' TH) RO-) OF TH) C-I)NT# TH) *-+NNIN3 SU*)R9ISOR +ND TH) D)SI3N)R

@.1 The Cons ruc ion ADesign and 1anagemen B Regula ions The Construction 0Design and @anagement1 -egulations <<: 0CD@ -egulations1, as amended in 3000, are aimed at impro$ing the o$erall management and co)ordination of operati$e health, safety and welfare throughout all stages of the construction pro%ect. The CD@ -egulations place duties on all those who can contribute to the health and safety of a construction pro%ect, including clients, designers and contractors. The regulations create a new duty holder, the Planning (uper$isor, and introduce new safety documents, the health and safety plans and the health and safety file. The CD@ -egulations apply to most construction pro%ects with the following e6ceptionsA)

V Construction wor! other than demolition that does not last longer than 40 days and doe\ not
in$ol$e more than four people.

V Construction wor! for a domestic client. V Construction wor! carried out inside offices and shops or similar premises without interrupting
the normal acti$ities in the premises and without separating the construction acti$ities from the other acti$ities.

V The maintenance or remo$al of insulation on pipes, boilers or other parts of the heating or water
systems. The CD@ regulations can be purchased asA) (tatutory "nstrument <<: Co. 4 :0, The Construction 0Design and @anagement1 -egulations <<: (tatutory "nstrument 3000 Co. 34L0, The Construction 0Design and @anagement1 0'mendment1 -egulations 3000 From The Publications Centre, P9 8o6 3J=, London (EL IDT, Tel> 0LJ0 =00 II33, Fa6A 0LJ0 =00 II44 9r can be obtained on)line fromA) www.legislation.hmso.go$.u!DsiDsil<<:DB!si] <<:4 :0]en]l.htm www.legislation.hmso.go$.u!DsiDsi3000D300034L0.htm @.( The role o" he clien The role of the client is summarised in the Health and (afety ?6ecuti$e 0H(?1 "nformation sheet ) Construction (heet Co. 4< Construction 0Design and @anagement1 -egulations <<:A The role of the client. The client, or a competent agency acting on the client&s behalf, has the following dutiesA)

V 'ppoint a planning super$isor 0see (ection L.41. V Pro$ide to the planning super$isor any information that is rele$ant to the health and safety of the
building pro%ect. This could include information about the site, the premises, wor! processes or acti$ities where the construction wor! is to be underta!en.

V 'ppoint a principal contractor 0see (ection 01. V ?nsure that the appointees are competent and ade#uately resourced to carry out their health and
safety responsibilities. The H(C guidelines 0H(C <<I, 300 1 pro$ide detailed guidance on the issues of competence and ade#uate resources for health and safety.

2 CCF-' 3004

Hygienic Design. Construction and Layout of Food Processing Factories

V ?nsure that the principal contractor has prepared a suitable health and safety plan before
construction wor! commences. The client can as! the planning super$isor to ad$ise on whether the plan is suitable, a tas! that the planning super$isor is obliged to do 0if as!ed1. The degree of detail in the health and safety plan should be in proportion to the si.e and le$el of health and safety ris!s in$ol$ed in the pro%ect and further information can be gained from H(? Construction "nformation (heet Co. :4, !he health and safet# plan during the construction phase- "n practice, not all information rele$ant to the pro%ect will be a$ailable to de$elop the health and safety plan fully prior to construction starting. Howe$er, the health and safety plan should be sufficiently de$eloped so thatA)

V The general framewor! for dealing with the management organisation, emergency
procedures, arrangements for monitoring, communications and welfare is in place.

V "t addresses the !ey tas!s of the early wor! pac!ages.

N ?nsure that the health and safety file passed on at the end of the pro%ect is !ept a$ailable for future use. The health and safety file is prepared by the planning super$isor and details all the !ey health and safety ris!s that ha$e to be managed during future maintenance, repair or construction wor!. Further information can be gained from H(? Construction "nformation (heet Co. ::, !he health and safet# file-

@.6 The role o" he planning super/isor The role of the planning super$isor is summarised in the H(? "nformation sheet )Construction (heet Co. :0 Construction 0Design and @anagement1 -egulations <<:A The role of the planning super$isor. The client should appoint a competent and ade#uately resourced planning super$isor as earh as possible during the design and planning wor!. This is to allow the planning super$isor sufficient time to complete their duties and ad$ise on the subse#uent appointment of others, as necessary. "n the ma%ority of cases, the planning super$isor will be an organisation 0e.g.. architectural practice, consulting engineers, pro%ect managers, contractors1 with design and construction e6perience and with !nowledge of health and safety. 9nly for the smallest pro%ects is it li!ely that the planning super$isor will be an indi$idual. The planning super$isor&s duties are toA)

V ?nsure that the H(? is notified of the building pro%ect 0if the construction wor! will last for 40
days or more or in$ol$e more than I00 person days1.

V ?nsure co)operation between designers. This is li!ely to in$ol$e ensuring that rele$ant
information flows freely between the designers, ensuring that designers ta!e proper account of health and safety in their design and ensuring that designers co)ordinate their wor! to see how the different aspects of design interact with each other and affect health and safety.

V ?nsure that designers comply with their duties 0see (ection L.:1. V ?nsure that a pre)tender stage health and safety plan is prepared. The plan needs to be a$ailable
before the selection of a principal contractor so that 0a1, prospecti$e principal contractors can prepare outline submission to it during tendering and 0b1, the planning super$isor or client can assess the tender submissions. Further information on the pretender stage health and safety plan can be found in H(? Construction "nformation (heet Co. :3, !he pre.tender stage health and safet# plan-

V 'd$ise the client when re#uested to do so on the competence of designers and contractorF and
on the suitability of the health and safety plan prepared by the principal contractor for the construction phase.

2 CCF-' 3004

Hygienic Design. Construction and Layout of Food Processing Factories

N ?nsure that a health and safety file is prepared 0see (ection L.31. @..

The role o" he designer The role of the designer is summarised in the H(? "nformation sheet ) Construction (heet Co. : Construction 0Design and @anagement1 -egulations <<:A The role of the designer. Designers are organisations or indi$iduals who carry out design wor! for a construction pro%ect and include architects, consulting engineers, #uantity sur$eyors, chartered sur$ey iA technicians, specifiers, and principal and specialist contractors. Designers play a !ey role within the building pro%ect in ensuring the health and safety of those who are to construct, maintain or repair a structure and those who might be affected by this wor! 0e.g. members oil the public1. Designers ha$e the following dutiesA)

V ?nsure that clients are aware of their duties under the CD@ regulations. V ;i$e due regard to health and safety in their design wor!. The o$erall design process does not
need to be dominated by a concern to a$oid all ris!s during construction and maintenance and has to also consider costs, fitness for purpose, aesthetics, buildability and en$ironmental impact. Ehen considering health and safety in the design wor!, the designer is only e6pected to do what is reasonable at the time the design is prepared. "t may be possible for ha.ards that cannot be addressed at the feasibility stage to be e6amined during detailed design. To help ensure that health and safety is considered in design wor!, the following steps are suggestedA)

V "dentify the significant health and safety ha.ards li!ely to be associated with the design and
how it may be constructed and maintained.

V Consider the ris! from the ha.ards that arise as a result of the design being incorporated into
the pro%ect.

V "f possible, alter the design to a$oid the ris! or, if not reasonably practicable, reduce it. V Consider if the ha.ard can be pre$ented from arising so that the ris! can be a$oided 0i.e. alter
the design to a$oid the ris!1.

V "f this cannot be achie$ed, the ris! should be combated at source 0e.g. ensure that the design
details of items to be lifted include attachment points for lifting1.

V Failing this, priority should be gi$en to measures to control the ris! that will protect all people
0e.g. establish a one)way system for deli$ery and spoil remo$al $ehicles1.

V 9nly as a last resort should measures to control ris! by means of personal protection 0e.g.
safety harnesses1 be assumed.

V Pro$ide ade#uate information about the health and safety ris! of the design to those who need it.
"f, following design wor!, there are ris!s that it is not reasonably practicable to a$oid, information must be included with the design to alert others to the ris!s which they cannot reasonably be e6pected to !now.

V Co)operate with the planning super$isor and, where appropriate, other designers in$ol$ed in the
pro%ect. "t is unli!ely that all the design wor! will be underta!en by one designer and designers therefore need to liaise with the planning super$isor and other designers so that wor! can be co) ordinated to see how the different designs impact on each other with respect to health and safety. The planning super$isor has a duty to ensure that cooperation is underta!en and that designers are fulfilling their duties.

2 CCF-' 3004

Hygienic Design, Construction and Layout of Food Processing Factories

The H(? Construction "nformation (heetsA) Co. 4< Co :0 Co. : Co. :3 Co. :4 Co. :: The role of the client The role of the planning super$isor The role of the designer The pre)tender stage health and safety plan The health and safety plan during the construction phase The health and safety file

Can be obtained from local H(? 9ffices or H(? 8oo!s, P9 8o6 <<<, (udbury (uffol!. C9 0 3E', TelA 0 JLJ LL =I, Fa6A 0 JLJ 4 4<<I 9r online from httpADDwww.hse.go$.u!DpubnsDconinde6.htm

2 CCF-' 300.

C. D)9)-O* CONSTRUCTION ,RI)F

9nce the decision has been made to proceed, the onus is on the Design Team to prepare detailed information in order to compile a Construction 8rief. Ehilst the design team will wor! together to produce the information re#uired, the information can be di$ided into the elements that each Consultant needs to produce as followsA

-42-

Hygienic Design, Construction and Layout of Food Processing Factories

Design )lemen Consul an -oom layoutsDfloor plans 'rchitect V Merbs V Ealls V Floor fallsDle$els V Doors V "nternal drainage -oom data sheets 'rchitect ?le$ations 'rchitect

Inpu Client, building regulations

No e

Client

Typical room data sheet 0Table <. 1

D CCFR+ (006

Hygienic Design, Construction and Layout of Food Processing Factories

Detailed cross)sections 'rchitect -oof plans 'rchitect Ceiling plans 'rchitect 9ffices and amenities 'rchitect V Plans V Cross)sections V Details V Finishes schedules Fire protection, means of 'rchitect escape, compartmentation

Client, building regulations 0inc disability in the wor!place1 Client&s insurance, building regulations, structural engineer Client Client, highways authority Client

Loading doc! details 'rchitect ?6ternal wor!s layout ) 'rchitect (ecurity 'rchitect V Fencing and gates V ;ate house

D CCFR+ (006

Hygienic Design, Construction and Layout of Food Processing Factories

(tructural frame loadings and (tructural engineer Client, architect, type 0portalDtrussDspecial1 ser$ices designers 0process engineer1 building regulations

Clear spans, ceiling weights, ser$ices weights ai locations. (uspended process e#uipment and ser$ices

2 CCF-' (006

Hygienic Design, Construction and Layout of Food Processing Factories

Foundations

(tructural engineers ;round in$estigation 0Ci$il1

2 CCF-' (006

Hygienic Design, Construction and Layout of Food Processing Factories

;round wor!s

remedial

?n$ironmental consultants (itesV

;roundDcontamination -elates to in$estigation Y8rownfield

Floor details

slabs

(tructural engineers 8uilding regulations, Eeights and positi

2 CCF-' (006

nstruction and Layout of Food Processing Factories

0Ci$il1

architect, 0process engineer1 of e#uipment

Hygienic Design, Construction and Layout of Food Processing Factories

?6ternal wor!s 0Ci$il1 V -oads V ^ards and hardstandings V Car and lorry par!s V 8ases

(tructural engineers 'rchitect, highways authority 0process engineer1

;reen tra$el to wo' plan may be re#uired by planning authori#

2 CCF-' (006

Hygienic Design, Construction and Layout of Food Processing Factories

@ain Drainage V (urface water V Foul V ?ffluent

(tructural engineers 'rchitect, 0Ci$il1 building regulations

2 CCF-' (006

Hygienic Design, Construction and Layout of Food Processing Factories

(er$ices )refrigeration

Consultant or -oom data design and build sheets, 0process specialist contractor engineer1 Consultant or -oom data design and build sheets, 0process specialist contractor engineer1

High ris! air flow> 0Table <.31

(er$ices )mechanical

High ris! air flowA 0Table <.41

(er$ices )electrical

Consultant or design -oom data sheets, and build specialist 0process engineer1 contractor Consultant or design -oom data sheets, and build specialist 0process engineer1 contractor of 'rchitec t Pro%ect team design

0Table <.:1

(er$ices )general

0Table <.I1

@anagement drawings

'n e6ample of a typical drawing isa sheet is shown in Table <.J

Notes: Disability in the wor!place Following a suitable ris! assessment, the design of the building to incorporate disabled access will need to be considered. 'd$ice can be found in Design of /uildings and their approaches to meet the needs of disa/led people . Code of practice) 8ritish (tandard L400A300 .

(pecification "n addition to the information detailed abo$e, specifications for all elements of wor! need to be prepared by the Consultants in$ol$ed.

Le$el of Detail D 8ills of Guantities The le$el of detail re#uired at this stage will depend on the method of appointing the @ain Contractor 0see (ection 1.

2 CCF-' (006

Hygienic Design, Construction and Layout of Food Processing Factories

Programme The design team leader should produce an outline timetable that reflects the priorities set by the Client. ' typical timetable in the form of a simple bar chart is shown in Table <.=, and demonstrates the number of !ey elements within the construction pro%ect and how they are inter)dependent on time.

Design Design wor! must be completed by this stage. 'ny changes to the proposed pro%ect plan from this stage forward will incur cost and time penalties.

2 CCF-' (006

Hygienic Design, Construction and Layout of Food Processing Factories

Ta&le C.1 Room Da a Shee eDample -99@A -99@ C9A ("_?A 9CCBP'CC^A -9LL C9CT'"C?- E'(H 'CD (T9-';? ;P3 :@ H I.4@ 3

Ealls

Con combustible cored insulated panels with Foodsafe finish both sides, on an insulated stainless steel !erb, concrete filled.

2 CCF-' 3004

Hygienic Design, Construction and Layout of Food Processing Factories

Floor

(eamless floor finish laid to falls, to channel drains

2 CCF-' 3004

Hygienic Design, Construction and Layout of Food Processing Factories

Ceiling

Con combustible cored insulated panels.

2 CCF-' 3004

Hygienic Design, Construction and Layout of Food Processing Factories

Doors

(liding insulated doors, on fermod trac! into other areas, am personnel doors to ha$e $ision panels, and stainless steel do, furniture. Co handwash sin!, 3 Co washdown points, drainage chani hose down point, HE feeds to e#uipment and cold feed. ='TPTC soc!et outlets, 4' soc!et outlets, tannoy, ?FM& fire alarm, both sounder and _enon beacons, 8roen $al$es.

DrainageDPlumbing

?lectrical (er$ices

2 CCF-' 3004

Hygienic Design, Construction and Layout of Food Processing Factories

Lighting

:I0 lu6, emergency lighting and lighting controller.

2 CCF-' 3004

Hygienic Design, Construction and Layout of Food Processing Factories

OentilationD'CDHeating (pecial -e#uirements

8alanced $entilation system, no recirculated air, 30 change/ hour. P' spea!ers 0speechDmusic1, supplies to traywash 0fed from bar trun!ing in roof $oid1, 3 no compressed air

2 CCF-' 3004

Hygienic Design, Construction and Layout of Food Processing Factories

Fi6tures and Fittings

(ingle sin! 08elfast1

2 CCF-' 3004

Hygienic Design, Construction and Layout of Food Processing Factories

?#uipment

Easher ) 00ME electrical loading to be confirmed. Easher water re#uires 3I0 itresDhr, preferably hot

2 CCF-' 3004

Hygienic Design, Construction and Layout of Food Processing Factories

Coise le$el

:0D:I d8 '

2 CCF-' 3004

Ta&le C.1 Room Da a Shee eDample

-99@A -99@ C9A ("_?A 9CCBP'CC^A

-9LL C9CT'"C?- E'(H 'CD (T9-';? ;P3 :@ H I.4@ 3

Ealls

Con combustible cored insulated panels with Foodsafe finish both sides, on an insulated stainless steel !erb, concrete filled. (eamless floor finish laid to falls, to channel drains Con combustible cored insulated panels. (liding insulated doors, on fermod trac! into other areas, any personnel doors to ha$e $ision panels, and stainless steel door furniture. Co handwash sin!, 3 Co washdown points, drainage chanrV hose down point, HE feeds to e#uipment and cold feed. =' TPTC soc!et outlets, 4' soc!et outlets, tannoy, ?FM fire alarm, both sounder and _enon beacons, 8roen $al$es.

Floor Ceiling Doors

DrainageDPi umbi ng

?lectrical (er$ices

Lighting OentilationD'CDHeating (pecial -e#uirements

:I0 lu6, emergency lighting and lighting controller. 8alanced $entilation system, no recirculated air, 30 changes hour. P' spea!ers 0speechDmusic1, supplies to tray wash 0fed from trun!ing in roof $oid1, 3 no compressed air (ingle sin! 08elfast1 Easher ) 00ME electrical loading to be confirmed. Eashei water re#uires 3I0 itresDhr, preferably hot bar

Fi6tures and Fittings ?#uipment

Coise le$el

:0D:I d8 '

Ta&le C.( )Dample ; Con rac ors ,rie" 1echanical and )lec rical A1E)B Chec5lis ' Re"rigera ion Discre e or cen ral plan V Di$ersity of load ) how many indi$idual temperature controlled .ones V Difference between minimum and ma6imum duty V -eliability ) Percentage standby capacity V Plant room or weatherproof enclosure V 'llowance for future e6pansion Re"rigeran V 2$ow initial cost . high on.cost- High initial cost . low on.cost3 V 'mmonia, HFC 0- 4:', -:0:', -I0J, -:0JC1, HC 0isobutene, propane1 V Consider secondary cooling> glycol, brine, water V Long pipe runs, high refrigerant charge V Pumped refrigerant system $ direct e6pansion V "s the life cycle of the plant long term, medium or shortF V "s refrigerant lea! detection included or offeredF *roduc loads A he cooling du y depends on he empera ure and imeB V Type of product V (torage or temperature reduction V ?ntry temperature V Final temperature V -eduction duration V Thermal properties of product, si.e, shape, water content V "s the product wrapped or openF S andards and legisla ion A-egisla ion demands ha s andards are o&ser/edB V (afety (tandard ?C4JL> is installer con$ersantF

V Pressure ?#uipment Directi$e <JD34D?C V "nstitute of -efrigeration Codes of Practice

1ain enance V (er$ice inter$als for main items, e.g. compressors V Does the installer ha$e maintenance facilities and #ualified staffF V @aintenance inter$als 0Client dri$en1 0Daily, wee!ly, monthly, #uarterly1 )""iciency V Bse items which attract ?nhanced Capital 'llowances 0?C's1 V Temperature difference between condensing and ambient

V V V V V V

Temperature difference between room and e$aporating 9$ersi.e allowed on the dri$e motors 'ir)cooled condensers or e$aporati$e condensers Eater supply for e$aporati$e condensers Oariable speed dri$es on pumps Low load efficiency of compressors.

)n/ironmen al V Coise limits V 'mbient temperature

Ta&le C.6 )Dample Con rac ors ,rie" 1E) )Dample Chec5lis ' 1echanical

V Confirm that ade#uate gas supply is a$ailable. V Contact regional electricity company and energy pro$ider to ad$ise of possible increase in
demand.

V Confirm desired en$ironmental temperatures and relati$e humidity for each area. V Confirm any specific $entilation re#uirements. V Confirm air cleanliness criteria. V 'd$ise of anticipated areas to be utilised for plant space, etc. V Pro$ide information of cleaning agents, detergents, or sol$ents to be used which may gc to
drain and therefore re#uire effluent treatment.

V Pro$ide information of e6isting ser$ices infrastructure and plant type correctly used. V Pro$ide a brief description of the scope of wor!s 0series of bullet points1 i.e.

V ;as V Eater 0flow rate1 V Compressed air 0#uality 0oil)free1, pressure, flow rate, dew point, etc1 V (team 0temperature, saturation, flow rates1 V Cleaning systems V 8uilding management and energy systems V Contact insurers to establish if sprin!ler system or any other pro$ision is re#uired. V 'd$ise on any particular re#uirements with respect to refrigerant type or refrigeration general. V 'd$ise of particular coo!ing re#uirements, such as steam, thermal oil, etc.
Ta&le C.. )Dample Con rac ors ,rie" 1E) )Dample Chec5lis ' )lec rical

V Confirm that ade#uate electrical supply capacity is a$ailable. V Contact regional electricity company and energy pro$ider to ad$ise of possible increase in
demand.

V 'd$ise of desired lighting le$els.

) CoteA "f this is not !nown, pro$ide a description of the tas! and si.e of the ob%ect being handled and comple6ity of the tas! so that the engineer can establish an appropriate lighting le$el.

V 'd$ise of the anticipated power re#uirement for general usage. V Contact insurers and obtain ad$ice with respect to the le$el of fire protection re#uired to the
building and the production e#uipment.

V 'd$ise of anticipated areas to be utilised for electrical distribution e#uipment, i.e.

Transformers, (witchgear, Panels etc.

V Pro$ide brief description of the scope of wor!s 0series of bullet points1 i.e. A V ?lectrical power re#uirement 0$oltage, loads 0!E11 V Data re#uirement 0type of installation 0cat I or =1 number of points1 V (ecurity systems 0CCTO, "ntruder1 V 'd$ise on any particular automation re#uirements for production e#uipment. V Pro$ide information of e6isting ser$ices infrastructure and plant used. V (pecification for installing cable trays andDor ducts to a hygienic standard will need to be
stated

Ta&le C.0 )Dample Con rac ors ,rie" 1E) )Dample Chec5lis ' 3eneral

V Confirm layout of proposed production e#uipment. V Confirm ser$ices re#uirements to each item of production e#uipment.
) CoteA This is best completed as a matri6 with all the ser$ices across the top and each piece of e#uipment down the left. N Confirm #uantities of ser$ices re#uired for each item of e#uipment> i.e. m 4Ds 0air1, Ds 0gases and fluids1, !E 0electricity1. ) CoteA ' simple ^esDCo is not sufficient to complete a design. This information can usually be found with the e#uipment manufacturers& data sheets. N 'd$ise of anticipated areas to be utilised for production facility, welfare, etc.

Ta&le C.< Typical ime a&le mapping ou main s ages and imings in a "ac ory cons ruc ion proFec
Main Contractor Mobilisation

3 4 : I = J L < 0 3 4 < 30 3 33 34 3: 3I

Start on Site Site establishment, facilities and preparation Excavate and hardcore to site compound Site offices and facilities inc. utilities Temporary security fencin to site and compound !ul" excavations to #$ sub base level %ardcore oversite to #$ level Substructures and basement structure Concrete column bases - f level S&' and concrete to toe beam and ret. (all ) rid *+, Concrete perimeter ed e beam - retainin (all .n slab draina e and ducts - f level Concrete bases etc to office buildin S&' and concrete external basement (alls %ardcore and concrete to #$ slab %ardcore and concrete basement slab /erimeter ed e beam to office buildin .n slab draina e and ducts - office buildin %ardcore and concrete #f slab - office buildin Super structure Structure steel frame - main buildin /urlins and sheetin rails 0 main buildin 1oadin doc" retainin (all Structural steel frame - office buildin /urlins and sheetin rails - office buildin /recast concrete floor units /recast concrete floors and stairs to office buildin External envelope

3= 'oof claddin 3J 'oof claddin to office buildin 3L 'oof li hts to circulation area 3< $lat panel (all claddin 40 .nstallation of doc" levellers 4 Curtain (allin to office and lin" brid e 43 2all la3in panels 44 .nstallation of personnel and industrial doors 4: Solar shadin to office buildin 4I Curtain (allin to lin" structure
Internal finishes: Plnntroom (irons

I0 Suspended ceilin s I Ceramic (all and floor tilin I3 Toilet installations I4 Canteen installation I: Carpenter 2nd fix and fittin s II Decorations and floor finishes I= Duct(or" and pipe(or" in roof-service void IJ Duct(or" drops to ceilin level IL Electrical fittin s etc in f area I< !elo( ceilin pipe(or" etc =0 Electrical cable trays etc in roof-service void = #rilles and louvres etc =3 Electrical cablin and fittin s in roof-service void =4 Mechanical installation =: Electrical installation =I 1ift installation
Plantroom Office building Mechanical and electrical installations Production areas

== 4%56s and duct(or" etc =J Electrical installation to plantroom =L .nstallation of flues etc =< Electrical and s(itch ear controls and panels J0 1T%2 boilers and associated plant J Compressed air system J3 /rocess coolin (ater plant J4 Electrical (irin to e7uipment J: Chiller plant JI 2ater stora e tan"
General

J= Test and commission - certification JJ Commence installation and production e7uipment

* 2 + 9:

; *< ** *2 *+ *4 *8 *9 *: *= *; 2< 2* 22 2+ 24 28 29 2: 2= 2; +< +* +2 ++ +4 +8 +9 +: += +; 4< 4* 42 4+ 44 48 49 4: 4= 4; 8< 8* 82

Ta&le C.? Typical dra$ing issue shee used o manage archi ec ural dra$ings

dra ing issue sheet

pro!ect "#

PROJECT A

sheet "#

D D M M C D

> = * < * * * < < < < < $% * *

* < * < G

* > + ? 2 i * . * < * * d < * * @ < * 6

. t A

. S * * < < * *

2 < * * < *

2 @ < * n * G 8 *

2 : . A < *

2 ; t B < *

< : < * E

dra ing title

dra ing "#

re$ision

state & status

SITE PLAN AT 1:500 GROUND FLOOR PLAN AT 1 200 FIRST FLOOR PLAN AT 1:200 SECOND FLOOR PLAN AT 1 200 PRELIMINARY DRAINAGE PROPOSED SITE LEVELS SIGN BOARD ROOF PLAN AT 1 200 SITE LOCATION PLAN AT 1 2500 GATE OUSE ! SUPERCEDED SECTIONS A!A AND B!B SECTIONS C!C# D!D AND E!E SETTING OUT !GROUND FLOOR PRODUCTION EAST$1 100 SETTING OUT!GROUND FLOOR PRODUCTION %EST 1 100 SETTING OUT!FIRST FLOOR EAST$ 1 100 SETTING OUT!FIRST F L OOR %EST$ 1 100 SETTING OUT!SECOND FLOOR EAST# 1 100 SETTING OUT!SECOND FLOOR %EST# 1 IOC GROUND FLOOR OFFICES$ 1 50 FIRST FLOOR OFFICES# 1 50

1340 100 1340 101 1340 102 1340 103 1340 104 1340 105 1340 106 1340 107 1340 108 1340 10" 1340 110 1340 111 1340 112 1340 113 1340 114 1340 115 1340$ 116 1340# 117 1340 118 1340$ 11"

recipient name

classification

number of copies &

action re'uired

status ( ) preliminar* + ) presentation & planning , ) tender - ) construction E ) final issue

number of copies

etc$$$ . sent as a data file ) -

action re'uired ( ) for information & reference onl* / ) revised issue, please destro* or0!ina , ) please return ith comments & a - ) please return ith information r E ) other (details on dra ing1

Ccfp2QOl Ajl-rghts reserved

10. )ST+,-ISH CONTR+CT +ND S)-)CT 1+IN CONTR+CTOR

Prior to underta!ing any construction wor!, clients need to establish the construction contract and select appropriate contractors. "n addition to this, the CD@ -egulations " see (ection L. 1 re#uire clients to appoint a principal contractor.

10.1 *rincipal con rac ors Principal contractors are usually the main or managing contractors. ' principal contractor must be a contractor, that is someone who underta!es, carries out or manages construction wor!. Principal contractors need to satisfy prospecti$e clients that they are competent and ade#uately resourced. "f clients manage their own construction wor! and are competent to manage the pro%ect in)house. they may appoint themsel$es. Principal contractors mustA)

V (atisfy themsel$es that the designers and contractors they engage are competent and
ade#uately resourced 0clients must consider these issues for designers and contractors they appoint directh i.

V ?nsure that a suitable construction phase health and safety plan 0called &the plan& in this
section1 isA

V prepared before construction begins> V implementedA and V !ept up to date as the pro%ect progressesA V Promote co)operation betweea all contractors V -estrict entry to the site to aaaaomcd people> V ?nforce any site rulesA V Display the pro%ect on site; V Pro$ide rele$ant information to contractors> including any who are self)employed

V Pro$ide the planning super$isor promptlywith any information rele$ant to the health and
safety file.

10.( Con rac procuremen op ions ?$ery construction pro%ect re#uires some form of design wor! and the e6ecution of construction operations on site. "f a satisfactory result is to be obtained in a particular case, procedures must be adopted which will deal with the organisation and co)ordination re#uireV for the problems associated with that situation. The traditional way to design and construct a food factory is to engage an architectDdesigner, whose role is to interpret the client&s re#uirements into a specific design and specification. The builder would then be appointed to carry out the wor!, to the instructions of the designer. "n recent years, howe$er, as pro%ects ha$e become more comple6 and demanding, some of the features of the traditional route, such as the strict segregation of design and construction, ha$e led to problems. 'lternati$e approaches ha$e now been de$eloped to meet the demands of clients for greater fle6ibility and accountability. These can be split into two categories as described in Planning to /uild8 A practical introduction to the construction process 0Potter, <<I1 asA)

i.

@ultipoint ) a procurement route with &multipoint& accountability to the client, with indi$idual organisations responsible for particular aspects of the design and construcrioV ii. (ingle point ) a procurement route which pro$ides single point accountability with a single organisation assuming responsibility for all aspects of both design and construction @ultipoint routes may beA)

V Designer led ) the traditional form of contracting where the design team lead the design and
construction process.

V @anagement contracting ) the builder is appointed on a fee basis before wor! starts on site to
assist the design team. He is responsible for the construction wor! carried out b* separate wor!s contractors.

V Construction management ) a construction e6pert is appointed to manage the constru process. He

super$ises the trade contractors and may co)ordinate the wor! of the design team.

(ingle point routes may beA Design and manage ) a consultancy organisation is appointed to pro$ide a design and management ser$ice for an agreed fee. The organisation is responsible for co)ordinating the design and construction. Design and build ) an organisation is appointed to pro$ide some or all of the design and carry out the construction for an agreed price. (ystem pac!age ) a company supplies and erects a building of its own design, modified to the client&s need as much as possible.

11. UND)RT+2) ,UI-DIN3 7OR2

This section contains information for managing building wor! on sites where food manufacture is ta!ing place at the same time. (ome of these recommendations would not be necessary for greenfield sites.

11.1 ,uilding cons ruc ion ha%ards and heir managemen Food product contamination, arising from ha.ards generated during building operations, is an e$er) present ha.ard. ' contaminant found in the food by the consumer will be blamed o the manufacturer who, in turn 0if building wor! is ta!ing place1, is most li!ely to claim that it was the contractor&s fault. This cycle of blame, howe$er, may be a pointless e6ercise as the damage has been done and the manufacturer will ha$e been blamed and recei$ed ad` t publicity. Bnli!e in the building industry, product contamination cannot be &de)snaggedY an the food manufacturer will, therefore, want to set up a control system which monitors what is happening and gi$es an assurance that contamination ha.ards are minimised. "n addition as well as the ob$ious product safety ris!s, both the food manufacturer and contractor will be !een to adopt a management control system that gets the %ob done, safely, on)time, and u both parties& satisfaction. Product contamination arising from building acti$ities may be from chemical, physical or biological ha.ards and e6amples are gi$en in Table .

T+,-) 11.1 T4*)S OF CONT+1IN+TION

HA9A,D
CH?@"C'L 0'nything tainting or to6ic1 PH^("C'L 0Foreign bodies1

0:A;P$0"
Diesel fuel, sol$ents 0e.g. paraffin, white spirits1, wood preser$ati$es, disinfectants 0particularly phenolics1, unsuitable cleaning materials, non)food compatible oils, greases or mastics etc. Dust, dirt, rubble, feathers, fibres, hairs, wood splinters, bro!en nails, plasters and dressings, paper, labels, pieces of plastic or wire, bits of wrff brushes, machinery parts, nuts, bolts, washers, fastenings, earrings, par6)Y clips, staples, cigarette ends etc

8"9L9;"C'L 0@icroorganisms &bugs& and pests1 or

Flying and crawling insects, rodents, birds. @icroorganisms 0could include $isteria) coliforms, Clostridium-

"almonella3 from the en$ironment 0particularly soil1 and

from remo$ed structures, fi6tures / fittings mo$ed from food processing areas.

F CC$'4 .223

;ood strategies and effecti$e management can reduce the ris! of food product contamination. These are outlined in sections .3) .: which consider the re#uirements for contractors by the food manufacturer, re#uirements for food manufacturers by contractors and ongoing contract dialogue. Three points, howe$er, can be highlighted at an early stage as being critical to the success of the contract. . @ore than anything, good communications between the contractor and food company are essential and fre#uent re$iew meetings need to ta!e place to ensure the success of the pro%ect. ?fforts should be made to reduce the Yus and themY syndrome. 2. Contractors must recognise that whilst on)site, they must regard themsel$es as food wor!ers and beha$e accordingly. 4. Food manufacturers must recognise that the contractors ha$e similar e6pertise in their industry as ihey do in theirs and that sufficient time and faeihties ha$e to he pro$ided to enable the contractors to complete their tas!s professionally and on time. 11.( Re!uiremen s "or con rac ors &y he "ood manu"ac urer The food manufacturer 0client1 should pro$ide to the contractor all the necessary information about its business to enable the contractor to wor! safely and reduce product contamination, and all facilities necessary for the contractor to complete the wor! professionally and effecti$ely. Ehere$er possible, a separate, self) contained compound should be pro$ided with all necessary amenities. (pecific re#uirements could includeA) N The client&s Health and (afety at Eor! Policy N The clients& Company -ules and -egulations, and specific sections of the Company&s Guality @anual, co$ering for e6ampleA N 'ccess N Cranes ) ade#uate insurance N (ecurity N Fire policy N 'ccidents ) action and reporting s

N ;lass, metal and other foreign body policy N Persona l hygiene N ?n$iron ment N 'sbesto s) chec! on)site register before wor! comme nce

9f the abo$e Company -e#uirements, personal hygiene regulations are perhaps the m important. ' typical set of personal hygiene rules are gi$en in Table .3 "f asbestos is present on the client&s site and will be disturbedDremo$ed, this must be done by a licensed contractor. Full details are a$ailable $ia the H(? publication &@anaging 'sbestos in Premises& 0www.hse.go$.u!DpubnsDindg334.pdf1. (ite maps and locations of designated areas 0location of wor! area, loc!er rooms, canteen, storage areas, first aid room, areas which are Yout of boundsY etc.1 should be pro$ided to the contractor. 9n a large or comple6 site, a map may be needed for indi$iduals to find intended wor! areas and it may also be necessary to install signposting. Consideration of the need for a contractors& compound for the security of contractorsY tools and e#uipment. For a large %ob which ta!es time, facilities 0e.g. telephones, water, sewerage1 may need to be pro$ided.

Easte remo$al arrangements need to be agreed. For small contracts it may be possible tt use e6isting facilities, though for larger pro%ects, specific waste collection may be re#uired for solid and li#uid wastes. The potential for pest infestation ris!s surroundX )waste collection areas should be considered and the client&s Pest Control company may need to be in$ol$ed. Ehether inside or outside the compound, areas will need to be allocated for storage of materials and e#uipment. 'rrangements need to be made for the remo$al of old e#uipment and building waste. "t is recognised that when walls and floors are disturbed, particularly in high ris! food manufacturing areas, pathogens such as $isteria monoc#togenes) which may be endemic in the subfloor and wall structure, become e6posed. Care has to ta!en in both the screening off of these areas from production and also how building materials are remo$ed. (ome food companies insist that, for e6ample, old &sandwich& wall panels are L co$ered in plastic o$erwrap before they are remo$ed through food production areas. Par!ing will be needed for contractor&s goods $ehicles and cars. 8uilding wor! may ha$e an effect on traffic patterns, both for $ehicles and people. "n some plants there is a need to confine YdirtyY $ehicles, e.g. farm mil! tan!ers, to specific routes. People also may bring in physical and microbiological contamination on footwear when passageways are common to both production wor!ers and contractors. -is! assessments may be re#uired to assess the effect of the building wor! on food product safety. 'ccess routes for the area being refurbished need to be established for e#uipment, materials, people and waste. The ideal is to ha$e access directly from the outside of the & building, but if a way has to be through a production or ingredient storage area, precautions may be needed. 'gain, ris! assessments may be re#uired to assess the effecs of the building wor! on food product safety.

V Contractors may need to wear client sourced protecti$e clothing, e.g. hats and beard snoods.
'rrangements will need to be made for their issue and either disposal 0if they are disposable1 or return for cleaning.

V "t is preferred that contractors use their own canteen facilities. "f this is not practicable, it may
be possible to ha$e special times of ser$ice for contractors andDor a designated seating area, partly because the nature of their wor! means that clothing is more li!ely to be soiled or greasy.

V Toilets and washrooms will ha$e to be pro$ided. ' decision is needed on whether the e6isting
facilities can be shared andDor e6tra pro$ision is needed.

11.6 Re!uiremen s "or he "ood manu"ac urer &y he con rac or

The contractor must assure the food manufacturer that the wor! that they will underta!e will be completed safely, hy gienically and with due regard to the protection of the food product. (pecifics could includeA)

V ' Company (afety Policy. Table

contractors wor!ing on site.

.4 is an e6ample of a handout that can be gi$en to

V 'de#uate insurance as re#uested by the Company (ecretary. V Confirmation of Construction "ndustry Ta6 conformity with details on type of card held, the
number and e6piry date.

V Proof of competency, for instance in operating specialist e#uipment 0e.g. @obile ?le$ated
Eor! Platforms 0@?EPs1.

V @embership of health and safety Ypassport& scheme for all contractors. These schemes co$er
general health and safety issues generic to construction wor!, though not all specifically co$er hygiene. They are a$ailable from, for e6ampleA)

V ?ngineering Construction "ndustry Training 8oard ) ClientDContractor Cational (afety

;roup 0CCC(;1 schemeA www.ecitb.org.u!

V Construction "ndustry Training 8oard ) Construction (!ills Certificate (cheme 0C(C(1>

www.citb.co.u!

V "nstitution of 9ccupational (afety and HealthA www.iosh.co.u! V Processing and Pac!aging @achinery 'ssociation 0PP@'1 www.ppma.co.u! V "f contractors do not ha$e the YpassportY, they may be re#uired by the client to undergo basic
hygiene training if they are li!ely to wor! in food processing areas.

V Training in andDor an understanding of food product contamination ha.ards and ris!

assessment. 11.. 1anagemen and super/ision o" con ac $or5 Lines of communication need to be established between contractors and the client to ensure that both parties share the common aim to get the %ob well done, safely, hygienically, on time and within budget. (pecifics could includeA) V ' client liaison officer should be appointed by the food manufacturer and a contract liaison officer should be appointed by the contractor so that a delegated point of contact is established on both sides.

V -e$iew meetings should ta!e place between the client and contractor at appropriately
scheduled inter$als to formally re$iew progress and to confirm that hygiene and good house!eeping standards are being achie$ed. "t is important that re$iew meetings stress both the positi$e and negati$e aspects of progress.

V ' security system needs to be agreed so that contractors can be easily identified. V The contractor&s super$ision should be e6pected to control their personnel in a way
appropriate to wor! in a food factory.

V Company employees should be able to challenge a contractor&s employee who is brea!ing site
rules, as outlined to contractors 0see .31.

V @anagers and super$isors of ingredient and pac!aging stores and also production departments
0areas1 YownY their areas. They therefore ha$e prime responsibility for all wor! going on in their areas. This means that they ha$e the responsibility for reporting any non)compliances, and the resulting action ta!en to rectify them, to the client&s senwi management, contractor&s liaison officer etc.

V ' record of all pro%ect non)compliances should be maintained by a designated person. This
record should be re$iewed by both parties and remedial actions agreed, impleme and signed off. This can be done $ia the client&s non)compliance log or through a separate record set up for the pro%ect. "n addition to the agreement of formal meetings and responsibilities, a general way of hygienic wor!ing should be adopted. Two areas are particularly importantA)

. 'ccess routes. Contractors should go to their wor! area by an appro$ed route. Ehere$er possible this route should not pass through a production area, and in some cases it may be possible t ma!e temporary entrances 0e.g. remo$ing windows or panels1 to allow direct access to wor! areas. "f in doubt, contractors should chec! with the client liaison officer.

3. "solation of the area. The ob$ious ha.ard is that of dust, although bro!en glass may also be a
problem sin fragments can fly considerable distances 0e.g. 0) I metres1. Dustproof partitions are therefore needed and should be full height, i.e. from floor to ceiling. These can be constructed from thin composite panels or hea$y duty polythene held in place by telescopic supports. "t may be possible to use wooden supports, pro$iding the supports are on the wor! area side of the partition and that suitable food safe materials, fully sealed, are presented to

the food manufacturing side. 'll %oints should be sealed with Wdtecpmvf, adhesive tape. With thick plastic e.g. pol!eth!lene" sheeting, care is needed to ensure that all %oints are securely taped and to a$oid punctures, tears or damage to the plastic. "t has been !nown for hot metal, e.g. from cutting or welding, to perforate plastic sheeting. Particular care must be ta!en when installing dustproof partitions at ceilings, steel beams 0framing1 and around ser$ice lines. The irregular openings need to be sealed, usually with plastic sheeting and adhesi$e tape. "n multi)storey areas, wor! on floors or ceilings must include appropriate protection of the ad%acent floor le$els. "f the re)routing of wor! access routes, or the isolation of wor!s areas is significant, the client may need to reconsider fire procedures. 9ther specifics could includeA) N "n an area being refurbished, there are li!ely to be implications for the $entilation or air) conditioning system because of dust. Bsually the system in the area is isolated or the input and output lou$res sealed. "t may well be necessary to pro$ide $entilation after painting or floor curing, but care must be ta!en to !eep odours away from air inta!es for the remainder of the plant. N Food processing e#uipment that can be remo$ed from the area to be refurbished should be. "f this is not possible, it should be protected against physical damage and dust by shielding, blan!ing off open pipewor! and the use of cloth or plastic sheeting. (eal with waterproof adhesi$e tape. N Contractors must not handle ingredients, pac!aging materials or finished goods themsel$es. "f they need to be mo$ed, contact the client liaison officer. N 'ny surface or substance li!ely to come onto contact with ingredients or foods or pac!aging materials must be of food contact grade, non)tainting and inherently unli!ely to cause contamination in use, e.g. by splintering. N Bse only appro$ed materials for temporary or permanent wor!. This includes cleaning materials, glues, paints etc. "f in doubt, contractors should chec! with the client liaison officer. This is to pre$ent the use of to6ic 0poisonous1 or tainting materials. N -eplace all trun!ing co$ers after use. The use of string to support trun!ing is forbidden. ) Do not refuel any motors within the building.

V N Put waste product in proper designated waste containers. Do not get rid of building,
construction, painting or similar waste down product drains or sewer

V -emo$e waste and rubble from the wor! area by the most direct route, through non)
production areas.

V Ce$er use ingredient containers, food product containers or pac!aging materials for anything
other than their proper purpose.

V Contractors should inform the client liaison officer of any incident which they thin! might
possibly contaminate or affect a product. This is e6tremely important to the cheat so that he can ta!e appropriate action 0e.g. isolate, re)wor!, destroy etc.1 as soon as possible.

V Ehen the wor! is completed, contractors should lea$e the area clean and tidy with protecti$e
screening and sheeting remo$ed. Contractors should inform the client liaisoa F officer before they lea$e the site so that they can arrange a hygienic clean)up operatic n

11.0 1anaging change Bnder ideal conditions, the design aspects of the building pro%ect are agreed at an early and are not changed throughout the construction phase. Bnfortunately howe$er, the client may wish to change design aspects of the pro%ect whilst building wor! is being underta!eV. a These changes may be simple, e.g. a different colour paint on the walls, or more ma%or, structural alterations, e.g. the fitting of additional doors into a high ris! production area. 9ften clients underestimate the impact of such changes on both the cost and timescales of the pro%ect and the contractual obligations of the contractor. For this reason it is necessary to ha$e a &Cotification of "ntent to Oary& 0C"O1 procedure which is used to $ary the proposed wor!s from the initial contractors proposal. This procedure both informs the client of the li!ely costDdelays of the intended change and also S protects the contractor against claims of breach of contract. The procedure should ta!e no longer than I days and a typical approach is detailed as followsA

. Ehen a potential $ariance is identified by either the client or any member of the pA team, the
re#uest has to be firstly chec!ed against the most current contractor&s proposals, by whoe$er recei$ed the client instructions or identified the $ariance. 't this point, whoe$er has recei$ed the potential C"O should refer the re#uest to the Pro%ect @anager.

3. "f it is found that the re#uest is a $ariance from the contractor&s proposals, an C"O fofl should
be raised and issued to the Pro%ect @anager 0P@1 and the Guantity (ur$eyor 0G(1.

4. The potential C"O should be discussed at the design team meeting and a design concept agreed) to the evens of a quic+ response /eing re#uired, the P@DG( shall issue the C"O to all team members for comment. :. 'll team members must respond to the C"O with details of any implications to the Programme and Design. The response must be made e$en %ust to confirm that there is no impact. I. Designers ma# need to pro$ide simple hand)drawn s!etches of the proposed wor! so that the C"O can be costed and the programme implications e$aluated. 'ny additional fees re#uired to cany out the C"O should also be identified for discussion with the P@. =. The G( will establish the C"O costs in con%unction with the subcontractors and in)house departments. J. The Planner will determine programme implications. @. The P@DG( will maintain the C"O register and determine whether the C"O is design de$elopment or attributable to a client change.
F CC$'4 2<<+

) <: )

<. "f it is considered to be a client change, the C"O will be issued to the client and the P@ will acti$ely chase for authorisation. 0. Drawings and other documents shall NOT be changed until the client has appro$ed the C"O andDor the P@ has instructed team members to proceed with the change. . 'll document re$isions shall contain the associated C"O number relating to the change.

Notes N 'ny change from the original ?mployer&s -e#uirement document or contractor&s proposals, whether it be positi$e, negati$e or cost neutral $ariance, shall constitute an C"O. N The.cSient&s Contract 'dministrator is the only person the main contractor should recei$e instruction from. N 8ecause of the re#uirement to follow the abo$e scheme, and the implications of costDtimescales, clients are ad$ised to restrict changes to a minimum

Hygienic Design. Construction and Layout of Food Processing Factories

X Ta&le 11.( )Dample Con rac orHs *ersonal Hygiene Rules )/eryone $or5ing in a "ood "ac ory has an o&liga ion o comply $i h he la$ and a responsi&ili y o $or5 sa"ely and o pro ec "ood "rom possi&le con amina ion

Contractors shouldA)

V Complete any re#uired client&s medical screening procedures. These screening procedures
ascertain whether operati$es are suffering from, or ha$e been in contact witn. any infectious disease which may be transmitted by the food product.

V "nform your client liaison officer if you are suffering from infectious diseases 0e.g. s!in
irritation or boils, upset stomach, $omiting or diarrhoea1 and are wor!ing in a food production area. ^ou should not remain at wor! on this site in a production area, and in some plants a medical certificate may be re#uired to confirm that the illness has been cured before re) commencement of wor!.

V @aintain a high standard of personal cleanliness. 'lways wash your hands before
starting wor! and after using the la$atory.

V Co$er hand wounds with an appro$ed coloured 0usually blue1 metal detectable plaster or
bandage 0issued by the client1 when wor!ing in or near production areas, open ingredients or pac!aging materials

V -eport all in%uries to the medical departmentDfirst aid room. "f food handling e#uipment or
ingredients, food product or pac!aging materials are in$ol$ed, inform the client liaiseV officer #uic!ly 0telephone 666, bleep 661 so that appropriate action may be ta!en as soaa as possible.

V Eear full, clean, protecti$e clothing. 8oiler suits or o$eralls should be regularly laundered and
close fitting with .ips or metal studs. 8uttons or loose fasteners are not acceptable. The client may insist that only the client&s protecti$e clothing, is worn in food processing areas.

V Hair 0e6cept in designated areas1 must be !ept co$ered either by a hard hat 0where
appropriate1 or a soft cap. 8eards must be co$ered by a snood. ?ar defenders must worn in designated Yhigh noiseY areas. Fingernails should be short and un$arnished aad no false finger nails, eyelashes etc. should be worn.

V (mo!ing, eating or drin!ing is allowed only in designated areas. (pitting is forbidden

anywhere on site. Consumption of alcohol on site is forbidden at all times

V Co %ewellery or watches, e6cept for a plain wedding band and YsleeperY earrings, are Z" be
worn in areas where open ingredients or pac!aging materials are stored or in production areas or departments.
F CC$'4 2<<+

Ta&le 11.6 )I+1*-) H)+-TH E S+F)T4 INDUCTION H+NDOUT Si e Sa"e y Cons rain s and Si e Rules'

. No persons are permi ed on si e un il HES induc ion is recei/edJ howe$er, inducted personnel may escort $isitors. 3. +H Super/isors "or 7or5s *ac5age Con rac ors are o su&mi la&our re urn shee s o Si e 1anagemen . This procedure will enable effecti$e Yroll)callY following e$acuation. 4. Hard hats T safety footwear mus &e $orn in all areas of the site. :. "nduction labelDstic!er is to be displayed on side of safety helmet. I. 'll operations underta!en on site shall be in accordance with tas! specific 1e hod S a emen # Ris5 +ssessmen # COSHH +ssessmen which will ha$e been $etted by the Principal Contractor prior to wor!s commencing. 'ny stated PP? re#uirements mus &e implemented. =. 'ny wor! underta!en in dangerous breach of @ethod (tatements andDor Health T (afety -egulations is li!ely to lead to dismissal of the offending indi$idual0s1D super$isor0s1D contractor0s1. J. The Principal Contractor has the authority to issue a KHeal h E Sa"e y 7arning No iceK to any indi$idual or contractor. -epeated offences will lead to dismissal.
=$ 'ny person found smo5ing in the building will be dismissed.

<. 'ny person found urina ing in the building, other than in toilet pro$ided, will be dismissed. 10. 'ny person found de"acing or damaging any item or component comprising part of the wor!s, safety e#uipment, or Eelfare Facilities will be instantly dismissed

.eral In"orma ion and Re!uiremen s'

'll matters should be addressedDreported to the (ite @anager, including any health an safety concerns. 'll accidentsDin%uriesDdangerous occurrences mus be reported to the (ite @anager at the earliest opportunity. The &'ccident 8oo!& is located in the (ite 9ffice. H.(.?. notification will be underta!en by the Principal Contractor when re#uired. @embers of the (ite @anagement Team are appointed First 'iders. The First 'id !itA located in the (ite 9ffice. The Si e No ice ,oard is located in the CanteenD@essroom. Principal Contractor (afety Policy, safety notices, and other information are displayed. 'ny person re#uired to operate plant must produce a licence. 'ny defecti$e plant or e#uipment should be reported to the (ite @anager. There are no particularly dangerous acti$ities to be underta!en, but do be aware of other persons wor!ing abo$e, below, or alongside. 4ou mus comply $i h $arning no ices# and must not enter cordoned)off areas. 0)$olt electrical tools and e#uipment are preferred. 3:0)$olt may be used with a suitable -CD, and Principal Contractor authorisation. "t is re#uired that all areas of the $or5place are maintained in a sa"e# idy# and clean condi ion a all imes. +ll con rac ors are re!uired o clean up heir $or5 areas a D+I-4 ,+SIS. Failure to comply will result in &Clean up& notices being issued. Par!ing is pro$ided in the designated areas only. The client&s staff car par! is ou ;o"; &ounds. Fire Sa"e y Fire points are situated at $arious points around the building and are identified on the emergency fire escape plan which is displayed in the CanteenD@essroom. (ite 9ffice, and at each indi$idual Fire Point location. ?6tinguishers are also located in the CanteenD@essroom. and (ite 9ffice.

3.

4.

:.

I.

=.

J.

L.

<.

F CC$'4 2<<+

3.

(mall fires may be fought with the e6tinguishers pro$ided. "f the bla.e cannot be controlled, raise the alarm 0shout F"-?Dacti$ate Mla6onDstri!e brea!)glass1, and e6it the building $ia the fire escape e6its. "f alarm sounds, e6it the building $ia the nearest, safe, fire e6it door, and proceed to the Fire 'ssembly Point, located in the site car par!. Do no return to the building until notified that it is safe to do so by (he @anager, or Fire 8rigade. -oll call will be made using the Ysigning)inY sheet. "f persons are missing, the (ite @anager will search the building, if safe to do so. or will ad$ise the Fire 8rigade on arri$al. Ho 7or5 *ermi s are re#uired for any bare flame acti$ities, and can only be obtained from the (ite @anager.

4.

:.

7el"are Facili ies' 1essroom and Toile s'

Drin!ing water, a !ettle, sealing and tables are pro/ided in the Canteen @essroom. Please place rubbish in dus &in pro/ided a he end o" eLery &rea5. Please use the toilet and $ashroom in a ci/ilised manner.

3.

1(. UND)RT+2) )8UI*1)NT INST+--+TION

' programme of plant installation should be drawn up which ta!es account of the following !ey interfaces with the builder, the ser$ices suppliers and any e6isting production.

3.

-arge e!uipmen

;enerally, items of significant weight or larger than .I m in any direction will re#uire a assessment and method statement for their deli$ery, placement and installation. The larger the item the more li!ely it will need to be installed during the factory construction period rather than after hand o$er. Large items may need wall or roof sections to be left open or opened and sealed to allow craneage or transport to the final area. Deli$ery may ha$e to &e planned around time related use of access roads, loading D unloading areas or lorry par!s under control of either the contractor0s1 or the client&s business.

The machinery or prefabricated sections may need to be lifted within the building using a crane or hea$y for!lift. Consideration should be gi$en at an early stage to the pro6imity of ser$ices such as bas!et, tray, conduit, lights, fans, ducts, pipewor! etc. (ections may ha$eX be remo$ed or left to a later date to enable plant installation. Consideration should be gi$en to protecting completed flooring on the plant access routes u pre$ent damage or staining.

3.3 Ser/ices ins alla ions

@a%or items such as water tan!s, e$aporators, transformers, compressors, switch gear, distribution boards, air handling units and pipe rac!s will usually be re#uired to be incorporated in the building wor!s so that the necessary ser$ices are in place and are reach to be connected when the plant is deli$ered. These may all impact on the programming ofY the wor!s, to ensure that trades are gi$en sufficient safe access to complete their tas!s.

3.4 *ene ra ions

Plant or ser$ices may re#uire full or partial access through walls, floors, ceilings or roofs, schedule of all penetrations should be de$eloped and where necessary designed and de so that the builder can prepare them. ?ach plant supplier should be as!ed to pro$ide theV re#uirements to the building designer for detailing. "t may be necessary for the builder to return to the site to complete the penetrations and ma!e them both weather)tight and $ermin proof after the plant installation.

1(.. Heal h and sa"e y issues 9n most sites the &Principal Contractor& will be the builder and he will control the H T ( procedures to be adopted. Plant suppliers may not be &in contract& with the builder but with the Client. "t is imperati$e that the Client aligns each plant supplier to the &Principal Contractor& for all Health and (afety control. This will include deli$eries, access routes, hoisting, welding, wor!
F CC$'4 2<<+

at heights and amenities for the staff. 't some stage in the programme, the builder will wish to withdraw from the site when the building has been &handed o$erY. 't the same moment they will usually relin#uish their role as &Principal Contractor&. "f plant installations are still continuing, then under the CD@ -egulations, an alternati$e person must be appointed by the Client 0who may appoint himself1 who has sufficient understanding and resource to ta!e on the role.

1(.0 Hygiene issues and e!uipmen pre;cleaning

'round the time of initial plant commissioning, the site should impose the hygiene management procedures that will be used in manufacturing. 'n audit of all building and plant areas should be underta!en to identify all hygiene issues and these may then be addressed ) usually by a specialist industrial cleaner. Eith respect to new e#uipment, there are li!ely to be few microbial pathogens associated with the e#uipment, though the e#uipment may contain general engineering debris 0oils, greases, swarf1 that may need to be remo$ed before the e#uipment enters the building. For e#uipment mo$ed from another company site, or purchased secondhand, it may need to be refurbished or modified prior to use and it is essential that it is thoroughly cleaned and disinfected 0most suitably incorporated with a ma%or strip down1 before it enters the production areas. There ha$e been many e6amples of pathogens being introduced into new factories from e#uipment being transferred from other food manufacturing sites.

1(.< *rogramme and cos To secure the fastest route to production and hence commence the paybac! it is usual to start plant installation whilst the building is still under construction. Howe$er, there will be a cost implication, sometimes #uite se$ere, due to the delay and disruption that will ine$itably be caused to the builder, who may, in turn, ha$e to delay and then accelerate his wor!s

,Ins alla ion The potential for well designed and constructed e#uipment to be operated in a hygienic manner may be easily impaired by inade#uate attention to its location and installation. "n generalA)

V 'll parts of the e#uipment should be installed at a sufficient distance from walls, ceilings and
ad%acent e#uipment to allow easy access for inspection, cleaning and maintenance, especially if lifting is in$ol$ed. ' minimum distance of l)3m is recommended.

V 8ase plates used to support and fi6 e#uipment should ha$e smooth, continuous and sloping
surfaces to aid drainage. They should be co$ed at the floor %unction. 'lternati$ely, ball feet should be fitted.

V For e#uipment not installed flush to the floor, there should be sufficient height 0minimi66
300mm1 below e#uipment to allow ade#uate access for e#uipment inspection, cleaning and maintenance, and for the cleaning of the floor.

V 'ncillary e#uipment, control systems and ser$ices connected to the process e#uipment should
be located so as to allow access for maintenance and cleaning.

V Pipewor! and $al$es should be supported independently of other e#uipment to reduce the
chance of strain and damage to e#uipment, pipewor! and %oints. Ehere mounted agairrfi a wall, a minimum gap of I0mm should be left to allow space for cleaning.

3.L )!uipmen ins alla ion chec5lis

"t is useful for contractors to produce an e#uipment installation chec!list to facilitate obtaining the pertinent information re#uired from the e#uipment manufacturer 0si.e, weight, ` ser$ices etc.1 and to help co)ordinate the installation programme. ' typical e6ample of an installation chec!list is shown in Table 3.

Ta&le 1(.1 )!uipmen Ins alla ion Chec5lis . Ris5 assessmen s:me hod s a emen s ) Has the rele$ant documentation been forwarded and accepted &e"ore any e#uipment is deli$ered to siteF 3. Coun ry o" origin ) There may be procurement and deli$eryDshipping restrictions 0i.e. customs1. 4. O"";loading measures ) 8e mindful that some e#uipment can be loaded at source onto $ehicles using special measures 0e.g. e6tended for!s, craneage etc.1. :. Responsi&ili y "or o"";loading ) Preferably the e#uipment installer. I. +gree machinery ser/ices ma riD ) Finalise and agree matri6 with e#uipment supplier well in ad$ance of deli$ery. 'gree scope of wor!s, demarcation points and distances. =. )!uipmen dimensions ) will it fit through any doc! le$eller openingF J. )!uipmen $eigh ) is there a low or high centre of gra$ityF L. )!uipmen access ) route through building to be agreed at design stage and any temporary openings to be detailed. Particularly important where e#uipment is to be located on st floor areas. Temporary hardcored ramps to be considered as well as openings through e6ternal cladding if e#uipment is too large to fit through any industrial doorsDdoc! le$ellers. <. Rou e ) Carry out a dilapidation sur$ey on ceilings, walls T floors along the machine access route and issue a copy to the e#uipment installer for their reference and agreement 0copy to be gi$en to Client1. 0. *rogramme ) Consider the $ulnerability of the floorsDwallsDceilingsDser$ices and the impact any e#uipment installations would ha$e on these. 'rrange any protection and agree dates with ade#uate notice, and ensure area is clear and complete if possible. . 9isual chec5 ) Chec! and record any damages to pac!aging or e#uipment on arri$al. 3. Temporary po$er re!uiremen s ) 're there ade#uate numbers of transformers a$ailable for tools and tas! lightingF "f the e#uipment installer is an o$erseas contractor there must be ade#uate pro$ision for 340O supply, or ensure that they arri$e on site with 0O tools. 4. ,uilders $or5 ) "dentify plinths and any supports re#uired, as well as openings in wallsDceilings etc. "dentify responsibilities for carrying out associated builders& wor!.

:. Dus eD rac ion ) ?nsure that ade#uate measures are in place if e#uipment has to be bolted to finished floors. I. *os ;ins alla ion ) 'gree training dates, operation and maintenance information, including spare parts lists

F CC$'4 2)G,+

) 0I)

16. *ROM)CT CO1*-)TION

Following the construction of the processing facility and the installation of the e#uipment, it is now possible to begin initial trials to assess whether the facility can produce the desired food product in a safe, hygienic and efficient manner. To allow this to happen, howe$er, postages ha$e first to be underta!en. The initial stage is a thorough cleanup of the e#uipment and process areas to allow an assessment of the condition of the building and the operation of the e#uipment and ser$ices. The second stage is the identification of any building and e#uipment faults, their successful repair, and the hando$er of the buildingDe#uipment from the contractor to the client.

16.1 *lan and e!uipmen cleanup Prior to any production trials it is essential that all contamination be remo$ed from the e#uipment and processing en$ironment toA

V pre$ent such contamination getting into the product V protect pumps, mi6ers and other e#uipment from damage caused by such debris.
"t is ine$itable that $isible contamination will be present, including swarf, welding rods, pieces of wire, unused fastenings 0e.g. nuts, bolts, washers1, builders& materials, rubble, dust, dirt, small and large pieces of plastic, pac!aging, cigarette ends, cloth fibres, soilDdebris brought in on footwear, oil and grease. "n addition, &in$isible& contamination may be preser6 such as debris bloc!ing drains or present in HO'C ducting. ' cleanup strategy is re#uired, therefore, to ensure the remo$al of all contamination, and thV should be underta!en in a manner in which the contamination itself is not spread into food processing e#uipment. ' suggested strategy is as followsA

Pic! up all gross debris at floor le$el using manual 0brush and sho$el1 or $acuum techni#ues. Co water should be used at this stage as it spreads contamination too far. 9nce the floor is free from debris, the process lines and o$erheads 0e.g. using step ladders or &cherry pic!ers&1 can be safely accessed. Pic! up gross debris from process lines using manual or $acuum techni#ues ) again no water should be used at this stage as it may spread contaminants further into the fabA of the process lines.

3.

F CC$'4 2<<+

) 0= )

4.

Co$er the process lines and electrical supplyDmonitoring units to protect them from ingress of contaminants and cleaning fluids. :. Bsing appropriate access e#uipment, manually clean o$erhead structures 0e.g. beams, light fittings, ledges or pipewor! where nuts, bolts, washers etc. may ha$e been left1 and HO'C ductwor!. 8y cleaning at the highest le$els first, nothing should subse#uently &drop& into the processing e#uipment. This is initially a dry cleaning operation using manual techni#ues and $acuum. "f, howe$er, these techni#ues do not remo$al all soiling, wet cleaning techni#ues will ha$e to be used. From this stage on, all water used should be of potable #uality. (imilarly, all cleaning and disinfectant chemicals used must be food grade and from a reputable supplier. They may not necessarily be the chemicals finally chosen for routine cleaning and disinfection 0see 4.41 as they will be primarily chosen to remo$e oils, grease, lubricants etc., but their use at this stage allows the food product to be processed in initial trials to be &tasted& if desired. I. Eet clean the drains followed by the walls and the floor using appropriate detergents and disinfectants as re#uired. This should produce a clean wor!ing en$ironment in which to tac!le the processing e#uipment. =. -emo$e all the process line co$ers, isolate all e#uipment and dismantle the e#uipment as necessary to pro$ide total access for cleaning fluids. J. Clean all processing lines using a rinse)detergent)rinse)disinfectant)rinse strategy. For li#uid handling e#uipment, put water down pipelines dropping to waste on the floor. Do not initially operate pumps unless there is ade#uate protection, e.g. by a sie$e immediately upstream. "f pumps are not used and pipewor! does not drain naturally to the floor, disconnect the lines at the lowest point and flush from a hose to remo$e debris. Clean electrical supplyDmonitoring units with damp cloths or alcoholic wipes. 9nly use water hoses if the units are suitably protected 0*"P==1. L. Following cleaning, fully inspect the processing lines. This may re#uire further dismantling of pipewor! etc to ensure that debris has been remo$ed. "f debris is remaining, the line should be recleaned and or reconfigured as appropriate. C. Clean any residual debris off the floor in a way that does not spread the contamination bac! onto the processing e#uipment. 0. Finally, following any reconfigurationDmaintenance wor!, reclean the process lines again to ma!e absolutely sure that contamination has been remo$ed. 't this point the plant cleaning and hygiene specialist needs to be in$ol$ed because the area and its e#uipment will need $ery thorough cleaning before production commences.

. Discard the first product through in subse#uent production trials as, occasionally, $iscous product may mo$e debris that thin li#uids such as water or detergents fail to mo$e. 16.( ,uilding and e!uipmen snagging lis s and con rac or:clien hando/er Practical completion of a pro%ect is achie$ed when, in the opinion of the architect or contr]. administrator, completion of the wor!s has been achie$ed. ' &Certificate of Practical Completion& is issued confirming the date of completion, an e6ample of which is shown in Figure 4.4. Prior to practical completion, the client&s representati$e 0architectDPro%ect @anager1 inspe).A)the wor! carried out by the contractor. ' schedule is prepared on a room by room basis, an e6ample of which is shown in Figure 4. . This is issued to the contractor for his action. Prior to the Y(nagging "nspectionY the contractor should ha$e carried out his inspection to enable the wor!s to be offered to the architect in a satisfactory state. 't the same time as general construction snagging is ta!ing place, the ser$ices 0mechanical, electrical and refrigeration1 should be inspected and snagged. (imilar schedules are drawn up and issued. The final balancing of the ser$ices may not ta!e place until the en$ironment has reached its wor!ing capacity. "t is sensible to complete as many snagging items as possible before accepting the wor! a)YPractically CompleteY as it is $ery disrupti$e to future production schedules if contractor)need to enter the production areas to complete any outstanding wor! or ma!e good any defects identified in the snagging sheets. To aid this purpose, indi$idual snagging lists can be signed off, an e6ample of which is shown in Figure 4.3. Practical completion can be achie$ed and certificates issued with a schedule of outstanding items, howe$er, if the client and the contractor agree it. The acceptance and issue of the Practical Completion Certificate releases the contractor of certain obligations, most importantly the insurance of the building. The insurance of the building after the date of practical completion is the responsibility of the client. The client usually carries building insurance for refurbishment wor!s to e6isting premises. Phased practical completion and snagging can be agreed with the client to allow the installation of manufacturing e#uipment. Partial possession is gi$en to the client but the YsiteY remains the responsibility of the contractor. Careful monitoring of those areas Yhanded)o$erY is re#uired as damage caused by the e#uipment installers 0e.g. floors, walls, !erbs1 is then the responsibility of the client.

F CC$'4 2<<+

) 0L )

' similar snagging inspection is carried out, usually one year later. This is !nown as the &Defects Liability "nspection&. 'ny defect that has occurred during this period is the responsibility of the contractor. Bnder &Partial Possession& this defects liability period begins from the date a particular area was occupied. Damage caused during the normal operation of the building is C9T a defect. The contractor must be gi$en reasonable access to ma!e good any defect. Bsually a detailed programme is drawn up between the parties to coincide with windows of opportunity in production. 16.6 Clien commissioning Following the issue of the Practical Completion certificate, the client has numerous tas!s to underta!e before the product is ready to go to mar!et. "t is beyond the scope of this chapter to co$er all these tas!s, though the following gi$es information on some of the !ey points. Health and safety The factory manager must ensure that a Fire -is! 'ssessment is carried out in the new building or e6tension. This is a legal re#uirement under the Fire Precautions 0Eor!place1 -egs <<J 0(" <<J no. L:01. ' new or re$ised Fire Certificate may be re#uired and ad$ice should be sought from the local Fire 9fficer. Please note that whilst 8uilding -egulations 'ppro$al will ha$e been addressed by this stage, it is the client&s responsibility to ensure that a Fire Certificate is obtained. The assessment should identify all areas that re#uire impro$ement or action. ' Fire ?mergency Plan must be de$eloped and implemented and all employees must be trained in the Fire Procedures needed to safely e$acuate the building. The @ain Contractor must hand o$er the Fire Detection andDor Fire 'larm system to the client and ensure that sufficient employees with authority are trained in the use andDor maintenance of the system. The client must arrange for the system maintenance to be underta!en at the correct inter$als and for the Ycall outY emergency system to be subscribed. The client must ta!e the 9peration manuals into safe!eeping. 'fter the installation of all the processing e#uipment and commissioning, it may be necessary to install further ?scape (ignage, ?mergency Lighting, 8eacons, (ounders, protected routes and the li!e. This is because the full si.e, shape, and noise of the processing e#uipment may ha$e reduced the effecti$eness of the Fire ?#uipment originally designed and installed. (ecurity The client must control access onto the premises to pre$ent unlawful entry and possible sabotage or spoilage. Depending on the si.e of the premises the client may use CC

T'll points at which food products are accessible within the premises 0i.e. not within the factory building1, such as water tan!s or where deli$ery hoses are necessary for bul! ingredients inta!e, must be either fenced off or ha$e padloc!ed inspection co$ersDend caps " pre$ent adulteration.

(taff and training The client may need to employ new staff on the process line or e$en for office based functions. This is a time consuming process and early thought is needed to ensure that ad$ertising, inter$iewing, selection, induction and training is completed to the correct time frame for plant commissioning. For all food processing operations, medical screening of new staff should be underta!en to ensure that they do not present a microbiological ris! to the product. Cew staff must be trained to the necessary le$el in Food Hygiene Procedures and a record o the training must be !ept. Cew and e6isting staff will ha$e to be trained in the operation)and procedures re#uired for the production $olume planned. The e#uipment supplier should assist with this tas! and a record of the training recei$ed must be !ept by the client and counter)signed by the operati$e.

;ood manufacturing practices 0;@Ps1 Pro$ision must be made to ensure correct operati$e personnel hygiene. Production trials in which product will be consumed by food handlers should not be underta!en before operati$es are appropriately clothed and can underta!e rele$ant personal hygiene routines, e.g. toilet facilities and handwashing. The client must ensure that house!eeping 0during production1 and cleaning and disinfection procedures 0post production1 are de$eloped to clean the factory and the processing e#uipment. @any of the larger cleaning supplies companies are able to offer assistance and e$en to underta!e the de$elopment of the cleaning programme. The client must still audit their wor! programme.

The cleanliness of the factory perimeterDyard areas should also be included. The client must ensure that procedures bor regular cleaning are de$eloped. This should include at least annual cleaning of all underground drainage systems and emptying of fat interceptors and petrol interceptors as necessary. The client needs to consider how best to minimise the ris! of pest infection on site. This may in$ol$e training their own operati$es in pest control or, more usually, employing Pest Control

Hygienic Design. Coo

pro$iders. 'gain, production trials in which product will be consumed should not be underta!en until all pest control de$ices are installed. 9nce production trials ha$e begun, solid waste disposal 0primarily waste pac!aging and product1 should be considered. This is li!ely to in$ol$e the contracting of a waste disposal company and consideration for the siting and control of waste collection de$ices 0e.g. s!ips1. Process plant commissioning <Dr# < commissioning The client should ha$e recei$ed the operation and maintenance 09T@1 manuals and the C? certification and ha$e been trained in the plant operation. The plant should then be run, without product whene$er possible, so that any ob$ious mechanical, electrical or control issues are identified and brought to the attention of the supplier. "t has been !nown for motors to ha$e been cross)wired so that they operate in the re$erse direction and pipe and $al$e connections to ha$e been made incorrectly. 's these are rectified the client may wish to chec! the efficiency of the e#uipment, but without product this may not be possible. (ometimes it happens that a piece of e#uipment has to be commissioned before the refurbishment is complete. This is where good communications and relations with the contractor0s1 are more than useful. (uch commissioning needs careful planning but unless contamination ris!s are, and can be shown to be, as low as that of normal production, anything produced should be #uarantined for appropriate disposal. This is li!ely to be by dumping under super$ision to be sure that it is not inad$ertently used. (imilarly, there may be issues with the late commissioning of e#uipment. This may ha$e implications on the segregation andDor cleaning of this e#uipment if product is being processed. <1et< commissioning The client should ha$e completed the factory and plant cleaning so that product could be treated as saleable. The ingredients D raw materials and pac!aging are now introduced at th

F CC$'4 2<<+

appropriate times into the process. The finished products must be e6amined and, if necessary, analysed to ensure compliance with the specification limits. These tests may include colour, te6ture, weight, $olume, shape, chemical composition, ;@9 analysis, microbiological analysis, nutritional analysis and pesticide residue analysis. The process plant may then need to be ad%usted or controls amended to ensure that product is correct in all respects. 9nly when the client has carried out his due diligence re#uirements should the product be offered for sale to the public.

Eor! planning D scheduling The client must de$elop a method, either manually or by computer, to ensure that the proeec lines are run at their most efficient. @ost food production lines produce se$eral products and their shelf life will dictate the production fre#uencies. "f more staff are re#uired at product change) o$ers then these could be planned for change)o$er periods when two shifts could be present. Long product runs could be arranged for night shifts if appropriate. The client must ensure that the plan produces all the necessary data for raw materials and pac!aging procurement in sufficient time for ordering and deli$ery.

H'CCP 'n initial H'CCP plan will ha$e been underta!en as part of chapter 1, Define product and business plan. This can now be updated with the establishment of practical process flows and operations.

Guality systems ' Guality @anagement (ystem should be de$eloped which comprises of a #uality policy statement, information on the company&s organisational structure, responsibilities and management and a #uality manual which details all wor!ing methods and practices critical to product safety, legality and #uality.
F CC$'4 2<<+

"n addition to plant structure and ;@P&s, a #uality manual would typically co$er product design, process control, control of physical and chemical product contamination ris!s, control of non) conforming product, product release, e#uipment calibration, product analysis, shelf life testing, ingredient and product specifications, purchasing, documentation, record !eeping, complaint handling, internal audits, correcti$e actions and product recall.

Figure 16.1 )Dample o" a room &y room &asis snagging lis

snagging list
*ROM)CT' *R)S)NT' Da e' O D U ) T S T + N D I N 3 F ) C T I 9 ) CO11)NTS Bnable to inspect flooring

ROO1 NO' CI* ROO1 N+1)' IT)1 NO' CoteA all cleaning outstanding @astic seal to wall base channelDconc. !erb Lea!ing pipewor! to EH8 abo$e !erb Eall to energy centre ) fill gap to birdsbea!D!erb 8und ad%. energy centre ) fill gaps to inner birdsbea! 'll unfinished cone, !erbing 8irdsbea! to top of co$ing to floor finish ) mastic all corner %oints Complete floor co$ing at remo$able panel position 8und to whey wall ) all comments as : T = Merbing to remo$able panel ) @.;. !erb finish and clean birdsbea! Complete installation of drench showers D)SCRI*TION OF IT)1S

3 4 : I = J L < 0

(uggest co$er flashing

(uggest sealer coat )client to ad$ise

Figure 16.( Cer i"ica e o" Comple ion o" 1a5ing 3ood De"ec s

"ssued byA

H. Potter 'ddressA S. (mith Foods Limited Ha.el '$enue ;reenfields "ndustrial ?state Hogwarts Eorcestershire E- 0 4@P S. (mith Foods Limited Hogwarts site Sob -eference ) I004 Certificate CoA "ssue DateA :th February 3003

?mployerA 'ddressA

ContractorA S. 8loggs Construction Ltd 'ddressA Lane. @ortarfield, 8ristol 8- CM( Eor!sA

Contractors Court, 8uilders

Bpgrade and refurbishment of e6isting facility including construction of new

Loading T @arshalling 'rea (ituated atA S. (mith Foods Limited, Hogwarts site ContractA 'mendments Bnder Clause 3.I of the abo$e)mentioned Contract, " Hereby certify that all the defects, shrin!ages or other Faults ha$e been made good. To be (igned by or for The "ssuer named abo$e SCTD"FC <L with

(igned............................................................?mployer DistributionA 9riginal ) S. 8loggs Construction Ltd CopyA S. (mith Foods Limited. CopyA @ain File Figure 4.3 Certificate of Comple ion o" 1a5ing 3ood De"ec s

"ssued byA 'ddressA

H i ) . S. (mith Food) Limited ;reenfields "ndustrial ?state Hogwarts Eorcestersriire E- 0 4@P

?mployerA S. (mith Foods Limited 'ddressA Hoewar.) she

Sob -eference ) I004 Certificate CoA "ssue DateA :th February 3003

ContractorA 'ddressA

S. 8loggs Construction Ltd Contractors Court. 8uilders Lane. @ortarfield. 8ristol 8- CM( Bpgrade and refurbishment of e6isting facility including construction of new Loading T @arshalling .'rea

Eor!sA

(ituated atA

S. (mith Foods Limited. Hoswarts site

ContractA

SCT^"FC <L with 'mendments

Bnder Clause '-6 of the abo$e)mentioned Contract. " Hereby certify that all the defects, shrin!ages or other Faults ha$e been made sood. To be (igned by or for The "ssuer named abo$e

(igned............................................................?mployer DistributionA 9riginal ) S. 8loggs Construction Ltd CopyA S. (mith Foods Limited. CopyA @ain File Figure 16.6 Cer i"ica e o" *rac ical Comple ion
Sob -eference A P-9S?CT P-?@"?- ) I004 Certificate Co. 0 "ssue Date 33nd 'ugust 3000

"ssued byA 'ddress

H. Potter S. (mith Foods Limited Ha.el '$enue ;reenfields "ndustrial ?state Hogwarts Eorcestershire E- 0 4@P S. (mith Foods Hogwarts site

?mployer 'ddress Contractor 'ddress

S. 8loggs Construction Ltd Contractors Court. 8uilders Lane, @ortarfield, 8ristol 8- CM( Bpgrade and refurbishment of e6isting Facility including construction of new Loading T @arshalling 'rea S. (mith Foods Limited, Hogwarts site

Eor!s SCTD"FC <L with 'mendments (ituated Contract at

Bnder the terms of the abo$e ) mentioned Contract, " D Ee hereby certify that Practical Completion of Bpgrade and refurbishment of e6isting Facility including construction of new Loadi @arshalling 'rea 0e6cludingA)8utchery 0 , Feedstoc! "nta!e 0:. 9rganics 0I T Canteen 0I:, T -efurbishment of e6isting Loading Doc! 0441 was achie$ed on A 33nd 'ugust 3000 ' list of the outstanding and defecti$e wor!s at Practical Completion was agreed at the time between Foods Ltd. and (nagfree Construction, a copy of which is attached The 3 months defects liability period will e6pire onA 3 st 'ugust 300 To be signed by or for the "ssuer named abo$e

(igned A ................................................................................H. Potter. S. (mith Foods Limited (igned A ..........................................,...................................-) 8lac!adder. S. 8loggs Construction DistributionA 9riginal S. 8loggs Construction " Copy ) H. Potter, S. (mith Foods Limited

;ood strategies and effecti$e management can reduce the ris! of food product contamination. These are outlined in sections .3) .: which consider the re#uirements for contractors by the food manufacturer, re#uirements for food manufacturers by contractors and ongoing contract dialogue. Three points, howe$er, can be highlighted at an early stage as being critical to the success of the contract.

. @ore than anything, good communications between the contractor and food company are
essential and fre#uent re$iew meetings need to ta!e place to ensure the success of the pro%ect. ?fforts should be made to reduce the Yus and themY syndrome. 3. Contractors must recognise that whilst on)site, they must regard themsel$es as food wor!ers and beha$e accordingly. 4. Food manufacturers must recognise that the contractors ha$e similar e6pertise in their industry as ihey do in theirs and that sufficient time and faeihties ha$e to he pro$ided to enable the contractors to complete their tas!s professionally and on time.

11.( Re!uiremen s "or con rac ors &y he "ood manu"ac urer

The food manufacturer 0client1 should pro$ide to the contractor all the necessary information about its business to enable the contractor to wor! safely and reduce product contamination, and all facilities necessary for the contractor to complete the wor! professionally and effecti$ely. Ehere$er possible, a separate, self)contained compound should be pro$ided with all necessary amenities. (pecific re#uirements could includeA)

V The client&s Health and (afety at Eor! Policy V The clients& Company -ules and -egulations, and specific sections of the Company&s
Guality @anual, co$ering for e6ampleA

V 'ccess V Cranes ) ade#uate insurance V (ecurity V Fire policy V 'ccidents ) action and reporting V ;lass, metal and other foreign body policy V Personal hygiene V ?n$ironment V 'sbestos ) chec! on)site register before wor! commences.