Sepp Messmer

Designing of Food Processing
Plants for Optimum Hygiene and

Food Safety
Josef Memer
PHT
Presented by Delne Koekemoer
PHT-SA
AVI AFRICA 2011
2 June 2011
Designing of Food Processing Plants
for Optimum Hygiene and Food Safety
Introduction
Plant layout & Plant flow
Plant construction
Equipment
Cleaning and disinfection
Maintenance
Personal hygiene
Training
Summary
Conclusion
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Introduction
Hygiene refers to the set of practices associated with the
preservation of health and healthy living
Derives from the Greek word hygeia the Greek goddess of
health, cleanliness and sanitation.
Medical hygiene
Food hygiene
Personal hygiene
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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For optimum hygiene:
A high standard of hygiene is a prerequisite for safe food
production, and the foundation on which HACCP and other
safety management systems depend
There should be measures in place to prevent contamination of
food from a physical, microbiological or chemical sources
It is important to maintain a clean and wholesome environment
during slaughtering, processing, packaging and storage
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Designing a Food processing plant
Site
Size, Location, Properties
Flexibility
Further expansion, material flow, fixed building parts
Structure
Hygiene
Building quality
Environmental aspects
Ecological aspects
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Product flow
Work flow patterns and plant layout
Handling of food
Personnel flow
Factory entrances
High risk areas
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Work flow patterns and plant layout
Kotchevar and Terrell (1977) listed 8 principles for
the efficient flow of work in food production areas:
1. Functions should proceed in proper sequences
directly, with a minimum criss-crossing and back
tracking
2. Smooth rapid production should be sought with
minimum expenditure of worker time and energy
3. Delay and storage of materials should be
eliminated as much as possible
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4. Workers & Materials should cover minimum
distances
5. Materials and tools should receive minimum
handling, and equipment minimum worker
attention
6. Maximum utilization of space and equipment
should be achieved
7. Quality control must be sought at all critical points
8. Minimum cost of production should be sought
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GUIDELINES FOR WORK FLOW
Straight line process flow is regarded most efficient
Layouts should minimize the chances of
recontamination of a semi-processed or processed
food by unprocessed or raw material
Cross contamination must be effectively prevented
Raw materials and processed foods must be kept
apart and far removed from each other
Linear flow
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Routes of Contamination:
Product
Air
Water
Environment
People/food handlers
Equipment
Drains
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GUIDELINES FOR PEOPLE FLOW
Straight line flow is regarded most efficient as with products
People movement in and out of facilities should minimize the
chances of recontamination of people that had already gone
through the change room and hygiene facilities.
Hand washing and boot washing facilities before entering
processing areas and in between processing and high risk areas
Hand washing and boot washing facilities before in between
different processing areas and before high risk areas
Cross contamination must be effectively prevented between
people and products
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PLANT CONSTRUCTION
Plant site
Plant building
General design principles and structural techniques
Roofing and lighting
Constructions of the ceilings, walls,
Floors and drainage systems
Ventilation and Air
Noise and Vibration
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EQUIPMENT
Apply hygienic design principles
Construction material i.e.. Stainless steel
Finished or polished surface
Simple and open construction
Easy to clean
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MAINTENANCE
Preventative maintenance
Outside production area
Outside production hours
Spare parts management
Tools
Training
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CLEANING AND DISINFECTION SYSTEMS
An effective cleaning and sanitation program for equipment and
premises must be in place to prevent contamination of food
Low pressure foam cleaning systems
Avoid product contamination
Cleaning and disinfecting agents
Water saving
Biofilm risk
An effective cleaning and sanitation
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HYGIENE REQUIREMENTS
Legislation
Health Act 1977
Meat Safety Act of 2000
Code of practices
SANS 10049:2011
HACCP
EU Guidelines
USDA
IFS international standards
Individual Client requirements
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Personnel hygiene
Source of contamination
Controlling and preventing contamination
Personal hygiene practices
Hand hygiene
Feet hygiene
Access control
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Hand hygiene
With and without splash wall
Knee and sensor operated
Wall mounted and with pedestal
Aqua flow
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Dispensers
Soap
Disinfectant
Paper towels
Hairnets
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Feet hygiene
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Feet hygiene
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Sole cleaning
Stand-alone or Walk-through
cleaning of soles
Optimal cleaning and disinfection
Automatically adjustable dosing of
detergents and disinfectants
Hinged brush covers
Removable brushes without tools
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Boot cleaning
Stand-alone or Walk-through
cleaning of boot legs and soles
Optimal cleaning and disinfection
Automatically adjustable dosing of
detergents and disinfectants
Secure hold due to lateral hand rail
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Access control
Ensures hand cleaning and hand
disinfection
Controlled passage for up to 20 persons
per minute
Step 1: Automatic application of Soap
Step 2: Hand Cleaning
Step 3: Hand drying
Step 4: Hand disinfection
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Access control
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Combined shoe and boot
cleaning systems
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Modular systems
A modular system for the integration of cleaning and
disinfection modules as well as access control units
forms the basis of a wide range of applications
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All in one systems
Step 1
Soap dispenser
Step 2
Cleaning basin
Step 3
Paper towel dispenser
Step 4
Disinfectant dispenser
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Boot drying and disinfection systems
Safe disinfection by ozone
Modular construction
Short drying time ensured by hot air operation
Machine made completely from Stainless Steel
Compact design
Optimum hygiene and health
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Apron washing and storage
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Knife and safety glove storage
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Knife and safety glove
cleaning and sterilizing
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TRAINING
Introduction
Follow up training
Evaluation
Corrective training
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TRAINING
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SUMMARY
Plant layout & Plant flow
Plant construction
Equipment
Cleaning and disinfection
Maintenance
Personal hygiene
Training
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Conclusion
To design a food plant for optimum hygiene and
food safety you have to consider everything from
plant layout, construction, equipment, cleaning
and disinfection, maintenance, to personal
hygiene, training and introduction. You can not
have the one without the other, they go hand in
hand to ensure optimum hygiene and food safety
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PHT OFFER AND DESIGN HYGIENE SOLUTIONS FOR ANY
KIND OF REQUIREMENTS
Hand cleaning and disinfection systems
Shoes sole and boot cleaning systems
Controlled access systems
Apron cleaning and storage systems
Boot drying and disinfection systems
Knife and safety glove cleaning and storage systems
Dispensers for paper towels, gloves, etc.
Change room equipment
Complete drainage systems
Foam cleaning systems
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Thank you
www.pht-sa.co.za

Sepp Messmer

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Designing of Food Processing

Plants for Optimum Hygiene and

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