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food processing
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Designing of Food Processing
Plants for Optimum Hygiene and
Food Safety
Josef Meßmer
PHT
Presented by Deléne KoekemoerPHT-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
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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Designing a Food processing plant
• SiteSize, Location, Properties
• FlexibilityFurther expansion, material flow, fixed building parts
• Structure• Hygiene
• Building quality• Environmental aspects• Ecological aspects
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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Product flow
Work flow patterns and plant layout Handling of food
Personnel flow
Factory entrances High risk areas
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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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
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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 points8. 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
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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Routes of Contamination:
• Product • Air• Water• Environment• People/food handlers
• Equipment• Drains
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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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
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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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
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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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
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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MAINTENANCE
• Preventative maintenance Outside production area Outside production hours
• Spare parts management• Tools• Training
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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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
Designing of Food Processing Plants for
Optimum Hygiene and Food SafetyAn 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
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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Personnel hygiene
• Source of contamination• Controlling and preventing contamination• Personal hygiene practices• Hand hygiene• Feet hygiene• Access control
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
• Hand hygiene
With and without splash wall
Knee and sensor operated
Wall mounted and with pedestal
Aqua flow
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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
• Dispensers
Soap
Disinfectant
Paper towels
Hairnets
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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
Feet hygiene
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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
Feet hygiene
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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
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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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
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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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
Access controlEnsures 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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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
Access control
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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
Combined shoe and boot
cleaning systems
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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
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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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
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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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
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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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
Apron washing and storage
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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
Knife and safety glove storage
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Designing of Food Processing Plants for Optimum Hygiene and Food Safety
Knife and safety glove
cleaning and sterilizing
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TRAINING
• Introduction
• Follow up training
• Evaluation
• Corrective training
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
HY
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TRAINING
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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SUMMARY
• Plant layout & Plant flow• Plant construction• Equipment• Cleaning and disinfection• Maintenance• Personal hygiene• Training
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
HY
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NE
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
HY
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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
Designing of Food Processing Plants for
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
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
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Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
HY
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NE
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety
HY
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NE Thank you
www.pht-sa.co.za
Designing of Food Processing Plants for
Optimum Hygiene and Food Safety