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Principles for hygienic design and zoning

Quality and Safety Issues in Fish Handling-----

A course in quality and safety management in

fishery harbours in Sri Lanka

NARA, DFAR, ICEIDA and UNU-FTP

Icelandic International Development Agency (ICEIDA)

Iceland

United Nations University Fisheries Training Programme (UNU-FTP)

Iceland

National Aquatic Resources Research and Development Agency (NARA)

Sri Lanka

Department of Fisheries and Aquatic Resources (DFAR)

Sri Lanka

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Content

• Sources of contamination• Hygienic design – key criteria• Zoning of harbour

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Learning Objectives

After this lecture participants will be familiar with:• how seafood can be contaminated

• how the hygienic design criteria and zoning can reduce the contamination during handling

• requirements for different zones

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Increased pressure on fish handlers regarding hygiene:

• "New" hygienic problems (e.g. bacteria, viruses)• More demanding specifications from buyers • Increased interest in further processing of foods

and in chilled products• Consumption of raw or minimally processed

seafood e.g. Sushi, sashimi, cold smoked fish

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Origin of bacteria in seafood -environmental routes

• surface• directly via product’s contact surfaces

• e.g. pallets, tables knives

• indirectly via other routes • e.g. drains, floors, pier

• people and animals (dogs, cats, crows)

water – harbour seawater

• air

• sewage from toilet waste • fish waste, blood water,

• trash fish

“Cleaning” fish with harbour water

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Basic problems in handling and processing fish:

• high number of bacteria and/or• presence of pathogenic bacteria or indicators thereof

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Bacterial load in fish

(Ganegamarachchi, et al 2004)

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A home of pathogenic bacteria

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Hygienic design of food handling/processing facilities and

equipment

• Three major benefits to food manufacturers• maintains product in the main product flow - Quality

• prevents contamination of the product with substances that would adversely affect the health of consumer - Safety

• reduces time required for an item of equipment to be cleaned - Efficiency

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Basic hygienic design requirement

1. Materials for construction

2. Surface finishes

3. Joints

4. Fasteners

5. Internal angels and corners

ohreinindi og hraefnisleifar

samfelld suda

RONG HONNUN

RETT HONNUN

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Stainless steel –AISI 304:2B • untreated (RA:0,16-0,17)

• polished (RA:0,16-0,22)

• glassbeaded (RA: 0,7-0,8)

1

2 3

50

50 50

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Basic hygienic design requirements (cont.)

6. Drainage

7. Bearings and shaft seals

8. Instrumentation

9. Doors, covers and panels

10. Controls

11. Dead spaces

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Hygienic design?

Good or bad?

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Most common materials used for construction in the food industry

• Stainless steel – AISI-304, AISI-316 and AISI 316L

• Plastics– polypropylene (PP), polyvinyl chloride unplasticised (PVC), Acetal

copolymer, polycarbonate (PC), high density polyethylene (PE)

• Elastomer– ethylene propylene diene monomer (EPDM), nitrile rubber,

nitrile/butyl rubber (NBR), Silicone rubber, fluororelastomer (Viton)

• Lubricants– food grade

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Use of wood???????

• Use of wood is only acceptable when:• it plays a favourable role e.g.

cheese ripening, wine and vinegar production

• its mechanical properties cannot be obtained with other available materials e.g. butcher's block

• Splinters can result in foreign body contamination

• Wood cutting tableWooden surfaces must be

cleaned effectively and disinfected

because they can retain

microorganisms which can grow

in the presence of nutrients

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Break up of processing areas - Zoning

• In a fish handling environment there are various demands

regarding cleanliness in each area

• hygienic requirements

• low risk area and high risk area

• traffic of people and vehicles

• The areas must be separated according to these demands

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Harbour activity

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Zoning for prevention

• Keeping away unwanted items, animals and people from the product contact point is a major step towards prevention of food hygiene problems…………….

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Zoning of harbour Different zone are:

1. Pier - unloading area 2. Auction hall3. Loading area for buyers4. Loading of provisions to boats5. Cleaning of boats6. Other facilities

1. toilets, canteens, offices, fuel sheds, 2. parking areas,3. ice-plants4. net-maintenance5. waste treatment/disposal6. repair areas7. more?

high hygienic demands

Most important zoning will be ineffectivewithout coaching and correct attitudes

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Zoning for prevention

………must remain realistic and affordable

• What is to be prevented?• What are the contamination sources of concern? • What services are necessary?

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What is wrong in this picture?????

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Requirement for the pier – unloading area

• Good access and easy to clean • Restrict unnecessary traffic• No direct landing of fish on the pier

• access to boxes, plastic baskets and pallets

• land directly into boxes or baskets and then onto pallets in the auction hall

• Easy access to potable water

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Requirement for auction halls

• Easy access to potable water• Access to ice made from potable water • Washing table/basin for the fish• Cleaning facility – cleaning programme – high

pressure equipment (20-70bar)• Waste bins• Cutting table

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Requirement for auction halls

• Floors should be made of waterproof materials that are easy to clean and disinfect • concrete• ceramic tiles• seamless resin screeds ( heavy duty, self-levelling and coatings)

• Water must drain away easily• slight slope towards the drain (1 in 40 or 1 in 60)

• Hygienic drainage system for waste water is an absolute necessity• durable and easy to clean material • should be as straight as possible

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Channels and aperture channel drain design

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Auction hall

Auction hall to close to pier

Wrong use of auction hall

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Requirement for other areas

• Toilets • high standard to ensure maximum lifetime,

• properly maintained with adequate water supply to flush

• never open to a work area where fish is being handled due to risk of flooding from blocked drains

• wrong use of toilet

• Wash hand basins• adequate number in each toilet block

• hand - or foot -operated faucets and soap available at all time

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Requirement for other areas (cont.)

• Showers• the importance of showers in a hot climate should not be

underestimated

• Signs and bill boards • listing food hygiene regulation for the harbour area

• prohibition of dumping spillage into the harbour basin

• prohibition of using seawater from harbour basin

• indication of directions e.g. to toilets

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Requirement for other areas (cont)

• Ice-plant • Ice made from potable water

• Cleaning programme

• Restrict traffic

• Protective clothing

• Canteen• Hygienic requirement

• Restroom• Hygienic requirement

• Fuel shed

• Repair/ maintenance area

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Ideal arrangement for the fish harbour

Ref: Ice in fisheries. FAO fisheries technical paper no. 331 (1992)

unloadingLoading

Auction hall

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References

• Marriott, G. M.(1997). Essentials of food sanitation. Chapman and Hall. New York and London

• Training material from UNU-FTP/Icelandic Fisheries Laboratories

• Guide to Hygiene within the Fish Industry (2000). Eastfish - Fachpresse Verlag, Michael Steinert, An der Alster 21, D-20099, Hamburg

• EHEDG (European Hygienic Engineering & Design Group)

• document 8 – Hygienic equipment design criteria, second edition 2004

• document 13 – Hygienic design of equipment for open processing, 1996

• Edt. H.L.M. Lelieveld, M.A. Mostert, J. Holah and B. White (2003) Hygiene in food processing:. Wood Head Publishing Limited. Cambridge, England.

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References

• Ice in fisheries. FAO fisheries technical paper no. 331 (1992)

• Fishery Harbour Manual on the Prevention of Pollution – Bay of Bengal Programme. FAO report, BOBP/MAG/22, 1999

• Ganegama Arachchi, G.J. Kariyawasam, M.G.I.U., Heenatigala, P.P.M. Ariyaratne, T. Dahanayeka, T. and Jayasinghe, J.M.P.K. (2004) An investigation on the quality and handling practices of skipjack tuna (Katsuwonus pelamis) along the main commercial distribution channels of Beruwala fishery harbour. Sri Lanka J. Aquat. Sci. 9: 109-121