Sepp Messmer

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



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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



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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 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



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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


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



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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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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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• Dispensers

Soap

Disinfectant

Paper towels

Hairnets

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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 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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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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www.pht-sa.co.za



http://www.pht-sa.co.za/



Sepp Messmer

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