Guidelines for the Hygienic Design,Construction and Layout of FoodProcessingFactories

8/13/2019 Guidelines for the Hygienic Design,Construction and Layout of FoodProcessingFactories

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Hygienic Design, Construction and Layout of Food Processing Factories

INTRODUCTION

Hygienic design

philosophy

The primary concern

of foodmanufacturers is to produce a productthat is bothwholesome,and safe, i.e. freefrom pathogenicmicroorganisms andchemical andforeign bodycontamination.

The schematicdiagram shown inFigure 0., which istypical for all foodfactories, showsthat the productionof safe, wholesomefoods stems from athorough ris!analysis. "ndeed,this is now a legal

re#uirement. The diagram also shows that, gi$en specified rawmaterials,there are four ma%or &building bloc!s& that go$ern the way thefactory is operated to ensurethat the safe, wholesome food goal is realised. Hygieneconsiderations 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 therespecti$e integrity of these two dependables.Figure 0.1 Schemaic sages re!uired o ensure sa"e# $holesome "ood producs

H'CCP (pecified raw material))* Hygienic design +* Hygienic practices (afe, wholesome food

))Process de$elopment ))Process control

-is! analysis encompasses indentifying the haards 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 ascritical Control Point H'CCP1.

Such ha%ards are usually descri&ed as'

2 CCF-' 3004



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. 8iological, e.g. bacteria, yeasts, moulds

. Chemical, e.g. cleaning chemicals, lubricating fluids

. Physical, e.g. glass, insects, pests, metal, dust

' haard 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. Thisallows the design of the production facility to play a ma%or role in haard elimination or ris! reduction. To restrict the potential of food contamination, a haard analysis should also beunderta!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 thoseaspects of hygienic design concerned with the factory building, including building siting andconstruction, the segregation of wor! areas to control haards, the flow of raw materials and product, and the mo$ement and control of people.The document addresses the design and construction of factories from first principles andadopts a systematic approach as illustrated by Figure 0.3. The human resources that ma$ be

re#uired to underta!e this approach, from both the fn . a sources that may beindicated in Figure 0.4. The approach ta!en in fig. 3 is not necesarly se#uintal andsome of the stages can run in parallel, particularly those from after defining the product tothe !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 8rown, <<=> Timperley, 3003,30041.

8efore underta!ing design and construction wor! food manufactures should consult H(?information on the CD@ -egulations <<: H(C, 3001.

Figure 0.( Ne$ "ood "acory 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

site, factory, high hygiene, product enclosure1

Determine e#uipment and factory layout

?stimate the sie of factory re#uired and consider new build

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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 contractors1

Bnderta!e building wor!

Bnderta!e e#uipment installation

Pro%ect completion

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1. D)FIN) *RODUCT +ND ,USIN)SS *-+N

ew 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, readersare referred to Product de$elopment guide for the food industry (haw <<=1."t is also recognised that there may be a new building re#uirement if it is wished to increasethe output of e6isting products or if the e6isting processing en$ironmente#uipment isoutdated or does not meet currentfuture legislation.

1.1 Resource

The de$elopment of new products is normally underta!en in)house and should encompass asmany people as possible becauseA)?$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$elopment of new products, whether it be the sourcing of new raw materials, sourcing new !it, planningfactory trials, e$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$ities such asmanufacture and sales. Eithout the support from senior management downwards, new product de$elopment will not ha$e the necessary support to ensure that the ideasgenerated at the earliest stage end up as products on retail display ot all food and drin! companies conduct their creati$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 studiesmar!et research.

1.( The need "or ne$ producs

ew products are designed to increase business profits stemming from increased sales$olume andor increased profit margin on products sold. ew products may also benecessary forA)Defensi$e action ) a competitor may introduce a new product range that needs to bematched or impro$ed on

(trategycorporate 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 #ualityreduce costs by adopting a new range of products

For &commodity& type products it may be possible to either e6pand sales $olume bye6panding the mar!et or e6pand mar!et share by de$eloping new products in those partthe sector which are growing or de$elop new mar!ets1. @any food manufacturers aremo$ing into &added $alue& products, which may be characterised as beingA)

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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$elop one or more new products, product de$elopmentis underta!en in three !ey stepsA). "dea generation3. "dea acceptance4. ;eneration of a product specification brief and business plan

1.3Idea generaiondea generation can be internale6ternal or a combination of both. "nternally,

competiti$eness in food mar!ets has led many companies to ta!e positi$e action to stimulatethe 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 watchingAwhat is happening in the mar!et place and as!ing #uestions such asA)Ehat are our competitors doingEhat new launches are occurring in other sectors which suggest new general mar!ettrends e.g. children&s snac!s, &healthier foods&, ethnic cuisine, new forms of pac!aging1Ehat is happening in other world mar!ets

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$e to be addressed include A)"s there a mar!et for the productEhat is the mar!et sie in terms of sales. Can we actually ma!e it. 're raw materials a$ailable) Can we produce the recipe at a production le$el) "s it microbiologically safe) Eill the shelf life be long enough. Ehat is the result of consumer trials ) do people li!e it

"f so ) how much will they pay for itCan we ma!e it for what people would pay) Ehat are the raw materialrecipe costs) Ehat are the processing costs) Ehat are the pac!aging costs) Ehat margin do we wish to add. "s there the need for long term technical de$elopment to bring the pro%ect to fruition/

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. "s capital e6penditure re#uired and, if so, what is the paybac! time

. Has the company a suitable sales and distribution networ! for the product type

1. Ne$ produc speci"icaion and &usiness plan

"f a new product is appro$ed for further de$elopment, it normally progresses from small bench scaletest !itchen wor! through pilot plant studies to production scale factory trials.The purpose of these studies is to deri$e the breadth of information necessary for the productto first be manufactured and then be distributed and sold, both in the short and long term.(uch information, which can be used to formulate a business plan for the new product,encompassesA)Product detailsProduct description ) what the product is> any reference to e6isting products> whether itfalls within e6isting legally)recognised categories> consider the need for "P- protection,e)g. of trade mar!s, copyright, patents, design rights.-aw materials)commerciall$ a$ailable to a set specification> satisfy any labeling claims> thenically the

most appropriate and cost effecti$e> > must be permitted in foodstuffsi1 of the proposed type and ii1and in the mar!ets where the product will be sold>define any Health and (afet$ re#uirements for their safe handling-ecipe ) properly documented> any labelling claims which must be met by theformulation ) e.g. dietary, &free from& claims, use of specific ingredients> any legalre#uirements in the mar!ets where the product will be sold compositional standards for some products e6ist1

Process details ) all process parameters timestemperaturespressures etc.1 should bedetailed> assess potential processing product lossesProcess flow chart ) all stages of the proposed process should be detailed on a flow chart

to facilitate H'CCP and #uality analysesH'CCP study ) using the C9D? approach as detailed in, for e6ample, H'CCPA '

Practical ;uide ;ae, 30041, determine all potential haards to the consumer, how theycan be eliminated or controlled by factoryprocess design and any Critical Control Pointswhich 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 analyticalcompositional specifications and methods of testing

@icrobiological standards ) what are the microbiological ris!s> detail microbiologicalspecifications are these being met during production trials1 and re%ection criteria> whattype of in)production testing is re#uired

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

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en$ironmental testing specifications including microbiological standards as appropriate.

Pac!aging specification ) define the pac!aging specification> define the pac!aging designlabelling information, declarations including e6port considerations1 and

customerconsumer instructions

(helf life ) must be established either by real time storage trials or prediction includingmicrobiological models1 based upon similarrelated products> manufacturing anddistribution time and temperature limitations

Finished product weights$olumessiesshapes ) detail any statutory re#uirements andtolerances

,usiness plan

Pro%ected unit cost

Pro%ected wholesale andor retail pricePro%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 $olumesPredicted ne6t I years product sales $olumesDecide whether the new product re#uires a new manufacturing technologyDecide whether the new product re#uires new manufacturing e#uipmentDecide whether the new product re#uires additionalrefurbished manufacturing space for an e6isting manufacturing site1 or a new food manufacturing facilityConsult with source of financial bac!ing and obtain agreemeni in principle to proceed.

(. SIT) -OC+TION +SS)SS)NT +ND RIS2 +N+3))NT *HI-OSO*H4'ssuming that a building pro%ect is re#uired, this section ta!es the designed product to the ne6t stageand 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) housefacilities to design new factories often with preferred building consultants contractors1 to smallcompanies 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 ofsuch products to fruition, though the degree of such support will $ary tremendously, depending on thein)house capabilities of the food company and the nature of the building pro%ect. For e6ample, manyfood companies would attempt to underta!e the first J sections of this document themsel$es for a smallarea 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 architectdesigner, whoserole is to interpret the clientKs re#uirements into a specific design and specification. The builder wouldthen 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 consistingof an 'rchitect, Pro%ect @anager, Guantity (ur$eyor, (er$ices ?ngineer, (tructural ?ngineer, Ci$il

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?ngineer, ?n$ironmentalist and Planning (uper$isor see (ection .41. The design team then considersstatutory design and Health and (afety re#uirements, assesses cost limits and time scale, and preparess!etch plans for appro$al. Then contract drawings and bills of #uantities are prepared and tendersapplied 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, andsuper$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 familiarwith the general concepts of food factory design and for more specific food manufacturing operationse.g. chilled foods1, e6perience in that particular food commodity. "nformation on the performance ofcontractors 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 'rchitectsN ?ngineering Construction "ndustry 'ssociationN @echanical and ?lectrical Consulting ?ngineersN ational etwor! of Chartered (ur$eyors and Oaluers

Sie plan

For refurbishments or e6tensions, the first consideration is ) do you really need to build at all "s it possible that you can get by using different production methodstimes etc "f this is not possible, or if itis a new build pro%ect, the ne6t consideration is to decide on a geographical area for the constructionsite.' suitable geographical area should ideallyA)

N 8e close to raw material sources.N 8e close to the finished product consumer.N Ha$e easy access to a suitable transport distribution networ! to ease the supply of otheringredients and to facilitate transport of finished product to the customer.N Ha$e a readily a$ailable source of trained operati$esN Ha$e undergone a flood ris! assessment9nce a suitable geographical area has been found, a specific site needs to be chosen. "n addition to new build pro%ects, the attributes of a suitable site may also need to be considered for refurbishments ande6tensions. Considerations includeA)N 9wnership of the land freehold, leasehold1 and any legal responsibilities that arise fromleasing.N Possibilities for obtaining outline planning permission if the site does not already ha$e planning permission for industrial use ) 8l, 83 or 81, including any constraints on buildingstyleheight 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 assessment of any surrounding haards that may affect site access.N Possibilities for obtaining grants that could reduce business costs.

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N (ufficient space a$ailability to incorporate initial and predicted future needs.N (ufficient energy supplies to ser$ice power and process heatingcooling needs.N (ources of potential haards from surrounding operations, e.g. sewage wor!s, landfill,farming, particle emitting processes.

N ?ase of remo$al of solid wastesN Li!elihood of obtaining discharge consent for li#uid wastes't this concept stage, appropriate members of the design team should consider !nown facts, buildingcosts, plus problems uni#ue to the proposed site which could include the land e.g. pre$ioususecontamination 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 andControl "PPC1, a system following the ?uropean Community Directi$e <=<1, is being implementedand will introduce a more integrated approach to controlling pollution from industrial sources, across?ngland and Eales. Further details on this and other legislation can be found atA)httpAwww.defra.go$.u!en$ironmentppcinde6.htm.

For pro%ects in which e6isting operati$es will be used, but the new product range has a higher le$el ofris!, e.g. companies mo$ing into chilled foods, the fle6ibility of staff is important. -esources and timeshould be allowed for managing the cultural change needed to re)educate staff to the re#uirements forhigher hygiene standards.3.3 Ris5 managemen

't a fundamental le$el, the management of any food processing facilities must ta!e proacti$e steps inorder 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 inorder to eliminate or minimise their effect and thus ensure the e6istence of the company. -is!s to thesuccess of the food business, for e6ample, can focus on the followingA)N The staff employed

N The sourcing of raw materialsN -aw material #ualityN The factory buildings in which the food is processedN Hygienic design and manufacturingN The pro$ision of utilitiesN The performance of the food processing machineryN (torage, dispatch and transport of finished productN Pre$ention of product adulterationThis document is primarily concerned with the ris!s associated with the temporary or permanent loss ofthe buildings, primarily due to fire, and how this can be managed. Clearly the buildings are asignificant proportion of company assets, and are fundamental to allowing the company to manufacturefood."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. 9nema%or insurer estimates that claims made for the food industry are 3.I times the premium. Firesin$ol$ing such panels, and the way they are tac!led by fire fighters see Firefighting options for firesinvolving sandwich panels at www.homeoffice.go$.u! 1, typically result in both the total loss of the

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building and of the product through destruction or potential smo!e damage or tainting1. 's far as thefood industry is concerned, insurance is currently a hardK mar!et> that is to say insurance pro$isionwill only be considered if the food manufacturer underta!es specific ris! management strategies. Thefood industry is thus seen by insurance companies as high ris!, with conse#uent high losses, and as

such, both premiums and the le$el of e6cess are rising significantly.Eith respect to fire, good ris! management is designed toA)N -educe the ris!s of fires startingN Control fires and other ris!s by restricting their impact to particular areasN Pro$ide an early warning of impending disaster N Pro$ide an immediate means of controlling that disaster when it has ta!en place prior to thearri$al of fire fighting assistance-is! management uses both passi$e and acti$e tools. Passi$e ris! management tools for fire include theuse of incombustible building materials, the pro$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, bycompartmentation 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 thehighest life safety standard, L", or preferably the higher property standard, P" where all rooms andsignificant $oids are protected1 set out in 8(I4<A Part A 3003 ) code of practice for system design,installation,commissioning and maintenance 'non 30031. "t should be a fully addressable system, configuredacross the site and recei$ing signals from automatic smo!e, heat, rate of rise etc. detectors, the FirePanel being fitted, ideally, in a permanently manned location on site. The fire signal should then betransmitted to a remote 'ppro$ed 'larm -ecei$ing Centre, $ia a 8T -edCare monitored1 line, with procedures in place for initial in$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 firee6tinguishers are needed or where automatic gas flooding is re#uired in the coo!ing area and fluearrangements. "deally such high ris! areas should ha$e one hour fire resistance construction, in terms ofinsulation and integrity, around them ) this can be reduced to a 40 minutes fire resistance if the premises are sprin!ler protected. 9ther high fire ris! areas include those for bul! storage of oils andfats, and these should be !ept separate. Ehere thermal fluid heating systems are installed, the LPC-ecommendations -C3= rganic !hermal Fluid Heating "#stems gi$e e6cellent guidance. @uch ofthe food industry has been reluctant to fit sprin!lers, with concerns o$er hygiene potential lea!s ofmicrobially contaminated water and difficult to clean o$erhead constructions1 and inad$ertent useleading to loss of product through water damage. Howe$er, it should be remembered that in cool andcold 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$ation of a sprin!ler head that the systemwill fill with water. @any insurers strongly recommend the fitting of sprin!lers in large factories andwarehouses, and they should be consulted.;eneral information on fire protection of buildings can be found in the Loss Pre$ention Councildocument !he $PC Design %uide for the Fire Protection of &uildings '((() in particular Part J.3,details a$ailable atA httpAwww.thefpa.co.u!PagesPublications'd$ice on suitable building materials is contained in $ist of Approved Fire and "ecurit#* Products and

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"ervices The LPC8 &-ed 8oo!K, Oolume 1 Fully -e$ised ?dition, and is a$ailable atAhttpAwww.brecertification.co.u!lpcbredboo!.htmlEith respect to sandwich panels from a fire protection $iewpoint, fillings should ideally be made ofLPC8 ;rade ' appro$ed materials, that include rigid Polyisocyanurate P"-1, or better still

mineralglass wool ha$ing at least =0 minutes fire resistance and fire insulation properties. Polystyrenewill produce copious amounts of smo!e, whereas polyurethane and polyisocyanurate foam produceless> modified phenolic foam produces e$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 "(8 0 <03=J 3<):. There is also a possible issue of moistureingress at low temperatures that can lead to delaminating of the surface panel from the different typesof core, thus e6posing the core to a fire, as well as the creation of a microbiological haard. "mpactdamage to the panels can also e6pose the core directly to a fire. (ometimes holes are punched throughthe panels for ser$ice pipes and electrical cables, and without suitable grommets and seals such areas

ha$e been !nown to be the seat of fires within the panels. These panels can also #uic!ly delaminate in afire situation, in any e$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( A"ssue 4 <<<, Fire performance requirements for metal.faced fire.resisting insulated panels LP( 30A"ssue <<I and thus 8( :J= Part 33A <J. Full details can be found athttpAwww.bre.co.u!frsinde6.html. @aterials that ha$e passed this test are also listed on the abo$eQbrecertificationR website. Currently, LPC8 Qappro$edR panel construction is either P"- or mineralwool, although it should be recognised that the testing procedure is somewhat limited in scope and maynot fully reflect the haards in$ol$ed in using P"-. ' new $ersion of LP( is planned to be published in 3004.

The re#uirement for segregation and compartmentation of specific heat processes, e.g. o$ens andfryers, has long been recognised in the food industry, and the special protections re#uired are generallywell understood. There is a new recognition, howe$er, that the creation of large open spaces abo$e processing areas by the use of false, and structured, ceilings, can create problems as fires can spreadrapidly o$er a large area in these roof spaces, some of which can become QtemporaryR storage areas tosome e6tent. Compartmentation of this roof space is strongly recommended. "n addition strict controlson any maintenance and hot wor! processes in the $icinity of the panels is of paramount importance.Eith arson forming a significant part of total fire claims, it is important that wooden pallet storage isnot a$ailable for use by arsonists, near either the buildings or boundary fences. (torage of such palletsshould 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 areconsulted about building and insulation materials, fire protection and ris! management strategies.

6.D)T)RIN) *ROC)SS +ND +SS F-O7

Following the de$elopment of a product, the selection of a site and an assessment of the businessKsris!s, the preliminary design of the factory can commence. The #uality of the building design, thesuitability of the process and how well a factory or process layout flows, are the !ey to ensuring that

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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$elop the more detailed design for agreed stageappro$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 briefbusiness plan. "f not readily to hand,some information can be found by obser$ing and recording current operations of e6isting products. "nthe absence of !ey information, estimates can be made to #uic!ly build up a general plan. This sectionconcentrates on determining process and mass flow whilst further details of factory segregation ande#uipment and layout design are dealt with in (ections : and I respecti$ely. "n practice, all theseacti$ities are de$eloped in parallel. ,aw materialsDefine 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 e.g.$egetables from meat1 How much storage is re#uired for final pac!aging "s there there#uirement for a separate dry goods store

Ehat are the ingredients to be stored in bag, bo6, tray, bins, silo etc.1 and at what temperature Howmuch room is re#uired for initial de)bo6ingEhat is the number of days storage re#uired per ingredient "s a %ust)in)timeK operation en$isaged orwill deli$eries be once per wee!month etcEhat is the ideal goods inK arrangement Eill deli$eries be by $an or large lorry "s there a need fortemperature controlled doc!ing How will ingredients be transferred to a preferred1 recei$ing doc! ) isthere a need for for!lift truc! storagerechargingEhere and how will incoming ingredient pallet separation be controlled Eill internal plasticaluminium etc. be used Ehere will they be storedFigure 6.1 Schemaic diagram o" a &asic lasagne process "lo$ line

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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 yields Ehat are the estimated, futureunit operationsK massesEhere is there li!ely to be the re#uirement to store wor! in progress Ehat is the re#uiredstorage temperature and tolerances're specific processes re#uired, e.g. coo!ing, steaming, ba!ing, frying, chilling, freeingEhat are the coo!ing and cooling throughput per product and the coo!cool residence timesEhat is the general process plant type and location see (ection I1How many product flow streams are re#uired, i.e. how can process lines be optimised to acceptthe ma6imum number of intended products with the fewest linesEhat are the re#uirements for for!lifthand pallet mo$ement charging if re#uired1.

8y the time raw materials and the process has been considered, it is possible to construct product flowdiagrams. Figure 4. gi$es an e6ample of a basic lasagne flow and helps $isualise the re#uirements forother factors, e.g. people, wastes, cleaning and ser$ices. Finished goodsN Ehat are the final product pac!aging dimensions and print re#uirementsN Ehat are the re#uirements for final product storage and the number per cratepallet5Type te6t7



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N Ehat are the final product pac! sie, dimensions and weight"torage and distriution

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 controlleddoc!ingN Eill traysbins etc. be returned that need cleaning before re)pac!ingN Eill the transport $ehicles be company owned or contracted "s there the re#uirement for$ehicle garagingser$icing 0nvironment N For each storage and processing area, define the re#uired room temperatures and tolerances.N Eill there be the re#uirement to remo$e condensation or dust particlesN Ehat are the re#uired le$els of air filtration, air changeshour and air pressures see(ection :1N "s there a re#uirement for controlled relati$e humidity air control see (ection :1

N Has the runoff of fire fighting water been consideredN 're there any special re#uirements for chimneys or $ents People

N How many people are re#uired, administration, laboratory if re#uired1, engineers and foodoperati$es including nightshiftcleaners1, to staff the operationN Ehat is the li!ely mi6 of males to females This will help sie changing areas.N Ehat shift patterns are en$isaged and what is the number per shift, i.e. what is thema6imum number of people on site at any one timeN 're separate entrances re#uired for food operati$es, office staff, $isitorsN "s there the need for High Care Low -is! entrance barriers see (ection :1N Eill the company supply catering ser$ices or pro$ide a canteenrestroom area

N Define the company smo!ing policy, including the pro$ision of any smo!ing areasN Eill the company pro$ide a medical roomN Ehat is the re#uirement for disabled access in all processing areasN Ehat are the management and administration re#uirements1astes

N How will ingredient pac!aging waste be handledN How will solid process waste be handledN How will pac!aging waste be handledN Eill wastes be stored outside in co$ered containers or within the buildingsN Eill li#uid wastes re#uire screening within the factory e.g. drain bas!ets1 or

e6ternallyN Eill li#uid wastes be discharged directly to the municipal sewer or be first

treated onsiteCleaning

N Eill cleaning be underta!en in)house or contracted outN Eill chemicals be sourced locally or from a cleaning ser$ice pro$ider "f a cleaning ser$ice pro$ider, contact should be made at the earliest possible stage to enable them to ha$e design input.

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N How many purpose built cleaning rooms will be re#uired, including e#uipment dirty storageand cleaned and drying storage areasN Ehere will cleaning e#uipment and chemicals be storedN How will cleaning chemicals be deli$ered and in what $olumes ) 3I litre drums or larger

transport tan!sN How will cleaning fluids be distributed around the processing areas ) manually or $ia cleaningring mainsN "s there a need for a $acuum ring main"en*ices

N Ehat is the re#uirement for power H.O. and ;as1 consumption "s a bac!)up electricity supplynecessaryN Ehat is the re#uirement for water 's far as possible the main cold water feed to thefactory should be installed underground and not within the building, as this would causethe water temperature to go up and increase the chance of $egionella bacteria occurring.N Ehat is the re#uirement for compressed air

N Ehat is the re#uirement for hot waterN Ehat is the re#uirement for steamN Does the company ha$e a refrigeration policyN Ehat is the re#uirement for storm water controlN "s there a re#uirement for effluent treatment on siteN Define the drainage layout including segregation of any low and high ris! drainsN Ehat building management systems will be re#uiredN Define the re#uirements for "T, telephones, fibre optics and burglar alarmsN Ehat is the re#uirement for fire control sprin!ler systems, fire alarms, firehydrants1N Ehat is the re#uirement for engineering stores and wor!shops

N Define the need for on)line or off)line analyses of raw materials, process intermediates and final products. D)T)RIN) TH) R)8UIR)D -)9)- OF S)3R)3+TION

N 3eneral consideraions

N Le$els of hygienic designTo pro$ide protection from general contamination physical, chemical and biological haards1 duringmanufacture, food is protected by a barrier system, made up of up to : barriers Figure :.1. Theseencompass the site 1, the factory building 31, a high ris! or high hygiene one 41 and a productenclosure one :1. "n this system, the degree of control of the production en$ironment increases suchthat finally, fully processed products are manipulated in controlled en$ironments in whichcontaminants are acti$ely e6cluded.Figure .1 Schemaic diagram o" he le/els o" hygiene &arrier poenially "ound in

"ood "acories

The produc and is 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 thefinal consumer.

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Low ris! products, typically either raw materials or ambient shelf stable products, include eggs, rawmeat and fish, fruit, $egetables, dried goods, canned foods, ba!ery and ba!ed products, confectionery,snac!s, brea!fast cereals, oils and fats, food additi$esingredients and be$erages.High)ris! products, typically short shelf life ready)to)eat foods, include coo!ed and smo!ed meat and

fish, prepared $egetables, prepared fruit, mil!, cream, cheese, yoghurt, ice cream, sandwiches andready meals.The number of factory barriers re#uired will be dependent on the nature of the food product and thenature of the haard, and will be established from the H'CCP study. For low ris! products, the firsttwo barriers only are re#uired. For some high ris! products, e.g. sandwiches, in which some of thecomponents are decontaminated e.g. washing salad ingredients in chlorinated water1 rather than heat pasteuried, the use of the third barrier is re#uired for microbiological control. For fully coo!ed ready)to)eat products, microbiological shelf)life may be e6tended by underta!ing all processingmanipulations, from coo!ing to pac!ing, in an enclosed atmosphere.There is some confusion o$er terminology related to the third, high hygieneK barrier one, with theterms high care and high ris! area often used. To help clear up this confusion, the Chilled Foods

'ssociation in the BM 'non, <<Ja1 established guidelines to describe the hygiene status of chilledfoods based upon microbiological criteria1 and indicate the area status of where they should be processed after any heat treatment. Three le$els were describedA high ris! area H-'1, high care areaHC'1 and good manufacturing practice ;@P1 area. Their definitions wereA)H-' 'n area to process components, +H of which ha$e been heat treated to *<0UC for 0 min for psychrotrophic Clostridium otulinum spores1 or *J0UC for 3 min for $egetati$e pathogens1, and inwhich there is a ris! of contamination between heat treatment and pac! sealing that may present a foodsafety haard.HC' 'n area to process components, Some of which ha$e been heat treated to *J0UC for 3 min, and inwhich there is a ris! of contamination between heat treatment and pac! sealing that may present a foodsafety haard.

;@P 'n area to process components, None of which ha$e been heat treated to *J0UC for 3 min, and inwhich there is a ris! of contamination prior to pac! sealing that may present a food safety haard."n practice, the definition of HC' has been e6tended to include an area to further process componentsthat ha$e undergone a decontamination treatment, e.g. fruit and $egetables after washing in chlorinatedwater, or fish after low temperature smo!ing and salting.@uch of the re#uirements for the design of H-' and HC' operations are the same, with the emphasison pre/ening contamination in H-' and minimising contamination in HC' operations, respecti$ely'non, <<Ja1. "n considering whether a high ris! or high care area is re#uired and therefore whatspecifications should be met, chilled food manufacturers need to carefully consider their e6isting andfuture product ranges, the haards and ris!s associated with them and possible de$elopments in the nearfuture. "f budgets allow, it is always more economic to build to the highest standards from the onset ofconstruction rather than try to retrofit or refurbish at a later stage.The re#uirements for high careris! segregation for appropriate foodstuffs is now recognised by thema%or food retailers and is a re#uirement in the !echnical "tandard and Protocol for Companies"uppl#ing ,etailer &randed Food Products 'non 30001.N (egregation9ther than for microbiological reasons, it may be necessary to segregate areas for the processing ofdifferent product ingredients. This is to pre$ent the possibility of contamination ofA organic foods with

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non)organic components> non);@9 with ;@9 deri$ed foods> $egetarian foods with non $egetariancomponents> religious based foods e.g. Mosher or Halal1 with foods that do not conform with thesecriteria> and non)allergenic foods> with allergenic components e.g. nuts1."deally, manufacturers who manufacture organic, $egetarian, ;@9 free, religiousK or allergenic

products should do so on separate sites such that there is no chance of crosscontamination fromdifferent ingredients. "f this is not possible, production of organicnon) organic etc. foods can be processed on the same site pro$iding the whole process, from goods in through raw material storageand processing to primary pac!aging, is segregated. (ome manufacturers ha$e segregated processes bytime, 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)nutcontaining products is then re)commenced. "f segregation by time is to be considered, a thoroughH'CCP study should be underta!en to consider all aspects of how the haard e.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 e.g. a single 3 line

meat slicing hall into 4 fully segregated sub)units of : slicing lines1, cross)contamination between linescan be eliminated when some lines need to be shutdown for cleaning or maintenance whilst the othersneed to remain in production."n many factories it is necessary to segregate areas to !eep product dry, e.g. special areas for thehandling of dry ingredients or con$ersely specific areas for wet cleaning or traywashing. "n addition itmay be necessary to segregate particularly noisy pieces of e#uipment> see ,educing noise exposure in

the food and drin+ industries) Food "nformation (heet o. 43, httpAwww.hseboo!s.co.u! N ,arrier 1' Sie

'ttention to the design, construction and maintenance of the site, from the outer fence and the area upto 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 ofdomestic animals etc.3.: Eell)planned and properly maintained landscaping of the grounds can assist in thecontrol of rodents, insects and birds by reducing food supplies and breeding and harbourage sites. "naddition, 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 ofground le$el contamination from flooding.3.= 'n area of at least 4m immediately ad%acent to buildings should be !ept $egetation free andco$ered with a deep layer of gra$el, stones, pa$ing or roadway etc. This practice helps maintain controlof the fabric of the factory building.3.J To help pre$ent flying insects from entering buildings, install security lighting awayfrom factory openings so that insects are attracted away from them.3. Processes li!ely to create microbial or dust aerosols, e.g. effluent treatment plants, wastedisposal units or any preliminary cleaning operations, should be sited such that pre$ailing winds do not blow them directly into manufacturing areas.N ,arrier (' Facory &uilding

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3.J Eindows should be glaed with either polycarbonate or laminated. @etal or plastic frames withinternal sills sloped 30U):0U1 to pre$ent their use as temporaryK storage places and with e6ternal sillssloped at =0U to pre$ent bird roosting, should be used. ' glass register, detailing all types of glass usedin the factory, and their location, should be maintained.

N Ehere opening windows are specifically used for $entilation particularly in tropical areas1 theymust be screened and the screens be designed to withstand misuse or attempts to remo$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 companionCCF-' documentsA) ;uideline o. :0, %uidelines for the design and construction of floors for food

production areas and ;uideline o. :, %uidelines for the design and construction of walls) ceilings

and sen*ices for food production areas see -eferences1.3.3 ,arrier 6' High care:ris5 areas

The building structure, facilities and practices associated with the high careris! referred to as simplyhigh ris! in the following te6t1 production and assembly areas pro$ide the third barrier. Together withthe 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 processN 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$e to be passed between low and high ris! "tructureThe design of the high ris! food processing area must allow for the accommodation of fi$e basicre#uirements, namelyA

N Processed materials and some ingredientsN Processing e#uipmentN (taff concerned with the operation of such e#uipmentN Pac!aging materialsN Finished productsThere is a philosophy which has considerable support, that states that all other re#uirements should beconsidered as secondary to these fi$e basic re#uirements and, where$er possible, must be !ept out ofthe 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 $entilation ducts.N Compressors, refrigeration units and pumps.N @aintenance personnel associated with any of these secondary re#uirements. Heat treated product Ehere a product heat treatment forms the barrier between low and high ris! e.g. an o$en, fryer ormicrowa$e tunnel1, the heating de$ice must be designed such that as far as is possible, the de$ice formsa 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 lowhigh ris! floor

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%unction should be fully sealed to the highest possible height. 9ther points of particular concern forheating 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! duringcleaningN 'ny $entilation system in the coo!ing area should be designed so that the area is $entilatedfrom low ris!> $entilation from high ris! can draw into high ris! large #uantities of low ris! air.N Mettles should be installed within low ris! and transfer product by pumping, gra$ity, $acuumetc.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 decontaminationFresh 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 disinfectantusually a #uaternary ammonium compound1, or dry, using BO light.'s with heat barriers, decontamination systems need to be installed within the lowhigh ris! barrier tominimise the free space around them. 's a minimum, the gap around the decontamination systemshould be smaller than the product to be decontaminated.This ensures that all ingredients in high ris! must ha$e passed through the decontamination system andthus must ha$e been decontaminatedther product transfer

'll ingredients and product pac!aging must be de)bo6ed and transferred into high ris! in a way thatminimises the ris! of cross)contamination into high ris!. (ome ingredients, such as bul! li#uids thatha$e been heat)treated or are inherently stable e.g. oils or pasteurised dair* products1, can be pumped

across the lowhigh ris! barrier directly to the point of use. Dry. stable bul! ingredients e.g. sugar1 canalso be transferred into high ris! $ia sealed con$eyors.For non)bul! #uantities, it is possible to open ingredients at the lowhigh ris! barrier and decant themthrough into high ris! $ia a suitable transfer system e.g. a simple funnel set into the wall1 into arecei$ing container. Transfer systems should, preferably, be closeable when not in use and should bedesigned to be cleaned and disinfected, from the high ris! side, prior to use as appropriate. Pac+aging Pac!aging materials film reels, cartons, containers, trays etc.1 are best supplied to site double baggedK. Ehen called for in high ris!, the pac!aging material is brought to the lowhigh ris! barrier, theouter plastic bag remo$ed and the inner bag and pac!aging enters high ris! through a suitable hatch.The hatch, as with all openings in the lowhigh ris! barrier, should be as small as possible and should be closeable when not on use. This is to reduce airflow through the hatch and thus reduce the airflowre#uirements for the air handling systems to maintain high ris! positi$e pressure. For some pac!aging materials, especially hea$y film reels, it may be re#uired to usea con$eyor system for mo$ing materials through the hatch. 'n opening door or preferably, double doorairloc! should only be used if the use of a hatch is not technically possible and suitable precautionsmust be ta!en to decontaminate the airloc! after use. $iquid and solid wastes

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9n no account should li#uid or solid wastes from the low ris! areas1 be remo$ed from the factory $iahigh ris!, and attention is re#uired to the procedures for remo$ing high ris! wastes. The handling ofli#uid wastes from low and high ris! is described in CCF-' ;uideline o. :0 see -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$erse direction to the product. For small #uantities of bagged waste, e6isting hatches should be used, e.g. the wrapped product e6it hatches or the pac!aging materials entrance hatch, as additional hatches increase the ris!of e6ternal contamination and put e6tra demands on the air handling system. For waste collected in bins, it may be necessary to decant the waste through purpose built, easily cleanable from high ris!1,waste chutes that deposit directly into waste s!ips. Personnel The high ris! changing room pro$ides the only entry and e6it point for personnel wor!ing in or $isitingthe area and is designed and built to both house the necessary acti$ities for personnel hygiene practicesand minimise contamination from low ris!. "n practice, there are some $ariations in the layout offacilities of high ris! changing rooms. This is influenced by, for e6ample, space a$ailability, product

throughput and type of products, which will affect the number of personnel to be accommodated andwhether the changing room is a barrier between low and high ris! operati$es or between operati$esarri$ing from outside the factory and high ris!. ;enerally higher construction standards are re#uired forlowhigh ris! barriers than outsidehigh ris! barriers because the le$el of potential contamination in lowris!, both on the operati$esK hands and in the en$ironment, is li!ely to be higher Taylor 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 wallappro6imately =0cm high1, that allows floors to be cleaned on either side of the barrier withoutcontamination by splashing etc. between the two.

N 9pen loc!ers at the barrier to store low ris! footwear.N ' stand on which capti$e, high ris! footwear is displayeddried. 8oot baths and boot washersare not recommended as a means of decontaminating footwear between low and high ris! areas as theyare not an effecti$e means of microbial control. The use of bootwashers in high ris! should only beused to help control the ris! of operati$es slipping if the floors are particularly slippery1 by controllingfood debris build)up in the soles of the boots.N 'n area designed with suitable drainage for bootwashing operations. -esearch has shownTaylor et ai) 30001 that manual cleaning preferably during the cleaning shift1 and industrial washingmachines are satisfactory bootwashing methodsN Hand wash basins to ser$ice a single, hand wash. Handwash basins should ha$e automatic or!neefoot operated water supplies, water supplied at a suitable temperature that encourages handwashing1 and a waste e6traction system piped directly to drain. "t has been shown that hand wash basins positioned at the entrance to high ris!, which was the original high ris! design concept to allow$isual monitoring of hand wash compliance, gi$es rise to substantial aerosols of staphylococcal strainsthat can potentially contaminate the product.N (uitable hand drying e#uipment, e.g. paper towel dispensers or hot air dryers and, for papertowels, suitable towel disposal containers.

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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! $ia a purpose built air handling system or can enter into thearea from e6ternal uncontrolled sources e.g. low ris! production, pac!ing, outside1. For high ris!areas, the goal of the air handling system is to supply suitably filtered fresh air, at the correcttemperature and humidity, at a slight o$erpressure to pre$ent the ingress of e6ternal air sources.'ir #uality standards for the food industry were first re$iewed by 8rown <<=1 and thedesign 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 andinstallations. For high care applications, a series of filters is re#uired to pro$ide air to the desiredstandard and is usually made up of a ;:FI panel or poc!et filter followed by an FJ)< rigid cell filter.For some high ris! operations an H0 or Hll final filter may be desirable.N The pressure differential between low and high ris! should be between I)I Pascals or be

.Imsec or greater through openings. The desired pressure differential will increase as both thenumber and sie 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$e the heat load imposed by the processingen$ironment processes and people1 and pro$ide operati$es with fresh air, though in a high ris! areawith large hatchesdoors that are fre#uently opened, up to :0 air changes per hour may be re#uired.N The re#uirements for positi$e pressure in high care processing areas are less stringent andceiling mounted chillers together with additional air ma!e)up may be acceptable.N 's well as recirculating temperature controlled air, the system may need to be designed to dumpair directly to waste during cleaning operations and to recirculate ambient or heated air after cleaningoperations to increase en$ironmental drying. Eith respect to drafts, the ma6imum air speed close to

wor!ers to minimise discomfort through wind) chillK should be 0.4m s&

. This is typically achie$edwith airsoc!s, positioned directly o$er the product linesN Soint BM go$ernment sponsored wor! at CCF-' and the (ilsoe -esearch "nstitute hasin$estigated the measurement of both air flows and airborne microbiological le$els inactual food factories, from which computational fluid dynamics CFD1 models ha$e been de$eloped to predict air and particle including microorganism1 mo$ements 'non,3001. This has allowed the design of air handling systems that pro$ide directional air that mo$es particles away from the source of contamination washrooms, hatches, doors, people etc.1, in adirection 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$ecomfort. Low humidities can cause drying of the product with associated weight and #uality loss,whilst higher humidities maintain product #uality but may gi$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 'non, <<3a1 re#uire thatthe Qtemperature in all wor!places inside buildings shall be reasonableR, which, in the supporting Approved Code of Practice 'non <<3b1, is normally ta!en to

' generic layout for a changing room should accommodate the following re#uirements.

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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 appro6imately

=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 displayeddried. 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 if 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 Taylor et al )

30001 that manual cleaning preferably 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 !neefoot

operated water supplies, water supplied at a suitable tempen that 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. paper towels, suitable

towel disposal containers.

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 e.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$erpre pre$ent

the ingress of e6ternal air sources.'ir #uality standards for the food industry were first re$iewed by 8rown <<=1 and the design of theair handling system should now consider the following issuesA)N Filtration of air is a comple6 matter and re#uires a thorough understanding of filter types andinstallations. For high care applications, a series of filters is re#uired to pro$ide air to the desiredstandard and is usually made up of a ;:FI panel or poc!et filter followed by an FJ)< rigid cell filter.For some high ris! operations an H0 or H" final filter may be desirable.

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N The pressure differential between low and high ris! should be between I)I Pascals or be .Imsec orgreater through openings. The desired pressure differential will increase as both the number and sie ofopenings 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 processes and people1 and pro$ide operati$es with fresh air, though in a high ris! area with large hatchesdoors thatare fre#uently opened, up to :0 air changes per hour may be re#uired.N The re#uirements for positi$e pressure in high care processing areas are less stringent and ceilingmounted chillers together with additional air ma!e)up may be acceptable.N 's well as recirculating temperature controlled air, the system may need to be designed to dump airdirectly to waste during cleaning operations and to recirculate ambient or heated air after cleaningoperations to increase en$ironmental drying. Eith respect to drafts, the ma6imum air speed close towor!ers to minimise discomfort through &wind)chill& should be 0.4m sY. This is typically achie$ed withairsoc!s, positioned directly o$er the product linesN 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$els in actual food factories, fromwhich computational fluid dynamics CFD1 models ha$e been de$eloped to predict air and particleincluding microorganism1 mo$ements 'non, 3001. This has allowed the design of air handlingsystems that pro$ide directional air that mo$es particles away from the source of contaminationwashrooms, 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$ecomfort. Low humidities can cause drying of the product with associated weight and #uality loss,whilst higher humidities maintain product #uality but may gi$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 'non, <<3a1 re#uire that the

Ytemperature in all wor!places inside buildings shall be reasonableY, which, in the supporting Approved Code of

Practice '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 'non, <<I1 as well as those imposed by their retail customers. To help sol$e this conflict, a

document entitled %uidance on achieving reasonale wor+ing temperatures and conditions during production of chilled

foods 8rown, 30001, which e6tends the information pro$ided in H(? Food (heet o.4 -e$1 1or+room temperatures in

places where food is handled 'non, <<<1 has been produced. The guidance document 8rown, 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 or 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.

7tensilsEhere$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$ision of storage areas or areas in which utensils can be maintained orcleaned. Typical e6amples includeA)N The re#uirement for ingredient or product transfer containers trays, bins etc1 should be minimised but where these areuna$oidable they should remain within high ris! and be cleaned and disinfected in a separate wash room area.N (imilarly, any utensils e.g. stirrers, spoons, ladles1 or other non)fi6ed e#uipment e.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. Theroom should preferably be sited on an outside wall that facilitates air e6traction and air ma!e)up. 'n outside wall alsoallows 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 $ery wet operations, may include barrier drains at the entrance ande6it to pre$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 e.g. traywash1 as appropriate, and a holdingdryingarea where e#uipment can be stored prior to use. These areas should as segregated as possible.N 'll cleaning e#uipment, including hand tools brushes, s#ueegees, sho$els etc1 and larger e#uipment pressure washers,floor scrubbers and automats etc.1 should remain in high ris! and be colour coded to differentiate between high and low ris!e#uipment if necessary. (pecial pro$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 which 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$ice items and spares etc., together with the necessary hand tools to underta!e theser$ice, should be stored in high ris!. For certain operations, e.g. blade sharpening for meat slicers, specific engineeringrooms may need to be constructed.N Pro$ision should be made in high ris! for the storage of utensils that are used on an irregular basis, but that are too large to pass through the lowhigh ris! barrier, e.g. stepladders for changing the air distribution soc!s.:.I 8arrier :A Product enclosureThe high ris! air handling system pro$ides control of airborne contamination e6ternal to high ris!, but pro$ides only partialcontrol of aerosols, generated from personnel, production and cleaning acti$ities, in high ris!. 't best, it is possible todesign 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 producttemperatures.' %oint CCF-'(ilsoeLeatherhead Food -esearch 'ssociation, BM ;o$ernment sponsored pro%ect has e6amined the use ofsystems designed to fully or partially enclose products further processed in high ris! areas. ;lo$ebo6es offer the potential tofully 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$es little manual manipulation. The more complicated the productmanipulation, the more ingredients to be added, the faster the production line or the shorter the product run, the less fle6ibleglo$ebo6es become. 9perating on a batch basis, pre)disinfected glo$ebo6es gi$e the potential for a temperature controlleden$ironment with a modified atmosphere if re#uired " e.g. high C93, low 93 or $ery high 93 concentrations1, that can bedisinfected on)line by gaseous chemicals e.g. oone1 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 airflowwith the ob%ecti$es ofA)

V Pro$iding highly filtered H" )31, chilled air directly o$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 mt Figure :.3 andshows a schematic diagram of a con$eyor that has chilled, filtered air directei o$er it, sufficient to maintain thelow 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. Thiswor! has been report in 8urfoot et ai, 3000.

Figure .( Chilled air is supplied "rom air ducs on eiher side o" a produc con/eyoc The chilled airmainains he produc emperaure $hils is mo/emen# spilling o/er he duc sur"aces# pro/ides a &arrier

o microorganism peneraion.

-ocalised air deli/ery ; roughs

(olid or fabric air supplyducts

Food product

. D)T)RIN) )8UI*)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 (ection =1.

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 small 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$icedV Consider total lifecycle costs and calculate the benefits of purchasing new or secondhand

.( )!uipmen needs

@any new build factories are designed and built around the most efficient production line configuration. "t isessential, 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

assemblyfillingpac!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

$entilatione6traction re#uirements. 'ny other Health (afety re#uirements. ?#uipment waste solid and

li#uid1 disposal re#uirements. Degree of space re#uired around the line to facilitate operation, maintenance

and cleaning.

.6 Facory layou

The factory layout should start with a list of all of the roomspace re#uirements re#uired for all of the acti$itiesneeded to facilitate the production of the product. "t is impossible to list all such areas here but a list could

includeA)

V goods in

V raw material storage> chilled, ambient, froen, dry etc

V pac!aging storage

V water storage

V for!lift truc! storage and maintenance

V preparation areas

V processing areas

V high ris! areasV in)process product storage

V final product storage

V wash)up facilities

V waste disposal area

V plantroom

5Type te6t7



5Type te6t7

V engineering wor!shop

V cleaning stores

V microbiology, chemistry and GC laboratories and test !itchens

V pilot plant areaV changing facilities

V restrooms

V canteens

V medical rooms

V area for $isiting inspectors

V obser$ation areas$iewing galleries

V finished goods dispatch

V warehousing

V office spaceV reception

V board room

V security room

V "Tser$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 moreefficient in terms of handling. "t is also easier to segregate clean and dirty process operations andrestrict 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 ofeither 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 internally 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 e.g. wal!ways

acrossunder the line1 to allow operati$es to access all necessary wor!control 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 car$antruc!lorry par!ing and manoeu$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 appearancepotential nuisance to the community.

V The need for site security security fencing, gatehouse, traffic barriers, CCTO, burglar alarms1.

2 CCF-' 3004






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 howe$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 haards 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 ew 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 customersretailers.

V o 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 salewrite downwrite off costs.

V Potential loss of e6isting !ey staffs!ills and staff culture.

V @ay need to find new raw materialingredientser$ice pro$iders.

Eith new build sites, it is also necessary to consider freehold or leasehold ownership. Leasehold hasthe ad$antage that building cost rent1 is low compared to capital in$estment and the landlord ta!esresponsibility for building maintenance and the ris! of building con$ersion to the company&s designif the design is not successful1. The disad$antages arc that the landlord may put unacceptableconstraints on the building designuse 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$elop the business, but in thelong term offers the company control, fle6ibility and !nown o$erheads.

<.( Sie plan

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

) CCF-' (006



Figure <.1 ,asic "acory plan "or he producion o" lasagne. The plan gi/es su""icien in"ormaion on >lie layou o" he "acory

$ihou going ino oo much deail on he insallaion o" process lines and ser/ices






9nce this information is a$ailable, a case for a construction pro%ect can be presented to thecompany board for a decision on whether to proceed with the pro%ect with or withoutmodifications1 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$ironmental issues, someof which will only be apparent from reports, e.g. when trial holes ha$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




@. CONSTRUCTION AD)SI3N +ND +N+3))NTB

R)3U-+TIONS 1' TH) RO-) OF TH) C-I)NT# TH)

*-+NNIN3 SU*)R9ISOR +ND TH) D)SI3N)R

@.1 The Consrucion ADesign and anagemenB Regulaions

The Construction Design and @anagement1 -egulations <<: CD@ -egulations1, as amended in

3000, are aimed at impro$ing the o$erall management and co)ordination of operati$e health, safetyand 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 theother 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 <<: o. 4:0, The Construction Design and @anagement1 -egulations <<:(tatutory "nstrument 3000 o. 340, The Construction Design and @anagement1 'mendment1-egulations 3000

From The Publications Centre, P9 8o6 3J=, London (E IDT, Tel> 0J0 =00 II33, Fa6A 0J0 =00

II44

9r can be obtained on)line fromA)

www.legislation.hmso.go$.u!sisil<<:B!si]<<:4:0]en]l.htm

www.legislation.hmso.go$.u!sisi30003000340.htm

@.( The role o" he clien

The role of the client is summarised in the Health and (afety ?6ecuti$e H(?1 "nformation sheet )

Construction (heet o. 4< Construction Design 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 see (ection .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 see (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 H(C <<I, 3001 pro$ide detailed guidance on the

issues of competence and ade#uate resources for health and safety.

2 CCF-' 3004

http://www.legislation.hmso.gov.uk/si/sil994/Uksi_19943140_en_l.htm

http://www.legislation.hmso.gov.uk/si/si2000/20002380.htm

http://www.legislation.hmso.gov.uk/si/sil994/Uksi_19943140_en_l.htm

http://www.legislation.hmso.gov.uk/si/si2000/20002380.htm




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 if as!ed1. The degree of

detail in the health and safety plan should be in proportion to the sie 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 o. :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

o. ::, !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

o. :0 Construction Design 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 e.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 if 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 see (ection .: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 a1, prospecti$e principal contractors can

prepare outline submission to it during tendering and b1, 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 o. :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 contractor and

on the suitability of the health and safety plan prepared by the principal contractor for the

construction phase.

2 CCF-' 3004




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

The role o" he designer

The role of the designer is summarised in the H(? "nformation sheet ) Construction (heet o. :Construction Design and @anagement1 -egulations <<:A The role of the designer.

Designers are organisations or indi$iduals who carry out design wor! for a construction pro%ect andinclude architects, consulting engineers, #uantity sur$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 structureand those who might be affected by this wor! e.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 haards that cannot beaddressed 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 haards li!ely to be associated with the design and

how it may be constructed and maintained.

V Consider the ris! from the haards 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 haard can be pre$ented from arising so that the ris! can be a$oided i.e. alter

the design to a$oid the ris!1.

V "f this cannot be achie$ed, the ris! should be combated at source e.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

e.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 e.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




The H(? Construction "nformation (heetsA)

o. 4< The role of the client

o :0 The role of the planning super$isor

o. : The role of the designer

o. :3 The pre)tender stage health and safety plan o. :4 The health and safety plan during the construction phase

o. :: The health and safety file

Can be obtained from local H(? 9ffices or H(? 8oo!s, P9 8o6 <<<, (udbury (uffol!. C903E', TelA 0JJ =I, Fa6A 0JJ 44<<I

9r online from

httpAwww.hse.go$.u!pubnsconinde6.htm

2 CCF-' 300.

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

9nce the decision has been made to proceed, the onus is on the Design Team to prepare detailedinformation 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

- 4 2 -

http://www.hse.gov.uk/pubns/conindex.htm

http://www.hse.gov.uk/pubns/conindex.htm




Design )lemen Consulan

-oom layoutsfloor plans 'rchitectV Merbs

V EallsV Floor fallsle$elsV DoorsV "nternal drainage

-oom data sheets 'rchitect

Inpu

Client, building

regulations

Client

Noe

Typical room datasheet Table <.1

?le$ations 'rchitect

D CCFR+ (006




Detailed cross)sections 'rchitect -oof plans 'rchitect

Ceiling plans 'rchitect

9ffices and amenities 'rchitect

V PlansV Cross)sectionsV DetailsV Finishes schedules

Fire protection, means of 'rchitect escape,compartmentation

Loading doc! details 'rchitect ?6ternal wor!s layout

) 'rchitect

(ecurity 'rchitectV Fencing and gatesV ;ate house

Client, building regulations incdisability in the wor!place1

Client&s insurance, buildingregulations, structuralengineer

Client

Client,

highways authority Client

D CCFR+ (006




(tructural frame loadings and (tructural engineer Client, architect,type portaltrussspecial1

ser$ices designersprocess engineer1

buildingregulations

Clear spans,ceiling weights,ser$ices weightsai locations.

(uspended process e#uipmentand ser$ices

2 CCF-' (006




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

2 CCF-' (006




;round remedialwor!s

?n$ironmental ;roundcontamination -elates toconsultants in$estigation Y8rownfield(itesV

Floor slabsdetails

(tructural engineers 8uilding regulations, Eeights and positi

2 CCF-' (006






?6ternal wor!sV -oads

V ards and

hardstandingsV Car and lorry par!sV 8ases

(tructural engineers 'rchitect,highways authorityprocess engineer1

;reen tra$el to wo' plan may bere#uired by

planning authori#

2 CCF-' (006

Ci$il1




@ain DrainageV (urface water V Foul

V ?ffluent

(tructural engineers 'rchitect,Ci$il1 building regulations

2 CCF-' (006




(er$ices)refrigeration

Consultant ordesign and buildspecialist contractor

-oom datasheets, processengineer1

High ris! airflow> Table <.31

(er$ices)mechanical

Consultant ordesign and buildspecialist contractor

-oom datasheets, processengineer1

High ris! airflowA Table <.41

(er$ices )electrical Consultant or design -oom data sheets, and build specialist process engineer1 contractor

Table <.:1

(er$ices )general Consultant or designand build specialistcontractor

-oom data sheets,process engineer1

Table <.I1

@anagement ofdrawings

'rchitect

Pro%ect designteam

'n e6ample of atypical drawingisa sheet is shownin Table <.J

Notes:

Disability in the wor!place

Following a suitable ris! assessment, the design of the building to incorporate disabled accesswill need to be considered. 'd$ice can be found in Design of uildings and their approaches to

meet the needs of disaled people . Code of practice) 8ritish (tandard 400A300.

(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 8ills of Guantities

The le$el of detail re#uired at this stage will depend on the method of appointing the @ainContractor see (ection 1.

2 CCF-' (006




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 thenumber of !ey elements within the construction pro%ect and how they are inter)dependent ontime.

Design

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

2 CCF-' (006




Ta&le .1 Room Daa Shee eample

-99@A -9LL C9T'"?- E'(H 'D (T9-';?-99@ 9A ;P3

("_?A :@ I.4@9CCBP'C A 3

Ealls on combustible cored insulated panels with Foodsafe finish bothsides, on an insulated stainless steel !erb, concrete filled.

2 CCF-' 3004






Ceiling on combustible cored insulated panels.

2 CCF-' 3004




Doors (liding insulated doors, on fermod trac! into other areas, am

personnel doors to ha$e $ision panels, and stainless steel do

furniture.

DrainagePlumbing o handwash sin!, 3 o washdown points, drainage chani hose

down point, HE feeds to e#uipment and cold feed.

?lectrical (er$ices ='TP soc!et outlets, 4' soc!et outlets, tannoy, ?FM& firealarm, both sounder and _enon beacons, 8roen $al$es.

2 CCF-' 3004




Lighting :I0 lu6, emergency lighting and lighting controller.

2 CCF-' 3004




Oentilation'CHeating 8alanced $entilation system, no recirculated air, 30 change/ hour.

(pecial -e#uirements P' spea!ers speechmusic1, supplies to traywash fed from bar

trun!ing in roof $oid1, 3 no compressed air

2 CCF-' 3004






?#uipment Easher ) 00ME electrical loading to be confirmed. Easher waterre#uires 3I0itreshr, preferably hot

2 CCF-' 3004




oise le$el :0:I d8 '

2 CCF-' 3004



Ta&le .1 Room Daa Shee eample

I



-99@A -99@ 9A

("_?A

9CCBP'C^A

-9LL C9T'"?- E'(H 'D (T9-';? ;P3

:@ I.4@ 3



Ealls on combustible cored insulated panels with Foodsafe finish both

sides, on an insulated stainless steel !erb, concrete filled.

Floor

Ceiling

Doors

(eamless floor finish laid to falls, to channel drains

on 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.

DrainagePi umbi ng

?lectrical (er$ices

o handwash sin!, 3 o washdown points, drainage chanrV

hose down point, HE feeds to e#uipment and cold feed.

=' TP soc!et outlets, 4' soc!et outlets, tannoy, ?FM firealarm, both sounder and _enon beacons, 8roen $al$es.

I





oise le$el :0:I d8 '



Ta&le .( )ample ; Conracors ,rie" echanical and )lecrical AE)B Chec5lis'

Re"rigeraion

Discree or cenral 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 -4:', -:0:', -I0J, -:0JC1, HC isobutene, propane1

V Consider secondary cooling> glycol, brine, water

V Long pipe runs, high refrigerant chargeV Pumped refrigerant system $ direct e6pansion

V "s the life cycle of the plant long term, medium or short

V "s refrigerant lea! detection included or offered

*roduc loads Ahe cooling duy depends on he emperaure 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, sie, shape, water content

V "s the product wrapped or open

Sandards and legislaion A-egislaion demands ha sandards are o&ser/edB

V (afety (tandard ?4J> is installer con$ersant



V Pressure ?#uipment Directi$e <J34?C

V "nstitute of -efrigeration Codes of Practice

ainenance

V (er$ice inter$als for main items, e.g. compressors

V Does the installer ha$e maintenance facilities and #ualified staff

V @aintenance inter$als Client dri$en1 Daily, wee!ly, monthly, #uarterly1

)""iciency

V Bse items which attract ?nhanced Capital 'llowances ?C's1

V Temperature difference between condensing and ambient

V Temperature difference between room and e$aporating

V 9$ersie allowed on the dri$e motors

V 'ir)cooled condensers or e$aporati$e condensersV Eater supply for e$aporati$e condensers

V Oariable speed dri$es on pumps

V Low load efficiency of compressors.

)n/ironmenal

V oise limits

V 'mbient temperature

Ta&le .6 )ample Conracors ,rie" E) )ample Chec5lis' echanical

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 series of bullet points1 i.e.



V ;as

V Eater flow rate1

V Compressed air #uality oil)free1, pressure, flow rate, dew point, etc1V (team temperature, 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 . )ample Conracors ,rie" E) )ample Chec5lis' )lecrical

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.

) oteA "f this is not !nown, pro$ide a description of the tas! and sie 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 series of bullet points1 i.e. A

V ?lectrical power re#uirement $oltage, loads !E11

V Data re#uirement type of installation cat I or =1 number of points1

V (ecurity systems CCTO, "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 andor ducts to a hygienic standard will need to be

stated



Ta&le . )ample Conracors ,rie" E) )ample Chec5lis' 3eneral

V Confirm layout of proposed production e#uipment.

V Confirm ser$ices re#uirements to each item of production e#uipment.

) oteA 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. m4s air1, s gases

and fluids1, !E electricity1.

) oteA ' simple eso 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 .< Typical imea&le mapping ou main sages and imings in a "acory consrucion proec

Main Contractor Mobilisation

3 Start on Site

Site establishment, facilities and preparation

4 Excavate and hardcore to site compound

: Site offices and facilities inc. utilities

I Temporary security fencin to site and compound

= !ul" excavations to #$ sub base level

J %ardcore oversite to #$ level

Substructures and basement structure

Concrete column bases - f level

< S&' and concrete to toe beam and ret. (all )rid *+,

0Concrete perimeter ede beam retainin (all

n slab drainae and ducts - f level3Concrete bases etc to office buildin

4S&' and concrete external basement (alls %ardcore and concrete to #$ slab %ardcore and concrete basement slab /erimeter ede beam to office buildin n slab drainae and ducts - office buildin %ardcore and concrete #f slab - office

buildin

Super structure

<Structure steel frame - main buildin

30/urlins and sheetin rails 0 main buildin

31oadin doc" retainin (all

33Structural steel frame - office buildin

34/urlins and sheetin rails - office buildin

3:/recast concrete floor units

3I/recast concrete floors and stairs to office buildin

External envelope

3='oof claddin

3J'oof claddin to office buildin

3'oof lihts to circulation area

3<$lat panel (all claddin

40 nstallation of doc" levellers

4Curtain (allin to office and lin" bride

43all la3in panels

44 nstallation of personnel and industrial doors

4:Solar shadin to office buildin4ICurtain (allin to lin" structure

Internal finishes: Plnntroom (irons



I0Suspended ceilins

ICeramic (all and floor tilin

I3Toilet installations

I4Canteen installation

I:Carpenter 2nd fix and fittins

IIDecorations and floor finishes

Mechanical and electrical installations Production areas

I=Duct(or" and pipe(or" in roofservice void

IJDuct(or" drops to ceilin level

IElectrical fittins etc in f area

I<!elo( ceilin pipe(or" etc

=0Electrical cable trays etc in roofservice void=#rilles and louvres etc

=3Electrical cablin and fittins in roofservice void

Office building

=4Mechanical installation

=:Electrical installation

=I1ift installation

Plantroom



== %56s and duct(or" etc

=JElectrical installation to plantroom

= nstallation of flues etc

=<Electrical and s(itchear controls and panels

J01T% boilers and associated plant

JCompressed air system

J3/rocess coolin (ater plant

J4Electrical (irin to e7uipment

J:Chiller plant

JIater storae tan"

General

J=Test and commission certification

JJCommence installation and production e7uipment



* 2 + 4 89 :

; *< ** *2 *+ *4 *8 *9 *: *= *; 2< 2* 22 2+ 24 28 29 2: 2= 2; +< +* +2 ++ +4 +8 +9 +: += +; 4< 4* 42 4+ 44 4849 4: 4= 4; 8< 8* 82



Ta&le .? Typical dra$ing issue shee used o manage archiecural dra$ings



draing issue sheet pro!ect "#





DD

>

= *<

*<

*2

>

i

+*

? t

S

2<

2<

@

2:

2;

<:

MM

*<

*<

*<

*<

d

*<

< **

**

A **

**

**

n A

t B

<*

<*

<*

$%

G @ 6

<*

<*

<*

<*

8*

G <*

<*



draing title draing "# re$ision state & status





recipient name classification number of copies & action re'uired





Ccfp2QOl Ajl-rghts reserved

10. )ST+,-ISH CONTR+CT +ND S)-)CT +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 .1 re#uire

clients to appoint a principal contractor.

10.1 *rincipal conracors

Principal contractors are usually the main or managing contractors. ' principal contractor must bea 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 clients must consider these issues for designers and contractors they

appoint directh i.

V ?nsure that a suitable construction phase health and safety plan called &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 contractorsV -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





10.( Conrac procuremen opions

?$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 associatedwith that situation.

The traditional way to design and construct a food factory is to engage an architectdesigner, 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 Potter, <<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 theconstruction 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 consrucion ha%ards and heir managemen

Food product contamination, arising from haards generated during building operations, is an e$er)

present haard. ' contaminant found in the food by the consumer will be blamed o the manufacturer

who, in turn if 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

haards 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

haards and e6amples are gi$en in Table .



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



HA9A,D

CH?@"C'L

'nything tainting or

to6ic1

0:A;P$0"

Diesel fuel, sol$ents e.g. paraffin, white spirits1, wood preser$ati$es, disinfectants

particularly phenolics1, unsuitable cleaning materials, non)food compatible oils,

greases or mastics etc.

PH^("C'L

Foreign bodies1

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

@icroorganisms or

&bugs& and pests1

Flying and crawling insects, rodents, birds. @icroorganisms could include $isteria)

coliforms, Clostridium- "almonella3 from the en$ironment particularly soil1 and

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

F CC$' .223



;ood strategies and effecti$e management can reduce the ris! of food productcontamination. These are outlined in sections .3).: which consider there#uirements for contractors by the food manufacturer, re#uirements for foodmanufacturers by contractors and ongoing contract dialogue.Three points, howe$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 foodcompany are essential and fre#uent re$iew meetings need to ta!e place to ensurethe success of the pro%ect. ?fforts should be made to reduce the Yus and themYsyndrome.2. Contractors must recognise that whilst on)site, they must regard themsel$es asfood wor!ers and beha$e accordingly.4. Food manufacturers must recognise that the contractors ha$e similar e6pertisein their industry as ihey do in theirs and that sufficient time and faeihties ha$e tohe pro$ided to enable the contractors to complete their tas!s professionally and ontime.11.( Re!uiremens "or conracors &y he "ood manu"acurer

The food manufacturer client1 should pro$ide to the contractor all the necessaryinformation about its business to enable the contractor to wor! safely and reduce product contamination, and all facilities necessary for the contractor to completethe wor! professionally and effecti$ely. Ehere$er possible, a separate, self)contained compound should be pro$ided with all necessary amenities. (pecificre#uirements could includeA)N The client&s Health and (afety at Eor! PolicyN The clients& Company -ules and -egulations, and specific sections of theCompany&s Guality @anual, co$ering for e6ampleAN 'ccessN Cranes ) ade#uate insuranceN (ecurity

N Fire policyN 'ccidents ) action and reporting

N ;lass,metalandotherforeign

body policyNPersonalhygieneN?n$ironmentN'sbestos )

chec!on)siteregister beforewor!commence

s

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 disturbedremo$ed, this must be done by a

licensed contractor. Full details are a$ailable $ia the H(? publication &@anaging 'sbestos in

Premises& www.hse.go$.u!pubnsindg334.pdf

1.

(ite maps and locations of designated areas location 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 e.g. telephones, water, sewerage1 may

need to be pro$ided.

http://www.hse.gov.uk/pubns/indg223.pdf

http://www.hse.gov.uk/pubns/indg223.pdf



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 if 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 andor 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 andor e6tra pro$ision is needed.

11.6 Re!uiremens "or he "ood manu"acurer &y he conracor



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

contractors wor!ing on site.

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 e.g. @obile ?le$ated

Eor! Platforms @?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 ) ClientContractor ational (afety

;roup CC(;1 schemeA www.ecitb.org.u!

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

www.citb.co.u!

V "nstitution of 9ccupational (afety and HealthA www.iosh.co.u!

V Processing and Pac!aging @achinery 'ssociation PP@'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 andor an understanding of food product contamination haards and ris!

assessment.

11. anagemen and super/ision o" conac $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.

http://www.ecitb.org.uk/

http://www.citb.co.uk/

http://www.iosh.co.uk/

http://www.ppma.co.uk/


http://www.ecitb.org.uk/

http://www.citb.co.uk/

http://www.iosh.co.uk/




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 see .31.

V @anagers and super$isors of ingredient and pac!aging stores and also production departments

areas1 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&sliaison 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 e.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 haard is that of dust, although bro!en glass may also be a problem sin fragments can fly considerable distances e.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





11. anaging change

Bnder ideal conditions, the design aspects of the building pro%ect are agreed at an early and arenot 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. 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 &otification of "ntent to Oary& "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 costdelays 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 "O should refer the re#uest to the Pro%ect @anager.

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

G(1.

4. The potential "O should be discussed at the design team meeting and a design conceptagreed) to the evens of a quic+ response eing re#uired, the P@G( shall issue the "O to allteam members for comment.:. 'll team members must respond to the "O with details of any implications to the Programmeand 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

"O can be costed and the programme implications e$aluated. 'ny additional fees re#uired tocany out the "O should also be identified for discussion with the P@.=. The G( will establish the "O costs in con%unction with the subcontractors and in)housedepartments.J. The Planner will determine programme implications.@. The P@G( will maintain the "O register and determine whether the "O is designde$elopment or attributable to a client change.

F CC$' 2<<+) <: )






X

Ta&le 11.( )ample Conracors *ersonal Hygiene Rules

)/eryone $or5ing in a "ood "acory has an o&ligaion o comply $ih he la$ and a

responsi&iliy o $or5 sa"ely and o proec "ood "rom possi&le conaminaion

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 e.g. s!in

irritation or boils, upset stomach, $omiting or diarrhoea1 and are wor!ing in a food productionarea. 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 usually blue1 metal detectable plaster or

bandage issued 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 departmentfirst aid room. "f food handling e#uipment oringredients, food product or pac!aging materials are in$ol$ed, inform the client liaiseV officer

#uic!ly telephone 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 e6cept in designated areas1 must be !ept co$ered either by a hard hat where

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 o %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$' 2<<+



Ta&le 11.6 )+*-) H)+-TH E S+F)T4 INDUCTION H+NDOUT Sie Sa"ey

Consrains and Sie Rules'

. No persons are permied on sie unil HES inducion is recei/edJ howe$er, inducted personnel may escort $isitors.

3. +H Super/isors "or 7or5s *ac5age Conracors are o su&mi la&our reurn shees o

Sie anagemen. This procedure will enable effecti$e Yroll)callY following e$acuation.

4. Hard hats safety footwear mus &e $orn in all areas of the site.

:. "nduction labelstic!er is to be displayed on side of safety helmet.

I. 'll operations underta!en on site shall be in accordance with tas! specific ehod Saemen#

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 andor Health (afety-egulations is li!ely to lead to dismissal of the offending indi$iduals1 super$isors1contractors1.

J. The Principal Contractor has the authority to issue a KHealh E Sa"ey 7arning NoiceK toany indi$idual or contractor. -epeated offences will lead to dismissal.

=$ 'ny person found smo5ing in the building will be dismissed.

<. 'ny person found urinaing 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 thewor!s, safety e#uipment, or Eelfare Facilities will be instantly dismissed



.eral In"ormaion and Re!uiremens'

. 'll matters should be addressedreported to the (ite @anager, including any health an

safety concerns.

3. 'll accidentsin%uriesdangerous 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.

4. @embers of the (ite @anagement Team are appointed First 'iders. The First 'id !itA

located in the (ite 9ffice.

:. The Sie Noice ,oard is located in the Canteen@essroom. Principal Contractor (afety

Policy, safety notices, and other information are displayed.

I. '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 $ih $arning noices# and

must not enter cordoned)off areas.

J. 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

condiion a all imes. +ll conracors 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"ey

. Fire points are situated at $arious points around the building and are identified on the

emergency fire escape plan which is displayed in the Canteen@essroom. (ite 9ffice, and

at each indi$idual Fire Point location. ?6tinguishers are also located in the

Canteen@essroom. and (ite 9ffice.

F CC$' 2<<+



3. (mall fires may be fought with the e6tinguishers pro$ided. "f the blae cannot be

controlled, raise the alarm shout F"-?acti$ate Mla6onstri!e brea!)glass1, and e6it the

building $ia the fire escape e6its.

4. "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 *ermis are re#uired for any bare flame acti$ities, and can only be obtained

from the (ite @anager.

7el"are Faciliies' essroom and Toiles'

. 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.

3. Please use the toilet and $ashroom in a ci/ilised manner.

1(. UND)RT+2) )8UI*)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 thanafter 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 unloading areas or lorry par!s under control of either the

contractors1 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 insallaions

@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 *eneraions

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(. Healh and sa"ey issues

9n most sites the &Principal Contractor& will be the builder and he will control the H (

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$' 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 who

may appoint himself1 who has sufficient understanding and resource to ta!e on the role.

1(. 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 specialistindustrial cleaner.Eith respect to new e#uipment, there are li!ely to be few microbial pathogens associated with thee#uipment, though the e#uipment may contain general engineering debris oils, greases, swarf1that may need to be remo$ed before the e#uipment enters the building. For e#uipment mo$edfrom 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 most suitablyincorporated with a ma%or strip down1 before it enters the production areas. There ha$e beenmany e6amples of pathogens being introduced into new factories from e#uipment beingtransferred from other food manufacturing sites.

1(.< *rogramme and cosTo 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$er, there will be a costimplication, sometimes #uite se$ere, due to the delay and disruption that will ine$itably be causedto the builder, who may, in turn, ha$e to delay and then accelerate his wor!s



,Insallaion

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 minimi66

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. )!uipmen insallaion 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 sie, 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 Insallaion Chec5lis

. Ris5 assessmens:mehod saemens ) Has the rele$ant documentation been forwarded andaccepted &e"ore any e#uipment is deli$ered to site

3. Counry o" origin ) There may be procurement and deli$eryshipping restrictions i.e.customs1.

4. O"";loading measures ) 8e mindful that some e#uipment can be loaded at source onto $ehiclesusing special measures e.g. e6tended for!s, craneage etc.1.

:. Responsi&iliy "or o"";loading ) Preferably the e#uipment installer.

I. +gree machinery ser/ices mari ) Finalise and agree matri6 with e#uipment supplier well inad$ance of deli$ery. 'gree scope of wor!s, demarcation points and distances.

=. )!uipmen dimensions ) will it fit through any doc! le$eller opening

J. )!uipmen $eigh ) is there a low or high centre of gra$ity

. )!uipmen access ) route through building to be agreed at design stage and any temporaryopenings to be detailed. Particularly important where e#uipment is to be located on st floorareas. Temporary hardcored ramps to be considered as well as openings through e6ternal claddingif e#uipment is too large to fit through any industrial doorsdoc! le$ellers.

<. Roue ) Carry out a dilapidation sur$ey on ceilings, walls floors along the machine accessroute and issue a copy to the e#uipment installer for their reference and agreement copy to begi$en to Client1.

0. *rogramme ) Consider the $ulnerability of the floorswallsceilingsser$ices and the impactany e#uipment installations would ha$e on these. 'rrange any protection and agree dates withade#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$er re!uiremens ) 're there ade#uate numbers of transformers a$ailable fortools and tas! lighting "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 inwallsceilings etc. "dentify responsibilities for carrying out associated builders& wor!.





.

F CC$' 2)G,+)0I)





4. Co$er the process lines and electrical supplymonitoring units to protect them from ingress of

contaminants and cleaning fluids.:. Bsing appropriate access e#uipment, manually clean o$erhead structures e.g. beams, light fittings,ledges or pipewor! where nuts, bolts, washers etc. may ha$e been left1 and HO'C ductwor!. 8ycleaning 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, thesetechni#ues do not remo$al all soiling, wet cleaning techni#ues will ha$e to be used. From this stageon, all water used should be of potable #uality. (imilarly, all cleaning and disinfectant chemicals usedmust be food grade and from a reputable supplier. They may not necessarily be the chemicals finallychosen for routine cleaning and disinfection see 4.41 as they will be primarily chosen to remo$eoils, grease, lubricants etc., but their use at this stage allows the food product to be processed ininitial trials to be &tasted& if desired.

I. Eet clean the drains followed by the walls and the floor using appropriate detergents anddisinfectants 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 necessaryto pro$ide total access for cleaning fluids.

J. Clean all processing lines using a rinse)detergent)rinse)disinfectant)rinse strategy. For li#uidhandling 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$e immediately upstream. "f pumps are notused and pipewor! does not drain naturally to the floor, disconnect the lines at the lowest point andflush from a hose to remo$e debris. Clean electrical supplymonitoring units with damp cloths oralcoholic wipes. 9nly use water hoses if the units are suitably protected *"P==1.

. 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 berecleaned and or reconfigured as appropriate.

. Clean any residual debris off the floor in a way that does not spread the contamination bac! ontothe processing e#uipment.

0. Finally, following any reconfigurationmaintenance wor!, reclean the process lines again to ma!eabsolutely sure that contamination has been remo$ed. 't this point the plant cleaning and hygienespecialist needs to be in$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 liss and conracor: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 architectPro%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 mechanical,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$ed andcertificates issued with a schedule of outstanding items, howe$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$en to the client but the YsiteY remains theresponsibility of the contractor. Careful monitoring of those areas Yhanded)o$erY is re#uired as

damage caused by the e#uipment installers e.g. floors, walls, !erbs1 is then the responsibility of

the client.

F CC$' 2<<+

)0 )



' 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 9T 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 tounderta!e before the product is ready to go to mar!et. "t is beyond the scope of this chapter toco$er all these tas!s, though the following gi$es information on some of the !ey points.Health and safetyThe factory manager must ensure that a Fire -is! 'ssessment is carried out in the new building ore6tension. This is a legal re#uirement under the Fire Precautions Eor!place1 -egs <<J (" <<Jno. :01. ' new or re$ised Fire Certificate may be re#uired and ad$ice should be sought fromthe local Fire 9fficer. Please note that whilst 8uilding -egulations 'ppro$al will ha$e beenaddressed 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$ement or action. ' Fire ?mergencyPlan must be de$eloped and implemented and all employees must be trained in the FireProcedures needed to safely e$acuate the building. The @ain Contractor must hand o$er the FireDetection andor Fire 'larm system to the client and ensure that sufficient employees withauthority are trained in the use andor maintenance of the system. The client must arrange for thesystem maintenance to be underta!en at the correct inter$als and for the Ycall outY emergencysystem to be subscribed. The client must ta!e the 9peration manuals into safe!eeping.'fter the installation of all the processing e#uipment and commissioning, it may be necessary toinstall further ?scape (ignage, ?mergency Lighting, 8eacons, (ounders, protected routes and theli!e. This is because the full sie, shape, and noise of the processing e#uipment may ha$e reduced

the effecti$eness of the Fire ?#uipment originally designed and installed.(ecurityThe client must control access onto the premises to pre$ent unlawful entry and possible sabotageor spoilage. Depending on the sie of the premises the client may use CC



T'll points at which food products are accessible within the premises i.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$ersend caps " pre$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.

ew staff must be trained to the necessary le$el in Food Hygiene Procedures and a record o the

training must be !ept. ew 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 ;@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$es areappropriately clothed and can underta!e rele$ant personal hygiene routines, e.g. toilet facilities

and handwashing.

The client must ensure that house!eeping during production1 and cleaning and disinfection

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



Hygienic Design. Coo

pro$iders. 'gain, production trials in which product will be consumed should not be underta!enuntil all pest control de$ices are installed.9nce production trials ha$e begun, solid waste disposal primarily waste pac!aging and product1should be considered. This is li!ely to in$ol$e the contracting of a waste disposal company andconsideration for the siting and control of waste collection de$ices e.g. s!ips1.

Process plant commissioning <Dr# < commissioning The client should ha$e recei$ed the operation and maintenance 9@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$ious mechanical, electrical or control issues areidentified and brought to the attention of the supplier. "t has been !nown for motors to ha$e beencross)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 thee#uipment, but without product this may not be possible.(ometimes it happens that a piece of e#uipment has to be commissioned before the refurbishmentis complete. This is where good communications and relations with the contractors1 are morethan useful. (uch commissioning needs careful planning but unless contamination ris!s are, andcan 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$ision to be surethat it is not inad$ertently used. (imilarly, there may be issues with the late commissioning ofe#uipment. This may ha$e implications on the segregation andor 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 treatedas saleable. The ingredients raw materials and pac!aging are now introduced at th

F CC$' 2<<+



e

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 scheduling

The client must de$elop a method, either manually or by computer, to ensure that the proee

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$' 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 )ample o" a room &y room &asis snagging lis

snagging list

Dae'

*ROM)CT' O DU )

*R)S)NT'T

S

F

)

T C

ROO NO' CI* + T

N I

ROO D 9

N+)' I

N

)

IT)

NO'

D)SCRI*TION OF IT)S 3 CO)NTS

oteA all cleaning outstanding Bnable to inspect

flooring @astic seal to wall base channelconc. !erb3 Lea!ing pipewor! to EH8 abo$e !erb4 Eall to energy centre ) fill gap to

birdsbea!!erb

(uggest co$er flashing

: 8und ad%. energy centre ) fill gaps to inner

birdsbea!

I 'll unfinished cone, !erbing (uggest sealer coat)client to ad$ise

= 8irdsbea! to top of co$ing to floor

finish ) mastic all corner %ointsJ Complete floor co$ing at remo$able panel position 8und to whey wall ) all comments as : =< Merbing to remo$able panel ) @.;. !erb finish and

clean birdsbea! 0 Complete installation of drench showers

Figure 16.( Ceri"icae o" Compleion o" a5ing 3ood De"ecs

"ssued byA H. Potter 'ddressA S. (mith Foods Limited Hael '$enue

;reenfields "ndustrial ?state Hogwarts Eorcestershire E-0 4@P

?mployerA S. (mith Foods Limited Sob -eference ) I004

'ddressA Hogwarts site Certificate oA

"ssue DateA :th February 3003

ContractorA S. 8loggs Construction Ltd 'ddressA Contractors Court, 8uilders

Lane. @ortarfield, 8ristol 8- CM(

Eor!sA Bpgrade and refurbishment of e6isting facility including construction of new





?mployerA S. (mith Foods Limited 'ddressA

Hoewar.) she

Sob -eference ) I004

Certificate oA

"ssue DateA :th February 3003

ContractorA S. 8loggs Construction Ltd'ddressA Contractors Court.

8uilders Lane.

@ortarfield.

8ristol 8- CM(

Eor!sA Bpgrade and refurbishment of e6isting facility including construction of new

Loading @arshalling .'rea



(ituated atA S. (mith Foods Limited. Hoswarts site



ContractA SCT^"FC < 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 Ceri"icae o" *racical Compleion

Sob -eference A P-9S?CT P-?@"?- ) I004

Certificate o. 0

"ssue Date 33nd 'ugust 3000



"ssued byA'ddress

?mployer

'ddress

Contractor

'ddress

Eor!s

(ituated at

Contract

H. Potter

S. (mith Foods Limited Hael '$enue

;reenfields "ndustrial ?state Hogwarts

Eorcestershire E-0 4@P

S. (mith Foods Hogwartssite

S. 8loggs Construction Ltd Contractors

Court. 8uilders Lane, @ortarfield, 8ristol8- CM(

Bpgrade and refurbishment of e6isting Facility including construction of new Loading @arshalling 'rea

S. (mith Foods Limited, Hogwarts site

SCT"FC < with 'mendments



Bnder the terms of the abo$e ) mentioned Contract, " Ee hereby certify that Practical Completion of

Bpgrade and refurbishment of e6isting Facility including construction of new Loadi

@arshalling 'rea e6cludingA)8utchery 0, Feedstoc! "nta!e 0:. 9rganics 0I Canteen

0I:, -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 3st 'ugust 300

To be signed by or for the "ssuer named abo$e

(ignedA ................................................................................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 thefood 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!uiremens "or conracors &y he "ood manu"acurer



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Guidelines for the Hygienic Design,Construction and Layout of FoodProcessingFactories

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