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