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Hygienic design of food factoriesEdited by J Holah, Campden BRI, UK and H L M Lelieveld, formerly Unilever R&D, The Netherlands
Woodhead Publishing Series in Food Science, Technology and Nutrition No. 216
This book encompasses all the relevant and important topics regarding food facility design, construction and renovation.
Croatian Journal of Food Science and Technology
This book is an essential source of all relevant information on food facility design…I warmly recommend this book.
Croatian Journal of Food Science and Technology
The comprehensive coverage of the subject in this book makes it an important addition to the literature on food factory hygienic design.
This book is likely to become the standard industry reference for this highly important aspect of safe food provision.
International Journal of Dairy Technology
- an authoritative overview of hygiene control in the design, construction and renovation of food factories
- examines the implications of hygiene and construction regulation in various countries on food factory design
- describes site selection, factory layout and the associated issue of airflow
Food safety is vital for consumer confidence, and the hygienic design of food processing facilities is central to the manufacture of safe products. Hygienic design of food factories provides an authoritative overview of hygiene control in the design, construction and renovation of food factories.
The business case for a new or refurbished food factory, its equipment needs and the impacts on factory design and construction are considered in two introductory chapters. Part one then reviews the implications of hygiene and construction regulation in various countries on food factory design. Retailer requirements are also discussed. Part two describes site selection, factory layout and the associated issue of airflow. Parts three, four and five then address the hygienic design of essential parts of a food factory. These include walls, ceilings, floors, selected utility and process support systems, entry and exit points, storage areas and changing rooms. Lastly part six covers the management of building work and factory inspection when commissioning the plant.
With its distinguished editors and international team of contributors, Hygienic design of food factories is an essential reference for managers of food factories, food plant engineers and all those with an academic research interest in the field.
ISBN 1 84569 564 X
ISBN-13: 978 1 84569 564 4
October 2011
824 pages 234 x 156mm hardback
£195.00 / US$330.00 / €235.00
Usually dispatched within 24 hours
About the editors
John Holah is Head of Food Hygiene at Campden BRI, UK.
Huub Lelieveld was President of the European Federation of Food Science and Technology for four years, and was President of the European Hygienic Engineering and Design Group (EHEDG) for over 12 years. He has also been Chair and Co-founder of the Nonthermal Processing Division and Chair of the International Division of the Institute of Food Technologists, of which he is a Fellow. Until his retirement he was with Unilever, responsible for novel food preservation techniques and hygienic processing and plant design. For his outstanding commitment to food safety he was awarded the Food Safety Magazine Distinguished Service Award at the 2012 annual meeting of the Institute of Food Technologists (IFT) in Las Vegas, 2012.
Titles which may also be of interest:
Handbook of hygiene control in the food industry
Hygiene in food processing
Principles and practices for the safe processing of foods
Advances in microbial food safety
Hygiene in food processing
Contents
PART 1 REGULATORY ISSUES AND RETAILER REQUIREMENTS
PART 2 SITE SELECTION AND FACTORY LAYOUT
PART 3 HYGIENIC DESIGN OF WALLS, CEILINGS AND FLOORS
PART 4 HYGIENIC DESIGN OF SELECTED FIXTURES, UTILITY SYSTEMS AND PROCESS SUPPORT SYSTEMS
PART 5 HYGIENIC DESIGN OF SPECIFIC FACTORY AREAS
PART 6 MANAGING BUILDING WORK AND ADDITIONAL FACTORY DESIGN CONSIDERATIONS
Business case assessment and design essentials for food factory building projects
J Holah, Campden BRI, UK
- Introduction
- The need for a new or refurbished food factory
- A new product: generation, approval, specification and business plan
- Determine process and mass flow
- Conclusion
- References
Determining equipment and process needs and how this affects food factory design
H Schmidt, Endress+Hauser Messtechnik GmbH, Germany
- Introduction
- Brownfield projects: processes and equipment
- Greenfield projects: processes and equipment
- Future trends
- References
PART 1 REGULATORY ISSUES AND RETAILER REQUIREMENTS
EU food hygiene law and implications for food factory design
M van der Velde and B van der Meulen
- The relevance of EU food hygiene law for the design of food factories
- The objectives of EU food hygiene law
- The EU General Food Law (GFL)
- EU food hygiene law
- Four types of EU food hygiene law
- The combination of EU food hygiene law and other law in the design of food factories
- Conclusions
- References
Regulations on the hygienic design of food processing factories in the United States
N D Fortin, Michigan State University, USA
- Introduction
- Regulatory requirements in the United States
- Guidance documents
- Other agencies and considerations
- Case study: a milk processing plant
- Conclusion
- References
Regulation relevant to the design and construction of food factories in Japan
N Nakagawa, Kibun Foods Inc. and H Omura, The Japan Food Machinery Manufacturers’ Association, Japan
- Introduction
- Contents of regulatory requirements
- Legal regulations concerning the Food Sanitation Act
- Legal regulations other than those concerning the Food Sanitation Act Industrial Safety and Health Act
- Legal regulations concerning the environment
- Case study
- Future trends
- References
Regulation and non-regulatory guidance in Australia and New Zealand with implications for food factory design
J Gruber and D Panasiak, Food Liaison, Australia and I Thomas, Food Assurance Systems, New Zealand
- Introduction
- Food regulatory requirements in Australia and New Zealand
- Trade regulations and requirements
- Building requirements
- Case study: food safety in meat processing
- Future trends
- Conclusion
- References
- Appendix 1: Australasian standards for building and construction
- Appendix 2: Relevant food acts and regulations
Regulatory requirements for food factory buildings in South Africa and other Southern African countries
A Murray, Andrew Murray Consulting, South Africa
- Introduction
- South African regulations and standards
- Regulations and standards in other Southern African Development Community (SADC) countries
- Future trends
- Sources of further information
- References
Retailer requirements for hygienic design of food factory buildings
S Pfaff, Food Information Service (FIS) Europe, Germany
- Introduction: private labels and retailers’ responsibility
- Background to the British Retail Consortium (BRC Food) and the International Food Standard (IFS Food)
- Global Food Safety Initiative
- Retailers’ requirements
- Future trends
- Sources of further information and advice
- References
Food factory design to prevent deliberate product contamination
M Hennessey, F Busta and E Cunningham, National Center for Food Protection and Defense and J Spink, Michigan State University, USA
- Introduction
- Historical incidences of intentional food contamination
- Food fraud versus intentional contamination
- Prevention of intentional contamination [new section heading]
- Future trends
- Conclusions
- References
Minimum hygienic design requirements for food processing factories
J Holah, Campden BRI, UK
- Introduction
- Site
- Building design
- Internal divisions
- Building fabric
- Services
- References
PART 2 SITE SELECTION AND FACTORY LAYOUT
Aspects to be considered when selecting a site for a food factory
H L M Lelieveld, formerly of Unilever R&D, The Netherlands
- Introduction
- Product
- Utilities
- Sources of contamination
- Regulations
- Protection of the environment
- Industrial zoning
- Financial aspects
- Personnel
- Security
- Access
- Climate
- Research and development
- Conclusions
- Sources of further information and advice
- References
The impact of factory layout on hygiene in food factories
R R Maller Jr., PepsiCo America Beverages, USA
- Introduction
- Layout of plant grounds and outer perimeter
- Layout of the outer plant building
- General interior building layout requirements
- Manufacturing layout
- Future trends
- References
Hazard control by segregation in food factories
J Holah, Campden BRI, UK
- Introduction
- Barrier 1: site
- Barrier 2: factory building
- Barrier 3: high care/risk areas
- Barrier 4: product enclosure
- Future trends
- References
Managing airflow and air filtration to improve hygiene in food factories
S Wray, Filtration Engineering Ltd, UK
- Introduction
- Airflow
- Air handling equipment
- Air filtration
- Air handling system monitoring and maintenance
- Future trends
- Further reading
- References
PART 3 HYGIENIC DESIGN OF WALLS, CEILINGS AND FLOORS
Hygienic wall finishes for food processing factories
D Cattell, Kemtile Ltd., UK
- Introduction
- High performance paint coatings
- Thermoplastic wall cladding systems
- Stainless steel cladding
- Reinforced resin laminates
- Insulated panel walls and ceilings
- Wall tiling
- Future trends
Hygienic design of ceilings for food factories
F Wessels, Unilever R&D, The Netherlands
- Introduction
- Hygiene levels in food processing factories
- Other factors affecting the type of ceiling system used in a food factory
- Types of hygienic suspended ceiling systems
- Walk-on type ceiling consisting of sandwich panels
- Selection of the type and make of sandwich panels
- Non-walk-on acoustical lay-in hygienic tiling systems
- Hygienic coatings for production facilities without suspended ceilings
- Hygienic coatings
- Lighting
- Heating ventilation and air conditioning (HVAC)
Hygienic floor finishes for food processing areas
K Cook, Altro Ltd, UK
- Introduction
- Establishing requirements for floor finishes in food processing factories
- Selection of floor-finish materials
- Substrate requirements
- Detailing within the design
- Hygiene control during the renovation of existing floor finishes
- Cleaning and maintenance
- Future trends
- Sources of further information and advice
- References
Hygienic design of floor drains in food processing areas
M Fairley, ACO Technologies plc, UK
- Introduction
- Channel and gully system functional overview
- Floor drains as a point of contamination
- Material choice for floor drainage
- Modelling flow in drainage channels
- Incorporating hygienic design principles in drain design
- Layout and zoning areas
- Load capacity
- Slip resistance
- Fire prevention
- References
PART 4 HYGIENIC DESIGN OF SELECTED FIXTURES, UTILITY SYSTEMS AND PROCESS SUPPORT SYSTEMS
Hygienic supply of electricity in food factories
F Moerman, European Hygienic Engineering and Design Group, Belgium
- Introduction
- Standards and regulations with which electrical equipment has to comply
- Use of electrical equipment in the food industry
- Materials of construction
- Hygienic supply of electricity
- Electrical cabinets and field boxes
- Hygienic design and installation of electrical equipment
- Data/telecommunication and control systems
- References
Hygienic design of lighting in food factories
F Moerman, European Hygienic Engineering and Design Group, Belgium
- Introduction
- Electric lighting standards
- Use of daylight
- Light intensity and uniformity of illumination
- Functional lighting
- Application of the appropriate lighting in warehouses
- Lamps
- Selection of armatures
- Cleaning and maintenance of lamps and armatures
- Innovative energy-saving lighting techniques and strategies
- Hygienic recommendations with respect to electric lighting
- Special duty lighting
- References
Hygienic design of piping for food processing support systems in food factories
F Moerman, European Hygienic Engineering and Design Group, Belgium
- Introduction
- Location of support systems and building services within the food factory
- General hygienic requirements for food processing support piping within the factory
- Specific hygienic design requirements for food processing support piping in rooms of different hygienic class
- References
Hygienic design of exhaust and dust control systems in food factories
F Moerman, European Hygienic Engineering and Design Group, Belgium
- Introduction
- Mechanical ventilation
- Hygienic design of exhaust systems for the removal of steam, heat, odours, grease- and water-laden vapour outside the food factory
- Hygienic design of specific exhaust systems used to handle effluents produced during the processing of food by means of heat
- Installation of exhaust systems within the food factory
- Cleaning of exhaust systems
- Inspection and maintenance of exhaust systems
- Hygienic design of exhaust facilities applied to extract heat, aerosols, bio-burden, odours, toxic vapours out of process rooms and technical areas
- Hygienic design of dust control systems
- Influence of the exhaust system on the air flow and air quality
- References
Managing steam quality in food and beverage processing
R Stanley and F Pedrosa, Spirax Sarco Ltd., UK
- Introduction
- Steam grade definitions
- Plant steam
- Filtered steam
- Clean steam
- Pure steam
- Installation, operation and maintenance
- Boiler installation
- Steam pipe insulation
- References
- Appendix 1
- Appendix 2
- Appendix 3
Hygienic design of walkways, stairways and other installations in food factories
H Schmidt, Endress+Hauser Messtechnik GmbH, Germany
- Introduction
- Determining the equipment needs
- Future trends
- Sources of further information and advice
- Acknowledgement
PART 5 HYGIENIC DESIGN OF SPECIFIC FACTORY AREAS
Hygienic design of entries, exits, other openings in the building envelope and dry warehousing areas in food factories
D Graham, Graham Sanitary Design Consulting LLC, USA
- Hygienic design of foundations, support structures, external walls and roofs
- Hygienic design of entry, exit and storage points
- Entry doors – visitors and employees
- Truck docks (loading and unloading)
- Storage – dry warehousing
- Cold storage (including freezer storage)
- Sanitary design of openings in the building envelope
- Future trends
- References
Effluents from the food industry
G Tommaso, University of Sao Paulo, Brazil
- Introduction
- Effluent characterization
- Sequence of processes and operations
- Microbiological hazards for the food factory
- Sources of further information and advice
- References
Design of food storage facilities
J Hofmann, Hygienic Design Weihenstephan, Germany
- Introduction and definitions
- General design requirements
- Storage facilities for dry products and dry cleaning requirements
- Wet cleaning of storage facilities and storage of liquid products
- Future trends
- References
Design, installation and operation of cleaning and disinfectant chemical storage, distribution and application systems in food factories
P Brougham, Ecolab Ltd., UK
- Introduction
- Storage of industrial detergents, disinfectants and associated products
- Hygiene chemical distribution and point of use location within production areas
- Dose, control and application of hygiene chemicals
- Dry cleaning and goods area
- Cleaning rooms and utensil washing
- Maintenance and cleaning of the cleaning systems
- Requirements for transition to operation
- Future trends
- References
Design of food factory changing rooms
D Smith and J Holah, Campden BRI, UK
- Introduction
- Legislation
- Facilities design
- Low risk/high risk barriers
- Cross-contamination risks
- Future trends
- References
PART 6 MANAGING BUILDING WORK AND ADDITIONAL FACTORY DESIGN CONSIDERATIONS
Managing a factory building project: from development of a construction brief to commissioning and handover
K England, Morgan Sindall Professional Services, UK
- Introduction
- Business case justification
- Project definition
- Construction brief
- Contractual arrangements
- Model contracts
- Selecting a contractor
- Overview
- Managing construction
- Equipment procurement, testing and installation
- Commissioning and handover
- Future trends
- Sources of further information and advice
Inspecting hygienic design, hygiene practices and process safety when commissioning a food factory
P Overbosch, Metro AG, Germany and M Freund, Kraft Foods, USA
- Inspecting for commissioning of manufacturing sites for hygienic design and practice
- A site that has been newly designed and built for food manufacture
- An existing manufacturing site that is being acquired by another company
- An existing site that has no history of food production is to be adapted for food purposes
- Preparing the team
- Conclusion
- References
An insurance industry perspective on property protection and liability issues in food factory design
H Haymerle, Zürich Versicherungs – Aktiengesellschaft, Austria
- Introduction
- Hazard analysis
- Requirements for property insurance (fire, natural hazards, business interruption)
- Requirements for liability insurance (occupational safety, third party, product and environmental liability)
- Prevention and protection
- Future trends
- Checklist for easy reference
- Sources of further information and advice
- References