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Hygienic Design of Food Factories
John Holah (Edited by), Huub L. M. Lelieveld (Edited by)
9780081016350, Elsevier Science
Paperback / softback, published 19 August 2016
824 pages
23.4 x 15.6 x 5 cm, 1.13 kg
"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
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.
Contributor contact details Woodhead Publishing Series in Food Science, Technology and Nutrition Dedication Preface Chapter 1: Business case assessment and design essentials for food factory building projects Abstract: 1.1 Introduction 1.2 The need for a new or refurbished food factory 1.3 A new product: generation, approval, specification and business plan 1.4 Determine process and mass flow 1.5 Conclusion Chapter 2: Determining equipment and process needs and how these affect food factory design Abstract: 2.1 Introduction 2.2 Brownfield projects: processes and equipment 2.3 Greenfield projects: processes and equipment 2.4 Future trends Part I: Regulatory issues and retailer requirements Chapter 3: EU food hygiene law and implications for food factory design Abstract: 3.1 The relevance of EU food hygiene law for the design of food factories 3.2 The objectives of EU food hygiene law 3.3 The EU General Food Law (GFL) 3.4 EU food hygiene law 3.5 Four types of EU food hygiene law 3.6 The combination of EU food hygiene law and other law on the design of food factories 3.7 Conclusions Chapter 4: Regulations on the hygienic design of food processing factories in the United States Abstract: 4.1 Introduction 4.2 Regulatory requirements in the United States 4.3 Guidance documents 4.4 Other agencies and considerations 4.5 Case study: a milk processing plant 4.6 Conclusion Chapter 5: Regulation relevant to the design and construction of food factories in Japan Abstract: 5.1 Introduction 5.2 Contents of regulatory requirements 5.3 Legal regulations concerning the Food Sanitation Act 5.4 Legal regulations other than those concerning the Food Sanitation Act 5.5 Industrial Safety and Health Act 5.6 Legal regulations concerning the environment 5.7 Case study 5.8 Future trends Chapter 6: Regulation and non-regulatory guidance in Australia and New Zealand with implications for food factory design Abstract: 6.1 Introduction 6.2 Food regulatory requirements in Australia and New Zealand 6.3 Trade regulations and requirements 6.4 Building requirements 6.5 Case study: food safety in meat processing 6.6 Future trends 6.7 Conclusion 6.9 Appendix 1: Australasian standards for building and construction 6.10 Appendix 2: Relevant food acts and regulations Chapter 7: Regulatory requirements for food factory buildings in South Africa and other Southern African countries Abstract: 7.1 Introduction 7.2 South African regulations and standards 7.3 Regulations and standards in other Southern African Development Community (SADC) countries 7.4 Future trends 7.5 Sources of further information Chapter 8: Retailer requirements for hygienic design of food factory buildings Abstract: 8.1 Introduction: private labels and retailers’ responsibility 8.2 Background to the British Retail Consortium (BRC Food) and the International Food Standard (IFS Food) 8.3 Global Food Safety Initiative 8.4 Retailers’ requirements 8.5 Future trends 8.6 Sources of further information and advice Chapter 9: Food factory design to prevent deliberate product contamination Abstract: 9.1 Introduction 9.2 Historical incidences of intentional food contamination 9.3 Food fraud versus intentional contamination 9.4 Prevention of intentional contamination 9.5 Future trends 9.6 Conclusions Chapter 10: Minimum hygienic design requirements for food processing factories Abstract: 10.1 Introduction 10.2 Site 10.3 Building design 10.4 Internal divisions 10.5 Building fabric 10.6 Services 10.7 Sources of further information and advice Part II: Site selection and factory layout Chapter 11: Aspects to be considered when selecting a site for a food factory Abstract: 11.1 Introduction 11.2 Product 11.3 Utilities 11.4 Sources of contamination 11.5 Regulations 11.6 Protection of the environment 11.7 Industrial zoning 11.8 Financial aspects 11.9 Personnel 11.10 Security 11.11 Access 11.12 Climate 11.13 Research and Development 11.14 Conclusions 11.15 Sources of further information and advice Chapter 12: The impact of factory layout on hygiene in food factories Abstract: 12.1 Introduction 12.2 Layout of plant grounds and outer perimeter 12.3 Layout of the outer plant building 12.4 General interior building layout requirements 12.5 Manufacturing layout 12.6 Future trends Chapter 13: Hazard control by segregation in food factories Abstract: 13.1 Introduction 13.2 Barrier 1: site 13.3 Barrier 2: factory building 13.4 Barrier 3: high care/risk areas 13.5 Barrier 4: product enclosure 13.6 Future trends Chapter 14: Managing airflow and air filtration to improve hygiene in food factories Abstract: 14.1 Introduction 14.2 Airflow 14.3 Air handling equipment 14.4 Air filtration 14.5 Air handling system monitoring and maintenance 14.6 Future trends 14.7 Sources of further information and advice Part III: Hygienic design of walls, ceilings and floors Chapter 15: Hygienic wall finishes for food processing factories Abstract: 15.1 Introduction 15.2 High performance paint coatings 15.3 Thermoplastic wall cladding systems 15.4 Stainless steel cladding 15.5 Reinforced resin laminates 15.6 Insulated panel walls and ceilings 15.7 Wall tiling 15.8 Future trends Chapter 16: Hygienic design of ceilings for food factories Abstract: 16.1 Introduction 16.2 Hygiene levels in food processing factories 16.3 Other factors affecting the type of ceiling system used in a food factory 16.4 Types of hygienic suspended ceiling systems 16.5 Walk-on type ceiling consisting of sandwich panels 16.6 Selection of the type and make of sandwich panels 16.7 Non-walk-on acoustical lay-in hygienic tiling systems 16.8 Hygienic coatings for production facilities without suspended ceilings 16.9 Hygienic coatings 16.10 Lighting 16.11 Heating, ventilation and air conditioning (HVAC) Chapter 17: Hygienic floor finishes for food processing areas Abstract: 17.1 Introduction 17.2 Establishing requirements for floor finishes in food processing factories 17.3 Selection of floor finish materials 17.4 Substrate requirements 17.5 Detailing within the design 17.6 Hygiene control during the renovation of existing floor finishes 17.7 Cleaning and maintenance 17.8 Future trends 17.9 Sources of further information and advice Chapter 18: Hygienic design of floor drains in food processing areas Abstract: 18.1 Introduction 18.2 Channel and gully system functional overview 18.3 Floor drains as a point of contamination 18.4 Material choice for floor drainage 18.5 Modelling flow in drainage channels 18.6 Incorporating hygienic design principles in drain design 18.7 Layout and zoning areas 18.8 Load capacity 18.9 Slip resistance 18.10 Fire prevention Part IV: Hygienic design of selected fixtures, utility systems and process support systems Chapter 19: Hygienic supply of electricity in food factories Abstract: 19.1 Introduction 19.2 Standards and regulations with which electrical equipment has to comply 19.3 Use of electrical equipment in the food industry 19.4 Materials of construction 19.5 Hygienic supply of electricity 19.6 Electrical cabinets and field boxes 19.7 Hygienic design and installation of electrical equipment 19.8 Data/telecommunication and control systems Chapter 20: Hygienic design of lighting in food factories Abstract: 20.1 Introduction 20.2 Electric lighting standards 20.3 Use of daylight 20.4 Light intensity and uniformity of illumination 20.5 Functional lighting 20.6 Application of the appropriate lighting in warehouses 20.7 Lamps 20.8 Selection of armatures 20.9 Cleaning and maintenance of lamps and armatures 20.10 Innovative energy-saving lighting technologies and strategies 20.11 Hygienic recommendations with respect to electric lighting 20.12 Special duty lighting Chapter 21: Hygienic design of piping for food processing support systems in food factories Abstract: 21.1 Introduction 21.2 Location of support systems and building services within the food factory 21.3 General hygienic requirements for food processing support piping within the factory 21.4 Specific hygienic design requirements for food processing support piping in rooms of different hygienic class Chapter 22: Hygienic design of exhaust and dust control systems in food factories Abstract: 22.1 Introduction 22.2 Mechanical ventilation 22.3 Hygienic design of exhaust systems for the removal of steam, heat, odours and grease–contaminated vapour outside the food factory 22.4 Hygienic design of specific exhaust systems used to handle effluents produced during the processing of food by means of heat 22.5 Installation of exhaust systems within the food factory 22.6 Cleaning of exhaust systems 22.7 Inspection and maintenance of exhaust systems 22.8 Hygienic design of exhaust facilities applied to extract heat, aerosols, bio-burden, odours and toxic vapours out of process rooms and technical areas 22.9 Hygienic design of dust control systems 22.10 Influence of the exhaust system on the air flow and air quality Chapter 23: Managing steam quality in food and beverage processing Abstract: 23.1 Introduction 23.2 Steam grade definitions 23.3 Plant steam 23.4 Filtered steam 23.5 Clean steam 23.6 Pure steam 23.7 Installation, operation and maintenance 23.8 Boiler installation 23.9 Steam pipe insulation 23.11 Appendix 1: Typical applications where steam is used in direct contact with the product/process 23.12 Appendix 2: Typical chemicals, which are generally added to the feedwater as part of a water treatment programme 23.13 Appendix 3: Chemicals that are approved by the Food and Drink Administration (FDA) in the USA for use with food and beverage products with acceptable concentration for each chemical Chapter 24: Hygienic design of walkways, stairways and other installations in food factories Abstract: 24.1 Introduction 24.2 Determining the equipment needs 24.3 Future trends 24.4 Sources of further information and advice 24.5 Acknowledgement Part V: Hygienic design of specific factory areas Chapter 25: Hygienic design of entries, exits, other openings in the building envelope and dry warehousing areas in food factories Abstract: 25.1 Hygienic design of foundations, support structures, external walls and roofs 25.2 Hygienic design of entry, exit and storage points 25.3 Entry doors – visitors and employees 25.4 Truck docks (loading, unloading) 25.5 Storage – dry warehousing 25.6 Cold storage (including freezer storage) 25.7 Sanitary design of openings in the building envelope 25.8 Future trends Chapter 26: Effluents from the food industry Abstract: 26.1 Introduction 26.2 Effluent characterisation 26.3 Sequence of processes and operations 26.4 Microbiological hazards for the food factory 26.5 Sources of further information Chapter 27: Design of food storage facilities Abstract: 27.1 Introduction and definitions 27.2 General design requirements 27.3 Storage facilities for dry products and dry cleaning requirements 27.4 Wet cleaning of storage facilities and storage of liquid products 27.5 Future trends Chapter 28: Design, installation and operation of cleaning and disinfectant chemical storage, distribution and application systems in food factories Abstract: 28.1 Introduction 28.2 Storage of industrial detergents, disinfectants and associated products 28.3 Hygiene chemical distribution and point of use location within production areas 28.4 Dose, control and application of hygiene chemicals 28.5 Dry cleaning and goods area 28.6 Cleaning rooms and utensil washing 28.7 Maintenance and cleaning of the cleaning systems 28.8 Requirements for transition to operation 28.9 Future trends Chapter 29: Design of food factory changing rooms Abstract: 29.1 Introduction 29.2 Legislation 29.3 Facilities design 29.4 Low risk/high risk barriers 29.5 Cross-contamination risks 29.6 Future trends Part VI: Managing building work and additional factory design considerations Chapter 30: Managing a factory building project: from development of a construction brief to commissioning and handover Abstract: 30.1 Introduction 30.2 Business case justification 30.3 Project definition 30.4 Construction brief 30.5 Contractual arrangements 30.6 Model contracts 30.7 Selecting a contractor 30.8 Overview 30.9 Managing construction 30.10 Equipment procurement, testing and installation 30.11 Commissioning and handover 30.12 Future trends 30.13 Sources for further information and advice Chapter 31: Inspecting hygienic design, hygiene practices and process safety when commissioning a food factory Abstract: 31.1 Inspecting for commissioning of manufacturing sites for hygienic design and practice 31.2 A site that has been newly designed and built for food manufacture 31.3 An existing manufacturing site that is being acquired by another company 31.4 An existing site that has no history of food production is to be adapted for food purposes 31.5 Preparing the team 31.6 Conclusion Chapter 32: An insurance industry perspective on property protection and liability issues in food factory design Abstract: 32.1 Introduction 32.2 Hazard analysis 32.3 Requirements for property insurance (fire, natural hazards, business interruption) 32.4 Requirements for liability insurance (occupational safety, third party, product and environmental liability) 32.5 Prevention and protection 32.6 Future trends 32.7 Checklist for easy reference 32.8 Sources of further information and advice Index
Subject Areas: Food & beverage technology [TDCT], Medical toxicology [MMGT], Medical microbiology & virology [MMFM]
