Hygienic Design of Food Factories

2nd Edition - May 25, 2023
Editors: John Holah, Huub Lelieveld, Frank Moerman
Language: English
Paperback ISBN:
9 7 8 - 0 - 1 2 - 8 2 2 6 1 8 - 6
eBook ISBN:
9 7 8 - 0 - 1 2 - 8 2 2 6 1 9 - 3

Advances in food safety knowledge, combined with the continuing rapid development of new food products, have had an impact on the need for improved hygiene in the food ma… Read more

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Advances in food safety knowledge, combined with the continuing rapid development of new food products, have had an impact on the need for improved hygiene in the food manufacturing infrastructure. This has created a need for the second edition of Hygienic Design of Food Factories, which expands all existing chapters and includes new topics, such as cold storage and the control of air in food refrigeration facilities. Additionally, chapters explore the prevention of food contamination when building during production, the risk assessment of which is becoming important globally, and hygienic building design regulations in Russia and Brazil.

Divided into 6 parts, the book is now thoroughly updated and expanded. Part one reviews the implications of hygiene and construction regulation in various countries on food factory design, while taking into account retailer requirements as well. Part two describes site selection, factory layout and the associated issue of airflow. Parts three through four and five then address the hygienic design of the 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, 2nd edition, continues to be an essential reference for managers of food factories, food plant engineers and all those with an academic research interest in the field.

Cover image
Title page
Table of Contents
Front Matter
Related Titles:
Copyright
Contributors
Preface
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
References
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
References
Part I: Regulatory issues and retailer requirements
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
References
Short title: GFL
Further reading
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
References
5: Legal requirements concerning hygienic and safety design of machinery, construction and reconstruction of food factories in Japan
Abstract
5.1: Introduction
5.2: Major laws concerning the food industry in Japan
5.3: Case study
5.4: Future trends
References
6: Regulation relevant to the design and construction of food factories in Russia
Abstract
6.1: Introduction
6.2: Food regulations
6.3: Regulations for food processing machines and engineering facilities
6.4: Future trends
7: Regulatory building requirements for food business in Brazil
Abstract
7.1: Introduction
7.2: Regulations issued by ANVISA (National Agency of Sanitary Surveillance)
7.3: Regulations issued by MAPA (Ministry of Agriculture, Livestock, and Food Supply)
7.4: Non-food safety standards
7.5: Key elements of hygienic design in Brazilian legislation
7.6: Future trends
Further reading
8: Regulations and guidance in Australia and New Zealand with implications for food factory design
Abstract
8.1: Introduction
8.2: Food regulatory requirements in Australia and New Zealand
8.3: Trade regulations and requirements
8.4: Building requirements
8.5: Future legislative changes in New Zealand
8.6: Sources of further information
9: Regulatory requirements for food factory buildings in South Africa and other Southern African countries
Abstract
9.1: Introduction
9.2: South African regulations and standards
9.3: Regulations and standards in other Southern African Development Community (SADC) countries
9.4: Future trends
9.5: Sources of further information
References
10: Retailer requirements for the hygienic design of food factory buildings
Abstract
10.1: Introduction: Private labels and retailers' responsibility
10.2: Background to the British Retail Consortium (BRC food) and the International Food Standard (IFS food)
10.3: Global food safety initiative
10.4: Retailer requirements
10.5: Approach to hygienic factory design
10.6: Future trends
10.7: Sources of further information and advice
References
11: Food factory design to prevent deliberate product adulteration
Abstract
Acknowledgments
11.1: Introduction
11.2: Historical incidences of intentional food contamination
11.3: Food fraud versus intentional adulteration
11.4: Prevention of intentional adulteration
11.5: Future trends
11.6: Conclusions
References
Further reading
12: Minimum hygienic design requirements for food processing factories
Abstract
12.1: Introduction
12.2: Site
12.3: Building design
12.4: Internal divisions
12.5: Building fabric
12.6: Services
12.7: Sources of further information and advice
References
Part II: Site selection and factory layout
13: Aspects to be considered when selecting a site for a food factory
Abstract
13.1: Introduction
13.2: Product
13.3: Utilities
13.4: Sources of contamination
13.5: Regulations
13.6: Protection of the environment
13.7: Industrial zoning
13.8: Financial aspects
13.9: Personnel
13.10: Security
13.11: Access
13.12: Climate
13.13: Research and Development
13.14: Conclusions
References
14: Hazard control by segregation in food factories
Abstract
14.1: Introduction
14.2: Barrier 1: Site
14.3: Barrier 2: Factory building
14.4: Barrier 3: Basic hygiene hazard reduction
14.5: Barrier 4: High hygiene areas
14.6: Barrier 5: Product enclosure
14.7: Future trends
References
15: Managing airflow and air filtration to improve hygiene in food factories
Abstract
15.1: Introduction
15.2: Airflow
15.3: Air handling equipment
15.4: Air filtration
15.5: Hygiene requirements for ventilation systems (VDI 6022)
15.6: GMP and cleanroom technology in food production
References
16: Air infiltration control to reduce hygiene hazards in refrigerated food processing and storage facilities
Abstract
Acknowledgment
16.1: Introduction
16.2: Infiltration of warm, humid air in refrigerated facilities
16.3: Consequences of air infiltration
16.4: Step-by-step strategy to eliminate air infiltration sources
16.5: Building design and installation routines to minimise the infiltration
16.6: Predictive modelling
16.7: Good operator practices to reduce infiltration
16.8: Proper maintenance to reduce air infiltration
16.9: Indoor climate control
16.10: Future research needs and technology advancement
16.11: Concluding remarks
References
Further reading
Part III: Hygienic design of walls, ceilings and floors
17: Hygienic wall finishes for food processing factories
Abstract
17.1: Introduction
17.2: High performance paint coatings
17.3: Thermoplastic wall cladding systems
17.4: Stainless steel cladding
17.5: Reinforced resin laminates
17.6: Insulated panel walls and ceilings
17.7: Wall tiling
17.8: Future trends
References
18: Hygienic floor finishes for food processing areas
Abstract
18.1: Introduction
18.2: Establishing requirements for floor finishes in food processing factories
18.3: Selection of floor finish materials
18.4: Substrate requirements
18.5: Detailing within the design
18.6: Hygiene control during the renovation of existing floor finishes
18.7: Cleaning and maintenance
18.8: Future trends
18.9: Sources of further information and advice
References
19: Hygienic design of ceilings in food factories
Abstract
19.1: Introduction
19.2: Hygiene levels in food processing factories
19.3: Other factors affecting the type of ceiling system used in a food factory
19.4: Types of hygienic suspended ceiling systems
19.5: Hygienic coatings for production facilities without suspended ceilings
19.6: Ceiling penetrations and other services
19.7: Heating, ventilation and air conditioning (HVAC)
References
20: Hygienic design of floor drains in food processing areas
Abstract
20.1: Introduction
20.2: Channel and gully system functional overview
20.3: Floor drains as a point of contamination
20.4: Material choice for floor drainage
20.5: Modelling flow in drainage channels
20.6: Incorporating hygienic design principles in drain design
20.7: Layout and zoning areas
20.8: Load capacity
20.9: Slip resistance
20.10: Fire prevention
References
Part IV: Hygienic design of selected fixtures, utility systems and process support systems
21: Hygienic supply of electricity in food factories
Abstract
21.1: Introduction
21.2: Standards and regulations with which electrical equipment has to comply
21.3: Use of electrical equipment in the food industry
21.4: Materials of construction
21.5: Hygienic supply of electricity
21.6: Electrical cabinets and field boxes
21.7: Hygienic design and installation of electrical equipment
21.8: Data/telecommunication and control systems
References
22: Hygienic design concepts for lighting in the food industry
Abstract
22.1: Introduction
22.2: Use of daylight
22.3: Light bulbs
22.4: Outdoor lighting
22.5: Light intensity and uniformity of illumination
22.6: Factors responsible for variations in light intensity and uniformity
22.7: General lighting
22.8: Local lighting (task lighting)
22.9: Luminaires
22.10: Lighting control and energy efficiency
22.11: Cleaning and maintainance of lamps and luminaires
22.12: Hygienic design requirements for lamps
22.13: Hygienic design requirements for luminaires
22.14: Hygienic installation of luminaires
22.15: Hygienic design requirements for evacuation and emergency lighting
22.16: Conclusions
References
23: Hygienic design principles for exhaust and dust control systems in food factories
Abstract
23.1: Introduction
23.2: Mechanical ventilation
23.3: Hygienic design of exhaust systems for the removal of steam, heat, odors and grease-contaminated vapor outside the food factory
23.4: Hygienic design of specific exhaust systems used to handle effluents produced during the processing of food by means of heat
23.5: Installation of exhaust systems within the food factory
23.6: Cleaning of exhaust systems
23.7: Inspection and maintenance of exhaust systems
23.8: Hygienic design of exhaust facilities applied to extract heat, aerosols, bio-burden, odors and toxic vapors out of process rooms and technical areas
23.9: Hygienic design of dust control systems
23.10: Influence of the exhaust system on the air flow and air quality
References
24: Managing steam quality in food and beverage processing
Abstract
24.1: Introduction
24.2: Steam grade definitions
24.3: Plant steam
24.4: Filtered steam
24.5: Clean steam
24.6: Pure steam
24.7: Installation, operation and maintenance
24.8: Boiler installation
24.9: Steam pipe insulation
Appendix 1: Typical applications where steam is used in direct contact with the product/process
Appendix 2: Typical chemicals, which are generally added to the feedwater as part of a water treatment programme
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
References
25: Hygienic design of walkways, stairways, and other installations in food factories
Abstract
Acknowledgment
25.1: Introduction
25.2: Determining the equipment needs
25.3: Future trends
25.4: Sources of further information and advice
Part V: Hygienic design of specific factory areas
26: Hygienic design of entries, exits, and other openings in the building envelope and dry warehousing areas in food factories
Abstract
26.1: Hygienic design of foundations, support structures, external walls, and roofs
26.2: Hygienic design of entry, exit, and storage points
26.3: Entry doors – Visitors and employees
26.4: Truck docks (loading and unloading)
26.5: Storage – Dry warehousing
26.6: Cold storage (including freezers)
26.7: Sanitary design of openings in the building envelope
26.8: Future trends
27: Design, installation and operation of cleaning and disinfectant chemical storage, distribution and application systems in food factories
Abstract
27.1: Introduction
27.2: Safety
27.3: Delivery and storage of industrial detergents, disinfectants and associated products
27.4: Hygienic chemical distribution and location of point of use within production areas in open plant foam cleaning
27.5: Dose, control and application of hygiene chemicals
27.6: Dry cleaning
27.7: Cleaning rooms and utensil washing
27.8: Maintenance and cleaning of the cleaning systems
27.9: Requirements for transition to operation
27.10: Future trends
References
Further reading
28: Design of storage facilities for food
Abstract
28.1: Introduction and definitions
28.2: General design requirements
28.3: Storage facilities for dry products and dry cleaning requirements
28.4: Wet cleaning of storage facilities and storage of liquid products
28.5: Future trends
References
29: Design of food factory changing rooms
Abstract
29.1: Introduction
29.2: Legislation
29.3: Facilities design
29.4: Medium/high hygiene barriers
29.5: Cross-contamination risks
29.6: Future trends
References
Further reading
Part VI: Managing building work and additional factory design considerations
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
31: Hygienic design of piping for food processing support systems in food factories
Abstract
31.1: Introduction
31.2: Location of support systems and building services within the food factory
31.3: General hygienic requirements for food processing support piping within the factory
31.4: Specific hygienic design requirements for food processing support piping in rooms of different hygienic class
References
32: Inspecting for commissioning of manufacturing sites for hygienic design and practices
Abstract
32.1: Introduction
32.2: A site that has been newly designed and built for the purpose of food manufacture
32.3: An existing manufacturing site that is being acquired by another company
32.4: An existing site that has no history of food production is to be adapted for food purposes
32.5: Preparing the team
Further reading
33: Prevention of contamination of food products when production is continued during building activities
Abstract
33.1: Introduction
33.2: Initial hazard analysis
33.3: Undetaking building maintenance and construction work
33.4: Return of work activity area to production
References
34: An insurance industry perspective on property protection and liability issues in food factory design
Abstract
34.1: Introduction
34.2: Hazard analysis
34.3: Requirements for property insurance (fire, natural hazards, business interruption)
34.4: Requirements for liability insurance (occupational safety, third party, product and environmental liability)
34.5: Prevention and protection
34.6: Future trends
34.7: Checklist for easy reference
34.8: Sources of further information and advice
Index

John Holah

Prof. Dr. John Holah is an applied microbiologist focused on the prevention of microbial, chemical, and foreign body contamination of food during manufacture and retail distribution. He is currently Technical Director of Holchem Laboratories (UK), a major supplier of cleaning chemicals, disinfectants and hygiene services. He is a Visiting Professor in Food Safety at Cardiff Metropolitan University and was previously Head of Food Hygiene at Campden BRI. He has been a member of the EHEDG (the European Hygienic Engineering and Design Group) since 1989 and has also chaired ISO Working Groups producing standards on hygienic design and lubricants and chaired the GFSI Working Group on the hygienic design of food facilities and equipment. He is a co-editor in the other two Elseveir books. He has published and presented hundreds of scientific papers, technical articles and presentations in food safety and hygienic design.

Affiliations and expertise

Technical Director, Holchem Laboratories; Visiting Professor, Food Safety Cardiff Metropolitan University, UK

Huub Lelieveld

Prof. Dr. h.c. H.L.M. (Huub) Lelieveld is President of the Global Harmonization Initiative and Fellow of the International Academy of Food Science and Technology, and was formerly at Unilever in Vlaardingen, The Netherlands. He editor or co-editor of numerous books, including several on hygiene and food safety management; novel food processing technologies and harmonization of food safety regulations. He produced chapters for many books and encyclopaedia, hundreds of scientific articles and articles for magazines and presented hundreds of papers, globally. He has been awarded doctor honoris causa at the National University of Food Technologies in Kiev, Ukraine.

Affiliations and expertise

President of the Global Harmonization Initiative (www.globalharmonization.net)

Frank Moerman

Frank Moerman graduated with an MSc. in Bioengineering from the University of Ghent (1991), and a BSc. in Education from Artevelde University College Ghent (2006). He worked as a fine chemical production engineer for Aji-no-moto, Co. and as a food technologist/quality manager for Kerry Ingredients. Currently he is a doctoral researcher in food/phyto-chemistry at the Catholic University of Leuven/KU Leuven. In 2002, he became a member of the European Hygienic Engineering and Design Group (EHEDG), acting as chairman of the Belgium regional section until 2005 and received an achievement award for his services in 2013. He participated in the European 5th framework project “HYFOMA” (2002-2004) on the Steering Committee. He is an active member of several EHEDG working groups, is author of a number of articles and book chapters on hygienic engineering & design and is an active trainer in hygienic design and cleaning technologies.

Affiliations and expertise

Catholic University of Leuven/KU Leuven, Belgium