Consuming high quality & safe food

Transcription

1 Hygienic Building Concepts as a basis for adequate Frank Moerman 1 & Karel Mager 2 1 Catholic University of Leuven - KU Leuven & EHEDG Belgium 2 Givaudan - EHEDG Netherlands Workshop : Trends in the Food Industry, Consuming high quality & safe food 1

2 Barbeque: Fridge Essential elements to preserve the quality and safety of food during food manufacturing 2

3 Certifying Bodies Hygienic Design HACCP Cleaning + Disinfection Pest Management Personal Hygiene + GMP Objectives of hygienic design of food factories 3

4 Hygienic food factory design provides: Defense against external factory hazards. Defense against internal factory hazards: No pests harbourage Easy to clean Internal flows of people, product, packaging, air and wastes to prevent cross-contamination. Security against deliberate contamination (food defense program). The maintenance of hygienic conditions via structure rigidity appropriate foundations, steelwork, floor slabs. The Maintenance of hygienic conditions via material durability Compliance with customer/gfsi best practice. Control of pests based on the principles of HACCP 4

5 Principles of HACCP also apply to pest control: Identify the hazards Control the hazards Monitor the effectiveness of the controls Site selection 5

6 Site selection Building pest free food factories Environmental risks Available wildlife?? We don t want this!! Rats & mice = food safety risk! Site selection No adjacent farms with animals Avoid long grass Avoid adjacent water bodies No shrubs adjacent to factory walls No adjacent refuse dumps No adjacent animal rendering plant 6

7 Site selection Cheese factory Ditch: habitat for rodents, birds and insects One advantage: unwanted intruders (e.g., terrorists) have poor access to the food factory (food defense). Orientation Food Factory 7

8 Orientation of the food factory Prevailing winds must hit the visitor parking lot and administrative side of the building. Loading docks and refrigerated warehouses on the opposite side, away from the quarter with maximum sunshine, wind and/or rain. Exhausted air must be immediately carried away and diluted without entering the factory s air intake system. Surrounding environment 8

9 Barriers: fencing against cats, dogs, etc. Keep free of vegetation! Immediate surrounding of the food factory: vegetation 9 m Minimum >2 m hardstanding 100mm vegetation-free strip. Prefer 6 mm pebbled rock, 10 cm deep. 9

10 Immediate surrounding of the food factory: vegetation Areas in a perimeter of 3 m of the factory kept free of vegetation. Gravel strip and path around the factory building of at least 90 cm. No shrubs or plants in the close vicinity of the factory building. Place exterior lighting in locations away from the building From This Design To This More Sanitary Design Lighting angled downward, or towards the building Lights showing outward attract insects to the building at night 10

11 Recommendations for exterior lighting Provide bird spikes Avoid overhead electrical power transmission lines From This Design To This More Sanitary Design External lighting placed away from the building to avoid attraction of insects towards the building. Car parking and building lights should be angled downward, or towards the building. External lighting shielded to make light not visible from above. Low UV-producing lighting (e.g., no mercury vapour lamps). Exterior light fixtures may not allow roosting and nesting of birds. Use low UV-light producing lighting Energy distribution of the most important lamp types (without ballast) Source % Conduction/ convection heat % Total radiation % visible light % IR light % UV light Efficacy lm/w Incandescent lamp Tungsten Halogen Tubular fluorescent lamp ca. 40 ca Compact fluorescent High-pressure sodium lamp White SON < Low-pressure sodium lamp High-pressure mercury lamp Metal halide lamp LED lighting ~ Daylight Source: Light Industry Federation Ltd., 2001 Don t use high UV-producing lighting 11

12 Foundation Foundation preventing entry of burrowing rodents Curtain wall against burrowing rodents: at least 600 mm below ground level with a bottom member turned outwards for a distance of 300 mm 12

13 Exterior walls Avoid holes in exterior walls Example: Lizards 13

14 Seal all holes and cracks in exterior wallls Concrete may crack due to pipe expansion!! 6,30 mm metal hardware cloth Exterior walls: seal all wall openings Cover to prevent access of insects, rodents, snakes, lizards, etc. in weep holes From This To This More Design Sanitary Design 14

15 Exterior walls Bird slide From This To This More From This To This More Design Sanitary Design Design Sanitary Design Karel Mager & Frank Moerman Exterior walls From This Design To This More Sanitary Design 15

16 Roofing Roof design must prevent access and breeding of pests Many places where pests may hide Places where birds may perch Non weather- and waterproof asphalted roof. Liquids may leak to the inside through the many crevices in the asphalt barrier. Roof does not allow adequate drainage and cleaning. Open roof openings Roofs containing stone ballast should be avoided in the food industry as they are not cleanable. 16

17 Roof design must prevent access and breeding of pests Weather- and waterproof asphalted roof. Liquids will not leak to the inside. Roof allows adequate drainage and cleaning. All roof openings are closed hermetically. Little places where pests may hide or where birds may perch. Roof drainage downpipes 17

18 Prevent rodents from climbing roof drainage downpipes Bird spikes Spikes to prevent rodents from climbing the roof drainage downpipe Cover plate makes climbing of roof drainage downpipes by rodents more difficult Rat stop Outside piping 18

19 Provide outside piping with collars to prohibit climbing and entry of rodents in the food factory Interior walls 19

20 Seal all holes and cracks in interior walls Interior walls: preferably seal all pipe and cable penetrations From This Design To This More Sanitary Design 20

21 Ceiling Avoid nesting of birds close to the ceiling Pests control them externally! The swallow is protected! Excrements 21

22 Avoid nesting of birds close to the ceiling From This Design To This More Sanitary Design Use bird nets From This Design To This More Sanitary Design Use plastic strips Use doors Ceiling support structure Many places where rodents may walk on horizontal beams & ledges. Many places where pests may hide 22

23 Ceiling support structure From This Design To This More Sanitary Design Minimum amount of piping near the ceiling A lot of piping upon which rodents may walk From This Design To This More Sanitary Design 23

24 Ceiling: preferably seal all pipe and cable penetrations Sealed pipe penetration Floors and Drains 24

25 Floor penetrations Openings in floors for pipes should be guarded with a sleeve. Sleeve boot for single pipe floor penetrations leaves no floor opening. Seal gaps and cracks in floors Holes in the floor Cracks in the floor 25

26 Avoid drains that allow entry of rodents in the factory Don t use P-traps Utilities 26

27 Utilities Worn cladding: pests may penetrate in the fibre insulation Don t use entangled cabling: pests may harbour between the cables Door openings and doors 27

28 Doors Unsealable gap between door and floor if floor levels are not maintained! Gap provides access of pests (rodents, insects, etc.) Fast acting doors Don t use guiding channels that may accumulate dirt. Horizontal sliding doors Dirt on bottom side can fall into the product Vertical roller door Vertical sliding doors 28

29 Vestibules provide double barrier against pests Air lock with floor plinth acting as a traffic barrier to prevent transfer from contaminants from one area to another area. Door opening: appropriate plastic strip curtains Plastic strips no longer suitable to prevent entry of insects From This To This More Plastic strips suitable to prevent entry of insects, not of rodents Design Sanitary Design 29

30 Door opening: appropriate air curtain Inappropriate air curtain allows entry of insects Air curtain prohibits entry of insects, but not of rodents Double air curtain barrier: less risk for entry of insects Rodent/bird access still possible!! From This Design To This More Sanitary Design 30

31 Inside ligthing Low Lux Less insects attracted More insects attracted High Lux Light intensity required in food areas Location lux (lm/m 2 ) Exterior, plant perimeter 110 Receiving docks 110 Shipping docks Warehouses 220 Process areas Inspection points Packaging area Offices Corridors 220 Note: Luminance is a measure of the intensity of illumination on a surface, and reveals how much luminous flux, as a measure of the total "amount" of visible light, is spread over a given area. The amount of lux is the ratio of the totally received amount of light, expressed in lumen, and the size of the illuminated area expressed in square metres (1 lux = 1 lm/m²). Core of the food factory Outer shell of the food factory Lower light levels in the outside shell of the food factory: less insects attracted 31

32 Loading docks Loading docks with dock-seals may prevent/reduce pests Dock shelters such as canopies above and dock-seal systems such as cushion-closure seals around the truck doorways will reduce the entry of insects, rodents & birds. 32

33 Loading docks without pits are required Dock levellers should not have pits under the plates Pit open to the outside environment allowing access of insects and rodents to the pit and finally the factory From This To This More Design Sanitary Design Loading docks without pits are required Dock leveller with pit Pit open to the outside environment provides pests access to the food factory Dock leveller without pit From This To This More Design Sanitary Design 33

34 Loading docks without pits are required Step makes the entry of rodents more difficult Special design allows opening of trailer doors at the inside of the food factory, providing increased protection against pests. Dock levellers installed at the inside No entry of pests via the dock leveller possible Plastic curtain at loading dock opening Open plastic curtains when meat carcasses pass through!!! Plastic strips suitable to prevent entry of insects, not of rodents!! Plastic strips may be a source of cross-contamination (e.g., carcasses) 34

35 Good housekeeping Good house keeping Waste and no longer used equipment may not be stored outside the factory as they may act as a refugee for pests 35

36 Good house keeping No accumulation of waste inside the food factory Good house keeping All process equipment must be packaged or sealed All openings of equipment components must be sealed 36

37 Good house keeping Store all items in good order and keep the storage rooms tidy Whole mess may provide shelter to pests All items stored in good order (minimal shelter for pests) Pest Control Questions? Karel Mager Toxic Bait inside?! 37