Sanitary Design and Construction of Food Processing and Handling Facilities
Sanitary Design and Construction of Food Processing and Handling Facilities
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FSHN0408/FS120: Sanitary Design and Construction of Food Processing and Handling Facilities
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Topics: Food Science and Human Nutrition | Commercial Food Safety | Schmidt, Ronald
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Introduction
To ensure safe food and adequate sanitation programs, the facility and surroundings in which food processing and handling operations
are conducted must be designed and constructed with sanitary design principles in mind. Many existing facilities do not have optimum
sanitary design and construction. Certain adjustments and/or renovations, where feasible, may be necessary. While often discussed
separately, sanitary construction and sanitary design are inter-related terminology.
The objectives of designing and constructing a sanitary food handling facility are to minimize harborages, eliminate the entrance of pests
and other sources of contamination. To design and build in features that protect the food product from contamination should be the
ultimate goal of planners and designers. The sanitary design features of a facility should be thoroughly evaluated on a periodic basis.
Such evaluation should include the following:
Premises, surroundings, and building site;
Exterior building design and construction features;
Interior building design and construction features; and
Operational flow and facility layout.
Location
As with real estate, an important feature of a sanitary food facility is "location, location, location". Ideally, a facility should be located away
from any contamination source (e.g., chemical plant, sewage treatment facility, salvage yard, livestock housing, cow pasture, or body of
water). For many existing facilities, the location may not be in the control of the facility management as other industries may have moved in
around the food facility. If, in the evaluation of the facility, it is found that sources of contamination are adjacent or near the building, special
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precautions are necessary to keep odors and contaminants from entering the yard or facility. When building a new facility, an inquiry
should be made regarding the previous occupants and the type of operations previously conducted at that location.
Exterior Lighting
A qualified lighting contractor should be consulted to evaluate adequacy and location of exterior lighting. While adequate lighting in
external areas of a facility is important for an overall sanitary operation, it is also necessary for security protection. However, since outdoor
lights may attract insects, the location of these fixtures is of critical importance for preventing insects from entering the facility. The location
of fixtures, especially when positioned over doorways, needs special attention. While high intensity, ultraviolet lights are often used for
security purposes, these lights are especially attractive to insects. It is recommended that lighting be mounted on poles or standards, be
at least 30 feet from buildings, and the light directed towards doorways and entrances (Graham, 1991). Lighting fixtures should be
shielded with a non-breakable, transparent material.
Exterior Walls
Building materials used for exterior walls vary in their need for preventative maintenance with regard to re-caulking of joints. For example,
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a poured concrete wall, while being expensive, needs less maintenance than other materials becuase it does not have seams. A
concrete block wall, if appropriately sealed, is also fairly maintenance free. Low-density concrete block (e.g., cinder block), commonly
used in domestic building, should be avoided unless an adequate sealer is used to avoid moisture intrusion and penetration of mold and
mildew. Concrete block walls should be sealed at the base and capped at the top. Corrugated metal siding is the least desirable material
for wall construction in a food handling facility. If used, it is imperative that it be adequately caulked along the base and at the seams.
Further, corrugated metal siding needs a good maintenance program to maintain an effective seal. The maintenance frequency is also
affected by climate conditions.
Roofs
Roof construction and design should not be overlooked. The roof should be designed and built so it can be kept clean, especially where
there is the possibility of product spillage or deposition on the roof. Food related dust (e.g., flour, powdered milk, or grain) can accumulate
on the roof and is an invitation to birds and insects. Smooth membrane type roofs are often the most desirable type of roof for food
processing facilities. Tar and gravel roofs are usually not recommended as they tend to attract dust and are very difficult to clean and
maintain.
Interior Walls
A cleanable, sanitary wall is one that is
hard, flat, and smooth;
free of pits, cracks, checks, and crevices;
impervious and non-absorbent;
resistant to cleaning and sanitizing chemicals;
corrosion resistant;
durable, easily maintained, and wear resistant; and
properly installed, sealed, and covered.
The wall should be installed and maintained to assure these properties are met from the floor to the ceiling. In addition, if used openings
and windows are used they should be installed and sealed to maintain the floor to ceiling properties.
There are several acceptable surfaces and materials available for walls in food processing and handling areas. Some of these are
described below:
Seamless Poured Concrete is often recommended, because of its lack of seams and associated maintenance requirements. However,
such walls should be finished smooth
and sealed. They can be improved by painting with a semi-gloss or gloss epoxy enamel. Specialized spray coatings for concrete walls
using epoxies and fiber glass are the most recent innovations which have proven to be impervious, cleanable, and durable.
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Concrete Block walls should be heavy density, non-porous blocks. Concrete block walls should be installed in a stack bond pattern (with
reinforcement), rather than a running bond pattern (see Fig. 1), as there is less hold up of dust and moisture. As stated previously, the
concrete blocks should be installed with a solid cap on the top course and without ledges or crevices. For additional durability and
cleanability concrete block walls should be appropriately sealed and finished by painting with semi-gloss or gloss epoxy enamel paint
covering.
Ceilings
Ceilings in food handling facilities are often neglected from a sanitary design and construction perspective. Ceilings should meet the
same objectives mentioned for walls. In addition, they need to be included in a preventative maintenance program. Improperly installed
ceilings, ceilings that promote condensation, or poorly maintained ceilings (e.g., flaking paint) can actually increase the potential for
overhead contamination of food products.
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Concrete ceilings are often recommended due to durability and minimal maintenance requirements. The most recommended
installation is the concrete slab with exposed double tee beam construction, which avoids ledges associated with I-Beam construction.
Concrete ceilings should be ground smooth, appropriately finished, and caulked at the joints.
Metal ceilings are not recommended due to condensation maintenance problems. Joints in metal panel ceilings are very difficult to
maintain. Corrugated or ribbed sheet metal ceilings are very difficult to clean and maintain, and have areas for harborages of insects and
rodents.
Wood ceilings, due to their porosity, are impossible to clean and maintain and must be avoided.
Dropped ceilings are acceptable only if properly installed. False ceilings, which create a crawl space above the ceiling for utilities and
services, should be avoided. The crawl space also becomes very attractive to insects and rodents, increasing the potential of product
contamination. Because fiberglass panels can be glued in and sealed at the joints they are acceptable in dropped ceiling application.
However, they are very difficult to maintain in a continuously sealed condition. Permanent dropped ceilings, which essentially create a
walk-on second floor above the processing area, are more desirable, especially those with a permanent smooth concrete ceiling. The
additional floor is used to run utilities, air handling ducts, fans, and similar services. In dairy and beverage plants, clusters of air operated
valve systems are used in automated process control systems for transporting liquids and cleaning solutions. Due to the complexity of
such valve clusters, they can create dust collection points over processing areas. They are often conveniently located in this upper floor
over a dropped ceiling and away from the processing area. Pipes, conduits, and similar accoutrements can be installed in vertical runs
through the ceiling into the upper floor. However, the junctures of these pipings need to be properly sealed and the seals maintained in
good repair.
Insulation
Insulation materials available do not meet the requirements for walls and ceilings in a food facility and are easily punctured or torn. Thus,
insulation, where used, should be installed so that it is not exposed and is sealed off from food processing and handling areas. The type
of insulation material used must also be considered. The insulation material should be:
nontoxic;
odorless;
unattractive to pests; and
non-contaminating.
With these criteria in mind, asbestos insulation is avoided. Fiberglass batting insulation should also be avoided as it attracts insects and
rodents, and the fibers may become airborne causing a contamination hazard. Acceptable materials may include: Styrofoam panels, foam
glass, and urethane. For special applications requiring insulation of equipment (e.g., steam piping), it is recommended that
manufacturers supply documentation of acceptance of the material in food applications.
Floors
Due to heavy day to day exposure to a variety of chemicals and food products, the floor in a food processing and handling facility is the
most difficult surface to maintain. Floors should be smooth, impervious, non-absorbent, corrosion resistant, cleanable and in good repair.
For safety considerations, floors should not be so smooth that they cause employees to slip and fall. In addition to being constructed and
sealed adequately, the floor should be installed to provide adequate slope for drainage and prevention of pooled water.
Today, highly acceptable materials are available for constructing and surfacing of floors in a food processing and handling facility. The
most recommended are sealed concrete, epoxy sealed concrete, quarry tile, and glazed tile. Each of these materials would provide an
acceptable floor surface if properly installed and maintained in good repair. Once the integrity of any of these surfaces becomes
compromised, they can harbor microorganisms, especially in wet areas. Unsealed concrete floors should be avoided as they are highly
porous and break down with continued exposure to chemicals. Once cracks, crevices, spalls, or other damage occurs, a concrete floor is
especially vulnerable to harboring microorganisms. Quarry tile or glazed tile floors require additional maintenance as grout lines can
erode causing a multitude of problems. As mentioned for walls and ceilings, metal and wood must be avoided as a floor construction
material.
Drains
Floor drains are a major source of microbial contamination in a food processing facility. Thus, they require special attention. Floor drains
should be:
of adequate number and size;
appropriately located;
designed and installed so that they are cleanable; and
maintained in good repair.
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Circular, catch basket drains are most often recommended provided that they are appropriately sealed and grouted to the floor, and are
maintained in good repair. Trench drains, although used in many operations, can have problems. A trench drain should be constructed
and installed to provide adequate slope or grade ensuring there is no standing water in the trench. The grouting and sealing of trench
drains at the floor junctures is also more difficult to maintain than the seals of circular drains.
Interior Lighting
Adequate lighting is important for all operations conducted in a food facility. This is especially true in cleaning and sanitizing and related
operations. Recommended lighting levels vary between regulatory officials and other sources. A general suggested range of lighting
recommendations has been presented in Table 1.
Table 1.
Light Intensity
Area
(Foot Candles)
Raw material receiving
20 - 30
Ingredient warehouse
20 - 30
30 - 40
Processing departments
55 - 65
Product inspection
110 - 130
Packaging
70 - 80
20 - 30
Maintenance areas
70 - 80
Administrative offices
60 - 90
Cafeteria
40 - 50
Locker rooms/restrooms
30 - 50
Light fixtures should be of the type approved for food facilities, and should be equipped with break resistant lenses or shatterproof
shielding. The fixtures should be designed to be moisture resistant and cleanable.
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Handwashing sinks
Handwashing sinks, lavatories, or stations should be:
conveniently located near food operations;
of sufficient number based on the size and function of the operation;
constructed and installed to meet plumbing codes including appropriate backflow prevention and no submerged inlets;
installed with faucets of sanitary design (preferably foot or electric eye operated);
supplied with hot (not steam) and cold water in order to provide an adequate flow of water at 85 - 100 F;
provided with an adequate supply of soap, single service towels, and a covered waste receptacle; and
maintained, cleaned, and kept in good repair.
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Figure 3.
Physical Separation
As much as is practicable, there should be a physical separation between raw and finished products and minimal entry into critical areas.
Such physical separation should be accomplished by installation of walls and doorways with anti-back tracking features, and by adjusting
air handling systems to provide positive pressure in finished product rooms. As the best physical separation can be undermined by
human error or improper personnel flow, there should be an operational and philosophic separation between raw and finished product.
This can be accomplished by barring employees working with raw materials from entering finished product rooms, this includes
maintenance and janitorial staff. It is recommended that standard operating procedures be developed and implemented regarding
product flow.
In addition to providing procedures for personnel and equipment within the facility, the movement of equipment in and out of the facility by
maintenance crews should also be considered. Color-coding is often used, with different colors identifying different areas of the facility.
Color-coding can be applied to clothing (e.g., uniforms, frocks), cleaning supplies (e.g., brushes, brooms, pails), containers (e.g. ,pails,
lugs), gaskets, forklifts, and any other equipment. Separation can also be accomplished by the installation of sanitizer systems (e.g., foot
baths, spray systems) inside entrance doors to critical areas. It is imperative that these sanitizer systems be maintained in good repair
and working order and that they are used. Visitors, suppliers, laboratory personnel, truck drivers, inspectors, management, and all other
individuals should be made aware of operating procedures with regard to separation between raw and finished products. Selfinspections by quality assurance personnel, regulatory inspections, or tours should be done in a counter product traffic direction starting
with finished product rooms and ending in raw material handling areas.
References
Food and Drug Admin. Current Good Manufacturing Practices in Manufacturing, Processing, Packing, or Holding Foods, 21 CFR 110
www.fda.gov (accessed May 9, 2005).
Food and Drug Admin. Grade A Pasteurized Milk Ordinance. www.fda.gov (accessed May 9, 2005).
Food Safety and Inspection Service. US Inspected Meat and Poultry Packing Plants, A Guide to Construction and Layout.
www.fsis.usda.gov (accessed May 9, 2005).
Graham, D. J. 1991. A Mind Set. Dairy Food Env. San. (July): 388-389; (August): 454-455; (Sept.): 533-534;(Oct.): 600-601;(Nov.): 669-670;
(Dec.): 740-741.
Graham, D. J. 1992. A Mind Set (Part VII). Dairy Food Env. San. (Jan.): 28-29; (March): 168-169.
Graham, D. J. 2004. Using Sanitary Design to Avoid HACCP Hazards and Allergen Contamination. Food Safety Magazine (June/July): 6671.
Footnotes
1. This document is FSHN04-08, one of a series of the Food Science and Human Nutrition Department, UF/IFAS Extension. Original
publication date May 2005. Reviewed: May 2008, Reviewed June 2014. Visit the EDIS website at http://edis.ifas.ufl.edu
2. Ronald H. Schmidt, PhD, Food Science and Human Nutrition Department, UF/IFAS Extension, Gainesville, FL 32611; and Daniel J.
Erickson, Harold Wainness and Associates, St. Paul, MN 55113.
The Institute of Food and Agricultural Sciences (IFAS) is an Equal Opportunity Institution authorized to provide research, educational information and other
services only to individuals and institutions that function w ith non-discrimination w ith respect to race, creed, color, religion, age, disability, sex, sexual
orientation, marital status, national origin, political opinions or affiliations. For more information on obtaining other UF/IFAS Extension publications, contact
your county's UF/IFAS Extension office.
U.S. Department of Agriculture, UF/IFAS Extension Service, University of Florida, IFAS, Florida A & M University Cooperative Extension Program, and Boards
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