The key to reducing the risk of food poisoning is hygiene. That is why the place where food is prepared or processed and the equipment used must be designed and built in accordance with the principles of hygienic and sanitary design in the food industry. The aim is to reduce or eliminate the risk of food contamination caused by microorganisms, chemical residues, or foreign bodies. In addition, the facility should be easy to clean and disinfect.
The 3 principles of hygienic and sanitary design in the food industry
Exterior design
Considering that the first physical barrier for food is outside the building where it is handled, it is important to maintain the surroundings of the factory.
It is important to place rodent traps both on the perimeter fence and at the foundations and main entrances, as well as protective screens on windows and automatic doors. In addition, the exterior should be free of weeds and brush and, if possible, covered with gravel to facilitate inspection.
It is recommended to pave the exterior and create a good vehicle route to prevent mud or dust from entering.
Waste or garbage should not be accumulated in open containers to prevent animals from accessing food, insects from breeding, and bad odors from developing.
Interior design
Inside the building, choose flooring that is non-slip and, above all, easy to clean. The joints should be properly sealed, leaving no pores that could allow water to seep in and cause microorganisms to grow beneath the surface.
Floors should facilitate drainage and prevent accumulation. To do this, they should be built with a slight slope and drains should be placed in strategic locations.
The walls must be finished with waterproof, non-absorbent, washable, and non-toxic materials. A U-shaped channel is normally used between the floor and the wall joint for a complete seal without corners.
Lighting must be sufficient in all areas of the building and used in such a way as to avoid attracting insects.
2.1 Cleaning and disinfection plan
Every sanitation plan begins with cleaning and disinfection capable of eliminating the microorganisms present. This procedure increases the chances of complying with regulatory requirements and thus preventing food contamination. It also increases the storage life of food and delays the spread of pathogens.
Cleaning and disinfection products must be non-toxic, non-corrosive, non-adhesive, easy to measure, and stable during storage. In addition, all equipment must be rinsed and disinfected daily, and in some cases every time there is a shift change. Once the manufacturing process is complete, all equipment must be washed and disinfected before being used again.
2.2 Machinery and equipment
Equipment used for food processing must be designed and constructed so that all internal contact points and external surfaces can be cleaned.
The European Committee for Standardization (CEN) has created standards for equipment manufacturers to comply with the requirements of Directive (89/392/EEC, revised 98/37/EC).
Equipment can be classified into three groups:
- Aseptic equipment (high demand): can be cleaned without removal, eliminating microorganisms and spores without any dismantling.
- Class I hygienic equipment: can be cleaned in place and relevant microorganisms eliminated without dismantling.
- Class II hygienic equipment: can be cleaned after dismantling and relevant microorganisms can be eliminated by sterilization, pasteurization, or chemical treatment after assembly.
Valves are essential components of machines and equipment used in food processing. Their quality has a strong influence on microbiological safety, so they must be free of sharp edges, threads, or materials that could trap the product or prevent cleaning.
Mechanical seals are commonly used for pumps, agitators, mixers, and other types of rotating equipment.
For a mechanical seal to be designed correctly, it must be cleanable and capable of being disinfected.
In this case, the real problem is caused by the bonding of microorganisms that grow on surfaces, called microbial biofilms. These are microflora that adhere to processing equipment during production and resist cleaning and disinfection procedures. Current theories believe that hydrophobic surfaces favor the adhesion of bacteria. In addition, it is known that the presence of certain surface proteins and glycoproteins plays an important role in the adhesion of vegetative cells of various bacteria, such as Enterococcus faecalis or Staphylococcus aureus.
2.3 Personal hygiene
Good personal hygiene practices for both workers and visitors to the factory are very important, as both are potential sources of pathogenic microorganisms. In this case, worker training plays a crucial role in preventing food contamination.
Washing hands with water and plenty of soap prevents approximately 25% of pathogen transmission to food, especially after using the bathroom, coming into contact with garbage and dirty materials, or handling uncooked meat, egg products, or dairy products.
In addition, caring for the skin, nails, and hair reduces the likelihood of contamination from residues. Nail polish, makeup, watches, and bracelets are areas where microorganisms grow and are difficult to clean.
Protective clothing and footwear not only prevent workplace accidents but also reduce staff contact with food.
It is important to avoid eating, chewing gum, smoking, and drinking in the production area, as well as contact with the product being processed when you have an infected wound, a boil, or any other skin infection. In case of illness, factory managers should be notified, who will select clean and healthy employees.
Control
Once a factory’s hygiene and health plan has been designed, the effectiveness of the sanitation program can be evaluated through visual inspection, microbiological analysis, or ATP bioluminescence. However, it is important to keep in mind that results must be generated quickly enough to take corrective measures or prevent contaminated surfaces.