Plant Design Student PPT PDF

Process Plant Design 1 OUTLIN E PROCESS EQUIPMEN PLANT PLANT T DESIGN SANITATIO DESIGN N 2  o Objective of food industry is to supply consumer with high...

Process Plant Design 1 OUTLIN E PROCESS EQUIPMEN PLANT PLANT T DESIGN SANITATIO DESIGN N 2  o Objective of food industry is to supply consumer with high quality products that are safe and suitable for consumption Introducti o Types of contamination that will on compromise food safety includes biological, chemical, physical agent, foreign matter or substances that are NOT Safet intentionally added y o Good hygiene practices, good Quality manufacturing practices, hygienic design of processing equipment, good plant layout are able to minimize these contaminations 3  Leading causes of food recalls in US in 2019 Milk – 49 Nuts – 24 Egg – 21 Soy – 15 Sulphites - 13 4 5 6 7 8  FOOD PROCESSING This Photo by Unknown Author is licensed under CC BY-SA ESTABLISHMENT o Food processing establishment is where food business operators carry out processing activities to the food products i.e. premise where food is being manufactured, processed, packaged to be distributed to wholesalers and retailers. o In Singapore, food processing establishments processing meat and/or seafood products are classified as “Meat and/or Fish processing establishment” while other manufacturing activities are classified under “Other Processing Food”. o Licensed food processing establishments in Singapore are subjected to regular inspections by Singapore Food Agency (SFA) to ensure that the food produced is safe and fit for human consumption. SFA also collect food samples from the licensed establishments for laboratory analysis to ensure that they comply with Wholesome Meat & Fish Act, Sale of Food Act and standards stipulated in the Food Regulations. Additional responsibilities : Uphold hygiene & cleanliness of food products produced 9 The areas of audit assessment of food establishments are as follows: Premises (general cleanliness and housekeeping) Food Storage Food Processing Equipment and Facilities Pest Control Program Food Handling and Staff Facilities Product Identification and Traceability Dispatch & Transport Product Inspection and Lab Testing Foreign Body Control Rework Management of Allergen Implementation of Quality Control Programs Staff Competency and Food Hygiene Training Documentation and Records Violation Records 10  o Food establishments should consider the appropriate location, hygienic design, good layout and suitable construction to minimize food contaminations. PROCESS o Factors to be considered include the PLANT following: DESIGN  Protection against pest access and harborage  Plant design and factory layout should permit maintenance, cleaning and sanitation and prevent contamination  Food contact surface and materials should be non-toxic  Availability of facilities such as lighting, ventilation, temperature, humidity control  Provision of personnel hygiene facilities and toilets 11  Premises classified under Premises classified under “Meat and/or Fish processing” “Other food processing” CONDITIONS of LICENSING FOR FOOD ESTABLISHME NT in SINGAPORE Source: SFA, 2010 12 Guidelines on Food Premises o Location and suitability of premises should not pose a threat to food safety i.e. should be located away from:  Area prone to attract or harbour pests, birds or rodents  Environmentally polluted areas i.e. smoke or dust  Areas whereby waste cannot be removed effectively o Premises designed to facilitate easy cleaning and inspection of food hygiene/cleanliness o Openings into premises must have screen to prevent entry of rodents e.g. doors must have good fittings to both frames and floors, windows well fitted and protected using wire screening o Separations such as partition are to be included to prevent contaminations e.g. between raw materials and finished goods area 13 Factory Layout o Layout of food premises should separate work areas in the premises to ensure that workflow is smooth and straight (i.e. one directional production flow) with no back tracking and minimal criss-crossing to prevent or minimize cross- contamination. o Raw material and finished product areas or wet and dry areas to be separated via partition or other physical means. Different storage areas for raw material, final products, chilled products, frozen products, packaging materials and cleaning chemicals. o Layout is designed so that processing area is not open directly into outdoor areas. o Layout is designed to minimize non-essential movement of personnel e.g. through processing and packaging areas. 14 o Design and layout should ensure adequate maintenance, cleaning and ease of Architectural Plan or Layout Plan a) Layout plan should be drawn to minimal (1:50) scale and all dimensions must be clearly indicated. b) To label the various rooms/doors and illustrate the location of the processing equipment. c) To illustrate the temperatures of the various processing / storage rooms (if required): Walk-in freezer (- 18°C) Walk-in chiller (4°C) Air conditioned (A/C) Ambient or 15 Mechanical Process flow 6 chart a) Process flows should be provided with a heading for 1 each product category (If required) and the processing steps must be 3 numbered in sequence. 2 Key processing temperatures should also be indicated. 5 b) Numbered processing steps must be indicated directly into the 4 layout plan. c) A legend should be provided at the side of the layout plan. You may use different colour coding labels if different product 16 categories are Step 2: Apply to SFA for a licence The following documents are required for SFA’s preliminary evaluation. Layout plan Process flow chart Particulars of Products 17  Internal Structures Structures must be made with sound, durable, non toxic and and inert materials that are easy to clean, maintain & sanitize (where appropriate) Fittings  Smooth surface within  Sloping flat surfaces  Coving corners Food o Walls and partitions erected up to height of ceiling. Premises o Surface of walls, partitions and floors – impervious, crack- resistant materials that is easy to clean and sanitise (where appropriate). o Floors constructed to allow adequate cleaning and drainage  E.g. if concrete it should be sufficiently dense and waterproof or if floor tiles then joints must be acid-resistant  Even flooring and sloped towards floor traps to prevent 18 ponding  Floor with Coving 19  o Ceiling and overhead fixtures (e.g. lighting) should be made from shatterproof and moisture resistant materials. It should prevent shedding of particles and minimize the building up of dirt/condensate. Internal  Proper vents to prevent moisture/ condensation accumulation Structures and  Horizontal beams and pipes be avoided over exposed Fittings within products or food contact surfaces Food Premises o Windows should be easy to clean and minimize any building of dust/dirt. If it cannot be closed, removable and cleanable insect-proof screen should be installed to reduce dust and prevent entry of pest. o Door should be made using smooth, impervious, impact- resistant material that is easy to clean and sanitise (if appropriate).  Made using stainless steel, aluminium or corrugated metal with no holes or crevices with joints/hinges rust resistant o Food contact surfaces made of smooth, non-absorbent 20 Spot it? CL2827 Food Processing 21  Drainage and waste disposal facilities Faciliti o Provide adequate drainage, waste disposal systems and facilities to minimize risk of contaminating food or the potable water es supply.  Protect waste against rodents, insects and exposure to warm temperatures  Disposal site located away from premises to prevent pest infestation  Waste be placed in durable and easy to clean waste receptacles. Waste to be removed promptly Cleaning facilities o Provide adequate facilities for cleaning & sanitizing utensils and equipment with supply of both hot and/or cold potable water with proper drainage.  Stainless steel splashboard to 1m height be lined above commercial sink in processing area for washing Source: Remco, 2013  Separate sinks for hand washing and food washing 22  Lifts for Raw Goods & Refuse Lifts for Raw Goods & Finished Products 23  Personnel hygiene facilities and toilets o Provide sufficient and adequately designed and appropriately located washing and toilet facilities to maintain good personal hygiene to prevent any contamination of food  Self-closing toilet door, auto-sensor or foot- operated for hand washing sinks with soap dispenser and disposable paper towels  Adequate hand washing and drying facilities located at entrance to processing area, in all Facilitie processing areas where staff are required to wash/sanitize their hands  Staff room separated from processing areas. s Lockers sloped at the top to prevent accumulation of dust while base sealed to concrete base. Temperature o Ensure adequate facilities for food operations to ensure food safety E.g., freezer for frozen food storage, chiller for refrigerated foods. 24 Facilitie s Air quality and ventilation o Provide adequately natural/mechanical ventilation. Ventilation system designed and constructed to prevent air from contaminated areas from entering clean areas.  Prevent excessive heat, condensation and contamination with dusts, odors or smoke.  Ventilation openings equipped with air filters and easily removable screens. Lighting o Ensure adequate lighting to carry out operation in hygienic manner and cannot alter the colour of foods.  General working area, minimum 220 lux  Examination area, minimum 540 lux o Lighting fixtures enclosed/protected to ensure broken glass will not be introduced and watertight. o UV insect trap to be provided at strategic location 25 Facilitie Storage Facilities o Provide adequate and separate facilities for storage of finished products, food ingredients, s packaging materials and non-food chemicals (E.g., cleaning chemicals, lubricants).  Stores for storage must be rodent proof, ease of cleaning and maintenance.  Adequate shelving racks made from materials that are impervious, durable and corrosion- resistant  Food products to be placed on racks. Minimum 30cm above ground level.  Provide suitable environment for storage to prevent food deterioration (E.g., sufficient temp. and humidity control).  Chiller to maintain product temp. between -4oC to 7oC. Fluctuation of temp.