Ideal requirements for certifiable food safety design
As far as is possible, the project will incorporate food safety procedures (FSP) and good manufacturing practice (GMP) and will comply with international food safety standards such as HACCP, IFS, BRC, ISO 22000, FDA (USDA).
In order to achieve this, where the budget permits, the following aspects should be included within the planning process:
• Water management.
• Cleaning and disinfection.
• Disease and pest control.
• Staff training and development.
• Supplier management.
• Traceability.
• Allergens control.
• Glass and hard plastics.
• Calibration.
• General premises and equipment maintenance management.
• Temperature control.
• Management of by products and residues.
In addition, critical potential hazards will be identified, such as:
• Ingredients (origin, raw materials etc.).
• Physical and chemical characteristics (multiplication, composition, health problems).
• Processing operations (destruction phases, toxins, spores, re-contaminations).
• Microbiological composition (product feature).
• Design of premises (separation of areas, circuits).
• Design and use of equipment.
• Packaging (method, materials, etc.).
• Cleaning and hygiene (methods, products, etc.).
• Storage conditions.
• Intended use and consumer type.
In order to achieve this, all possible aspects of food security that emanate from the programme of pre-requisites at the design stage should be considered:
• Carry out a hazard analysis.
• Establish the CCP (Critical control points).
• Set critical limits.
• Set up a surveillance system.
• Establish corrective actions.
• Determine verification procedures.
• Establish documentation check.
The 10 point check list to obtain the necessary information and establish appropriate requirements for food safety certifiable design are as follows:
1. Construction and processing flows of buildings and associated spaces.
2. Workflows including employee facilities.
3. Utilities: water, air, energy and other.
4. Services, including emissions, waste disposal and sewage.
5. Equipment: preventive maintenance, sanitary design, accessibility for maintenance and cleaning.
6. Purchasing and supply management, support services and outsourcing.
7. Measures for prevention of cross contamination.
8. Cleanliness and hygiene.
9. Pest control.
10. Personal hygiene of personnel.
In order to avoid cross contamination of allergens between products, special consideration should be given to the design stage so that it complies with regulations, in particular when dealing with special sauces, cleaning conditions or separate manufacturing lines.