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Hygienic Design of Food Factories
- 2nd Edition - May 25, 2023
- Editors: John Holah, Huub Lelieveld, Frank Moerman
- Language: English
- Paperback ISBN:9 7 8 - 0 - 1 2 - 8 2 2 6 1 8 - 6
- eBook ISBN:9 7 8 - 0 - 1 2 - 8 2 2 6 1 9 - 3
Advances in food safety knowledge, combined with the continuing rapid development of new food products, have had an impact on the need for improved hygiene in the food ma… Read more
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Request a sales quoteAdvances in food safety knowledge, combined with the continuing rapid development of new food products, have had an impact on the need for improved hygiene in the food manufacturing infrastructure. This has created a need for the second edition of Hygienic Design of Food Factories, which expands all existing chapters and includes new topics, such as cold storage and the control of air in food refrigeration facilities. Additionally, chapters explore the prevention of food contamination when building during production, the risk assessment of which is becoming important globally, and hygienic building design regulations in Russia and Brazil.
Divided into 6 parts, the book is now thoroughly updated and expanded. Part one reviews the implications of hygiene and construction regulation in various countries on food factory design, while taking into account retailer requirements as well. Part two describes site selection, factory layout and the associated issue of airflow. Parts three through four and five then address the hygienic design of the essential parts of a food factory. These include walls, ceilings, floors, selected utility and process support systems, entry and exit points, storage areas and changing rooms. Lastly part six covers the management of building work and factory inspection when commissioning the plant.
With its distinguished editors and international team of contributors, Hygienic Design of Food Factories, 2nd edition, continues to be an essential reference for managers of food factories, food plant engineers and all those with an academic research interest in the field.
- Presents an authoritative overview of hygiene control in the design, construction and renovation of food factories
- Examines the implications of hygiene and construction regulation in various countries on food factory design
- Describes site selection, factory layout and associated issues of service provision
Managers of food factories, food plant engineers, food safety inspectors. All those with an academic research interest in the field of Food Engineering and Food Safety
- Cover image
- Title page
- Table of Contents
- Front Matter
- Related Titles:
- Copyright
- Contributors
- Preface
- 1: Business case assessment and design essentials for food factory building projects
- Abstract
- 1.1: Introduction
- 1.2: The need for a new or refurbished food factory
- 1.3: A new product: Generation, approval, specification and business plan
- 1.4: Determine process and mass flow
- 1.5: Conclusion
- References
- 2: Determining equipment and process needs and how these affect food factory design
- Abstract
- 2.1: Introduction
- 2.2: Brownfield projects: Processes and equipment
- 2.3: Greenfield projects: Processes and equipment
- 2.4: Future trends
- References
- Part I: Regulatory issues and retailer requirements
- 3: EU food hygiene law and implications for food factory design
- Abstract
- 3.1: The relevance of EU food hygiene law for the design of food factories
- 3.2: The objectives of EU food hygiene law
- 3.3: The EU general food law (GFL)
- 3.4: EU food hygiene law
- 3.5: Four types of EU food hygiene law
- 3.6: The combination of EU food hygiene law and other law on the design of food factories
- 3.7: Conclusions
- References
- Short title: GFL
- Further reading
- 4: Regulations on the hygienic design of food processing factories in the United States
- Abstract
- 4.1: Introduction
- 4.2: Regulatory requirements in the United States
- 4.3: Guidance documents
- 4.4: Other agencies and considerations
- 4.5: Case study: A milk processing plant
- 4.6: Conclusion
- References
- 5: Legal requirements concerning hygienic and safety design of machinery, construction and reconstruction of food factories in Japan
- Abstract
- 5.1: Introduction
- 5.2: Major laws concerning the food industry in Japan
- 5.3: Case study
- 5.4: Future trends
- References
- 6: Regulation relevant to the design and construction of food factories in Russia
- Abstract
- 6.1: Introduction
- 6.2: Food regulations
- 6.3: Regulations for food processing machines and engineering facilities
- 6.4: Future trends
- 7: Regulatory building requirements for food business in Brazil
- Abstract
- 7.1: Introduction
- 7.2: Regulations issued by ANVISA (National Agency of Sanitary Surveillance)
- 7.3: Regulations issued by MAPA (Ministry of Agriculture, Livestock, and Food Supply)
- 7.4: Non-food safety standards
- 7.5: Key elements of hygienic design in Brazilian legislation
- 7.6: Future trends
- Further reading
- 8: Regulations and guidance in Australia and New Zealand with implications for food factory design
- Abstract
- 8.1: Introduction
- 8.2: Food regulatory requirements in Australia and New Zealand
- 8.3: Trade regulations and requirements
- 8.4: Building requirements
- 8.5: Future legislative changes in New Zealand
- 8.6: Sources of further information
- 9: Regulatory requirements for food factory buildings in South Africa and other Southern African countries
- Abstract
- 9.1: Introduction
- 9.2: South African regulations and standards
- 9.3: Regulations and standards in other Southern African Development Community (SADC) countries
- 9.4: Future trends
- 9.5: Sources of further information
- References
- 10: Retailer requirements for the hygienic design of food factory buildings
- Abstract
- 10.1: Introduction: Private labels and retailers' responsibility
- 10.2: Background to the British Retail Consortium (BRC food) and the International Food Standard (IFS food)
- 10.3: Global food safety initiative
- 10.4: Retailer requirements
- 10.5: Approach to hygienic factory design
- 10.6: Future trends
- 10.7: Sources of further information and advice
- References
- 11: Food factory design to prevent deliberate product adulteration
- Abstract
- Acknowledgments
- 11.1: Introduction
- 11.2: Historical incidences of intentional food contamination
- 11.3: Food fraud versus intentional adulteration
- 11.4: Prevention of intentional adulteration
- 11.5: Future trends
- 11.6: Conclusions
- References
- Further reading
- 12: Minimum hygienic design requirements for food processing factories
- Abstract
- 12.1: Introduction
- 12.2: Site
- 12.3: Building design
- 12.4: Internal divisions
- 12.5: Building fabric
- 12.6: Services
- 12.7: Sources of further information and advice
- References
- Part II: Site selection and factory layout
- 13: Aspects to be considered when selecting a site for a food factory
- Abstract
- 13.1: Introduction
- 13.2: Product
- 13.3: Utilities
- 13.4: Sources of contamination
- 13.5: Regulations
- 13.6: Protection of the environment
- 13.7: Industrial zoning
- 13.8: Financial aspects
- 13.9: Personnel
- 13.10: Security
- 13.11: Access
- 13.12: Climate
- 13.13: Research and Development
- 13.14: Conclusions
- References
- 14: Hazard control by segregation in food factories
- Abstract
- 14.1: Introduction
- 14.2: Barrier 1: Site
- 14.3: Barrier 2: Factory building
- 14.4: Barrier 3: Basic hygiene hazard reduction
- 14.5: Barrier 4: High hygiene areas
- 14.6: Barrier 5: Product enclosure
- 14.7: Future trends
- References
- 15: Managing airflow and air filtration to improve hygiene in food factories
- Abstract
- 15.1: Introduction
- 15.2: Airflow
- 15.3: Air handling equipment
- 15.4: Air filtration
- 15.5: Hygiene requirements for ventilation systems (VDI 6022)
- 15.6: GMP and cleanroom technology in food production
- References
- 16: Air infiltration control to reduce hygiene hazards in refrigerated food processing and storage facilities
- Abstract
- Acknowledgment
- 16.1: Introduction
- 16.2: Infiltration of warm, humid air in refrigerated facilities
- 16.3: Consequences of air infiltration
- 16.4: Step-by-step strategy to eliminate air infiltration sources
- 16.5: Building design and installation routines to minimise the infiltration
- 16.6: Predictive modelling
- 16.7: Good operator practices to reduce infiltration
- 16.8: Proper maintenance to reduce air infiltration
- 16.9: Indoor climate control
- 16.10: Future research needs and technology advancement
- 16.11: Concluding remarks
- References
- Further reading
- Part III: Hygienic design of walls, ceilings and floors
- 17: Hygienic wall finishes for food processing factories
- Abstract
- 17.1: Introduction
- 17.2: High performance paint coatings
- 17.3: Thermoplastic wall cladding systems
- 17.4: Stainless steel cladding
- 17.5: Reinforced resin laminates
- 17.6: Insulated panel walls and ceilings
- 17.7: Wall tiling
- 17.8: Future trends
- References
- 18: Hygienic floor finishes for food processing areas
- Abstract
- 18.1: Introduction
- 18.2: Establishing requirements for floor finishes in food processing factories
- 18.3: Selection of floor finish materials
- 18.4: Substrate requirements
- 18.5: Detailing within the design
- 18.6: Hygiene control during the renovation of existing floor finishes
- 18.7: Cleaning and maintenance
- 18.8: Future trends
- 18.9: Sources of further information and advice
- References
- 19: Hygienic design of ceilings in food factories
- Abstract
- 19.1: Introduction
- 19.2: Hygiene levels in food processing factories
- 19.3: Other factors affecting the type of ceiling system used in a food factory
- 19.4: Types of hygienic suspended ceiling systems
- 19.5: Hygienic coatings for production facilities without suspended ceilings
- 19.6: Ceiling penetrations and other services
- 19.7: Heating, ventilation and air conditioning (HVAC)
- References
- 20: Hygienic design of floor drains in food processing areas
- Abstract
- 20.1: Introduction
- 20.2: Channel and gully system functional overview
- 20.3: Floor drains as a point of contamination
- 20.4: Material choice for floor drainage
- 20.5: Modelling flow in drainage channels
- 20.6: Incorporating hygienic design principles in drain design
- 20.7: Layout and zoning areas
- 20.8: Load capacity
- 20.9: Slip resistance
- 20.10: Fire prevention
- References
- Part IV: Hygienic design of selected fixtures, utility systems and process support systems
- 21: Hygienic supply of electricity in food factories
- Abstract
- 21.1: Introduction
- 21.2: Standards and regulations with which electrical equipment has to comply
- 21.3: Use of electrical equipment in the food industry
- 21.4: Materials of construction
- 21.5: Hygienic supply of electricity
- 21.6: Electrical cabinets and field boxes
- 21.7: Hygienic design and installation of electrical equipment
- 21.8: Data/telecommunication and control systems
- References
- 22: Hygienic design concepts for lighting in the food industry
- Abstract
- 22.1: Introduction
- 22.2: Use of daylight
- 22.3: Light bulbs
- 22.4: Outdoor lighting
- 22.5: Light intensity and uniformity of illumination
- 22.6: Factors responsible for variations in light intensity and uniformity
- 22.7: General lighting
- 22.8: Local lighting (task lighting)
- 22.9: Luminaires
- 22.10: Lighting control and energy efficiency
- 22.11: Cleaning and maintainance of lamps and luminaires
- 22.12: Hygienic design requirements for lamps
- 22.13: Hygienic design requirements for luminaires
- 22.14: Hygienic installation of luminaires
- 22.15: Hygienic design requirements for evacuation and emergency lighting
- 22.16: Conclusions
- References
- 23: Hygienic design principles for exhaust and dust control systems in food factories
- Abstract
- 23.1: Introduction
- 23.2: Mechanical ventilation
- 23.3: Hygienic design of exhaust systems for the removal of steam, heat, odors and grease-contaminated vapor outside the food factory
- 23.4: Hygienic design of specific exhaust systems used to handle effluents produced during the processing of food by means of heat
- 23.5: Installation of exhaust systems within the food factory
- 23.6: Cleaning of exhaust systems
- 23.7: Inspection and maintenance of exhaust systems
- 23.8: Hygienic design of exhaust facilities applied to extract heat, aerosols, bio-burden, odors and toxic vapors out of process rooms and technical areas
- 23.9: Hygienic design of dust control systems
- 23.10: Influence of the exhaust system on the air flow and air quality
- References
- 24: Managing steam quality in food and beverage processing
- Abstract
- 24.1: Introduction
- 24.2: Steam grade definitions
- 24.3: Plant steam
- 24.4: Filtered steam
- 24.5: Clean steam
- 24.6: Pure steam
- 24.7: Installation, operation and maintenance
- 24.8: Boiler installation
- 24.9: Steam pipe insulation
- Appendix 1: Typical applications where steam is used in direct contact with the product/process
- Appendix 2: Typical chemicals, which are generally added to the feedwater as part of a water treatment programme
- Appendix 3: Chemicals that are approved by the Food and Drink Administration (FDA) in the USA for use with food and beverage products with acceptable concentration for each chemical
- References
- 25: Hygienic design of walkways, stairways, and other installations in food factories
- Abstract
- Acknowledgment
- 25.1: Introduction
- 25.2: Determining the equipment needs
- 25.3: Future trends
- 25.4: Sources of further information and advice
- Part V: Hygienic design of specific factory areas
- 26: Hygienic design of entries, exits, and other openings in the building envelope and dry warehousing areas in food factories
- Abstract
- 26.1: Hygienic design of foundations, support structures, external walls, and roofs
- 26.2: Hygienic design of entry, exit, and storage points
- 26.3: Entry doors – Visitors and employees
- 26.4: Truck docks (loading and unloading)
- 26.5: Storage – Dry warehousing
- 26.6: Cold storage (including freezers)
- 26.7: Sanitary design of openings in the building envelope
- 26.8: Future trends
- 27: Design, installation and operation of cleaning and disinfectant chemical storage, distribution and application systems in food factories
- Abstract
- 27.1: Introduction
- 27.2: Safety
- 27.3: Delivery and storage of industrial detergents, disinfectants and associated products
- 27.4: Hygienic chemical distribution and location of point of use within production areas in open plant foam cleaning
- 27.5: Dose, control and application of hygiene chemicals
- 27.6: Dry cleaning
- 27.7: Cleaning rooms and utensil washing
- 27.8: Maintenance and cleaning of the cleaning systems
- 27.9: Requirements for transition to operation
- 27.10: Future trends
- References
- Further reading
- 28: Design of storage facilities for food
- Abstract
- 28.1: Introduction and definitions
- 28.2: General design requirements
- 28.3: Storage facilities for dry products and dry cleaning requirements
- 28.4: Wet cleaning of storage facilities and storage of liquid products
- 28.5: Future trends
- References
- 29: Design of food factory changing rooms
- Abstract
- 29.1: Introduction
- 29.2: Legislation
- 29.3: Facilities design
- 29.4: Medium/high hygiene barriers
- 29.5: Cross-contamination risks
- 29.6: Future trends
- References
- Further reading
- Part VI: Managing building work and additional factory design considerations
- 30: Managing a factory building project: From development of a construction brief to commissioning and handover
- Abstract
- 30.1: Introduction
- 30.2: Business case justification
- 30.3: Project definition
- 30.4: Construction brief
- 30.5: Contractual arrangements
- 30.6: Model contracts
- 30.7: Selecting a contractor
- 30.8: Overview
- 30.9: Managing construction
- 30.10: Equipment procurement, testing and installation
- 30.11: Commissioning and handover
- 30.12: Future trends
- 30.13: Sources for further information and advice
- 31: Hygienic design of piping for food processing support systems in food factories
- Abstract
- 31.1: Introduction
- 31.2: Location of support systems and building services within the food factory
- 31.3: General hygienic requirements for food processing support piping within the factory
- 31.4: Specific hygienic design requirements for food processing support piping in rooms of different hygienic class
- References
- 32: Inspecting for commissioning of manufacturing sites for hygienic design and practices
- Abstract
- 32.1: Introduction
- 32.2: A site that has been newly designed and built for the purpose of food manufacture
- 32.3: An existing manufacturing site that is being acquired by another company
- 32.4: An existing site that has no history of food production is to be adapted for food purposes
- 32.5: Preparing the team
- Further reading
- 33: Prevention of contamination of food products when production is continued during building activities
- Abstract
- 33.1: Introduction
- 33.2: Initial hazard analysis
- 33.3: Undetaking building maintenance and construction work
- 33.4: Return of work activity area to production
- References
- 34: An insurance industry perspective on property protection and liability issues in food factory design
- Abstract
- 34.1: Introduction
- 34.2: Hazard analysis
- 34.3: Requirements for property insurance (fire, natural hazards, business interruption)
- 34.4: Requirements for liability insurance (occupational safety, third party, product and environmental liability)
- 34.5: Prevention and protection
- 34.6: Future trends
- 34.7: Checklist for easy reference
- 34.8: Sources of further information and advice
- Index
- No. of pages: 992
- Language: English
- Edition: 2
- Published: May 25, 2023
- Imprint: Woodhead Publishing
- Paperback ISBN: 9780128226186
- eBook ISBN: 9780128226193
JH
John Holah
Prof. Dr. John Holah is an applied microbiologist focused on the prevention of microbial, chemical, and foreign body contamination of food during manufacture and retail distribution. He is currently Technical Director of Holchem Laboratories (UK), a major supplier of cleaning chemicals, disinfectants and hygiene services. He is a Visiting Professor in Food Safety at Cardiff Metropolitan University and was previously Head of Food Hygiene at Campden BRI. He has been a member of the EHEDG (the European Hygienic Engineering and Design Group) since 1989 and has also chaired ISO Working Groups producing standards on hygienic design and lubricants and chaired the GFSI Working Group on the hygienic design of food facilities and equipment. He is a co-editor in the other two Elseveir books. He has published and presented hundreds of scientific papers, technical articles and presentations in food safety and hygienic design.
Affiliations and expertise
Technical Director, Holchem Laboratories; Visiting Professor, Food Safety Cardiff Metropolitan University, UKHL
Huub Lelieveld
Prof. Dr. h.c. H.L.M. (Huub) Lelieveld is President of the Global Harmonization Initiative and Fellow of the International Academy of Food Science and Technology, and was formerly at Unilever in Vlaardingen, The Netherlands. He editor or co-editor of numerous books, including several on hygiene and food safety management; novel food processing technologies and harmonization of food safety regulations. He produced chapters for many books and encyclopaedia, hundreds of scientific articles and articles for magazines and presented hundreds of papers, globally. He has been awarded doctor honoris causa at the National University of Food Technologies in Kiev, Ukraine.
Affiliations and expertise
President of the Global Harmonization Initiative (www.globalharmonization.net)FM
Frank Moerman
Frank Moerman graduated with an MSc. in Bioengineering from the University of Ghent (1991), and a BSc. in Education from Artevelde University College Ghent (2006). He worked as a fine chemical production engineer for Aji-no-moto, Co. and as a food technologist/quality manager for Kerry Ingredients. Currently he is a doctoral researcher in food/phyto-chemistry at the Catholic University of Leuven/KU Leuven. In 2002, he became a member of the European Hygienic Engineering and Design Group (EHEDG), acting as chairman of the Belgium regional section until 2005 and received an achievement award for his services in 2013. He participated in the European 5th framework project “HYFOMA” (2002-2004) on the Steering Committee. He is an active member of several EHEDG working groups, is author of a number of articles and book chapters on hygienic engineering & design and is an active trainer in hygienic design and cleaning technologies.
Affiliations and expertise
Catholic University of Leuven/KU Leuven, BelgiumRead Hygienic Design of Food Factories on ScienceDirect