Design of a new plant
- Optimization of process analysis
- Block of contamination, proliferation removal, sterilization method setting
- Layout: Cross-contamination measures, flow measures, Access Procedure
- Zoning : Cooperation between pollution area and non-pollution area and sterile system setting
- Building : Structure, floor, ceiling, wall, door, interior materials
- Facilities : Piping, drainage, ventilation, lighting, dust collecting design
- Construction production Installation
- Eligibility (IQ, OQ, PQ)
- SOP
- HACCP
Remodeling of existing plants
- Analysis and adjustment of machine placement of current plant
- Deriving problems by comparing with ideal situation
- Deriving measures by comparing non-pollution area setting
- Flow and access plan
- Flow and access plan
- Sequential implementation in the steps of eligibility, SOP, HACCP
Temperature·humidity of food plant (general criteria)
Classification | Proper temperature | Temperature deflection | |
Temperature (℃) | Summer | 25 | 25 ± 2 |
Spring · Autumn | 23 | 23 ± 2 | |
Winter | 20 | 20 ± 2 | |
Humidity (%) | 50~60 | 60 ± 10 |
Summary of British Standards Institute (BS.5295-1)
Management Area | Airflow method | Air sampling and particle calculation cycle | Units / ㎡ (㎛) | Final filter efficiency (%) | ||||
0.5≥ | ≥1 | ≥5 | ≥10 | ≥25 | ||||
Class1 (Class100) | Laminar flow | Measuring everyday or by auto measuring instrument | 3,000 | Not applicable | - | - | - | 99.99 |
Class2 (Class10,000) | Laminar flow | Every week | 300,000 | Not applicable | 2,000 | 30 | - | 99.97 |
Class3 | Laminar flow or Turbulent flow | Every month | 100,000 | 20,000 | 4,000 | 300 | 95.00 | |
Class4 | Turbulent flow | Every 3 months | 200,000 | 40,000 | 4,000 | 70.00 |
Cleanliness of Food plant
Type of business | Work process | Cleanliness class |
Fish cake processing | fishpaste cooling room | 1,000 |
fishpaste packing room | 10,000 | |
Meat Processing | hamburger insertion | 10,000 |
hamburger cooling | 1,000~10,000 | |
hamburger packaging | 10,000 | |
ham packaging | 10,000 | |
ham packing room | 100,000 | |
sausage packing room | 100,000 | |
Confectionery | castella packaging | 10,000 |
pancake packaging | 1,000 | |
Preparation of raw confectionery and fresh cream | 10,000 | |
Beverage plant | lactic acid bacteria soda filling room | 10,000 |
juice drink filling room | 10,000 | |
milk filling room | 1,000~10,000 | |
Dairy plant dairy products | powdered milk filling room | 10,000 |
cheese studio packing room | 10,000 | |
ice cream filling packing room | 10,000 | |
butter margarine packing room | 10,000 | |
Jam plant Rice cake plant Noodle plant Side dish kimchi plant Sugar Soy sauce soybean paste | filling chamber | 10,000 |
cooling packing room | 1,000~10,000 | |
cooling packing room | 1,000~10,000 | |
packing room | 10,000~100,000 | |
refining room | 100 | |
aseptic packing room | 10,000 | |
Farming | shiitake mushroom culture medium culture room | 1,000~10,000 |
Measures by hazard element
Proliferation decomposition deterioration by condensation, dust particles, foreign substances, animals or animal secretions, larva, inflow of plants and microorganism etc. are caused by air, operators, machines, buildings, temperature, humidity, raw and subsidiary materials, transportation equipment used, water supply and drainage, insects, rats, seasonal wind etc. In particular, since microorganisms are proliferated and deteriorated in proper conditions such as temperature and humidity etc., pollution and the proliferation control should be especially focused.
Measures to prevent intrusion from outside Proper placement (Layout)
- Separation from dirty place, hazardous materials
- In case that placement of machines or workroom especially cleanliness of food raw materials and finished goods is different according to process order, it should be away by 1st placement.
Design of flow
To prevent cross-contamination and confusion during the process, cross-collision should be avoided by reviewing raw material flow, worker flow, product shipment flow.
Design of zoning and air conditioning system
It sets required cleanliness by process and workroom. It designs the air conditioning system by block.
- Example of number of ventilation
Clean zone (finished packaging room, cooling room) 10 times/more than h, semi clean zone (heating, cooking room, processing room etc.) 6-10times/h, general room (washing room, refrigerator, warehouse) 4 times/h - Prevent intrusion by inside clean zone 10Pa (1mmH2O), semi clean zone 5Pa(0.5mmH2O).
- Air filtration system
Pre-filter
Pre-filter + middle filter
Pre-filter + middle filter + HEPA filter - Ventilation
Be careful for dust, using pre-filter - Cleanliness
Polluted area: unmanaged area
Unmanaged area : general management room class 100,000-300,000, semi cleanroom class: 10,000-100,000, It can be subdivided into cleanroom class 100-10,000. To manage cleanliness, around a clean room should be semi-clean room and it is for managing cleanliness and airflow should be flowed to low clean room.
. - Airflow direction
Ventilation should be done downward if possible but upward hood ventilation should be made in the area where steam separation occurs. - Access, in and out of room
External clothes of a worker → Clothes changing outfit room within the workplace,
Clothes within workplace → Outfit room for cleanroom (this part is directly connected to cleanroom)
There are washing facilities. After removing an outer cover of raw materials and disinfection, in case of the airlock, it is brought in to cleanroom via pass box, etc. and goods brought in is brought out to general room via pass box or airlock. - Exists and windows are closed and insects, rats etc. are blocked.
- Air filtration system
Inner wall measures to prevent proliferation
Building structure and quality of the materials
Materials should be smooth, hard and not cracked not materials that hygroscopic surface is vulnerable and encourages microorganism proliferation (wood, timber, etc.) And materials should be proof against an antiseptic solution. Corners should be round not for dirt to be accumulated and easy to clean. For walls, sandwich panels of baking paint treated for waterproof are proper and Mepoksi urethane coating is good for the floor. With about 1/100 of cline, water should flow well and cleanness should be easy and it should be well dried. For the ceiling, cleanness should be easy and dirt should not be accumulated and condensed water should not drop. For door, waterproof materials should be used and closed so that insects and rats cannot break-in. Lighting and ventilation should be easy.
Measures to prevent condensation
For the food manufacturing process, there are many processes of occurrence of steam especially water scattering, etc. and water is condensed and drops because of difference with the outer air. Condensed water can pollute food by melting pollutants of ceiling and walls and proliferating microorganisms. Materials for warming and ventilation facilities should be used properly.
Temperature · humidity control
Temperature and humidity are prerequisites for microorganism proliferation and proper temperature maintenance is needed. Work living condition should be 18℃-25℃, cooling less than 10-15℃, cold storage less than 5℃, freezing less than 18℃. Humidity promotes deterioration by heightening water activation. In general, less than 75%RH is desirable.
Ventilation
Processes such as heating, frying, steaming are sterilized. Dirt from a fan of the cooling process becomes the contamination. Sterilized air should be supplied and contamination of fan should be removed.
Sterilization or Pasteurization
- Sterilization by air filter
- Structure should be easy for cleaning, disinfection and cleaning of manufacturing machines.
- There is sterilization method by heating, ultraviolet rays, chemicals etc. and fumigation method can be used in a place where microorganism contamination should be careful.
Process Inventory Management
- By considering handling ability of machines, storing conditions of Intermediate materials, ventilation, temperature · humidity, etc. stay of raw materials and materials should not belong.
- First in, first out should be maintained well and management should be done so that processing can be terminated in the shortest amount of time.