[AIB Product Quality] Sanitation by Design

Equipment and building design are a primary considerations for the sanitation, maintenance, quality assurance, and production departments. Whether the facility is a new construction, remodel or existing operation, design must be taken into consideration. Poorly designed equipment can place unnecessary demands on the sanitation department. Inadequate sanitation can make equipment maintenance very difficult and can create considerable food safety risks. Also, poor sanitation efforts directly affect product quality.

A manufacturing facility’s blueprints or design plans are essential to understanding sanitation concerns. The design of plant equipment should allow the production department to complete required orders while facilitating the sanitation program. Input from the sanitation department is critical to successfully plan equipment design. Sanitation procedures must be developed to address equipment voids and eliminate their potential to becoming a source of poor cleaning, contamination, or microbial growth. Equipment should be spaced adequately to allow personnel to practice proper cleaning techniques and successfully remove production debris and residue. The blueprints should allow space for any equipment that may be required in the sanitation process. The plans should include simple items such as equipment anchoring that should be designed to facilitate detailed cleaning.

Food facilities should be inspected for cavities, voids, or locations that may not be immediately accessible. These areas are often overlooked or not scheduled on an adequate frequency. Most new construction designs limit voids, hollow walls, and drop ceilings over production areas. Basic design information is available from recognized experts such as Thomas J. Imholte, Michael M. Cramer, Peggy Stanfield, and Antonio L’opez-C’omez. These experts can be used as a resource, but the plant sanitarian must take the lead when developing cleaning methods prior to installation.

Penny Hancock is a food safety auditor at AIB International.