Hygienic Project

Nestle Hygienic Engineering
INDEX
No.
Teme
Page
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
ROOFS
CEILING
DOORS
WINDOWS & LOUVERS
STAIRS
LIFTS & ELEVATORS
AIRLOCKS
DRAINS
SEWAGE
WASTE WATER TREATMENT PLANT
BUILDING STRUCTURE
DOCKS
FLOORS & FINISHES
MACHINERY FOUNDATIONS
WALLS
ENERGY & UTILITY SUPPLIES
WATER
PERSONNEL FACILITIES
ELECTRIC INSTALLATION
LIGHTING
NATURAL VENTILATION
FORCED VENTILATION
INTERNAL TRANSPORT
WASTE HANDLING
CLEANING EQUIPMENT
SENSORS
ROBOTIC
LAYOUT & EQUIPMENT
MATERIALS & FINISHING
INSULATION FOR PIPES
INSTALLATION OF EQUIPMENT
SOPPORTS
PLATFORMS
CONVEYORS
TIPPING RAW MATERIALS
Elab. J.Glz.J.
02
10
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18
27
30
34
41
48
51
55
60
64
70
74
80
91
96
110
119
123
125
141
148
157
159
160
163
165
170
172
185
193
213
224
Hygiene Considerations
ROOFS
Nestl Good Hygienic Engineering

Section 3.2.10.3
There are three important hygiene aspects for roofs:
barrier against infiltrations
ease of drainage
good construction and protection at expansion joints or building connections - to prevent

infiltrations.
Pitched roofs generally offer better drainage, but may then require additional treatment of the
resulting ceiling structure, on the interior of the plant.
Other important features for hygiene:
All roof openings (eg. vents, air intakes, exhausts) must be properly protected against ingress of
water (rain), debris and pests.
Access to roofs, especially in plants having medium to high hygiene levels, should:
either be equipped with an area to afford shoe changing and/or cleaning
or have access can be via outside staircase which serves also as the fire-escape.
Roofs
Picture 3.2.10.3.1
Pitched roofs offer better
drainage.
Note: The down pipes
should not pass through
high hygiene process areas.
They must also not cross
lines in medium hygiene
zones.
Pictures: 1 2 3 4 5 6 7 8 9 10
Roofs
Picture 3.2.10.3.2
Ease of drainage is
important - even a so
called flat roof needs a
slight slope towards the
drain - otherwise puddles
will collect on the surface
and damage will occur.
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Pictures: 1 2 3 4 5 6 7 8 9 10
Roofs
Picture 3.2.10.3.3
Good construction and
protection at expansion
joints or building
connections - to prevent
infiltrations.
Note: Joint must be
covered at roof level.
Pictures: 1 2 3 4 5 6 7 8 9 10
Roofs
Picture 3.2.10.3.4
joints or building
infiltrations.
Note: Joint must be
covered at roof level.
Pictures: 1 2 3 4 5 6 7 8 9 10
Roofs
Picture 3.2.10.3.5
joints or building
infiltrations.
Note: Wall to roof joints
covered at connection to
prevent infiltration.
Pictures: 1 2 3 4 5 6 7 8 9 10
Roofs
Picture 3.2.10.3.6
All roof openings (e.g.
vents air intakes exhausts)
must be properly protected
against ingress of water
(rain) debris and pests.
Pictures: 1 2 3 4 5 6 7 8 9 10
Roofs
Picture 3.2.10.3.7
Access to roofs especially
in plants having medium to
high hygiene levels should:
either be equipped with an
area to afford shoe
changing and/or cleaning
or have access can be via
outside staircase which
serves also as the fireescape.
Pictures: 1 2 3 4 5 6 7 8 9 10
Roofs
Picture 3.2.10.3.8
All roof openings must be
properly protected against
ingress of water(rain)
debris and pests. Particular
attention must also be paid
to condensation created by
vents. Water and product
residues at such points can
attack roof covering.
Regular cleaning helps.
Pictures: 1 2 3 4 5 6 7 8 9 10
Roofs
Picture 3.2.10.3.9
Maintenance of roof
covering is essential to
ensure it remains
waterproof.
Pictures: 1 2 3 4 5 6 7 8 9 10
Roofs
Picture 3.2.10.3.10
Product residues at
exhaust points can attack
roof covering. Regular
cleaning is essential to
prevent attack of roof
covering and to prevent
development of bacteria
and attraction of pests
especially birds. reservoir
of contamination on the
roof could eventually
become the origin of
interior problems.
Pictures: 1 2 3 4 5 6 7 8 9 10
Chapter 3
25 Jul. 2008 14:12:00
2009 Nestec S.A. All rights reserved.
Recommendations

Recommendations
Section 3.2.10.4
The roof is a critical part of the building and as it collects debris and contamination from various
sources, it should:
be waterproof
be self-draining
not provide harbourage for pests
be easily cleanable
be accessible for maintenance - without risk for interior
high/medium hygiene areas
Choice of roof may also be a compromise - between needs for hygiene and local climatic conditions.
Roofs
Recommendations
Picture 3.2.10.4.1
The roof is a critical part of
the building and as it
collects debris and
contamination from various
sources it should: be
waterproof be selfdraining not provide
harbourage for pests be
easily cleanable be
accessible for maintenance
- without risk for interior
high/medium hygiene areas
Note: Poor drainage and
damage to covering will
lead to infiltration at wall
to roof connection.
Pictures: 1 2
Roofs
Recommendations
Picture 3.2.10.4.2
The roof is a critical part of
the building and as it
collects debris and
contamination from various
sources it should: be
waterproof be selfdraining not provide
harbourage for pests be
easily cleanable be
accessible for maintenance
- without risk for interior
high/medium hygiene
areas.
Note: This example shows
the correct slope but drain
is above surface level water levels will eventually
lead to infiltration.
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Recommendations
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Hygiene Consdierations
CEILINGS

Section 3.2.11.3
real ceilings (for process areas) - should have a smooth surface (usually brushed concrete) to
avoid dust collection. Attachments for pipe-work, air ducting, wiring, lights etc. must be made
without causing residue collecting points - especially important in high hygiene areas.
Framework needs to be of appropriate quality and have tight joints.
Cavities and honey-combs, must be filled in immediately with a low shrinkage cement mortar.
Note: Warehouse ceilings (also the inside of roofs) can be of metal girders and corrugated
sheets with air-vents (with pest protection).
false ceilings - utilized for architectural reasons (eg.) to:
house lighting elements
hide ductwork
reduce ceiling height
or for noise abatement.
Acceptable for auxiliary buildings and low hygiene areas but in process areas - they represent an
inaccessible area which (if not sealed) can harbour residues and pests.
walk-on ceilings - especially suitable for high hygiene areas as ceiling surface on process side:
will have no (or minimal) attachments for dust collection
also allow maintenance without influencing process
will be normally constructed from 'sandwich' panels with smooth, impervious, cleanable
surfaces.
Design must include:
appropriate access - sufficient space above the panels for cleaning and maintenance
structure for a point load of 150kg for personnel traffic.
equipment and ducting suspended separately
Ceilings
Picture 3.2.11.3.1
Real ceilings (for process
areas)
should have a smooth

surface (usually
brushed concrete) to
avoid dust collection
framework needs to be
of appropriate quality
and have tight joints
cavities and honeycombs must be made
good immediately with
a low shrinkage cement
mortar.
Note: Internal expansion

joints must be checked for
infiltration.
Pictures: 1 2 3 4 5
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Ceilings
Picture 3.2.11.3.2
Attachments for pipe-work,
air ducting, wiring, lights
etc. must be made without
causing residue collecting
points - especially
important in high hygiene
areas.
Pictures: 1 2 3 4 5
Ceilings
Picture 3.2.11.3.3
Warehouse ceilings (also
the inside of roofs) can be
of metal girders and
corrugated sheets with airvents (with pest
protection).
Pictures: 1 2 3 4 5
Ceilings
Picture 3.2.11.3.4
Walk-on ceilings especially suitable for high
hygiene areas as ceiling
surface on process side:
will have no (or minimal)
attachments for dust
collection also allow
maintenance without
influencing process will be
normally constructed from
'sandwich' panels with
smooth impervious
cleanable surfaces.
Pictures: 1 2 3 4 5
Ceilings
Picture 3.2.11.3.5
Walk-on ceilings - design
must include: appropriate
access - sufficient space
above the panels for
cleaning and maintenance
structure for a point load
of 150kg for personnel
traffic equipment and
ducting suspended
separately.
Pictures: 1 2 3 4 5
Chapter 3
22 Jul. 2008 09:12:00
DOORS

Section 3.2.12.3
Exterior doors must be primary barriers to infestation and ingress of dust etc. Tight fitting
frames and lack of gaps at floor-to-door contact will be necessary.
Interior doors often play an important role - not only in separating zones with different hygiene
levels, but also in maintaining positive air pressures in areas requiring higher hygiene levels.
Door fitting tightly in the frame is important.
Other than for low hygiene areas, interior doors can either be solid (or of a single sheet) but if
hollow, spaces in doors should be foamed-filled with PU (polyurethane). They must not harbour
residues.
Door closing systems are important in relation to hygiene. However, with the exception of
automatic opening and closing systems for entries of traffic, personnel entries do not need such
systems.
The closing device must not collect residues and therefore floor level devices which have hollow
bodies should be avoided.
Doors
Picture 3.2.12.3.1
Exterior doors must be
primary barriers to
infestation and ingress of
dust.
Note: Tight fitting frames
and lack of gaps at the
floor-to-door contact are
necessary.
Pictures: 1 2 3 4 5
Doors
Picture 3.2.12.3.2
Interior doors often play an
important role - not only in
separating zones with
different hygiene levels but
also in maintaining positive
air pressures in areas
requiring higher hygiene
levels. This example shows
an interior high hygiene
dry area single sheet door.
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Pictures: 1 2 3 4 5
Doors
Picture 3.2.12.3.3
This example shows the
details of hygienic closing
device on a high hygiene
dry area door.
Pictures: 1 2 3 4 5
Doors
Picture 3.2.12.3.4
This example shows details
of hygienic closing device
on a high hygiene dry area
door.
Pictures: 1 2 3 4 5
Doors
Picture 3.2.12.3.5
Door fitting tightly in the
frame is important - a door
which does not close
properly will allow entry of
dusts and pests.
Pictures: 1 2 3 4 5
Other relevant sections in
this GI
3.2.5
Loading and unloading docks
3.2.5.5 Hygiene Considerations trains/rail cars
Chapter 3
08 Aug. 2008 12:57:00
Recommendations

Recommendations
Section 3.2.12.4
Design of the doors may depend on local possibilities, material availability etc., but there can be
no compromise if the door is a barrier to a high hygiene area.
Solid doors are essential in high hygiene areas but plastic doors of air-tight construction are
acceptable.
Doors in forklift or pallet areas must be of heavy duty construction, reinforced with frames and
plates.
Plastic strip doors are not efficient barriers. Although costing more, roller doors (or rapid closing
doors) are best.
The use of air curtains on exterior doors should be discouraged as they are not effective especially if potential pests are not just flying insects.
Where the door does not give access to a high or medium hygiene area - and it is desirable to
use it for ventilation purposes - then a double door with a well-fitted screen on the outside and a
solid door on the inside, is acceptable.
Doors
Recommendations
Picture 3.2.12.4.1
solid doors doors with

windows - for
personnel safety
doors having fire
resistance and special
closing mechanisms
Note: Door fitting tightly in

the frame is important.
Pictures: 1 2
Doors
Recommendations
Picture 3.2.12.4.2
Recommendations Plastic
strip doors are not efficient
barriers.
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Recommendations
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Hygiene Considerations Windows
WINDOWS & LOUVERS

Section 3.2.13.3
Window frames should be made from solid materials.

In high (and some medium) hygiene production areas, windows should be fixed, sealed and
flush with the interior wall.
Exterior and interior window sills should be sloped to avoid accumulation of debris.
When only for lighting purposes, prevention of entry of infiltrations is critical and glass blocks
are a good alternative to fixed windows - especially in high hygiene areas.
Note: In locations with seismic activity, glass blocks are likely to crack and alternatives will be
necessary
Trying to seal an openable window to make it fixed is only a temporary, unacceptable alternative
and leads to infiltration.
When windows are also used for ventilation - tight fitting, properly sized screens must be in
place to prevent the ingress of insects, particularly nymph stages. Screens must be removable
for cleaning.
Openable windows should open outwards - to allow easy cleaning from the outside.
Windows and louvers

Windows
Picture 3.2.13.3.1
Windows - also used for
ventilation - must have
insect screens.
Note: Screens must be
removable for cleaning preferably to outside to
avoid dirtying inside floor.
Pictures: 1 2 3 4 5 6 7 8 9 10
Windows and louvers
Windows
Picture 3.2.13.3.2
Window frames should be
made from solid materials.
Note: Hollow framed
windows which can be
opened are unacceptable
for high or medium hygiene
areas.
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Windows and louvers
Windows
Picture 3.2.13.3.3
In high (and some
medium) hygiene
production areas windows
should be fixed sealed and
flush with the interior wall.
Pictures: 1 2 3 4 5 6 7 8 9 10
Windows and louvers
Windows
Picture 3.2.13.3.4
Exterior and interior
window sills should be
sloped to avoid
accumulation of debris.
Pictures: 1 2 3 4 5 6 7 8 9 10
Windows and louvers
Windows
Picture 3.2.13.3.5
When only for lighting
purposes prevention of
entry of infiltrations is
critical and glass blocks are
a good alternative to fixed
windows - especially in
high hygiene areas.
Note: In locations with
seismic activity glass
blocks are likely to crack
and alternatives will be
necessary.
Pictures: 1 2 3 4 5 6 7 8 9 10
Windows and louvers
Windows
Picture 3.2.13.3.6
Trying to seal an openable
window to make it fixed is
only a temporary
unacceptable alternative
and leads to infiltration.
Pictures: 1 2 3 4 5 6 7 8 9 10
Windows and louvers
Windows
Picture 3.2.13.3.7
When windows are also
used for ventilation - tight
fitting properly sized
screens must be in place to
prevent the ingress of
insects particularly nymph
stages.
Screens must be removable
for cleaning.
Pictures: 1 2 3 4 5 6 7 8 9 10
Windows and louvers
Windows
Picture 3.2.13.3.8
Openable windows should
have top hinges - to allow
easy cleaning from the
outside.
Note: This type of window
is only for low hygiene
areas.
Pictures: 1 2 3 4 5 6 7 8 9 10
Windows and louvers
Windows
Picture 3.2.13.3.9
In high hygiene production
areas windows should be
fixed sealed and flush with
the interior wall.
Pictures: 1 2 3 4 5 6 7 8 9 10
Windows and louvers
Windows
Picture 3.2.13.3.10
In high hygiene production
areas windows should be
fixed sealed and flush with
the interior wall.
This is a special case for a
window in an area with
seismic activity - an
expensive solution but the
window is sealed in its
frame and bought as a unit
and will not crack during
seismic activity.
Pictures: 1 2 3 4 5 6 7 8 9 10
Chapter 3
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Hygiene Considerations Louvers

Section 3.2.13.4
If used for light and natural ventilation - louvers need to be screened. These screens need to have
the same properties as screens for windows.
Windows and louvers
Louvers
Picture 3.2.13.4.1
When used for light and
natural ventilation, louvers
need to have screens which should be easily
removable for cleaning with two options:
1. Internal screens with
drop-down cover on outer
surface (as shown here)
which allows protection of
louvers in very heavy
storms. For cleaning they
must be removed to inside,
dirtying floor area acceptable in a lower
hygiene areas.
2. For higher hygiene areas
(e.g. ventilation in roller
dryer rooms) screens must
be removed to outside for
cleaning.
Pictures: 1 2 3 4
Windows and louvers
Louvers
Picture 3.2.13.4.2
If used for light and natural
ventilation - louvers need
to be screened. These
screens need to have the
same properties as screens
for windows.
Pictures: 1 2 3 4
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Windows and louvers

Louvers
Picture 3.2.13.4.3
for windows.
Pictures: 1 2 3 4
Windows and louvers
Louvers
Picture 3.2.13.4.4
for windows.
Pictures: 1 2 3 4
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Recommendation

Recommendation
Section 3.2.13.5
In high and medium hygiene processing environments - avoid the use of windows or louvers
whenever possible. Adequate lighting is better supplied by hygienically designed and installed light
fixtures.
However, some windows may be necessary for personnel safety reasons. Local legislation will
influence this point.
Windows and louvers

Recommendation
Picture 3.2.13.5.1
In high and medium
hygiene processing
environments - avoid the
use of windows or louvers
whenever possible.
However some windows
may be necessary for
personnel safety reasons.
Note: In this high hygiene
building windows have
been installed for light but must be fixed (not
openable). An exception to
this rule - infant cereals
high hygiene roller drier
rooms need louvers for
ventilation.
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STAIRS

Section 3.2.14.3
Although hygiene is critical, compromises may be necessary as stairs/steps must be safe under
working conditions and emergencies.
The relative dimensions of tread and step must be ergonomically correct and in compliance with local
regulations.
Specifically for hygiene requirements - stairs/steps:
must be easy to clean
must be self-draining (if wet-cleaned)
avoid points that provide any accumulation points (or harbourages)
must not have hollow handrails - if there is a direct contamination risk for the product.
Stairs
Picture 3.2.14.3.1
Steps must be easy-toclean.
There should be no points
where residues accumulate.
Note: The point under and
behind first step should be
filled in - as it is often a
tempting typical
'temporary storage' place.
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Recommendations

Recommendations
Section 3.2.14.4
The hygiene level of the area will help determine the appropriate type of stair - and whether
attention has to be paid to a surface covering of the stairs or to avoiding residue collecting points.
General recommendations are as follows:
If a concrete stairway is not part of the high hygiene area - it is not necessary to neither coat
the steps (eg. with epoxy) nor install solid handrails.
If single step stairs are chosen - cleanness is obviously of greatest concern in the high hygiene
areas.
Latticed metal plate should be used - instead of difficult-to-clean open metal grid - unless there
is a specific need for air circulation.
Stairs
Recommendations
Picture 3.2.14.4.1
For continuous or single
step metal stairs details
will depend on hygiene
requirements of area.
In a high hygiene area care
needs to be taken with
installation and cleanness.
Note: Solid handrails are
necessary where steps are
near product.
Pictures: 1 2 3
Stairs
Recommendations
Picture 3.2.14.4.2
If a concrete stairway is
not part of the high
hygiene area - it is not
necessary to coat the steps
(e.g. with epoxy) nor
install solid handrails.
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Recommendations
Stairs
Recommendations
Picture 3.2.14.4.3
Latticed metal plate should
be used - instead of open
metal grid (difficult to
clean) - unless there is a
specific need for air
circulation.
Pictures: 1 2 3
Other relevant section in
this GI
3.5.8
Platforms
3.5.8.7 Recommendations design of stairs and ladders
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LIFTS & ELEVATORS

Section 3.2.15.3
Lifts connecting areas of different hygiene levels can present major hygiene problems. Such
situations are typically found in older factories - where the lift/elevator was installed before zoning
was planned. In this case, if modifications cannot be made to resolve the access problem - the
design details of the lift/elevator are very critical in preventing the installation from becoming a
source of cross-contamination. General hygiene details are as follows:
Wooden elements - should not be used in lifts in high hygiene areas.
Cleanness - is important because of diverse items etc. that can be transported.
Floors (base of lift) - may have to be of chequered plate for safety reasons, even though this
constitutes a surface which is more difficult to clean.
Note: Such problems can be minimized by certain details such as trying to ensure continuity of
the plate with the side of the lift/elevator to avoid residue collection.
Where the lift/elevator opens into the room (or other area) - should be as free as possible of
dust collecting points or points difficult to clean.
Inside the lift/elevator - there should be no hollow bodies, no open light fixtures - all of which
could collect dust or insects.
Lift shafts - should not be air tunnels - bringing in dust and should not affect air balances where
a room is pressurized.
Note: The lift/elevator well can be a source of contamination (microbial and insects), but
for personnel safety reasons neither access nor design can be greatly modified to avoid this
problem.
Access to such areas should be limited to specialists and in most cases should form part of the
service contract. However the hygienic risks that could emanate from these areas should be known
and such points discussed with the lift/elevator company.
Lifts and elevators
Picture 3.2.15.3.1
Where the lift/elevator
opens into the room (or
other area) - should be as
free as possible of dust
collecting points or points
difficult to clean.
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Lifts and elevators

Picture 3.2.15.3.2
Hygiene considerations
Inside the lift/elevator there should be no hollow
bodies, no open light
fixtures - all of which could
collect dust or insects.
Note: Wooden elements
(eg. lift lining panels may
be used for protection - but
should not be used in lifts
in critical areas.
Pictures: 1 2 3
Lifts and elevators
Picture 3.2.15.3.3
Lift shafts - should not be
air tunnels - bringing in
dust and should not affect
air balances where a room
is pressurized. For lifts/
elevators in high hygiene
areas: as many elements as
possible (e.g. walls floors
and doors) should be made
of stainless steel.
Poor sealing of elements
leads to points where
residues collect - and are
difficult to clean.
Pictures: 1 2 3
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Recommendations

Recommendations
Section 3.2.15.4
Lay-out and lift/elevator location: For future projects or during modifications - the aim
should be to prevent a lift/elevator being a contact point between areas of different hygiene
levels - especially between high hygiene zones and other areas.
Design features: The details of the lift/elevator, within the limits of personnel safety - should
facilitate cleaning and eliminate points where dirt or insects could accumulate. Such
requirements need to be discussed with the suppliers.
For lifts/elevators in high hygiene areas: as many elements as possible (eg. walls, floors
and doors) should be made of stainless steel.
Lifts and elevators

Recommendations
Picture 3.2.15.4.1
For lifts/elevators in high
hygiene areas: as many
elements as possible (e.g.
walls floors and doors)
should be made of stainless
steel.
Note: This design is not
suitable for high hygiene
areas.
Pictures: 1 2
Lifts and elevators
Recommendations
Picture 3.2.15.4.2
For lifts/elevators in high
hygiene areas: as many
elements as possible (e.g.
walls floors and doors)
should be made of stainless
steel.
Pictures: 1 2
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Recommendations
22 Jul. 2008 08:37:00

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AIRLOCKS

Section 3.2.16.3
Design requirements will vary according to the type of air-lock - to be decided by its intended use.
Typically - an intermediate area air-lock will be required between a high level zone and another zone.
Depending on the type of air-lock the lay-out will include some or all of the following summarised as
additional information:
entry and exit doors (tightly fitting) maybe with self-closing device (not floor level, as these
constitute hollow bodies)
insectocutors inside the area - better installed just outside the outer door rather than in the airlock
floor sloping towards the wet side - if the air lock connects a critical dry area to a wet area
no drains normally required - definitely not on the critical side - but there maybe a drain on the
contaminated side
shoe change facilities
shoe change barrier - should be fixed and is best constructed of brick - may be movable (made
of stainless steel) - but must remain 100%, with no gaps at floor level
open grills or supports - for dirty shoes on non-critical side and clean ones on clean side (not
closed - to avoid odour development)
small air exhaust - (if the area is small) to remove shoe odours
hand washing facilities - with hand drying (preferably not hot air dryers) - should be located on
the non-critical side.
Airlocks
Hygiene Coonsiderations
Picture 3.2.16.3.1
This chart shows how
design requirements will
vary according to the type
of air-lock - to be decided
by its intended use.
Note: Typically - an
intermediate area air-lock
will be required between a
high level zone and another
zone.
Types
A=
personnel entry
B = personnel or material
entry - to more areas with
regular (but controlled)
wet cleaning
C = personnel or material
entry - to more critical dry
areas
D = personnel or material
exit - from areas where
pathogens may be present
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Pictures: 1 2 3 4 5 6 7 8
Airlocks
Picture 3.2.16.3.2
Personnel shoe change is
required for entry to high
hygiene dry area.
Note: The bench is a solid
barrier to floor level.
Pictures: 1 2 3 4 5 6 7 8
Airlocks
Picture 3.2.16.3.3
The shoe change barrier
must stretch right across
the air-lock with no gaps.
Note: As a compromise a
movable barrier to allow
material entry is
acceptable - as long as it is
still a solid barrier to floor
level when in position.
Pictures: 1 2 3 4 5 6 7 8
Airlocks
Picture 3.2.16.3.4
The shoe change barrier
should be fixed - and is
best constructed of brick.
Pictures: 1 2 3 4 5 6 7 8
Airlocks
Picture 3.2.16.3.5
This diagram shows an airlock entry to a high
hygiene area - with shoe
change.
Note: Hand wash is on the
lower hygiene side of the
bench (before shoe
changing) - because
wherever there is a hand
wash station the
surrounding floor becomes
wet.
This avoids wet spots on
the dry high hygiene side.
After shoe change, hands
can be cleaned again with a
disinfectant spray.
Pictures: 1 2 3 4 5 6 7 8
Airlocks
Picture 3.2.16.3.6
Typically - an intermediate
area air-lock will be
required between a high
level zone and another
zone. The shoe change
barrier may be movable made of stainless steel but must remain 100%
with no gaps at floor level.
Note: In this example the
gate for entry of other
material is not 100%.
Pictures: 1 2 3 4 5 6 7 8
Airlocks
Picture 3.2.16.3.7
This diagram shows a
typical design for shoe
supports.
Note: Plates for shoe
support are only fixed in
place by a 'u-pin' - and can
then be removed to a wet
area for adequate
scrubbing, cleaning and
drying.
Pictures: 1 2 3 4 5 6 7 8
Airlocks
Picture 3.2.16.3.8
typical personnel exit from
a potentially highly
contaminated area where
raw chickens are handled.
Contaminated shoes and
clothes may be changed only contact with 'cooked
chicken' side is via
autoclave - no people
contact.
Water from contaminated
area must flow directly to
the waste water treatment.
Reception area for chickens
must be cleanable - but no

contaminated water must
flow to general factory
personnel routes.
Pictures: 1 2 3 4 5 6 7 8
Chapter 3
22 Jul. 2008 08:32:00
Recommendations

Recommendations
Section 3.2.16.4
Airlocks
Recommendations
Picture 3.2.16.4.1
This chart identifies some
specific recommendations
by type of airlock.
Material change is typically
from wood to plastic
pallets and removal of
packaging outers.
Pictures: 1 2 3
Airlocks
Recommendations
Picture 3.2.16.4.2
This diagram shows an airlock entry to a high
hygiene area - with shoe
change.
Note: Hand wash is on the
lower hygiene side of the
bench (before shoe
changing) - because
wherever there is a hand
wash station the
surrounding floor becomes
wet.
This avoids wet spots on
the dry high hygiene side.
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Recommendations
After shoe change, hands

can be cleaned again with a
disinfectant spray.
Pictures: 1 2 3
Airlocks
Recommendations
Picture 3.2.16.4.3
typical personnel exit from
a potentially highly
contaminated area where
raw chickens are handled.
Contaminated shoes and
clothes may be changed only contact with 'cooked
chicken' side is via
autoclave - no people
contact.
Water from contaminated
area must flow directly to
the waste water treatment.
Reception area for chickens
must be cleanable - but no
contaminated water must
flow to general factory
personnel routes.
Pictures: 1 2 3
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DRAINS

Section 3.2.17.3
Wet drains
Baskets in milk processing area should be able to retain particles of 3-5mm. In processing area,
where large amounts of particles are on the floor (ie. in vegetable processing areas) - the
particles should be retained by the grating before passing the siphon.
Siphons must be maintained full of water (or water and disinfectant) - to prevent back-flow of
aerosols and odours into processing and/or packaging areas.
Design of the drain should be chosen as a direct function of:
amount of liquid to be evacuated
frequency of cleaning
need (in some cases) to prevent possible aerosols from drains which could be sources of
contamination.
Stainless steel drains are preferable, though in low hygiene areas, compromises could be made
for other material. Channels (if not in stainless steel) should be coated with an acid-resistant
finish.
Drains should be located as close as possible to the sources of the effluents.
Drains should be easily accessible (not under equipment). In wet processing areas, drain lines
can be at right angles to the process/product flow - which allows for flexibility of change of
equipment position, whilst keeping accessibility.
Water drainage path should avoid crossing traffic ways of personnel and goods.
Contact of the drain element to the floors needs special attention to avoid a residue collecting
point and sub-floor seepage.
Floors should slope to the drain - either across whole area or as 'diamond' around the drain.
Areas to be drained should not exceed 30-40 m2 per drain.
Top of grating should be the lowest point of the floor (ie. the upper surface of the grating should
not be above the floor level).
Drain diameter should be dimensioned according to the amount of water, but not be less than
100mm.
Drains in areas with heavy traffic should be anchored firmly in the ground, to prevent cracking
between floor and drain.
Drainage pipes should not cross high hygiene areas - and especially not equipment.
Drains in controlled wet areas can have a 'plug system' to seal them when not in use.
Dry drains
must not be an 'air-chimney' from low to high hygiene areas
must remain totally dry - when not in use
outlet to exterior drainage must be
either sealed when not in use
or via a tank - which can be drained.
Drains
Picture 3.2.17.3.1
Wet drains for wet area must have basket with
siphon.
Note: These must be
maintained full of water
(plus some chlorine) and
be regularly cleaned - to
prevent back flow of
odours and creation of
contaminated aerosols.
Controlled wet area drains
may have solid lid to
replace grating - only to be
opened for cleaning.
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Drains
Picture 3.2.17.3.2
Channels - if not in
stainless steel - should be
coated in acid-resistant
finish.
The slope to drain is critical.
Good contact between
drain and floor surface needs checking and
maintaining.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Drains
Picture 3.2.17.3.3
Dry drains - typically found
in drying tower buildings
and other medium/high dry
zones.
Note: Must not be an 'airchimney' from a lower
hygiene area - there must
always be a break between
the down pipe and the
receiving funnel.
Outlet to exterior drainage
must be either sealed when
not in use or exit via a
tank/siphon system.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Drains
Picture 3.2.17.3.4
Dry drains - typically found
in drying tower buildings
and other medium/high dry
zones.
Note: Must not be an 'airchimney' from a lower
hygiene area - there must
always be a break between
the down pipe and the
receiving funnel.
Outlet to exterior drainage
must be either sealed when
not in use or exit via a
tank/siphon system.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Drains
Picture 3.2.17.3.5
Baskets in milk processing
area should be able to
retain particles of 3-5mm.
In processing area where
large amounts of particles
are on the floor (ie. in
vegetable processing
areas) - the particles
should be retained by the
grating before passing the
siphon.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Drains
Picture 3.2.17.3.6
Wet drains can be sealed or
capped for periodic use seal or cap can make 100%
cover or can have still
some drainage holes at the
perimeter.
Note: This is a typical drain
for a medium or high
hygiene controlled wet
area - where cleaning is
only done (eg.) every few
days or once a week.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Drains
Picture 3.2.17.3.7
Channels (if not in
stainless steel) should be
coated with an acidresistant finish.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Drains
Picture 3.2.17.3.8
Drain diameter should be
dimensioned according to
the amount of water but
not be less than 100mm.
Drains in areas with heavy
traffic should be anchored
firmly in the ground to
prevent cracking between
floor and drain.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Drains
Picture 3.2.17.3.9
Drain diameter should be
dimensioned according to
the amount of water but
not be less than 100mm.
Drains in areas with heavy
traffic should be anchored
firmly in the ground to
prevent cracking between
floor and drain.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Drains
Picture 3.2.17.3.10
Stainless steel drains are
preferable though in low
hygiene areas
compromises could be
made for other material.
Channels (if not in
stainless steel) should be
coated with an acidresistant finish.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Drains
Picture 3.2.17.3.11
must remain totally dry

- when not in use
outlet to exterior
drainage must be:
- either sealed
when not in use - or
via a tank - which
can be drained.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Drains
Picture 3.2.17.3.12
These examples show how
a specific type of drain
should be chosen according to type of
cleaning or hygiene level.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
this GI
3.2.7
Floors and finishes
3.2.7.3 Hygiene considerations
3.2.7
Floors and finishes
3.2.7.4 Recommendations
Chapter 3
13 Aug. 2008 07:33:00
SEWAGE

Section 3.2.18.3
For pipe line lay-out and pipe quality:
Design and lay-out of the clear water and sewer lines depends not only on the type of water, but
also on their location. Lay-out must avoid any cross-contamination, (back-flows of highly
contaminated water) which could bring potential hazards near to product.
Pipe quality has to be selected according to the type of chemicals present in the water and the
hygiene risk involved:
clear water: PVC, cement or cast iron
CIP: stainless steel (up to dilution tank)
process waste water: PE, PP or cast iron
laboratory: PE, PP, stainless steel
oil handling: PVC or mild steel, depending on oil type.
Note: In all cases, the material selected must prevent leaks which could occur.
General requirements are:
Lines: for waste as well as clear water - must not cross medium/high hygiene areas/open
process lines. Leaks can occur with infiltration of potential contaminants.
Downpipes: from roofs should be outside the building where possible. If inside due to
climatic conditions (eg. very cold winters) they have to be placed in technical galleries or
stair cases, whenever possible.
Access: to man-holes, pits, oil separators, septic tanks etc. should be not be in main
personnel corridors.
Sewage
Picture 3.2.18.3.1
Lines for waste as well as
clear water - must not
cross medium/high
hygiene areas/open
process lines.
Leaks can occur with
infiltration of potential
contaminants.
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Recommendations

Recommendations
Section 3.2.18.4
Sewage systems must not adversely affect the product.
Careful planning of sewage flows is essential in the early stages of plant layout.
For typical different types of effluents to be treated, typical potential problems and recommended
measures will have to be considered.
Sewage
Recommendations
Picture 3.2.18.4.1
Careful planning of sewage
flows is essential - (e.g.)
planning separate routing
of:
water that can go

straight to the factory
outlet (e.g. clear
water)
water must pass via the
waste water plant.
Pictures: 1 2 3
Sewage
Recommendations
Picture 3.2.18.4.2
Sewage systems must not
adversely affect the
product.
Careful planning of sewage
flows is essential in the
early stages of plant layout.
Certain sewage lines due to
the contaminated material
they will carry must be
separated from process
waste collection systems.
All risks of back-flows or
cross connections from
hazardous systems to
process systems must be
prevented.
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Recommendations
Sewage
Recommendations
Picture 3.2.18.4.3
The potential problems
described in the previous
chart can be prevented by
following some simple
steps in sewage system
design.
Pictures: 1 2 3
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WASTE WATER
TREATMENT PLANT

Section 3.2.19.3
All associated steps that could be the origin of potential cross-contamination need attention. This is
particularly important where the waste water treatment plant is handling sewage from the personnel
facilities and factory housing.
Location of the waste water treatment plant in relation to the factory premises is critical. This can be
the first step in preventing the plant affecting processes. The waste water plant should ideally:
have a natural tree barrier to reduce any droplet transfer

be separated by the greatest (yet practical distance) possible
have access routes only for the installation
have its own laboratory.
Waste water treatment plants

Picture 3.2.19.3.1
The waste water plant
should ideally:
be downwind of the
factory
have a natural tree
barrier to reduce any
droplet transfer
be separated by the
greatest yet practical
distance possible from
the processing
buildings.
Pictures: 1 2
Picture 3.2.19.3.2
The waste water plant
should ideally:
have a natural tree

barrier to reduce any
droplet transfer.
Pictures: 1 2
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this GI
2.2
Master plan
2.2.1
Introduction and Purpose
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Recommendations

Recommendations
Section 3.2.19.4
The plant must be located as far as possible to be practical from the processing buildings.
Sludge sedimentation areas and sludge removal systems must not become a potential source of
contamination nor attract insects - open channels can be a problem in warm climates.

Recommendations
Picture 3.2.19.4.1
Sludge sedimentation areas
and sludge removal
systems must not become
a potential source of
contamination nor attract
insects - open channels can
be a problem in warm
climates.
Pictures: 1 2 3
Recommendations
Picture 3.2.19.4.2
and sludge removal
climates.
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Recommendations

Recommendations
Picture 3.2.19.4.3
and sludge removal
climates.
Pictures: 1 2 3
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Hygiene considerations vertical elements
BUILDING STRUCTURE

Section 3.2.3.3
Columns and masonry walls should be:
of steel or reinforced concrete - but without accessible routes for passage of contaminants or
pests
in sufficient numbers - to span distance to prevent weak points, which could crack and become
residue collection sites and/or harbourage for pests
flush with the interior side of adjacent walls - to reduce residue collection
not of open steel structures with H or I type profiles - which have large areas where dust and
residues can accumulate and are difficult to clean
connected to masonry walls - with minimal risks of crack development, thereby minimising dust
accumulation points and possible harbourage sites.
Note:
To improve connections with masonry walls, steel columns can be embedded with concrete - but
then the wall to column connections must be properly maintained.
easy to clean:
for high hygiene areas - columns or walls should be embedded in reinforced concrete to
about 60cm high - slanted at the top
for medium/low hygiene areas - H or I type profiles should be filled at floor level with
concrete
protected (if exposed to heavy traffic) - with steel angles to a minimum height of 1.5m - to
prevent broken edges becoming a source of hygiene problems, especially in processing
areas.
Building structure
vertical elements
Picture 3.2.3.3.1
Easy to clean - not open steel
structures - especially in high
hygiene areas.
Protected with steel angles to
prevent broken edges especially important in areas
with significant fork-lift traffic.
Pictures: 1 2
Building structure
vertical elements
Picture 3.2.3.3.2
Steel structures can be
grouted - filled in with sloping
material (cement) - to prevent
presence of a sharp angled
area which collects residues.
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Pictures: 1 2
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Hygiene considerations horizontal elements

Section 3.2.3.4
Floor slabs - ground floor - suspended and made of re-enforced concrete:
Critical points to be noted:
joint cracks - must be avoided between slab and building - especially where there is potential
rising humidity and residues could collect in the cracks
hygienic voids - can exist for suspended sewage piping - and can become places where
contamination can start, insects such as cockroaches can accumulate.
Access for maintenance and inspection must be provided - if the void cannot be eliminated.
Floor slabs - upper floors:
good joints - without cracks that can harbour residues
Floor slabs - all floors:
expansion joints - must have special attention - although flexible they should not made of
material that accumulates residues
metallic joints - across floors can be difficult to clean.
Building structure
horizontal elements
Picture 3.2.3.4.1
Floor slabs - ground floor.
Note:
Joint cracks must be
avoided.
In a new building, some
allowance for settling must
be made - but this gap
must not be left as a void where residues could
collect.
Pictures: 1 2
Building structure
horizontal elements
Picture 3.2.3.4.2
Wherever there are
expansion joints regular
checking and maintenance
are necessary.
Note:
Obviously correct initial
installation helps - but
maintenance is critical - as
expansion joints can
quickly become points of
residue accumulation particularly in humid wet
areas.
Weakest points are where
expansion joints cross high
traffic areas - and where a
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joint meets a drain channel.
Pictures: 1 2
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Recommendations

Recommendations
Section 3.2.3.5
Note:
Details of building structures are directly related to the hygienic needs of processes or other
operations that are to be protected.
Local climatic conditions and construction facilities are also important considerations.
Some important recommendations:
Exposed steel structures are only suitable for processes with lower hygiene requirements.
Mixed steel/concrete structures with metal decking are not suitable for process areas - difficult
to clean.
Building elements must not allow passage of vectors of contaminants - especially from outside to
inside.
Surface finishes are critical - to protect the building element and to prevent residue collecting
points.
In humid (or aggressive) environments, improved corrosion protection is required. Epoxy type
floor covering (or brick tiles etc.) should be employed to prevent corrosion and surface damage
to concrete structures
All expansion joints need special attention - both during installation and maintenance.
Building structure
Recommendations
Picture 3.2.3.5.1
Details of building
structure are directly
related to the hygienic
needs of the processes that
are to be protected.
This structure is typical for
housing a high hygiene
drying tower.
Surface finishes are critical
- to prevent residue
collecting points.
Expansion joints need
special attention (e.g.
between staircase element
and tower building) - to
prevent infiltrations.

this GI
3.2.9
Walls external and internal
3.2.9.2 Basic types
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Hygiene considerations road transport
DOCKS

Section 3.2.5.4
For handling sacks, pallet loads, bulk solid products in big boxes or big bags from road transport,
ideal hygienic designs include the following details:
System by which the transporter can be attached to the dock and warehouse/storage facility.
Such systems normally have a self-closing 'concertina' form or a device (eg. a roller door) to
provide a total barrier - when there is no off-loading (or loading) underway. These details are
necessary to protect the incoming goods or products - and to prevent entry of pests.
Plastic curtains are not adequate barriers.
Sliding doors must have pest barriers at the bottom rail.
Air curtains cannot prevent entry of pests.
The area needs adequate lighting so that necessary inspections of incoming goods, products or
actual transports are possible.
The surfaces, floors and platforms, should be installed to facilitate cleaning. Cleaning up of any
spilled product is a critical part of a pest prevention programme.

road transport
Picture 3.2.5.4.1
Systems by which the
transports can be attached
to the dock and
warehouse/ storage facility
normally have a selfclosing 'concertina' form or
a device (e.g. a roller door)
to provide a total barrier when there is no offloading (or loading)
underway.
These details are necessary
to protect the incoming
goods or products - and to
prevent entry of pests.
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road transport
Picture 3.2.5.4.2
Systems by which the
transports can be attached
to the dock and
warehouse/ storage facility
normally have a selfclosing 'concertina' form or
a device (e.g. a roller door)
to provide a total barrier when there is no offloading (or loading)
underway. These details
are necessary to protect
the incoming goods or
products - and to prevent
entry of pests.
Pictures: 1 2 3 4 5 6
road transport
Picture 3.2.5.4.3
At unloading or loading
docks, sliding doors must
have pest barriers at the
bottom rail.
Pictures: 1 2 3 4 5 6

road transport
Picture 3.2.5.4.4
At loading or unloading
docks, doors should have a
self-closing device (e.g. a
roller door).
It is critical that this roller
door sits in a channel when
closed - forming an
adequate barrier against
pest and dust entry.
Also side rails must be
tight - to prevent entry of
pests and dust.
Pictures: 1 2 3 4 5 6
road transport
Picture 3.2.5.4.5
Sliding doors must have
pest barriers at the bottom
rail.
Pictures: 1 2 3 4 5 6
road transport
Picture 3.2.5.4.6
Plastic curtains are not
adequate barriers against
entry of pests.
Pictures: 1 2 3 4 5 6
Chapter 3
18 Aug. 2008 14:29:00
FLOORS & FINISHES

Section 3.2.7.3
Floors and finishes are chosen according to hygiene levels and types of cleaning.
Local possibilities should also be considered - such as the availability of companies and their
expertise on installing a particular type of floor finish.
For floors in wet/controlled wet areas - contact points to drains can be areas where residues can
collect - and must be well maintained.
Floors and finishes
Picture 3.2.7.3.1
For floors in wet/controlled
wet areas - contact points
to drains can be areas
where residues can collect
- and must be well
maintained.
Pictures: 1 2 3 4 5 6
Floors and finishes
Picture 3.2.7.3.2
Floors and finishes are
chosen according to
hygiene levels and types of
cleaning. This example
shows a typical smooth
epoxy finish for a high
hygiene dry zone.
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Floors and finishes

Picture 3.2.7.3.3
Note:
Correct floor to wall finish
for high hygiene dry area.
Pictures: 1 2 3 4 5 6
Floors and finishes
Picture 3.2.7.3.4
Note:
This example shows an
ideal concrete finish for a
low hygiene dry corridor.
No 5of 6 (Addition to
Photos 1 Word doc)
Pictures: 1 2 3 4 5 6
Floors and finishes
Picture 3.2.7.3.5
In wet/controlled wet
areas - contact points to
drains can be areas where
residues often collect.
Note:
This example shows how
such joints must be well
maintained.
Pictures: 1 2 3 4 5 6
Floors and finishes
Picture 3.2.7.3.6
Types of features which
need to be taken into
consideration for hygiene.
Pictures: 1 2 3 4 5 6
Chapter 3
30 Jul. 2008 10:47:00
Recommendations

Recommendations
Section 3.2.7.4
The type of finish has to be selected in line with the process hygiene requirements as follows:
zone - dry or wet or controlled wet
resistance required - mechanical, chemical, impact, thermal
contact areas - between floor surfaces and walls must not collect residues - these areas should
be curved and easy to clean
ease of wet cleaning
types of cleaning chemicals/tools
temperature and frequency at which cleaning is done
ease of dry cleaning
types of dry cleaning systems
frequency.
Floor finishes should be selected in accordance with hygiene and operational requirements. In
some cases compromises may be necessary to meet both - (eg.) although a very smooth floor is
good for cleaning, some roughness may be essential for safety of personnel.
Floors and finishes

Recommendations
Picture 3.2.7.4.1
This diagram shows the
contact between floor
surfaces and walls curved
and easy to clean.
It is critical that there is
adequate grouting - to
prevent seepage under the
tiles.
Pictures: 1 2 3 4 5
Floors and finishes
Recommendations
Picture 3.2.7.4.2
This diagram shows the
contact between floor
surfaces and walls curved
and easy to clean.
It is critical that there is
adequate grouting - to
prevent seepage under the
tiles. Tiles will only form
the curve and maybe the
first few cms. of the wall after first tile the wall
should be coated (e.g. with
epoxy) - wall tiles can have
hollow voids behind them
due to spot grouting and
are to be avoided.
In a low (and even some
medium) hygiene areas the
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Recommendations
floor slab can be without

coating - but still the
contact to the wall coating
must be curved.
Pictures: 1 2 3 4 5
Floors and finishes
Recommendations
Picture 3.2.7.4.3
Ease of cleaning: for wet
cleaning: types of cleaning
chemicals/tools temperature and frequency
at which cleaning is done
for dry cleaning: -types of
dry cleaning systems.
Note:
This example shows a
typical smooth epoxy
surface for area to be only
dry cleaned.
Pictures: 1 2 3 4 5
Floors and finishes
Recommendations
Picture 3.2.7.4.4
Contact areas between
floor surfaces and walls
must not collect residues these areas should be
curved and easy to clean.
Recommendations
Pictures: 1 2 3 4 5
Floors and finishes
Recommendations
Picture 3.2.7.4.5
This table gives a summary
of recommended floor
finishes which could be
selected in accordance with
hygiene (H) and
operational (O)
requirements.
In some cases
compromises may be
necessary to meet both.
For example although a
very smooth floor is good
for cleaning some
roughness may be
essential for safety of
personnel.
Pictures: 1 2 3 4 5
Chapter 3
25 Jul. 2008 13:56:00
MACHINERY
FOUNDATIONS

Section 3.2.8.3
Generally the following aspects are important:
Foundations must not have hollow sections.

For high/medium hygiene areas (being an extension of the floor) the floor surface should extend
over the plinth - with rounded edges at the floor contact point to facilitate cleaning:
if the floor has an epoxy surface - covering should be of the same material
if the floor is tiled - the plinth will need a resin or epoxy covering, as tiles on a plinth present
the same problem as tiles on a wall - risk of infiltrations into hollow bodies.
In low hygiene areas with concrete floors - the plinth does not need a coating.
To facilitate cleaning - the machinery is best embedded in the concrete, plinth surface coatings
then make a smooth contact with the machinery surface. If the machinery is not embedded
(standing clear of the surface) cleaning will be difficult. Residues can go under the support and
efforts to seal with silicone will not provide a solution.
Maintenance of the connection point is critical - as there will be movement of the machinery.
Filling cracks with silicone is only a temporary solution.
There must be space around the plinth for cleaning.
If the foundation is in an area with much traffic - exposed edges must be protected with 'L'
shaped metal strips, whose contacts with surface coatings must be dust tight.
Machinery foundations
Picture 3.2.8.3.1
For high and medium
hygiene areas the floor
surface should extend over
the plinth bearing the
support and equipment.
Fixing the machinery
support directly on the
floor with bolts will only
lead to problems - residues
and humidity (in a wet
area) will seep under the
support and into the bolt
holes.
Pictures: 1 2 3 4
Picture 3.2.8.3.2
For high/medium hygiene
areas the floor surface tiles or epoxy - should
extend over the plinth with rounded edges at the
floor contact point to
facilitate cleaning.
The machinery is best
embedded in the concrete,
the coatings then making a
smooth surface with the
machinery.
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Pictures: 1 2 3 4
Picture 3.2.8.3.3
areas (being an extension
of the floor) the floor
surface should extend over
the plinth - with rounded
edges at the floor contact
point to facilitate cleaning:
if the floor has an

epoxy surface covering should be of
the same material
if the floor is tiled - the
plinth will need a resin
or epoxy covering, as
tiles on a plinth present
the same problem as
tiles on a wall - risk of
infiltrations into hollow
bodies.
Pictures: 1 2 3 4
Picture 3.2.8.3.4
If the foundation is in an
area with much traffic exposed edges must be
protected with 'L' shaped
metal strips whose
contacts with surface
coatings must be dust
tight.
Pictures: 1 2 3 4
Chapter 3
11 Jul. 2008 14:01:00
Recommendations

Recommendations
Section 3.2.8.4
A raised machinery foundation is an option to avoid direct contact points between the floor and
the machinery surface.
Such foundations are recommended for any area, but the higher the level of hygiene - the more
attention that should be paid to installation and finishing details.
Recommendations
Picture 3.2.8.4.1
raised machinery
foundation is an option to
avoid direct contact points
between the floor and the
machinery surface. Such
foundations are
recommended for any area
but the higher the level of
hygiene - the more
attention that should be
paid to installation and
finishing details.
Pictures: 1 2
Recommendations
Picture 3.2.8.4.2
raised machinery
foundation is an option to
avoid direct contact points
between the floor and the
machinery surface. Such
foundations are
recommended for any area
but the higher the level of
hygiene - the more
attention that should be
paid to installation and
finishing details.
Pictures: 1 2
Chapter 3
11 Jul. 2008 14:02:00
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WALLS

Section 3.2.9.3
Typical faults and characteristics will vary between walls of traditional construction and prefabricated walls and preventive measures to ensure hygiene will similarly depend on climatic
conditions.
Picture 3.2.9.3.1
Correct installation of
panels on their supports is
critical.
areas the floor surface
should curve and extend up
and over the panel support
- for cleanability - also for
protection.
Panels can easily be
damaged by traffic impact.
The support wall is the first
protection at ground level.
At higher levels - where
panels are exposed - metal
(open profile) bars can be
added at points with high
density traffic.
Pictures: 1 2 3 4 5 6 7 8
Picture 3.2.9.3.2
This diagram shows typical
external wall construction inside and out - designed
to avoid points where
residues can collect.
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Picture 3.2.9.3.3
Panel walls with brick/
block supports are quite
common and acceptable in
Nestl.
The panel normally needs
to be supported off the
floor - allowing an easier
floor-to-wall connection with a curved floor
connection.
Where the wall panel
meets the ceiling panel a
coving avoids a sharp angle
difficult to clean.
A critical point is where
energy supplies or ducting
must enter an area across
the panelling. The panelling
'filling' material must be
protected from dust and
insects.
Pictures: 1 2 3 4 5 6 7 8
Picture 3.2.9.3.4
The panelling can also be
the internal shell of a
building.
Note: In this example, it is
critical to avoid
inaccessible cavities.
The space between the
panel and the wall should
ideally be large enough to
allow for example placing
of pest control devices.
Pictures: 1 2 3 4 5 6 7 8
Picture 3.2.9.3.5
Typical faults
This chart shows features
of walls and some typical
characteristics which need
to be taken into account
when considering hygiene
and the prevention of
problems.
Pictures: 1 2 3 4 5 6 7 8
Picture 3.2.9.3.6
Preventive measures for
hygiene
Attention and concern
about these features for
hygiene will be influenced
by climatic conditions major external
temperature variations will
stress the joint structures.
Note: If care is not taken:
cracks will occur
infiltrations can start
pests can penetrate.
Pictures: 1 2 3 4 5 6 7 8
Picture 3.2.9.3.7
No wall finish will
withstand repeated impact
from trollies or forklifts.
Protection is necessary.
Pictures: 1 2 3 4 5 6 7 8
Picture 3.2.9.3.8
No wall finish will
withstand repeated impact
from trollies or forklifts.
Protection is necessary
especially at corners.
protection as an integral
smooth part of the corner.
Pictures: 1 2 3 4 5 6 7 8
Chapter 3
28 Jul. 2008 07:18:00
Recommendations

Recommendations
Section 3.2.9.4
Choice between a traditional and a pre-fabricated wall depends on:
product
local possibilities
costs.
Whatever the choice there are hygienic features recommended for both traditional and prefabricated wall types.

Recommendations
Picture 3.2.9.4.1
Details of wall finishes can
be chosen according to
several details of
processing:
whether the area is to

be dry or wet cleaned
whether the area is
high/medium/low
hygiene.
Note: All wall finishes must

be protected - no wall
finish will withstand
repeated impact from
trolleys or forklift trucks.
Damaged walls will be a
point of residue
accumulation.
Pictures: 1 2
Recommendations
Picture 3.2.9.4.2
Details of wall finishes can
be chosen according to
several details of
processing:
whether the area is to

be dry or wet cleaned
whether the area is
high/medium/low
hygiene.
Note: All wall finishes must

be protected - no wall
finish will withstand
repeated impact from
trolleys or forklift trucks.
Damaged walls will be a
point of residue
accumulation.
Pictures: 1 2
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Recommendations
16 Jul. 2008 08:46:00

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ENERGY & UTILITY

SUPPLIES

Section 3.3.1.3
The most important consideration is that the supply lines will normally pass from the central supply/
energy production point to the point of use. This means that the service piping will often pass
between areas of different hygiene levels.
Wherever the services are located, there will be a need for access for maintenance.
The ideal situation is:
most of the supply piping kept away from the process areas where product is exposed
vertical (or horizontal) energy supply galleries installed where minimal piping is needed in high
hygiene zones.
In relation to these two factors, the following potential problems need to be considered for
prevention of potential contamination.
Service piping can have:
points which can accumulate dust and product residues

gaps around its passageway from one area to another - allowing transfer of contaminants and
entry of pests
points with condensation
insulation with microbiological contamination and harbourage for infestation.
Depending on the area, the following preventive measures will be necessary:
To avoid residue collecting points, piping networks should have clearances of:
100mm between each pipe
75mm (minimum) from the walls
250mm (minimum) free space left between parallel rows.
Covering piping only creates an area where dust accumulates.
Wall openings can be sleeved with a 100mm ridge slab opening.
To prevent entry of contaminants to a medium/high hygiene zone - the area around pipes
should be minimal - but as piping is subject to movement due to expansion, contraction or
vibration, at least a 50mm clearance is necessary.
To create a total barrier - seals of flexible material are necessary - or a material which expands
and contracts in a similar way to the pipe.
Note: Passage of insulated pipelines through walls - especially from one hygiene zone to
another with differences in air pressures - requires the sealing of the portal - to reduce waste of
energy of the air-handling system in the maintenance of over-pressure.
Pipe hangers and brackets should be strong but of simple design - to facilitate cleaning. Angles
and channels (if used) must be oriented so that dust and debris do not accumulate. Painted mild
steel supports in wet processing areas present a continual problem with flaking paint - even in
dry areas painted surfaces should be avoided. Stainless steel is the preferred material.
Correct choice of insulation material (with well-executed installation) will prevent problems
common with insulated pipelines.
Piping for 'high or low temperatures' service lines (eg. steam, hot or cold water) should never be
painted - paint will peel.
Energy and utility supplies

liquid and gaseous
Picture 3.3.1.3.1
Area around pipes passing

from one zone to another
should be minimal.
For pipes passing from
outside to low hygiene
zone, area around pipe can
be protected by a stainless
steel sheath.
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Note: The material must be

similar to pipe - allowing
similar expansion and
contraction.
At outside edge, entry
point should be drainable
to prevent point of
infiltration.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.2
Channels - if not in
stainless steel - should be
coated in acid-resistant
finish.
To avoid residue collecting
points, piping networks
should have adequate
clearances - as shown in
this example.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.3
Piping on supports - from

wall or on floor - must be
distanced from the wall or
floor to allow for cleaning both underneath and
around.
Note: Supports should be
of simple design.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.4
Pipe hangers and brackets

should be strong but of
simple design - to facilitate
cleaning.
Note: Pipes must be
suspended with space
between the pipe and the
ceiling - never attached
pipes directly to walls or
ceilings - as cleaning will
be impossible.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.5
The most important

consideration is that the
supply lines will normally
pass from the central
supply/energy production
point to the point of use.
This means that the service
piping will often pass
between areas of different
hygiene levels.
The ideal situation is:
most of the supply

piping kept away from
the process areas

where product is
exposed
vertical (or horizontal)

energy supply galleries
installed where
minimal piping is
needed in high hygiene
zones.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.6
Wherever the services are

located there will be a need
for maintenance access.
Note: This example is a
special case - in a high
hygiene tower all the
services are located in a
vertical gallery away from
the process area where
product could be exposed.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.7
Service piping can have

points which can
accumulate dust and
product residues.
Note: Covering pipes and
wiring may present a clean
external appearance - but
residues and insects can
accumulate inside.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.8
Passage of insulated
pipelines through walls or
ceilings (especially from
one hygiene zone to
another with differences in
air pressures) requires the
sealing of the portal - to
reduce waste of energy.
Note: This example also
shows clear labelling of
pipes.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.9
Passage of pipelines
through walls (especially
from one hygiene zone to
Note: Where pipes pass
from area to area of same
hygiene level - space can
be left around entry points.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.10
Passage of insulated (or

non-insulated) pipelines
through walls (especially
from one hygiene zone to
Note: Where pipes enter
high hygiene and/or airconditioned rooms the
entry points must be sealed
- with a metal plate to
accommodate any
expansion and contraction.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.11
To create a total barrier seals of flexible material

are necessary - or a
material which expands
and contracts in a similar
way to the pipe.
Passage of insulated
pipelines through walls
(especially from one
hygiene zone to another
with differences in air
pressures) requires the
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.12
To create a total barrier seals of flexible material

are necessary - or a
material which expands
and contracts in a similar
way to the pipe.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.13

cleaning.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.14

cleaning. To avoid residue
collecting points piping
networks should have
clearances of:
100mm between each

pipe
75mm (minimum) from
the walls
250mm (minimum)
free space left between
parallel rows.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.15
Correct choice of insulation

material (with wellexecuted installation) will
prevent problems common
with insulated pipelines.
: Poor insulation (or just
poorly maintained
insulation) can lead to
points for residue and pest
harbourage.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.16
Piping for 'hot' service

lines (e.g. steam or cold
water) should never be
painted - paint will peel.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
liquid and gaseous
Picture 3.3.1.3.17

cleaning. Angles and
channels (if used) must be
oriented so that dust and
debris do not accumulate.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
this GI
Other Nestl reference
material
3.5.5
Insulation for pipes, tanks and other equipment
TM-240.0
Piping Engineering Reference
TM-240.5
Sanitary Fittings and Piping
External reference material CCFRA Technical Manual 44 - Dec.'94
Guidelines for the Design and Construction of Walls, Ceilings and Services for Food Production Areas
Chapter 3
27 Mar. 2009 07:07:00

Recommendations

Recommendations
Section 3.3.1.4
Piping layout should be installed in a neat and logical manner which will facilitate installation,
supports, insulation, cleaning and maintenance. This applies even on outside 'bridges' (eg.
between boilers and process buildings).
Condensation on piping should be avoided - but insulation must be well executed.
The nearer the product and the higher the hygiene concern - the more attention is required to
details. The energy and utility supplies are an integral part of the hygienic layout plans for each
zone. They also are often the bridge between two areas of different hygiene levels.
When layouts are made, all service routes must be noted and their effects on hygiene
requirements minimised. Plan for high hygiene where possible - walk-on ceilings, vertical
technical galleries and galleries on the exterior of process areas.

liquid and gaseous
Recommendations
Picture 3.3.1.4.1
The most important
consideration is that the
supply lines will normally
pass from the central
supply/energy production
point to the point of use.
Piping layout should be
installed in a neat and
logical manner which will
facilitate installation
supports insulation
cleaning and maintenance.
This applies even on
outside 'bridges' (e.g.
between boilers and
process buildings).
Chapter 3
25 Jul. 2008 14:36:00
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WATER

Section 3.3.10.3
Product contamination from water - causing unacceptable hygienic problems can be caused by
factors related to:
quality of source - regular analysis is critical coupled - with knowledge of the history of the
catchment area.
original raw water quality - and its inappropriate treatment - either place of treatment being
too far from point of use or wrong /insufficient chemicals.
treatment systems - carbon beds for de-chlorination and de-ionisation plants are notorious
places where bacteria can actually grow adding to water contamination.
Note: such systems need monitoring - with regular treatments to prevent development of an
unwanted flora.
water storage - the state of the storage tank, its design, its exposure to other contamination,
infiltrations. If water stagnates in a storage tank - problems can arise.
distribution systems - very long and with dead ends. In such cases monitoring of water must
be done at many points of the system including that furthest removed from the point of
treatment.
closed circuits - (eg. for tempering) where contamination builds up - all closed circuits must be
monitored regularly - and appropriate controlling procedures installed such as re-chlorination
followed by de-chlorination (but the latter only if necessary - if tempering circuit pipe material is
susceptible to corrosion).
chilled water systems contaminated - by exposure to outside environment - all chilled water
circuits must be monitored and treated with food grade chemicals where necessary to ensure
potable quality is retained.
type of process - even if water appears to be potable and suitable - specific process steps can
concentrate water borne elements and make the water eventually or finally unacceptable.
Re-used water - this should only be introduced if there are no associated and uncontrollable
factors.
Treatment chemicals - disinfection: chlorination is the most widely accepted and applied method
of water disinfection - using gaseous or liquid chlorine.
Potable water must have a residual level of 0.2 - 0.3ppm water. Water specifically for cooling (eg.
canned food) must have 0.8-1.0ppm.
Water
Picture 3.3.10.3.1
Chilled water systems can
become contaminated
during their cooling and
exposure to the
environment. Food grade
biocides are required - as
well as disinfectants to
maintain the chilled water
at potable standards.
Pictures: 1 2 3 4 5 6
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Water
Picture 3.3.10.3.2
Contamination can build in
closed circuits.
Note:
This water tank (which
supplies the closed circuit)
has not been monitored or
treated.
The evidence is mould
growth on the lid and the
water appearance. Such
water if (eg.) for tempering
circuits could contaminate
product by micro leaks.
Pictures: 1 2 3 4 5 6
7 8
Pictures: 1 2 3 4 5 6
7 8
Water
Picture 3.3.10.3.3
Chilled water systems for
cooling installations can
receive good air flow on
the roof but then aerosols
could be drawn into
process rooms below.
Water
Picture 3.3.10.3.4
Tempering water systems should be well labelled and
have sampling points for
regular monitoring.
Pictures: 1 2 3 4 5 6
7 8
Pictures: 1 2 3 4 5 6
7 8
Water
Picture 3.3.10.3.5
Note:
Older tempering water
circuits are sometimes
made of metals susceptible
to corrosion (as in this
example). Therefore if
shock chlorination is used
for disinfection - some decholrination may be
necessary to avoid
corrosion.
Water
Picture 3.3.10.3.6
water tower may be
necessary. In this case the
state of the tower's tank
should be checked.
Pictures: 1 2 3 4 5 6
7 8
Pictures: 1 2 3 4 5 6
7 8
Water
Picture 3.3.10.3.7
Chilled water systems for
cooling installations can
receive good air-flow on
the roof but then aerosols
could be drawn into
process rooms below.
Also the installation can
leak and lead to eventual
infiltrations
Water
Picture 3.3.10.3.8
These are examples of how
originally acceptable
potable water systems
became unacceptable.
Complacency and the

assumption that water
once considered to be
safe will always remain
safe - is dangerous.
During HACCP water
must especially be
considered as an
ingredient - if as shown
a process step could
increase the level of the
potential problems.
Any re-use of water
needs very careful
consideration - for
safety and ethical
reasons.
Pictures: 1 2 3 4 5 6
material
7 8
CP-254.6
Guidelines for the establishment of a QMS for water in production facilities
GI-00.800-2
Culinary Steam
Technical
Communications Water Management
3/95
External reference material Guidelines for Drinking Water
World Health Organisation Water Quality Vol.1 '93
ISBN 924.154460.0
Chapter 3
30 Jul. 2008 11:17:00
Hygiene considerations general rules
PERSONNEL
FACILITIES

Hygiene considerations general rules
Section 3.3.11.3
Between these two extremes (see above - section 3.3.11.2), there will be various sizes of catering
facilities, but some golden rules of design for hygiene must always be applied:
All risk of cross-contamination between raw, high-risk items and cooked food (either in the
preparation area or in the stores) must be prevented, using well-planned lay-out and choice of
equipment.
A suitable system for keeping food hot whilst awaiting service must be provided.
Note:
Most cases of food-poisoning are caused by food inadequately re-heated and held warm (25-40
C) - not hot.
Personnel facilities canteens
general rules
Picture 3.3.11.3.1
Kitchen personnel have
their own toilets and
changing facilities.
There must be adequate
and separate washing
areas - for kitchen
equipment and eating
utensils and plates.
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Hygiene considerations kitchen areas

Section 3.3.11.4
area designed on the principle of a factory - food entering at one end (for storage) passing to
the next 'zone' for preparation and then onto the service area, at the other end of the kitchen
rooms (if volume merits) planned for frozen and chilled food:
in the chilled room, it should be possible to separate raw from ready-to-eat
or even better, plan two separate stores
a dry store is needed for food and one for cleaning items.
washing areas for kitchen utensils and service items for personnel
entries designed to reduce risks of pest entry
for catering personnel - separate toilet facilities (not connected directly to the kitchen) and hand
wash stations in the kitchen
collection area for waste and its disposal
apply the principals of the factory - design for cleanability and easy maintenance - normally
drains are not necessary except in wet areas near washing-up
adequate ventilation over cooling area - but with no condensation dripping onto food
equipment (as in the factory) stainless steel as the material of choice, raised off the floor for
cleaning underneath, smooth work surfaces - avoiding wood surfaces.

kitchen areas
Picture 3.3.11.4.1
- kitchen areas
Kitchen area should be
design on the principles of
the factory:
cleanability
easy maintenance
use stainless steel.
Good lighting and

extraction hoods to prevent
condensation in cooking
area are important.
Pictures: 1 2 3
kitchen areas
Picture 3.3.11.4.2
- kitchen areas
the factory:
cleanability
easy maintenance
Good lighting and

area are important. Kitchen
staff should be given
adequate space to carry
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out their tasks well.
Pictures: 1 2 3
kitchen areas
Picture 3.3.11.4.3
- kitchen areas
the factory:
cleanability
easy maintenance
Good lighting and

area are important.
Pictures: 1 2 3
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Hygiene considerations serving and eating areas

Section 3.3.11.5
separate hot and cold servery - with adequate separation between clients and food
separate area for return of dirty service - trays and waste food, trolleys - or special hatch
equipment:
must be cleanable (stainless steel)
have well controlled systems for keeping food hot or cold.
protection of food from insects.
Note:
In some warm countries where the canteen is in the open air, installations are necessary to
exclude/kill flies.
In some warm countries where the canteen is in the open air, installations are necessary to exclude/
kill flies.
tables and chairs arranged to permit easy cleaning of the area
adequate ventilation - either natural or from air handling units
systems to prevent pests.

serving and eating areas
Picture 3.3.11.5.1
- serving and eating areas
There should be adequate
separation between clients
and food.
bright pleasant place to eat
motivates staff.
Pictures: 1 2
serving and eating areas
Picture 3.3.11.5.2
- serving and eating areas
A bright pleasant place to
eat motivates staff.
Tables and chairs should be
arranged to permit easy
cleaning of the area.
Adequate ventilation - can
be natural but some
screening maybe necessary
against insects.
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Hygienic considerations

Section 3.3.12.3
Two important design detail points:
must prevent risk of any contamination and/or odours being transferred from the facilities to
process areas
must permit maintenance in a state which corresponds to Nestl hygienic standards.
Lay-out and design will depend on numbers of people and management decisions on separation of
more senior staff and supervisors from other line staff.
Note:
There must always be provision for separate facilities for contractors and lorry drivers.
In the case where all services are together - the lay-out must allow for:
a logical flow from initial entrance:
to changing area
to showers
to toilets
finally to hand-wash facilities
before exit to work areas
adequate light - but obviously respecting privacy
adequate ventilation - with preference for ventilation to non-process sides of the building
temperature and humidity control systems where necessary.
General requirements:
floors made for regular wet-cleaning and being non-slip (tiles probably a solution)
sloping floors - especially towards the shower area
drains limited to areas where there must be a regular drainage (ie. shower area with a barrier at
the exit of shower) and possibly toilet area
walls painted with bright colours so that changing areas do not become a dim (unattractive)
place - where dirt cannot be seen
toilets for females and toilets and urinals for males.
Note:
Turkish-type toilets are not recommended where there is no local requirement. Foot operated
flushing is preferred (legal in some countries).
hand-wash basins - preferably with automatic water sources (legal in some countries) or a knee
operated system - with water mix system
disposable paper towels for hand drying - not hot air hand dryers - which:
are slow to dry
can spread contamination
can cause wet areas created around point of use
lockers installed off the floor and to prevent places where infestations and rubbish could collect with sloping top to avoid accumulation of dust and other material.
Personnel facilities, locker

rooms, toilets
Picture 3.3.12.3.1
This layout allows for a
logical flow - from initial
entrance into changing
room - then into toilets
with hand washing before
starting work.
Note:
In some layouts, hand
wash is preferred in the
last position before entry
into process areas whether exiting changing
room or toilets.
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Showers - used once a day

- are at the end of the flow.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.2
Lockers are installed off
the floor - to prevent
places where infestations
and rubbish could collect.
The sloping top prevents
storage on top of lockers.
Doors have ventilation to
eliminate odours.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.3
Hand-wash basins must be
installed - preferably with
automatic water sources.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.4
Hand-wash basins must be
installed - preferably with
automatic water sources.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.5
Lockers should be located
off the floor - to prevent
places where rubbish can
collect. They should be
bright and easy-to-clean
with adequate lighting and
space.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.6
Hand wash basins need
adequate soap dispensers
and disposable paper
towels for hand drying.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.7
space.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.8
space.
Note:
An important feature in
this example is that the
lockers have grills for
doors. This is not to permit
inspection but to allow
aeration - stored clothes
and shoes can create
odours.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.9
Toilets should be well
designed with easy-toclean surfaces.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.10
Locker-rooms should have
an attractive entrance and
clothes dispensing area at
entry to locker room.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.11
Toilets should (if possible)
have foot operated flush
and an adequate supply of
toilet paper - as well as
easy-to-clean floors.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.12
Hand wash stations can
have foot operated water
as alternatives.
Note:
In this example: hand
drying is with a hot air
blower - these are
inefficient and can spread
contamination and a wet
area is created under the
dryer a hand disinfectant
as well as soap dispenser is
added - hand disinfection is
an added luxury but not
essential unless operators
are handling food.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
rooms, toilets
Picture 3.3.12.3.13
Hand wash stations can
have knee operated water
as alternatives.
Note:
This is an excellent
example of a well installed
unit.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13
Chapter 3
14 Jul. 2008 12:53:00
Recommendations

Recommendations
Section 3.3.12.4
As it is expected that personnel will respect hygiene rules within process areas, it is critical to
provide them with the necessary services for maintaining their own standards of personal
hygiene.
Design of such areas must in no way risk cross-contamination to process areas.
Toilets, hand-wash facilities, showers and general design features should adhere to the Nestl
Good Manufacturing Practice requirements and any other local and/or stricter standards.

rooms, toilets
Recommendations
Picture 3.3.12.4.1
This chart shows typical
adequate numbers of toilet
facilities, based on general
recommendations taken
from legislation in some
countries.
Note:
They may need adapting to
local or national
regulations or building
codes.
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ELECTRIC
INSTALLATIONS

Section 3.3.2.3
Requirements are process dependent and concern:
proximity to the product
level of hygiene in the area
typical cleaning procedures.
Some general guidelines are:
Cables can pass from one zone to another - needing special design details to avoid their
passageway being also a route for contaminants and pests.
The type of cable support is related to hygiene levels and also cable protection. Open grid (eg.
Cabl-o-fil) is common for more critical areas, but compromises may be necessary by putting
cables for high voltage supplies in tubes. When in tubes, entry must be sealed to prevent entry
of dust and insects.
Note:
Sealing may be done with silicones but this must be checked and maintained.
Where possible, cables under lines should be avoided - especially in areas where they might
become covered with product residues.
Power panels are best enclosed in dedicated rooms close to the control panels.
Open control centres should not be installed in production areas.
Control panels installed in production areas should be water and dust tight. In wet/controlled
wet zones the seals should be able to withstand the effects of chemicals and water pressures
normally used during the clean-up cycles - even though typical practice may be to cover (eg.) a
control box.
Control panels should be elevated from the floor, using a solid concrete plinth, steel framework
or affixed to the wall, leaving a 100mm minimum space between the wall and the panel.
Push button controls should be dust-proof and water-proof.
Electric Installations
Picture 3.3.2.3.1
Area around pipes passing
from one zone to another
should be minimal.
Some cables may have to
be put in tubes for safety
and protection.
Note: Aperture around
cables must be sealed to
prevent entry of dirt and
insects.
The seal must be properly
maintained.
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Picture 3.3.2.3.2
Power panels are best
enclosed in dedicated
rooms.
The fewer electrical
services and panels in
more sensitive high/
medium hygiene rooms the easier is the cleaning.
Note: Such locations will
also protect panels (eg.
from dust and wet
cleaning).
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.3
Piping on supports - from
wall or on floor - must be
distanced from the wall or
floor to allow for cleaning both underneath and
around.
Note: Supports should be
of simple design.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.4
The type of cable support is
related to hygiene levels
and also cable protection.
Open grid (e.g. Cabl-o-fil)
is common for more critical
areas.
Note: The example shown
here is suitable for high
and medium hygiene areas
- but too elaborate for low
hygiene.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.5
The type of cable support is
related to hygiene levels
and also cable protection.
Open grid (e.g. Cabl-o-fil)
is common for more critical
areas.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.6
Control panels should be
elevated from the floor
using a solid concrete
plinth steel framework or
affixed to the wall leaving a
100mm minimum space
between the wall and the
panel.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.7
Where possible cables
under lines should be
avoided - especially in
areas where they might
become covered with
product residues.
correct feeding of cables to
line from above.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.8
Compromises may be
necessary by putting cables
for high voltage supplies in
tubes. When in tubes entry
must be sealed to prevent
entry of dust and insects.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.9
Compromises may be
necessary by putting cables
for high voltage supplies in
tubes. When in tubes entry
must be sealed to prevent
entry of dust and insects.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.10
Where possible cables
under lines should be
avoided - especially in
areas where they might
become covered with
product residues. No 8of 11
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.11
Control panels installed in
production areas should be
water and dust tight. In
controlled wet/wet zones
the seals should be able to
withstand the effects of
chemicals and water
pressures normally used
during the clean-up cycles even though typical
practice may be to cover (e.
g.) a control box.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.12
100mm minimum space
panel.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.13
Push button controls
should be dust-proof and
water-proof. Control panels
should be elevated from
the floor using a solid
concrete plinth steel
framework or affixed to the
wall leaving a 100mm
minimum space between
the wall and the panel.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.14
Positioning and routing of
all electrical installations
must be planned at the
same time as equipment
lay-out.
Note: Cables behind
equipment collect residues
and are difficult to clean
and maintain.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.2.3.15
100mm minimum space
panel.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
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25 Jul. 2008 14:37:00
Recommendations

Recommendations
Section 3.3.2.4
Generally:
Positioning and routing of all electrical installations must be planned at the same time as
equipment lay-out.
The nearer the cables approach the product - the more important it is that they do not become a
source of contamination.
Electrical installations should be protected from food residues and chemicals.
Specific recommendations apply for wet, controlled wet and dry medium/high hygiene areas:
Wet and controlled wet areas:
A compromise between hygiene needs and protection of the electrics is often necessary.
Although temporary protection can be made for some cleaning, in some cases it may be better
to put cables in sealed tubes.
Dry areas:
Cables should be on open grids - unless for technical reasons they should be in tubes.
Control panels should be installed off the floor and away from the wall.
Recommendations
Picture 3.3.2.4.1
Positioning and routing of
all electrical installations
must be planned at the
same time as equipment
lay-out.
Note: Cables behind
equipment collect residues
and are difficult to clean
and maintain.
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LIGHTING

Section 3.3.3.3
First priority: lighting is an essential element for quality assurance activities for:
hygiene monitoring in factories
controlling visual sensory attributes at the line
effective cleaning.
Intensities must be:
350-500 Lux for areas where inspection is important
150-250 Lux in processing areas is generally adequate.
Other considerations:
Installations must not become a source of contamination of dust, insects or foreign material.
For ease of cleaning or maintenance in areas where product is exposed, it preferable that
fittings can be removed from their support (eg. attached to wall or ceiling only by a cable
and plug-in socket). An alternative is to have light fittings accessible from a walk-on ceiling.
Light bulbs and tubes in areas (where product and product contact surfaces are exposed either during processing or just during cleaning and maintenance) must be protected with a
protective cover - not made of glass.
Any exposed part of fittings, tube, bulb or cover, must be made of shatter-proof glass or
plastic.
Care needs to be taken to prevent lights attracting insects. Sodium vapour lights do not
produce UV and therefore do not attract insects.
Light bulb or tube housings must not allow ingress of product.
Note 1:
In a new plant lighting losses are high. Within 6 months of operation a loss of up to 30% of the
original intensity can be experienced, due to reflection on dirty surfaces. Maintenance is
essential.
Note 2:
In some cases, UV lights have been installed at entries to critical areas and laboratories. The
idea is that this light disinfects the air. This is not the case and such lighting is a waste of money
and can attract insects.
Lighting
Picture 3.3.3.3.1
First priority: lighting is an
essential element for
quality assurance activities
for: hygiene monitoring in
factories controlling visual
sensory attributes at the
line effective cleaning.
Note: Specifying adequate
lighting is one of the first
steps in planning a project.
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Lighting
Picture 3.3.3.3.2
For areas where inspection
is important intensities
must be 350-500 Lux.
Pictures: 1 2 3 4 5 6
Lighting
Picture 3.3.3.3.3
In processing areas
Intensities of 150-250 Lux
are generally adequate.
Pictures: 1 2 3 4 5 6
Lighting
Picture 3.3.3.3.4
For ease of cleaning or
maintenance in areas
where product is exposed it
preferable that fittings can
be removed from their
support (e.g. attached to
wall or ceiling only by a
cable and plug-in socket).
Pictures: 1 2 3 4 5 6
Lighting
Picture 3.3.3.3.5
Any exposed part of fittings
tube bulb or cover must be
made of shatter-proof glass
or plastic.
Note: Over exposed
product avoid non-hygienic
fittings which collect dust.
Pictures: 1 2 3 4 5 6
Lighting
Picture 3.3.3.3.6
The design and intensity
must be chosen in relation
to the QA activities at that
point.
Operators cannot be
expected to carry out line
controls and analysis
without adequate light.
Pictures: 1 2 3 4 5 6
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25 Jul. 2008 14:39:00
NATURAL VENTILATION

Section 3.3.4.3
Ventilation elements must:
be properly screened to prevent ingress of insects or other pests
not allow entry of unacceptable odour, dirt, fumes and rain water
be cleanable, having detachable parts (eg. screens for easy cleaning/maintenance).
Natural Ventilation
Picture 3.3.4.3.1
Ventilation elements must:
be properly screened to
prevent ingress of
insects or other pests
not allow entry of
unacceptable odour dirt
fumes and rain water
be cleanable having
detachable parts (e.g.
screens for easy
cleaning/maintenance).
Note: This is a good

example showing easy
access to remove and clean
insect screens.
Pictures: 1 2 3
Natural Ventilation
Picture 3.3.4.3.2
An exhaust with product
residues is a point where
contamination can develop.
incorrect positioning of air
intake (even though just a
louver for natural
ventilation). This intake
could still ventilate a
medium hygiene area (or
even a high hygiene area
for infant cereals).
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Natural Ventilation
Picture 3.3.4.3.3
For warehouse ventilation
screened louvers can be at
roof level.
Pictures: 1 2 3
this GI
3.2.11
Ceilings
3.2.13
Windows and louvers
3.2.13.3 Hygiene considerations windows
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FORCED VENTILATION

Section 3.3.5.3
Filters in ventilation systems may vary from simple coarse filters to HEPA filters depending on
the process/product. Very rarely HEPA filters will be used for air to process areas.
All air intakes have at least a rough pre-filter (G4) followed by a final filter as required by the
type of product and zone.
Intake and exhaust vents must be designed and positioned to exclude:
birds
insects
odours
fumes
dust from exhausts
water - from rain, condensation or droplets from cooling units and waste water treatment
plant
Air-handling units design considerations:
separate modules for each operation (heating, cooling, de-humidification)

generated condensation within the air-handling units must be evacuated from unit via
properly sized siphons to a drain - preferably with an air gap to prevent any potential risk of
pulling foul air back into the unit
manometers (or pressure drop gauges) to indicate when filters need to be replaced
Note: Washing of filters should be avoided - as they can lose filter capacity and can
disintegrate.
adequate access, clearances etc. - for maintenance activities
internal condensation at hot/cold joints must be avoided.
Air-ducts should:
be avoided in high hygiene areas
have access for inspection and cleaning
have removable ducting for cleaning - if ducts are too small for access
have air socks as a preferred alternative, as these can be easily taken down and laundered.
air socks are particularly suitable for chilled air - to give an even distribution.
All areas supplied with forced ventilation should maintain an over-pressure relative to
surrounding areas of lower hygiene requirements - to avoid flow of potentially contaminated air
into a critical zone. Correct descents of air pressures are difficult - unless the factory has been
designed with air-flow in mind.
Forced ventilation process area

Picture 3.3.5.3.1
Air handling units generate
condensation - and this must
be evacuated via properly
sized siphons to a drain.
Note: There must be a siphon
- and preferably an air gap to prevent pulling foul air back
into the unit.
The siphon can have a simple
valve system - to help prevent
such back flows.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
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Picture 3.3.5.3.2
Air handling units generate
condensation - and this must
be evacuated via properly
sized siphons to a drain.
Note: There must be a siphon
- and preferably an air gap to prevent pulling foul air back
into the unit.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.3
Air handling units must have
easy access for inspection and
cleaning filters. Filters must be
tight in the frames so air only
passes through the filters - not
around the edges.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.4
typical air handling unit
located on the roof giving easy
access for maintenance and
filter changing.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.5
Manometers (or pressure drop
gauges) indicate when filters
need to be replaced.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.6
Maintenance of ventilation
systems is essential for the
supply of properly filtered air
to a process area.
Note: Factors detracting from
efficiency of system:
poorly maintained filters

filters fitting poorly in
frames - allowing air
passage past frames
filters structure impaired
by washing.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.7
Air ducts can have air socks as
an alternative to duct work as
these can be easily taken
down and laundered. Air socks
are particularly suitable for
chilled air - to give an even
distribution.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.8
Air handling units can have air
socks as an alternative to duct
work as these can be easily
taken down and laundered. Air
socks are particularly suitable
for chilled air - to give an even
distribution.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.9
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.10
Intake and exhaust vents
must be designed and
positioned to exclude birds
and insects.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.11
Manometers (or pressure drop
gauges) indicate when filters
need to be replaced.
Manometers are best located
in a panel in the room being
ventilated (if AHU is above)
where it can be regularly
checked.
filters need to be changed.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.12
Internal condensation at hot/
cold joints must be avoided.
Note: Good construction and
good sealing of joints prevents
condensation.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.13
Intake and exhaust vents
must be designed and
positioned to exclude:
birds
insects
odours
fumes
dust from exhausts
water - from rain

condensation or droplets
from cooling units and
waste water treatment
plant.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.14
Generated condensation within
the air-handling units must be
evacuated from unit via
properly sized siphons to a
drain - preferably with an air
gap to prevent any potential
risk of pulling foul air back into
the unit.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Picture 3.3.5.3.15
Generated condensation within
the air-handling units must be
evacuated from unit via
properly sized siphons to a
drain - preferably with an air
gap to prevent any potential
risk of pulling foul air back into
the unit.
Note: This condensation
outlet has no siphon contaminated air could be
drawn back into the AHU. The
constantly wet drain area
could also be a new point of
contamination development.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
this GI
3.2.19
4.4
Maintenance of equipment
4.4.3
Other relevant documents
TMN-364.6
Pressurising and Air conditioning of SCM Filling Rooms
TMN-215.5
Egron Secondary Air Handling
Technical
Communications Requirements for AHU in the Food Industry
2/92
Chapter 3
20 Nov. 2008 09:57:00


Section 3.3.6.3
It is important to remember that there is often an interdependence of forced ventilation between the
process area and its process equipment.
Decisions on process area ventilation are related to the protection (or treatments with air) built into
the equipment.
The primary source of air for process equipment may be air in the process area.
Forced ventilation process
equipment
Picture 3.3.6.3.1
Filtered and maybe cooled
heated and/or
dehumidified air for
transport of product (e.g.
powders after tipping
drying) addition to product
as ingredient (e.g. ice
cream overrun).
Note: In high hygiene
situations the transported
air (eg. for milk powder) after the primary filtration
into the room - will require
another filtration at its
intake. Maintenance of this
filter and installation of a
pressure drop gauge is
essential.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
equipment
Picture 3.3.6.3.2
heated and/or
dehumidified air - having
as purpose cooling of
product (e.g. milk powder
after Egron chocolate).
Note: Residues behind
filter shop air was passing
beside frame and not
through filter.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
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equipment
Picture 3.3.6.3.3
heated and/or
dehumidified air for cooling
of product (e.g. milk
powder after Egron
chocolate).
Note: for high hygiene
situations:
air in room prefiltered/ de-humidified

air at intake to cooling
unit re-filtered
filters tight in frames
pressure drop gauge in
place.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
equipment
Picture 3.3.6.3.4
Note: Residues indicate
inadequate filtration of air.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
equipment
Picture 3.3.6.3.5
Note: Growth of mould on
cooling coils indicates
inadequate filtration of air.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
equipment
Picture 3.3.6.3.6
Note: Coil section can be
slid in and out for
maintenance and cleaning.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
equipment
Picture 3.3.6.3.7
Note: Well installed units accessible for maintenance
and filter changing.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
equipment
Picture 3.3.6.3.8
Note: Correct siphon for
condensation - essential
that the outlet to the drain
can be inspected - constant
water flow indicated that
the siphon is not dry.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
equipment
Picture 3.3.6.3.9
Note: Suitable filter units
of AHU to facilitate
Pictures: 1 2 3 4 5 6 7 8 9 10 11
equipment
Picture 3.3.6.3.10
Air-handling units must
have adequate access
clearances etc. - for
maintenance activities.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
equipment
Picture 3.3.6.3.11
It is important to
remember that there is
often an interdependence
of forced ventilation
between process area and
its process equipment.
Note: Well installed units with easy access for
Pictures: 1 2 3 4 5 6 7 8 9 10 11
this GI
3.6.4
Cooling powder/particles/larger product forms
3.3.5
Chapter 3
13 Aug. 2008 08:10:00
Recommendations

Recommendations
Section 3.3.6.4
This section deals with the following tables in detail:
Conversion table: European vs. US filter classification
Forced ventilation for process equipment
The following general information on filter grades to be used recommends filter classes for both
process areas and for process equipment (in contact with product).
Note:
Adaptations may have to be made according to the locally applicable laws and practises as well as the local environmental situation (eg. excessive external dust and/or potential
contamination).
1st stage filtration:
used in all systems with cooling (room or product)

coarse filters are installed to protect internals of the air handling unit and supply duct - and
to reduce amount of dust and dirt carried to the room.
Note:
Particles not retained by the coarse filter (at least 50% by weight) will accumulate in the
AHU - and ducting and distribution and may serve as nutrients for microbial growth. A fine
filter F7 - after the coarse one - prevents this happening (2nd stage filtration).
Where, for a high proportion of the time, the relative humidity (RH) is higher than 85%,
filters can act as a reservoirs for bacterial growth. The installation of a preheater to
increase inlet temperature by 3 C will reduce RH to less than 85% and minimise growth.
Appropriate hoods and droplet separators are important for the same reason.
For normally polluted air - synthetic G4 bag filters are suitable. They can be dry cleaned for
a few times but not washed.
For highly loaded air - more filter changes or other means of separation are required. Then it
is recommended that additional washable or roll type pre-filters are used. Pre-filters also
protect finer (more expensive) filters.
Note:
1st stage filtration is always installed before 2nd stage filter - except for cases with intake
of very clean air (eg. intake in a room with already pre-filtered air).
2nd stage filtration:
is critical in those areas where hygiene is of medium/high importance

apart from treating air to the room or process equipment - such filtration helps prevent
microbiological growth in the duct.
Material - rigid filter from glass-fibre paper F7 or F9

Note:
These fine filters cannot be cleaned - only can maintained and replaced.
1st and 2nd stage filters should be installed before the cooling coils.
3rd stage filtration:
is a HEPA filter (High Efficiency Particulate Air) required for special applications.
is quite limited and must be clearly justified (eg. by a HACCP study) because of high
investment and operating costs.
Note:
Such filters are used e.g. where product needs specific protection to prevent potential
growth of microbes in storage
These filters should be installed as close as possible to the product to be protected.

Conversion table:
European vs. US filter
classification
EN
779
ASHRAE
52.2-1999
MERV
G1
Coarse
filters
Fine
G2
G3
G4
7,8
F5
F6
11
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Recommendations
filters
F7
13
F8
14
F9
16
source: Camfil Farr

Forced ventilation for process
equipment
Recommendations
Picture 3.3.6.4.1
Filters are referred to
according to several
international standards - as
shown in the chart.
Suppliers normally classify
their filters according to
one of these international
systems.
Room / zone over
pressure: The higher the
protection required - the
higher the overpressure
(cascading).
Note: In the factory filter
types should be specified
for each point where air is
handled.

this GI
3.3.5
3.3.5.4
Recommendations
3.6.5
Filling of powders/dry particles/other products with aw <0.8
3.6.5.4
Recommendations
Chapter 3
13 Aug. 2008 08:11:00
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INTERNAL TRANSPORT

Section 3.3.7.3
In general all transport systems/equipment should have the following design features:
smooth easy-to-clean surfaces
no hollow bodies or voids where debris and contamination could accumulate
made of durable, impervious material, which can withstand the usual range of chemicals used in
automatic washing systems (eg. chlorinated alkaline cleaners)
without open lubrication systems (eg. chains, sprockets etc.)
with wheels made from durable and impervious material, easy-to-clean (eg. no intricate tread
patterns)
if motorised, not using energy source giving off fumes or leaving oil drips.
Note:
Pallets for medium/high hygiene zones should be of plastic (durable) with no hollow bodies.
Internal transport systems/

equipment
Picture 3.3.7.3.1
Note: In this example both
transporter and pallet have
potential hygiene
problems. The pallets could
have hollow bodies and the
transporter has wheels and
structure which are
difficult to clean.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.2
hygienic wheel used for
transport but also with a
stop system for safety.
Note: The wheels are made
from durable and
impervious material which
is also easy-to-clean.
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Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.3
hygienic wheel used for
transport but also with a
stop system for safety.
Note: The wheels are made
from durable and
impervious material which
is also easy-to-clean.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.4
equipment Hygiene
considerations
Note: Although these
wheels are made from
durable and impervious
material which is also easyto-clean the design causes
them to collect residues
and sampling is necessary
to detect contamination.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.5
Note: Although these
wheels are made from
durable and impervious
material which is also easyto-clean the design will
cause them to collect
residues and they will be
difficult to clean.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.6
Pallets for medium/high
hygiene zones should be of
plastic (durable) with no
hollow bodies.
Note: These pallets may
appear less hygienic than
the attractive smooth
surface non-lattice type but
generally lattice type
pallets without hollow
bodies are more hygienic though admittedly
requiring more time for
cleaning.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.7
Waste containers should
have smooth easy-to-clean
surfaces.
Note: There should be no
voids underneath where
debris could accumulate.
All surfaces must be
checked.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.8
rather complex waste
container with a design
that will be difficult to
clean - but suitable for low
hygiene areas.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.9
Complying with the need
for smooth easy-to-clean
surfaces can be difficult for
fork-lifts (by virtue of their
function). In this case
extra care is needed to
inspect and clean them especially points in contact
with containers of
products. Watch for foreign
material in areas where
product is exposed - and no
motors with fumes!
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.10
All surfaces should be
smooth and easy-to-clean..
Note: Some factories may
make their own prototype
transporters such as this
one for packaging. Designs
must ensure that they are
cleanable and without
hollow bodies if in contact
with (eg.) packaging that
will be in contact with
product.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.11
All surfaces should be
smooth and easy-to-clean..
Note: Some factories may
make their own prototype
transporters such as this
one for packaging. Designs
must ensure that they are
cleanable and without
hollow bodies if in contact
with (eg.) packaging that
will be in contact with
product.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
equipment
Picture 3.3.7.3.12
If any items of equipment
are cleaned before re-entry
into the process area they
must be dry.
Note: In this case the forklift belongs to a low
hygiene area. The golden
rule is that it is better to
clean high hygiene zone
transporters in their own
area - unless they leave it
(eg. for maintenance).
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12
Chapter 3
22 Jul. 2008 08:14:00
WASTE HANDLING

Section 3.3.8.3
Waste handling is an increasingly critical problem due to several factors - influencing general
requirements for any system:
increased quantity of waste produced by the factory
higher cost for disposal of general waste
increased opportunity to generate revenue through sorted waste materials and pressure to
increase re-cycling
stricter legislation about hygiene conditions for food production
higher internal consciousness of hygiene requirements.
Waste area attached to factory:

For collection areas the following points must be considered:
cleanability - during the day the facility will be exposed to frequent spills of liquids and waste
products, requiring frequent hosing down to prevent attracting insects and rodents:
floor to wall junctions should be coved

walls should be water-impermeable and protected from damage caused by fork-lifts and
waste containers
floors should be designed for heavy traffic as well as frequent water cleaning and should be
sloped away from entry to process area for drainage
ceilings can be the open joist concept - resistant to rusting.
airlock - entry to the waste facility must be through two interlocking doors and should be
designed to have a negative air pressure relative to the production building. An insectocutor
should be strategically located within the enclosure.
Note:
Cooling of ambient air is recommended in hot climates.
Waste area outside/detached from factory:

For waste collection areas separate from factory:
area must be cleanable to reduce insect attraction
area should be protected from rain - if possible
transport system of waste containers (which will return into production) must have minimal
contact - containers with outside/soil on roads - even if washed again for entry - 'trains' can be
used to collect containers
General considerations for all waste collection areas:
rodent/insect infestation - details of exterior doors or openings facility must prevent entry of
pests
recycled materials: storage of dry re-cycled materials (eg. paper, corrugated card and
plastics) should be separate from the 'WET' areas (eg. the container wash area).
washing of waste containers:
if the facility is attached to the production hall - a wash area for internal containers is
necessary
if the waste facility is in a separate building from production - the wash area should be
located at the point of entry into the factory
if a compactor is included in the waste facility - special attention is required for cleaning
access under the compactor and hydraulic ram. The floor should be sloped to a drain located
beside the compactor unit.
Boundary fences and walls

Basic types
Picture 3.3.8.3.1
This example shows typical
waste handling facilities
attached to factory - which
has large tonnage output
and multi products (e.g.
large frozen food plant
Note:
An important feature
attached to the factory is
the airlock - to prevent
cross contamination, back-
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flow of odours and ingress

of insects.
Internal waste containers
must be washed before
returning to production.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Basic types
Picture 3.3.8.3.2
attached to factory - which
has medium to small
tonnage output.
Note:
An important feature
attached to the factory is
the airlock - to prevent
cross contamination, backflow of odours and ingress
of insects.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Basic types
Picture 3.3.8.3.3
isolated from factory.
Note:
Area needs to be protected
with a cover from rain and
should be cleanable.
Such an area should be
downwind of the factory.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Basic types
Picture 3.3.8.3.4
Note:
totally unacceptable waste
collection area - too small
with insufficient protection
- and with no organisation
of different waste.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Basic types
Picture 3.3.8.3.5
Note:
detached waste area
outside factory - cleanable
and easy to use - but it
should be closed off to
avoid pest attraction.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Basic types
Picture 3.3.8.3.6
Note:
This example shows an
airlock entry to a waste
area in the facility (and in
the case of a detached
facility must be through
two interlocking doors) - to
prevent pest entry.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Basic types
Picture 3.3.8.3.7
Note:
For a compactor special
attention is required for
cleaning access under the
compactor and hydraulic
ram. Otherwise build up of
debris will be a breeding
ground for pests
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Basic types
Picture 3.3.8.3.8
The storage of dry recycled materials (e.g.
paper corrugated card and
plastics) should be
separate from the 'WET'
areas (e.g. the container
wash area).
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Basic types
Picture 3.3.8.3.9
Note:
This is a good example of a
transport system of waste
containers - with minimal
contact with the area
outside.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Basic types
Picture 3.3.8.3.10
Note:
outside.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Basic types
Picture 3.3.8.3.11
Note:
outside.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
this GI
3.2.12
Doors
Chapter 3
08 Aug. 2008 13:22:00
Recommendations

Recommendations
Section 3.3.8.4
Each factory will have to select an appropriate waste handling system, depending on its actual
layout and type of product.
However, as general guidance on the selection of a preferred system, see chart of typical
systems specified according to type of product (ie. low, medium or high risk).
The choice of a system may also be influenced by local regulatory requirements.
It is important that the chosen system prevents cross-contamination - see chart of general
guidelines for prevention with zoning.
Note:
Waste is incinerated in certain countries - but then environmental considerations are critical (eg.
no unacceptable fumes from burning certain materials).
Waste handling wet and dry
solids
Recommendations
Picture 3.3.8.4.1
All internal bins bag

carriers or internal
containers need regular
cleaning.
If there is no container
transport system
(train) the internal
containers must be
washed at re-entry
point into building.
With a transport
system to the outside
containers can be
washed at waste
collection point - then
transported back inside
building.
Food waste bins must
be cleaned and
disinfected before
return to high hygiene
zone.
Pictures: 1 2
Waste handling wet and dry

solids
Recommendations
Picture 3.3.8.4.2
All internal bins bag

carriers or internal
containers need regular
cleaning.
If there is no container
transport system
(train) the internal
containers must be
washed at re-entry
point into building.
With a transport
system to the outside
containers can be
washed at waste
collection point - then
transported back inside
building.
Food waste bins must
be cleaned and
disinfected before
return to high hygiene
zone.
Pictures: 1 2
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Recommendations
Chapter 3
30 Jul. 2008 11:10:00
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Recommendations
CLEANING EQUIPMENT

Recommendations
Section 3.4.1.4
See chart of typical designs of CIP systems to achieve effective results.

Equipment (pipes etc.) used for different circuits - stored when not in use - must be stored dry
and off the floor.
Cleaning In Place systems

Recommendations
Picture 3.4.1.4.1
Equipment can be used for
different circuits - when
not in use must be stored
dry and off the floor - (e.g.)
on these pipe racks.
Pictures: 1 2 3
Recommendations
Picture 3.4.1.4.2
Equipment can be used for
different circuits - when
not in use must be stored
dry and off the floor - (e.g.)
on these pipe racks.
Pictures: 1 2 3
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Recommendations

Recommendations
Picture 3.4.1.4.3
For the design of effective
Cleaning-in-Place systems
there are a number of
essential rules.
Pictures: 1 2 3
Chapter 3
22 Jul. 2008 11:47:00
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SENSORS

Section 3.5.10.3
Some examples are as follows:
Whatever their purpose the sensors must be capable of being cleaned and disinfected by the CIP
system - or be easy to dismantle for manual cleaning and disinfection.
If cleaned by CIP, the sensor must not adversely affect the '4T's' with the result that cleaning is
no longer efficient.
Sensor installation must not:
create hollow bodies
have un-drainable points
have points where product will accumulate.
It is desirable that the sensor can be accessed for inspection (even though periodic).
Any possible contamination of the product by components of the sensor (eg. fluids etc.) must be
eliminated.
Sensors
Picture 3.5.10.3.1
Sensor installation must
not have un-drainable
points - or points where
residues can accumulate.
Chapter 3
28 Jul. 2008 08:50:00
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ROBOTIC

Section 3.5.12.3
The following are design details to be considered for a robot with product contact where hygienic
requirements become important:
Vacuum source - the vacuum for the picking units should be supplied from a central vacuum
system -remote to the robot - preferably in the general services area.
Exhaust - the exhaust from the picking system can contain unknown loads of bacteria
(especially if the vacuum source is not central) - and must be directed out of the process room preferably to the atmosphere. Exhaust can be directed to a return air system - if the filtration is
adequate.
Picking arm material - the cup (or whatever design is used to pick up the product) must be
pliable enough to be functional - and still able to stand up to common cleaning chemicals. The
design of the vacuum tube should avoid folds or pleating as these are difficult to clean.
Support structure - in the case of vacuum assisted robots, support structure must be
cleanable - using common plant cleaning methods. Dropped product and broken containers
introduce product into the support structures - resulting in the growth of microbes (which are
then picked up by the vacuum in the picking arms) - potentially contaminating other product
and/or the surrounding environment.
Waterproofing of electronics - ideally the electronics and motors running the robotic system
will all be waterproof, resistant to commonly used cleaning and disinfection chemicals permitting cleaning by foaming and rinsing protocols.
Robotics
3.5.12.3.1
Robots not having contact
with exposed products (e.
g. just with tins or
packages) do not have to
meet strict hygienic design
criteria.
Note: As soon as intimate
product contact is possible
- the design of the loading
machine becomes critical and must comply with
general hygienic equipment
requirements.
Cleanability and minimal
risk of lubricant contact
with product are important.
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Section 3.5.12.3
The following are design details to be considered for a robot with product contact where hygienic
requirements become important:
Vacuum source - the vacuum for the picking units should be supplied from a central vacuum
system -remote to the robot - preferably in the general services area.
Exhaust - the exhaust from the picking system can contain unknown loads of bacteria
(especially if the vacuum source is not central) - and must be directed out of the process room preferably to the atmosphere. Exhaust can be directed to a return air system - if the filtration is
adequate.
Picking arm material - the cup (or whatever design is used to pick up the product) must be
pliable enough to be functional - and still able to stand up to common cleaning chemicals. The
design of the vacuum tube should avoid folds or pleating as these are difficult to clean.
Support structure - in the case of vacuum assisted robots, support structure must be
cleanable - using common plant cleaning methods. Dropped product and broken containers
introduce product into the support structures - resulting in the growth of microbes (which are
then picked up by the vacuum in the picking arms) - potentially contaminating other product
and/or the surrounding environment.
Waterproofing of electronics - ideally the electronics and motors running the robotic system
will all be waterproof, resistant to commonly used cleaning and disinfection chemicals permitting cleaning by foaming and rinsing protocols.
Robotics
3.5.12.3.1
Robots not having contact
with exposed products (e.
g. just with tins or
packages) do not have to
meet strict hygienic design
criteria.
Note: As soon as intimate
product contact is possible
- the design of the loading
machine becomes critical and must comply with
general hygienic equipment
requirements.
Cleanability and minimal
risk of lubricant contact
with product are important.
Chapter 3
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Recommendations

Recommendations
Section 3.5.12.4
If a robot is in contact with the product, its design and installation must meet all those criteria which
are critical points for any other equipment.
Robotics
Recommendations
3.5.12.4.1
If a robot is in contact with
the product, its design and
installation must meet all
those criteria which are
critical points for any other
food contact equipment.
Note: Cleanability is as
important as functionality.
Chapter 3
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LAYOUT EQUIPMENT

Section 3.5.3.3
All equipment layout must:
maintain recommended levels of hygiene whilst remaining technically efficient and safe for
personnel
specifically prevent hygiene problems related to cross-contamination and inability to clean.
Layout of equipment
Picture 3.5.3.3.1
All equipment layout must
maintain recommended
levels of hygiene whilst
remaining technically
efficient and safe for
personnel.
Layout must specifically
prevent hygiene problems
related to cross
contamination and inability
to clean.
a well planned and
installed process area particular attention has
been paid to access for
cleaning under equipment.
Pictures: 1 2
Layout of equipment
Picture 3.5.3.3.2
All equipment layout must
maintain recommended
levels of hygiene whilst
remaining technically
efficient and safe for
personnel.
Layout must specifically
prevent hygiene problems
related to cross
contamination and inability
to clean.
a well planned process
area - particular attention
has been paid to access for
cleaning under equipment.
Pictures: 1 2
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Recommendations general

Recommendations general
Section 3.5.3.4
Factory layout - and in particular processing equipment layout - are the most important factors
influencing the achievement of good hygiene results
Processing equipment layout - should be optimised for a given manufacturing process and
product type.
A well executed HACCP study - is critical in providing input the decision making process on layout.
Best results are obtained when:

this GI
access ways for personnel and material traffic - are planned to be clear and straightforward
networks of piping - should follow the product flow and should be minimised - intersections
are more difficult to clean.
congestion in process areas - makes cleaning and maintenance difficult
material storage (both raw and packing) is inadequate and/or congested - thereby
increasing the risk of contamination - mainly when transferring to the processing areas.
Internal partitions and walls:
use up a lot of space between equipment
present additional surfaces to be cleaned and maintained
distance between processing units - is as short as possible - but generous enough to

facilitate operation, supervision, opening, maintenance and ease of cleaning
Poor results are obtained when:
processing equipment - is placed in a simple, logical and functional way in relation to the
process flow sheet and manufacturing step
should be kept to a minimum - and used only to implement a zoning concept - to isolate
operations requiring different hygiene levels.
Separation of dry processes from wet ones (as well as separation of low, medium and high
hygiene processes) by means of physical barriers must be given careful consideration.
2.2
Master plan
2.2.2
Generation of the Master Plan
2.3
Zoning and barriers
2.3.1
General considerations
Chapter 3
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MATERIALS &
FINISHING

Section 3.5.4.3
The variety of product and associated equipment found within Nestl means that the
requirements for materials and finishings vary considerably.
Details concerning materials and finishings can only be decided by application of HACCP and
factors causing other quality deviations.
Generally materials and finishings should:
be accessible and cleanable
be inert and non-porous
be non-corrosive
be resistant to chosen cleaning chemicals - though the chemicals may have to selected
relative to material required for technological reasons - certain metals chosen for heat
exchange (eg. in extruders, on roller-drier surfaces) are very sensitive to chemicals
be resistant to industrial fluids and lubricants
not be source of foreign material
not be a source of flavour or odour
not be painted where product is exposed.
Materials and finishing

Picture 3.5.4.3.1
Generally materials and
fittings should not affect
cleanability:
Note: These complex
fittings are difficult to
clean and may not have
passed a preliminary
HACCP study - if one had
been done.
Pictures: 1 2 3 4 5 6 7 8 9
Picture 3.5.4.3.2
Materials should not be
painted where product is
exposed.
Note: This example is old
equipment - newer models
being of stainless steel.
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Picture 3.5.4.3.3
Materials must be inert and
non-porous - generally of
stainless steel - and well
welded or as one piece - as
in this blender.
Pictures: 1 2 3 4 5 6 7 8 9
Picture 3.5.4.3.4
Generally all materials
should be non-corrosive - if
one part is not in stainless
steel this could corrode and
contaminate the product
with foreign material.
Pictures: 1 2 3 4 5 6 7 8 9
Picture 3.5.4.3.5
Materials should not be
painted where product is
exposed.
Note: This example is old
equipment - newer models
being of stainless steel.
Pictures: 1 2 3 4 5 6 7 8 9
Picture 3.5.4.3.6
should be non-corrosive
Note: This motor was
placed in equipment to be
CIP'd. It was not resistant
to the chosen cleaning
chemicals.
Pictures: 1 2 3 4 5 6 7 8 9
Picture 3.5.4.3.7
should be non-corrosive.
Note: This blender shaft
material was completely
incompatible with the
cleaning chemicals and
would lead to foreign
material in the product.
Pictures: 1 2 3 4 5 6 7 8 9
Picture 3.5.4.3.8
Pictures: 1 2 3 4 5 6 7 8 9
Picture 3.5.4.3.9
Materials and finishings
must be compatible.
Note: These mixed
materials will lead to
problems of cleanability.
Pictures: 1 2 3 4 5 6 7 8 9
material
External reference material
TM- 205.4
Stainless Steel Corrosion
TMN-402.4
Specifications for Stainless Steel Equipment in the Dairy Industry
EHEDG Sept. '93

Welding Stainless Steel to meet Hygienic Requirements
EHEDG Nov. '93
Hygienic Design of Closed Equipment for Processing Liquid Food
EHEDG March '96
Hygienic Design of Equipment for Open Processing
Chapter 3
30 Jul. 2008 14:01:00
INSULATION FOR PIPES Nestl Good Hygienic Engineering

Section 3.5.5.3
Insulation media or material:
must prevent passage of hot or cold and unacceptable temperature changes
must in no way contaminate products
must not become a breeding ground for insects or harbour dirt
must be impervious to moisture.
Note: not for hygiene but must not in any way endanger the health of personnel.
Covering of the insulation:
must protect solid material from humidity and infiltration of insects and dirt
must prevent escape of gaseous or liquid media
must be continuous and any joints must be well sealed and stay sealed.
Pipe insulation:
the point at which the pipe leaves its protection is critical. This point must be well sealed though allowing for some expansion and contraction.
Insulation for pipes, tanks and

other equipment
Picture 3.5.5.3.1
Insulation material must
not harbour dirt.
Note: These residues
escaping from between the
equipment surface and the
insulation cover are a sure
sign that the insulation
material has become wet
and contaminated with
product residues. These
can be hazardous sources
of contamination. They
indicate that maintenance
of the equipment surface
and/or insulation cover
may be necessary.
Pictures: 1 2
Insulation for pipes, tanks and
other equipment
Picture 3.5.5.3.2
The point at which the pipe
leaves its insulation
protection is critical.
Note: In this example the
insulation material is
exposed and it will become
damp and maybe
contaminated with residues
and insects.
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Hygiene considerations installation layout
INSTALLATION OF
EQUIPMENT

Hygiene Considerations installation layout
Section 3.5.6.3
Whenever possible, equipment should be grouped onto a common framework - and then the
framework fixed to the floor, minimizing the number of contacts with the floor.
Control systems, services and auxiliaries must to be accessible for cleaning and maintenance.
When piping is used to transfer product from one unit to another - this should be done over the
shortest distance, without changes in diameter and without dead ends exceeding 2-3 diameters
(where product is liable to be trapped).
Equipment drainage should be conducted to a drainage point - avoiding draining directly on
floors.
Drainage collection for chronic condensation points should be provided.
Ledges, recessed corners, 'nooks and crannies' should all be avoided.
Installation of equipment
installation layout
Picture 3.5.6.3.1
Equipment drainage should
be conducted to a drainage
point.
Note: Draining directly
onto the floor will
eventually destroy the floor
surface and residues will
build up in cracks.
Pictures: 1 2 3
installation layout
Picture 3.5.6.3.2
Control systems must be
accessible for cleaning and
maintenance.
Note: Space under the
control panels makes
cleaning easy.
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Hygiene considerations installation layout
Pictures: 1 2 3
installation layout
Picture 3.5.6.3.3
Piping used to transfer
product from one unit to
another should have no
dead ends.
During audits of CIP
absence of dead ends
should be confirmed.
Piping (and its supports)
should be arranged to
facilitate cleaning and
access for maintenance.
Pictures: 1 2 3
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Hygiene considerations space/accessibility

Hygiene Considerations space/accessibility
Section 3.5.6.4
Sufficient height should be allowed for:
operation
inspection
cleaning of equipment and surrounds
maintenance.
To ease cleaning - all equipment should be elevated at least 150mm from the floor. If this is not
feasible, total equipment support should be sealed onto the floor, or on a foundation - thus
avoiding residue build-up under the machine.
For wall mounted small equipment, supports and electrical cabinets - a clearance of 50-100mm
to the wall must be provided, or better still, apply 'The Cleaning Tool Criteria' "Leave at least enough space behind (and around) equipment to be able to introduce a brush or
vacuum cleaner accessory."
Overhead installation of equipment should be reduced to a minimum - access, maintenance and
cleaning are all difficult.
All parts of large equipment should be installed at a sufficient distance (c.700mm) from wall,
ceilings and adjacent equipment. More space may be required if other operations (eg. lifting,
opening etc.) are involved.
space/accessibility
Picture 3.5.6.4.1
For wall-mounted small
equipment and electrical
cabinets - a clearance of 50100 mm to the wall must
be provided for cleaning
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.2
Sufficient height should be
allowed for cleaning of
equipment and surrounds.
Note: Apply the "cleaning
tool criteria" and test (as in
this example) that a brush
or vacuum cleaner
accessory can be
introduced under the
equipment.
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space/accessibility
Picture 3.5.6.4.3
To ease cleaning all
equipment should be
elevated 150mm from the
floor.
Note: It will be very
difficult to clean under this
motor and its support
contact with the floor will
accumulate residues.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.4
equipment should be
floor.
one solution - only a check
of the sealing between the
floor and around the motor
support will be necessary.
But vibration from the
motor could crack the seal
more rapidly.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.5
equipment should be
floor.
Note: There is no
possibility to clean under
this equipment. Insects
were found to be
harbouring in product
residues under the motor
support.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.6
All parts of large
equipment should be
installed at a sufficient
distance from the wall
ceilings and adjacent
equipment.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.7
If equipment cannot be
elevated the equipment
support should be sealed to
the floor.
Note: The contact between
the floor covering (in this
case epoxy) and the
equipment should be
continuous. As the
equipment vibrates
maintenance will be
required to repair any
developing cracks in such
joints.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.8
All parts of large
equipment should be
installed at a sufficient
distance from the wall
ceilings and adjacent
equipment.
Note: Correct mountings
and floor covering
continuous with foundation
covering are other good
features of this example.
Pipes are well arranged on
the wall and there is space
for access between pipes
and equipment.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.9
the floor.
case epoxy) and the
equipment should be
continuous. As the
equipment vibrates
maintenance will be
joints. This example is a
well installed Milo vacuum
oven.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.10
the floor.
case epoxy) and the
equipment should be
continuous. As the
equipment vibrates
maintenance will be
joints. In this Passeburg
vacuum oven the distance
between the piping
supports and the wall and
ceiling allows access for
maintenance.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.11
Sufficient height and space
should be allowed for
operation and inspection
under the tanks.
Note: There is space
around these tanks for
access and to the upper
parts of the tanks access is
via the ladders and
platform.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.12
To ease cleaning
equipment should be
elevated at least 150 mm
from the floor. Equipment
and piping supports should
be of simple design. Access
to drains must be assured
for their inspection and
cleaning
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.13
To ease cleaning
equipment should be
from the floor. Equipment
and piping supports should
be of simple design. Access
to drains must be assured
for their inspection and
cleaning
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
space/accessibility
Picture 3.5.6.4.14
To ease cleaning
equipment should be
from the floor.
Note: As in this example
from the hydrolisation
plant for infant cereals the
design of the supports for
equipment and piping
should be simple. Access to
drains must be assured for
their inspection and
cleaning
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
this GI
3.5.3
Layout of equipment
3.5.3.5 Recommendations additional elements
Chapter 3
08 Aug. 2008 13:32:00
Hygiene considerations support elements

Hygiene Considerations support elements
Section 3.5.6.5
Number of supporting legs, frames, walls and ceiling mountings should be minimized.
Supports should preferably be constructed from full section material - but if tubular must be
sealable to prevent entry of water or soils.
Spot and tack welding (that cause incompletely sealed seams) should be avoided.
Projecting bolt threads should be avoided.
Vibration of equipment may cause cracks and micro-fissures at point of support connections to
the floor or wall.
Note: They may be checked and maintained as they could collect water or soils.
Base plates to support and fix equipment must be smooth, continuous and with slope to allow
drainage.
Equipment covers, safety covers, housings etc. should also be smooth, continuous and with
slope to allow drainage.
Piping supports (and supports in general) should be placed at required intervals to avoid sagging
(eg. 3m between supports).
Equipment and piping supports should be of simple design - no residue collecting points.
In process areas stainless steel is to be preferred to painted mild steel.
Angle iron, channel, I or H beams and T sections are good materials for construction of supports,
but their orientation must be studied for hygienic design to avoid accumulation of residues.
support elements
Picture 3.5.6.5.1
Equipment supports into
the floor require special
attention - they are never
an ideal solution.
Note: Equipment vibration
may cause cracks and
micro-fissures - allowing
penetration of residues.
Regular checks and
maintenance are critical.
Pictures: 1 2 3 4 5
support elements
Picture 3.5.6.5.2
Angle iron, channel, I or H
beams and T sections are
good materials for
construction of supports.
Note: Their orientation
must be made to avoid
accumulation of residues.
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support elements
Picture 3.5.6.5.3
Angle iron channel beams
and T sections are good
materials for construction
of supports.
Note: If L shapes are used
and they are boxed in
under equipment product
residues and insects will
accumulate as seen in
these chocolate residues.
Pictures: 1 2 3 4 5
support elements
Picture 3.5.6.5.4
of supports.
However with other shapes
residues will accumulate.
Such residue
accumulations are
unacceptable on a support
under a platform in a high
hygiene area next to (e.g.)
the after cooler.
Pictures: 1 2 3 4 5
support elements
Picture 3.5.6.5.5
of supports.
If introduced as overhead
equipment supports
inspection and regular
cleaning are necessary
Pictures: 1 2 3 4 5
this GI
3.5.7
Supports
Chapter 3
08 Aug. 2008 13:32:00
SUPPORTS

Section 3.5.7.3
Main requirements for supports are that the design and installation:
avoid points for dust or residue accumulation
avoid any hollow bodies
allow easy cleaning
facilitate maintenance.
Free-standing units present fewer cleaning problems.

Most problems are the fixing of pumps and similar equipment on floors - especially in areas
requiring wet cleaning. Supports sunk into the floor reduce points where residues could
accumulate between support and floor surface.
Note: These points must be checked for necessary re-sealing - as (eg.) motor vibration can
crack connection between support and floor.
Supports
Picture 3.5.7.3.1
Fixing pumps on the floor
causes problems.
Supports sunk into the
floor reduce points where
residues could accumulate
between the support and
the floor surface.
Note: These points need
checking for the need to reseal when motor vibration
causes fissures.
Pictures: 1 2 3 4 5 6 7
Supports
Picture 3.5.7.3.2
Fixing pumps on the floor
causes problems - so does
fixing them on a metal
stand - which is not a true
machinery foundation.
The solution is a support
sunk into the floor.
Note: Such supports reduce
points where residues
could accumulate between
the support and the floor
surface.
These points need checking
for the need to re-seal
when motor vibration
causes fissures.
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Supports
Picture 3.5.7.3.3
Most problems occur when
fixing pumps on floors.
Note: Putting the pump in
an inaccessible place under
the tank causes the worst
problems.
Pumps should be installed
beside the tank - and off
the floor on a support - to
facilitate cleanability.
Pictures: 1 2 3 4 5 6 7
Supports
Picture 3.5.7.3.4
Main requirements for
supports are that the
design and installation
must allow easy cleaning.
Note: It is easy to pass a
vacuum cleaner under
these chocolate tempering
units.
Pictures: 1 2 3 4 5 6 7
Supports
Picture 3.5.7.3.5
Supports on the floor
should be minimised - most
problems are encountered
when fixing pumps on
floors - especially in areas
requiring wet or controlled
wet cleaning.
Note: This set-up is well
designed - but supports
sunk into the floor points
(where residues could
accumulate) must be kept
to a minimum. They need
checking for cracks and
needs for maintenance.
Pictures: 1 2 3 4 5 6 7
Supports
Picture 3.5.7.3.6
Avoid points for dust and
residue collection.
Note: In a high hygiene dry
area this equipment is
raised on its supports off
the foundation - and allows
for easy cleaning.
Pictures: 1 2 3 4 5 6 7
Supports
Picture 3.5.7.3.7
Avoid fixings and supports
on floors wherever
possible. Sealing with
silicone is temporary and
gives a false sense of
security.
Note: This support is now
in a controlled wet zone.
When zone is wet washed
(though infrequently wet
and contaminated)
residues will accumulate
under the support.
Pictures: 1 2 3 4 5 6 7
Chapter 3
22 Jul. 2008 06:41:00
Recommendations

Recommendations
Section 3.5.7.4
Supports on the floor should be minimized - as much as possible.
Install as many services and pieces of unnecessary equipment outside critical rooms as possible.
Avoid fixings on floor - whenever possible.
Install spacers to allow for cleaning behind equipment - minimum space should be 250mm.
Keep the design very simple.
Avoid many bolts and screws.
Minimize surface contact areas between support and equipment and supporting medium.
Supports
Recommendations
Picture 3.5.7.4.1
Avoid excessive nuts and
bolts.
Note: Cavities around nuts
and bolts can often have
residue collecting points if not installed correctly.
Pictures: 1 2 3 4 5 6 7
Supports
Recommendations
Picture 3.5.7.4.2
on floors wherever
security.
in a dry zone. At one time
the zone had been wet
washed (see the corroded
screw support). During a
salmonella source search
residues found in these
holes under this support
contained salmonella - a
hazardous situation!
Pictures: 1 2 3 4 5 6 7
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Recommendations
Supports
Picture 3.5.7.4.3
on floors wherever
security.
in a controlled wet zone.
When zone is wet washed
(though infrequently wet
and contaminated)
residues have accumulated
under the support. During a
salmonella source search
residues found in under
this support contained
salmonella - a hazardous
situation!
Pictures: 1 2 3 4 5 6 7
Supports
Picture 3.5.7.4.4
Supports on the floor should
be minimised.
Note: These three legged
motor supports help minimise
floor to equipment contact.
Pictures: 1 2 3 4 5 6 7
Supports
Picture 3.5.7.4.5
on floor if possible.
Note: This example is an
alternative solution - a free
standing tube support on a
metal floor tile for added
strength
Recommendations
Pictures: 1 2 3 4 5 6 7
Supports
Picture 3.5.7.4.6
Note: Minimise contacts of
support with the floor such as in these conveyor
belt supports.
Pictures: 1 2 3 4 5 6 7
Supports
Picture 3.5.7.4.7
Minimise contacts of
support with the floor such as in these conveyor
belt supports
Note: It is important to
avoid placing supports on
drains so that drains can
not be opened.
Recommendations
Pictures: 1 2 3 4 5 6 7
Chapter 3
22 Jul. 2008 06:42:00
PLATFORMS

Section 3.5.8.3
Through its design and installation - the platform must not become a place where residues
collect that could contaminate a product.
Anywhere a platform passes over exposed product (forming a bridge) - the product must be
protected by a cover - removable for cleaning.
It is critical to avoid:
hollow bodies - where direct contact (or close contact) with exposed product is possible
residue collecting points - between the platform and its floor, wall or equipment supports
areas with small gaps or inaccessible points underneath the platform surface - especially at
support points where residues collect
surfaces that are difficult to clean - although some compromises may be necessary to
provide a non-slip surface for personnel safety.
Platforms
Picture 3.5.8.3.1
Anywhere a platform
passes over exposed
product (forming a bridge)
- the product must be
protected by a cover.
Note: This has not
happened for this line and
particles can fall onto
products.
Pictures: 1 2 3 4
Platforms
Picture 3.5.8.3.2
Anywhere a platform
passes over exposed
protected by a cover removable for cleaning.
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Pictures: 1 2 3 4
Platforms
Picture 3.5.8.3.3
Note: Areas underneath the
platform surface are points
where residues can collect
- if the platform is not
properly installed and
sealed.
Pictures: 1 2 3 4
Platforms
Picture 3.5.8.3.4
Anywhere a platform
passes over exposed
protected by a cover removable for cleaning.
Pictures: 1 2 3 4
External reference material
CCFRA 3rd Reprint '86

Hygienic Design of Food Processing Equipment
Chapter 3
30 Jul. 2008 14:04:00
Recommendations mobile platforms

Recommendations mobile platforms
Section 3.5.8.4
Mobile platforms are highly recommended:
for reducing contact points required for supports (eg. to equipment or walls)
where several locations need infrequent access and can be served with one mobile platform
for a platform running parallel with equipment, where the possibility of moving the platform is
desirable for equipment surface cleaning.
Platforms
Recommendations mobile
platforms
Picture 3.5.8.4.1
Mobile platforms are
recommended where
several locations need
infrequent access and can
be served with one mobile
platform.
Note: Attention has to be
paid to the hygienic design
of the wheels and cleaning
of any more complex parts
- necessary for changing
the height of the platform.
Pictures: 1 2
Platforms
Recommendations mobile
platforms
Picture 3.5.8.4.2
Mobile platforms are highly
recommended for a
platform running parallel
with equipment where the
possibility of moving the
platform is desirable for
equipment surface cleaning.
Pictures: 1 2
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Recommendations choice of material

Section 3.5.8.5
Considering total cost (ie. investment plus maintenance) stainless steel is often the most
economic solution.
Stainless steel should be used for high and medium hygiene situations - but in lower hygiene
areas galvanised is acceptable.
Chequer plate' profile should be used - never metallic grating (which is difficult to clean) - unless
required for (eg.) air circulation.
Platforms
Recommendations choice
of material
Picture 3.5.8.5.1
Note: Never use metallic
grating - which is difficult
to clean.
Pictures: 1 2 3
Platforms
of material
Picture 3.5.8.5.2
Note: Stainless steel should
be used for high hygiene
situations. In this example
of infant cereals production
the product film is very
exposed and there is a risk
that paint from the railings
could enter the product
flow.
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Platforms
of material
Picture 3.5.8.5.3
Note: Never use metallic
grating if it can be avoided.
Such grating is difficult to
clean - and hazardous if
near to where product is
exposed.
Pictures: 1 2 3
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Recommendations installation of fixed platform

Section 3.5.8.6
Install self-supporting design as far as possible (eg. by bending up the kick board for strength).
Preferably support the platform from ceiling, wall or equipment itself - avoiding platform legs on
the floor, which create more points difficult to clean.
Keep the platform free from the other surfaces to facilitate cleaning.
Platforms
Recommendations
installation of fixed
platform
Picture 3.5.8.6.1
Platforms should be
installed to facilitate
cleaning.
Note: The necessary deck
mounting and sealing
should not have residue
accumulating points.
Care must be taken with
the welds and countersink
screw attachments to the
mounting.
Pictures: 1 2 3 4 5 6 7 8 9
Platforms
Recommendations
platform
Picture 3.5.8.6.2
Note: Attention must be
paid to minimising residue
collecting points under the
platform surface - at its
support contact and at the
contact with the handrail.
Supports must have a
cleanable profile.
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Platforms
Recommendations
platform
Picture 3.5.8.6.3
Note: If it is necessary to
support the first step on
the floor then the support
"leg" should have as little
contact with the floor as
possible.
A possible option with
equipment mounting is to
embed the foot in a raised
plinth. In a high hygiene
area this should be covered
with epoxy (or other
appropriate floor covering)
to make a continuous easyto-clean surface.
The photo shows a typical
medium hygiene situation
Pictures: 1 2 3 4 5 6 7 8 9
Platforms
Recommendations
platform
Picture 3.5.8.6.4
Install self-supporting
design whenever possible.
Bend up kick-plate for
strength.
Good welding is important.
Pictures: 1 2 3 4 5 6 7 8 9
Platforms
Recommendations
platform
Picture 3.5.8.6.5
good welding of checker
plate.
Pictures: 1 2 3 4 5 6 7 8 9
Platforms
Recommendations
platform
Picture 3.5.8.6.6
Note: This example is
suitable for a low hygiene
area - or a medium hygiene
area where product is not
exposed. The railings are
designed for opening to
allow passage (eg.) of a
pallet of raw materials.
Care then that the fixing
does not lead to the
railings being hollow
bodies where residues and
insects could collect.
Pictures: 1 2 3 4 5 6 7 8 9
Platforms
Recommendations
platform
Picture 3.5.8.6.7
Note: This is a typical
example for a medium
hygiene area - the platform
is suspended from the
ceiling - reducing supports
on the floor.
Pictures: 1 2 3 4 5 6 7 8 9
Platforms
Recommendations
platform
Picture 3.5.8.6.8
example of a well installed
fixed platform.
Pictures: 1 2 3 4 5 6 7 8 9
Platforms
Recommendations
platform
Picture 3.5.8.6.9
example for a medium
hygiene area - but possible
accumulations of product
under the stairs supports
will need attention.
Pictures: 1 2 3 4 5 6 7 8 9
Chapter 3
21 Jul. 2008 14:54:00
Recommendations design of stairs and ladders

Section 3.5.8.7
Use self-supporting designs whenever possible (eg. bonded steps - either single or continuous).
Steps should be welded continuously to the side board particularly in high hygiene areas.
Stairs should preferably be supported from the ceiling, the wall, or the equipment itself avoiding stair legs on the floor.
Avoid hollow sections where product is exposed or can be exposed during (eg.) cleaning or
maintenance.
Platforms
Recommendations design
of stairs and ladders
Picture 3.5.8.7.1
All platforms, their steps
and handrails should be
easy to clean and not
collect residues.
When platform legs are on
the floor - keep contact to
the minimum.
Steps should be
continuously welded especially in high hygiene
areas.
Use flat (solid) bars where
product is exposed.
Where a platform crosses a
line with exposed product cover the product.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.2
The stairs should
preferably be supported off
the floor.
the floor - the support 'leg'
should have as little
possible - or be embedded
in a sealed cavity.
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Platforms
Picture 3.5.8.7.3
The stairs should
the floor.
Note: The foot should
never just be screwed to
the floor.
If it is necessary to support
the first step on the floor
then the support "leg"
possible.
Distances around and
under the step or ladder
should allow for cleaning.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.4
The stairs should
the floor.
Note: The foot should
never just be screwed to
the floor.
If it is necessary to support
the first step on the floor
then the support "leg"
possible.
Distances around and
under the step or ladder
should allow for cleaning.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.5
Steps should be welded
continuously to the side
board - particularly in high
hygiene dry areas.
Note: Typical dimensions
shown here are related as
much to personnel safety
as to food safety.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.6
the floor - the support 'leg'
possible.
Fat solid bars should be
used for handrails in high
hygiene areas near to the
line.
Tubing can be used in other
areas - but in wet
situations care must be
taken to ensure that these
are self-draining - no drills
holes into the tube to allow
entry of water or powder.
Typical dimensions shown
here are related as much to
personnel safety as to food
safety.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.7
It is critical to avoid
residue collecting points
between the steps and the
side board. In high hygiene
areas steps should be
welded continuously to the
side board.
adequate for a medium
hygiene area but not for a
high hygiene zone. Trying
to seal the contact between
the steps and their
supports is temporary.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.8
Note: These steps in a high
hygiene area should be
side board. As this is a high
hygiene area near to
product railings are solid
with no hollow bodies. No
2of 8
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.9
Note: These fixed steps in a
high hygiene zone for tote
bin handling will be points
where residues collect especially at their contact
with the floor.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.10
Note: In a high hygiene
zone steps should be
side board to facilitate
cleaning.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.11
Note: These types of steps
are adequate for a medium
hygiene zone. However
stainless steel would be
preferable because paint
could chip and enter the
product.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.12
example of stairs for a high
hygiene area - with steps
welded continuously to
side board.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.13
Note: Stairs in a high
hygiene area should be
preferably supported from
the equipment or platform
itself avoiding locating
them on the floor eliminating support
contacts with the floor.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Platforms
Picture 3.5.8.7.14
In high hygiene zones
steps which are welded
continuously are easy to
clean - after contact with
shoes.
Note: Also when cleaned
product residues will not
accumulate and residues
will not be then transferred
and carried around by the
shoes.
Pictures: 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Chapter 3
28 Jul. 2008 08:47:00
Recommendations design of handrails

Section 3.5.8.8
Use flat (solid) bars for the hand rail itself without hollow bodies where product is exposed especially in high hygiene zones.
Tubing can be used (if well sealed) but avoid drilling holes in tubes.
Use T bar for the supports (ie. avoid closed profiles).
Platforms
of handrails
Picture 3.5.8.8.1
All platforms, their steps
and handrails should be
easy to clean and not
collect residues.
When platform legs are on
the floor - keep contact to
the minimum.
Steps should be
continuously welded especially in high hygiene
areas.
Use flat (solid) bars where
product is exposed.
Where a platform crosses a
line with exposed product cover the product.
Pictures: 1 2 3 4
Platforms
of handrails
Picture 3.5.8.8.2
line.
Note: Tubing can be used
in other areas - but in wet
Pictures: 1 2 3 4
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Platforms
of handrails
Picture 3.5.8.8.3
line.
There should be no sharp
right angled parts (difficult
to clean) and corners must
be rounded.
Some typical
measurements are given
for handrail installation.
Pictures: 1 2 3 4
Platforms
of handrails
Picture 3.5.8.8.4
line.
There should be no sharp
right angled parts (difficult
to clean) and corners must
be rounded.
Some typical
measurements are given
for handrail installation.
Pictures: 1 2 3 4
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Hygiene Considerations general
CONVEYORS

Section 3.5.9.3
For all conveying systems there are some general hygiene design requirements:
Characteristics of item to be moved - must be considered.

Product (re)contamination risks associated with the equipment (and therefore necessary
preventive measures) - must be identified.
Systems - must never contaminate the item being transported.
Extra overhead protection - may be added to the conveyor to protect the item being transported
- but this may be a compromise - as the extra cover could represent another potential source of
hygiene problems - collecting residues
There should be no leaks or spills associated with the equipment.
Raw material, product or packaging must not be trapped by the equipment.
If raw material or product adheres to the conveying surfaces, a system (permanent or

intermittent) is necessary for residue removal. This system in itself must not constitute a (re)
contamination risk for the raw material or product.
All conveying systems must be constructed to permit easy cleaning - not only of conveying
surfaces, but also of under and side supports. Enclosed conveying systems must have removable
parts so all surfaces can be cleaned.
Pest prevention must be considered - when designing the system.
Conveying systems passing from lower hygiene to higher hygiene areas - must not form a
bridge that could permit cross contamination and entry of pests. Minimize opening size and
(where possible) close off when not in use (eg. split conveyor system).
Systems to operate the conveying - must not become a potential source of contamination:
motors should be placed to side of conveyor to avoid collection of residues (eg. not under
conveyors)
lubrication must not contaminate the transport surfaces
all electric wiring and cables must be installed to prevent the collection of residues
avoid cables under lines - with power feeds from above if possible.
The material for the conveyor housing will be decided by their location and the sensitivity of the
item to be transported:
stainless steel (or high grade flexible material) will be the choice for most conveyors with
sensitive product contact and risk of contamination
other materials can be used for protected/packed product
Conveyors
general
Picture 3.5.9.3.1
Systems to operate the
conveying must not
become a potential source
of contamination.
Note: Motors should not be
placed under conveyors to avoid collection of
residues.
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Conveyors
general
Picture 3.5.9.3.2
Systems to operate the
conveying must not
become a potential source
of contamination.
Note: Motors should not be
placed under conveyors to avoid collection of
residues. Placing this
motor on a tray as support
creates yet another surface
that will collect residues.
Motors should be placed to
the side of the conveyor but must not be a safety
problem for operators. All
electric wiring and cables
must be installed to
prevent the collection of
residues.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Conveyors
general
Picture 3.5.9.3.3
Note: Extra overhead
protection may be added to
the conveyor to protect the
item being transported - in
this cases open packaging which could otherwise
become contaminated with
foreign material.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Conveyors
general
Picture 3.5.9.3.4
All conveying systems must
be constructed to permit
easy cleaning - not only of
conveying surfaces but also
under and side supports.
Pest prevention must be
considered.
Enclosed conveying
systems can accumulate
residues and become a
breeding ground for pests.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Conveyors
general
Picture 3.5.9.3.5
easy cleaning - especially
of under and side supports.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Conveyors
general
Picture 3.5.9.3.6
General principles of
equipment design and
installation apply - (e.g.)
the screw must be
removable for cleaning. If
this is not the case in an
existing model an
adaptation can be made
with a hinged door to allow
access to the screw for dry
cleaning.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Conveyors
general
Picture 3.5.9.3.7
easy cleaning - especially
of under and side supports.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Conveyors
general
Picture 3.5.9.3.8
Note: Conveyor frames
must not be channel in
shape. Where possible
supports for the belt must
have minimal contact with
the belt as in this example.
The supports become less
coated with residues and
cleaning is easier.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Conveyors
general
Picture 3.5.9.3.9
Where possible supports
for the belt must have
minimal contact with the
belt.
Note: In this example this
support has become coated
with residues and cleaning
is difficult.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Conveyors
general
Picture 3.5.9.3.10
Conveying systems passing
from lower to higher
hygiene areas must not
form a bridge that could
permit cross contamination
and also entry of pests.
Note: The opening must be
minimised - as in this
example.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
Conveyors
general
Picture 3.5.9.3.11
Open mesh type found in (e.
g.) frozen food factories.
Note: Conveyor frames
must not be channel in
shape. Where possible
the belt as in this example.
The supports become less
coated with residues and
cleaning is easier.
Pictures: 1 2 3 4 5 6 7 8 9 10 11
this GI
2.3.9
Barriers
2.3.3.1 Types and Uses
External reference material CCFRA 3rd Reprint '86

Hygienic Design of Food Processing Equipment
Chapter 3
08 Aug. 2008 13:34:00
Hygiene Considerations related to conveyor type

Section 3.5.9.4
Belt conveyors - flat (band or metal latticed grid):
belt must be made of a material that is compatible with the item being transported
the surface should be smooth and non-absorbing
joints in belts should be carefully made
if ridges are added to the flat band to raise items, embedded support wires must be made of
stainless steel.
roller conveyors are almost impossible to clean - unless they are in a manual system and
can be removed from their supports.
if buckets are in an enclosed system, the covers must be easy to remove for cleaning and
inspection
buckets should be removable for cleaning
Screw conveyors:
for screw conveyors, general principles of equipment design and installation apply:
the screw must be removable for cleaning
wavy shaped edges are very difficult to clean - and should be employed only when
absolutely necessary
Bucket elevators or lifts:
elevating elements must be designed to cause minimum of risks for hygiene
Roller conveyors:
conveyor supports are critical - contact between rolling supports and band must be
minimised.
Belt conveyors for elevating:
conveyor frames or belt guides must not be channel in shape - to avoid residue collecting
points.
there should be no dead in the shaft area - where product can accumulate and where
cleaning is impossible.
Pneumatic conveyors:
properly designed pneumatic conveying system will be virtually self cleaning.
the most important point for hygienic design is the quality of the transport medium (eg.air).
Conveyors
related to conveyor type
Picture 3.5.9.4.1
cleanable - the conveyor is
manually operated and the
rollers can be removed
from the support for
cleaning. At the same time
the frame can be cleaned.
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Conveyors
Picture 3.5.9.4.2
Note: This type of conveyor
system is not easy to clean
- but the design in this
example is quite open and
buckets are removable for
cleaning.
Pictures: 1 2 3 4 5 6 7 8
Conveyors
Picture 3.5.9.4.3
Note: This example is a
compromise - the support
for the metallic conveyor
band is shielded within the
bend making cleaning
difficult. However this
design is technically
important for the band to
function and in this case
meticulous attention to
cleaning is important.
Pictures: 1 2 3 4 5 6 7 8
Conveyors
Picture 3.5.9.4.4
Note: This example is fitted
with plates specifically for
ice cream transport into
the freezer. Being directly
in contact with food their
design is critical - plates
should be removable for
cleaning and disinfection.
Pictures: 1 2 3 4 5 6 7 8
Conveyors
Picture 3.5.9.4.5
Note: If ridges are added to
the flat band to raise items
- embedded support wires
must be made of stainless
steel. In this example the
support wires are made of
iron and corroded pieces
would contaminate product.
Pictures: 1 2 3 4 5 6 7 8
Conveyors
Picture 3.5.9.4.6
Note: Where possible
the belt - not as in this
example. This support has
become coated with
residues and cleaning is
difficult. Also the conveyor
is installed so close to the
wall that cleaning becomes
very difficult.
Pictures: 1 2 3 4 5 6 7 8
Conveyors
Picture 3.5.9.4.7
Note: Wavy shaped edges
are very difficult to clean and also have a tendency
to become used very
quickly. It is probable that
some of these pieces ended
up as foreign material! If
there is no alternative inspection after cleaning
for a used belt needing to
be changed is essential.
Pictures: 1 2 3 4 5 6 7 8
Conveyors
Picture 3.5.9.4.8
Note: Note: Conveyors like
this example are rare - but
are found especially in
chilled meat factories. They
are difficult to clean and
alternatives with a better
and smoother design
should always be preferred.
Pictures: 1 2 3 4 5 6 7 8
this GI
3.3.6
Forced ventilation for process equipment
Chapter 3
08 Aug. 2008 13:34:00
TIPPING RAW
MATERIALS

Section 3.6.1.3
General considerations:
Being a dusty operation - all parts of the tipping equipment must be easy to clean.
In particular there must be no points where residues could accumulate - and become breeding
areas for insects.
For periods of non-use - the tipping station to receiving hopper should have a well fitting lid - to
prevent entry of dirt, particles of paper/plastic or insects.
Extraction hoods should be cleanable to avoid fall-back on product.
Inside the tipping station - there will be a sieve to retain large particles and foreign material.
This sieve should be removable for cleaning.
If the equipment layout includes a pit - it should be cleanable and not become damp or an entry
point for bad odours and insects.
Considerations for products of most concern - high hygiene:

For example: tipping station for ingredients for dry mix for an instant product with sensitive
consumers:
Wooden and dirty pallets carrying bags - should be brought to the stripping area - but must
never cross the barrier to the high hygiene zone.
A surface must be provided - on which to clean each bag - by brushing and/or vacuum cleaning
before stripping.
Lay out of the bag dumping station - should allow for transfer of stripped bags - without risk of
their contamination:
either to a clean pallet - which will be transported to the tipping station
or to the belt conveyor - which transports the bag directly to the tipping station.
A split conveyor is critical with the belt conveyor system to stop transfer of any dirt to the high
hygiene side. The dirty conveyor must not pass through the entry hatch.
Entry for personnel to the high hygiene area is via an air-lock with shoechange.
If the design requires the tipping equipment to discharge into installations in a pit - it is
important to ensure that the pit can be cleaned - noting particularly the risk of water seepage
into the pit (due to waterbed levels).
Considerations for products of average concern - medium hygiene, consumed without

preparation:
For example: tipping station for ingredients for (eg.) chocolate manufacture or for toppings for ice
cream.
The equipment and its lay-out (or the method of transfer of the material to the tipping point at
the line) should allow for:
either transfer of bags or ingredient containers to hygienic pallets

or a distance to be created between the original wooden pallet and the tipping point to avoid
contamination.
Outer bags maybe cleaned - but equipment arrangements for stripping may not be necessary depending on HACCP and local situation (eg. bag and container quality).
Tipping equipment should allow operators to inspect outer containers to prevent any extraneous
material falling into the material receiver during tipping.
Considerations for products of less concern - medium hygiene products - consumed after
cooking and low hygiene processes:
No zoning is required.
The layout of equipment must permit transfer and emptying of containers - avoiding
contamination (eg. from wooden pallets) by foreign material.
Design must provide for respect of minimal NGMP's - see above - 'General considerations'.
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Tipping raw materials/

ingredients/semi-finished
products for dry mix
Picture 3.6.1.3.1
For periods of non-use - the
tipping station to receiving
hopper should have a well
fitting lid - to prevent entry of
dirt particles and/or insects.
Note:
In this example the fixed slide/
support for opening the sack
prevents the lid being closed.
Note also that the conveyor is
boxed-in and will collect
residues and be difficult to
clean.

this GI
2.3.3
Barriers
2.3.3.1 Types and Uses
2.3
Zoning and barriers
2.3.2
Zoning Details
Chapter 3
13 Aug. 2008 08:38:00
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Nestle Hygienic Engineering

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barrier against infiltrations

good construction and protection at expansion joints or building connections - to prevent

either be equipped with an area to afford shoe changing and/or cleaning

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not provide harbourage for pests

be accessible for maintenance - without risk for interior

high/medium hygiene areas

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false ceilings - utilized for architectural reasons (eg.) to:

house lighting elements

reduce ceiling height

or for noise abatement.

will have no (or minimal) attachments for dust collection

also allow maintenance without influencing process

Design must include:

structure for a point load of 150kg for personnel traffic.

equipment and ducting suspended separately

should have a smooth

Note: Internal expansion

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solid doors doors with

Note: Door fitting tightly in

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Hygiene Considerations Windows

WINDOWS & LOUVERS

Nestl Good Hygienic Engineering

Window frames should be made from solid materials.

Windows and louvers

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Hygiene Considerations Windows

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Hygiene Considerations Windows

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Hygiene Considerations Windows

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Hygiene Considerations Windows

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Hygiene Considerations Windows

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Hygiene Considerations Louvers

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Hygiene Considerations Louvers

Windows and louvers

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