Food must be prepared in a manner that ensure safety. Hence, design is important in warding off potential hazards. Foods that are not prepared in facilities with the appropriate design to prevent hazards are deemed by the FDA as adulterated, regardless of the quality of the food. As a former food plant inspector, I have had many opportunities to visit facilities to inspect them for compliance with local and federal laws. For me, an inspection of a food facility begins as I drive up to the location. I observe to confirm that the facility is located in an area that is free from sources of contamination such as garbage, sewage and animal traffic. As I enter the premises the question on my mind is, how secure is it? How easy is it for unauthorized individuals to gain access? Is it secure enough to prevent and control movement of personnel and vehicles in and out of the facility? This is an important question, considering the threat of bioterrorism.
A quick look around the yard tells me if the operators care about food safety. Is it clean and well groomed? Is there evidence of junk or uncovered garbage that may harbor pests? Is the lawn kept low? Are paving’s well swept? Are shrubs and trees cut away from the building? A quick walk around the building can give me some more information. Are the windows closed or if opened, are they fitted with meshed screens to block pest entry? Are there holes in the outside walls of the building? Holes in walls where pipes enter and exit the building can be a big source of pest contamination. One general rule is that if the hole is big enough to allow a pencil to go through, then a mouse can get in; not to mention a host of other smaller pests. Holes should be backfilled and finished with concrete or covered with echelon plates. Temporary fixes can include stuffing the holes with steel wool or copper meshing.
A look at the design of the external doors will tell me if there are additional entry points for pests. Are the gaps between the base of the doors and the floor wide enough to allow rodents and insects? Door brushes can be installed to provide good barrier. Plastic curtains and air curtains are also helpful in keeping pests out, especially flying insects. Some operators install automatic door closures to ensure that doors are not inadvertently left open. This is a good strategy. Fly traps and UV bug zappers may be used to capture flies that escape doors, but they should be positioned in a manner that will not contaminate foods being prepared or processed.
OK, I now enter the plant and my head is bobbing up and down. First the floors. Are floors showing signs of cracks and erosion? Can I see puddles of water? This problem points to poor design or maintenance. Floors should be cleanable and free from cracks. To prevent water-pools, the flooring should be sloped 1-2% towards the drain. For endurance, they should be resistant to high temperature, acid, heavy traffic, and impact. Where the floors meet the walls, the intersections should be coved to prevent dead spots that are hard to clean.
I am interested to see that the walls are smooth, impervious and cleanable. Also, I check that there is sufficient clearance between equipment and walls and equipment and flooring to allow adequate cleaning. As I continue to survey the production area, I need to see that no doors open to the outside, to toilets or to locker rooms. Hand washing stations must be available in strategic locations in the production area based on employee traffic pattern. These should be accompanied by appropriate signage. Wash stations should preferably be of a hands-free design.
A scan of the equipment should indicate to me that they are of a type and design that will facilitate thorough and easy cleaning. Hence, they should be nontoxic, impervious, and durable under the desired range of treatment conditions that they are subjected to. Stainless steel will have these characteristics. The use of board is discouraged because of its porous nature which makes it difficult to clean. Glass is also problematic due to breakage problems. Cadmium, mercury and lead should be avoided due to their toxic nature.
I am not done yet. I inspect the roof for indications of dust, cobwebs and signs of overhead condensation that may fall into food. Also, I want to see that the lighting fixtures on the ceiling are covered with shatter-proof covers to control glass if breakage occurs. The illumination coming from the lighting should be adequate for efficient and safe working conditions. Before I leave the production area, I also check to verify that a strategy for controlling employee traffic can be observed. For example, color-coding of floors, color-coding of uniforms and protective equipment, and appropriate signage to identify high-risk areas.
Generally, the last places I visit are the toilets, locker areas, and designated eating facilities. These areas should be adequate for the number of employees and should be kept in a clean and hygienic condition. I do not want to see any garbage, filth, eating or handling of tobacco in any of these areas.
Overall what I am trying to figure out during my inspection is whether the facility is designed to prevent food contamination and maintain the safety of the food they produce. Without proper design, the food establishment cannot support a HACCP plan. Watch the following video to get more ideas on facility design.
