“Dairy” tile or pavers should be consid-
ered for areas with heavy traffic and those
that come in contact with product or clean-
ing solutions. This material, when properly
installed with acid resistant bonds, is very
durable and has minimal sanitary problems.
It is cleaned easily and can be manufactured
with a non-slip finish. It is an expensive
option but can be the most economical.
Floors in specialized areas, such as coolers
and freezers, must be constructed with
appropriate materials designed for their
intended uses and be properly insulated and
ventilated. An uninsulated freezer floor will
eventually permit the ground beneath to
freeze deep and hard enough to cause crack-
ing or buckling of the freezer floors, with
resultant jamming of the doors.
Ventilation and Dust Control
Dust control is very important.
Although organisms from unprocessed
low-moisture materials are usually harm-
less, they have been found to contain Sal-
monella, pathogenic mold spores, and other
undesirable organisms. The manufacturing
process, by heating the product above the
pasteurization temperature, usually kills
vegetative organisms, but spores may sur-
vive in the interior, especially in relatively
soft, high-moisture baked foods. Further-
more, finished food can become contami-
nated from raw material dust within the
plant, especially in coolers and packaging
equipment.
To maintain acceptability, facilities must
be designed so that finished foods are not
contaminated. This requires a superb sani-
tation design and follow-through proce-
dures, proper equipment arrangement, and
proper ventilation and dust control. The
proper selection of temperature/humidity
controls will minimize the opportunity for
bacterial growth.
Equipment Considerations
Equipment features that will enhance pro-
ductivity include separating heating and
cooling equipment from the process areas by
using a mechanical mezzanine, high-effi-
ciency motors and electrical equipment (see
Figure 15–1), the latest technology in con-
trols and automation to the maximum
degree that is cost-effective, and flexible
modular design for responding to changing
markets and business demands. Further-
more, all equipment should meet the latest
requirements from regulatory or advisory
agencies.Sanitary Considerations
Because an operation such as bread mak-
ing is a fermentation process, it is necessary
for facilities such as bakeries to be easily
maintained in a sanitary condition. Natu-
rally occurring organisms must be prevented
from fermenting the dough in competition
with the desired yeast inoculum. An ineffec-
tive sanitary facilities design can result in the
growth of wild microbial strains such as
Bacillus subtilisormesentericus“rope” form-
ers, which can degrade product acceptability.
Once established in the facility, these organ-
isms are very difficult to remove totally and
to control.
Sanitation features that are integrated
into plant design were given increased
emphasis by the FDA's promulgation of
Good Manufacturing Practices (GMPs).
For low-moisture food products, current
(CGMPs) as they relate to the design and
construction should:- Provide adequate space for equipment
installation and storage of materials. - Provide separation of operations that
might contaminate food. - Provide adequate lighting.
- Provide adequate ventilation.
- Provide protection against pests.
Low-Moisture Food Manufacturing and Storage Sanitation 271