Meat Industry Guide (MIG) Part 2 - Food Standards Agency

438 Pages·2014·4.39 MB·English

by  Food Standards Agency

PART TWO
1. DESIGN AND FACILITIES

Section Page

Contents 1

1.1 Why are design and facilities important? 2

1.2 General information 3

Approval of Premises, Standards, Technical advice

1.3 1 What are the legal requirements for design & facilities? 5

A. General rules for all food premises and foodstuffs 5

B. Rooms where food is handled 15

C. Equipment 21

D. General requirements for slaughterhouses 23

E. Red meat slaughterhouses: lairages and livestock transport 31

F. White meat slaughterhouses: reception and transport of animals 34

G. Facilities for on-farm slaughter of poultry & game 36

H. Meat cutting and production establishments 39

I. Edible co-product premises – see separate guidance 41

1.3.2 What are the official control requirements? 42

1.3.3 Applying procedures continuously and properly 43

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1.1 WHY ARE DESIGN AND FACILITIES IMPORTANT?

The location, design, layout and construction of food premises and the choice of fixtures, fittings and
equipment are crucial to ensure that food businesses can operate under hygienic conditions and
produce food safely. Poorly designed and constructed buildings and equipment are potential
source of physical, chemical and microbiological hazards. Such hazards could cause illness or
injury to consumers and so must be prevented or minimised.
For example:
▪ Food premises that are sited in inappropriate locations (e.g. one that is prone to flooding, or
adjacent to a business using toxic chemicals or producing a lot of dust) could increase the
likelihood of food becoming contaminated.
▪ Badly designed buildings and equipment could create ‘dirt traps’ and make future cleaning and
maintenance difficult, if not impossible, and thus become a source of microbiological
contamination.
▪ Poorly constructed buildings and equipment might allow pest entry. Contamination could also
be caused by water leaks, condensation or poor drainage.
▪ The use of inappropriate construction materials might result in surfaces that could not be kept
clean, or which deteriorate and shed dirt, dust and other particles onto food.
▪ Poor layout (e.g. inadequate separation between ‘clean’ and ‘dirty’ areas or inappropriate flow
lines for food in relation to waste, people etc.) would increase the chances of microbiological
cross contamination of food products by food poisoning bacteria, such as Salmonella.
▪ Insufficient space for the operations being carried out or for the quantity of animals/food being
handled would produce cramped conditions where cross contamination would be likely.
▪ Lack of adequate hygiene facilities, such as toilets and hand-washing basins, would prevent
staff from following personal hygiene procedures and could lead to product contamination.
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1.2 GENERAL INFORMATION
• Approval of Establishments
All operating meat plants require approval under the hygiene regulations unless specifically
exempt. See PART ONE Chapter 7 (Approvals) for further information about exemptions and
approval procedures. Operations may need to be discontinued or special arrangements made
to protect food from possible contamination if building work is to be carried out while premises
are operating.
• Construction Standards
The siting, design, layout, and construction of premises and of equipment used in the
production and storage of food products needs to meet certain standards to achieve food
safety. Similar food safety standards apply to the exterior of the premises, animal handling
areas, refuse stores, staff changing facilities, wrapping and packaging stores etc.
• Technical advice
Technical advice on the design and construction of new food premises or the rebuilding,
refurbishment and alteration of existing premises should be obtained from suitably qualified and
competent professionals. Such work may require consent from the relevant environmental and
planning authorities. Food Standards Agency officials cannot give advice on technical matters
but can advise on the legal food safety and hygiene requirements to be met.
When employing professional advisers or contractors for building work or the installation of
equipment, fixtures and fittings, it is advisable to use businesses or individuals that understand
the operational and hygiene requirements of food establishments. They also need knowledge
of other legislation (e.g. animal welfare, health and safety) and building regulations that will
influence the design, layout and facilities. Inexperienced contractors may carry out work that is
sub-standard or does not meet the requirements, which then has to be remedied or upgraded
at considerable expense.
As well as specialist companies, there are many sources of information and guidance available,
including:
 Meat Plant Design Manuals: Manuals to assist those involved in the construction
and modification of slaughterhouses, cutting plants and processing plants giving
technical information on materials, design points, layout etc. Contact the ML Services Ltd,
Stoneleigh Park, Kenilworth, Warwickshire, CV8. Tel: [phone]
(http://www.mlcsl.co.uk/mlcsl/publications.asp)
 Slaughterhouse Manual: ISBN 978-1-0-4437-28-4
 Cutting Plants Manual: ISBN 978-1-904437-29-1
 Processing Plants Manual: ISBN 978-1-904437-30-7
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 Meat Hygiene 10th edition (1999) (ISBN 0 7020 2258 6) by J F Gracey, D S Collins, R J
Huey published by W B Saunders Company Ltd.
 Livestock Handling and Transport (ISBN 0 85199 409 1) edited by Temple Grandin,
published by CAB Wallingford, Oxon OX10 8DE, Tel: [phone] Fax: [phone]
829292 E-mail: [email protected] International
 Guidance on slaughter facilities and equipment
Humane Slaughter Association, The Old School, Brewhouse Hill, Wheathampstead, Herts, AL4
8AN UK, Tel: [phone] Fax: [phone] (http://www.hsa/org.uk/)
 Machinery
The European Hygienic Equipment Design Group (EHEDG) is a consortium of equipment
manufacturers, food industries, research institutes and public health authorities founded in 1989
which promotes hygiene during the processing and packing of food products. It produces
guidelines to help industry comply with European Commission (EC) legislation for hygienic
machinery. (www.ehedg.org)

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OPERATOR’S OBLIGATIONS ADVICE

1.3.1 WHAT ARE THE LEGAL REQUIREMENTS FOR DESIGN & FACILITIES?
The following sections set out the design and facilities requirements of the regulations that apply to
slaughter, dressing and further processing of meat.

A. GENERAL RULES FOR ALL FOOD PREMISES & FOODSTUFFS
A1. The layout, design, construction, siting and size of food premises are to:
a) Permit adequate maintenance, cleaning and/or disinfection, avoid or minimise air­
borne contamination, and provide adequate working space to allow for the hygienic
performance of all operations;
b) be such as to protect against the accumulation of dirt, contact with toxic materials,
the shedding of particles into food and the formation of condensation or
undesirable mould on surfaces;
c) permit good food hygiene practices, including protection against contamination
and, in particular, pest control;
852/2004 Annex II Food Premises: Chapter I points 2a-c
A2. At all stages of production, processing and distribution, food is to be protected against
any contamination likely to render the food unfit for human consumption, injurious to
health or contaminated in such a way that it would be unreasonable to expect it to be
consumed in that state.
A3. Adequate procedures are to be in place to control pests. Adequate procedures are also
to be in place to prevent domestic animals from having access to places where food is
prepared, handled or stored (or, where the competent authority so permits in special
cases, to prevent such access from resulting in contamination).
A4. … Food businesses manufacturing, handling and wrapping processed foodstuffs are
to have suitable rooms; large enough for the separate storage of raw materials from
processed material and sufficient separate refrigerated storage.
A5. Hazardous and/or inedible substances, including animal feed, are to be stored in
separate and secure containers.
852/2004 Annex II Foodstuffs: Chapter IX points 3, 4, 5 & 8
A6. Adequate provision is to be made for the storage and disposal of food waste, non-
edible by-products and other refuse. Refuse stores are to be designed and managed in
such a way as to enable them to be kept clean and, where necessary, free of animals
and pests.
852/2004 Annex II Food Waste: Chapter VI point 3
A7. Wrapping materials are to be stored in such a manner that they are not exposed to a
risk of contamination.
A8. Wrapping and packaging operations are to be carried out so as to avoid contamination
of the products.
852/2004 Annex II Wrapping & packaging: Chapter X points 2 & 3
Siting/Location
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OPERATOR’S OBLIGATIONS ADVICE

• Site food premises in For new premises, consider factors such as:
locations that avoid or ▪ Suitability of the ground for building;
minimise potential threats to ▪ Availability of services, especially power, drainage and
food safety. potable water - see Chapter 2 (Water Supply),
A1a-c ▪ Access/exit routes for vehicles delivering livestock or raw
materials or transporting product and for staff transport;
▪ Need to dispose of animal by products,
▪ Proximity to residential areas,
▪ Prevailing wind.
Avoid locations close to, for example:
▪ Environmentally polluted areas,
▪ Industrial activities that might present a risk of
contamination (e.g. chemical production),
▪ Areas prone to flooding.
Site Plan – Retain a copy of the site plan(s) provided when
applying for approval of the meat establishment. Alterations
may be such as to require further approval and submission of
revised plans incorporating the changes. See PART ONE
Chapter 7 (Approvals).
Operational Space & Contamination
Design, lay out and construct Avoid carrying out too many activities in one area or trying to
food premises so that: handle too great a quantity of animals/food for the available
space and facilities. Cramped conditions will compromise the
 there is sufficient space to
ability to carry out good hygienic practices and increase the
allow good food hygiene
risk of spreading contamination between carcases, people
practices to be followed in all
and surfaces and/or the environment.
operations, and adequate
maintenance, cleaning and/or
disinfection to be carried out
Cleaning, disinfection, maintenance and pest control –
A1a
the requirements for these hygiene practices are set out in
 operations are protected at all other chapters – see Chapter 3 (Maintenance), Chapter 4
(Cleaning) and Chapter 5 (Pest Control).
stages of food production,
processing, wrapping and
packaging, storage and
Condensation / ventilation - see A12 below.
distribution, from
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contamination , particularly

from airborne dirt and dust,
In designing new or altering existing premises, consider
rain, accumulation of dirt,
factors such as:
contact with toxic materials,
▪ Expected daily throughput of animals (of each species);
shedding of particles (e.g.
carcases, meat and products and possible future
paint, rust) formation of
expansion.
condensation or mould, and
▪ Need for sufficient space for hygienic processing and
pests.
disposal of waste.
A1c, A1d, A2, A3, A6, A7, A8, B1, C1a
▪ Facilities for inspecting and keeping animals.
 the food premises and, in ▪ Chapter 9 (Acceptance & Slaughter of Animals).
particular, the floors, walls, ▪ Provision of adequate number of processing and
ceilings, windows and other storage rooms.
openings, doors and surfaces ▪ Provision for staff facilities.
in rooms where foodstuffs are ▪ The turning circles of transport vehicles.
handled, and equipment, are

capable of being cleaned,
Separation - good hygienic practice requires that all
disinfected and maintained in
operations are organised to minimise the opportunity for
sound condition.
contamination to be introduced or to spread. This normally
A1a, B1,
means ensuring that ‘clean’ and ‘dirty’ operations are carried
 domestic animals are out in separate rooms, or separate areas if adequate
prevented from having access arrangements are made to avoid contamination. In premises
to places where food is where throughput is low, separation of operations in time
prepared, handled or stored rather than space may be possible with interim cleaning and
or, if allowed by the disinfection. See also Section D below, and Chapters 9
competent authority, to (Acceptance & Slaughter of Animals) and 14 (Wrapping,
prevent such access from packaging and transport hygiene).
resulting in contamination.

A3
Loading and unloading operations – prevent
 there are suitable rooms for
contamination of meat from, for example, diesel fumes, dust,
separate storage of raw
flies, birds, leaves, poor weather conditions, during loading
materials from processed
and unloading between premises and vehicles. This is best
foodstuffs.
achieved by using a vehicle docking system or, where this is
A4
not possible (e.g. for planning reasons), a canopy or awning
may be sufficient. In limited situations (e.g. because
 there is space for separate
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OPERATOR’S OBLIGATIONS ADVICE

and secure storage of vehicles have to be loaded/unloaded on the street) it will be
containers for hazardous necessary for the operator to set out satisfactory procedures
and/or inedible substances for protecting exposed meat from contamination.
and adequate provision for

storage and disposal of food
Access/Security - Secure the perimeter of the site so that
waste, non edible by products
access can be controlled. See also Chapter 5 (Pest Control)
and other refuse.
A5, A6
 there is space for storage of
wrapping materials so that
they are not exposed to a risk
of contamination.
A7

A9. And, where necessary, provide suitable temperature-controlled handling and storage
conditions of sufficient capacity for maintaining foodstuffs at appropriate temperatures
and designed to allow those temperatures to be monitored and, where necessary,
recorded.
852/2004 Annex II Food Premises: Chapter I point 2d
A4. Raw material, ingredients, intermediate products and finished products likely to support
the reproduction of pathogenic micro-organisms or the formation of toxins are not to be
kept at temperatures that might result in a risk to health.
Food businesses manufacturing, handling and wrapping processed foodstuffs are to
have suitable rooms; large enough for the separate storage of raw materials from
processed material and sufficient separate refrigerated storage.
852/2004 Annex II Foodstuffs: Chapter IX point 5
Temperature Control
• Provide enough storage Make sure that storage facilities are capable of maintaining
capacity for keeping meat at the mandatory temperature requirements for meat. See
appropriate temperatures. Chapter 8 (Temperature Controls).
A9
Particular consideration should be given to how to meet the
requirements in periods of high throughput or high ambient
• If manufacturing, handling or
temperatures.
wrapping processed
foodstuffs provide sufficient Free-standing chilled storage - if used to store chilled meat,
separate refrigerated storage free-standing ‘reefers’ must provide an acceptable level of
for raw materials and protection and temperature control that meets legal
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processed materials. requirements. Particular attention must be paid to the:
A4 ▪ Nature, condition and cleanliness of interior surfaces
▪ Maintenance of temperatures
▪ Temperature monitoring and recording
▪ Protection from contamination during loading and
unloading.
Such facilities are rarely appropriate for chilling meat.

A10. An adequate number of flush lavatories are to be available and connected to an
effective drainage system. Lavatories are not to open directly into rooms in which
food is handled.
852/2004 Annex II Food Premises: Chapter I point 3
Toilets
Make sure that: The number of flush toilets required is regulated by the
Workplace (Health Safety and Welfare) Regulations 1992 in
 there are sufficient flush
GB and the Workplace (Health Safety and Welfare)
toilets for the number of
Regulations (Northern Ireland) 1993 in NI.
employees are available.
A10 Toilets must not open directly into a food room. Preferably,
they should be in the same or a connected building as the
 toilets do not open directly
food operation. Exceptionally, where staff numbers are very
into food-handling areas.
small and the premise is next door to a house with access
A10
throughout working hours, the house toilet may be sufficient.
 toilets are connected to a
Allow space near the toilets so that staff can remove and hang
mains sewerage system or
up their protective clothing before using the toilet.
septic tank.

A10

A11. An adequate number of washbasins is to be available, suitably located and
designated for cleaning hands. Washbasins for cleaning hands are to be provided
with hot and cold running water, materials for cleaning hands and for hygienic drying.
Where necessary, the facilities for washing food are to be separate from the hand-
washing facility.
852/2004 Annex II Food Premises: Chapter I point 4
Hand Washing Basins
Make sure that: The number of washbasins required to maintain good
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hygiene depends on the number of staff and on the nature
 there are enough designated
and location of the operations being carried out.
hand washbasins for the
number of employees at Position – hand washbasins should be placed conveniently
suitable locations. close to toilets, entry points for food-handling areas and
workstations, to encourage staff to wash their hands after
 hand washbasins are supplied
visiting the toilet, before entry into food handling areas and
with hot and cold running
during food handling activities.
water.
Water Supply - hot and cold water can be supplied through
 hand washbasins have
separate taps, but a mixed supply is preferable. Water
supplies of soap or detergent,
should be at a suitable and comfortable temperature so that
and hand drying facilities.
staff are not discouraged from using the facilities provided.
 hand washing facilities are
Soap/hand drying etc. – see Chapter 7 (Personal Hygiene).
separate from food washing
facilities. Food Washing Facilities – separate basins are required for
A11 hand and for food washing - see B3 below.

A12. There is to be suitable and sufficient means of natural or mechanical ventilation.
Mechanical airflow from a contaminated area to a clean area is to be avoided.
Ventilation systems are to be so constructed as to enable filters and other parts
requiring cleaning or replacement to be readily accessible.
A13. Sanitary conveniences are to have adequate natural or mechanical ventilation.
852/2004 Annex II Food Premises: Chapter I points 5 and 6
Ventilation
Make sure that: Adequate ventilation is important to minimise the build up of
heat and/or humidity that may compromise the safety of food.
 there is enough ventilation to
It helps prevent the development of drops of water that may
avoid or minimise air-borne
contaminate food.
contamination, and to protect
against the formation of
condensation or undesirable
The ventilation system may be natural or mechanical.
mould on surfaces.
Natural ventilation by opening windows (fitted with fly
A12, A1a, A1b
screens) is unlikely to be sufficient except in very small
 where screens or filters are premises.
fitted to ventilation systems,
Mechanical ventilation systems may be simple wall or window
they are placed and fitted so
mounted fans, steam extractors, or more sophisticated
that they can easily be
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