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11.Specific Processing Facilities

• Scope
• 11.1Outcome
• 11.2General Principles
  • 11.2.1
  • 11.2.2Good manufacturing practice
  • 11.2.3Cross contamination
  • 11.2.4Physical separation
    • 11.2.4.1
    • 11.2.4.2
    • 11.2.4.3
  • 11.2.5Process room atmosphere
• 11.3Thermal Processing and Ready-To-Eat Products
  • 11.3.1
  • 11.3.2
  • 11.3.3
  • 11.3.4Commercial sterilisation
    • 11.3.4.1
    • 11.3.4.2
    • 11.3.4.3
    • 11.3.4.4
    • 11.3.4.5
    • 11.3.4.6
• 11.4Dry and Protected Food
• 11.5Bakery Product Processing
  • 11.5.1
  • 11.5.2
  • 11.5.3
• 11.6Smoking
  • 11.6.1
  • 11.6.2
• 11.7Boning and Cutting
  • 11.7.1
  • 11.7.2Suspension and transfer of carcasses
  • 11.7.3Pre-trim areas
    • 11.7.3.1
    • 11.7.3.2
    • 11.7.3.3
  • 11.7.4Waste removal
  • 11.7.5Non-food contact surfaces
  • 11.7.6Packaging materials
• 11.8Casings and Green Offals
  • 11.8.1Emptying and cleaning
    • 11.8.1.1
    • 11.8.1.2
  • 11.8.2Refining of clean offals
  • 11.8.3Processing of clean casings
  • 11.8.4Processing of clean or refined clean offals
  • 11.8.5Storage of clean casings casks
• 11.9Deer Antler, Pizzles, Tails and Sinews
  • 11.9.1
    • 11.9.1.1
    • 11.9.1.2
  • 11.9.2

11.Specific Processing Facilities

Scope

This section outlines the requirements for facilities used for specific food processing and preservation operations within any of the following categories of premises:

AB, ME, PH, PPH, APH.

11.1Outcome

Processing facilities shall be designed and constructed to facilitate hygienic food processing and prevent post-process contamination.

Processing facilities shall be designed in such a way that operations which might give rise to cross contamination are separated physically or by time. Other effective means may be considered by the CMVO. Wherever possible, facilities should be designed so that the principle of one-way-flow of food can be implemented.

11.2General Principles

11.2.1

Specific processing facilities identified within this section shall be designed and constructed to meet the specific requirements outlined in this section in addition to the applicable requirements of other sections in IS 2.

11.2.2Good manufacturing practice

Hygienic food processing is ultimately effected through good manufacturing practice so as to ensure the finished food is safe and suitable for the intended purpose.

The design and construction of processing facilities shall be suitable for the intended operations of the premises and shall ensure compliance with the operational requirements of the applicable processing and sanitation and hygiene procedures. Refer also to Manual 6: Processing of Edible Product and Manual 3: Sanitation and Hygiene.

11.2.3Cross contamination

The design of premises shall prevent cross contamination from raw to finished food areas. Where there is potential for cross contamination, finished food shall not enter raw food preparation areas and the movement of personnel shall be controlled so that they do not go directly from a raw material area into a finished exposed food area.

The entry of personnel to finished food areas should not be possible except through facilities which provide for clean protective clothing, hand washing and either a change of footwear or going through a sanitising foot bath.

11.2.4Physical separation

Physical separation shall be provided between the following functions:

11.2.4.1	handling of unclean and clean raw food where there is a potential for cross contamination;
11.2.4.2	handling of raw and cooked or ready-to-eat food;
11.2.4.3	processing of wet and dry food.

The following examples indicate several means for separation of process functions: Unclean raw food handling: Raw unprocessed vegetables that require washing and peeling prior to incorporation into the product mix are stored and washed and peeled in a physically separate facility from the preparation of raw meat or other vegetables suitable for direct incorporation in to the product mix. Clean raw food handling: Mincing, cutting and the preparation of raw meat are performed in a physically separate temperature-controlled facility. Mincing of raw meat is conducted within the same facility as a cooking operation where the facility is not temperature-controlled and the mincing is a single brief operation conducted on an "as required for cooking" basis. The raw meat would otherwise be stored in a suitable temperature-controlled store and only brought into the cook facility as required in production. Thermal processing: Cooking of product is conducted in a physically separate dedicated facility according to the specific product requirements. Product is cooked in the same facility as the cooked product handling operations. Raw prepared food is transferred to this facility for immediate cooking and subsequent handling operations of the cooked product are not jeopardised by the cooking operation.

11.2.5Process room atmosphere

Process rooms shall be designed and constructed to maintain process room atmospheres in accordance with the requirements of Manual 3.

11.3Thermal Processing and Ready-To-Eat Products

11.3.1	A specifically designated location shall be provided for personnel handling cooked or ready-to-eat food to hang or place their protective clothing before leaving the area. The use of disposable protective coverings is an acceptable alternative.
11.3.2	Separate facilities shall be provided for the storage of unprotected, raw and cooked or ready-to-eat food.
11.3.3	Equipment used to heat food shall be designed to achieve the required temperatures as rapidly as necessary to achieve food safety objectives. Equipment shall be designed to allow temperatures to be monitored and controlled. Refer also to IS 2: Section 6.4.

11.3.4Commercial sterilisation

11.3.4.1	Retorting areas shall meet food area construction standards. Where the process itself will ensure that risk of post-process contamination to the product is minimised, alternatives may be approved.
11.3.4.2	Steam supply to the thermal processing system shall be adequate to ensure that sufficient pressure is maintained during thermal processing, regardless of any other demands for steam.
11.3.4.3	The areas or rooms used for mixing and cooking hot fill foods shall be physically separate from a room used for mixing cold fill foods.
11.3.4.4	Provision shall be made, where required, for the washing and sterilising of containers prior to filling, and protecting them against recontamination.
11.3.4.5	Retorts shall be located in a separately curbed and drained area or shall be directly ducted to the drainage system.
11.3.4.6	Suitable facilities shall be provided for container cooling and drying so as to minimise the potential for post-sterilisation contamination.

11.4Dry and Protected Food

Facilities designated as dry food areas shall be used exclusively for the processing, packing, storage and/or transport of dry foods or protected food.

Where practical, there should be no water or steam lines in dry food processing areas. If such lines are necessary, they shall be kept to a minimum and maintained in good repair so they do not leak or permit the formation of condensate. There should also be a ban on the use of water (for example, hose pipes, foot baths, drains, etc.).

11.5Bakery Product Processing

11.5.1

The cleaning programme will define the compatible functions of the production area.

Raw dough, pastry and bakery foods may contain water at a level that will exclude the area it is processed in from being defined as a dry processing area. However, the cleaning requirements may require a mix of dry and wet cleaning procedures, due to the nature of processing equipment and operations.

11.5.2	Facilities subject to both dry and wet cleaning shall be provided with drainage outlets where required, and be physically separate from other processing areas that may use full wet cleaning or full dry cleaning.
11.5.3	Raw meat preparation areas shall be physically separate from raw dough/pastry preparation areas.

11.6Smoking

11.6.1	Smoke cabinets or rooms shall be designed, constructed and operated so that smoke is contained within the facility and exhausted to the exterior.
11.6.2	Physically separate, dedicated facilities shall be provided for the storage of materials used to generate smoke and be located so that contamination of food is prevented.

11.7Boning and Cutting

11.7.1	The design and layout of the boning and cutting rooms shall ensure a smooth and orderly flow of product, packaging and personnel and facilitate inspection of operations.

11.7.2Suspension and transfer of carcasses

Unprotected carcasses sides and quarters shall be suspended and transferred by a means that will minimise contact with non-food contact surfaces. Refer also to Manual 3.

11.7.3Pre-trim areas

11.7.3.1	A dedicated pre-trim area shall be provided within the boning room, or in an area adjoining the boning room which is subject to the same temperature control. In the case of hot boning, a non-temperature controlled area is acceptable. Refer also to Manual 6.
11.7.3.2	Facilities shall be provided to contain and dispose of waste material.
11.7.3.3	Ready access to hand wash and steriliser units shall be provided in the pre-trim area.

Where necessary, stands for high and low trimming functions should be provided. They should be large enough to allow inspection personnel to monitor trimming.

11.7.4Waste removal

Provision shall be made for the removal of waste material (fat and bones) on a continuous or regular basis to a separate facility outside the boning room.

11.7.5Non-food contact surfaces

Facilities, or alternatively appropriate procedures, shall be in place for the handling of product that has come in contact with non-food contact surfaces. Refer also to Manual 3.

11.7.6Packaging materials

Facilities for holding packaging materials for immediate use during production in boning and cutting rooms shall be designed, constructed and located to facilitate the hygienic delivery of the materials.

11.8Casings and Green Offals

11.8.1Emptying and cleaning

Facilities that are physically separate from other food areas shall be provided asdedicated facilities for the following purposes:

11.8.1.1	separating, stripping or emptying and cleaning of intestines and green offals.
11.8.1.2	processing of green casings that have not been fully stripped and cleaned, and green offals that have not been cleaned (emptied only).
	Where these processing functions of green casings and green offals are conducted in the same facility, they shall be separated by distance.

11.8.2Refining of clean offals

Physically separate, dedicated facilities shall be provided for the refining of clean offals. Alternatively, refining may occur in the same room as cleaning where specialised processing machinery is used that fully encloses the product (e.g. tripes, including omasal tripes) and the finished refined product is discharged into a physically separate room.

11.8.3Processing of clean casings

Physically separate dedicated facilities shall be provided for any further processing (measuring, classing, salting, etc.), and packing of clean casings.

11.8.4Processing of clean or refined clean offals

Physically separate, dedicated facilities may be provided for any further processing (cooking, salting, drying, etc.), and packing of clean or refined clean offals. Alternatively, further processing and packing may occur in a food area separated by distance from other products of an equivalent status.

11.8.5Storage of clean casings casks

Facilities shall be provided for the storage of clean empty casings casks to minimise contamination prior to entering the food area for filling.

11.9Deer Antler, Pizzles, Tails and Sinews

11.9.1	Processing of deer antler, pizzles, tails or sinews shall be carried out either in:
11.9.1.1	physically separate, dedicated facilities; or
11.9.1.2	a food area separated by time from other processing.
11.9.2	Facilities dedicated to processing deer antler only are exempt from the requirements for room temperature control.