Facilities Design & Construction

Creating a Safe Food Environment

Our Goals

To provide information that can be used to ensure your facilities are safe for the preparation of food.

To help guide decisions for the design and construction of new operations; and renovation of existing foodservice operations.

Learning Objectives

To provide information about:

1. Construction and layout of facilities2. Walls & Ceilings3. Floors4. Stairs, catwalks and mezzanines5. Utilities - lighting, ventilation, plumbing,

water supply and sewage6. Food waste and garbage7. Hand washing stations8. Restroom facilities9. Janitorial facilities 10.Storage areas

Building Design & Construction

A foodservice building must be constructed and located to meet:

• Local building ordinances;• Public Health regulations;• Fire and safety regulations; and• Approved construction standards for

use in the area.

Building Location

• It is important that the site is free from any hazardous conditions.

• Conditions such as dust, foul odours, smoke, pest infestation and airborne hazards can lead to contamination.

• Foodservices should be away from offensive/hazardous industry such as waste disposal facilities.

Renovation

• If you plan on construction or alterations/renovations, be sure to consult the local regulatory authority.

• Many jurisdictions require plans for new construction, alterations and extensive remodeling to be approved by the local Health Department or regulatory agency.

Design

• The design and layout of facilities should provide a safe food environment in which work can be done effectively.

• Ensure the materials selected are easily cleaned and maintained.

• Facility materials must be resistant to excess moisture, temperature fluctuations and constant traffic flow.

Pest Control

• Eliminating pests from a facility can be difficult.

• Pests can spread disease, damage food, supplies and facilities.

• The building must be constructed in a way that helps prevent the entrance of pests such as insects and rodents.

Equipment

• Equipment location should allow for safe access during use.

• It should be designed and constructed to be durable under normal use and conditions.

• Must comply with international sanitation standards.

Facility Layout

• Facility layout should be designed in one direction following the flow of food.

• Non-food preparation areas (i.e. dishwashing area) should be reasonably separated from the food preparation areas.

Flow of Food

• The design should follow the flow of food in one direction.

Receive Store Prepare Serve

Flow Cont’d.

If you’re not currently following flow-of-food production, change food preparation to avoid cross contamination.

• Develop a diagram of the flow-of-food and identify areas of potential cross-contamination.

• Rearrange equipment and food preparation tasks to eliminate the potential cross-contamination.

Separate

• There should be an area for handling, storing, cleaning, and preparing raw food ingredients.

• This area should be separate from the cooked, ready-to-eat food display, handling, and serving areas.

Non-food Preparation Areas

• Non-food preparation areas or activities, such as cleaning supplies and chemical storage areas, should be separated from food preparation areas.

• All cleaning supplies and chemicals should be stored in a separate, locked, dry and well-lit area.

Walls & Ceilings

Wall and ceiling surfaces should be:– hard, – smooth, – non-absorbent, – light coloured materials, – which are easily cleaned.

• Such materials include tile, plaster, sealed brick and stainless steel.

• Ceilings should be white to reflect light.

Wall & Floor Joints

• All wall and floor joints should be tight and sealed or coved.

• Coving is a curved or sealed edge between the floor and wall.

• This prevents pests from entering and living in the facility; and

• Permits effective cleaning and sanitation.

Floors

Materials•smooth, •non -slip, •durable, •easily cleaned and normally •resistant to acids, alkalis, grease or organic matter•resist cracking, denting, heaving, or buckling from equipment weight or the action of mobile equipment.

Examples of flooring materials include quarry tile and terrazzo.

Floors

SlopeSloped floors reduce pooling liquids and help drain water used for cleaning.  The floor must be sloped a minimum of 2% to a drain.

If water pools, mop the area frequently to eliminate any standing water and minimize the growth of microorganisms.

Floors

Drains•must meet plumbing codes. •cross connections are not permitted• take immediate action if cross connections are discovered •must be located so they can be accessed and cleaned•must be cleaned on a regular basis to promote effective draining of liquids and eliminate flooding. •must be individually trapped and vented to the outside. Drains and drain lines can eliminate the accumulation of liquids. The separation of floor drains from sewage drains prevents the contamination of floor drains with human waste and other sewage.

Carpet

• Carpet is difficult to clean, absorbs water and can harbour bacteria, odours, dust and other contaminants.

• It should be laid over firm, sealed under flooring, and only where permitted.

• Carpet should only be used in the dining or public areas (excluding washrooms).

• It should be clean and not damaged.

Stairs, catwalks and mezzanines

• Should not be located over food preparation areas.

• They should be accessible and easily cleaned.

• They should be constructed of solid masonry or metal with raised edges to prevent contaminants from falling onto areas below.

Lighting

• Clean – so contaminants don’t fall into food;

• Shielded – so glass does not contaminate food;

• Bright – so food handlers can see what they are doing and to help see any dirt.

Ventilation

Hood – removes hot air and vapours including grease from the kitchen

Filters - designed to be easily cleaned or replaced regularly.

Exhaust - Filtered exhaust is vented to the outside.

Air Intake - Clean air is returned into the building.

Plumbing

The plumbing system is important to food safety.

Consider the plumbing system’s:

•Design;

•Installation;

•Backflow; and

•Maintenance.

Plumbing Design

All plumbing systems must be:• Made in accordance with local Plumbing

Code regulations; • installed and maintained in accordance

with local regulations; and • approved by the building authorities.

Plumbing lines should not be above food preparation areas or above food storage.

Overhead plumbing lines must never be exposed.

Plumbing Installation

• Installed and maintained by licensed plumbers

• Plumbing lines should be installed within permanent walls, ceilings, or floors.

• Clearly identify potable and non-potable water lines.

Back-flow

• The plumbing system must not permit back-flow; back-siphonage and cross-connections.

• ‘Air gaps’ and ‘vacuum breakers’ that prevent back-flow must be installed.

Plumbing Maintenance

• Plumbing system must be properly maintained (i.e. no drips or leakage).

• Pipes must be large enough to handle the required volume of water and sewage.

• Maintenance should be done by licensed plumbers.

Water & Steam

• Must be potable (safe to drink).

• From an approved source such as municipal water supply.

• Private water supplies such as wells must be tested by a government or accredited laboratory at least monthly and meet the Guidelines for Canadian Drinking Water Quality. (For your local requirements check with your Health Authority.)

• Water tanks or mobile water supplies must be held in sanitary containers approved by health authorities.

Water Capacity

• You must have hot and cold water:– In all areas food is prepared;– In all areas where equipment and utensils are

washed; and– At all hand wash stations.

• Meet peak demands (i.e. have enough hot water to properly clean and sanitize dishes, equipment and utensils during meal periods); and

• Check temperatures during peak periods with a calibrated thermometer.

Non-potable Water

• Water that is not safe to drink can only be used in:

– Air conditioning units; and

– Fire protection/sprinkler systems.

• Must be labeled and kept completely separate from potable water; and

• Cannot come into contact directly or indirectly with food, food contact surfaces, food equipment or hand wash stations.

Sewage

• Health Authorities must approve sewage disposal systems to ensure no cross connections exist that could contaminate the water supply.

• Sewage systems should be flushed periodically to maintain cleanliness.

• Operations must be closed immediately if there is a back-up of the sewage system it must be corrected by a licensed plumber and the entire facility and equipment cleaned and sanitized prior to re-opening.

Water Emergencies

A "boil water" advisory may be issued as a result of any of the following:

1.Bacteria or parasites within the water source;

2.Other indications that the water is not safe-to-drink;

3.An outbreak that has been linked to the drinking water.

Always, follow the local health authorities recommendations on water use.

If allowed to remain open, the following steps must be taken to ensure potable water is available.

Shut Down Equipment

Turn off and unplug all equipment that uses water such as:

– coffee & tea makers– pop/soda dispensers– ice machines– dishwashers

A sign must be put on the equipment that tells people not to use it.

Water shutoffs should be closed.

Use Bottled or Boiled Water

Use bottled water or thoroughly boiled water for:

•beverages,

•washing food and,

•ingredients in food recipes.

Procedure for boiling water

1. Put water in a clean and sanitized pot;

2. heat water until it is brought to a rapid rolling boil;

3. continue rolling boil for at least five minutes; and

4. after five minutes, if necessary, cool water by placing it in another sanitized container and storing it in the refrigerator.

Use Commercial Ice

If the water supply is contaminated the ice in your ice machine will also be contaminated.

Use commercially prepared ice or make ice only from boiled water.

Cleaning

• Use boiled water for essential cleaning such as food contact surfaces.

• Single-use plates and utensils help minimize washing requirements.

Hand washing

• Have a supply of warm (previously boiled) water for hand washing.

Plan for Emergencies

• Ensure you fridges and freezers are cold enough.

• If power is out for more than 4 hours move your food into insulated coolers with ice.

• Stock foods that don’t require refrigeration such as canned goods and shelf stable foods.

• Make sure you have a manually operated can opener to use during an emergency.

During a Power Outage

• Bacteria stops growing in frozen food. 

• Don’t open the fridge or freezer doors.

• Storing frozen food outside, even in the winter, can be dangerous as the sun’s heat may cause it to thaw.

There is also a risk that wildlife could contaminate the food.

After a Power Outage

• If food has thawed and been at room temperature for more than two hours it must be thrown away.

• If in doubt - throw it out.  • Food can be refrozen if it still contains

ice crystals.• If raw food has leaked during thawing,

clean and disinfect the areas the food has touched. Cleaning cloths cannot be re-used until they are washed in hot water.

After a Flood

• Commercially prepared foods in sealed, unopened, undamaged containers can be used.

• Throw away raw foods which have come in contact with flood waters.

• Commercially prepared cans or pouches can be saved if properly cleaned, sanitized and labelled.

• Allow washed and sanitized food containers to air dry.

• Use a marker to re-label containers, and include the expiration date.

Food Waste & Garbage

• Can be a source of contamination, odours, insects, and rodents.

• Must be handled in a way that will prevent food contamination or pest infestation.

• Operators must properly store and dispose of food waste.

Indoor Containers

Must be:• Leak-proof, non-absorptive, easily cleaned

containers with tight-fitting covers; • Designed to minimize pests and airborne

contamination; • In sufficient number and accessible; • Emptied when full or at least daily; • Labelled to indicate waste, refuse,

recyclable materials; and • Cleaned on a regular basis.

Outdoor Containers

Must be:

• Maintained so as not to attract pests;

• Equipped with covers that are closed when not in use;

• Cleaned on a regular basis; and

• Emptied when full or at least two times per week.

Cleaning

Garbage/solid waste containers must be: •Manually cleaned and sanitized inside and out after each use; or•Mechanically, cleaned with a steam pressure hose or pressure washing equipment; and•Cleaned away from food preparation, storage and service areas.

Hand Wash StationAll hand wash stations must be equipped with liquid soap dispensers.

Hand wash stations must have adequate hot and cold, (warm) running water.

Self-closing faucets should flow for at least 20 seconds, without the need to reactivate the faucet.

Single-use hand drying devices such as paper towel dispensers.

A hand washing sign with proper hand washing procedures.

A waste receptacle for used paper towels and gloves (if used).

Restroom Facilities

Foodservice operations should have separate restroom facilities for customers and employees that:

– Are enclosed with a tight-fitting, self-closing door; – Have hand washing facilities in the room; – Have hand washing signs prominently displayed; – Are conveniently located and accessible to workers

during all hours of operation; – Provide hooks outside the toilet enclosure to hang

aprons, white coats, etc; – Are easily cleanable, well ventilated, and well lit; – Don’t open directly into a food preparation or food

storage area; and – Have a garbage can for disposable paper towels.

Dressing Rooms

• Putting uniforms on at home can result in contamination of these clothes at home, during transit to work, and during other non-work related occasions.

• Dressing rooms can promote the practice of having dedicated clean and sanitary work uniforms.

• Separate dressing rooms can minimize potential contamination and the wearing of street clothes in food preparation areas.

Dressing Room Design

Dressing areas should:

• Be easily cleanable;• Be well lit and ventilated; • Provide a suitable place for storing

workers' possessions; • Be enclosed with a lockable door, unless

separate facilities are provided for each sex; and

• Be located separate from food storage, handling, preparation or serving areas.

Janitorial Facilities

• In a foodservice operation, a janitorial facility should: – Be located away from food handling

areas; – Be equipped with a service sink or

curbed cleaning facility to dispose of waste water;

– Be equipped with a floor drain, for the cleaning of mops and for the disposal of mop water and similar liquid waste;

– Have a place to store brooms, mops, pails and cleaning equipment.

Storage Areas

• Food,

• food ingredients,

• equipment,

• non-food materials (i.e. utensils, linens, packaging) and

• chemical agents.

All food items must be stored in a separate location away from non-food items including packaging materials.

Storage Guidelines

Keep food 5cm (2 inches) away from the wall.

Keep food 15cm (6 inches) off the floor.

Storage Location

Storage areas should never be located: • In areas used for soiled linens; • In locker rooms; • In toilet rooms; • In garbage rooms; • In mechanical rooms; • Under sewer lines that are not shielded

to intercept potential drips; and • In the same room or near chemicals or

pesticides.

Non-food Storage

• Keep linens, packaging, and single service utensils/containers away from contamination from food, equipment and non-food materials such as chemicals.

• Landscaping tools, marketing materials and posters must also be stored to minimize contamination of food.

• Store personal belongings of employees separately from food storage and food preparation areas.

Recyclables

• Recyclables need to be stored in a sanitary manner and removed regularly to prevent pest infestations.

• Un-rinsed, improperly stored food containers can attract insects.

Summary Locate buildings away from potential sources of

contamination and design with a forward flow to reduce cross contamination;

Floors walls and ceilings must be easy to clean and maintain;

Utilities such as lighting, ventilation, plumbing, water supply and sewage must be safe and sufficient;

Garbage must be properly stored and frequently removed to prevent contamination of food and infestation of pests;

Personal hygiene must be supported with facilities such as hand wash stations, restrooms and dressing rooms; and

Food and non-food storage areas must be properly designed to prevent contamination of food.

QUIZ