Food Facility
Design of a Food Facility
We have spent most of our time so far discussing the importance of maintaining the integrity of the food we serve. Although no one should argue that the HACCP-type issues, such as time and temperature, are the pivotal points in this process, it would be foolish to suggest that a clean house (or “physical plant” as it is called) is not important. In fact, the entire attitude toward food safety is reflected in the appearance of the food establishment.
Remember this: a good food safety system begins with a clean and well-maintained physical plant. As in presenting a home for sale, first impressions of order, cleanliness and efficiency set the tone — you apply these principles to a restaurant when you consider eating there, don’t you?
Let’s conduct a mock inspection of a food facility. As we walk around the outside of the building, there should be no physical damage to the exterior which would allow entrance of pests or dirt — or suggest their presence. Doors and windows should be closed or screened — if closed and screened, the screens should be clean and intact. Debris should be removed, landscaping cut away from the building and garbage receptacles covered, clean and contained.
Once, when entering a restaurant, I could smell the strong scent of bleach, as the dumpster area was being cleaned. Instead of being repelled, I loved it!
As we enter the physical plant, let’s examine the floors, walls, etc. First, floors should be of a non-skid surface to prevent falls. At the same time, they should not be so rough that they are not easily cleanable. They should be nonporous to prevent stains from soaking in.
Types of good materials for floors include tile and terrazzo. Avoid the use of vinyl, carpeting and wood. Concrete is acceptable if properly sealed — it seldom makes a good impression, however. Mats are appropriate in any area where spills make falls more likely, such as the dish washing or cooking areas.
Walls and ceilings should be painted in a light color to show dirt easily. They should be smooth, non-absorbent and easily cleanable. Where food is likely to splash, such as in a prep area, a stainless steel wall covering is useful. Fluorescent lights must be shielded to prevent shattered glass from entering the food area should a bulb break.
Kitchen Layout
The layout of the kitchen is more important than is first realized, as it not only influences efficiency but also safety. Service, preparation and ware washing areas should be separated to discourage cross contamination and allows each area to function efficiently.
Lighting
In all areas, lighting should be adequate to support the worker. It not only is fundamental in promoting a good work environment, but lighting also reduces error and accidents.
Lights should not promote glare or shadows. Fluorescent lights must be shielded to prevent shattered glass from entering the food area should a bulb break.
Specific light intensities may be required in your jurisdiction; check with your local health department. In general, low lighting (10 footcandles) is required in storage areas, moderate lighting (20 footcandles) for warewashing or hand washing, brighter lighting (50 footcandles) where preparation or safety is an issue. (Adapted from the Food Code)
Furniture and Equipment
Many pieces of equipment are used in a food establishment. They may be as large as a walk-in refrigerator or as small as a paring knife. Equipment needs are menu driven. That is, the type of menu served will determine the specific equipment needed. This demands careful consideration when planning a new facility. Several factors are common to all types of industrial food service equipment.
- Construction materials must be durable enough to withstand constant use and abuse. Various types of metals , including stainless steel, heavy gauge plastic or hard woods are some examples.
- Surfaces should be smooth, easily cleanable (there’s that word again), easy to take apart and reassemble and with no sharp edges.
- Wiring must be of industrial grade; no home appliances are allowed.
- The National Sanitation Foundation (NSF), Underwriters Laboratories Inc. (UL) or the American Gas Association (AGA) should approve all equipment.
- All floor equipment must be sealed to the floor or elevated at least six inches above the floor. Table mounted equipment must be four inches from the table surfaces.
HVAC (Heating, Ventilation and Air Conditioning)
Have you ever had to work in a kitchen with a temperature of 107°F (42°C)? Many people do, and it is more than unpleasant — it’s dangerous. Proper ventilation and air conditioning are extremely important. Basically, proper ventilation is needed to control smoke, odors, temperatures, grease build-up, condensation and fumes.
Good ventilation includes cooling/heating, humidity control, circulation and air filtering. The goal is
always to provide an atmosphere that is safe and promotes worker comfort and productivity. Systems usually include a hood, intake and exhaust ducts, vents and fans. Of course, all equipment should be made of durable material and cleaned regularly.
Recently I was doing a sanitation check with a person new to these aspects of food safety. As we examined the hood over the stove, I suggested that he remove the canister, which collects grease from the hood. As he moved the box toward him, it was so over-full that grease ran down his arm, covering his shirt. “Ugh!” was the nicest thing he said.
This very messy lesson about the importance of regular cleaning schedules is only part of the story. Many fires are caused in food establishments by grease accumulation, and once started, grease fires are difficult to extinguish quickly enough to prevent substantial smoke and heat damage. A grease fire can really ruin your day!
Plumbing Hazards
Obviously, a clean water supply is necessary for a safe food operation. At times, this supply can become contaminated through a “cross connection.” A cross connection allows contaminates from wastes to enter the potable (safe for consumption) water supply.
Pest Control
The best food safety program can be destroyed if insects and rodents are allowed to contaminate foods and preparation surfaces. The best illustration I can think of is the health inspector who thought he was examining a bag of white rice mixed with wild rice. As he looked closer, he discovered the dark entities were not wild rice, but rodent droppings. As he inquired of the cook as to how he dealt with this, the cook replied, “Oh, that’s no problem. The rat just floats to the surface when I cook it and I just skim it off.” Enough said.
Pests need entry, a breeding place, food and water to survive. Our control measures will concentrate on these areas. It is to be remembered that no amount of repellents or poisons are a substitute for a good cleaning program; all efforts start with keeping a food area clean.
I remember visiting a Mexican restaurant located in a town that was so fly-infested, this insect was considered the city bird. The restaurant was housed in an old warehouse, some of which was not in the best of repair. I was amazed at the lack of any sign of pest infestation. The answer lay in the cleanliness of the food preparation area. It was so clean that it exceeded the condition of my home kitchen.
Any food establishment or home has periodic problems with pests. A good pest management program, however, will keep such problems from escalating. Our discussion will concentrate on flies, roaches and rodents.
Flies
If you saw the hit movie The Fly, you know that the first thing a fly does when it lands on food is vomit. Usually, when people see a fly on their food, they swish it away and continue to eat the food — and the vomit. (In addition, a fly defecates every 4 min.) People are quite surprised to hear that flies carry far more diseases than roaches. Fly associated bacteria that cause food poisoning include: Staph, Salmonella, and E. coli (STEC).
Where do flies spend most of their time? In dumpsters and on animal and human waste. As they travel in these areas, they pick up bacteria on their hairy legs and sticky feet, and ingest bacteria while eating.
Flies can smell food from a great distance. In a private home, the doors may be open all morning with no flies present. When lunch is prepared, however, flies appear. This is due to their strong sense of smell. Once they land on the food, the bacteria from their legs and the bacteria contained in their vomit are dispersed to the food.
The control of flies is twofold:
- Keep the doors shut. Receiving doors should be equipped with air curtains (fans that cover the surface of the doorway when the door is opened). Doors must not be allowed to stand open. In harsh climates, this is not a problem, but where the weather is friendlier, it can be a significant one.
- Keep garbage well contained. I observed the best illustration of this at a nursing facility. Flies were a problem in the kitchen, and were entering through the side door. Outside, approximately 100 yards away, were three dumpsters. All lids were open, which is not recommended. One was used for office debris such as papers. No flies were present. The second was used for kitchen waste. Flies were very prevalent. The third was used for housekeeping refuse, much of which would be highly attractive to flies. No flies were present at all in this dumpster. Why? Because all refuse was securely tied in double bags as was required by state law. What a visual lesson! Rule number two: all garbage must be tightly contained.
FLY FACTS
- Flies are a greater problem to human health than roaches or rodents.
- Flies can smell food for great distances.
- Flies can enter through an opening the size of a pinhead.
Roaches
Roaches have a very bad reputation. In many cases, it is quite undeserved. Actually, roaches are considered clean, compared to the filth of flies. However, the diseases associated with them are dangerous enough to warrant careful control.
Roaches are nocturnal creatures and usually seek their food at night. If roaches are seen in the daylight, they have likely overrun their nesting areas, indicating an extremely large and active infestation. Roaches seek warm, moist areas. They need very small amounts of food; even a crumb will provide a meal for a roach. In fact, they can live off the toothpaste residue on your toothbrush.
You have to admire them: they can endure loss of limb or antennae, survive extreme temperature variations, endure depressurization and go for extended periods of time without food or water. Part of their survival can be attributed to their alertness and speed. Even the smallest wind current will cause them to run for cover quickly.
Also their versatility: they can flatten their bodies and crawl through a crack thinner than a dime. While growing up in south Florida, I had ample opportunity to become well acquainted with the Palmetto bug, one of the largest types of cockroach. With a size greater than two inches in length, they got more than your casual attention. I have witnessed them squeeze between corners in a paneled wall, where there wasn’t even a visible crack!
Roaches will eat anything. One of their favorite foods is glue. Peeling wallpaper, then, is a buffet for these creatures. In some states, the storage of cardboard boxes in a storeroom is prohibited due to the presence of glue. They also love grease, and in a pizza prep area or near a deep fryer, a thin layer of grease is almost always present.
There are many approaches to the control of this pest. Most focus on preventing entry by carefully checking incoming goods, enclosing food tightly and keeping the food area clean.
FOR ROACH CONTROL
- Keep food in tightly closed containers.
- Check incoming deliveries for infestation.
- Keep all areas clean.
Rodents
Every bone in a rodent’s body is detachable. This means that they can enter through an opening the size of their skull. Those familiar with gerbils or hamsters as pets, may have seen them squeeze between the rungs of the ladder in their cages. Obviously an open door or a damaged physical plant gives easy access to rodents.
Rodents are enormous carriers of disease throughout the world. Their control is difficult since they breed rapidly and are very adaptable. Rodents are ready for mating in 2 months, have up to 20 young in each litter and do this four or more times per year. They do millions of dollars worth of damage to food establishments. Since they also are nocturnal, their presence may best be detected by looking for signs of infestation.
Rodent droppings are the most obvious sign. These may range from jelly-bean sized down to what may be mistaken for coffee grounds. The size of the droppings is indicative of the size of the rodent. Rats typically stick to one path, usually in the perimeter of the area. The perimeter allows their very sensitive whiskers to touch the wall, providing security. (They have very poor eyesight.) Droppings will most likely be found here. Rub marks may also indicate their presence. These marks are created by the filth and grime of the rats as they run along the base of the walls. Mice, however, usually don’t leave these marks. Gnawings may also be indicative of infestation, particularly on food items such as bags and boxes.
Besides eating and destroying food, rodents use non-food items to build nests. I wondered what was happening when I saw Styrofoam cups in my garage being eaten. I knew what the problem was when I looked at the bag of rabbit food in the corner. A small hole was present. The leaking rabbit food soon gave way to rodent droppings and I knew this food stash had been discovered. Before these uninvited guests were brought under control, however, we had sustained a $600 bill for damage to our car, as they had also used pieces of hoses and wires for their nests!
There are two lessons here: don’t store any food in a garage in a soft container such as paper or cardboard, and avoid delay in solving a rodent problem. Control of rodents sounds simple:
- Block their entry.
- Don’t feed them.
However, implementation can be difficult.
Again, keep doors constantly closed. Check building integrity: a rodent can enter an opening the size of a quarter. In the case of our garage, entry was easy; there was a half-inch gap under the side door with no threshold. (There’s a threshold now!) Check the outside of the building also and remove any litter or unused materials. Be sure garbage areas are well maintained. Inside, store food in tight containers, never loose or open. Glass and metal cans are good for this purpose; larger rodents will gnaw through even heavy grade plastic.
FOR RODENT CONTROL
- Keep entry ways closed.
- Pick up debris outside of building.
- Keep food in tightly sealed containers.
Pest Control Operator (PCO)
Managers of food establishments are experts in producing excellent food. They are not experts in pest control. In this regard, it is highly recommended that the food operation contract with a Pest Control Operator (PCO) to accomplish this task. PCOs use a procedure called Integrated Pest Management. In this system, a combination of chemical, mechanical and sanitation methods are used. All pest control programs start with cleanliness; no amount of chemical or mechanical means will make up for a dirty environment. PCOs will use a variety of means to control pests as rodents, especially, quickly become wise to control efforts. Chemicals are used only as a last resort since they introduce risk to you, your employees and the customer. Only chemicals approved for use in a food establishment may be used. As always, check with your local jurisdiction for ordinances concerning this.
The National Pest Control Association recommends a five step process for pest management:
- Inspection
- Identification
- Sanitation
- Application of two or more pest management procedures
- Evaluation of effectiveness through follow-up inspections
If, despite this good advice, you decide to do your own pest control, it is imperative that you implement correct procedures. The phrase, “You’re not at home” is especially important here. Hurrying to the store to acquire sprays and aerosol bombs may be your first thought at home and yet would be entirely unacceptable in a food establishment.
Pesticide use is regulated by federal, state and local jurisdictions. In some areas, it may be illegal for you to administer pesticides in your establishment; you may be required to use the services of a pest control operator. Be sure that you check with your local regulations and maintain appropriate files.
Remember that chemicals must be stored away from food. In this case, chemicals may prove very dangerous and should be maintained in a locked area. It is always the manager’s responsibility that all aspects of the food operation are safe.
Never allow chemicals to be transferred from the original container to a new, more easily used container. We covered this in the section on chemical contamination. The application of this principle is most obvious here.
Anyone applying chemicals must wear protective gear and be instructed in the proper use of the materials. We will discuss the safe work environment further in the next module. Hands and clothing must be thoroughly washed after using chemicals. Finally, remember to follow directions carefully and thoroughly. Two doses are NOT better than one.
Continuing our discussion of protecting the environment, pesticide disposal falls under hazardous waste disposal regulations. Even empty containers contain small amounts of chemical. These containers need to be disposed of according to the manufacturer’s directions. Never rinse containers in a sink used for food preparation, always in a mop or utility sink. Be very careful with aerosol cans as the contents, even when empty, are under pressure. Storing these cans near heat or trying to crush them when empty may result in a serious explosion.
Prevention becomes the operative word here. Maintaining a clean establishment will minimize the attraction of pests. Preventing their entry will always help. Working with a HACCP program will help establish priorities that make prevention easier. Elimination of breeding and hiding places will also help. No one likes pests and no worker likes to work in an area where pests are a problem. The team approach is important between you, your employees and your pest control operator if this hazard is to remain under control.
Maintaining a Safe Work Environment
OSHA
Most managers take notice when a health inspector comes. As well they should. But when OSHA comes calling this not-routine visit is serious indeed. As its name implies, Occupational Safety and Health Administration, OSHA is there to check on worker safety. If OSHA finds an infraction, their fines are stiff.
Established in 1970, OSHA is charged with promoting occupational safety and health standards. They develop regulations, conduct inspections and issue penalties for noncompliance. It is the responsibility of the employer to provide the worker with safe working conditions. OSHA is particularly concerned about the chemicals that workers use. This is where material safety data sheets come in.
Safety Data Sheets
As you have learned, various chemicals are used in cleaning and sanitizing a food establishment. OSHA requires that Safety Data Sheets (SDS) be kept for all chemicals. These sheets are prepared by chemical manufacturers and must be maintained in files within the food establishment. They provide information to food workers concerning the hazards of the chemicals being used. The following information may be included on the
SDS sheets:
- Data regarding health hazards, dangers
- Safe handling of the chemical
- Physical and chemical characteristics of the chemical
- Personal protective equipment that should be used
- Emergency procedures to use if necessary
OSHA will issue a substantial fine if SDS sheets are not readily available. All employees, if asked, must know where they are, how to access them and basic information that they contain.
Existing Agencies
There are various agencies that are involved in regulations for food safety. The federal system alone consists of 35 laws and involves 12 different agencies, six of which have major roles in carrying out food safety and quality activities.
Some organizations inspect food during its manufacturing, such as the USDA overseeing meat packing plants. Other organizations are involved at the retail level, such as health departments inspecting a restaurant. Government agencies collectively perform four functions:
- establishment of safety standards
- monitoring and inspecting to observe compliance
- enforcement
- tracking food safety problems
Numerous written regulations exist in all of these areas.
A national set of recommendations published by the Food and Drug Administration is called the Food Code. This publication has been referred to many times in this course. The Food Code is not law but may be adopted in whole or in part by a state. Each state has its own set of laws governing food safety. Also, individual counties may have additional regulations. It is most important that each manager have a thorough knowledge of the regulations governing his/her establishment.
During an Inspection
A health inspector (or health specialist, as they are also titled) is an important resource in efforts toward supplying safe food. They have broad experience and extensive knowledge of the subject. They often can offer solutions to problems and answers to questions. The relationship established with this person may be very rewarding, especially if it extends over time.
Several considerations may make this more likely:
- Even if the inspection occurs during an inconvenient time, be cordial to the inspector. Often they are considered (as is any government inspection) ‘bad news’ and an exception to this is obviously quite welcome.
- Have industry related questions ready for discussion. Read articles on food safety for this purpose. This helps to stimulate conversation; shows interest and develops relationships.
- Offer your availability to the inspector, walk with them if you have time and this seems appropriate. Sometimes they would rather just have you available if they have questions.
- Have records handy. Losing points during an inspection simply because records were not located is especially disappointing. Keep your past inspections on file for your reference. The inspector already has them available.
- If possible, fix any infraction at the time of the inspection. Prompt response to improper conditions shows concern. Even if the inspector retains the deficiency, ask him/her to mark on the sheet that the problem was corrected at the time of visit.
- Be sure that any deficiency is corrected by the next visit. Nothing is less impressive than an establishment that does not care to fix problems. This does not help to build rapport.
- Remember that all inspection reports are open to the public. More than a piece of paper, these ‘can and will be used against you’ if a lawsuit should ever occur. For instance, a defense of a case of hepatitis is hopeless if single or multiple inspection reports show lack of adequate handwashing facilities.
Increasingly, inspection forms are taking on a HACCP appearance, citing terms such as critical control point, corrective actions, etc. In fact, the approach of HACCP in a local jurisdiction is great dialog material. Whatever form is in use in your area, be familiar with it and have your staff familiar with it also. Training shift leaders and other appropriate individuals to do a mock inspection is a great educational tool and services all goals.
Safe Operation of Equipment
Employees understand the use of ovens and microwaves. But they don’t understand steamers, meat slicers, the sharp edge of a box of plastic wrap, even a box cutter. And they are certainly not prepared to operate in the hectic environment of a food service operation. Hence, training and communication is essential.
We discussed basic safety issues concerning cuts, burns and falls earlier in the course. Here, we will deal with more serious situations:
- Be sure that employees are aware of all manufacturers’ directions in the use of power equipment. Large pieces of equipment such as grinders and slicers, are often equipped with a device called a dead man’s switch. Basically, this device requires the full attention of the employee to enable the piece of equipment to operate, thus preventing accidental deployment of the equipment and serious injury. At times, such switches can be permanently taped in the ‘on’ position. This situation is illegal. Be sure to check with state laws regarding age requirements for operation of various pieces of equipment.
- Be sure that all power equipment is in the ‘off’ position and disconnected before removing food or cleaning.
- Be sure that all safety guards are checked regularly and in place prior to operation.
Important: Employee training sessions should be documented for each employee operating power equipment.
Fire Safety
Fires cause significant damage in the food industry. Causes of fires in order of occurrence is:
- Grease fires
- Electrical fires
Careful attention to maintenance of hoods and filters are especially important in preventing fires; hood fires are the number one cause of fires in food establishments. Flash points of oil must be carefully identified as each oil has a different use and flash point. For example, peanut oil, often used in stir fry, has a relatively high flash point. Electrical fires, the number two cause of fires, may be caused by overloading electrical outlets. A reminder that only equipment approved for industrial use may be utilized in a food establishment. Check wiring frequently.
Types of fires are consistent with types of fire extinguishers. Use of the incorrect type of fire extinguisher may cause a worsening of the fire. For example, pressurized water is not recommended in a food establishment due to the possibility of using it on a grease fire. It is essential that employees know proper fire safety procedures. They may be the ones called on to act first.
Types of Fires and Extinguishers
Fires are distinguished according to the type of material that catches fire.
Class: A
Material: ordinary combustible material such as wood, paper or cloth
Color: GREEN
Class: B
Material: flammable liquids and grease
Color: RED
Class: C
Material: Electrical: motors, switches
Color: BLUE
Extinguishers must be maintained and checked regularly. Most need to be recharged every six months. Your local authorities will make regular checks and are usually happy to provide instructional sessions for your staff and provide appropriate written information. Again, the importance of employee education cannot be overemphasized.
Two other systems, hoods and sprinklers, are part of your fire prevention program. Usually hood systems are installed over cooking and dishwashing equipment and are designed to remove heat, smoke and vapors. Employees need to be aware of their operation as well as the proper procedures for cleaning these important pieces of equipment. Some hood systems may also include fire extinguishing systems.
Sprinkler systems are often required in new establishments. The same aspects of maintenance and education apply here also. Sprinkler systems are one of the two systems that may use non-potable water (air conditioning systems are the other). Therefore, all facility supplies must be maintained the proper distance away from sprinkler heads. Contact the sprinkler service for proper repairs needed to this very important system.
Fire causes panic. If your staff is not comfortable in appropriate responses and procedures, all the equipment that you have will be useless. It is suggested that you hold regular training sessions that include the following:
- Location and use of different fire extinguishers.
- Contact telephone numbers in case of emergency and the location of these numbers.
- Mock evacuation procedures that identify all exits routes and doors.
- Review of posted diagrams of evacuation routes.
The danger posed to human life by fire, especially one that is handled incorrectly, may be the gravest threat we face. It must be emphasized that the food industry itself poses greater risks by its very nature. Employees often don’t recognize this because ‘they all have kitchens at home’. That is one more reason why respect for the professional food preparation area is vital.
First Aide
Despite the best prevention program, accidents, both to employees and guests, do occur. As you might expect, training and preparation are the keys here.
Accident prevention programs should include eliminating hazards in the environment and provision of protective equipment for workers. Think ahead: what could go wrong here? Involve your workers in accident prevention.
Keep a well stocked first aid kit in an obvious place. A good manual is also essential. Contact local organizations such as the American Red Cross or a local hospital for information and training.
It is imperative that you recognize the difference between an injury that can be treated at the work site and one that requires more sophisticated treatment. Frequently, a worker feels that he/she can go on working, only to find out later that an injury is more extensive than first thought. Falls are a classic example of this. An accident report must be filled out on each incident. Forms are available through your insurance company, OSHA or workers’ compensation programs. You will be preparing one of these as a project for this module.
Finally, a word about choking or cessation of breathing or pulse. Two procedures are often mentioned here: the Heimlich Maneuver (used for choking victims) and Cardiopulmonary Resuscitation, CPR. These types of assistance may be needed by either a customer or a worker. It is best to check with your local jurisdiction about the administration of these procedures or the requirement to post signs, etc. Thorough training and literature are available through the American Red Cross.