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Help Me Design Our Dream Facility!

design layout new bakery upgrade build

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#1 bakeryscience

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Posted 09 October 2018 - 06:34 PM

Nothing is official yet, but it's looking like we'll be moving to a new (bigger!) facility soon! If you were in this situation, what would be on your list for your "dream facility"?

 

We are a bread bakery.

 

I just wanted to throw this out here since I know a lot of you will have ideas I haven't though of yet. Feel free to suggest anything even if it's not necessarily food safety related. We obviously have a budget to stick to, but for the sake of this post, anything goes.



#2 Scampi

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Posted 09 October 2018 - 06:50 PM

Lucky you!   Don't forget a mitigation plan if you move in before it's all completed (tarps for condition and cleanliness, contractors etc etc)

 

Card lock doors!  Employees all wear a card on a breakaway lanyard (inside coat of course) that is used not only to restrict access to where employees of different kinds can go, but for payroll etc

 

The absolute best air exchange system you can get

 

Sanitary drains that have covers etc that come apart easily for cleaning

 

Dosatrons and compressed air (if you need it) everywhere so you don't have miles and miles of hose laying around (cause they are nasty)

 

An intercom system/interior cell service----if it's a big plant and things go to s**t it's nice not to have to run 5 minutes to get anyone to help (thinking also employee safety here)

 

Automatic floor sanitizer system...............I know you want it dry (makes sense) and there are some really good granules out there in quat form that break when people step through them and they help with the transition from hallways to production

 

Small little walkies for moving totes of production...........maintenance usually buys them and they are always too big

 

Separate lunchrooms for ship/receiving and production employees

 

DATALOGGERS


Because we always have is never an appropriate response!


#3 012117

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Posted 10 October 2018 - 01:07 AM

redbudke.

 

What I normally do for this project is get the layout of the building and get how the layout of the equipment will be installed. Then I try to picture out the zoning or area segregation based on the risk of my product. Then from there I will start to have the proper "barriers" in place.

 

Before construction,  conduct soil injection for termite and ant treatment :)

 

From the segregation, install the necessary hygienic drain. There are hygienic drains intended for both wet and dry process.

 

Use the proper air handling. Make sure the intake air is not facing your waste water or material recovery facility. also use the proper duct sox that is washable.

 

Use cards whenever applicable, in other, use biometrics (since production will not be allowed to carry cards).

 

Follow the proper spacing for equipment and any other installation (the recommended height of the floor, recommended distance between equipment and recommended distance from the wall)  Always follow the saying:

 

"what you cannot see - you cannot inspect, you cannot maintain, you cannot clean". So always have these "spaces" available for you.

 

A wet cleaning room. If there are equipment you will clean wet from dry process areas.

 

Install lighting slanted to avoid dirt accumulation.

 

Minimize also I beam or H beam in horizontal installation to minimize dust accumulation.

 

Use LED lights whenever available.

 

For electrical cable, use the open type installation with the cables properly laid out.

 

Use automatic dispensers as much as possible.

 

In hand washing, if you can have interlocks that would facilitate following your minimum time for handwashing.

 

Proper size changing rooms depending on your process.

 

Barcode scanner system.

 

There is many more but should be logical to the process :)

 

Goodluck with that journey :)

 

.



#4 Gerard H.

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Posted 10 October 2018 - 07:43 AM

Dear Rebudke,

 

That's a nice development for your company and one bringing lots of challenges. Hereunder you find some points to consider:

  • Create a logical flow for your employees and the right working conditions (for mixing departments (flour dust), ovens (heat) and freezers (cold) for example)
  • Establish a logical flow in the building, following the production process and avoiding the crossing of different flows (raw materials, waste, rework, packaging materials and finished products)
  • See whether there is a need for conditioning rooms for your raw materials, because it's difficult and costful to build them afterwards
  • Create storage areas which are big enough for your materials, otherwise you will find these everywhere else. Foresee a storage up from the floor and from the walls
  • Design your process as dry as possible
  • As 012117 mentioned, let everything accessible for inspection and cleaning
  • Respect hygienic design principles for the building (Walls, doors, proofing, wall-floor / wall-roof joints). Make everything resistant to the movement if trucks or pallets
  • The sanitary drains have to work really well = The right inclination of the floor toward the drains without accumulation of dirtiness
  • Design and treat your different production zones as compartments = Really insulated from each other (So be carefull with cables, pipes and process utilities)
  • Anticipate on the (process) waste topic, which is often underestimated causing lots of problems afterwards

I hope the project will continue and I wish you good luck!

 

Kind regards,

 

Gerard Heerkens



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#5 adamperry2235

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Posted 10 October 2018 - 02:29 PM

Space space and more space. Make sure you have enough room to clean over under and around everything. Cleaning and sanitation is a huge part of anything we do so make sure that is a top priority when designing. I wish we had taken more time in our design to accommodate that. 



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#6 012117

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Posted 11 October 2018 - 01:10 AM

redbudke,

 

 

Forget to mention yesterady, you may want to refer to this or others (ANSI, 3A) for some building structures (or equipment design/installation). This is not regulatory but will give you good idea anyway :)

 

https://www.ehedg.org/guidelines/

 

 

:)



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#7 bakeryscience

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Posted 11 October 2018 - 02:05 PM

Thanks everyone!! All great ideas and advice!



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