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Plan Lay-out segregation high risk room from low risk area

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Posted 18 December 2019 - 02:09 PM

I need help to come up with away to enter my high risk room from low risk area.
We are ready-to-eat plant and we make seafood concentrate.
I have attached my plant layout and in red is my high risk room.
Arrows show when pails, containers and labels enter's the packing room trough a sliding window. I also have to big doors to enter the room. 
When we pack both doors are keep closed until all product is inclosed containers. The room as positive make up air also. 
Keep in mind that the rest of the plant it is low risk. 
Everything is packed into 25 lb Pails.
Once the product as been pasterised it's transfered in to the refregirated holding tank trough pipework.
Any suggestion would be so much help.
I've been busting my brains out on this one. 
FYI-we are preparing for our first BRC audit in 2020.



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Posted 18 December 2019 - 02:26 PM

You may want to consider engaging a BRC Consultant that can help in this area. 


We don't handle BRC, we handle SQF consulting on new construction, flow design, working with builders, ground up startups etc.


That may be best option to take.

All the Best,


All Rights Reserved,

Without Prejudice,

Glenn Oster.







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Posted 18 December 2019 - 04:22 PM



Can't see attachement


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Posted 18 December 2019 - 04:50 PM

there you go ! 

Attached Files


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Posted 19 December 2019 - 12:38 AM



Thks for layout. Some area lacks clarity (to me).


Not sure what "seafood concentrate" means ? Packing ?


As yr OP implies, a critical flow divisor is at low/high interface(s)  (materials, personnel etc).


There appears to be incomplete physical separation between some low/high risk areas, ie the red  area looks to need extending.


Why the rerigerated tanks ?


I deduce Finished Product "Freezer" = Storage Area ?


refrigerated tanks/etc, blast #1 looks to be part high risk area (unless product in latter already fully enclosed) ?.

Kind Regards,




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Posted 19 December 2019 - 12:44 PM

I appreciate you asking me questions and try to wrap your head around this. Thanks here is hopefully a clearer picture for you.


DAY1 - We make a special mix of raw seafood, lobster, shrimp, fish, ect.... those Crushed -> loaded by the screw conveyor into the Blendtherm Cooker. 

When the product is cooked the shells and liquid are separated into a screen ''Sweeco'' the liquid product is pump into the rt#1 or 2# (refrigerated Tanks) until the next day. Over night.


DAY2-The following day we transfer the product back into the Blendtherm Cooker to Evaporate water form the liquid to target a specific brix %. 

When the product achieved the target Brix's the concentrate is pasteurised then product is pump into the FPRT Finished Product Refrigerated Tank.

That's the tank in the packing room.


DAY3-Then the liquid is pump from the FPRT trough pipework into the Vmag -> Metal Detector-> pipe filler piston -> into containers -> on the packing conveyor line -> lid is sealed on then inkjet label, the table for final check and containers are placed into racks ->Blast freezer #1.


I Hope this give you a better understanding of the process.


Refrigerated Tanks are to keep the product temperature cold over night.

The Refrigerated tank in my packaging room is high risk because it’s ready to be packaged.

Both Refrigerated tanks RT#1 / RT#2 are low risk. The product that is in those holding tanks will be transferred into Blendtherm, evaporated then pasteurization, then pipework pump into the High-risk packing room Finish product holding tank.


The Blast #1 is used for the fully enclosed product.

Yes, finished product freezer is the Storage Area.

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