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Construction and layout for a new seafood processing facility

BRC Requirement for a constrt BRC REQUIREMENTS FOR LAYOUT

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#1 GAYATHRI VIDUSHIKA

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Posted 04 January 2021 - 08:33 AM

I'm working with a new project which is planning to construct a new facility of seafood processing and exporting factory. I need some clarification on what are the things I should concern when 1. Drawing the layout of factory  2.constructing the factory



#2 Scampi

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Posted 04 January 2021 - 01:18 PM

Can please narrow this down some?  

 

Layout----cleanest to dirtiest including waste removal (garbage/inedible/recycling)

 

Construction-easily cleanable/tare down if needed/ zero painted surfaces/no drop ceilings/

 

Also keep in mind employee safety---blind corners etc for fork lift traffic


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#3 Charles.C

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Posted 04 January 2021 - 09:31 PM

I'm working with a new project which is planning to construct a new facility of seafood processing  and exporting factory. I need some clarification on what are the things I should concern when 1. Drawing the layout of factory  2.constructing the factory

 

Hi Gayathri,

 

I would suggest you need to look for a Consultant.


Kind Regards,

 

Charles.C


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#4 GAYATHRI VIDUSHIKA

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Posted 05 January 2021 - 08:07 AM

Dear Scampi,

Thank you very much for the suggestions. I have done the processing layout up to now. There are some issues I had. In my  production layout  (seafood processing Plant)  the trimming and off cut parts which accumulated at processing area do not have direct access to the offal room. Is it a Problem in BRC certification. Our practice is to store them in bins with ice and remove them to the offal room after the production is it ok for the process  



#5 GAYATHRI VIDUSHIKA

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Posted 05 January 2021 - 08:09 AM

Hi Gayathri,

 

I would suggest you need to look for a Consultant.

Dear Charles,

thank you very much for the reply



#6 GAYATHRI VIDUSHIKA

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Posted 05 January 2021 - 08:09 AM

Can please narrow this down some?  

 

Layout----cleanest to dirtiest including waste removal (garbage/inedible/recycling)

 

Construction-easily cleanable/tare down if needed/ zero painted surfaces/no drop ceilings/

 

Also keep in mind employee safety---blind corners etc for fork lift traffic

Dear Scampi,

Thank you very much for the suggestions. I have done the processing layout up to now. There are some issues I had. In my  production layout  (seafood processing Plant)  the trimming and off cut parts which accumulated at processing area do not have direct access to the offal room. Is it a Problem in BRC certification. Our practice is to store them in bins with ice and remove them to the offal room after the production is it ok for the process  



#7 Charles.C

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Posted 05 January 2021 - 10:04 AM

 

Dear Scampi,

Thank you very much for the suggestions. I have done the processing layout up to now. There are some issues I had. In my  production layout  (seafood processing Plant)  the trimming and off cut parts which accumulated at processing area do not have direct access to the offal room. Is it a Problem in BRC certification. Our practice is to store them in bins with ice and remove them to the offal room after the production is it ok for the process  

 

 

If I understand yr post correctly, IMEX it is usual to remove "waste" seafood material semi-continuously from the (main) Production area to avoid possible contamination. Is there a reason why you cannot do this ?


Kind Regards,

 

Charles.C


#8 GAYATHRI VIDUSHIKA

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Posted 05 January 2021 - 10:40 AM

If I understand yr post correctly, IMEX it is usual to remove "waste" seafood material semi-continuously from the (main) Production area to avoid possible contamination. Is there a reason why you cannot do this ?

According to the Space we have in the site and land space, we have drawn a temporary layout and insert all the important components to it in practical way. i have attached here the drawing. After doing changes for all our requirements this is the one we finally end up with but here the problem to me is the off cut producing from production area have no direct access to offal room.



#9 Charles.C

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Posted 05 January 2021 - 12:44 PM

According to the Space we have in the site and land space, we have drawn a temporary layout and insert all the important components to it in practical way. i have attached here the drawing. After doing changes for all our requirements this is the one we finally end up with but here the problem to me is the off cut producing from production area have no direct access to offal room.

 

There is no attachment ?

 

Not sure what you mean by "offal room" but I assume this is a storage point for iced trimmings etc prior to local sale ?

 

It sounds like you have a significant difficulty.


Kind Regards,

 

Charles.C


#10 Scampi

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Posted 05 January 2021 - 01:05 PM

If your building from scratch, may i suggest floor troughs with water to flush all the waste directly to the offal room where it is dewatered.  FYI, you should be selling that waste to pet feed----there is big $$ in that---but then you need to handle it as such and it is no longer considered waste

 

There is zero point in building new and not automating as much as possible and in all likely hood yes, BRC will frown on once daily removal (its also just plain gross)

 

Charles--offal is the "meat waste" in any meat processing facility


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#11 Charles.C

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Posted 05 January 2021 - 01:22 PM

If your building from scratch, may i suggest floor troughs with water to flush all the waste directly to the offal room where it is dewatered.  FYI, you should be selling that waste to pet feed----there is big $$ in that---but then you need to handle it as such and it is no longer considered waste

 

There is zero point in building new and not automating as much as possible and in all likely hood yes, BRC will frown on once daily removal (its also just plain gross)

 

Charles--offal is the "meat waste" in any meat processing facility

 

 Hi scampi,

 

^^^(red) - Yes I know but IMEX the terminology is never used in seafood business. Maybe this is a combined operation. :smile:

 

Trimmings can be large/small depending on the fish. The usual large "waste" procedure disposal IMEX is to temporarily store trimmings iced in deep stackable trays which are then routinely moved to a separate room, accumulated and sold off day-by-day for various purposes. Some factories transform into fish blocks. Heads are a delicacy of course.

 

This obviously requires a "route" though.


Kind Regards,

 

Charles.C


#12 Scampi

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Posted 05 January 2021 - 01:31 PM

Well there's still the viscera to think about..............


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#13 Charles.C

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Posted 05 January 2021 - 01:40 PM

Well there's still the viscera to think about..............

 

Yes, this, segregated, usually follows a similar route but yr suggestion would permit more automation. All depends on the layout/process I suppose.


Kind Regards,

 

Charles.C


#14 GAYATHRI VIDUSHIKA

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Posted 15 January 2021 - 10:04 AM

 Hi scampi,

 

^^^(red) - Yes I know but IMEX the terminology is never used in seafood business. Maybe this is a combined operation. :smile:

 

Trimmings can be large/small depending on the fish. The usual large "waste" procedure disposal IMEX is to temporarily store trimmings iced in deep stackable trays which are then routinely moved to a separate room, accumulated and sold off day-by-day for various purposes. Some factories transform into fish blocks. Heads are a delicacy of course.

 

This obviously requires a "route" though.

Hi CHARLES,

The offal include all the -head,gut,blood,fins,trimming, and all other offcut from the fish. End of the day it collected and sell. 

And thank you for the suggesions



#15 GAYATHRI VIDUSHIKA

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Posted 15 January 2021 - 10:07 AM

If your building from scratch, may i suggest floor troughs with water to flush all the waste directly to the offal room where it is dewatered.  FYI, you should be selling that waste to pet feed----there is big $$ in that---but then you need to handle it as such and it is no longer considered waste

 

There is zero point in building new and not automating as much as possible and in all likely hood yes, BRC will frown on once daily removal (its also just plain gross)

 

Charles--offal is the "meat waste" in any meat processing facility

Hi scampi

yeah we are selling them end off the day. 



#16 GAYATHRI VIDUSHIKA

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Posted 15 January 2021 - 10:19 AM

This is the sketch of receiving ,de heading and processing area of the factory.I mean most of the waste generates at deheding area and it have a direct access for the offal room. But  there will be generate waste from  flesh trimming like things at processing are too. But there we do not have direct access for offal from processing area. So we have to store them in bins temporarily untill the cutting is finish. Is that a problem. I have attached a sketch here -

Attached File  fish plant.jpg   116.7KB   0 downloads


Edited by Charles.C, 15 January 2021 - 01:15 PM.
edited slightly


#17 Charles.C

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Posted 15 January 2021 - 01:07 PM

This is the sketch of receiving ,de heading and processing area of the factory.I mean most of the waste generates at deheding area and it have a direct access for the offal room. But  there will be generate waste from  flesh trimming like things at processing are too. But there we do not have direct access for offal from processing area. So we have to store them in bins temporarily untill the cutting is finish. Is that a problem. attachicon.gif 20201218_112218.jpgI have attached a sketch here

 

The acceptability likely depends on "appearance" (eg volume trimmings, No.bins, mode of storage [iced?], time involved) and final route to the offal room (?).

 

The lab appears to have direct access to beheading area ?. This may be  "problematic".


Kind Regards,

 

Charles.C


#18 GAYATHRI VIDUSHIKA

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Posted 18 January 2021 - 11:11 AM

The acceptability likely depends on "appearance" (eg volume trimmings, No.bins, mode of storage [iced?], time involved) and final route to the offal room (?).

 

The lab appears to have direct access to beheading area ?. This may be  "problematic".

volume may depend on the quantity of processing. aprox( 40kg per 1200kg of fish).Bins will be allocate with ice according to the volume of the shipment. Route to offal room  will be a small hatch  of 4'*2' from processing wall slightly above from 1' above from the floor. Attached File  20210118_162741.jpg   34.77KB   0 downloads this is the upgraded sketch



#19 GAYATHRI VIDUSHIKA

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Posted 18 January 2021 - 11:19 AM

and there is another one i want to clarify ,are there any floor finishing material which recommend for the floor of the processing area



#20 Scampi

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Posted 18 January 2021 - 12:59 PM

I would splurge for the epoxy coating with the anti slip grains mixed right in. It is not cheap, but protects the concrete over time from all the water and helps ensure your employees don't slip.  Smooth concrete is very slippery wet especially when it's brand new

 

Example:  https://diamondrockc...ring-solutions/           Not giving a company/product recommendation, just a material type 


Please stop referring to me as Sir/sirs


#21 GAYATHRI VIDUSHIKA

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Posted 20 January 2021 - 08:36 AM

I would splurge for the epoxy coating with the anti slip grains mixed right in. It is not cheap, but protects the concrete over time from all the water and helps ensure your employees don't slip.  Smooth concrete is very slippery wet especially when it's brand new

 

Example:  https://diamondrockc...ring-solutions/           Not giving a company/product recommendation, just a material type 

noted thanks for the information



#22 Charles.C

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Posted 20 January 2021 - 08:46 AM

volume may depend on the quantity of processing. aprox( 40kg per 1200kg of fish).Bins will be allocate with ice according to the volume of the shipment. Route to offal room  will be a small hatch  of 4'*2' from processing wall slightly above from 1' above from the floor. attachicon.gif 20210118_162741.jpg this is the upgraded sketch

 

IMEX, above "solution" may cause worker "traffic" problems ( a conveyor is useful but takes up space).

 

The lab positioning still looks "problematic".


Edited by Charles.C, 20 January 2021 - 12:35 PM.
added

Kind Regards,

 

Charles.C





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