Clean Room Areas Zoning

Hello there, I am looking for some information regarding Clean Room zoning. The building we are currently operating has a very large production room, however the empty spaces are being used for storage and miscellaneous uses, that in turn bring visitors to the area that are causing a protective clothing control problem. Not to mention the proximity of wooden pallets to open products. An external advisor suggested that we zone this area out, creating different levels of "PPE" requirements for each zone, which would be identified by signage and floor paint. However I am finding it hard to believe that we would be able to implement and control this without any physical barriers. Can anyone shed some light on this subject was we are also trying to comply with BRC standard? For reference we handle dry ambient powder. Any help would be greatly appreciated. Humbly, Tuan Garcia

Hi Tuan, welcome to IFSQN

Pallets near open product aren't an absolute no in BRC - it's about control/risk, and to some extent necessity, as there are some ingredients that are too large/heavy to move on their own.

Floor-based zoning can work and can be acceptable - I've done this before - but it does take a lot of training discipline, and generally getting on peoples' case about it, to make it actually routinely work and be adhered to.

Is it feasible in your production area to perhaps set up some dividers, either as mobile or permanent units? If total enclosure/segregation isn't needed due to product risk, then this should be enough of a physical barrier to help instil the relevant practices in the site staff.

Would cannot be stored in proximity of open food products. This will violate the the BRC requirements. If it is necessary to store there, then there shall be risk assessment and based on risk assessment control measures and monitoring shall be there to verify wood materials wont harm food. 

You can make entire floor as one zone (the highest possible zone shall be considered). Then for every one entering the zone only one type of uniform is sufficient. Or else as you told make physical barriers and different color coded uniforms for each zones can be done

ISO has clean room standards.  See the attached.

Hi Tuan, welcome to IFSQN

Pallets near open product aren't an absolute no in BRC - it's about control/risk, and to some extent necessity, as there are some ingredients that are too large/heavy to move on their own.

 

Floor-based zoning can work and can be acceptable - I've done this before - but it does take a lot of training discipline, and generally getting on peoples' case about it, to make it actually routinely work and be adhered to.

 

Is it feasible in your production area to perhaps set up some dividers, either as mobile or permanent units? If total enclosure/segregation isn't needed due to product risk, then this should be enough of a physical barrier to help instil the relevant practices in the site staff.

Thank you for your response.
I believe we might try the floor-based-zoning as we are sitting in a lot of space considered as "clean room", but the open product area is mostly concentrated together in the same corner of the room.

Physical barriers might create a disruption in our current flow, as each line of production ends with the boxed product pilled up in pallets that are rolled out into our warehouse.

Is there any kind of control I would have to create, for people to sign in, or just updating my site plan, signalize and providing training would be enough?

ISO has clean room standards.  See the attached.

Interesting. I will look for even more information about this.

Thanks for replying.

You can make entire floor as one zone (the highest possible zone shall be considered). Then for every one entering the zone only one type of uniform is sufficient. Or else as you told make physical barriers and different color coded uniforms for each zones can be done

My concern is that we get people from production, office, maintenance and warehouse coming and going from what we call the clean room, as in this building it is a large room that connects most of the other places.
And people don`t want to go through the change room everytime they need to come in to pick up something, or to see someone.
 

Thanks for replying.

My concern is that we get people from production, office, maintenance and warehouse coming and going from what we call the clean room, as in this building it is a large room that connects most of the other places.
And people don`t want to go through the change room everytime they need to come in to pick up something, or to see someone.
 

Hi Tuan,

As illustrated in Post 4, your use of the terminology "Clean Room" is perhaps a misnomer. (or a Canadian one ?) for typical food production purposes unless perhaps applied to, for example, an aseptic packing area or production for NASA.

https://en.wikipedia.../wiki/Cleanroom