Principles for hygienic design and zoning

1. Department of Fisheries and Aquatic Resources (DFAR) Sri Lanka National Aquatic Resources Research and Development Agency (NARA) Sri Lanka United Nations University Fisheries Training Programme (UNU-FTP) Iceland Icelandic International Development Agency (ICEIDA) Iceland Principles for hygienic design and zoning Quality and Safety Issues in Fish Handling ----- A course in quality and safety management in fishery harbours in Sri Lanka NARA, DFAR, ICEIDA and UNU-FTP

2. Content • Sources of contamination • Hygienic design – key criteria • Zoning of harbour

3. Learning Objectives After this lecture participants will be familiar with: • how seafood can be contaminated • how the hygienic design criteria and zoning can reduce the contamination during handling • requirements for different zones

4. Increased pressure on fish handlers regarding hygiene: • "New" hygienic problems (e.g. bacteria, viruses) • More demanding specifications from buyers • Increased interest in further processing of foods and in chilled products • Consumption of raw or minimally processed seafood e.g. Sushi, sashimi, cold smoked fish

5. Origin of bacteria in seafood -environmental routes • surface • directly via product’s contact surfaces • e.g. pallets, tables knives • indirectly via other routes • e.g. drains, floors, pier • people and animals (dogs, cats, crows) • water – harbour seawater • air • sewage from toilet waste • fish waste, blood water, • trash fish “Cleaning” fish with harbour water

6. Basic problems in handling and processing fish: • high number of bacteria and/or • presence of pathogenic bacteria or indicators thereof

7. Bacterial load in fish (Ganegamarachchi, et al 2004)

8. A home of pathogenic bacteria

9. Hygienic design of food handling/processing facilities and equipment • Three major benefits to food manufacturers • maintains product in the main product flow - Quality • prevents contamination of the product with substances that would adversely affect the health of consumer - Safety • reduces time required for an item of equipment to be cleaned - Efficiency

10. Materials for construction Surface finishes Joints Fasteners Internal angels and corners Basic hygienic design requirement

11. Stainless steel –AISI 304:2B • untreated (RA:0,16-0,17) • polished (RA:0,16-0,22) • glassbeaded (RA: 0,7-0,8) 50 1 50 50 2 3

12. Basic hygienic design requirements (cont.) • Drainage • Bearings and shaft seals • Instrumentation • Doors, covers and panels • Controls • Dead spaces

13. Hygienic design? Good or bad?

14. Most common materials used for construction in the food industry • Stainless steel • AISI-304, AISI-316 and AISI 316L • Plastics • polypropylene (PP), polyvinyl chloride unplasticised (PVC), Acetal copolymer, polycarbonate (PC), high density polyethylene (PE) • Elastomer • ethylene propylene diene monomer (EPDM), nitrile rubber, nitrile/butyl rubber (NBR), Silicone rubber, fluororelastomer (Viton) • Lubricants • food grade

15. Use of wood is only acceptable when: it plays a favourable role e.g. cheese ripening, wine and vinegar production its mechanical properties cannot be obtained with other available materials e.g. butcher's block Splinters can result in foreign body contamination Wood cutting table Use of wood??????? Wooden surfaces must be cleaned effectively and disinfected because they can retain microorganisms which can grow in the presence of nutrients

16. Break up of processing areas - Zoning In a fish handling environment there are various demands regarding cleanliness in each area hygienic requirements low risk area and high risk area traffic of people and vehicles The areas must be separated according to these demands

17. Harbour activity

18. Zoning for prevention • Keeping away unwanted items, animals and people from the product contact point is a major step towards prevention of food hygiene problems…………….

19. Zoning of harbour high hygienic demands Different zone are: • Pier - unloading area • Auction hall • Loading area for buyers • Loading of provisions to boats • Cleaning of boats • Other facilities • toilets, canteens, offices, fuel sheds, • parking areas, • ice-plants • net-maintenance • waste treatment/disposal • repair areas • more? Most important zoning will be ineffective without coaching and correct attitudes

20. Zoning for prevention ………must remain realistic and affordable • What is to be prevented? • What are the contamination sources of concern? • What services are necessary?

21. What is wrong in this picture?????

22. Requirement for the pier – unloading area • Good access and easy to clean • Restrict unnecessary traffic • No direct landing of fish on the pier • access to boxes, plastic baskets and pallets • land directly into boxes or baskets and then onto pallets in the auction hall • Easy access to potable water

23. Requirement for auction halls • Easy access to potable water • Access to ice made from potable water • Washing table/basin for the fish • Cleaning facility – cleaning programme – high pressure equipment (20-70bar) • Waste bins • Cutting table

24. Requirement for auction halls • Floors should be made of waterproof materials that are easy to clean and disinfect • concrete • ceramic tiles • seamless resin screeds ( heavy duty, self-levelling and coatings) • Water must drain away easily • slight slope towards the drain (1 in 40 or 1 in 60) • Hygienic drainage system for waste water is an absolute necessity • durable and easy to clean material • should be as straight as possible

25. Channels and aperture channel drain design

26. Auction hall Auction hall to close to pier Wrong use of auction hall

27. Requirement for other areas • Toilets • high standard to ensure maximum lifetime, • properly maintained with adequate water supply to flush • never open to a work area where fish is being handled due to risk of flooding from blocked drains • wrong use of toilet • Wash hand basins • adequate number in each toilet block • hand - or foot -operated faucets and soap available at all time

28. Requirement for other areas (cont.) • Showers • the importance of showers in a hot climate should not be underestimated • Signs and bill boards • listing food hygiene regulation for the harbour area • prohibition of dumping spillage into the harbour basin • prohibition of using seawater from harbour basin • indication of directions e.g. to toilets

29. Requirement for other areas (cont) • Ice-plant • Ice made from potable water • Cleaning programme • Restrict traffic • Protective clothing • Canteen • Hygienic requirement • Restroom • Hygienic requirement • Fuel shed • Repair/ maintenance area

30. Ideal arrangement for the fish harbour Loading unloading Auction hall Ref: Ice in fisheries. FAO fisheries technical paper no. 331 (1992)

31. References • Marriott, G. M.(1997). Essentials of food sanitation. Chapman and Hall. New York and London • Training material from UNU-FTP/Icelandic Fisheries Laboratories • Guide to Hygiene within the Fish Industry (2000). Eastfish - Fachpresse Verlag, Michael Steinert, An der Alster 21, D-20099, Hamburg • EHEDG (European Hygienic Engineering & Design Group) • document 8 – Hygienic equipment design criteria, second edition 2004 • document 13 – Hygienic design of equipment for open processing, 1996 • Edt. H.L.M. Lelieveld, M.A. Mostert, J. Holah and B. White (2003) Hygiene in food processing:. Wood Head Publishing Limited. Cambridge, England.

32. References • Ice in fisheries. FAO fisheries technical paper no. 331 (1992) • Fishery Harbour Manual on the Prevention of Pollution – Bay of Bengal Programme. FAO report, BOBP/MAG/22, 1999 • Ganegama Arachchi, G.J. Kariyawasam, M.G.I.U., Heenatigala, P.P.M. Ariyaratne, T. Dahanayeka, T. and Jayasinghe, J.M.P.K. (2004) An investigation on the quality and handling practices of skipjack tuna (Katsuwonus pelamis) along the main commercial distribution channels of Beruwala fishery harbour. Sri Lanka J. Aquat. Sci. 9: 109-121