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Best Practices in Safe Pet Food Manufacturing: Plant Design and Maintenance Guide

This training module focuses on plant design and maintenance standards for the safe manufacture of pet food. It highlights the importance of location, layout, and preventative measures against contamination. Key topics include maintaining clean areas around buildings, effective waste disposal, and ensuring proper drainage. The guide also covers equipment standards, hygiene protocols, staff facilities, pest control measures, and regulatory compliance. By following these guidelines, facilities can ensure food safety and improve operational efficiency in pet food production.

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Best Practices in Safe Pet Food Manufacturing: Plant Design and Maintenance Guide

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  1. FEDIAF Guide to Good Practice for the Manufacture of Safe Pet Food TRAINING PACKAGE Module V Plant design and maintenance Based on Version 9, 2009 of the Guide to Good Practice

  2. 5. PLANT DESIGN AND MAINTENANCE

  3. Trees away from buildings 5.1 Location • Localisation preventing contamination Clean area around buildings 5.2 Perimeter and grounds Tree close, wrong • Proper drainage • Waste collection in defined area • Buildings surrounded by clear/clean space Fence with vegetation Insects and rodents can nest and hide in the plants

  4. 5.3 Layout / product flow • FORESEE proper cleaning / disinfection • Sufficient WORKING SPACE • ONE-WAY FLOW: materials – intermediate – end products • SEGREGATE processed from unprocessed materials • Specific facilities for disposing unused ABPs

  5. 5.4 Buildings / materials • Smooth - easy to clean … • WALL and FLOOR SURFACES • Wall/floor JUNCTIONS AND CORNERS • DRAINAGES • CEILINGS – no accumulation of substances Cleaned drain Dirty drain

  6. 5.4 Buildings / materials (cont’d) • GLASS protected and controlled • Pest-proof OPENINGS • Adequate LIGHT for the operations • AIR FILTERING EQUIPMENT • No ‘higher’ to ‘lower’ risk areas AIR FLOWS • Labelled and segregated WATER SYSTEMS Plastic strip doors are not efficient barriers

  7. 5.5 Equipments / instruments • Food safety requirements in PURCHASE SPECIFICATIONS, e.g. • EASY TO CLEAN and DISINFECT • SPECIFIED for their purpose • Impervious and non-reactive SURFACES Badly sealed cable box Rarely opened equipment, ideal harbourage for pests Insect webbing

  8. 5.6 Maintenance • GMP criteria • CONTRACTORS under supervision Roof exhausts should be cleaned 5.7 Staff Facilities • CHANGING facilities prior to entry production • HAND WASHING • SMOKING banned or in designated areas • FOOD storage • WASTE disposal • WORKWEAR only in work premises

  9. 5.8 Risk of physical/chemical contamination • Use EU law for max. levels of contaminants • STORAGE of hazardous chemicals • GLASS policy • Minimise WOOD 5.9 Housekeeping hygiene • Cleaning/disinfection PROGRAMMES • Effectiveness VERIFIED • FOOD GRADE cleaning agents • Staff TRAINED for the purpose

  10. 5.10 Waste / waste disposal • Meet REGULATORY requirements • Minimise ACCUMULATION • Avoid CONTAMINATION • Defined WASTE AREAS • Dedicated CONTAINERS - regularly EMPTIED Inspect drains and sewers Waste areas can attract pests

  11. 5.11 Pest control • VERIFIED for effectiveness • RECORDS reviewed and kept • DRAINS with screens and traps • INCOMING raw materials checked • STORAGE minimising pest Harbourage areas Insect tracks in dust Rat tracks in dust Inspect incoming goods

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