ENGINEERING AT FOOD MANUFACTURING PLANT
PREMISED ON HACCP OPERATION- ENGINEERING CASE STUDY OF FOOD SAFETY IN JAPAN (Korean Society for Food Engineering (KSFE) Annual conference)(COEX-Seoul in Korea, Oct. 11, 2004, pp.151-165)

Dr. Carl K. Ishito, Kazuya Nanazoshi(NISSHIN ENGINEERING INC., Japan)< Abstract >As Nisshin Engineering has been offering the engineering service of food plant for over 30years, we are experienced with so many various situations of food plant construction. Today, weare focusing on the case study of basic plan of new food plant producing lunch box.

In thiscase study, we are going to discuss on the engineering approach of food plant basic planning,which is one of the most important key steps & technologies.

< Contents >1) Introduction2) Improvement of HACCP System and Hardware
3) Flow of Engineering Work in Construction of Food Manufacturing Plant
4) Hardware Planning5) Conclusion

1. INTRODUCTION
Food poisoning incidents four years before were of the largest scale in postwar Japan.
Not only the relevant food corporations, but many other food related businesses have received
extensive complaints from the consumers because of food related incidents such as foodpoisoning and mixture of foreign substances.

This is now undermining reliability of foodsafety.
The mission of the food corporations is to supply "safe and reliable food."

They have totry every method to secure safety, wholesomeness and soundness of food.
The HACCP system is effective as one of these methods and has been positively introduced
all over the world.

We initially heard of "HACCP" in the beginning of the 1990, but there

are now very few people in the food industry who do not know it.

Coverage of theabove-mentioned food poisoning incidents by mass media helped the system's social
recognition.

Not all people may understand the HACCP system well, but it is also true that1some people say, "the HACCP system is not good enough to secure safety of food."

For the"entire food industry" including every food related field as well as food manufacturing
companies, it will be necessary to bring it home to general consumers that if the HACCPsystem had been operated as it is intended, those incidents would not have occurred anddemonstrate its effectiveness to deepen their understanding of it.
In the future, introduction of the HACCP system into their manufacturing fields and its
strict operation (planning, execution, and verification) are more requested to the food business.
In such circumstances, we have been recently constructing plants compliant with the HACCP
system as an engineering corporation engaged in construction of food manufacturing plants.
We would like to present what we have in mind, based on our track record.

2. IMPROVEMENT OF HACCP SYSTEM AND HARDWARE
Upon introducing and operating the HACCP system, it is essential to improve a PP(Prerequisite Program), which is a prerequisite of the HACCP system for the system tofunction effectively and smoothly.

The PP is roughly classified into GMP (GoodManufacturing Practice) for hardware (facilities, equipment, etc.) and SSOP (Sanitation
Standard Operating Procedure) for software (management, administration, etc.).
necessary to improve both hardware and software in parallel.

ＰＰ （Prerequisite Program）
I. FACILITIES AND EQUIPMENT
1. Perimeter of the Facility
2. Structure of Facility
3. Sanitary Equipment
4. Water Quality Control
II. ACCEPTANCE AND STORAGE OF RAW MATERIALS
1. Acceptance of Perishable Raw Materials,
Non-perishable
Raw Materials and Packing Materials
2. Storage
III. STRUCTURE, LAYOUT AND MAINTENANCE
OF MACHINES
1. Structure of General Machine
2. Location of Machines
3. Preventive Maintenance of Devices
IV. HEALTH, SANITATION CONTROL AND TRAINING
OF EMPLOYEES
1. Manufacturing Techniques and HACCP
2. Health and Sanitation Control
V. SANITATION CONTROL OF FACILITIESAND EQUIPMENT
1. General Sanitation Control Items
2. Rats and Insects Control
VI. PRODUCT COMPLAINTS
1. Complaint Occurrences and Their Causes
2. Handling of Complaints and Their Record

HACCP
SystemＰＰ （Prerequisite Program）
・ＧＭＰ （Good Manufacturing Practice ）・ＳＳＯＰ(Sanitation Standard Operating Procedure ）Management Standard

Facilities Standard

HACCP System and ＰＰ （Prerequisite Program）

2It isIn considering the HACCP system, however, a balance of hardware and software naturally
depends on whether the plant is of apparatus-oriented or labor intensive type, and whether it isa new or existing one.
If it is the apparatus-oriented plant, there will be less areas that must be complemented bysoftware if hardware is highly improved.

This aspect seems to be contributing to relatively

advanced introduction of the HACCP system in the apparatus-oriented plants.
In case of labor intensive plant, on the other hand, if improvement of hardware (zoning or
setting of a physical barrier) is made stricter, the plant will have less freedom and will be
troublesome for workers; if priority is given to freedom in work, to the contrary, you will haveto bear a greater burden in software operation.
In the case of a new plant, realization of "what it should be" and improvement of hardware
are relatively easy by designing the plant considering the operation of the HACCP systemstarting from the planning phase. Improvement of software can be carried out in parallel.
Existing plants need renovation and have to solve various obstructive factors such as space,cost, shutdown period, and lower work efficiency.

In some cases, you may have to make acompromise to rely on operation with software.

If this is the case, quality of the HACCP

system could be low.
Due to the facts described above, it is presumable that setting and standardization ofhardware level (although it is naturally a voluntary standard) are fairly tough matters in thecurrent circumstances. However, importance of improvement of hardware is solid, judging
from the fact that quality of hardware has a direct effect on operation with software.
For these years, we have regarded that the HACCP system is introduced in food
manufacturing plants as quite natural when constructing them.

The following mainly states

our ideas on engineering work in construction of labor intensive plants and improvement ofhardware in the HACCP system.

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3.

FLOW

OF

ENGINEERINGWORKINCONSTRUCTIONOFFOODMANUFACTURING PLANT

The engineering work in plant construction is to be carried out in the flow shown in thefigure.
1. Feasibility Study-Study, analysis and examination of current requirements (market,location, environment, distribution, future plan, regulations, cost, etc.)

2. Basic Plan
- Creation of the master plan
- Decision of a concept

3. Basic Design- Basic design (equipment, layout, operating methods, information system,etc.)- Basic design specifications- Estimated budget

4. Detailed Design- Detailed design (civil engineering, architecture, building equipment,
production machinery, utilities, electric instrumentation)

5. Procurement- Procurement and manufacture of the devices and system- Inspection prior to delivery

6. Construction Work
- Preparation of application documents to the government agencies andvarious proceedings.
- Execution and management of construction work (civil engineering,architecture, building equipment, production machinery, electricinstrumentation)- Schedule management- Budget management

7. Test Run- Adjustment work
- Guidance to and training of operators

8. Operation and Maintenance- Maintenance- After-sale service

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The following describes the procedures of food manufacturing plant construction along theflow of the engineering work.
1) Feasibility Study
A business project is proposed by a business proprietor and various analyses are made on it.
Among external factors such as the market, conditions of location, legal regulations,environmental measures, and internal factors such as a personnel plan, sanitation control,automation, future plan, you make a rough program and compare it with a funding program to
examine whether the business will be successful.

The business project starts if its

implementation is decided.
2) Basic Plan
Once the project starts, you have to initially decide your concept including what kind ofplant you want to construct or should be constructed to unify awareness of the project
members.

Based on the concept, you set a production plan, personnel plan, master scheduleand process flow to create the basic plan.
3) Basic Design
To actualize the master plan, you must decide basics and framework in this phase, such as an
overall configuration plan, layout plan, elevation plan, zoning plan, flow plan.
The results of the basic plan and basic design are directly linked with the final performanceof the plant.

Therefore, it is necessary to invest great energy into design and examination

as to what kind of plant you want to construct.

Highest priority should be also given to full

examination of the HACCP system in this phase.
4) Detailed Design
Based on basic design, you design facilities required for construction in detail, such as civilengineering and architectural design, building equipment design, utilities design, production
equipment design, electric instrumentation design.

Furthermore, you examine mutualconnections, considering cost performance in line with basic design, and prepare thespecifications and drawings for implementation.
5) Procurement
6) Construction Work
7) Test Run
8) Operation and MaintenanceTaking design considerations into full account, you proceed to the plant construction phaseat the site.

Material procurement and construction work must be thoroughly managed sothat the construction work methods and term of works for each process will be properly
satisfied, causing no mistakes in construction work.

In order to finally actualize the quality

assumed at the time of design, management of design and construction work plays a very5important role in these phases.

Together with them, management of the schedule andbudget is also essential.
After construction work is completed and all the equipment is tested, you actually perform
test run of the manufacturing system.

The problems detected in this phase should be

examined and solved quickly and adequately to prepare for actual operation.

4. HARDWARE

PLANNING

To ensure product safety and uniformalize product quality, in which phase should theconcept of HACCP be introduced?
Starting from the phase of feasibility study, it is necessary to assume operation of HACCP.
By introducing the HACCP system, you must not only ensure product safety, but assume thesanitary level of the plant beforehand.

You need to make consideration of costs including

initial cost for improving hardware and running cost for operating the HACCP system in thisphase.
Then, you proceed to actualize preparation of plant hardware in the design phase and themost important point is how to address the HACCP system in the master plan and in the basic
design phase.

What you have to do first in this phase is to decide a process flow and work

flow chart.

Based on this flow, you will analyze and examine hazardous factors in theprocess and plan the following, taking those factors into account:
1. Layout plan
2. Zoning plan
- Classification of cleanliness- Classification of dryness/wetness- Classification of air pressure
3. Flow plan
- Flow lines of things- Flow lines of personnel- Flow lines of food container boxes/push cars
- Flow lines of waste
Here, you need to pay heed to the following items:
1. Prevention of cross contamination and secondary contamination
2. Shorter distance of flow lines (Particularly, minimize the flow lines of the objects which
could become contamination factors)
3. Location of the machines and devices
4. Work space and storage space
5. Work efficiency and personnel placement
66. Easy sanitation of the structures and devices
7. Prevention of insects and rats
8. Handling of waste
9. Flexibility at the time of remodeling, renovation and extension
It is important to proceed with design, concerting hardware and software with each other.
In each plan, you need to fully examine validity, consistency, operating methods and work
efficiency, avoid easy compromise as much as possible and materialize "what it should be" tothe maximum, even if you have to go back to the beginning.

Basic design with the HACCP

system in mind at this point will play a great role in sanitation management and operation of
the HACCP system after the plant has started running.

■Flow Diagram

The ManufacturingRooms

The Linen Closet

TheMedicine
Deposit

Goods Received
Werehouse( )1

The Packing
Preparation
Room

The VegetableStorage

The Fish andMeat DressingRoom

The Dressed Fishand Meat Storage

The
Refrigerator

The PC Deposit

Receipt
Receipt
ofofgoods
goods

Receipt
Receipt
ofofgoods
goods

The Chilled
Deposit
The outsidecontainer receiveroom

Receipt
Receipt
ofofoutside
outsidecontainercontainer
ss

Receipt
Receipt
ofofgoods
goods

出荷The ChilledAssortingRoom

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The Cooked RiceStorage

The Red-Bean RiceCooking RoomThe Rice CoolingRoom

The RiceThrow-inRoom

The Rice Storage

The Rice-Cooking Room

The insidecontainer
washing room

The outsidecontainer washingroom

The insidecontainer storage

The outsidecontainer RoomThe RiceMixing Room

Receipt
Receipt
ofofgoods
goods

The Rice Pre-Shipping Room

The Vegetable
Dressing Room

The Topping Room

The Vegetable
Refrigerator

The Rice Assorting Room

The armor
Bactericidal
StorageThe Storage(Non-Rice)

The Armor
Bactericidal
Room

The Refrigerator(Non-Rice)The Non-Heated
Refrigerator

The Cooling Room

The MeasuringRoom

The Differential
Cooking Room

Goods Received
Werehouse( )The Normal
Temperature
Deposit2〔〔 5〜10℃5〜10℃ 〕〕

The
Laver Storage

The coveringMaterial Deposit

The Vacuum
Cooking Room

〔20℃〕
〔20℃〕

Zone

The Cooking Room

Receipt
Receipt
ofof
goods
goods

The Cooking
Linen Closet

The Contamination Zone
The semi Clean Zone
The Clean Zone
The Clean Zone
The Contamination

sendingsendingofof
goods
goods

Zoning Concept
Cleaning (Inner Containers)

Sortingand Shipment

Dishing up

WarehousingandPre-processing
Storage ofCooling andCooking
Raw Materials
Storage of Products
Clean Area
Semi-clean Area
Contaminated Area

Cleaning
Manufacture Control,(Outer Containers)
Quality Control

Shoes
Sanitary

Sanitation
Control

Waste Storage

Warehouse(1) Classification of Contaminated and Non-contaminated Areas
3 levels of cleanliness are used in this project; clean area, semi-clean area and contaminated area. This classification is to
standardize the sanitary levels of the materials and products handled in each room of the plant and work details.

(2) Classification of Dry and Wet Areas
When a push car or worker enters a non-contaminated area from a wet area, the work environment should be analyzed toprevent contamination of the floor, materials and products in the non-contaminated area.

(3) Classification of Air Pressure Distribution
Each area should be differentiated to prevent entry of insects or floating germs into a manufacturing area inside/outside
the plant as much as possible and maintain the temperature and humidity levels in each room.

Flow separation of food and waste
Flow of Food Materials and Utensils
Flow of Waste

Cleaning(Outer Containers)

Dishing up and Packing

Manufacture Control,
Quality Control

Coolingand Storageof Products

Shoes
Sanitary

Cooking

Sanitation
Control

8Pre-processing

Sortingand Shipment

Waste Storage

Warehousing and Storage of Raw Materials

Cleaning (Inner Containers)

WarehouseFurthermore, more detailed specifications should be included in order to prevent hazards ineach process in detailed design.
When doing this, the following items are the basics:<1> Structure and specifications which do not allow entry of hazardous factors(microorganisms, insects, rats, foreign substances, etc.) into the plant or production
facilities- Air tightness of the exterior and interior- Air tightness and finishing methods of the goods inlet and outlet, entrance and exit,
openings, etc. and installation of the prior rooms- Method, structure, location and air pressure balance of air supply and exhaust ports- Illumination plan
<2> Structure and specifications which do not allow increased hazardous factors in the plantand production facilities- Selection of antibacterial materials- Dew condensation preventive measure (Material, heat insulation, air conditioning
method, etc.)- Accumulated powder, accumulated dust, standing water, realization of dryness- Drainage plan such as a drainage system, tilts, traps- Control and monitoring of the temperature and humidity<3> Structure and specifications which allow easy elimination of hazardous factors in theplant and production facilities- Smoothness and detergent properties of the materials- Chemical resistance and corrosion resistance of the materials- Illumination plan, and disinfection and insecticidal devices
Together with them, the following are also to be considered:<4> Sanitation method<5> Monitoring methodGenerally, food manufacturing plants cannot easily spare time for repairing andimprovement of each facility/equipment, but severe working conditions are imposed to thefloor of the boiling pot areas and hot water drainage areas in the heated cooking room.

In

order to minimize repairing work, durability should be fully examined in selecting floor
materials.
In addition, you also have to assume necessity of extension and remodeling works
attributable to changes of the raw materials, items, cooking methods, etc.

It is desired totake into account flexibility of the layout of the facilities and equipment, and thespecifications, so that responses to those changes are not big burdens to bear.
9Finally, it is naturally necessary to consider a balance with costs.
Even if hardware preparation has thus reached a satisfactory level, improper software
preparation could lead to insufficient operation as the HACCP system.
In that sense, we believe it essential to bring "5 S's" home, which are basics for everything.

[Bringing "5 S's" Home ]Arrangement (Seiri): Stagnation control of a flow of things.
Classify whether necessary orunnecessaryTidying up (Seiton): Manage definition and indication of things so that they can be usedwhenever necessary.
Cleaning (Seisou): Elimination of foreign substances.
Get rid of dust and stains.
Cleanliness (Seiketsu): Maintenance of cleanliness.
Clean the workplace.
Discipline (Shitsuke): Manage work so to observe the regulations.

[4 Steps for Arrangement and Tidying up ]1. Eliminate unnecessary articles. (An usable space is produced by eliminating
unused articles, even if you think that they will be used someday.
Basically,
allow only minimum requirement in the workplace.)
2. Store necessary articles, depending on their frequency in use. (Store more
frequently used articles on the near side and less frequently used ones on the lower
shelves or in the warehouse.)
3. Once the storage place is decided, put up an indication and avoid putting otherthings.
4. Make it a habit to immediately put back the used article to its fixed storage place.

5. CONCLUSION
The construction trend of the food manufacturing plant has changed to various styles, butthere has been no change made to the proposition to construct a plant designed to provide
tasteful, uniform, safe, and "high-quality products."
With this proposition being as the first principle, NISSHIN ENGINEERING has been
grappling with plant construction in concert with users.

Plant construction, composed ofvarious elements such as civil engineering, architecture, building equipment, production
equipment, electric equipment, information processing equipment, drainage equipment, etc.
requires enormous amount of work and we must put them up functionally and efficiently.
We believe it our role to understand all of those elements and put them up unitarily in theuser-desired direction through close cooperation.
We are an engineering company which has a food company as its parent and haveconstructed a variety of food manufacturing plants.
10Not only feeding back foodmanufacturing know-how in the manufacturing field, but based on our accomplishments ofplant construction other than food manufacturing plants such as medicines, fertilizers, forming
goods, toiletry goods, and distribution center, we are capable of providing users with plenty ofknowledge and experience.
From a standpoint of providing the engineering work in plant construction, we would like tocontribute to future development of the food industry.

High-quality,
High-efficiency
Production Plant

HACCP
Compliant Plant

Comfortable Plant

Construction ofOptimized Plant

Environmentally
Friendly Plant

Cost Performance- oriented Plant

Flexible Plant

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