6.1 - EXTERNAL STRUCTURE & FABRIC (BASE)

  • The Structure and fabric of the building must be suitable for use, weather proof and pest proof

6.2 - INTERNAL STRUCTURE (BASE)

  • Walls, floors, ceilings, drains and doors must be designed and maintained to allow effective cleaning

  • Walls, floors, ceilings, drains and doors must be maintained in good condition to prevent foreign body risks

6.2.1 - INTERNAL STRUCTURE (MEDIUM)

  • Walls, floors, ceilings drains and doors must be constructed of impervious materials in open food areas

  • Wall / floor junctions must be coved to allow easy cleaning

  • Walls must be protected against damage during normal use e.g. Crash barriers where appropriate

  • WGLL - swing doors with kick plates

  • WGLL - floors are anti-slip

6.2.2 - INTERNAL STRUCTURE (HIGH)

  • There must be a floor to ceiling physical barrier between low risk and high risk

  • Openings between low risk and high risk must be kept to minimum

  • Where openings exist between low risk / high risk they must be risk assessed, managed and verified ( excludes main personnel door)

6.2.3 - INTERNAL STRUCTURE (HIGH)

  • No roller lifting doors are acceptable in high risk as they will be in contact with floor and when raised May drip on materials / personnel

6.3 - FABRICATION JOINT (MEDIUM)

  • Fabrication joints must be sealed and free from mould and not pose a foreign body risk

6.4 - FLOOR GRADIENTS (BASE)

  • Floors must not pool water and have adequate slope to drainage

  • The floor gradient must not be excessive and cause wheel bases / trolleys to roll to drain

6.5 - SINKS (BASE)

  • All sinks in production areas must not be constructed from porous or breakable material

  • Sink waste water must be ducted directly to a drain

6.6 - DRAINS (BASE)

  • Drains must be accessible for cleaning and fitted with screens or traps to prevent pest entry, odours and debris from blocking drains

6.6.1 - DRAINS (MEDIUM)

  • A drain plan must be in place for the entire site (inside and outside)

6.6.2 - DRAINS (HIGH)

  • Drains must flow from high to low risk areas

  • A system must be place to prevent back flow

6.6.3 - DRAINS (ASPIRATIONAL)

  • A separate drainage system for high risk from low risk areas

6.7 - WALKWAYS OVER LINES (MEDIUM)

  • Walkways and steps over production lines must be fitted with back plates and enclosed sides to prevent product contamination

6.8 - WINDOWS (BASE)

  • Glass windows and doors in the production and storage areas must be protected from breakage

  • A risk assessment must be completed on surrounding areas to establish the potential risk of transfer

6.8.1 - WINDOWS (BASE)

  • Windows designed to be opened, must be suitably proofed to prevent pest entry (including canteens, toilets and locker facilities that adjoin the factory)

6.9 - EXTERNAL DOORS (BASE)

  • All external doors must be kept closed when not in use and effectively proofed against pests.

  • WGLL - Good door control in place (i.e. Doors not being left open for long periods to temperature controlled areas or allowing free access to pests)

  • If strip curtains are fitted, they must be maintained and kept clean

  • WGLL - Strip curtains are full length and intact

6.9.1 - EXTERNAL DOORS (MEDIUM)

  • There must be no external doors in open food handling areas with the exception of identified and controlled fire exits

6.9.2 - FIRE DOORS (HIGH)

  • Fire exits from high risk must be alarmed or tamper evident

6.9.2.1 - EXTERNAL DOORS (HIGH)

  • Where used, a removable wall section (pod door) between the high risk and low care wall (to allow for introduction / removal of large equipment) must be close fitting and sealed each time after opening.

  • A full deep clean of the high risk environment must be undertaken if removed, before production recommences

6.9.3 - EXTERNAL DOORS (ASPIRATIONAL)

  • Air curtain or automatic closing doors are fitted to external doors

6.10 - LIGHTING (BASE)

  • Lighting in all areas must enable safe working and good visibility

  • Lights must be protected by shatterproof covers and or sleeves (on the light tubes / bulbs)

  • Adequate lighting must be in place above product inspection areas

6.10.1 - LIGHTING (ASPIRATIONAL)

  • Lighting designed so that bulbs are replaced without entering production areas

6.11 - VENTILATION AND EXTRACTION (BASE)

  • Ventilation and extraction systems must be effective at preventing condensation, excessive dust, pest entry and not pose a risk to product

  • Similarly if heating is provided

  • WGLL - risk assessment may need to be used in order to determine that where condensate is present, samples may need to be sent away for microbiological assessment

6.11.1 - VENTILATION AND EXTRACTION (MEDIUM)

  • A documented risk assessment must be conducted to determine the requirement for air filtration

  • Where air filtration is in place, it must be regularly inspected and replaced

6.11.2 - VENTILATION AND EXTRACTION (HIGH)

  • An air filtration system must be in place and be regularly inspected and replaced

  • The filter grades used must be risk assessed to ascertain the risk from airborne contamination from the local environment and the likely occurrence of product contamination e.g. Time product is exposed

  • Positive air pressure (>5 Pascals) must be in place in high risk areas and monitored at defined frequencies

  • An initial assessment / study to measure air pressure must be held by the Site

  • WGLL - high risk - filtration to a minimum F9-H11 / 98% efficient filter grade must be in place and positive air pressure (classification of general ventilation filters EN779:2002)

  • WGLL - generally 5-25 air changes per hour are sufficient, however in areas with large doors / hatches that are frequently opened up to 40 changes may be required

6.11.3 - VENTILATION AND EXTRACTION (BASE)

  • Air socks must be cleaned and maintained at a scheduled frequency.

  • Frequency must be adequate to prevent build up of debris / mould growth

6.11.4 - VENTILATION AND EXTRACTION (HIGH)

  • Air socks must be identified for rotation - high risk and low risk air socks must be washed separately

6.12 - SERVICES (BASE)

  • All services must be designed from material suitable for the purpose and appropriate to the area where used, intact and allow easy and effective cleaning:

  • Pipe work for water

  • Pipe work for gas

  • Pipe work for steam

  • Pipe work for compressed air

  • Electrical cabling, conduits and sockets

  • Ventilation ducting

  • Compressors / pumps

  • Fire extinguishers / sprinkler systems

6.13 - STORAGE AREAS (BASE)

  • Storage areas must be fit for purpose and maintained in a clean / hygienic condition

  • Materials must not be stored directly on the floor or tight against the walls (space is required for pest inspection)

  • WGLL - racking where fitted is far enough away from the wall, to prevent pallets being pushed up tight against the wall

  • WGLL - there is enough space to allow walking access between materials and walls for inspection

6.14 - TEMPERATURE CONTROLLED AREAS (BASE)

  • Condensate drainage must be constructed and designed so as to minimise the risks of microbiological contamination

  • Drainage pipes must flow to drain and not drip on product, materials, packaging or production equipment

  • WGLL - drainage pipes end a few centimetres above the drain and are not ducted directly into the drain

6.14.1 - TEMPERATURE CONTROLLED AREAS (MEDIUM)

  • Condensate drainage must have a break near to the floor using a tun-dish to prevent any potential suck back from the drain into the evaporator

6.14.2 - TEMPERATURE CONTROLLED AREAS (HIGH)

  • A risk assessment must be carried out to determine if chemical sanitising rings are required in condensate drip trays

6.14.3 - TEMPERATURE CONTROLLED AREAS (ASPIRATIONAL)

  • Doors to temperature controlled areas are automatic closing or alarmed if not closed

6.14.4 - TEMPERATURE CONTROLLED AREAS (BASE)

  • Temperature controlled areas must be capable of maintaining the required temperature

  • Freezer areas must be adequately maintained to prevent excessive build up of ice on walls, floors and ceilings

6.15 - PRODUCTION OFFICES (BASE)

  • Offices within production / storage areas must be managed so that they do not pose a risk to product

  • Equipment must be kept to a minimum to allow easy cleaning

  • Eating and drinking is not permitted in these offices, with the exception of plain drinking water

  • WGLL - Offices have basic equipment (desk, chair, storage, computer etc) which is of an easy to clean construction

  • WGLL - they are not adorned with personal items (eg collect ambles, cups, bottles etc)

  • WGLL - stationary items are consistent with site rules and GMP (eg. Factory issue pens, no staples, no draw ing pins etc)

6.16 - PRODUCT ASSESSMENT AREAS (BASE)

  • Sampling of product must only be permitted in areas clearly designated for this purpose (following risk assessment)

  • After product sampling, hands must be washed

  • WGLL - a separate room containing hand washing facilities

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