Food Engineering logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Food Engineering logo
  • NEWS
    • Latest Headlines
    • Manufacturing News
    • People & Industry News
    • Plant Openings
    • Recalls
    • Regulatory Watch
    • Supplier News
  • PRODUCTS
    • New Plant Products
    • New Retail Products
  • TOPICS
    • Alternative Protein
    • Automation
    • Cannabis
    • Cleaning | Sanitation
    • Fabulous Food Plants
    • Food Safety
    • Maintenance Strategies
    • OEE
    • Packaging
    • Sustainability
    • More
  • EXCLUSIVES
    • Plant Construction Survey
    • Plant of the Year
    • Sustainable Plant of the Year
    • State of Food Manufacturing
    • Top 100 Food & Beverage Companies
  • MEDIA
    • Podcasts
    • Videos
    • Webinars
    • White Papers
  • FOOD MASTER
  • EVENTS
    • Food Automation & Manufacturing Symposium and Expo
    • Industry Events
  • RESOURCES
    • eNewsletter
    • Custom Content & Marketing Services
    • FE Store
    • Government Links
    • Industry Associations
    • Market Research
    • Classified Ads
  • EMAGAZINE
    • eMagazine
    • Archive Issue
    • Advertise
  • SIGN UP!

Form fits function

By Richard F. Stier
September 1, 2006
Choosing to build a new plant rather than renovate or expand an existing one is based on any number of necessary functions. The existing facility may be outdated and operating costs excessive. Or, a new location may offer advantages such as reduced labor costs, lower taxes, improved access to markets or simply the room to grow. Whatever the reason, it behooves operations and plant managers to plan carefully and understand where they are going and why. Today, a commitment to build a new plant is a commitment to sanitary design.





It starts at the bottom. Most production entails wet processing, which means wet cleaning. Plants must have floors with drains that can handle both food waste and water used in processing and cleaning. The drains must be installed as the floor is being installed. The last thing that anyone wants to do is jackhammer a floor to replace existing drains or install new ones. The floor should be properly graded so water flows toward the drains. And, the concrete needs to be protected. Options range from chemical resistant brick in a chemical resistant setting to a wide range of coatings and epoxies. The processor needs to select the surface that will be most effective, cleanable and safe, specifically, not too slippery. Remember to consider drain cleaning as well. Drains are known to be a prime source of Listeria monocytogenes.

When the walls go up, the wall and floor junctures should be coved to ensure that they drain freely and don't allow dirt to accumulate. The walls themselves should be constructed from materials that are easy to clean and maintain. Reinforced fiberglass and stainless steel may be the best materials, though many operations use tile. Keep in mind that tile can be problematic because it tends to break and grout can accumulate moisture, thus harboring microorganisms.

Consider the plant's overall workflow too. Plants that are designed so that the process flows in one direction are often the most efficient. Raw materials, whether they are frozen or refrigerated, wet or dry, may be unloaded into ingredient warehouses at one end of the plant and the finished goods stored at the opposite end.

For the equipment, use the same thought processes that went into building the plant. Plan ahead. A lower-priced unit may cost more in the long run. Equipment that is built to sanitary design principles allows sanitation operations to be conducted more quickly, efficiently and economically. Such equipment will also help minimize the potential for product adulteration, satisfy regulatory requirements and, most important, ensure that customers are satisfied.

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Richard stier 200px
Richard Stier is a consulting food scientist who has helped food processors develop safety, quality and sanitation programs. He believes in emphasizing the importance of how these programs can help companies increase profits. Stier holds degrees in food science from Rutgers University and the University of California at Davis. He is a Contributing Editor for Food Engineering. Email: rickstier4@aol.com

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • Global Organic Food & Beverage Market to Grow

    Global Organic Food & Beverage Market to Grow

    With a CAGR of 12.07%, Bonafide Research estimates this...
    People & Industry News
  • skilled MEP worker

    Predicting Food and Beverage Manufacturing Trends for 2024

    The two words that should be kept in mind are labor and...
    Automation
    By: Derrick Teal
  • cleaning and sanitation

    The basics of cleaning and sanitation in food plants

    Sanitation maintains or restores a state of cleanliness...
    Food Safety
    By: Richard F. Stier
Manage My Account
  • eMagazine
  • eNewsletter
  • Online Registration
  • Manage My Preferences
  • Customer Service

More Videos

Popular Stories

mechanical and chemical recycling

Clean Label Packaging Expands to Include Sustainability Considerations

Yoplait Protein Yogurt

General Mills Sells North American Yogurt Business

Bottling machine

How Sensing Technologies Can Help Avoid Food and Water Waste

CHECK OUT OUR NEW ESSENTIAL TOPICS

Alternative ProteinAutomationCleaning/SanitationFabulous Food Plants

Food SafetyMaintenance StrategiesOEE

PackagingSustainability

Events

June 17, 2025

Refrigerated & Frozen Foods’ State of the Cold Chain

On Demand Kelley Rodriguez, Editor in Chief of Refrigerated & Frozen Foods, will be joined in this 60-minute webinar by industry experts to help unpack the latest research.

July 10, 2025

Smarter Innovation With Practical AI: How to Stay Agile in Uncertain Times

Regulatory updates, supply chain shifts and evolving consumer demands keep the food and beverage industry in a state of constant change.

View All Submit An Event

Products

Recent Advances in Ready-to-Eat Food Technology

Recent Advances in Ready-to-Eat Food Technology

See More Products

Plant of the Year

Related Articles

  • Rick Stier

    Enhancing hygiene in your plant

    See More
  • Food Safety: The production versus quality dilemma

    See More
  • Food Safety: How safe are our products?

    See More
×

Elevate your expertise in food engineering with unparalleled insights and connections.

Get the latest industry updates tailored your way.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Food Master
    • Store
    • Want More
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing