Subchapter B. CONSTRUCTION AND LAYOUT OF
FROZEN FOOD PLANTS
GENERAL REQUIREMENTS Sec.
37.11. Application.
37.12. Separation from living quarters.
37.13. Objectionable conditions.
37.14. Accessways; parking areas.
37.15. Expansion.
37.16. Potable water.
37.17. Nonpotable water.
37.18. Equipment installation.
37.19. Hot and cold water; clean-up.
37.20. Sewage systems.
PLANT LAYOUT
37.31. Product preparation and processing.
37.32. Preparatory operations areas.
37.33. Refrigeration facilities.
37.34. Quick freezing facilities.
37.35. Waste storage rooms.
37.36. Storage of packaging and labeling materials.
37.37. Facilities for inedible products.
37.38. Cleaning room.
37.39. Dockage areas.
37.40. Dressing rooms; toilet rooms.
37.41. Eating.
PLANT CONSTRUCTION
37.51. Floors.
37.52. Walls.
37.53. Ceilings.
37.54. Window ledges.
37.55. Rodents; vermin.
37.56. Stairs.
37.57. Refrigerator doors.
37.58. Variations from requirements.
PLUMBING AND FLOOR DRAINAGE
37.61. Wet processing areas.
37.62. Hand washing facilities.
37.63. Sterilizers.
LIGHTING; VENTILATION
37.71. Work rooms and dressing rooms.
37.72. Fresh air intakes.
37.73. General light intensities.
GENERAL REQUIREMENTS
§ 37.11. Application.
(a) This subchapter shall be applicable to only those establishments initiating operations subsequent to the first inspection based upon the requirements of this chapter.
(b) —
(1) Existing plants shall, however, be subject to the provisions of this Chapter when a plant facility is remodeled or rebuilt subsequent to June 10, 1964.
(2) Existing plants include those plants or plant expansion under design or in the process of construction at the time this chapter becomes effective.
(3) Only that portion of the facility being remodeled or rebuilt shall be subject to the regulations of this chapter, unless such plant or plant facility constitutes an immediate health hazard.
§ 37.12. Separation from living quarters.
Frozen food preparation plants shall be completely separated from areas used as living quarters by solid, impervious floors, walls and ceilings, with no connecting openings.
§ 37.13. Objectionable conditions.
Food processing plants shall be located in areas reasonably free from objectionable odors, smoke, fly ash and dust or other contamination. Objectionable conditions are often prevalent in the environs of the following facilities, though not limited to such facilities:
(1) Oil refineries.
(2) City dumps.
(3) Chemical plants.
(4) Sewage treatment plants.
(5) Dye-works.
§ 37.14. Accessways; parking areas.
Adequate, dust-proof accessways for all vehicular traffic, connecting loading and unloading areas of the plant to the public streets, shall be available. Employe parking areas and access roads close by the food processing plant shall be hard surfaced with a binder of tar, cement or asphalt.
§ 37.15. Expansion.
When planning a plant, due consideration shall be given to providing for an arrangement of buildings and necessary space to permit future expansion. Coolers, freezers, and the various processing departments shall be so located that they may be enlarged without adversely affecting other departments.
§ 37.16. Potable water.
The plant shall have an ample supply of potable water available from an approved public or private source as specified in 42 CFR 72.101—72.105.
§ 37.17. Nonpotable water.
(a) Whenever a nonpotable water supply is necessary it shall not be used in a manner which will bring it into contact with the product or product zone of equipment.
(b) Nonpotable water systems shall be kept entirely separate from the potable water supply. The nonpotable water lines shall be positively identified by paint of a distinctive color.
§ 37.18. Equipment installation.
Equipment shall be so installed and used that back siphonage of foreign liquids into the potable water lines is impossible.
§ 37.19. Hot and cold water; clean-up.
(a) Hot and cold water in ample supply shall be provided for all plant cleanup needs.
(b) Hoses used for cleanup shall be stored on racks or reels when not in use.
§ 37.20. Sewage systems.
(a) Disposal of liquid wastes shall be through the public sewage system, if available and permitted by local ordinances, or by a properly designed and installed private facility.
(b) Private liquid waste treatment facilities shall be approved by the health authority having jurisdiction.
PLANT LAYOUT
§ 37.31. Product preparation and processing.
(a) Product preparation and processing (including freezing) departments shall be of sufficient size to permit the installation of all necessary equipment with ample space for plant operations, and with unobstructed truckways for conveyances of raw materials and processed products.
(b) The plant shall be so arranged that there is a proper production flow of materials, without undue congestion or back-tracking, from the time raw materials are received until the frozen, packaged article is shipped from the plant.
§ 37.32. Preparatory operations areas.
(a) Raw material storage rooms and areas where preparatory operations, such as washing and peeling of fruits and vegetables and the evisceration of poultry, are carried on shall be separate from areas where frozen food is formulated, processed and packaged.
(b) Doors connecting various rooms or openings to the outside shall be tight fitted and kept in a closed position by self-closing devices.
§ 37.33. Refrigeration facilities.
Facilities for holding products under refrigeration until processed shall be provided.
§ 37.34. Quick freezing facilities.
(a) Whenever facilities for quick freezing the processed product are used, they shall be so located as to be convenient to the food processing and packaging departments.
(b) Ample freezer storage shall be provided, located conveniently to the quick freezing facilities. Freezer storage shall not, however, be required if the frozen products are immediately removed from the establishment.
§ 37.35. Waste storage rooms.
(a) Separate rooms for storing inedible materials such as fruit and vegetable peels, and feathers and bones pending removal from the plant, shall be provided in a location convenient to the various preparation and processing areas.
(b) Waste storage rooms shall be of sufficient size to permit the proper storage of filled and empty metal or other relatively nonabsorbent refuse containers and their lids.
(c) Waste storage rooms shall be equipped with efficient power exhaust ventilation systems, hot and cold water outlets, and adequate floor drainage. The discharge from the exhaust system shall be located well away from fresh air inlets into the plant.
§ 37.36. Storage of packaging and labeling materials.
Packaging and labeling materials shall be stored in an area separate from but convenient to the packaging department, except that small quantities of such supplies which are necessary for maintaining continuity of operations may be stored in the processing and packaging departments.
§ 37.37. Facilities for inedible products.
Facilities for inedible products and catch basins, shall be located so as to avoid objectionable conditions affecting the preparation and handling of edible products.
§ 37.38. Cleaning room.
A separate room or area and the proper facilities for cleaning equipment such as trays, hand trucks and implements, shall be provided in a location convenient to the processing department. A power exhaust system shall be provided to dispel steam and vapors from the room.
§ 37.39. Dockage areas.
(a) Dockage areas shall be of adequate size, constructed of impervious materials and so drained as to minimize the entrance into the plant of dust, dirt and other contaminants from the receiving and shipping operations.
(b) If live animals are received a separate dock shall be provided for this purpose.
§ 37.40. Dressing rooms; toilet rooms.
(a) —
(1) Well located, properly ventilated dressing rooms and toilet rooms of ample size shall be provided for employes.
(2) Dressing rooms shall be separated from adjoining toilet rooms by tight, full height walls or partitions.
(3) Toilet rooms shall not be entered directly from a work room but through an intervening dressing room or a properly ventilated toilet room vestibule.
(b) Applicable Commonwealth or local codes shall govern such matters as the following:
(1) Ventilation and lighting of toilet and dressing rooms.
(2) Ratio of toilet, handwashing facilities, and urinals to the number of employes using such facilities.
(3) Type of fixtures used.
(4) Manner of installation of plumbing in such rooms.
(c) When a Commonwealth or local plumbing code is not in effect, it is suggested that the National Plumbing Code, American National Standards Institute, Inc., number ASA a 40.8—1955, published by A.S.M.E., 29 West 39th Street, New York, New York 10018, be used as a guide.
§ 37.41. Eating.
Employes shall not eat in food processing or packaging areas.
PLANT CONSTRUCTION
§ 37.51. Floors.
Floors shall be constructed of durable material which is easily cleaned and skid resistant. Where floors are wet cleaned, they shall be sloped to drain.
§ 37.52. Walls.
(a) Interior walls shall be constructed of smooth, cleanable, surfaces applied to a suitable base.
(b) Dressed lumber shall be used for exposed interior wood-work. Exposed wood surfaces shall be finished with nontoxic oil or plastic paint or treated with hot linseed oil or clear wood sealer.
(c) Coves with radii sufficient to promote sanitation shall be installed at the juncture of floors and walls in all processing rooms.
§ 37.53. Ceilings.
Ceilings shall be of adequate height and of smooth, cleanable material.
§ 37.54. Window ledges.
Window ledges shall be sloped at least 45° to the interior to promote sanitation.
§ 37.55. Rodents; vermin.
(a) Frozen food plants and warehouses shall be so constructed as to be rodent resistant.
(b) Exterior window and door openings shall be equipped with effective insect and rodent screens. Where doors in outside walls of food handling areas are used for loading or unloading, ‘‘fly chaser’’ fans and ducts or other effective means shall be provided at such doors to prevent the entrance of insects.
§ 37.56. Stairs.
Stairs in product handling departments shall be constructed with solid treads and closed risers and shall have side curbs of similar material, which shall be 6 inches high as measured at the front edge of the tread.
§ 37.57. Refrigerator doors.
(a) Refrigerator doors and jambs shall be covered with rust-resisting metal securely affixed to the doors and jambs.
(b) Joints necessary for installation shall be welded, soldered or otherwise effectively sealed.
(c) The juncture of the metal covering on jambs and walls shall be sealed with a flexible sealing compound.
(d) Doorways through which the product is transferred, either on overhead rails or on hand trucks, shall be sufficiently wide to permit free passage of the largest trucks or the widest suspended products without contact with the jambs.
§ 37.58. Variations from requirements.
The requirements for building materials listed in this chapter represent minimum requirements. Variations shall be acceptable provided the substitutions are equal to or exceed minimum requirements.
PLUMBING AND FLOOR DRAINAGE
§ 37.61. Wet processing areas.
(a) Floors shall be sloped and drains functionally located to provide adequate drainage.
(b) In wet processing areas the type and size of floor drains and sanitary sewage lines used and the method of installing such facilities and other plumbing equipment shall conform to Commonwealth or local regulations.
§ 37.62. Hand washing facilities.
(a) Hand washing facilities shall be located conveniently to all locations where products are prepared and processed.
(b) Lavatories shall be supplied with the following:
(1) Hot and cold or warm running water.
(2) Powdered or liquid soap in a suitable dispenser.
(3) An ample supply of single service towels or electric air dryers.
(4) A suitable receptacle for used towels.
§ 37.63. Sterilizers.
Where sterilizers are required they shall be large enough to allow complete immersion of tools and other implements. Sterilizing facilities shall have the following:
(1) A water line.
(2) A means of heating the water.
(3) An overflow outlet.
(4) A means of emptying the receptacle.
LIGHTING; VENTILATION
§ 37.71. Work rooms and dressing rooms.
(a) Work rooms and employe dressing rooms shall have means for furnishing adequate natural light, which may be accomplished by having windows or skylights of an area approximately 25% that of the floor area.
(b) Ventilation or efficient air conditioning or a mechanical ventilation system shall be provided.
(c) Adequate artificial light shall be provided.
§ 37.72. Fresh air intakes.
(a) Fresh air intakes for mechanical ventilation systems shall be equipped with effective replaceable filters to prevent the entrance of airborne contaminants.
(b) Fresh air intakes shall be located well away from power exhaust system discharges and other sources of airborne contaminants.
§ 37.73. General light intensities.
(a) The general light intensities in product preparation, processing and packaging areas shall be not less than 20 foot-candles as measured 30 inches above the floor.
(b) Where detailed visual tasks are required to assure a safe, wholesome product, the intensity of light on the surfaces of the product or product container shall be not less than 50 foot-candles.
(c) At least ten foot-candles of light shall be provided in all dressing rooms and at least 5 foot-candles in all other areas of the plant.
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