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FOODSERVICE FACILITIES DESIGN - CONSULTANCY GUIDE NOTES
(These notes and information will be constantly revued, added to and updated, please revisit)
CONTENTS
THE HYGIENIC DESIGN AND CONSTRUCTION OF FOOD PREMISES
INTRODUCTION - GUIDANCE NOTES FOR FOOD PREMISES
SECTION 1. THE PRINCIPLES
SECTION 2. PHYSICAL ASPECTS.
1. Structure. Floors, walls, ceilings
2. Corner, wall and door protection
3. Service Lifts and Hoists
4. Staff Facilities
SECTION 3. MECHANICAL & ELECTRICAL SERVICES
Water Services
Gas Services
Electrical Services
Lighting
IT/EPOS and Communications
SECTION 4. PUBLIC HEALTH SERVICES
Drainage
Grease Interception
SECTION 5. VENTILATION
SECTION 6. REFRIGERATION
SECTION 7. HYGIENE
Hand Wash Basin.
Pest Control
HACCP
SECTION 8. WASTE MANAGEMENT & RECYCLING
SECTION 9. ENVIRONMENTAL ISSUES
SECTION 10. EQUIPMENT
Dishwash Machinery
SECTION 11. STORAGE FACILITIES
Foodstuffs
Cold Rooms
Refuse
SECTION 12. LEGISLATION, CODES OF PRACTICE
Fire Regulations/Equipment & Suppression
Environmental Health
Licensing/Local Authority
4. CDM/Risk Assessment
INTRODUCTION - GUIDANCE NOTES FOR FOOD PREMISES
These Guidance Notes have been prepared to formally advise design team members and our clients of particular requirements involved in designing, remodelling or improving foodservice facilities.
The project Health & Safety Plan (CDM) includes those actions that must be performed to ensure that risks outside of our control are considered by the relevant members of the design team.
These notes are therefore provided as a guide to the principles of food premises design and clarify areas of design and specification that are not provided by kenwinchdesign directly.
Our policy is to ensure that by applying good advice we will achieve the best environmental conditions for the project and meet our responsibilities for aspects of the design that are specified by others.
It has been acknowledged within food hygiene circles that the risk of food contamination is less likely to occur when food-handling staff are provided with a comfortable environment. Staff who are made conscious of their responsibilities and who are employed in premises where work can be done in an orderly and unhurried manner can, and will, pay attention to the demands of hygiene. A well-ventilated and illuminated work place with readily accessible facilities and easily cleaned surfaces encourages employees to achieve and maintain high hygienic conditions and standards less arduously.
Drawings and specifications produced by kenwinchdesign will intend to assist and promote these ideals.
SECTION 1 - THE PRINCIPLES
Possible hazards will be identified at the initial stages of the construction and design of the project and issued as our Health and Safety Document (CDM).
This document should be read along with the CDM document.
No provision of foodservice facilities should be considered without the ability to provide appropriate amenities, i.e. water, drainage, power, heating and ventilation.
Where cooking facilities are fitted, extract ventilation to terminate at a location to comply with local authority regulations is essential.
The premises should protect against the ingress or harbourage of insects or vermin.
Proper attention will need to be paid to temperature monitoring practices. Not only will monitoring be necessary to demonstrate 'due diligence' as required by Regulation 4 of the Food Safety (General Food Hygiene) Regulations 1995 but all caterers will find that correct temperature control is necessary to allow proper Hazard Analysis of their operation. Kenwinchdesign will recommend the supply of an automatic temperature monitoring system.
The kitchens, food preparation areas, service areas should be provided to a sufficient size to provide adequate working space for safety of persons and the safe food production when all essential equipment is in position. Kenwinchdesign can advise on the required areas.
Consideration should be given to provide temperature controlled preparation areas where the ambient temperatures below should be maintained.
Cold Food Assembly 5C to 10C
Pastry/Larder/Meat & Fish Preparation 16C to 18C
Hot Cook Areas 24C
SECTION 2. PHYSICAL ASPECTS
1. Structure. Floors, walls, ceilings
The structure should provide a secure environment within which food preparation may be carried on without being exposed to hazards or risks to health.
The formation of voids, which provide egress for vermin in food areas, giving harbourage for nesting, vermin or insects, must be avoided.
Holes or routes to the outside, which allow vermin to enter food areas, must be filled.
All surfaces should be non-absorbent and easily cleanable.
A solid construction must form the basis for applied surfaces/floors.
In most areas a smooth, slip resistant, hard wearing, impervious and light-coloured floor finish with coved skirting flush with the wall finish to avoid dirt ledges, should be laid.
There is no standard test for slip resistance. One favoured test is carried out by the Road Research Laboratory using a pendulum test involving a rubber foot. Examples from this tests are:-
| Floor Type |
Dry |
Wet |
| Highly patterned paviour |
62 |
50 |
| Slip resistant ceramic tile |
76 |
62 |
| Terrazzo |
67 |
50 |
| Vinyl Safety Floor |
71 |
58 |
| PVC Sheet |
81 |
27 |
| Unpolished Linoleum |
71 |
34 |
| Reconstituted Marble |
84 |
12 |
The co-efficient of friction reading being interpreted as:-
35 - 64 good
25 - 34 marginal
24 and below unsatisfactory
On the basis of these tests the best floor for wet catering areas is a slip resistant ceramic tiles with Terrazzo and vinyl safety floor being suitable and re-constituted marble being the best surface for areas that can be guaranteed to be dry at all times.
It should be noted that vinyl flooring is not recommended in areas of direct downward heat (or areas with temperatures above 60 C) or, in our opinion, areas subject to constant exposure to hot soapy water.
The walls are to be finished to a smooth impervious and easily cleanable finish. Full height ceramic wall tiling or sheet vinyl cladding is recommended. Tiles must be affixed with no voids behind and with epoxy grout.
Walls with internal voids inherent in their construction must ensure that all access to these voids are sealed, including above the ceiling or that they are provided with identified access panels enabling the application of bait or spray to the void.
Corner, wall and door protection
External corners must be protected from damage and with proprietary stainless steel protectors being built into the fabric of the wall finish rather than applied to the wall face. It is essential that any voids behind the protectors be filled.
Stainless steel wall and corner protectors are recommended for inclusion to prevent damage and subsequent contamination.
We recommend built in, stainless steel protectors as shown on our drawings and which can be obtained from:-
Interflow Ltd Tel: 01986
Component Developments Ltd Tel: 01952 588488
Wade Tel: 01787 475151
Areas subject to constant heat and/or moisture will require special treatment. Stainless Steel cladding will be recommended in these areas.
Service Lifts and Hoist
The following specification applies to food premises. The normal engineering requirements for lifts must also be met.
The shaft should be totally enclosed and be of solid construction of adequate strength. It must be decorated to a smooth finish with no internal ledges.
An easily-locked access to be provided at the base of the shaft, with access flush at floor level.
The pit floor is to be of impervious material sloped forward to the floor of the food room to enable easy cleaning, and include a waste outlet.
The provision of protected, flush, artificial lighting is recommended for the hoist pit.
The car or cage to be of metal constructions, shelves to be removable for routine cleaning.
The cage to be fitted with a maximum load plate.
Electrically operated lifts are preferred.
Lift motor and operating machinery should not be sited in the lift pit.
Electrical interlocks to be provided to the lift shaft that must not allow the lift to be opened unless the cage is at the correct position.
A pit stop switch should be fitted in addition to an interlock.
Copies of the lift engineersí inspection reports should be kept at the premises (power ñ six monthly; non-power ñ annually).
Internal size of lift car will be confirmed by kenwinchdesign and will seldom be less than 900 x 750.
Staff Facilities
The workplace (Health, Safety & Welfare) Regulations 1993 came into force on the 1st January 1993 and minor changes enhance current practice for food premises.
Separate toilet and changing facilities for catering staff must be provided.
Any office staff who work in food premises should be treated as potential food handlers otherwise facilities should be separate.
As a general rule it will be found that the best provision for water closet and wash hand basins is that they are separately provided for either sex, except in the case of there being no more than five workers. All facilities must be clearly marked for use by foodservice personnel.
The approved code of practice states, 'Where separate sanitary accommodation is provided for a group of workers, men, women, office workers, manual workers, a separate calculation should be made for each group'.
Normally in food premises sanitary accommodation will need to be provided for staff and the general public. The latter for premises where it is proposed that the premises would apply for a liquor or Late Night Refreshment House Licence.
The following guide can be used but Local Authority Guidelines must be consulted.
Number of Workers
(Male or Female) |
Water Closets |
Wash Basins |
| 1-5 |
1 |
1 |
| 6-25 |
2 |
2 |
| 26-50 |
3 |
3 |
or (an alternative calculation where urinals are provided).
Number of Men at Work
| Number of Men at Work |
Water Closets |
Wash Basins |
| 1-5 |
1 |
1 |
| 6-25 |
2 |
2 |
| 26-50 |
3 |
3 |
Changing facilities, separate for each sex should be provided. Adequate storage and drying facilities for outdoor clothing must be provided. Each member of the permanent staff will need at least a personal half size (minimum) locker.
Under no circumstances must clothing, shoes and personal belongings be left in kitchens, food preparation areas or other rooms containing open food.
The provision of showers for food handlers should be considered.
Provision for privacy must be made throughout these facilities. Lobbies to WCís are a necessity in food premises.
Office space for managers and staff must be separated from food areas, be adequately lit and ventilated.
SECTION 3. MECHANICAL & ELECTRICAL SERVICES
Water Services
All works will be as described in our specification and drawings but generally our design will attempt to ëbuild iní to the stainless steel fabrication all possible water services. Each suite of equipment will be supplied with integral service distribution ducts, both horizontal and vertical. The vertical service duct will extend to 50mm above the false ceiling level and will accommodate incoming mains services.
To allow the mechanical works sub-contractor to provide the required main services in a method permitting formal testing of the first six works, we will ask for the incoming supplies to terminate in isolating valves in the location of the vertical riser duct at around 500mm below false ceiling level. When the equipment suites are installed the incoming services will be onwardly connected by the foodservice equipment tenderer.
Sinks used for the preparation of food (potable water) should be provided with a marked supply coming from the water mains, whereas washing up sinks must be supplied from a tanked, down service supply not directly connected to the mains supply sinks.
Adequate hot water storage is to be supplied for wash up sinks, and for use in dish or glass washing machines. Running supplies are required for use of wash hand basins.
Water services must conform to 'Model Water Byelaws'.
(Legionnairesí disease is caused by bacteria which may be found where water stands for long periods at lukewarm or warm temperatures in, for example, tanks or little used pipes.)
We shall advise on our drawings that a hot water return system must be provided but the design of this system will not be determined by kenwinchdesign. The M&E Design Consultant must advise the preferred method.
Gas Service
Electrical Services
All works will be as described in our specification but generally our design will ëbuild iní to the stainless steel fabrication all possible electrical fittings required to serve the foodservice equipment. Each suite of equipment will be supplied with integral service distribution ducts, both horizontal and vertical. The vertical service duct will extend to 50mm above the false ceiling level and will accommodate incoming mains services.
To allow the electrical works sub-contractor to provide the required main electrical services in a safe method which allows formal testing of the first fix works, we will ask for the incoming supply to terminate in an isolator, loosely fixed, in the general location of the vertical riser duct at 1 metre AFFL.
When the equipment suites are installed each isolator will be discarded and the incoming supplies connected to the distribution boards.
Where there are no fabricated items, electrical supplies must be supplied by the electrical works sub-contractor. These works shall be chased into the wall or ceiling wherever practicable. The use of surface-mounted conduits should be avoided.
Metal faced electrical sockets are recommended in kitchens to avoid damage that can be caused by heavy duty operations.
Electrical wiring should comply in all respects to the current IEE Wiring Regulations.
All earth bonding works to foodservice equipment installed on the project will be carried out by the foodservice equipment sub-contractor to points provided by the electrical works sub-contractor.
Emergency isolation switches ('knock off') controls are required to the facilities and their location must be approved by the Local Authority. The connection of these controls to any BMS system or solenoid isolation valve must be carried out by the electrical works sub-contractor.
RCD protection will be provided to the electrical works supplied by the foodservice equipment sub-contractor, at the integral distribution box. Particular protection to any electrical outlet will be assessed at the post equipment fabrication stage when the location of electrical outlets in proximity to wet areas can be better determined.
Where a coldroom is served by remote refrigeration plant, then a cable tray will be required between the remote plant and the coldroom. This tray will be routed, supplied and fitted by the electrical works sub-contractor. Kenwinchdesign will advise the tray size.
When the coldrooms are supplied the refrigeration lines and control cables will be fitted to the cable tray by the foodservice equipment sub-contractor.
Coldroom control panels and fire suppression control panels have ëno voltí contacts for connection to BMS/Alarm Systems. These works will be carried out by the electrical works sub-contractor.
Lighting
Foodservice preparation areas require good lighting to a minimum level of 500 lux at 900 mm above finished floor level, without excessive variation or obscuration of the light from one place to another.
Storage/passage areas can be to a minimum of 300 lux. At 900 mm above finished floor level. Extract canopies with integral lighting will be specified to comply with the above levels.
IT/EPOS and Communications
We will advise the services requirement for client supply items although this must be confirmed by the supplier of the particular system. We will include in our fabrication specification, empty back boxes and conduits to accommodate computer/epos/telephone services but the locations of these points must be confirmed by the client.
SECTION 4. PUBLIC HEALTH SERVICES
Drainage
Our drawings will indicate the requirement for drainage to serve the specified equipment. Generally, rising stubs will be requested to serve the equipment, terminating 400 mm AFFL with all further clamps and works between the stub and the appliances supplied and fitted by the foodservice equipment tenderer.
Where floor channels are required to serve equipment or for íwash downí purposes, these will be shown on our drawings and a performance specification (flow rate and size) indicated.
Channels/gullies do not form part of our design package and will be supplied and fitted by the appropriate sub-contractor.
We recommend protectors manufactured completely from stainless steel as shown on our drawings and which can be obtained from:-
Interflow Ltd Tel: 01986
Component Developments Ltd Tel: 01952 588488
Frost
All stubs, channels and gullies must be trapped either in or under the floor.
2. Grease Interception
The provision of grease traps will be subject to local authority requirements or may be a particular client requirement.
If a grease trap is required we will advise the equipment to be served, together with estimated flow rates. Usually we would route pan wash sinks, floor channels serving cooking equipment , water extractors and identified cleaners sinks through a grease trap.
Waste disposals and detergent based dishwashers must not be routed through grease traps
Grease traps should be in floor type and located outside foodservice areas where possible.
SECTION 5. VENTILATION
Most premises will require mechanical ventilation. This must be sufficient to provide an acceptable working environment. The effect of cooking, lighting refrigeration equipment and personnel on the ambient temperature must be taken into account at the initial design stage.
The statutory requirement is that effective and suitable provision shall be made to ensure that every enclosed workplace is ventilated by a sufficient quantity of fresh or purified air.
It is important for the safe preparation, storage, handling or display of food that working practices are not exacerbated by a workplace that contains stale air or air which is hot or humid.
Kenwinchdesign will specify a mechanical extraction system to remove operational exhausts/ discharges from the foodservice equipment. The specified works will not include any ductwork ,fan motors, controls, interwiring at all, only the canopy or ventilated ceiling plenum with spigots for onward connection by others. The specified works will include lighting within the canopy/ceiling where appropriate, which will be wired to a connection box on the canopy/ceiling for onward connection by others. The system is in no way intended to provide air conditioning or temperature regulation of the kitchen areas. These matters must be dealt with by the M & E consultant although we will advise heat gain into the area from the specified foodservice equipment.
When air is mechanically extracted, new air will be drawn into the area to maintain the even pressure. If this air is not provided mechanically then it finds its own way into the area causing draughts through doorways, hatches etc.
We recommend that air is replaced through a mechanical system. The rate of this make up air will be 80% of the extract rate. This ensures a negative flow of air from the surrounding area towards the canopy thus reducing the risk of the transfer of cooking smells to areas adjacent to the kitchen.
The M & E consultant must consider and confirm that this method of supply air is the best for the project.
The kitchen environment should be designed to ensure ambient temperatures in excess of 25C and relative humidity above 65% are avoided.
The final point of discharge for extracted air containing kitchen extracts or air heavily loaded with food smells should be at roof level and positioned so as not to give rise to nuisance to occupants of the building, or nearby buildings
It should be effectively separated from any windows that open, doors, ventilation grilles or air conditioning supply inlets.
The use of grease filters is essential and will be included in the kenwinchdesign specification. Particulate filters, activated carbon/UV filters and other forms of odour suppression may also be required.
SECTION 6. REFRIGERATION
SECTION 7. HYGIENE
Hand Wash Basins
Keeping hands clean is a basic requirement of hygienic food preparation and service and adequate facilities will be designed.
Basins shall be specified in all foodservice areas, kitchens, preparation areas, shops where open food is sold and places where open food is stored or handled including beer cellars.
Each hand washbasin must be supplied with a fixed soap dispenser, a paper towel dispenser and a chained nailbrush. We will determine the clientís policy regarding the supply of soap and towel dispensers, which may be supplied by a contracted hygiene company and specify appropriate dispensers if required.
The hand washing facilities must not be obstructed or used for any purpose other than the washing of hands by food handlers.
These hand washing facilities are in addition to those supplied for use with sanitary accommodation.
Pest Control
Within the area of pest control the underlying factor must be the PREVENTION of infestations, with the simple principal that prevention is better than cure.
Control of pests is paramount in preventing contamination of food and to stop the spread of bacteria from pests to the food product.
When considering the preventative action that can be taken, account should be taken of the following:
DESIGN and LAYOUT in order to prevent dead spaces and areas which are difficult to clean.
PROOFING to prevent pests from gaining entry to the premises, this can be done for example by window screening, sealing of holes in the structure and sealing of gaps.
HYGIENE to clean the structure and equipment and to remove all waste products.
STORAGE by proper stacking and product control, to prevent dead areas, stock held for a long time and stores which cannot be easily cleaned.
WE RECOMMEND THAT A CONTRACT IS TAKEN OUT BY THE CLIENT AFTER HANDOVER, WITH A REPUTABLE PEST CONTROL COMPANY
HAZARD ANALYSIS AND CRITICAL CONTROL POINT (HACCP)
This is a structured approach to analysing the potential hazards in the design of foodservice operations.
The points are identified in the operation where the hazards may occur and deciding which are critical to consumer safety.
This information is contained in our Health & Safety document and must be read in conjunction with this document.
The critical control points are monitored and remedial action, which is specified in advance, is taken if any of the critical control points are not within safe limits.
When applied to catering activities each stage of the operation is studied in depth so that all the potential hazards are identified, problems are foreseen and forestalled.
In short, each stage of the project is examined to consider if one of the following could occur.
Contamination with toxins or pathogenic organisms
Proliferation of pathogens
Survival of pathogens
Chemical or physical contaminants
Risk of personal Injury to operative
An essential feature of this system is its regular review by the team.
SECTION 8. WASTE MANAGEMENT & RECYCLING
SECTION 9. ENVIRONMENTAL ISSUES
SECTION 10. EQUIPMENT
1. Dishwash Machinery
Dishwash machinery will be specified with local water softener and class `A` air gap to meet water regulations.
Dishwash machinery will be specified with either condense extract canopy or direct spigot connection to the machine and in all cases the specified equipment will extend to 50mm above the false ceiling level for onward connection by others. The dishwash area is particularly subject to high humidity/temperature levels and this must be addressed by the M & E consultant.
Sinks, Washing up Machines, Dishwashers
The design will allow suitable and adequate sinks, complete with running hot and cold water must be provided for washing up and food preparation which should also be separate from any other use. Kenwinchdesign drawings will indicate the flow rate of each water outlet.
Where premises store or sell open food of any kind at least one sink must be provided for cleaning food equipment. Otherwise all food sold from the premises will need to be wrapped prior to delivery to the premises.
The provision of a dish washing machine is considered essential in all but the smallest units, where the premises provide drinks in glasses, in particular licensed premises where a designated machine for washing glasses is to be provided.
Water softening equipment must not be used to treat drinking water or water used in the preparation of food (potable). If a central water softening plant is not provided for the project then Kenwinchdesign will specify local water softening or water conditioning as appropriate.
Food utility machines such as ice makers, bains marie, coolers etc. which are provided with a waste discharge must do so with a designed air break before passing to the drainage system.
SECTION 11. STORAGE FACILITIES
Foodstuffs
Food storage design will be considered alongside current legislation in temperature control. Suitable and adequate food storage will be provided for fresh, chilled, frozen or dry goods that are consumed on the premises or sold by retail.
It is the responsibility of the client/operator to show that `due diligence` has been paid to the provision of good food hygiene practices and a regular record of all food storage area temperatures is a requirement. The installation of a computerised automatic temperature monitoring system will be proposed by kenwinchdesign for consideration, the alternatives being manual recording methods.
Separate refrigerated storage will be proposed for raw meat, poultry and fish, particularly but other categories will be recommended if applicable.
Air movement must be provided to dry storage areas and we recommend a mechanical system to allow a minimum of 6 to 10 air changes /hr.
Cold Rooms
Coldrooms will be specified with external walls extending 50mm above false ceiling level to allow false ceilings to be affixed to them.
Where possible, Coldrooms should have their insulated flooring recessed into the building screed. Kenwinchdesign will request a 100mm deep recess in the floor finish to accommodate the coldrooms. The recess will be oversized by 50mm overall to allow site movement and the building contractor must make good the recess after installation.
The coldrooms are completely self-contained rooms with integral lighting. They will require power and drainage
Coldroom floors will be specified as either stainless steel plating supplied with the coldroom, or with the kitchen floor continued into the coldroom.
Where the kitchen flooring is extended into the room we will specify the depth of the recess in the screed to accommodate the coldroom insulation, minimum screed and finish.
The screed and floor finish will be supplied and fitted by the flooring sub-contractor
3. Refuse Storage
Refuse incorrectly stored can attract vermin, give rise to odours and can be a fire hazard.
To reduce these problems refuse must always be kept in a clean and tidy manner, and removed on a regular basis.
We will ascertain the preferred method of waste handling procedure and design facilities accordingly.
Refuse Storage in Food Rooms
The quantity of refuse stored in the food room should be kept to a minimum.
Refuse must never remain in the food room overnight.
Storage areas for local refuse storage should be chilled to maintain an internal ambient temperature of 2C to 5C.
Sufficient refuse containers with close fitting lids will be specified.
Refuse Awaiting Collection
The main refuse storage area is often situated externally. Such an area should be paved,
drained, sheltered and adequately lit, but not be part of the highway. If the storage area is enclosed then we would recommend that it be chilled to maintain an internal ambient temperature of 2C to 5C.
If refuse is to be stored internally it must be within a proper storage area, sealed off from the rest of the premises but well ventilated and preferably chilled to an ambient temperature of 2C to 5C.
The refuse storage areas must be kept in a clean state. Regular sweeping and thorough cleaning will be necessary. The cleaning may be with pressure steam cleaning equipment and the area finishes should be specified to withstand this
Clean cardboard boxes should be broken down and neatly tied into bales or boxes.
Where premises produce large volumes of dry waste, consideration should be given to the provision of a compacting machine.
Consultation on waste handling/disposal procedures should be made with the Local Authority.
Refuse areas must open into a lobbied area.
SECTION 12. LEGISLATION, CODES OF PRACTICE
Fire Regulations/Equipment & Suppression
Kenwinchdesign is not responsible for any aspect of the submission for a fire certificate.
We are interested in the co-ordinated location of fire fighting equipment required in the foodservice areas but are not responsible for the specification of the fire fighting equipment
We will recommend the inclusion of an `Ansul` fire suppression system within ventilation canopies serving appropriate items of equipment and shall include the supply and fitting of the system in the foodservice package. The siting of the remotely operated pull stations will however be subject to approval by the local authority and we are not responsible for obtaining this approval.
The Ansul system control box can be connected to the building BMS/fire alarm system via `no volt` connections provided in the control box . The connection of these `no volt` points to BMS/Alarm systems are not the responsibility of Kenwinchdesign.
Environmental Health
Kenwinchdesign will submit all design layouts for comment/approval to the Local Authority Environmental Health Office.
3. Licensing/Local Authority
Kenwinchdesign are not responsible for obtaining any local authority/statutory approvals or notices, other than regarding the notification of the project to the local authority Environmental Health Office.
The Health Department has an input on all applications in respect of Food Safety & Hygiene and the application of the Health & Safety at Work etc. Act 1974
.
4. CDM/Risk Assessment
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