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Chapter 2 -
Establishment and Equipment Design and Construction
New Establishment Approval Process

2.4 General Concepts

2.4.1 Selection of a site for a registered establishment

Legislative requirements are found in subsection 28.1(a) of the Meat Inspection Regulations, 1990.

The principal considerations when selecting a site for a registered establishment are:

2.4.2 Layout and design of a registered establishment

Because of the specialized knowledge required to design and construct a durable and well laid out establishment, it is suggested that the applicant seek help from a consulting company specializing in establishment design. The names of known consulting companies may be obtained from the Area Office or the Chief, Plant and Equipment Evaluation, Food of Animal Origin Division.

The establishment shall be designed to facilitate hygienic operations by means of a regulated, one way flow in the process from the arrival of raw materials through to the packaging and shipping of finished product. This is a basic principle to be followed whether the establishment has one or more floors.

Consideration must be given to compatibility of operations throughout the establishment. For example, a slaughterhouse should be so designed that there is progression from the point where live animals are received through the slaughtering, dressing, chilling, processing, packaging, finished product storage and shipping areas to the loading docks.

In planning a registered establishment every effort should be made to provide for future expansion of all segments of the operation without causing serious congestion or other disruption to the flow of operation.

2.4.3 Separation between registered and non-registered facilities

The registered establishment shall be separate and apart from any non-registered facilities and retail outlets.

The separation between registered and non-registered areas or buildings has been interpreted over the years to mean no direct internal access between the two areas. This prohibits the access of animals directly from adjacent farms or feedlots; or direct access to the establishment by doorways, windows, stairs, elevators, passageways, or loading or unloading docks. This separation must be clearly established when the layout of the establishment is being designed.

Multiple building establishments must be located within one continuous and self enclosed piece of property. The property may be composed of one or several adjoining municipal numbers or lots. If part of the property is separate, there must be a connection by an underpass or overpass.

All rooms and areas with direct access to the registered establishment are considered part of the registered establishment. This does not mean that construction standards in non-meat product handling areas must meet the same standards as those required for meat product handling areas. The amount of latitude extended, in relation to construction standards, is based on the assessment of potential adverse effects on the operation of the meat product handling area. Non-meat product handling areas must also comply with the requirements of any other concerned agency.

No portion of a building housing a registered establishment shall be used as living quarters, unless such portion is permanently separated by means of a solid floor, wall or ceiling, and there must be no interior access from such quarters to any part of the establishment.

2.4.4 Separation of incompatible operations

Adequate physical separation of incompatible activities that could potentially result in the creation of a cross-contamination risk for meat product shall be provided. When there is no alternative (in existing registered establishments only), effective operational controls must be implemented. These operational controls shall be thoroughly described in writing (see section 2.3.2.4) and must be strictly followed at all times.

While performing inspection and other regulatory duties in the establishment, CFIA employees shall comply with the requirements of the operator’s HACCP system. When an inspector must move to and from incompatible areas, the operator will provide facilities to ensure this movement can occur in a hygienic manner.

2.5 General construction requirements

It is expected that every precaution, such as soil testing, will be taken to ensure an optimal building foundation and thereby minimize the settling and sagging of the facility. The materials used in the construction of the establishment shall be sufficiently strong and durable; and promote satisfactory maintenance. Masonry and steel construction have proven to be the most acceptable to date for this purpose. Good sound concrete or masonry and steel construction throughout, metal or metal-clad doors and door jambs, heavy metal screening of all accessible apertures and screening of sewer lines, will do much to prevent entry or habitation of rodents in a registered establishment.

All measurements are given in millimetres unless otherwise indicated.

2.5.1 Suitability of construction materials

The legislated requirements for construction materials are referenced in subsections 28.(1)(c), and 34.(8) and 35 of the Meat Inspection Regulations, 1990.

Detailed information concerning the review and acceptance procedures as well as Reference Listing of Accepted Construction Materials can be found at: http://www.inspection.gc.ca/english/ppc/reference/cone.shtml.

Room interior surfaces (floors, walls and ceilings) in areas where food animals are slaughtered, carcasses are dressed, and meat products are refrigerated, stored in refrigerated state, processed, packaged, labelled, inspected, shipped, received or otherwise transported must be smooth, hard and impervious to moisture to facilitate ease of cleaning and withstand working conditions. Anti-slip floor coverings or applications may be used for safety reasons.

Plastic or metal panels, when used as internal finishes, shall be laminated on their entire surface to the underlying structure(s) using CFIA accepted adhesives and in a manner such that no void spaces are left between the panel and the underlying structures. The use of rivets, screws or nails for attaching panel to the substructure is considered unacceptable.

2.5.1.1 Interior woodwork

Interior woodwork is permitted in administrative areas of the plant and in dry storage rooms. Smooth sawed or planed lumber shall be used for such interior woodwork.

2.5.1.2 Paint

The painting of product contact surfaces is prohibited.

The use of lime wash is not permitted except in livestock pens and drive chutes.

In general, painting is not recommended due to the possibility of flaking and chipping. However, it is permitted where:

2.5.2 Water supply

The legislated requirements concerning water supply are referenced in subsection 28.(1)(n) of the Meat Inspection Regulations, 1990.

There must be a supply of hot and cold potable water available under adequate pressure and in quantities sufficient for all operating and clean-up needs. All submerged water lines shall be equipped with vacuum breakers to prevent back siphoning.

Where non-potable water is used for fire prevention or for condensers on refrigeration systems, it must be kept entirely separate from the potable water system and clearly and distinctly identified. Under no other circumstance, may non-potable water be used where edible products are processed, handled, packaged or stored.

Where the supply of potable water is derived from a private well, adequate protection must be afforded to the well head to prevent contamination of the water supply. Similarly, where storage tanks are used, they must be located and constructed in such a way as to prevent contamination.

Automatic chlorinators used in a registered establishment must be equipped with a malfunction warning system.

For operational requirements on water used in registered establishments refer to Chapter 3 of the CFIA Meat Hygiene Manual of Procedures.

2.5.2.1 Hand washing facilities

Subsections 28.(3)(e), 28.(5) and 28.(6)(a) of Meat Inspection Regulations, 1990 require that every registered establishment in which animals are slaughtered, meat products are processed, packaged, reinspected, labelled or stored must have sufficient number of directly drained hand washing facilities that are operated in a hands-free manner.

Hand wash facilities must be capable of supplying hot and cold water and be easily accessible for production and inspection personnel. Such facilities must also be equipped with liquid or other dispensable type of soap, paper towels in suitable dispensers, and properly constructed and easily maintained receptacles for used towels. Roller-type cloth towels are considered unacceptable.

A registered establishment must have hand washing facilities at each and every entrance to meat processing handling rooms or areas. The number of hand wash facilities must be adequate for the number of employees.

Chemical hand dips, where provided, must be adjacent to hand washing facilities.

2.5.2.2 Drinking water fountains

Sanitary drinking water fountains, where provided, must operate in a hands-free manner, be directly drained, and easily accessible. If they are part of or adjacent to a hand wash sink, they must be located high enough to avoid splash from the sink.

2.5.2.3 Hot water sanitizers for utensils

Subsection 28.(1)(u) of the Meat Inspection Regulations, 1990 requires water sanitizers that are capable of being maintained at a temperature of not less than 82°C for the sanitizing of utensils in areas where utensils are used in the handling of meat products.

Sanitizers shall be made of rust resisting material, be of appropriate size, fitted with an overflow connected directly to a drain and be located to permit the convenient sanitizing of knives, saws and other tools/utensils.

In certain areas of a registered establishment, where the use of utensils is infrequent and where the risk of contamination of meat products is minimal, sanitizers need not be connected to a continuous overflow system.

For operational requirements of water sanitizers used in registered establishments refer to Chapter 3 of the CFIA Meat Hygiene Manual of Procedures.

2.5.2.4 Hose connections for room and equipment clean up

An adequate number of conveniently located hose connections must be provided throughout the registered establishment for room and equipment cleaning. Where required, temperature indicators shall be installed at hose connections supplying 82°C or higher water.

Suitable racks or reels for storage of hoses shall be provided.

2.5.3 Drainage and sewage system

The legislated requirements for drainage and sewage system are referenced in subsection 28.(1)(p) of the Meat Inspection Regulations, 1990.

Every means of plant effluent disposal must meet all municipal and provincial requirements. Submissions shall be accompanied, if requested, by a letter from the appropriate authority stating that it considers the proposed sewage system acceptable.

The drainage from toilets, urinals, and hand wash sinks in welfare areas shall be separate and apart from other sewage lines to a point outside of the facility. Under no circumstance, may the toilets, urinals, and hand wash sinks in welfare areas empty into a process water catch basin or grease interceptor. Areas such as boiler rooms, mechanical rooms, workshops, or battery rooms may drain into the system carrying human effluent.

Consideration should be given when designing the sewage system so that the effluent from the live animal receiving, animal holding, inedible product handling areas, as well as from evisceration rooms shall not pose the risk of contaminating edible meat product handling and storage areas. Back flow valves are not recommended as a means of prevention since they require regular cleaning and maintenance to be effective.

Overhead drain lines must not pose a contamination threat to meat products, packaging materials or the processing environment.

2.5.3.1 Drains

Adequate drainage must be present throughout the registered establishment where required and must be in compliance with the provincial plumbing code in which the establishment is located. The number, size and location of drains and drain inlets shall be in keeping with the nature of the operation. All floor and hub drains must be deep-seal trapped and all drain lines must be properly vented to the outside air and equipped with effective rodent screens.

Drain inlets should be at least 300 mm x 300 mm or equivalent with a minimum free area of 30% of the total in areas where significant amounts of water is being discharged during operations or sanitation. Drains may be equipped with smaller inlets in areas like coolers for fully packaged products, spice preparation rooms, or processing areas where water is not used for cleaning (e.g. edible oil/fats processing, dry soup mix preparation, etc). Drain covers shall be provided with apertures having a minimum size of 40 mm².

As a general rule, one drain inlet should be provided for each 40 m² of floor space. However, in areas where wash down cleaning is replaced by mechanical floor scrubbers, the number of floor drain inlets may be reduced. The number of drain inlets and their size must be increased in areas of high water discharge to provide proper and constant removal of the fluid wastes. Equipment discharging water shall be directly drained to prevent water from flooding the surrounding areas. Where several drainage lines discharge into one trunk line, the trunk line must be proportionately larger to efficiently handle the fluids discharged into it.

Floor drains are not recommended in areas used for dry goods storage and freezers.

2.5.3.1.1 Trench (channel) drains

Properly constructed and sloped trench drains are permitted in all areas of a registered establishment. The trench drains are regarded as a bigger than required drain inlet. The visual inspection of all surfaces of the trench drain must be possible without any tools.

The internal corners of the trench drain must be coved with a minimum radius of 6 mm (1/4 inch). The depth of the trench drain can not be bigger than its width. The width of the trench drain opening at the floor level must be equal to or bigger than its width at the bottom along its entire vertical surface.

Trench drains shall be covered with removable sectional grated covers. The sections of the covers shall not be longer than 1200 mm. In many instances it is necessary to provide a continuous flow of water within the channel to remove the heavier waste products.

Permanent structures or equipment shall not be placed over trench drains along their entire length. Trench drains shall not run through walls unless the size of the wall opening is equivalent to a man door.

2.5.3.2 Separation of organic matter from plant effluent

All means of separating organic matter from the plant effluent, where required by local authorities, such as catch basins, grease traps, interceptors, etc., shall be located outside of the plant or in an area with outside access only.

The area surrounding an outside separator shall have an impervious surface and shall be sloped towards the separator.

2.5.4 Lighting

The legislated requirements for lighting are referenced in subsection 28.(1)(g) and 28.(1)(h) of the Meat Inspection Regulations, 1990.

All rooms and areas of the establishment must be properly lighted by natural light, artificial light, or both. Special attention must be given to the amount and direction of lighting in inspection areas to prevent glare while providing the required maximum illumination. All light in meat product inspection areas shall be without shadow or glare and have a minimum colour rendering index value of 85 so as not to distort the normal colour of meat products. The intensity of the illumination shall not be less than 110 lux measured at 700 mm above the floor level or at the level at which the work is conducted with the exception of:

Where natural light is provided, it should be by means of glass blocks or other acceptable transparent or semi-transparent material.

Light sources and fixtures must not be a potential source of contamination to meat products. In this regard design and location are important considerations.

2.5.5 Ventilation

The legislated requirements for ventilation are referenced in subsection 28.(1)(g) and 28.(1)(m)(iii) of the Meat Inspection Regulations, 1990.

Adequate means must exist to provide sufficient exchange of air in all parts of the registered establishment so that air is kept fresh and free of objectionable odours, dust, steam and vapour. In refrigerated workrooms, mechanical ventilation shall be sufficient to keep walls and ceilings free of condensation.

Proper location of air intakes and use of effective filters are essential to prevent the introduction of air contaminated with insects, dust, smoke, objectionable odour, etc. Intake of outside air directly to exposed meat product handling rooms requires filters with 30% efficiency at 2 microns. Openings such as open windows and doors do not meet these criteria.

All equipment which produces heat, steam, vapour, smoke or odour must be properly vented. In addition, edible and inedible processing equipment in rendering departments such as driers and evaporators must be equipped with condensers.

Adequate ventilation must be provided in designated battery charging areas.

In planning and designing a registered establishment and developing its ventilation, every care must be taken to separate departments and control air movement, so that undesirable conditions, such as condensation, odours, dust, and variations in temperature are reduced or eliminated. Air flow must move from microbiologically sensitive areas towards the less sensitive areas (e.g., ready-to-eat departments towards raw meat processing). In other words, the ready-to-eat meat products handling departments must have positive air pressure versus the surrounding areas.

2.5.6 Walls

To promote acceptable sanitary maintenance, it is essential that walls be of smooth, hard and impervious material (e.g., accepted prefabricated panels or glazed tile), and be free of pitting, indentations, cracks, crevices and ledges. All corners and wall-floor junctions, except for office space, shall be coved with either a round cove with a radius of at least 25 mm or a minimum 35 mm face chamfer with open angles of 135°. Wall surfaces should be white or light-coloured for light reflection and to promote sanitation.

All mortar joints must be smooth and flush.

Walls made of prefabricated panels or covered with fibre reinforced panels (FRP) shall be protected at the base with 45° sloped curbs that protrude from the wall surface a minimum of 50 mm and have a minimum height of 400 mm to protect them from damage. The curb construction shall be smooth, impervious, and free of cracks, chipping or other surface defects. Alternative curbs designs may be proposed for acceptance provided the foregoing sanitary conditions are met.

While the surface finishes are of the utmost importance, we must also be concerned about the durability of the underlying structures (e.g., metal lathing rather than gypsum lathing; metal support rather than wooden support). Wooden support structures are liable to absorb moisture and with it become weak and a reservoir for microbial growth.

2.5.7 Ceilings

To promote acceptable sanitary maintenance, it is essential that ceilings be of smooth, hard and impervious material free of pitting, indentations, cracks, crevices and ledges. Ceiling surfaces should be white or light-coloured for light reflection and to promote sanitation.

The height of ceilings of 3000 mm or more has been found to be suitable. The ceilings which support overhead rail systems must accommodate the minimum required heights for rails as prescribed in section 2.5.11. Ceilings of rooms, such as those intended for poultry receiving, defeathering and evisceration require a height of at least 4000 mm. In addition the height of ceilings must accommodate a minimum required access for cleaning and inspection of processing equipment. Such access shall not be less than 800 mm (30").

Ceilings of interlocking, rust-resisting metal sheeting, such as heavy gauge, heavy duty, galvanized steel, anodized aluminium or stainless steel, are acceptable if fastened to metal infrastructure by acceptable means. When galvanized metal is used, the zinc coating must be at least ASTM A525M grade 350.

Open joist construction of ceilings is permitted in evisceration areas and also in carcass coolers where a carcass check trim station precedes further carcass processing or shipping. This type of ceiling is not permitted in other areas where there is exposed meat product handling. The open joist construction must be treated to prevent rusting and corrosion, spaced 900 mm or more on center, constructed as not to collect and harbour dust, and be readily cleaned and maintained in a sanitary condition.

While the surface finishes of ceilings are of the utmost importance, we must also be concerned about the durability of the underlying structures (see section 2.5.6).

2.5.8 Floors

Construction material such as dense, acid-resisting, non-dusting and waterproof concrete, masonry floor tile, vitrified bricks or synthetic materials have been found to be most suitable for floors.

Floors shall be properly graded (at least 1% toward drain inlets) for the effective removal of all fluid wastes.

Floors of freezers are to be provided with adequate protection to preclude damage due to frost penetration into the underlying soil.

2.5.9 Doorways and doors

Doorways must be wide enough to facilitate the movement of product, equipment and personnel. The minimum acceptable width for doors passing carcasses, smokehouse trees or trucks, or palletized product must be 300 mm wider than the widest equipment moving through the door.

Doors shall be self-closing and of durable construction. Doors should either be of rust-resistant metal or other accepted construction material throughout. See also: http://www.inspection.gc.ca/english/ppc/reference/cone.shtml

The door jambs shall be of rust-resisting metal or be rust-resisting metal clad. The juncture between the wall and the door jamb shall be effectively sealed with a flexible sealing compound.

The outside shipping and receiving doors shall be equipped with bumper door seals or equivalent.

2.5.9.1 Air curtains for entryways and doorways

Air curtains are intended to prevent flying insects, dust and other particulate airborne matter, odours, and cold or cooled air from passing through an opening. These expectations are the same as those for internal doors separating incompatible operations. However, air curtains are not recommended because the proper air balance is very difficult to maintain. They are not intended to prevent the passage of animals or to replace a security door.

In addition to general equipment construction standards the equipment required for air curtains shall meet the following requirements:

2.5.9.2 Plastic strip curtains

Plastic strip curtains cannot be installed in doorways where exposed product or personnel handling exposed meat products will be moving.

2.5.10 Windows and screens

To avoid damage to window panes the window sills shall be 1000 mm or more above the floor. Window sills shall be sloped internally at an angle of about 45°. Windows in areas where exposed products are handled must be non-opening and window panes must be made of approved shatter proof material. All windows and other exterior openings that could admit insects, birds, etc., shall be equipped with effective screens.

2.5.11 Rails and rail support systems

Rails and rail support systems shall be easily cleaned and constructed of materials which resist corrosion. The supporting suspension structures must also be capable of being maintained in a clean state and free of loose material that could possibly contaminate underlying products. Only acceptable coatings and lubricants may be applied to these structures. Surfaces of supporting beams must be free of crevices, constructed to facilitate cleaning and preclude the collection of potential contaminants.

Rail heights shall be sufficient to prevent suspended meat products from contacting the floor. The rail heights (mm) shall accommodate the following minimum distances from the carcass suspension contact point to the floor.

* When heads are not removed from dressed carcasses 2700 mm distance is required.

When a stand or platform is placed under hanging carcasses, the top of the stand or platform is deemed to be the floor for the above minimum distances.

Rails used for moving carcass quarters shall keep the lowest part of the carcass at least 300 mm from the floor.

All rails shall have a minimum distance of 600 mm from walls and pillars and the carcasses hanging on the rails shall be at least 300 mm from any building structure. The distance between rails shall be at least 600 mm on center.

2.5.12 Elevators, shafts, stairs, etc.

Elevator cars shall be of metal construction and maintained free of rust and corrosion. Shafts shall have smooth, hard and impervious surfaces which can be readily maintained in a clean and sanitary condition. The super-structure shall be completely enclosed except for the necessary cable apertures. The openings at each floor level shall be raised, or otherwise protected to prevent the spillage of floor wash-water into the shaft. All shaft pits shall be of concrete or its equivalent and sloped to a drain to facilitate cleaning.

Stairs in product handling areas shall be constructed of impervious material, such as concrete or metal, with solid treads, closed risers and curbed sides of at least 50 mm in height, measured at the front edge of the tread. Catwalks or mezzanines located above product handling areas shall be of solid masonry or metal construction with adequately raised edges. Expanded metal is not permitted.

2.5.13 Outside premises

The aprons of shipping and receiving docks shall be paved and properly drained (see subsection 28.(1)(l) of the Meat Inspection Regulations, 1990).

Railway tracks at loading docks and livestock chutes shall have suitable impervious gutters and drains to promote proper sanitary maintenance.

Roadways on the premises must be properly graded, compacted, dust proofed, and drained.