Differences in the design of food processing and non-food processing plants

Many of the elements of plant design are the same for food plants as they are for other plants. However, there are many significant differences which stem from the ways in which the processing of foods differs from the processing of industrial chemicals or other products. Such differences occur because of the following considerations:

• The storage life of foods is relatively limited and strongly affected by temperature, pH, water activity, maturity, prior history, and initial microbial contamination levels.

• Very high and verifiable levels of product safety and sterility have to be provided.

• Foods are highly susceptible to microbial attack and insect and rodent infestation.

• Successful processing requires the use of conditions, which ensure the dominance of desired strains of microorganism’s growth or activity.

• Enzyme-catalysed processes, like microbial growth and fermentation are very sensitive to temperature, pH, water activity and other environmental conditions.

• Crop-based products which require raw materials may only be available on a seasonal basis. Therefore, plant design may involve the modelling of crop availability.

• Food raw materials are highly variable, and that variability is enhanced by the ageing of raw material and uncontrollable variations in climatic conditions.

• Food processing generates wastes with high BOD loads.

• In the case of food products, samples must be consumer tested so as to assure market acceptability before larger scale productions are built.

• Packaging often requires care to maintain integrity of closure, and prevention of subsequent moisture and oxygen transfer. Segregation often causes problems in the packaging of powdered foods.

• Food processing techniques and formulations are sometimes constrained by standards of identity and good manufacturing practice regulations and codes.

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