Baking & Snack - September 2015 - 21

SPECIAL REPORT
Facility Planning

PURPOSE
vs. high-volume sprinkler systems, lighting control
systems, insulation R-values and an ante room between
the bakery and the freezer to prevent frost accumulation. Compressors should use variable-frequency
drives for maximum energy efficiency when a freezer is
not being used at full capacity.

Food safety remains top-of-mind
Food safety must be considered when designing and
constructing for baking operations. In an expansion
project, maintaining food safety throughout the construction process might require separating construction
personnel, creating air barriers that use differential air
pressure and preventing dust filtration.
Most bakeries today require significant air changes to
maintain a comfortable environment and exhaust dust
particles. Supply fans should be equipped with highefficiency filters to eliminate dust and other pollutants.
All fans, both supply and exhaust, should be equipped
with variable-frequency drives so the system can be balanced for positive pressure in the finished product and
packaging areas in relation to the bakery's wet end. An
air monitoring and control system should be incorporated to record air pressure and quality. Separate supply
and exhaust systems should be designed for washrooms.
It is extremely difficult to construct a plant that completely eliminates potential harborages for dust collection and possible bacterial growth. However, proper
sanitary design principles can significantly reduce risks.
Sealing floor-to-wall joints with a cove base or caulk,

flashing and caulking joist pockets as well as using
sloped covers on exposed girts and other horizontal surfaces all help keep bacterial growth and dust collection
to a minimum.
Exterior penetrations should be completely sealed or
receive screens and filters if applicable. The floor system
should be resistant to oils and ingredients in applicable
areas and easily cleanable. A high-density flooring system that does not dust or craze eliminates the need for
resinous flooring systems. Dust caps can be used on the
tops of hollow metal doors. Eliminate hanging materials such as Unistrut and threaded rod as well as open
grating on mezzanines and stairs. All exposed insulation
should receive PVC or aluminum jacketing.
While many of these considerations are basic in nature,
reinforcing and revisiting them ensures they are considered and incorporated into every bakery design and construction project. Upcoming changes associated with the
new FSMA regulations and the increasing desire of bakers
to adhere to BRC global food safety certification will lead
to renovations and improvements in many baking facilities. These improvements must be a collaborative effort
between bakers, designers and constructors to meet project goals, ever-changing governmental regulations and
increased social responsibility.

Considering food safety
when designing a new
plant or expansion can
prevent bakers' headaches in the long run.
AM King

Editor's Note: Stuart Jernigan is director of preconstruction
for A M King, Charlotte, NC. He's provided preconstruction, design and management for more than 50 bakery and
food projects with refrigerated spaces throughout the US.

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Baking & Snack - September 2015

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