Why Segregation is Important in Food Factories

The food industry is one of the most regulated sectors due to the high risks associated with contamination and food safety incidents. Therefore, segregation of processes, people and materials is paramount to ensure products are produced hygienically in any food factory.

This article will discuss why segregation is crucial in food factories and the measures you should take to ensure that your factory adheres to food safety standards.

Segregation in Food Factories

According to ScienceDirect, factories are segregated primarily to protect the food product from hazards in the environment, safeguard finished product from hazards associated with raw materials, segregate wet and dry materials, and to segregate mechanical and electrical services for food safety, and health & safety reasons.

Areas for microbiological food safety are designed to protect the product from cross-contamination after it has been cooked or otherwise processed. There are two primary reasons for this:

Protecting the Safety of Food Products

Cross contamination between different processes poses a significant threat to food safety. So much so that bacterial pathogens from one area can easily contaminate products in another area if there is no segregation in place. This could lead to food poisoning and other food safety incidents.

The four most significant bacterial pathogens that may contaminate food are Campylobacter, non-typhoidal Salmonella, Shiga toxin-producing E. coli O157 (STEC O157), and Listeria monocytogenes. Campylobacter infections were the most commonly reported bacterial cause of gastrointestinal illness.

As a food factory owner, it is imperative to implement proper segregation measures to prevent cross-contamination between different processes and products. This ensures that your facility as well as the products you use are deemed safe for human consumption.

Protecting the Quality and Integrity of Food Products

The shelf life of food products is an essential consideration for food manufacturing. When food products are not properly segregated during production, there is a higher chance of quality defects arising that reduce shelf life. These defects could include:

• Browning and discolouration due to exposure to light and air
• Texture changes caused by absorption of moisture from wet environments
• Flavour changes from absorption of odours from other products

Therefore, proper segregation of processes and products according to their requirements is crucial to:

• Maintain the visual appeal of products
• Retain the intended texture and consistency
• Preserve the distinctive flavours of products

This ensures that food products leaving the factory meet quality standards and consumer expectations in terms of appearance, texture and taste. With effective segregation measures in place, food products can also be stored for the intended shelf life, reducing waste and optimising profitability.

How to Segregate Properly in Food Factories

Proper segregation within food production establishments involves implementing physical and operational measures. Here are four things you can do to ensure effective segregation in your food production facility:

Implementing Clear Zoning Areas

Clear zoning areas in food plants refer to physically separating different production processes and product types. This can be done by:

• Designating separate rooms or sections for different production lines. For example, wet production like meat and seafood processing should be separated from dry production areas.
• Installing physical barriers like partitions, and curtains between areas.
• Using colour coding and signage to clearly demarcate zones.

Implementing clear zoning areas helps workers and inspectors easily identify which products belong in which area, reducing the chances of contamination.

Using Food Grade Hygiene Doors

Food grade hygiene doors should be installed to separate different production zones within food factories. These doors are made of materials that can be easily cleaned and sanitised, and have smooth surfaces that prevent dirt and debris from accumulating.

Hygiene doors can be sliding, swing, or high-speed doors. They should be self-closing and tightly sealed. This helps reduce the spread of contamination, odours and allergens between production areas.

Our food-grade high-speed doors at Tekta offer the perfect solution for maintaining hygiene standards in your facility. We’ve had the privilege of working with many of the UK’s top food producers, including ABP Food Group, Müller, Bakkavor, Hovis, and Saputo. Through these partnerships, we’ve gained a deep understanding of the demanding requirements in modern food processing, which has driven us to develop a range of specialist doors designed for food and hygiene-audited facilities.

Colour-Coded Equipment and Uniforms

Implementing a colour-coding system for equipment and uniforms is crucial in food factories to maintain strict hygiene and safety standards. This system helps staff quickly identify which tools and garments should be used in specific areas, reducing the risk of cross-contamination between zones. It also makes training new employees easier, as they can rely on the visual cues provided by colours to follow proper hygiene protocols.

Here are some common colours used in food factories and their functions:

• Red: Typically used for raw meat processing areas to avoid contamination with cooked or ready-to-eat products.
• Blue: Used for handling fish or seafood, which helps prevent contamination with other types of food.
• Green: Designated for produce and vegetable preparation areas, ensuring they stay separate from raw meats.
• Yellow: Reserved for handling raw poultry, keeping it distinct from other types of meat.
• White: Commonly used for baked goods or dairy products, reducing the risk of cross-contamination with high-risk foods.

By following this colour-coded system, food factories can ensure smooth operations while maintaining the highest levels of cleanliness and safety.

Implementing Strict Cleaning and Sanitation Protocols

Strict cleaning and sanitation protocols are essential in food factories to prevent contamination and ensure food safety. Regular and thorough cleaning helps eliminate harmful bacteria, allergens, and other contaminants that can compromise the quality of products. These protocols should be tailored to each production area, equipment type, and stage of processing, ensuring that high-risk zones receive the appropriate attention.

Effective sanitation practises also promote a safer working environment for staff, minimising the risk of accidents and foodborne illnesses. Clearly defined cleaning schedules, combined with documented procedures, help ensure that nothing is overlooked. By implementing these stringent protocols, food factories can maintain compliance with hygiene standards while fostering a culture of cleanliness and accountability among employees.

Ensuring Compliance with UK Food Safety Regulations

Compliance with UK food safety regulations is a legal obligation for all food factories and a critical step in protecting public health. The Food Standards Agency (FSA) outlines strict guidelines to ensure food is produced, handled, and stored in hygienic conditions that prevent contamination. Food businesses must follow laws such as the Food Safety Act 1990 and the Food Hygiene (England) Regulations 2006, which require facilities to adopt Hazard Analysis and Critical Control Point (HACCP) procedures to identify, monitor, and control risks at various stages of food production .

In addition to HACCP, factories must comply with food hygiene inspections carried out by local authorities, which can result in improvement notices or even legal action if standards are not met. Compliance also includes meeting requirements set out by the Brand Reputation through Compliance Global Standard (BRCGS), which mandates traceability of food products from farm to table. By adhering to these regulations, food factories can ensure the safety of their products and maintain trust with consumers and regulatory bodies alike.

Conclusion

Maintaining strict segregation practises in your food factory is essential for preventing contamination, protecting product quality, and ensuring compliance with food safety regulations. By implementing clear zoning areas, using food-grade hygiene doors, colour-coding equipment and uniforms, and adhering to strict cleaning protocols, you can create a safer and more efficient production environment.

At Tekta, we understand the challenges food factories face in meeting these high standards. Our food-grade high-speed doors are designed with your facility’s hygiene needs in mind, ensuring a reliable solution to help you maintain compliance. Explore our products to see how our food-grade doors can enhance your facility’s hygiene and safety standards.