GMP for Building & Facilities

Buildings and facilities play a crucial role in producing quality and safe products

GMP (Good Manufacturing Practice) can be applied starting from the buildings and facilities in food companies or industries. The scope of buildings in this context includes all structural elements, rooms, and sanitation facilities that mutually support each other. In the implementation of GMP, competent personnel, such as QA (Quality Assurance), can coordinate with GA (General Affairs) to identify areas using zoning determination methods. GA generally possesses area layouts and infrastructure facilities that serve as input for implementing GMP guidelines.

The principles of applying GMP to buildings and facilities are not always rigid but can be optional, meaning there is tolerance as long as it is considered reasonable, and the produced products still meet the standards of safety, quality, and food in Indonesia. Personnel or departments responsible for ensuring food quality are QFS/QA (Quality and Food Safety/Quality Assurance). A QA professional must have knowledge related to the structure of buildings and facilities in the food industry, to identify potential hazards that may arise from structures that do not comply with food safety standards. What are the things that need to be considered in the implementation of GMP for Buildings and Facilities? Let's find out!

1. Criteria of Building and Facilities

Buildings and facilities have specific criteria to facilitate the implementation of GMP (Good Manufacturing Practice). Here are the criteria: 

1. Strong Building and Construction; The building and construction must be sturdy and easy for cleanliness (sanitation) processes.

2. Adequate Workspace Size; The workspace should be appropriate for the number of personnel working inside, with unobstructed free movement and an ideal spatial layout

3. Design of Workspace for Easy Pest Control Access; The design of the workspace should facilitate access for pest control, such as rodents, similar vermin, flies, or contamination-causing insects)

4. Well-Mapped Production Area Layout; The layout of the production area should be well-mapped. If there are processes for cooking food, they should be separated from the processing of semi-cooked and fully-cooked food. The planning of the spatial layout should refer to the production process flow, requiring coordination with the production supervisor in the company

5. Waterproof Floor Surface; The floor surface must be waterproof and can use high-quality epoxy (non-porous, smooth, easy to sanitize), with sufficient slope to prevent water pooling 

6. Waterproof Wall Surface; The wall surface must be waterproof and can be managed using high-quality waterproofing paint. Brightly colored wall paint is preferable for easy periodic cleaning. Wall and floor corners should be rounded for easy cleaning

7. Ceiling Surface; The ceiling surface should be easy to clean, waterproof, flat without indentations, and should not accumulate contaminants during the production process

8. Windows and Doors; Windows and doors should be made of easily cleanable materials, open outward, and need to be equipped with automatic (hydraulic) covers

9. Ventilation or Air Vents; Ventilation or air vents should have dust filters to filter out dust from the outside area, preventing contamination

10. Airflow and Temperature Control; Ventilation or temperature control should be well-managed for the comfort of workers and to minimize odors in the production area

11. Handwashing Facilities; Handwashing facilities should be adequate and separated between washing raw materials and personal use. Handwashing facilities should be monitored for hygiene and sanitation, equipped with soap and hand dryers

12. Toilet Facilities; Toilet facilities should be separate from the production area, including the disposal area, and should be periodically cleaned for cleanliness

13. Changing Room/Locker Room Facilities; Changing room facilities should be well-provided, odor-free, well-ventilated, and waterproof

14. Water Source Facilities; Water source facilities should be separated between clean water and drinking water, and periodic laboratory testing should be conducted

15. Hot Water Facilities; Hot water facilities should have a minimum temperature of 60°C

16. Waste Disposal Facilities; Waste disposal facilities should be located far from the production area, sealed tightly, and undergo regular cleaning every day or according to production quantities

17. Food Storage Room; Food storage rooms must meet specific conditions (for dry goods, a minimum temperature of 25°C or room temperature, chiller with a temperature ≤5°C, and freezer with a minimum temperature of -18°C)

2. Category Area for GMP

The GMP implementation process can be facilitated by categorizing areas into three parts: red, yellow, and green zones. This categorization considers the potential contaminants with the following categories:

1. The red zone is an area that requires special restrictions on personnel entry and exit. Every worker cannot freely enter or exit this area and is often referred to as a restricted area. This area has a high level of contamination, such as raw food processing areas, storage of raw or semi-cooked food items (freezer or chiller rooms), preparation areas for food raw materials in direct contact with personnel, production/cooking/mixing areas, nutrition inspection areas (food industry), and product inspection areas (pharmaceuticals or products requiring high hygiene levels)

2. The yellow zone is an area that requires supervision regarding access entry and exit, but restrictions are not as strict as in the red zone. Some areas that fall into the yellow zone category include dry storage areas for raw materials, production equipment cleaning areas, and areas for serving fully cooked food to customers. The yellow zone needs periodic monitoring

3. The green zone is an unrestricted area that any personnel can access. Some areas that fall into the green zone category include office areas, cleaning service areas, and relaxation/waiting areas

Mapping of these areas needs to be coordinated with the GA department and facilities and then communicated to all personnel working in the respective areas.

3. How to Monitoring

Monitoring processes are necessary to ensure the effective implementation of GMP. The monitoring method can involve direct inspection of every aspect of GMP. The inspection should be conducted by competent personnel, with approval from the area supervisor, and should be scheduled.

The stages of inspection can begin with an understanding of the work area, direct examination of objects, on-site document inspection, and personnel inspection. Inspections will be more manageable if scheduled regularly and initiated with strong commitment. This process can be conducted independently or through joint inspections

4. How to Documenting

Documentation here is not limited to photos taken during activities but is more complex than that. Documented information is needed as an output for the successful implementation of GMP. How do you document an activity in a structured manner?

It starts with creating Standard Operating Procedures (SOPs) as a general working guide, followed by work instructions as technical guidance, and forms as records of activities.

Forms can include the time of activity execution, location, responsible person in charge (PIC), attached photos/evidence, and signatures if needed as proof of document authenticity. Documentation of activities is done sequentially, starting from the most recent time, making it easier for the GMP monitoring process later.

Those are the four things that can be outlined regarding GMP Building & Facilities. Hopefully, this article helps you understand GMP. Stay tuned for the next articles, and leave comments for further discussion. Have a great day, readers!