GMA Facility Design Checklist

Version 1.0 - June 2010

For detailed directions on the use of the checklist, please click on the tab marked "Directions."
Date:
Completed By:
Location:
Facility purpose:

Facilities, equipment and machinery must meet all federal, state and local food safety requirements as well
as personnel safety requirements during operation, cleaning and sanitizing. Any modifications must not
affect compliance with these requirements.
Points Points
# Description S M U NA Comments
Awarded Available
PRINCIPLE #1 - Distinct Hygienic Zones Established In The Facility
1.01 Facility drawings show hygienic zones, (Ready-to-eat vs. raw, high care vs. low
care, etc.) where applicable. Hygienic zones should be clearly demarcated on
the plant schematics with colors or other markings to facilitate easy identification Needs X 25.0

1.02 Separate locker rooms and lunch rooms should exist for RTE/high risk and non-
RTE/lower risk personnel, or provisions to separate high risk and low risk Needs X 25.0
employees exist
1.03 Restroom facilities are not located in RTE/high risk zones (see point 10.08)
Needs X 25.0
1.04 Separate storage areas for tools and spare parts exist to minimize contamination
from non-RTE/lower risk zones to RTE/high risk zones Needs X 25.0
1.05 Separate quality labs should exist for RTE/high risk and non-RTE/lower risk
Needs X 20.0
zones
1.06 Separate storage areas for sanitation crews exist for RTE/high risk and non-
RTE/lower risk zones (e.g., vacuums, mops, brooms etc. are segregated) Needs X 30.0

TOTAL POINTS FOR THIS SECTION 0.0 150.0

PRINCIPLE #2 - Personnel and Material Flows are Controlled to Reduce Hazards

2.01 Facility is designed such that movement of employees and visitors throughout
the facility is controlled in a manner that does not contribute to potential cross
contamination (e.g., employees working with raw product travel separate paths Needs X 25.0
from those working with RTE product)
2.02 Facility is designed such that movement of contractors and maintenance
personnel throughout the facility is controlled in a manner that does not Needs X 20.0
contribute to potential cross contamination (such as separate areas)
 2.03 Facility is designed to provide sanitary delivery of packaging materials,
ingredients, and rework into RTE/high risk zones in a manner that does not Needs X 25.0
contribute to potential cross contamination

2.04 Facility is designed for sanitary removal of trash from RTE/high risk zones (e.g.,
dedicated personnel/ travel paths/ dedicated and sanitized footwear for high to Needs X 30.0
low hygiene areas)
TOTAL POINTS FOR THIS SECTION 0.0 100.0

PRINCIPLE #3 - Water Accumulation Controlled Inside Facility

3.01 Floor design and drainage systems prevent standing water and avoid drain
Needs X 20.0
backups
3.02 Wall and curb surfaces drain freely without pockets, ledges and nooks Needs X 15.0
3.03 Areas above ceilings do not accumulate water Needs X 15.0
3.04 Equipment wastewater discharges are piped directly to drains Needs X 20.0
3.05 Drain pans are sloped to be free draining Needs X 15.0
3.06 All drip pans have continuous flow and are directed to a drain Needs X 15.0
TOTAL POINTS FOR THIS SECTION 0.0 100.0

PRINCIPLE #4 - Room Air Flow and Room Air Quality Controls

4.01 Room temperature meets process requirements Needs X 15.0
4.02 Measures are taken to prevent condensation through all seasons Needs X 20.0
4.03 Facility airflow is from clean to less clean areas (high hygiene to low hygiene,
Needs X 15.0
high to low risk zones, RTE to non-RTE areas)
4.04 Critical process air is adequately filtered Needs X 10.0
4.05 Outdoor makeup air is properly filtered for the process requirements Needs X 15.0
4.06 Air handling system components meet the 10 Principles of Equipment Sanitary
Needs X 15.0
Design
4.07 Where appropriate, provisions are made to capture high concentrations of heat,
moisture and particulates at the source Needs X 10.0
4.08 HVAC/refrigeration system components are located to avoid risks of product
contamination Needs X 15.0

4.09 HVAC/refrigeration systems are dedicated to specific areas (RTE vs. non-RTE)
and do not contribute to cross-contamination Needs X 10.0

TOTAL POINTS FOR THIS SECTION 0.0 125.0

PRINCIPLE #5 - Site Elements Facilitate Sanitary Conditions

5.01 Driveways, parking lots and pedestrian walkways are paved and self draining Needs X 5.0
5.02 Landscaping and grounds are designed to minimize attraction and harborage of
Needs X 5.0
insects and rodents
 5.03 Adequate trash receptacles in pedestrian traffic areas are provided.
Receptacles shall be covered and/or managed to not be a source of Needs X 5.0
contamination
5.04 Insect attractant lighting is positioned to draw insects away from the building.
Lighting on the building limits the attraction of insects Needs X 10.0

5.05 Roof surfaces should be cleanable and self draining Needs X 5.0
5.06 Finished floor elevation is higher than adjacent grades to prevent storm water
Needs X 5.0
ingress into building
5.07 External operations (e.g., trailer cleaning, bulk storage, trash and waste
management) are designed and positioned to prevent unsanitary impact Needs X 5.0
(splashing, overflow, cross contamination, residues etc.) on the facility
5.08 External drainage is adequate to prevent standing water Needs X 5.0
5.09 Detention and retention basins are properly designed, maintained and operating
Needs X 5.0
to eliminate unnecessary standing water
5.10 A minimum 30" wide border of asphalt, gravel or concrete border or other
Needs X 5.0
acceptable material, is present on all exterior sides of the facility
5.11 Space is provided for storage of clean portable equipment Needs X 5.0
5.12 Soiled laundry collection locations are established, where applicable Needs X 5.0
5.13 Space is provided for boot storage and cleaning, where applicable Needs X 10.0
5.14 Trash collection is located in a manner that does not pose a risk to the product
or the facility, and in locations that are cleanable and maintainable Needs X 10.0

TOTAL POINTS FOR THIS SECTION 0.0 85.0

PRINCIPLE #6 - Building Envelope Facilitates Sanitary Conditions

6.01 Building envelope (e.g., shell, skin) is constructed of materials that are solid,
impervious, and free of cracks and voids, and are compatible with cleaning Needs X 10.0
methods
6.02 Roof flashing systems prevent harborage of insects, birds and rodents
Needs X 5.0

6.03 Roof is sloped to provide positive drainage Needs X 5.0

6.04 Roof drainage is not a source of contamination Needs X 5.0
6.05 Canopies are totally closed Needs X 5.0
6.06 All louvers, fans, vents and openings have intact insect screens and are insect
proof and/or self-closing Needs X 5.0

6.07 Doors are impervious, fully weather stripped, fit well and have solid cores Needs X 5.0
6.08 All door jams and window sills are firmly anchored to the slabs and fully filled Needs X 5.0
6.09 Window frames and door headers are fully filled and mounted flush with walls to
eliminate edges Needs X 15.0
 6.10 All voids associated with utility penetrations (e.g., electrical weather heads, gas
mains, sprinkler risers) are fully filled with appropriate materials, then sealed Needs X 5.0

6.11 All concrete wall panels are caulked from roof to footing Needs X 10.0
6.12 Dock doors have a dock seal or shelter and are weather stripped Needs X 5.0
6.13 Dock pits, dock plates and levelers are designed to be cleaned and proper
utilities are in place to facilitate proper cleaning Needs X 5.0

TOTAL POINTS FOR THIS SECTION 0.0 85.0

PRINCIPLE #7 - Interior Spatial Design Promotes Sanitation

7.01 Aisles are wide enough for maintenance, sanitation and materials movement Needs X 10.0
7.02 There is sufficient access to building elements (e.g., columns, beams, bracing)
Needs X 10.0
for cleaning
7.03 There is sufficient access to the wall-floor interface for cleaning Needs X 10.0
7.04 Stationary equipment is sufficiently placed to allow cleaning and sanitation
underneath and above the equipment (18 inches for non-contact equipment and Needs X 5.0
30 inches for food contact surfaces)
7.05 The layout is coordinated to allow access to clean and inspect overhead
elements (e.g., ducts, piping, equipment, lights, diffusers) Needs X 5.0

7.06 There is a perimeter inspection zone of at least 18 “ between walls and any
Needs X 20.0
storage or placement of fixed equipment
TOTAL POINTS FOR THIS SECTION 0.0 60.0

PRINCIPLE #8 - Building Components and Construction Facilitate Sanitary Conditions

8.01 Interstitial spaces separate process areas from utility services and overhead
Needs X 5.0
structural components, and are accessible for cleaning
8.02 Suspended ceilings should be avoided whenever possible. If absolutely
necessary, a walk-on design should be used to allow personnel access for Needs X 5.0
cleaning and they shall be smooth, cleanable and at a uniform height
8.03 Walls, and ceilings are smooth and cleanable with minimal joints and no cavities
Needs X 5.0

8.04 All vertical and horizontal wall joints are sealed appropriately Needs X 5.0
8.05 All vertical surface to floor junctions have a cove and surfaces that are free of
pits, erosion and voids Needs X 5.0

8.06 Concrete surfaces are solid, smooth, and free of pits, erosions and voids Needs X 5.0
8.07 Curbs (stainless steel, concrete and concrete with stainless steel inlay) go the
full height to the curb-wall junction Needs X 5.0

8.08 Wall facings such as Fiberglass Reinforced Panels (FRPs) and Insulated Metal
Panels (IMPs) are factory laminated or foamed-in-place for insulation (Check Needs X 5.0
federal, state and local building code requirements)
 8.09 Cavity and voids are absent in floor, wall and ceiling assemblies. All floor joints
and cracks are sealed Needs X 10.0

8.10 Insulation that does not deteriorate, or retain or absorb moisture, such as closed
cell or encapsulated insulation, is used in the facility Needs X 5.0

8.11 Horizontal structural members have no flat surfaces where dust or soil could
Needs X 5.0
accumulate
8.12 All-thread rods and “Unistruts” are not used and other threaded surfaces are
Needs X 5.0
minimized
8.13 Bases of drains are supported to prevent settling Needs X 5.0
8.14 All cracks, joints and voids are filled with appropriate materials Needs X 5.0
8.15 Caulking is minimized and done in a manner that is not a source for potential
contamination (e.g., loose, flaking) Needs X 5.0

8.16 Items attached directly to a building surface have stand-offs Needs X 5.0
8.17 All mezzanine structures over a processing area are waterproof and drain
properly Needs X 5.0

8.18 Doors and windows are constructed to prevent insect and rodent access, and
harborage, are impervious, easily cleanable and resistant to wear and corrosion Needs X 5.0

8.19 Floors are constructed to prevent insect and rodent access and harborage, are
impervious, easily cleanable and resistant to wear and corrosion Needs X 5.0

TOTAL POINTS FOR THIS SECTION 0.0 100.0

PRINCIPLE #9 - Utility Systems Designed To Prevent Contamination

9.01 Horizontal piping, conduits, and light fixtures are not installed above exposed
Needs X 5.0
product or processing equipment
9.02 Piping and conduits are located and spaced to facilitate access, cleaning and
sanitation, and are routed outside of process areas wherever possible Needs X 5.0

9.03 Piping is adequately insulated to prevent condensation and the insulation is

covered with material able to withstand the operating conditions and the Needs X 5.0
cleaning methods used
9.04 Lockable fasteners are used on hangers and attachments to avoid risk of foreign
material contamination Needs X 5.0
9.05 Glass components are used only where necessary, and are properly protected
(e.g., shields or shatterproof coated) to avoid risk of foreign material Needs X 5.0
contamination
9.06 Controls are in place to prevent moisture accumulation in air lines and minimize
potential transfer of moisture through compressed air Needs X 5.0

9.07 Air gaps or mechanical backflow prevention devices, are used to prevent cross-
contamination of the potable water supply Needs X 5.0

9.08 Where steam will contact product, or product contact surfaces, the steam supply
system shall conform with requirements for the production of culinary steam Needs X 5.0
 9.09 Bulk ingredient tanks are designed for proper cleaning and are accessible for
regular inspection Needs X 5.0

9.10 Process and sanitary sewers are separated within the building Needs X 5.0
9.11 Waste and vent lines are not routed above product or process equipment Needs X 5.0
9.12 Where possible, drain cleanouts are installed outside the processing areas Needs X 5.0
9.13 Drains are accessible for cleaning and sanitation Needs X 5.0
9.14 Trench drains are avoided wherever an alternative is possible Needs X 15.0
9.15 Process sewers are made of materials compatible with the temperature and
Needs X 5.0
corrosiveness of the waste stream and cleaning compounds used
9.16 Air (gas) discharges from sewage lines, drain lines, and raw process areas are
Needs X 5.0
not vented in a manner that may contaminate air intakes
9.17 Sewage, drain lines, and air discharges from raw process areas are vented at
least twelve inches below the level of fresh air intakes when located within 50 Needs X 10.0
feet of each other (as these gases are typically heavier than air)
9.18 Drains are designed to avoid ingress of drain gasses into process areas (e.g.,
Needs X 5.0
‘P’ traps or other methods)
9.19 Interior drain lines do not run through high risk/high hygiene processing areas
Needs X 5.0

TOTAL POINTS FOR THIS SECTION 0.0 110.0

PRINCIPLE #10 - Sanitation Integrated Into Facility Design

10.01 Water temperature, flow and pressure meets specified requirements at point of
Needs X 10.0
use
10.02 Clean up stations are supplied with adequate hose hangars to keep hoses off
the floor and where possible outside of process areas Needs X 10.0

10.03 Rinse systems must be designed to deliver the minimum pressures needed to
Needs X 10.0
complete the desired cleaning procedures
10.04 Adequate hand washing and sanitizing stations are provided at locations as
Needs X 10.0
required to maintain adequate hygiene requirements
10.05 Adequate interventions (e.g., hygiene junctures, foot baths, doorway foamers,
Needs X 10.0
boot washers) are provided at locations as required to maintain zones of control
10.06 Adequate systems (e.g., vacuum systems, dust collection systems, COP, CIP,
equipment washers) are provided to facilitate proper cleaning, sanitizing and Needs X 10.0
drying of equipment
10.07 Microbiology laboratories are located and constructed in a manner to prevent
potential contamination to process areas (e.g., located in separate buildings, Needs X 10.0
double door entries, negative air pressure)
10.08 Restrooms do not open directly from or into any processing area Needs X 10.0
10.09 Restrooms are designed to maintain negative air pressure versus their
Needs X 5.0
surrounding area
TOTAL POINTS FOR THIS SECTION 0.0 85.0