DESIGN AND REQUIREMENTS FOR A FOOD LABORATORY
A ‘laboratory’ is a controlled environment in which scientific and technological research, experimentations, and measurements can be carried out. The various requirements of the specialists working within laboratories determine the establishment and material of laboratories. Laboratory designing is the process of arranging basic program elements as well as highly specialized blocks to ensure a safe and efficient space.
The biological, radiological, and chemical hazards, the work to be performed, as well as the implementation of risk controls are all important considerations when designing a laboratory. A risk and needs assessment must be accomplished to assess the kinds of laboratory activities planned in order to identify how the work can be performed effectively and safely. The risk assessment considers the likelihood of exposure to or release of a biological agent and the severity of the consequences.
The general requirements for a food laboratory are to conduct systematic sampling of food samples, chemical and microbiological tests, and packaging material testing to determine food quality.
1. Design considerations of a laboratory
The most important step in laboratory design would be the planning phase. The laboratory must be planned and designed based on the type of lab such as a testing lab, research lab or teaching labs. Thus, a few considerations must be noted before designing any laboratory.
1.1. Laboratory floor space: In any laboratory, sufficient movement and workspaces are crucial factors. Laboratories require adaptable spaces and areas that allow for collaboration, interaction, and creative thinking.
The space must be large enough to accommodate all of the necessary design elements of a fundamental laboratory, such as basins, benches, sinks, and worktops, as well as equipment like refrigerators and ovens. Additional floor space must be set aside for personnel use, storage, and laboratory coats. This space must be located outside the laboratory's working space.
When standing on the floor or on a 12" step stool, lab shelving must not be installed at heights or distances that require workers to reach 30 centimeter’s above shoulder level and extend arms more than 30 centimeter’s while holding objects weighing 16 kg or less.
1.2. Corridors, doors, and windows: The laboratory must be completely isolated from the outside area of production. Enclosures in laboratories help to contain spills, prevent unauthorized personnel from accessing areas where hazardous operations are carried out and ensure hygienic conditions.
For safety reasons and to allow trolleys to pass through, laboratory entrances should be built without door thresholds. Windows should be made of laminated glass and should be smoke-tight. The corridors and exits should be kept clear at all points of time to allow for emergency exits; they should not be used for storage.
1.3. Storage: Ample floor area and/or cabinetry must be accessible to store consumables and reagents safely and securely in the short and long term. Corrosive and flammable chemicals and gases should be stored away from the laboratory to reduce the risk of explosion or fire.
Specimen storage may necessitate a significant amount of refrigerator or freezer area within the facility. There must be enough floor space to store waste safely and securely before it is remediated or transferred for disposal. Cleaning and servicing of equipment must be possible in the spaces between seats, cabinets, and equipment.
1.4. Flooring and ceiling: For easy cleaning, all floor surfaces must be nonporous, smooth, water and chemical-resistant. In general, PVC or rubber floor covering is suggested. Wet rooms should have textured or anti-slip epoxy flooring or tiling. The laboratory rooms should have a minimum clearance height of 2.70 m, plus extra space for installations. The best solution is an exposed ceiling with all support/installations visible.
1.5. Facilities and systems:
1.5.1. Air Handling Specifications: The ductwork for laboratory ventilation or air conditioning must not be linked to the production system or other non-microbiological areas. Air should be replaced 5 to 10 times per hour in laboratories.
1.5.2. Lighting: Procedure lighting requirements should be assessed so that those requiring more light (or low light levels) can be suitably lit (or shaded) utilizing artificial means, while natural daylight should be used whenever feasible to save energy.
1.5.3. Electrical supplies: Electronic supplies should be of sufficient power and reliability to allow all electronic devices to operate safely and effectively. Installation of an uninterruptible power supply system or stabilizers may be considered where required or proposed to minimize voltage spikes and interruptions.
1.5.4. Hand washing: Hand-washing facilities must be available in each laboratory room where practices, including waste handling, are executed. These amenities should be located as close to the door as possible.
Sink lips or berms must be at least 0.25 inches thick and should be crafted to totally separate the lab bench or fume hood workspace from the drain.
1.5.5. Analytical Equipment Installation: The space required to house this equipment and the necessary utilities should be considered early in the laboratory design process. Equipment must be placed to allow for directional workflow from "low" to "high" risk activities.
1.5.6. Earthquake Restraints: Any equipment that is 48 inches or higher and has the potential to fall over during an earthquake, including but not limited to appliances and shelving, must be securely braced or affixed to the wall and/or floor.
Laboratories must have distinct zones based on the types of analyses performed and the functionality of the rooms. Factory laboratories, particularly microbiology areas, should never have direct access to the manufacturing area to avoid any cross-contamination.
sample reception areas, integrated with computer systems for data registration should be located close to the lab entry.
3. Requirements of a food laboratory:
3.1. Equipment and Instruments: Many items are shared by various analyses in a food lab. Provision must be made for the acquisition and storage of spares and replacement parts. Apparatus primarily made of glass are not repeated. A few commonly used instruments in a food lab are:
a. Analytical Balance
2. pH meter
3. UV-Spectrophotometer
4. atomic absorption Spectrophotometer
5. High-Performance Liquid Chromatograph (HPLC)
3.2. Utilities: Electricity must be either stable or perhaps the voltage should be stabilized. The lab should have an adequate number of electrical outlets. There should be multiple cold water taps bench to enable rinsing, condensers, and so on, but hot water should be limited to sinks where the apparatus is cleaned.
A distribution network for distilled or deionized water is useful in a larger laboratory. Drain pipes with screwed joints should be made of high-density polyethylene or polymer polypropylene.
3.3. Environmental Control: Appropriate temperature, humidity, and dust control are critical for employee comfort, instrument efficiency, and safety on the job. Test materials, reagents, and standards require controlled storage. Some substances are harmed by sunlight or fluorescent lighting and ought to be kept away from them.
3.4. Safety systems: The needs assessment determines the safety systems, which must comply with regulatory requirements and/or building codes. Fire extinguishers, first-aid boxes, escape routes, and safety showers are a few examples of emergency equipment. The lab must have a minimum aisle clearance of 24 inches. Main egress corridors should have a clearance width of at least 36 inches.
3.5. Personnel Requirements: Personnel must be technically qualified to perform their assigned duties, such as operating specific equipment, performing tests, evaluating results, and signing reports. Frequent as well as refresher training should indeed be organized to keep personnel current in their field of work.
3.6. Test methods: The laboratory shall only use official methodologies depending on the test requirement, its sensitivity, the nature of the commodity being tested, and the quality as well as safety factors to be defined.
In the case of non-official methods, verification of the methods according to set norms is required, as well as their detection/quantification range, and limitations.
3.7. Requirement of Microbiological area: Separate zones must be established in a microbiological laboratory for activities that may result in cross-contamination between the samples. This could be a physical condition, a visual or a physical barrier the area's demarcation. Storage compartments must be made available coats/shoes for the laboratory as well as non-laboratory clothing.
Some common equipment in a Microbiological area are:
a. Incubator
b. Hot air oven
c. Centrifuge
d. Laminar air flow
e. Autoclave
f. Microscope
g. Centrifuge
Conclusion
A good lab design solves the conundrum of fitting more scientific findings into less area while maintaining engineering and architectural balance. The factors to consider for designing a laboratory are the location and distance from the production, the analysis throughput times, the expense of the specific test, and the dependability of the results. Special consideration should be given to conditions that are associated with possible safety problems when designing a lab and assigning specific types of work to it. The lab must be zoned according to the requirement of analyses such as Microbiology area, chemical analysis, and sensory analysis.
References
1. https://www.madgetech.com/posts/blogs/food-laboratory-testing-and-techniques/
2. https://www.fssai.gov.in/upload/uploadfiles/files/Manual_GFLP_06_09_2018.pdf
3. https://www.fssai.gov.in/upload/uploadfiles/files/Standard_Spec_Equipment_Food_23_07_2021.pdf
4. https://www.mynewlab.com/blog/focus-on-lab-design-a-guide-to-different-research-suites/
5. https://www.ecvv.com/product/4991715.html
6. https://www.spacesaver.com/portfolio-posts/compact-cold-storage/
7. https://www.hamiltonflooring.co.uk/articles/best-flooring-for-laboratories-and-science-rooms/
8. https://www.istockphoto.com/photo/blue-sink-with-tap-water-set-up-into-bench-lab-in-chemistry-laboratory-room-white-gm1304816998-395868286
9. https://www.foodengineeringmag.com/articles/99891-getting-handwashing-right
10. https://en.wikipedia.org/wiki/Ultraviolet%E2%80%93visible_spectroscopy#/media/File:DU640_spectrophotometer.jpg
11. https://www.researchgate.net/figure/Safety-in-the-Lab_fig4_333650536
12. https://ehs.stanford.edu/manual/laboratory-standard-design-guidelines/laboratory-design-considerations
13. india.org/International_Workshop_and_Training_Program_on_Good_Food_Laboratory_Practices http://www.ilsi-
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