Layout, Product Flow & Segregation Procedure

Use production risk to define the zoning structure

The procedure requires a structured production risk zone assessment for products manufactured, processed or packed at the site. Technical or quality management determines the applicable zones using the recognised risk-zone definitions within the organisation’s food-safety framework and the susceptibility of the products to contamination.

The resulting zoning structure becomes the reference for facility layout, movement controls and segregation arrangements. This gives the site a risk-based basis for deciding how operational areas should be organised, rather than relying on layout convention alone.

Make routes, access points and segregation visible on the site map

A maintained site map provides the operational reference for layout control. The procedure requires it to show production risk zones, personnel access points, material and product access points, routes for personnel, raw materials, packaging, waste and rework, staff facilities, production process flows and any areas where time-based segregation is used.

By bringing these elements together on a controlled map, the procedure makes the relationships between zoning, traffic flow and segregation visible and reviewable. Where the mapped layout changes because of structural change, operational review or process modification, the map is updated through document control.

Control personnel, material and product movement through the facility

The procedure defines controls for the movement of personnel, raw materials, packaging, intermediate or semi-processed product, finished product, rework and waste so that traffic flow does not compromise product safety.

Operations management is responsible for maintaining the defined product and material flow in routine production, while technical or quality management confirms that the supporting contamination-control arrangements remain effective. Where movement controls or related arrangements fail and product may no longer meet safety, legality or quality requirements, the procedure links the response to the site’s non-conforming product and corrective-action controls.

Contractors, visitors and delivery drivers entering operational environments are also brought within the control. The procedure requires relevant area requirements, hazards and contamination risks to be communicated before or at entry so that non-site personnel understand the behavioural and hygiene expectations associated with the areas they visit.

Provide space and storage capacity for hygienic operation

The procedure treats working space and storage capacity as part of contamination control. It requires the premises and operational layout to provide sufficient space for production, handling and supporting activities to be carried out hygienically without obstruction or congestion.

It also requires storage capacity and warehouse practices to support the safe handling and flow of raw materials, packaging, intermediate products and finished products. This connects physical capacity with the practical ability to maintain orderly, hygienic movement and segregation.

Control temporary structures during building and refurbishment work

The procedure includes specific controls for temporary structures introduced during building work or refurbishment. Engineering management is required to ensure that their design and placement do not create pest harbourage or introduce contamination risks, while operations management applies protective controls so product safety and quality remain protected while the temporary arrangements are in place.

This extends layout and segregation control beyond the permanent facility, recognising that temporary changes to the production environment can affect the same hygiene and contamination risks as the normal site configuration.

Assign responsibility across the functions that shape site flow

The procedure distributes responsibility across the functions that design, maintain and use the layout. Senior management provides the facilities, resources and organisational support needed for effective segregation and hygienic operation. Technical or quality management establishes the zoning and segregation system and verifies contamination-control arrangements.

Operations management implements controlled product and material flow; engineering management controls structural changes and temporary structures; warehouse management maintains hygienic storage and sufficient capacity; security personnel communicate area requirements to visitors and contractors; and employees follow the movement and segregation controls that apply to their work.

This allocation connects technical zoning decisions with the operational, engineering, storage and access-control activities that determine whether the layout works as intended in practice.

A layout-control procedure within the wider FSQMS

Within the Food Industry Hub FSQMS Policies and Procedures Suite, this procedure provides the operational framework for production zoning, site mapping, traffic flow and segregation. It interfaces directly with document control, training, non-conforming product control, corrective action and the Site Standards & Infrastructure Policy.

For technical and operational teams, the procedure provides a structured way to connect the physical design of the site with the routes, behaviours and controls used during everyday production, making layout and flow a managed part of the FSQMS rather than a static facility description.