Clean room food processing systems, methods and structures

• US 20050249632A1
• Filed: 04/06/2004
• Published: 11/10/2005
• Est. Priority Date: 04/06/2004
• Status: Active Grant

• Current Assignee: West Liberty Foods LLC (Iowa Turkey Growers Cooperative)
• Original Assignee: West Liberty Foods LLC (Iowa Turkey Growers Cooperative)
• Inventors: Cook, Charles F., Garrett, Edward S., Woodford, Richard D.
• Granted Patent: US 7,707,931 B2
• Time in Patent Office: Days
• US Class Current: 422/32
• CPC Class Codes: A22C 18/00 Plants, factories, or the like for processing meat for processing poultry only A22C21/00; for processing fish only A22C25/00
• CPC Class Codes: A23B 4/005 Preserving by heating
• CPC Class Codes: A23L 3/165 in solid state
• CPC Class Codes: B26D 1/01 involving a cutting member which does not travel with the work
• CPC Class Codes: B65B 5/00 Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
• CPC Class Codes: E04H 3/00 Buildings or groups of buildings for public or similar purposes; Institutions, e.g. infirmaries or prisons
• CPC Class Codes: Y10T 83/202 With product handling means

Abstract

Some food pathogens are not well controlled by lethality treatments followed by refrigeration. A food processing facility according to this invention reduces the likelihood that food pathogens will be able to enter the food processing facility, or spread should they be able to enter. The food processing facility is divided into a plurality of area, with different areas having different allowed actions that can be taken on the food product, different rules and/or procedures for persons who are allowed entry, and/or different levels of cleanliness. The food processing facility includes a plurality of separate rooms for processing the food product, each including separate food processing machines, air handling systems, drain systems and/or often-used supplies and tools. Different air pressures within different areas limit the possible movement of airborne food pathogens. Sanitizing stations are placed between various ones of the different areas.

Claims

1. A method for reducing contamination by an undesirable micro-organism within a food processing facility that processes a food product, comprising:

transporting a food product into one of a plurality of food processing rooms, each food processing room comprising a single food processing line comprising at least one food processing device and at least one food packaging device;

processing the food product in that food processing room;

packaging the processed food product into a closed package in that food processing room such that any micro-organisms outside of the package will be unable to migrate into the interior of the package as long as the package remains closed; and

transporting the closed package out of that food processing room.

2. The method of claim 1, further comprising applying a lethality treatment to the food product before transporting the food product into that food processing room, wherein transporting the food product into that food processing room comprises transporting the treated food product into that food processing room.

3. The method of claim 2, wherein:

the food product comprises a processed meat product; and

applying the lethality treatment to the processed meat product comprises at least one of;

passing the processed meat product through a steam treatment;

passing the processed meat product through a hot liquid bath, and

passing the processed meat product through a radiant heat treatment, and

passing the processed meat product through a chemical sanitizer.

4. The method of claim 3, wherein passing the processed meat product through a hot liquid bath comprises passing the processed meat product through an oil bath, or a water bath.

5. The method of claim 3, wherein passing the processed meat product through a radiant heat treatment comprises passing the processed meat product through at least one infra-red heating treatment.

6. The method of claim 2, wherein transporting the treated food product into that food processing room comprises:

transporting the treated food product into a first area, at least that food processing room having a passage to the first area; and

transporting the treated food product from the first area into that food processing room through the passage.

7. The method of claim 6, further comprising:

having the first area at a first air pressure;

maintaining that food processing room at an air pressure that is greater than the first air pressure;

wherein transporting the treated food product from the first area into that food processing room comprises passing the treated food product through the passage from the first area into that food processing room while passing the ambient atmosphere through the passage from that food processing room into the first area.

8. The method of claim 7, wherein:

applying the lethality treatment to the food product before transporting the food product into that food processing room comprises applying the lethality treatment in a treatment room; and

transporting the treated food product into the first area comprises transporting the treated food product from the treatment room to the first area.

9. The method of claim 8, further comprising maintaining the treatment room at a second air pressure that is lower than the first air pressure, wherein transporting the treated food product from the treatment room to the first area comprises passing the treated food product through a passage from the treatment room into the first area while passing the ambient atmosphere through the passage from the first area into the treatment room.

10. The method of claim 9, wherein maintaining the treatment room at the second air pressure comprises exhausting the atmosphere in the treatment room to outside of the food processing facility at a rate that lowers the air pressure i the treatment room to a point below the first air pressure.

11. The method of claim 7, wherein maintaining that food processing room at an air pressure that is greater than the first air pressure comprises supplying air into that food processing room at a rate that increases the air pressure in that food processing room to a point that is above the first air pressure.

12. The method of claim 6, further comprising maintaining at least that food processing room and the first area at a first level of cleanliness when transporting the treated food product into the first area and when transporting the treated food product from the first area into that food processing room.

13. The method of claim 12, wherein maintaining at least that food processing room and the first area at the first level of cleanliness when transporting the treated food product into the first area and when transporting the treated food product from the first area into that food processing room comprises at least one of:

limiting access to at least that food processing room and the first area to persons having at least a first predetermined level of food safety training;

requiring persons entering at least one of that food processing room or the first area to wear a clean first-type set of clothing; and

requiring persons entering at least one of that food processing room or the first area to undergo a first cleaning procedure prior to entering the first area.

14. The method of claim 6, wherein transporting the treated food product into that food processing room further comprises passing the treated food product through a chilling device that chills at least a surface region of the treated food product to a temperatures that is at most about a freezing point of the treated food product.

15. The method of claim 14, wherein transporting the treated food product from the first area into that food processing room through the passage comprises transporting the chilled treated food product into that food processing room through the passage.

16. The method of claim 2, wherein:

applying the lethality treatment to the food product comprises applying the lethality treatment in a treatment room; and

transporting the food product into that food processing room further comprises transporting the treated food product from the treatment room at least indirectly into that food processing room.

17. The method of claim 16, wherein transporting the treated food product at least indirectly into that food processing room further comprises passing the treated food product through a chilling device that chills at least a surface region of the treated food product to a temperatures that is at most about a freezing point of the treated food product before transporting the treated food product into that food processing room.

18. The method of claim 1, wherein transporting the food product into that food processing room comprises:

holding the food product in a first area until the food product is to be processed in that food processing room;

transporting the food product from the first area into a second area, at least that food processing room having a passage to the second area; and

transporting the food product from the second area into that food processing room through the passage.

19. The method of claim 18, further comprising:

maintaining the first area at a first level of cleanliness when holding the food product in the first area and when transporting the food product from the first area into the second area;

maintaining at least that food processing room and the second area at least at a second level of cleanliness when transporting the food product from the first area into the second area and when transporting the food product from the second area into that food processing room.

20. The method of claim 19, wherein maintaining at least the first area at the first level of cleanliness when holding the food product in the first area and when transporting the food product from the first area into the second area comprises at least one of:

requiring persons having entered at least the first area from a third area, where the third area is at a third level of cleanliness that is less than the first level of cleanliness, to wear at least a first-type set of clothing when in the first area; and

requiring persons entering at least the first area from the third area to undergo a first cleaning procedure when passing from the third area into the first area.

21. The method of claim 20, wherein maintaining at least that food processing room and the second area at least at the second level of cleanliness when transporting the food product into the second area and when transporting the food product from the second area into that food processing room further comprises at least one of:

limiting access to at least that food processing room and the second area to persons having at least a first predetermined level of food safety training;

requiring persons entering at least one of that food processing room or the second area to enter from the first area;

requiring persons entering at least one of that food processing room or the second area to wear a clean second-type set of clothing; and

requiring persons entering at least one of that food processing room or the second area to undergo a second cleaning procedure when passing from the first area into at least one of that food processing room or the second area.

22. The method of claim 20, wherein maintaining at least the first area at the first level of cleanliness when holding the food product in the first area and when transporting the food product from the first area into the second area further comprises requiring persons leaving at least one of that food processing room or the second area to the first area to undergo a further cleaning procedure when passing from at least one of that food processing room or the second area into the first area.

23. The method of claim 19, wherein maintaining at least that food processing room and the second area at least at the second level of cleanliness when transporting the food product from the first area into the second area and when transporting the food product from the second area into that food processing room comprises maintaining at least that food processing room at a fourth level of cleanliness that is greater than the second level of cleanliness.

24. The method of claim 23, wherein maintaining at least that food processing room at the fourth level of cleanliness comprises limiting access to that food processing room to personnel operating food processing devices located in that food processing room, to appropriate supervisory personnel and to personnel maintaining that food processing room and equipment contained within that food processing room.

25. The method of claim 24, wherein maintaining at least that food processing room at the fourth level of cleanliness comprises:

having the second area at a first air pressure;

maintaining that food processing room at an air pressure that is greater than the first air pressure; and

transporting the food product from the second area into that food processing room through the passage comprises passing the food product through the passage from the second area into that food processing room while passing the ambient atmosphere through the passage from that food processing room into the second area.

26. The method of claim 19, wherein:

the first area comprises at least;

a first portion that includes a holding area where the food product is held before it is processed in that food processing room, and

a packaged food receiving area that receives the closed packages from that food processing room, at least that food processing room having a second passage to the packaged food receiving area; and

transporting the closed package out of that food processing room comprises transporting the closed package through the second passage to the packaged food receiving area; and

maintaining at least the packaged food receiving area at the first level of cleanliness when receiving the closed packages from that food processing room comprises at least one of;

(a) requiring persons passing between the first portion and the packaged food receiving area to undergo another cleaning procedure when passing between the first portion and the packaged food receiving area;

or (b) having the packaged food receiving area at a first air pressure,

maintaining that food processing room at an air pressure that is greater than the first air pressure, and

transporting the closed packages from that food processing room through the second passage into that food processing room while passing the ambient atmosphere through the passage from that food processing room into the second area;

or

(c) inspecting closed packages for faults,

sanitizing closed packages having faults, and

returning the sanitized closed packages having faults back into that food processing room.

27. The method of claim 19, wherein maintaining at least the first area at the first level of cleanliness when holding the food product in the first area and when transporting the food product from the first area into the second area further comprises preventing raw food products from entering the first area.

28. The method of claim 19, wherein maintaining at least the first area at the first level of cleanliness when holding the food product in the first area and when transporting the food product from the first area into the second area further comprises:

accepting only previously cooked and sealed food products into the first area;

cleaning an outer surface of a packaging that seals the previously cooked and sealed food product;

removing the packaging from around the previously cooked and sealed food product; and

applying a lethality treatment to the unsealed food product before transporting the unsealed food product into the second area.

29. The method of claim 28, wherein maintaining at least the first area at the first level of cleanliness when holding the food product in the first area and when transporting the food product from the first area into the second area further comprises:

cleaning the outer surface, removing the packaging and applying the lethality treatment in a treatment room of the first area that is maintained at a first air pressure;

having other portions of the first area and portions of the second area adjacent to the treatment room each at an air pressure that is above the first air pressure such that an ambient atmosphere in those other portions of the first area and the second area flows into the treatment room; and

exhausting an ambient air in the treatment room to outside of the food processing facility.

30. The method of claim 18, wherein transporting the food product from the first area into the second area comprises:

transporting the food product from a holding area of the first area into a treatment area of the first area;

applying a lethality treatment to the food product in the treatment area before transporting the food product into the second area, wherein transporting the food product from the first area into the second area comprises transporting the treated food product from the treatment area into the second area.

31. The method of claim 30, wherein:

the food product comprises a processed meat product; and

applying the lethality treatment to the processed meat product in the treatment area comprises at least one of;

passing the processed meat product through a hot liquid bath, and

passing the processed meat product through a radiant heat treatment.

32. The method of claim 31, wherein passing the processed meat product through a hot liquid bath comprises passing the processed meat product through an oil bath.

33. The method of claim 31, wherein passing the processed meat product through a radiant heat treatment comprises passing the processed meat product through at least one infra-red heating treatment.

34. The method of claim 18, further comprising:

having at least the second area at a first air pressure;

maintaining that food processing room at an air pressure that is greater than the first air pressure;

wherein transporting the food product from the second area into that food processing room comprises passing the food product through the passage from the second area into that food processing room while passing the ambient atmosphere through the passage from that food processing room into the second area.

35. The method of claim 18, wherein transporting the food product from the first area into the second area comprises:

transporting the food product from a holding area of the first area into a treatment area of the second area;

applying a lethality treatment to the food product in the treatment area before transporting the food product into that food processing room, wherein transporting the food product from the second area into that food processing room comprises transporting the treated food product from the treatment area into that food processing room.

36. The method of claim 35, wherein:

the food product comprises a processed meat product; and

applying the lethality treatment to the processed meat product in the treatment area comprises passing the processed meat product through a radiant heat treatment.

37. The method of claim 36, wherein passing the processed meat product through a radiant heat treatment comprises passing the processed meat product through at least one infra-red heating treatment.

38. The method of claim 1, wherein:

at least that food processing room has at least a first passage to a first area; and

transporting the closed package out of that food processing room comprises transporting the closed package from that food processing room into the first area through the first passage.

39. The method of claim 38, further comprising further packaging the closed packages of the processed food product for shipping to a downstream user of the food product.

40. The method of claim 39, further comprising transporting the closed packages to the downstream user.

41. The method of claim 38, further comprising:

having the first area at a first air pressure; and

maintaining that food processing room at an air pressure that is greater than the first air pressure;

wherein transporting the closed packages from that food processing room into the first area comprises passing the closed packages through the first passage from that food processing room into the first area while passing the ambient atmosphere through the first passage from that food processing room into the first area.

42. The method of claim 41, wherein at least that food processing room has a second passage to the first area, the method further comprising:

inspecting each closed package as it is transported out of that food processing room to identify any closed packages requiring repackaging; and

transporting each closed package requiring repackaging back into that food processing room through the second passage while passing the ambient atmosphere through the second passage from that food processing room into the first area.

43. The method of claim 42, wherein transporting each closed package requiring repackaging back into that food processing room through the second passage comprises sanitizing each closed package requiring repackaging before, after or as that closed package requiring repackaging is transported back into that food processing room.

44. The method of claim 38, further comprising maintaining the first area at a first level of cleanliness when transporting the closed packages from that food processing room into the first area.

45. The method of claim 44, wherein maintaining the first area at the first level of cleanliness when transporting the treated food product from that food processing room into the first area comprises at least one of:

requiring persons entering the first area to wear a clean first-type set of clothing; and

requiring persons entering the first area to have undergone at least a first cleaning procedure prior to entering the first area.

46. The method of claim 45, further comprising maintaining that food processing room at a second level of cleanliness that is greater than the first level of cleanliness when transporting the closed packages from that food processing room into the first area.

47. The method of claim 46, wherein maintaining the first area at the first level of cleanliness and that food processing room at the second level of cleanliness when receiving the closed packages from that food processing room comprises at least one of:

(a) having the packaged food receiving area at a first air pressure,

maintaining that food processing room at an air pressure that is greater than the first air pressure, and

transporting the closed packages from that food processing room through the second passage into that food processing room while passing the ambient atmosphere through the passage from that food processing room into the second area;

or

(b) having the packaged food receiving area at a first air pressure,

maintaining that food processing room at an air pressure that is greater than the first air pressure, and

inspecting each closed package as it is transported out of that food processing room to identify any closed packages requiring repackaging, and

transporting each closed package requiring repackaging back into that food processing room through the second passage while passing the ambient atmosphere through the second passage from that food processing room into the first area.

48. The method of claim 47, wherein transporting each closed package requiring repackaging back into that food processing room through the second passage comprises sanitizing each closed package requiring repackaging before, after or as that closed package requiring repackaging is transported back into that food processing room.

49. A method for reducing contamination by an undesirable micro-organism within a food processing facility that processes a food product, wherein the food processing facility comprises:

a plurality of food processing rooms, each food processing room comprising at least one food processing device and at least one food packaging device, each food processing room to be at a first level of cleanliness;

at least one distribution area, each distribution area adjacent to at least some of the food processing rooms, each distribution area to be at a second level of cleanliness that can be below the first level of cleanliness;

at least one receiving area, each receiving area adjacent to at least some of the food processing rooms, each receiving area to be at a third level of cleanliness that can be below the first and second levels of cleanliness;

at least one buffer area adjacent to at least one of at least one receiving area or at least one distribution area, the buffer area to be at least at the third level of cleanliness that can be below the first and second level of cleanliness;

at least one common area adjacent to the at least one buffer area, each common area to be at a fourth level of cleanliness that can be below the third level of cleanliness;

a plurality of sanitizing stations, at least one sanitizing station located between a common area and a buffer area and at least one sanitizing station located between a buffer area and an adjacent receiving or distribution area;

the method comprising;

requiring persons entering the at least one buffer area to have undergone a first sanitizing procedure prior to or upon entering that buffer area;

requiring persons remaining in the at least one buffer area or exiting a buffer area into the receiving area to wear a first-type set of clothing; and

requiring persons exiting the buffer area into the at least one distribution area or a food processing room to wear a second-type set of clothing;

limiting access to the distribution area, the receiving area and the food processing rooms to persons having at least a first predetermined level of food safety training;

limiting access to a food processing room to personnel operating food processing devices located in that food processing room, to supervisory personnel and to personnel maintaining that food processing room and equipment contained within that food processing room; and

requiring persons entering the at least one distribution area, the at least one receiving area or a food processing room to have undergone a second cleaning procedure prior to or upon exiting the buffer area.

50. A food processing facility, comprising:

a plurality of food processing rooms, each food processing room comprising at least one food processing device and at least one food packaging device, each food processing room at a first level of cleanliness;

at least one distribution area, each distribution area adjacent to at least some of the food processing rooms, each distribution area at a second level of cleanliness that can be below the first level of cleanliness;

at least one receiving area, each receiving area adjacent to at least some of the food processing rooms, each receiving area at a third level of cleanliness that can be below the first level of cleanliness;

at least one buffer area adjacent to at least one of at least one receiving area or at least one distribution area, each buffer area at a fourth level of cleanliness that can be below the second level of cleanliness;

at least one common area adjacent to at least one buffer area, each common area at a fifth level of cleanliness that can be below the fourth level of cleanliness;

a plurality of sanitizing stations, at least one sanitizing station located between a common area and an adjacent buffer area and at least one sanitizing station located between a buffer area and an adjacent receiving or distribution area.

51. The food processing facility of claim 50, further comprising a drain system comprising a plurality of drain lines and at least one catch basin, each drain line connected between one of the at least one catch basin and one of the plurality of food processing rooms.

52. The food processing facility of claim 51, wherein, each drain line is connected directly between the catch basin and the food processing room that it connects and each drain line connected to a particular catch basin connects to that catch basin at least at one of a) a unique position about the perimeter of the catch basin or b) a unique axial position along an axis of the catch basin.

53. The food processing facility of claim 51, wherein each drain line has a closing device that is usable to close that drain line such that that drain line can be filled with fluid from the closing device back to the food processing room to which that drain line is connected.

54. The food processing facility of claim 51, wherein the drain system further comprises a second drain line that is connected at one end to one of the at least one distribution area at least at one connection point and to one of the at least one catch basin at another end.

55. The food processing facility of claim 54, wherein the second drain line connects to that catch basin at least at one of a) a unique position about the perimeter of the catch basin or b) a unique axial position along an axis of the catch basin relative to any drain lines connected between that catch basin and one of the plurality of food processing rooms.

56. The food processing facility of claim 54, wherein that second drain line has a closing device that is usable to close that drain line such that the second drain line can be filled with fluid from the closing device back to that distribution area.

57. The food processing facility of claim 51, wherein the drain system further comprises a second drain line that is connected at one end, at least at one connection point, to at least one of a) at least one of the at least one buffer area or b) at least one of the at least one receiving area and to one of the at least one catch basin at another end.

58. The food processing facility of claim 57, wherein the second drain line connects to that catch basin at least at one of a) a unique position about the perimeter of the catch basin or b) a unique axial position along an axis of the catch basin relative to any drain lines connected between that catch basin and one of the plurality of food processing rooms.

59. The food processing facility of claim 50, further comprising a curb system comprising a plurality of curbs that reduce an ability of food pathogens to migrate along or under walls of the food processing facility between the plurality of food processing rooms, between a food processing room and the at least one distribution area, the at least one receiving area and the at least one buffer area, between the at least one distribution area and the at least one buffer area, between the at least one receiving area and the at least one buffer area and between the at least one buffer area and the at least one common area, the plurality of curbs comprising:

a first type of curb, the first type of curb used in at least the plurality of food processing rooms and providing a first level of protection against the migration of food pathogens;

a second type of curb, the second type of curb used in at least one of a) at least one of the at least one distribution area or b) at least one of the at least one buffer area, and providing a second level of protection against the migration of food pathogens that is less than the first level; and

a third type of curb, the third type of curb used in at least one of a) at least one of the at least one buffer area or b) at least one of the at least one receiving area, and providing a third level of protection against the migration of food pathogens that is less than the second level.

60. The food processing facility of claim 59, wherein the first type of curb comprises:

a mass of concrete adjacent to a wall and a floor of the food processing facility;

an antimicrobial-type stainless steel skirt around the mass of concrete, the stainless steel skirt extending between the wall and the floor and extending into the floor; and

a flexible sealant provided at a joint between the stainless steel skirt and the floor.

61. The food processing facility of claim 59, wherein the second type of curb comprises:

a mass of concrete adjacent to a wall and a floor of the food processing facility;

a non-anti-microbial stainless steel skirt around the mass of concrete, the stainless steel skirt extending between the wall and the floor and extending into the floor; and

a flexible sealant provided at a joint between the stainless steel skirt and the floor.

62. The food processing facility of claim 59, wherein the third type of curb comprises a mass of concrete adjacent to a wall and a floor of the food processing facility.

63. The food processing facility of claim 50, further comprising an air handling system, comprising:

a plenum connected to at least some of the plurality of food processing rooms;

a first bacterial-grade filter connected between the plenum and the ambient atmosphere outside the facility;

for each connected food processing room, a second bacterial-grade filter connected between the plenum and that food processing room; and

a plurality of separate ventilation and cooling subsystems, each ventilation and cooling subsystem connected to a different one of the at least some food processing rooms, each ventilation and cooling subsystem drawing air from that connected food processing room, chilling the withdrawn air and returning the chilled air to that connected food processing room.

64. The food processing facility of claim 63, wherein the ventilation and cooling subsystem comprises:

a housing;

a ventilation and cooling unit located in the housing;

a supply inlet from the associated food processing room into the housing;

a return outlet from the housing into the associated food processing room; and

an exhaust duct from the associated food processing room to the outside of the food processing facility, a controllable damper provided in the exhaust duct and useable to controllably open and close the exhaust duct.

65. The food processing facility of claim 64, wherein the ventilation and cooling unit provides air to the associated food processing room at a rate sufficient to raise an air pressure in the associated food processing room above an air pressure in an adjacent distribution area.

66. The food processing facility of claim 50, wherein at least one buffer area includes a treatment room where a lethality treatment is applied to the food product before it is processed in the food processing rooms, the treatment room connected to other portions of that buffer area and to at least one distribution area, the food processing facility further comprising an exhaust subsystem that connects the treatment room to an outside of the food processing facility, wherein the exhaust system maintains an air pressure in the treatment room at a level that is below an air pressure in the other portions of the buffer area and an air pressure in the at least one connected distribution area.

67. A food processing facility usable to process a food product in an environment having low risk for contamination, comprising:

a plurality of food processing rooms, each food processing room comprising at least one food processing device and at least one food packaging device;

a first area, at least some of the plurality of food processing rooms having a first passage to the first area;

a second area that includes at least some of a holding area, a treatment room, a buffer area and a packaged food receiving area, at least some of the plurality of food processing rooms having at least a second passage to the packaged food receiving area; and

a third area that includes at least some of a break room, restrooms, a locker room, at least one office and a reception area;

wherein;

the first area and the plurality of food processing rooms are each maintained at least at a first level of cleanliness;

the second area is maintained at a second level of cleanliness that is less than the first level of cleanliness; and

the third area has a third level of cleanliness that can be less than the second level of cleanliness.

68. The food processing facility of claim 67, further comprising a first transport system that conveys portions of the food product to be processed from the holding area to the treatment area.

69. The food processing facility of claim 68, further comprising at least one lethality treatment device in the treatment area, each lethality treatment device usable to apply a lethality treatment to the portions of the food product conveyed to the treatment area.

70. The food processing facility of claim 69, further comprising a second transport system that conveys the treated food product into the first area.

71. The food processing facility of claim 70, further comprising, in the first area, at least one of a chilling device that reduces a surface temperature of the treated food product to a desired temperature or at least one second lethality treatment device, the treated food product transported through at least one of the chilling device or at least one second lethality treatment device.

72. The food processing facility of claim 71, further comprising, at least partially in the first area, a third transport system that conveys the treated food product from the at least one of the chilling device or at least one second lethality treatment device into at least one food processing room through the first passage.

73. The food processing facility of claim 69, wherein the at least one lethality treatment device is at least one of:

at least one hot liquid bath;

at least one chemical sanitizer; and

at least one heat treating device that applies a radiant heat treatment.

74. The food processing facility of claim 73, wherein the at least one hot liquid bath comprises at least one oil bath.

75. The food processing facility of claim 73, wherein the at least one heat treating device comprises at least one infra-red treatment device that applies an infra-red heating treatment.

76. The food processing facility of claim 67, further comprising, in the first area, at least one of a chilling device that reduces a surface temperature of the food product to a desired temperature or at least one lethality treatment device, the food product transported through at least one of the chilling device or at least one lethality treatment device.

77. The food processing facility of claim 76, further comprising a transport system that conveys the food product from the at least one of the chilling device or at least one lethality treatment device into at least one food processing room through the first passage.

78. The food processing facility of claim 67, further comprising a ventilation and cooling system that ventilates and cools at least the plurality of food processing rooms.

79. The food processing facility of claim 78, wherein the ventilation and cooling system comprises:

a plenum connected to at least some of the plurality of food processing rooms;

a first bacterial-grade filter connected between the plenum and the ambient atmosphere outside the facility;

for each connected food processing room, a second bacterial-grade filter connected between the plenum and that food processing room; and

a plurality of separate ventilation and cooling subsystems, each ventilation and cooling subsystem located in a dedicated housing and connected to a different one of the at least some food processing rooms, each ventilation and cooling subsystem drawing air from that connected food processing room, chilling the withdrawn air and returning the chilled air to that connected food processing room.

80. The food processing facility of claim 79, wherein:

for each different one of the at least some food processing rooms, the separate ventilation and cooling subsystem of that connected food processing room supplies the chilled air to that food processing room such that that food processing room has an internal temperature near the freezing point of water and is at an air pressure that is greater than a first air pressure within the first area; and

the chilled air in that food processing room passes through the first passage from that food processing room into the first area.

81. The food processing facility of claim 80, further comprising an air handling subsystem usable to exhaust air from the treatment room to the ambient atmosphere outside of the food processing facility.

82. The food processing facility of claim 81, wherein the air handling subsystem maintains the treatment room at a second air pressure that is less than the first air pressure within the first area.

83. The food processing facility of claim 79, wherein:

for each different one of the at least some food processing rooms, the separate ventilation and cooling subsystem of that connected food processing room supplies the chilled air to that food processing room such that that food processing room has an internal temperature near the freezing point of water and is at an air pressure that is greater than a first air pressure within the packaged food receiving area; and

the chilled air in that food processing room passes through the second passage into the packaged food receiving area.

84. The food processing facility of claim 79, wherein each food processing room further includes a duct from that food processing room to the ambient atmosphere outside of the food processing facility, the duct having a device usable to controllably close the duct, the duct usable to exhaust air from that food processing room to the ambient air outside of the food processing facility.

85. The food processing facility of claim 67, further comprising a drain system comprising:

at least one collection basin, and, for each food processing room;

a drain in that food processing room;

a drain line connected solely between that drain and one of the at least one collection basin, an outlet of that drain line into that collection basin being offset from any other drain outlets ending at that collection basin; and

a closure structure that allows the drain line to be closed so that that drain line can be filled with a desired liquid.

86. The food processing facility of claim 67, further comprising a plurality of sanitizing stations, at least one sanitizing station located between the first area and the second area, at least one sanitizing station located between the second area and the third area, and at least one sanitizing station located between the packaged food receiving area and other portions of the second area.

87. The food processing facility of claim 67, further comprising a drain system comprising a plurality of drain lines and at least one catch basin, each drain line connected between one of the at least one catch basin and one of the plurality of food processing rooms.

88. The food processing facility of claim 87, wherein, each drain line is connected directly between the catch basin and the food processing room that it connects and each drain line connected to a particular catch basin connects to that catch basin at least at one of a) a unique position about the perimeter of the catch basin or b) a unique axial position along an axis of the catch basin.

89. The food processing facility of claim 87, wherein each drain line has a closing device that is usable to close that drain line such that that drain line can be filled with fluid from the closing device back to the food processing room to which that drain line is connected.

90. The food processing facility of claim 87, wherein the drain system further comprises a second drain line that is connected at one end to one of the at least one distribution area at least at one connection point and to one of the at least one catch basin at another end.

91. The food processing facility of claim 90, wherein the second drain line connects to that catch basin at least at one of a) a unique position about the perimeter of the catch basin or b) a unique axial position along an axis of the catch basin relative to any drain lines connected between that catch basin and one of the plurality of food processing rooms.

92. The food processing facility of claim 90, wherein that second drain line has a closing device that is usable to close that drain line such that the second drain line can be filled with fluid from the closing device back to that distribution area.

93. The food processing facility of claim 87, wherein the drain system further comprises a second drain line that is connected at one end, at least at one connection point, to at least one of a) at least one of the at least one buffer area or b) at least one of the at least one receiving area and to one of the at least one catch basin at another end.

94. The food processing facility of claim 93, wherein the second drain line connects to that catch basin at least at one of a) a unique position about the perimeter of the catch basin or b) a unique axial position along an axis of the catch basin relative to any drain lines connected between that catch basin and one of the plurality of food processing rooms.

95. The food processing facility of claim 67, further comprising a curb system comprising a plurality of curbs that reduce an ability of food pathogens to migrate along or under walls of the food processing facility between the plurality of food processing rooms, between a food processing room and the at least one distribution area, the at least one receiving area and the at least one buffer area, between the at least one distribution area and the at least one buffer area, between the at least one receiving area and the at least one buffer area and between the at least one buffer area and the at least one common area, the plurality of curbs comprising:

a first type of curb, the first type of curb used in at least the plurality of food processing rooms and providing a first level of protection against the migration of food pathogens;

a second type of curb, the second type of curb used in at least one of a) at least one of the at least one distribution area or b) at least one of the at least one buffer area, and providing a second level of protection against the migration of food pathogens that is less than the first level; and

a third type of curb, the third type of curb used in at least one of a) at least one of the at least one buffer area or b) at least one of the at least one receiving area, and providing a third level of protection against the migration of food pathogens that is less than the second level.

96. The food processing facility of claim 95, wherein the first type of curb comprises:

a mass of concrete adjacent to a wall and a floor of the food processing facility;

an antimicrobial-type stainless steel skirt around the mass of concrete, the stainless steel skirt extending between the wall and the floor and extending into the floor; and

a flexible sealant provided at a joint between the stainless steel skirt and the floor.

97. The food processing facility of claim 95, wherein the second type of curb comprises:

a mass of concrete adjacent to a wall and a floor of the food processing facility;

a non-anti-microbial stainless steel skirt around the mass of concrete, the stainless steel skirt extending between the wall and the floor and extending into the floor; and

a flexible sealant provided at a joint between the stainless steel skirt and the floor.

98. The food processing facility of claim 95, wherein the third type of curb comprises a mass of concrete adjacent to a wall and a floor of the food processing facility.

99. A method for returning a food processing room of a food processing facility to a first level of cleanliness after that food processing room has become contaminated with a food pathogen, wherein the food processing facility has a plurality of food processing rooms, each food processing room comprising at least one food processing device and at least one food packaging device, the method comprising:

raising a temperature within that food processing room to a desired temperature while maintaining at least one other food processing room in operation;

maintaining the temperature within that food processing room at the desired temperature for a period of time sufficient to kill the food pathogen; and

returning the temperature within that food processing room from the desired temperature to an operational temperature.

100. The method of claim 99, further comprising raising a temperture within at least one other food processing room that is close to that food processing room to a temperature that tends to avoid damage to the food processing facility that could occur when that food processing room is raised to the desired temperature.