Training on Good manufacturing practices
GOOD MANUFACTURING PRACTICES (GMP) GMP are sets of sanitation guidelines (methods, habits and work) for the handling of raw materials, processing and storage of foods for human consumption to assure a safe, wholesome and quality product. GMP Food Sanitation + Food Hygiene Safeguard workers and consumers’ Maintain quality & safety in health handling, preparation, processing & storage conditions/practices in a food plant
Eliminate, prevent sources of diseases & injuries from handling to point of consumption Why Clean? Why Sanitize? Product Safety Product Quality – o extend shelf-life GMP … It’s your CHOICE!!! It’s the LAW GMP’s :
- Safety, Wholesome, Sanitary
- Customer and and Employee Protection Comply with government regulations It’s Good Business Profits and Growth
Key for Global Competitiveness Prestige and Image
FAILURE:
Increase in Production Costs: returns, rejects, detentions Customer Dissatisfaction Lost of Markets Lost of Goodwill and Reputation Lost of Employee Moral Law suits: legal fees, fines Criminal Actions -Jail Increase of Insurance Premium Plant Closure
Or a you f f acing o one o or m of w pr oblems??? ar e y mor e o with tthese p Rewor ks Customer C Complaints Re jects/Retur ns/Detentions Closur e Law S Suits • • • • • • • • • •
HEALTHY AND SAFETY TIPS: A existing p pr ocesses a and f f ood s saf ety a and q quality s systems Assess e Ac A mor e iinf or mation o or on f f ood h hygiene a and p plant s sanitation Acquir e m Develop, m monitor a contr ol f f ood s saf ety a and q quality s systems and c Develop and maintain cultur e of f ood saf ety and quality thr u compliance with GMP • • • • • • •
HAND WASHING Outline:
Why is Hand Washing Important
When Should Hands Be Washed
Hand Washing Procedure
The Hand Washing Station
Using Hand Sanitizers
Other Hand Issues
Why is HAND WASHING Important?
Prevent food contamination Prevent the spread of food-borne illnesses It’s a food handler’s responsibility!
When Should Hands Be Washed?
After using using the restroom restroom Before and after handling raw food After touching touching the hair, face or body After sneezing, sneezing, coughing coughing or using a tissue After smoking, smoking, eating, eating, drinking drinking or chewing chewing gum gum or tobacco tobacco After using using any cleaning cleaning,, polishing or sanitizing sanitizing chemical chemical After taking taking out the the garbage garbage or trash After clearing clearing tables tables or busing busing dirty dishes After touching touching soiled soiled aprons aprons or clothing clothing After touching anything else that may contaminate contaminate the hands, such as unsanitized equipment, work surfaces, cleaning clothes, or money
Hand Washing Procedure
STEP 1 Wet hands with hot running potable water. The water should be as hot as the hands can comfortably stand. Approximately Approximately 110°F 110°F (43°C). (43°C). STEP 2 Apply enough enough soap soap to build build up a good good lather. Soap may be liquid, powder or bar soap. 2
STEP 3 Rub hands together for at least 20 seconds. One fun way to te ach this is to have the employee sing “Happy Birthday” while lathering their hands. STEP 4 Clean under fingernails and between fingers. A nail brush is recommended. But avoid splashing. STEP 5 Rinse hands thoroughly under running water. If the faucet is not automatic, turn it off with the elbows or use a disposable paper towel. STEP 6 Dry hands. Hands should be dried with clean, single use, disposable paper towels or hot air blow dryer.
Handwashing Station
Location must be convenient and accessible by the employees Stations must be functional, used only for hand washing, stocked and maintained. Stations are required in food preparation, service, equipment washing and restroom areas Should have warm potable running water 110°F (43°C) water must be available Soap may be liquid, bar or powder -
Liquid soap is preferred
To dry the hands – -
disposable paper towels
-
hot air dryer
U s i n g H a n d S a n i t i ze r s
Hand sanitizers are specially made liquids used to lower the number of microorganisms on the skin surface
They may be used after washing the hands
Sanitizers should never be used in place of proper hand washing
Other Hand Issues
Fingernails should be kept short and clean
Nail polish, false nails and acrylic nails should not be worn while handling food
Cuts and sores should be treated and kept covered with clean bandages 3
If hands or fingers are bandaged, gloves or finger cots should be used to protect the bandage and prevent it from falling into the foods
It may be necessary to move an employee to an area where food will not be handled
Strategically placed signs or posters may be helpful in reminding employees to wash their hands.
PERSONAL HYGIENE Outline:
Importance of Personal Hygiene
Protective Garments and Gears
Other Personal Hygiene Issues
Importance of PERSONAL HYGIENE •
To prevent contamination of food with:
Microorganisms Dirt Foreign bodies
•
To ensure that food handlers:
remain healthy while working for the company exercise a high level of personal cleanliness and tidiness
•
T o p r e v e n t s p r ea d o f g e r m s t o o t h e r e m p l o y e e s o r c u s t o m e r s t h r o u g h t h e food, equipment and utensils handled
Protective Garments and Gears •
•
Working clothes (pullovers, aprons, lab gowns, etc.) Headcaps or hairnets
Masks
Gloves
Boots
•
•
•
Must have a dressing roo m for chang ing into protective clothes
Working Clothes •
Clean and preferably white or light in color
•
It is the responsibility of the management to ensure adequate supply of laundered protective clothing and its repair
•
Staff must not be allowed to take out protective clothing from the production area
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H e ad c a p s a n d M a s k s
Must be clean and regularly washed; Preferably white or light in color
Gloves •
Disposable gloves should be changed as often as hands should be washed.
•
If non-disposable gloves such as rubber gloves are used in the facility they should be washed as frequently as bare hands.
•
Remember to wash hands before and after the usage of gloves.
Boots •
Boots or protective footwear must not be worn outside the factory, going to or taking breaks outside (exceptions for forklift truck drivers and external process workers).
•
There should be a suitable washing facility to clean them.
Locker Rooms •
Clothing, meals or snacks, or other personal belongings should be stored in lockers or break room areas that are located outside the processing area.
•
Changing areas must not be used for eating, drinking, and smoking.
•
Shower rooms may be provided.
Comfort Rooms •
The comfort room must have toilet paper, flush mechanism and handwashing station
•
Provide waste receptacles in each room
•
Provide footpath for workers especially if comfort room is outside the processing area.
Medical Examination Required for: •
Pre-employment health checks for new applicants
•
Annual medical examination for employees
•
Return from illness
Illness •
A sick person is often loaded with pathogenic bacteria and/or virus that could easily spread to food, food packaging material and food contact surfaces.
In case of illness or wounds...
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•
An employee with illness that can cause illness in others or food contamination should be assigned restricted duties or should stay home.
•
A person with an injury, cut or burn should use gloves to protect the food and the injury, or be assigned tasks that will not contaminate food.
•
Water-proof dressings used for wounds or cuts must be accounted for at the end of each shift and must be replaced before the start of each shift.
Illness symptoms •
Don’t handle food if you have at least one of these symptoms: •
Diarrhea
•
Fever, sore throat with fever
•
Vomiting
•
Jaundice (yellow skin or eyes)
•
Open skin sores and cuts
•
Boils
Diagnosed Infection •
Employees diagnosed with Salmonella typhi, Shigella, disease-causing E. coli, or hepatitis A should not perform jobs that require contact with food or food-contact surfaces until a doctor determines that they are disease free.
Perspiration •
Perspiration may contaminate the food, food-contact surfaces, hands, and clothing.
•
Wiping a sweaty brow with a cloth or hand introduces potential contamination.
•
Ideally, the processing facility should be maintained at cool temperatures to minimize perspiration.
House Rules
Signage/notices strategically posted inside the processing plant •
No eating / drinking
•
No smoking
•
No spitting
•
No unnecessary talking
•
No coughing and sneezing on food
•
No wearing of jewelry and other body accessories
•
•
•
Proper handwashing techniques Wear proper protective clothing Visitors must sign at the log book and be oriented on house rules and they must be subjected to the same personal hygiene guidelines
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•
Supervisor must conduct regular ocular inspection
of food handlers’ for
cleanliness, grooming and proper use of protective garments. •
Proper sanctions must be given to violators.
Employee Training •
Personal hygiene trainings
•
Orientation for new employees on personal hygiene
•
Records of training on personal hygiene should be filed
Employer’s responsibilities
1. Provide training in food handling and personal hygiene.
2. Conduct regular inspections of employees’ hygiene and hygienic work habits. Violations should be handled as disciplinary violations, and incentives for superior hygiene should also be provided. 3. Properly maintained sanitary facilities and supplies. This includes ample quantities of soap, disinfectant, working sinks, hairnets, etc.
FOOD PREPARATION Outline:
Write what you do – do what you write Prepare simple operational procedures Construct a flow diagram Include hygiene in your premises/surroundings and in your behavior/practices. How to prevent hazards
Recipes (Food Preparation Procedure) For each product, document : All ingredients used All volumes and weights All procedures and equipment involved Cooking time/temperature Packaging material Packaging Labeling Storage Shelf life • • • • • • • • •
Use flow diagram •
•
You will get a GOOD OVERVIEW if you construct a flow diagram covering your production. It will help you to DEFINE THE CRITICAL STEPS for good food hygiene in your production. 7
•
It will give GOOD IMPRESSION from people that look at/audit your production.
Construct flow diagram •
Include all steps (also transportation)
•
All side flows (spices, packaging, semi- finished products, rework, etc.)
•
Include details such as time and temperature for essential steps (heat treatment, chilling, etc.)
Sample Flow Diagram
1. Raw materials order 2. Receipt of raw materials 3. Storage 4. Preparation 5. Heat Treatment 6. Chilling 7. Packaging/labeling 8. Storage 9. Sales/Distribution
Production Area •
The process flow shall be arranged to prevent product contamination.
•
The premises shall allow safe and hygienic conditions.
•
There shall be separation between high and low risk operations.
•
Walls, floors, ceiling and windows shall be kept clean and withstand cleaning methods. Open windows shall be screened.
•
Floors shall have adequate fall and well-designed drainage to minimize risk of contamination.
•
Doors shall normally be closed or screened to prevent pest entrance.
•
Lighting shall be adequate and not possess a risk for glass splinters in the product.
Equipment • • •
Shall be suitably designed for the intended purpose. Shall be easy to keep clean. When necessary equipment shall be disassembled for thorough cleaning.
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Food Preparation •
Observe good personal hygiene
•
Separate raw and ready to eat food: chopping boards, utensils, surfaces.
•
Avoid unnecessary handling of food, use clean tongs, trays.
•
Keep chilled food out of the fridge for the shortest possible time.
•
Use potable water to wash and prepare food, or making ice.
Cooking
If your process includes a cooking step, you will kill bacteria, parasites and viruses at this step! •
Proper cooking kills a majority of food poisoning microorganisms such as Salmonella, Campylobacter , pathogenic E.coli , Listeria, (viruses) and parasites M i n im u m c o o k i n g t i m e f o r m e a t
60 °C – 45 min
75 °C – 30 sec
65 °C – 10 min
80 °C – 6 sec
70 °C – 2 min
Critical Operations 1. Heat treatment: •
D e f in e a n d m a i n t a i n c r i t i c a l t e m p e r a t u r e a n d t i m e f o r t h e h e a t t r e at m e n t t o e l i m i n a t e p a t h o g e n s .
Example: • • •
Burger needs to reach 68 °C for 30 sec. Milk is pasteurized at 72 °C for 15 sec. Drying at 93°C to achieve aw 0.85 to control pathogens in dried foods.
2. Acidification: •
C l o s t r i d i u m b o t u l i n u m c a n n o t g r o w a t p H u n d e r 4 .6 .
Example: •
Define how much acetic acid has to be added to pickled food to guarantee pH lower than 4.6.
3. Chilling: •
L o w t e m p e r at u r e s l o w s d o w n t h e g r o w t h o f s e v er a l p at h o g e n i c bacteria.
Example:
Creamy fruit cake is kept at 4 °C or lower to extend shelf life. Critical Operations 4 •
Hot food can be kept below 60°C for a maximum of two (2) hours. 9
•
Chilled food can be kept above 4°C for a maximum of (2) hours.
Prevention of Hazards In some products and processes, the following may be true: •
control at the receiving step (e.g., supplier declaration) to prevent pathogens and chemical hazards
•
control at the formulation or ingredient-addition step (e.g., pH adjustment or addition of preservatives)
•
control by refrigerated storage or chilling Elimination of Hazards
•
Cooking (biological hazards)
•
Metal detector (physical hazards)
•
Freezing (parasites, e.g. Anisakis in fish destined for raw consumption)
•
Manual sorting and automatic collectors (physical hazards)
•
Obtaining shellfish, prawns, poultry and other products from approved areas (biological & chemical hazards)
CROSS-CONTAMINATION O u t l i n e :
What iis c cr oss-contamination?
How d does iit h happen?
How tto p pr event iit f f r happening? ro m h
What iis C Cr oss-contamination? T h e t r a n s f e r o f b i o l o g i c a l o r c h e m i c a l c o n t a m i n a n t s t o f o o d p r o d u c t s f r o m r a w f o o d s , f o o d h q u i p m e n t . d h a n d l e r s , a n d f d f o o d p d p r o c e s s i n g e g e
T he c c ont ami nant s c c an b be t t r ra nsf er r re d :
D i r e c t l y , w h e n o n e f o o d t o u c h e s o r d r i p s o n t o a n o t h e r
f r o m h h a n d s , e e q u i p m e n t , w w o r k s s u r f a c e s , c c l o t h e s o o r k k n i v e s a a n d I n n d i r e c t l y , f o t h e r u t e n s i l s .
T he t y y p e of c r ro ss-c ont ami nat i io n most f r re quent l ly y i m pl i ic ca t ed i n f ood -bor ne i l ll l n ess oc c w hen pat hog eni c or v i ir ar e t t r r ead y cu r s w c bac t te r i ia o r u ses a ra nsf er r re d t o r y- t o-eat f ood s. Cr oss C Contamination One o of the m ma jo of f ood p poisoning. jor causes o How d does iit h happen? Stor ing r r aw a and r r eady- tto-eat f f ood ttogether Not w washing h hands a af ter touching r r aw f f ood 10
same c chopping b boar d o or knif e f f or r aw a and r r eady-to-eat f f ood Using tthe s Examples o of Poor Employee P Pr actices
H a n d l i n g r a w p r o d u c t , t h e n h a n d l i n g c o o k e d p r o d u c t W o r k i n g n a r o n h n d l i n g p g n e r o r o r o n t n t h e f e f l o o r , t h e n h a g p r o d u c t R e t u r n i n g f s h i n g h g f r o m c m c o m f o r t r t r o o m s w s w i t h o u t w t w a g h a n d s
S h o v e l u d t s t e , a l s o u l u s e d t o h o h a n d l e f e f l o o r w r w a o u s e d t d t o h o h a n d l e p e p r o d u c t
S c r a t c h i n g f c e , t h e n h g f a n h a n d l i n g p g p r o d u c t ; a ; a n d
T o u c h i n g u n c r d n d l e , t h e n h g u n c l e a n c o o l e r d o o r h r h a n h a n d l i n g p g p r o d u c t .
Sour ces o of pathogens tthat c could c cr oss-contaminate f f inished p pr oducts
Food h handler s a and o other plant p per sonnel
Raw f f ood
Equipment o or utensils
Pr ocessing p plant e envir onment
How tto p pr event?
Use dif f fe r ent (or pr oper ly cleaned and sanitized) sur f fa ces and utensils f or r aw and r r eady-to-eat f f ood.
separ ation o of r aw a and c cooked o or r eady-to-eat p pr oduct d dur ing r r eceiving, Ad Adequate s pr ocessing, s stor age a and s shipping.
Food handling or pr ocessing ar eas and equipment adequately cleaned and sanitized.
Keep f f ood iin c clean, c cover ed c container s s separ ate f f r chemicals. ro m c
Employee h hygiene, d dr ess a and h handwashing p pr actices
Employee ttr af f or movement a about tthe p plant. fi c o
Contr olling tthe m movement o of equipment f f r one a ar ea tto a another ro m o
Minimize Bare Hand Contact •
Use utensils, food grade paper
•
Use clean and/or disposable gloves
•
Wash your hands before touching gloves
•
Change gloves between tasks when they are dirty or torn when they are contaminated anytime that a hand would need washing
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Minimize Contamination & Cross-Contamination •
Don’t prepare food when you are sick
•
Wash your hands
•
Separate ready-to-eat foods from raw foods
•
Separate different types of raw foods
•
Clean and sanitize/disinfect between different
•
Use labels and color coding in segregating raw materials and utensils
types of food.
Corrections Concerning Cross-contamination •
•
•
•
Stop activities, if necessary, until the situation is corrected Take steps to prevent contamination from re-occurring Evaluate product safety and, if necessary, divert, reprocess or discard affected products; and Document what corrections were taken
FOOD S SAFET Y H HAZARD Outline: - A w a r e n e s s o s o f :
hazar ds Biological h hazar ds Chemical h hazar ds Physical h Aller gens - C h a r a c t e r i s t i c s o i n m n i s m s C s o f c f c e r t a n m i c r o o r g a
Food S Saf ety H Hazar d - A A biological, chemical or physical agent in f ood, or condition in f ood, with the potential tto c cause a an a adver se h health e ef f 22000:2005). fe ct ((ISO 2 Biological H Hazar ds / S Spoiler s Micr oor ganisms Yeast Mold Bacter ia Vir uses Pr otozoa Par asitic w wor ms •
•
Micr oor ganisms T hey c an b be:
b n e f i c i a l , e s s e n t i a ) l G o o d ( d ( b e B a d
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Chemical H Hazar ds N a t u r a l l y O c c u r r i n g n d d e d I n t e n t i o n a l l y a U n i n t e n t i o n a l l y a d d e d Types o of Natur ally O Occur r Chemical H Hazar ds ri ng C
M y c o t o x i n s ( e . g . a f l a t o x i n ) s ( e S c o m b r o t o x i n ( h m i n e ) h i s t a C i g u a t e r a f a l g a l t ) a f i s h p h p o i s o n i n g ( g ( a l t o x i n s S h e l l f i s h t r e d t ) h t o x i n s ( s ( r d t i d e
Molds… Multicellular, visible mycelium and pigmented fruiting structures Growth not as dependent on temperature as bacteria Exist in dormant state as spores which are resistant to low moisture, high heat, high acidity, or freezing Both spoilage and food safety concern Many molds produce mycotoxins Long-term toxicity Some are carcinogenic • • •
• •
Contr ol o of Af latoxins iin P Peanuts Ensure freshness (max 3-9 months) No insect damage No evidence of moisture No rancid or musty smell No black (moldy) spots Stored in dry, cool and dark place Batch analysis • • • • • • •
Intentionally A Added C Chemicals: F Food A Additives
P r e s e r v a t i v e s ex. n nitr ite a and s sulf iting a agents N u t r i t i o n a l a s l a d d i t i v e ex. v vitamin A C o l o r a d d i t i v e s r a ex. FD&C Yellow No. 5 (tartrazine)
C h e c k l e g a l l i m i t s Unintentionally o or Incidentally A Added C Chemicals l s A g r i c u l t u r a l c h e m i c a
E x . pe f er t ant i ib and g r hor mones pest i ic ci i d de s, f ti il l i iz ze r s, a i ot i ic c s a ro w t th h d s u b s t a n c e s ( P C B ) P r o h i b i t e P T o x i c e l e m e n t s a n d c c e s a d c o m p o u n d s
E x . h heav y c y P AH y met al s, c ya ni d de , P AH c o n d a r y d i r e c t a n d i n d i r e c t S e
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E x . l l ubr i ic c l le sani t c a nt s, c ani ng c om pound s, s ti iz ze r s, pai nt Stor age o of Chemicals All chemicals such as detergents, acids, bases, disinfectants and pesticides should be clearly separated from: Storage of raw materials and products Production area Chemicals must also be properly labeled •
•
Physical H Hazar ds
A n y p o t e n t i a l l y h a r m f u l f o r e i g n m a t t e r n o t n o r m a l l y f o u n d i n f o o d Glass p par ticles Wood s splinter s Stones Metal s shavings Har d p plastics Aller gens Naturally occurring proteins Minute (very small) amounts can cause allergic reaction Fatal reactions are known from: Peanuts, tree nuts, seafood • • •
List o of Aller gens Peanut Shellf ish Fish Egg Milk Soybean Contr ol o of Aller gens Label a all a aller gens u used Don’t m mix p pr oductions w with a and w without a aller gens. C Check r r aw m mater ial ((ingr edient declar ation) Separ ate p pr oduction iin s space o or time Keep ttr ack o on r r ewor k/r epr ocess • •
• •
FOOD CONTACT SURFACES Outline:
What are food c ontact surfaces
The proper design of food contact surfaces
T h e p r o p e r c l ea n i n g p r o c e d u r e s
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FOOD CONTACT SURFACES - Those surfaces that contact food and those surfaces from which drainage onto the food or onto surfaces that contact the food ordinarily occurs during the normal course of operations. Typical food contact surfaces include: - Utensils, knives, table, cutting boards, conveyor belts, ice makers, ice storage bins, gloves, aprons, etc. Goal: Monitoring should provide assurance that food contact surfaces including gloves and outer garments are properly designed, constructed and maintained to facilitate sanitation, and that they are adequately and routinely cleaned and sanitized.
Daily Monitoring Condition of the food contact surfaces Cleanliness and sanitation of food contact surfaces Type and concentration of sanitizer(s) used Gloves and outer garments which might contact food • • • •
How to Monitor Visual Inspection Surfaces in good condition Surfaces cleaned and sanitized Gloves and outer garments clean and in good repair Chemical Testing Sanitizer concentration (test strips or kits) Verification Checks Microbial tests of surfaces (test kit) •
• • •
•
•
•
•
Typical Corrections Observation:
•
Correction : Observation : Correction: Observation: Correction:
• • • • •
Detergent used does not remove dried food from working table. Change to a suitable alkaline detergent. Juncture of two table tops trap food debris. Separate tables to allow access for cleaning. Table surfaces show signs of corrosion. Refinish or replace damaged equipment and switch to less corrosive cleaning compound.
General Requirements for Food Contact Surface
Safe Material Non-toxic (no leaching of chemicals) Non-absorbent (can be drained and/or dried) Resist corrosion Inert to cleaning and sanitizing chemicals Fabrication Can be adequately cleaned and sanitized Smooth surfaces including seams, corners, and edges
•
– – – –
•
– –
Some Food Contact Surfaces Black iron or cast iron Concrete Glass Plastics
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Rubber Stainless steel Wood Galvanized metals Paint and sealants
Food contact surface materials which normally should be avoided if feasible Wood (microbial and physical concerns) Ferrous metals (corrosion concerns) Brass (variable corrosion resistance and product quality concerns, chemical contamination and accelerated oxidation) Galvanized metal (corrosion and chemical leaching concerns) • • •
•
Storage of Clothing and Gloves • •
•
Store clothing and gloves in clean and dry locations Ensure that clothing and gloves are not exposed to splash, dust or other contaminants Store clean garments separately from soiled garments and gloves.
Design and Install Food Contact Equipment to :
Drain and not entrap soils and water Provide access for cleaning and inspection Withstand plant environment
Five Steps of Cleaning and Sanitizing 1. Dry-clean
Physically removing food residues and dirt Brushes -- proper stiffness Pads -- proper cutting properties Pressure spray -- moderate pressure • • •
Clean as you go: Never allow food residues and dirt to build up. •
2. Pre-rin se This could involve:
Flushing with water Scrubbing Using pads
S e e t o i t t h a t t h e m a j o r p a r t o f f o o d r e s i d u e s a n d d i r t a r e r em o v e d .
3 . A p p l y d e t er g e n t
Types of Detergents General Purpo se (GP) Alkaline Chlor inated (chlo rinated alkaline) Acid Enzyme
• • • • •
A detergent’s effectiveness varies with: Contact time Temperature Physical disruption (scrubbing) • • •
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•
Water chemistry
P a d s , b r u s h e s an d b r o o m s s h o u l d b e d e d i c a t ed t o t a s k s f o r w h i c h t h e y a r e
designed O p t i m i z e s c l e a n i n g e f f ec t i v e n e s s M i n i m i z e s c r o s s - c o n t a m i n a t i o n b e t w e en a r e as o f t h e p r o d u c t i o n Color cod ing is advised C l ea n i n g a i d s w h i c h r e t a i n w a t e r s u c h a s s p o n g e s , w i p i n g c l o t h s a n d m o p s
shou ld not be used for routine cleaning in processing plants.
4. Post -rinse
-
Post-rinse with water (of drinking quality) will remove loosened soil and residues of detergent.
5. Disinfectio n • • •
When needed, a disinfection follows the proper cleaning. Disinfectant is applied according to suppliers’ instruction. Residues are rinsed with water (this is sometimes not needed).
-
A sanitizer will be effective if . . . the water is the proper temperature (171 °F or 77°C)
-
you have the right amount (concentration) of sanitizer
-
the item stays in contact with the sanitizer for the proper amount of time (at least 20 seconds)
What to Clean and Sanitize Surfaces that come in contact with food must be washed, rinsed and sanitized: •
each time you use them
•
when you begin working with another type of food
•
when you’re interrupted during a task
•
as often as possible, but at least every four hours if you’re using something constantly
Non-Food Contact Surfaces •
Keep all areas clean, organized, and in good repair.
•
Clean as needed to keep areas clean, free of dust, dirt and food residue at least daily for most surfaces including floors.
•
Protect food from contamination
Floors 1) Sweep
2) Mop on detergent solution
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3) Wash 4) Rinse
Drains - last step in daily cleaning
1) Use rubber gloves. 2) Remove grills. Clean out debris. 3) Flush drain thoroughly. Do not allow water to splash back out of drain. 4) Pour detergent on grills and in drain. 5) Scrub grills and drain area. 6) Sanitize (optional but recommended)
Periodic Confirmations for Sanitization
Microbiological Enumeration o
Contact plates
o
Swabs GOOD DESIGN PRINCIPLES
GOOD DESIGN PRINCIPLES ACCESSIB ILITY OF EQUIPMENT
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RAW MATERIALS Outline:
Raw m aterial qu ality
Raw material specification Raw material control Supplier approval Water is also a raw material Def ine R Raw M Mater ials List all Raw Materials Define the Quality Write it down = RM specification Agree on the specifications with the supplier R a w M t e r i a l S c i f i c a t i o n ss w M a l S p e
May b be b based o on… inter nal s standar ds s set b by tthe c company inter national p publications based o on s scientif ic r r esear ch national s standar ds buyer s’ s standar ds Should iinclude h how iit w will b be… r eceived stor ed handled a and tr anspor ted u under specif ied s sanitar y c conditions and a appr opr iate e envir onmental c conditions w which pr event contamination a and d deter ior ation. E x am pl e: S S pec i if ( P f i ic c a t i io n ( PE E A N U UT TS ) Brief Description Size Appearance 23
No molds, less than 0.5% outside spec Moist ure (< 8 %) Taste, flavor (no o ff flavor o r taste) A g e ( m a x im u m ? M o n t h s ) C o n t a m i n a n t s ( le g a l r e q u i r e m e n t s , W H O ) Packaging (food grade) Labeling (supplier, lot no., date of harvest…) Storage condition s (dark, dry, cold)
Raw M Mater ial R Receiving Should iinclude… sampling p pr ocedur es analytical m methodology limits f f or acceptance Certificates of Analysis (COA) - ensure that the raw materials have been tested - prove that the required specifications are met Letter of Guarantee -stating that the material has been produced in a way that the buyer’s specification s are met. Checking R RMs I n s p e c t a l l t h e R M s b e f o r e t h e y a r e a c c e p t e d ( at d e l i v e r y o r d i r e c t p u r c h a s e )
Keep reference sample for comparison Appearance, smell and taste (if relevant) Compare with your specification Document: supplier, date of reception, lot number, quantity Define shelf life and store properly Table o of Ingr edients a and R RM RAW MAT’L/ ING.
RECEIVING PROCEDURE
Example Bangus
Chilled (4 C) and placed in a clean ice chest
o
STORAGE RQMNTS.
SHIPPING RQMNTS.
PACKAG ING RQMNTS .
IN WHICH PRODUCT USED
FUNCTION IN THE PRODUCT
Stored in freezer o (-18 C)
Stored in freezer o (-18 C)
Packed in PE bags, sealed and placed in shipping cartons
Marinated deboned bangus
Main ingredient
Approve supplier Y o u d e p e n d o n y o u r s u p p l i er . S e e to i t t h a t y o u c a n t r u s t h i m /h e r .
What reputation does the supplier have? What are your experiences with the supplier? Are the RMs critical for the safety of your product? Audit the supplier = check how the RMs are handled (critical raw materials). Document approved suppliers.
RAW M MATERIALS S STORAGE
O r g a n i z ed
a n d s y s t e m a t i c m a n n e r o f s t o r i n g i n g r e d i e n t s a n d r a w m a t e r i al s
Label stored food with name, production date and “use by” DATE and inspection results Separate RMs from ready-to-eat food. 24
- (ex. Keep raw meat from salad) Never store food together with chemicals
Apply first in first out (FIFO); First Expire First Out (FEFO)
RAW M MATERIALS S STORAGE Store dried food in sealed containers to protect from pests and moisture.
Store food off the floor and off the wall. Storage areas should enable adequate inspection and clean-up procedure. Storage areas must be provided with
adequate ventilation system and
temperature controls to prevent off- odors and maintain ingredients’ and raw
materials’ optimum condition. Overstocking should not be allowed, as this would increase possibility of spoilage and contamination. Inspection/ analysis programs which will perform tests on raw materials must be implemented.
W a t er a s R A W M A T E R IA L
Al water in c contact w with f f ood a and f f ood c contact s sur f shall b be p potable. All w fa ces s Water should b be m monitor ed w with s suf f f r assur e s saf e w water . fi cient f re quency tto a A water supplier normally has a monitoring plan and can provide results from microbiological and chemical monitoring. But what about the quality of your tap water? It should also be checked.
PEST CONTROL Outline:
What are pests?
Why no pests in production area?
How to control pests?
What are pests? Cockroaches, flies, ants Mice, rats, bats, gecko lizards Birds including hens and fighting cocks Dogs, cats, pigs, (unauthorized people)
Pest Control is… Effective measures that prevent the entry and proliferation of pests such as flies, insects and its larvae in the receiving, processing, packaging and storage areas.
Establishments and surrounding areas should be regularly examined for infestation. Control measures involving chemical, physical and biological agents should be done under supervision of knowledgeable personnel to eradicate infestations. Should be a continuous activity and includes effective sanitation and use of chemicals.
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No PESTS in production area! All pests can transmit bacteria and viruses
Flies and cockroaches may transmit Salmonella, Staphylococcus, C. perfringens, C. botulinum, Shigella
Rodents are sources of Salmonella and parasites
Birds can spread a variety of bacteria, e.g. Salmonella, Listeria and others.
A consumer finding an insect in your product will probably go for another brand next time.
Pest control measures
Prevent pests from entering the production area
Remove shelters and other attracting sources such as waste and feeds in and outside the building.
Provide screens for open windows and doors.
Maintain good housekeeping and inspect for infestations regularly.
No domestic animals near production and never in the production area.
Get rid of pests
Keep rodent traps at strategic places
Insect traps catch flies, moths and mosquitoes in the production area.
Use insecticides to control infestations, but only when no production is ongoing.
R a w m a t er i a l s
Can be infested on arrival
Check your raw materials on delivery
Can attract pests when not properly stored
-
Check periodically
Northern Mindanao Food Safety Team (NMFST)
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