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 Its your CHOICE!!!

Its the LAW GMPs :

- Safety, Wholesome, Sanitary - Customer and Employee Protection Comply with government regulations Its 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 are you facing one or more of with these problems??? Reworks Customer Complaints Rejects/Returns/Detentions Closure Law Suits

HEALTHY AND SAFETY TIPS: Assess existing processes and food safety and quality systems Acquire more information or on food hygiene and plant sanitation Develop, monitor and control food safety and quality systems Develop and maintain culture of food safety and quality thru 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 Its a food handlers responsibility!

When Should Hands Be Washed? After using the restroom Before and after handling raw food After touching the hair, face or body After sneezing, coughing or using a tissue After smoking, eating, drinking or chewing gum or tobacco After using any cleaning, polishing or sanitizing chemical After taking out the garbage or trash After clearing tables or busing dirty dishes After touching soiled aprons or clothing After touching anything else that may 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 110F (43C). STEP 2 Apply enough soap to build up a good lather. Soap may be liquid, powder or bar soap.
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STEP 3 Rub hands together for at least 20 seconds. One fun way to teach 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 110F (43C) 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

Using Hand Sanitizers 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
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 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

To prevent spread of germs to other employees or customers through the 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 room for changing 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

Headcaps and Masks 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...

 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 Dont 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

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

Employers 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.
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 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.

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 Minimum cooking time for meat 60 C 45 min 65 C 10 min 70 C 2 min 75 C 30 sec 80 C 6 sec

Critical Operations 1. Heat treatment: Define and maintain critical temperature and time for the heat treatment to eliminate pathogens. Example: Burger needs to reach 68 C for 30 sec. Milk is pasteurized at 72 C for 15 sec. Drying at 93C to achieve aw 0.85 to control pathogens in dried foods.

2. Acidification: Clostridium botulinum cannot grow at pH under 4.6 .

Example: Define how much acetic acid has to be added to pickled food to guarantee pH lower than 4.6.

3. Chilling: Low temperature slows down the growth of several pathogenic 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 60C for a maximum of two (2) hours.
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 Chilled food can be kept above 4C 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
Outline: What is cross-contamination? How does it happen? How to prevent it from happening?

What is Cross-contamination? The transfer of biological or chemical contaminants to food products from raw foods, food handlers, and food processing equipment.

The contaminants can be transferred:

Directly, when one food touches or

drips onto another Indirectly, from hands, equipment, work surfaces, clothes or knives and other utensils. The type of cross-contamination most frequently implicated in food-borne illness occurs when pathogenic bacteria or viruses are transferred to ready-to-eat foods.

Cross Contamination One of the major causes of food poisoning. How does it happen?

Storing raw and ready- to-eat food together Not washing hands after touching raw food
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 Using the same chopping board or knife for raw and ready-to-eat food
Examples of Poor Employee Practices

Handling raw product, then handling cooked product Working near or on the floor, then handling product Returning from comfort rooms without washing hands

Shovel used to handle floor waste, also used to handle product Scratching face, then handling product; and Touching unclean cooler door handle, then handling product.
Sources of pathogens that could cross-contaminate finished products

Food handlers and other plant personnel Raw food Equipment or utensils Processing plant environment
How to prevent?

Use different (or properly cleaned and sanitized) surfaces and utensils for raw
and ready-to-eat food.

Adequate separation of raw and cooked or ready-to-eat product during receiving,

processing, storage and shipping.

Food handling or processing areas and equipment adequately cleaned and

sanitized. Keep food in clean, covered containers separate from chemicals. Employee hygiene, dress and handwashing practices Employee traffic or movement about the plant. Controlling the movement of equipment from one area to another 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 Dont 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 types of food.

Use labels and color coding in segregating raw materials and utensils

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 SAFETY HAZARD

Outline: -Awareness of:

Biological hazards Chemical hazards Physical hazards Allergens

-Characteristics of certain microorganisms Food Safety Hazard - A biological, chemical or physical agent in food, or condition in food, with the potential to cause an adverse health effect (ISO 22000:2005). Biological Hazards / Spoilers Microorganisms Yeast Mold Bacteria Viruses Protozoa Parasitic worms Microorganisms They can be: Good (beneficial, essential) Bad

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- Spoiler - Pathogenic (you get sick) = Hazard! Kinds of Microorganisms The Good (or helpful): We add them to foods or they are there naturally. They ferment foods to preserve them and/or create unique flavors and textures. Examples: kesong puti, nata de coco, puto, toyo, patis, suka, tocino, chorizo, ginamos The Spoilers change foods and cause them to go bad or spoil. Examples: Discolored or mushy vegetables; sour milk; and slimy, badsmelling meat; moldy bread

Use your nose for early detection!

The pathogens (disease-causing) The HAZARDS !!! Illness can range from mild to life-threatening. Examples include foods contaminated with pathogenic Salmonella or Escherichia coli. Common signs and symptoms include nausea, vomiting, and diarrhea.

Bacteria Are Found Everywhere In air, soil, and water In intestines of animals & humans On skins of fruits & vegetables On raw meat, poultry & seafood On insects & rodents On hand, skin, hair & clothing of people Factors Affecting Bacterial Growth Food - Nutrients, provided by most foods. Acidity - Most bacteria grow best at near neutral conditions (pH 6.5 7.5). Temperature - Temperature danger zone is 4 60oC. Growth increases with temperature. Time - Growth to dangerous levels can occur after 2 hours. Oxygen - Some require oxygen to grow, some require little or no oxygen. Most grow with or without oxygen. Moisture - Water requirements vary. Bacteria need the most. Yeasts and molds require less. Bacteria... Cause the greatest number of foodborne illnesses. Single-celled organisms. Invisible to the naked eye: Must be magnified 1,000 times to be seen. 500 million bacteria are equal to a grain of sugar in size.

Microbiological Hazards Bacteria

Viruses
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Protozoa

Bacterial Hazards Food poisoning - food infection - food intoxication

Spore forming and non-spore forming bacteria

Food Poisoning This is an unpleasant illness which usually occurs within 1-36 hours after eating contaminated or poisonous foods.

Symptoms are usually nausea, abdominal pain, vomiting and diarrhea.

Food Infection - W hen you eat food with harmful bacteria they can start to grow inside you. In the stomach and intestines In your blood and lymphatic system In other tissues in the body Food Intoxication Some harmful bacteria that can grow in food produce toxins. The toxins can remain in the food when the bacteria have been killed. W hen you eat the food you get intoxicated.

Infection vs. Intoxication Infection Bacteria is ingested through food. Ex. Ingestion of pathogenic E. coli in contaminated hamburger

Intoxication Toxin produced by bacteria is ingested through food.

Ex. Ingestion of toxin produced by Staphylococcus aureus in contaminated tuna sandwich

7 Main Causes of Food Poisoning Poor personal hygiene of food handlers Recent intestinal or respiratory upsets of food handlers Inadequate temperature control during transport, operation, storage or serving of
fo o d Food from unsanitary source of supply Bad food handling practices Dirty food premises and/or equipment Presence of insect and rodent pest

Ways to Prevent Food Poisoning

Protect Food from contamination prevent bacteria from getting into high risk foods

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STOP CONTAMINATION SEPARATE RAW AND HIGH RISK FOOD KEEP FOOD COVERED USE CLEAN UTENSILS AND WIPING CLOTH WEAR SUITABLE PROTECTIVE CLOTHING PREVENT INSECTS, RODENTS AND BIRDS FROM ENTERING USE CORRECT CLEANING AND SANITIZING PROCEDURES KEEP FOOD AND EQUIPMENT OFF THE FLOOR REMOVING W ASTE AND GARBAGE PROMPTLY

Prevent bacteria from multiplying

a. keep food at room temperature for the shortest possible time b. remove conditions for bacterial growth STOP MULTIPLICATION REFRIGERATED STORAGE BELOW 5C STORE FOOD OUT OF THE DANGER ZONE USE SUITABLE PRESERVATIVES SUCH AS SALT AND SUGAR NOT ALLOW ING DRIED FOODS TO ABSORB MOISTURE DURING PREPARATION, FOOD IS W ITHIN DANGER ZONE AT THE SHORTEST POSSIBLE TIME

Destroy food poisoning bacteria in food THOROUGH COOKING HEAT PROCESSING SUCH AS PASTEURIZATION, STERILIZATION AND CANNING SUFFICIENT TIME AND TEMP. COMBINATION TO DESTROY A SPECIFIC MICROORGANISM INTERNAL FOOD TEMPERATURE SHOULD BE ABOVE 60C W HEN COOKING

Spore-Forming Bacteria Clostridium botulinum Clostridium perfringens Bacillus cereus Non-Spore Forming Bacteria Campylobacter spp. Pathogenic Escherichia coli (e.g. E. coli O157:H7) Listeria monocytogenes Salmonella spp. (e.g. S. typhimurium, S. enteriditis) Pathogenic Staphylococcus aureus (e.g. coagulase positive S. aureus) Vibrio spp. (e.g. V. cholerae, V. parahaemolyticus, V. vulnificus) Yersinia spp. (e.g. Yersinia enterocolitica) Bacteria tend to form biofilms - Of concern to the food industry because they prevent sanitizers from reaching surface bacteria Examples of Biofilms Teeth (dental plaque) Surfaces that are continuously wet (drains, floors, food processing equipment) Hazards from Viruses in Foods What are viruses?
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Where do they come from? How do they reproduce? What are some examples? How can they be controlled?

Viral Hazards - Characteristics Very small particles that cannot be seen with a light microscope Do not need food, water or air to survive Do not cause spoilage Infect living cells and are species specific Reproduce inside the host cell Survive in human intestines, water or food for months Transmission usually by fecal-oral route and related to poor personnel hygiene All viruses require a host cell to multiply. How Viruses Reproduce The virus invades a cell, uses the cells equipment to replicate its own nucleic acid and protein coat, and then releases the new viruses from the cell. In bacteria, this process can be achieved in 30-60 minutes and in animals, it usually requires 12-24 hours. Examples of Virus Hepatitis A Norwalk Bird Flu Parasites in Foods Parasites are organisms that need a host to survive Thousands of kinds exist worldwide, but only about 100 types are known to infect people through food contamination
Two types of concern from food or water: Parasitic worms [e.g. roundworms (nematodes), tapeworms (cestodes), flukes (trematodes)] Protozoa Role of fecal material in transmission of parasites

Parasitic Protozoa and Worms Roundworms (nematodes)

Ascaris lumbricoides Trichinella spiralis Trichuris trichura

Tapeworms (cestodes)

Flukes (trematodes) Protozoa

Diphyllobothrium latum Taenia solium, T. saginata Entamoeba histolytica Giardia lamblia

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Chemical Hazards Naturally Occurring Intentionally added Unintentionally added Types of Naturally Occurring Chemical Hazards Mycotoxins (e.g. aflatoxin) Scombrotoxin (histamine) Ciguatera fish poisoning (algal toxins) Shellfish toxins (red tide) 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

Control of Aflatoxins in 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 Added Chemicals: Food Additives

Preservatives ex. nitrite and sulfiting agents Nutritional additives ex. vitamin A Color additives ex. FD&C Yellow No. 5 (tartrazine)

Check legal limits

Unintentionally or Incidentally Added Chemicals

Agricultural chemicals
Ex. pesticides, fertilizers, antibiotics and growth hormones

Prohibited substances (PCB) Toxic elements and compounds

Ex. heavy metals, cyanide, PAH

Secondary direct and indirect

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Ex. lubricants, cleaning compounds, sanitizers, paint Storage 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 Hazards Any potentially harmful foreign matter not normally found in food Glass particles Wood splinters Stones Metal shavings Hard plastics Allergens Naturally occurring proteins Minute (very small) amounts can cause allergic reaction Fatal reactions are known from: Peanuts, tree nuts, seafood List of Allergens Peanut Shellfish Fish Egg Milk Soybean Control of Allergens Label all allergens used Dont mix productions with and without allergens. Check raw material (ingredient declaration) Separate production in space or time Keep track on rework/reprocess

FOOD CONTACT SURFACES

Outline: What are food contact surfaces The proper design of food contact surfaces The proper cleaning procedures

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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-rinse This could involve: Flushing with water Scrubbing Using pads See to it that the major part of food residues and dirt are removed.

3. Apply detergent Types of Detergents General Purpose (GP) Alkaline Chlorinated (chlorinated alkaline) Acid Enzyme A detergents effectiveness varies with: Contact time Temperature Physical disruption (scrubbing)
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Water chemistry

Pads, brushes and brooms should be dedicated to tasks for which they are designed Optimizes cleaning effectiveness Minimizes cross-contamination between areas of the production Color coding is advised Cleaning aids which retain water such as sponges, wiping cloths and mops should 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. Disinfection 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 77C) 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 youre interrupted during a task as often as possible, but at least every four hours if youre 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 ACCESSIBILITY OF EQUIPMENT

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RAW MATERIALS
Outline: Raw material quality Raw material specification Raw material control Supplier approval Water is also a raw material Define Raw Materials List all Raw Materials Define the Quality Write it down = RM specification Agree on the specifications with the supplier Raw Material Specifications May be based on internal standards set by the company international publications based on scientific research national standards buyers standards Should include how it will be received stored handled and transported under specified sanitary conditions and appropriate environmental conditions which prevent contamination and deterioration. Example: Specification (PEANUTS) Brief Description Size Appearance
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 No molds, less than 0.5% outside spec Moisture (< 8 %) Taste, flavor (no off flavor or taste) Age (maximum ? Months) Contaminants (legal requirements, WHO) Packaging (food grade) Labeling (supplier, lot no., date of harvest) Storage conditions (dark, dry, cold) Raw Material Receiving Should include sampling procedures analytical methodology limits for 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 buyers specifications are met. Checking RMs Inspect all the RMs before they are accepted (at delivery or direct purchase) 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 of Ingredients and RM
RAW MATL/ ING. Example Bangus RECEIVING PROCEDURE STORAGE RQMNTS. SHIPPING RQMNTS. PACKAG ING RQMNTS . Packed in PE bags, sealed and placed in shipping cartons IN WHICH PRODUCT USED Marinated deboned bangus FUNCTION IN THE PRODUCT Main ingredient

Chilled (4 C) and placed in a clean ice chest

Stored in freezer o (-18 C)

Stored in freezer o (-18 C)

Approve supplier You depend on your supplier. See to it that you can trust him/her. 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 MATERIALS STORAGE

Organized and systematic manner of storing ingredients and raw materials

Label stored food with name, production date and use by DATE and inspection results Separate RMs from ready-to-eat food.
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- (ex. Keep raw meat from salad) Never store food together with chemicals

Apply first in first out (FIFO); First Expire First Out (FEFO)

RAW MATERIALS 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 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. adequate ventilation system and temperature controls to prevent off-odors and maintain ingredients and raw

Water as RAW MATERIAL All water in contact with food and food contact surfaces shall be potable. Water should be monitored with sufficient frequency to assure safe water. 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. Raw materials 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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