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GMP: Training the Trainers

Tutor: Odette Mangaban

26-27, May, 2014

1

About the Trainer:

Ma. Lourdes M. Mangaban

Academic Qualifications

Bachelor of Science in Food Technology, U. P. at

Los Banos

Master of Science in Food Science, U. P. at Los

Banos

Professional Qualifications

Research and Development

Quality Assurance

Food Quality and Safety Consultant

ISO 22000 Lead Assessor

Former QMR and FSTL

Training and Consultancy

Meat Processing

Dairy Processing

Spice Blending for Meat Seasonings, Sauces and

Marinades

Business

2

Training Agenda

DAY 01

08:00 – 8:30 Registration

08:30 – 9:00 Pre- Test

Session 1

Session 2

Session 3

09:00 – 10:00 Session 4

Session 5 and Workshop 1

10:00 – 10:15 Tea Break

Session 6 and Workshop 2

12:00 – 13:00 Lunch Break

Session 7 and Workshop 3

Session 8

15:00 – 15:15 Tea Break

Workshops 4 and 5

3

Training Agenda

DAY 02

08:00 – 10:00 Recap of Day 1

Session 9

Session 10

10:00 – 10:15 Tea Break

Session 11

Session 12

12:00 – 13:00 Lunch Break

Session 13 and Workshop 6

13:00 – 15:15 Tea Break

Session 14

Post Test

Course Evaluation

4

Training Objectives

For the participants to:

• Know the requirements of GMP based on Codex Alimentarius, General Principles of Food Hygiene

• Know the PRP requirements of global standards

• Know the application, implementation and verification of GMP

• Provide capacity to trainers on GMP training on its handling and delivery

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House Rules

6

Be punctual.

Lunch break at 12 noon. There will be a 15 min break in

the morning and afternoon.

Mobile phone on silent mode.

Do your share; participate, ask questions and do your

assignments, if there are any.

PRE-TEST

Duration: 15 minutes

7

Introduction to Food Safety

SESSION 01

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Foodborne Illness Outbreaks

• E. coli at Jack in the Box, 1993

With over 40 years of success in the fast-food world, the Jack in the Box franchise almost crumbled in 1993. After eating contaminated meat from Jack in the Box restaurants in Seattle, California, Idaho, Texas and Nevada, four children died and hundreds of other customers fell ill. The outbreak caused a national panic, and the Jack in the Box brand was suddenly tainted.

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Foodborne Illness Outbreaks

• Hepatitis A Outbreak at Chi-Chi’s, 2003

• In November 2003, a Chi-Chi’s restaurant in Monaca, Pennsylvania caused the death of four people and sickened hundreds of others, including high school students who passed it on to others. The cause was hepatitis A-infected green onions that were imported from Mexico.

• According to theCDC, this was the largest outbreak in U.S. history of hepatitis A, a virus caused through contact with feces. The restaurant chain no longer exists.

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Foodborne Illness Outbreaks

• Pilgrim’s Pride Meat Causes Listeria, 2002

• Occurred in Pennsylvania, New York, New Jersey, Delaware, Maryland, Connecticut, Massachusetts, and Michigan

• The widespread outbreak of Listeria monocytogenes. Listeriosis, an infection typically caused from eating contaminated food with Listeria monocytogenes, was linked, in this case, to sliced turkey deli meat from Pilgrim’s Pride Foods of PA.

• The outbreak, which included seven deaths, resulted in the recall of 27.4 million pounds of poultry products.

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Foodborne Illness Outbreaks

• E.coli Outbreak at Taco Bell, 2006

• In December 2006, two fast food taco restaurants had E. coli outbreaks linked to contaminated lettuce.

• The first involved 71 Taco Bell customers across five states on the East Coast. Eight of those people suffered kidney failure.

• The second outbreak involved the Taco John’s chain in Iowa and Minnesota, involving a total of 87 people. Following the outbreak, California (where the Taco Bell lettuce came from) enacted stricter standards for handling leafy greens.

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Foodborne Illness Outbreaks

• The Great Melamine Scare, 2008 -Six babies died and

as many as 300,000 became ill after consuming the

Sanlu product.

• Melamine-tainted infant formula in China

• Similar scare in March 2007 involving pet food - On

March 17, 2007 Menu Foods, Inc. a major manufacturer

of dog and cat food in North America recalled 60 million

containers of wet food after it received reports of pets

from suffering kidney failure.

• Government regulatory agencies around the world

developed scientific methods to detect melamine and its

metabolites

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Impact of Food Safety

BENEFITS • Happy customers

• Consumer confidence

• Good reputation

• Operating costs under control

• Profit

• Legal Compliance – no criminal prosecutions or civil lawsuits

• Healthy employees

• Pleasant working environment

Impact of Food Safety

COSTS

• Bad reputation and complaints

• Illness

• Hospitalizations

• Operating costs increase – lost work, reduced productivity , food wasted

• Legal fees

• Punitive damages

• Lost profit

• Business closures

Foodborne Illness

Definition

A disease caused by the consumption of contaminated food.

A foodborne disease outbreak is defined as an incident in which

two or more people experience a similar illness after eating a

common food.

Types of Foodborne Illness

• Food infection

• Food intoxication

Food Infection

• Disease caused by the ingestion of pathogenic microorganisms which penetrate into the body tissues

• Examples:

• Listeria monocytogenes –affects brain cells and causes meningitis

• E.coli and Clostridium perfringens-intestinal tract

• Salmonella –gall bladder or lymph nodes

Food Intoxication

• Disease that results from the ingestion of toxin produced by the microorganisms which are already in the food or in the body, formed and set free

• Enterotoxin produced by Staphylococcus aureus causes gastroenteritis

• Exotoxin produced by Clostridium botulinum causing respiratory failure or death to man

Contributors to Foodborne Outbreaks

• Unsafe sources

• Inadequate cooking

• Improper holding

• Contaminated equipment

• Poor personal hygiene

Food Safety Hazards and Control

Measures

SESSION 02

21

What are Food Safety Hazards?

• A biological, chemical or physical agent in,

or condition of, food with the potential to

cause an adverse health effect.

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Biological Hazards

o Bacteria

o Fungi ( molds and yeasts)

o Viruses

o Parasites

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Examples of Biological Hazards

• Salmonella species

• Clostridium perfringens

• Clostridium botulinum

• Bacillus cereus

• Staphylococcus aureus

• E. coli

• Hepatitis A

• Norwalk

• Vibrio

• Trichinella spiralis

• Giardia lamblia

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What are Microorganisms?

• germs that cause illness

• cause food spoilage

• invisible enemies

• they are living organisms that are not visible to the naked eye except when they had formed large colonies

Types of Microorganisms

• Bacteria

• Fungi

• Viruses

• Protozoan

• Algae

Types of Bacteria According to Shape

Streptococcus Bacteria

2 Types of Fungi

• Molds

• Yeasts

Molds

• Widely distributed in nature and adundant in the air

• Grow under a variety of conditions in which air and moisture are present.

Characteristics of Molds

Appearance:

– fluffy and filament-like

– moist and glossy

Mycotoxin

Food Safety Concern on Molds

MYCOTOXIN produced by molds:

Aflatoxin,

Fumonisin, Ochratoxin

Yeasts

• Spherical, elliptical or cylindrical shape.

• Yeasts love starchy, salty and high sugar foods

Bread Yeast

Viruses

• Small infectious agent that can replicate inside the cells of another organism

• Genes made from either RNA or DNA • Much smaller than bacteria, and they require a living

host (human, animal) in which to grow and reproduce • Do not multiply in foods

• Three viruses important to food establishments: Hepatitis ANorwalk Rotavirus

Parasites

• Small or microscopic creatures that need to live on or inside a living host to survive

• Examples • Anisakis spp• Cyclospora cayatenensis • Cryptosposidium parvum• Giardia lamblia• Taxosplasma gondii• Trichinella spiralis• Endamoeba sp.

Top Ten Least Wanted Foodborne

Pathogens

Campylobacter

Second most common bacterial cause

of diarrhea in the United States

Sources: raw and undercooked poultry

and other meat, raw milk and untreated

water

Clostridium botulinum

This organism produces a toxin which causes botulism,

a life-threatening illness that can prevent the breathing

muscles from moving air in and out of the lungs.

Sources: improperly prepared home-canned foods;

honey should not be fed to children less than 12 months

old.

E. coli 0157:H7

A bacterium that can produce a deadly toxin and causes

approximately 73,000 cases of foodborne illness each

year in the U.S.

Sources: beef, especially undercooked or raw

hamburger; produce; raw milk; and unpasteurized juices

and ciders.

Listeria monocytogenes

Causes listeriosis, a serious disease for pregnant women,

newborns and adults with a weakened immune system.

Sources: unpasteurized dairy products, including soft

cheeses; sliced deli meats; smoked fish; hot dogs; pate';

and deli-prepared salads (i.e. egg, ham, seafood, and

chicken salads).

Salmonella

Most common bacterial cause of diarrhea in the United

States, and the most common cause of foodborne

deaths. Responsible for 1.4 million cases of foodborne

illness a year.

Sources: raw and undercooked eggs, undercooked

poultry and meat, fresh fruits and vegetables, and

unpasteurized dairy products.

Staphylococcus aureus

This bacterium produces a toxin that causes vomiting

shortly after being ingested.

Sources: cooked foods high in protein (e.g. cooked ham,

salads, bakery products, dairy products) that are held too

long at room temperature.

Shigella

Causes an estimated 448,000 cases of diarrhea

illnesses per year. Poor hygiene causes Shigella to be

easily passed from person to person and from infected

individuals to food items.

Sources: salads, unclean water, and any food handled

by someone who is infected with the bacterium

Taxosplasma gondii

A parasite that causes toxoplasmosis, a very severe disease that can produce central nervous system disorders particularly mental retardation and visual impairment in children. Pregnant women and people with weakened immune systems are at higher risk;

Sources: raw or undercooked pork

• .

Vibrio vulnificus

Causes gastroenteritis, wound infection, and

severe bloodstream infections. People with

liver diseases are especially at high risk.

Sources: raw or undercooked seafood,

particularly shellfish.

Norovirus

The leading viral cause of diarrhea in the United States.

Poor hygiene causes Norovirus to be easily passed from

person to person and from infected individuals to food

items.

Sources: Any food contaminated by someone who is

infected with this virus.

FATTOM: Requirements of Microorganisms For

Growth

• F – food /nutrients

• A – acidity /alkalinity

• T – time

• T – temperature

• O – oxygen

• M – moisture

Food or Nutrients

Microorganisms need food to supply the energy for cell activity and growth.

Bacteria are more exacting in their nutrient requirements compared to yeasts and molds .

Some require growth factors as vitamins and amino acids to grow.

Acidity /Alkalinity (pH)

The proper pH must be provided for normal growth and development.

Most bacteria prefer neutral to slightly alkaline pH (6.5 – 7.5)

Yeasts prefer acidic environment (pH 3.5 – 4.5)

Molds tolerate a wider pH range ( pH 3.5 – 8.0)

pH Scale

Classification of Foods by Acidity

Categories pH

High-acid foods <4.5

Low-acid foods >4.5

Classification of Foods by Acidity

Low-acid foods High-acid foods

Dairy (cheese, milk)

Chocolate ( 6.5)

Meat and Poultry

(beef, chicken, fish and shell fish)

Vegetables (broccoli, beans)

Dairy (yoghurt)

Fruits (apple, oranges)

Vegetables (cucumber)

Classification of Microorganisms According to

Temperature Requirement

Temperature Requirements of Microorganisms

Psychrophiles- cold-loving bacteria (0-5oC)

Ex. Listeria, Bacillus cereus

Mesophiles- grow well at moderate temperature (5 – 20 oC)

Ex. E.coli, Salmonella

Thermophiles- heat-loving bacteria (35-45oC)

Ex. Methanobacteria

Temperature Danger Zone (TDZ)

• The temperature range at which most suitable for rapid bacterial multiplication

• 41⁰F ( 5⁰C) to 135⁰F ( 57⁰C)

Temperature Danger Zone (TDZ)

Unavoidable situations during food production when foods must pass through the TDZ such as :

• Cooking

• Cooling

• Reheating

• Food preparation (slicing, mixing, etc. )

Time-temperature Control

General Rules

• Keep hot food hot

• Keep cold food cold

• Keep frozen food frozen

Generation Time of Bacteria

Within 8 hours, a single bacterium cell can multiply up to 17 million cells

Generation time is the time it takes for bacterialcell to reproduce into two daughter cells

Bacterial Growth Curve

Oxygen Requirement

General Groups of Bacteria

• Aerobic (ex. Pseudomonas aeruginosa)

• Anaerobic (ex. Clostridium)

• Facultative Anaerobe (ex. E.coli)

Moisture

Aw (Water Activity)

This is the measure of the availability of water to microorganisms for metabolism.

Water Activity and Microorganisms

Time/temperature Control for Safety Food (TCS)

• Types of foods that have the ability to support rapid and progressive growth of infectious and toxin-producing microorganisms

• These are usually high in protein or carbohydrates and have a pH above 4.6 and water activity above 0.85.

Examples of TCS Food (FDA Food Code, 2013)

• Foods of animal origin that are raw or heat-treated e.g. cooked meat and poultry, meat or fish salads, eggs , shellfish and seafood

• Foods of plant origin that are heat-treated or consist of raw seed sprouts e.g. cooked rice , raw seed sprouts

• Cut melons

• Garlic and oil mixtures that are not modified in a way to inhibit the growth of microorganisms

Control of Foodborne Illnesses

• Cleaning and Sanitation

• Personal Hygiene such as proper

Handwashing, use of PPEs

• Process Controls such as control of

FATTOM

• Proper layout of establishment

- All of these are part of GMP

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Chemical Hazards

• Naturally Occurring Chemicals– Mycotoxins (e.g., aflatoxin) from mold

– Scombrotoxin (histamine) from protein decomposition

– Ciguatoxin from marine dinoflagellates

– Toxic mushroom species

– Shellfish toxins (from marine dinoflagellates)

– Paralytic shellfish poisoning (PSP)

– Diarrhetic shellfish poisoning (DSP)

– Neurotoxic shellfish poisoning (NSP)

– Amnesic shellfish poisoning (ASP)

– Plant toxins

– Pyrrolizidine alkaloids

– Phytohemagglutinin

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Chemical Hazards

• Added Chemicals

• Agricultural chemicals:

– Pesticides, fungicides, fertilizers, insecticides, antibiotics and growth hormones

– Polychlorinated biphenyls (PCBs)

– Industrial chemicals

– Prohibited substances (21 CFR 189)

– Direct

– Indirect

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Top 16 Food Allergens

Peanuts

Tree Nuts

Eggs and Egg Products

Soy and Soya Products

Fish and Fish Products

Wheat and Wheat Products

Milk and Milk Products

Crustaceans

Celery

Mustard

Sesame seeds

Sulfites

MSG

F&C Yellow Color No. 5

Gelatin

Hydrolyzed Proteins

Common Sources of Chemical Hazards

• Ingredients

• Cleaning products

• Products used in agriculture

• Pest control products

• Equipment

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Physical Hazards

o broken glass

o hair, fingernails,

o jewelry, hair pins

o unfrilled toothpick

o stones, leaves

o paper, packaging

o metal shavings

o pieces of worn equipment

o peeling paint

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Main Materials of Concern as Physical Hazards

and Common Sources (FDA)

Material Injury Potential Sources

Glass fixtures Cuts, bleeding; may require

surgery to find or remove

Bottles, jars, light, utensils,

gauge covers

Wood Cuts, infection, choking; may

require surgery to remove

Fields, pallets, boxes,

buildings

Stones, metal

fragments

Choking, broken teeth, cuts,

infection; may require surgery to

remove

Fields, buildings, machinery,

fields, wire, employees

Insulation Choking; long-term if asbestos Building materials

Bone Choking, trauma Fields, improper plant

processing

Plastic Choking, cuts, infection; may

require surgery to remove

Fields, plant packaging

materials, pallets, employees

Personal effects Choking, cuts, broken teeth;

may require surgery to remove

Employees

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Workshop 1Group the participants into 3 groups and have

each group prepare a list of chemical, physical

and microbiological hazards that may be

associated with identified products.

Teams will work on BIOLOGICAL, CHEMICAL

AND PHYSICAL HAZARDS associated with the

product. Use the template for Workshop 1.

Identify source and control measures that may

reduce or eliminate these hazards

Time limit: 30 minutes

Each group will report its findings using flipcharts

.

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Workshop 1: Food Safety Hazards

BIOLOGICAL /CHEMICAL /PHYSICAL HAZARD

SOURCE(S) CONTROL MEASURE

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Introduction to Food Safety Frameworks Relating

to GMP (Prerequisite Program - PRP)

SESSION 03

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GMP/ SSOP provide the basic foundation for the development of a HACCP system.

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Food Safety Standards

Objective of PRP

• The primary food safety objective for any food operation

is to supply food that is safe for human consumption.

• This training provides guidance on developing pre-

requisite programs such as GMP for hygienic and

operational conditions.

• These are universal steps or procedures that control the

conditions within a food operation.

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Function of PRP

• Effective pre-requisite programs promote conditions that

help to produce safe food. They are essential to support

the foundation of a preventive food safety control system

• Pre-requisite programs include many control measures

necessary for producing safe food. Implementation of

these control measures is encouraged before processing

begins.

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Documentation of PRP

• Maintaining appropriate documentation and records is an

important element of effective pre-requisite programs

because they provide an indication of whether the

control measures are implemented effectively.

• When pre-requisite programs are implemented, they

should include written policies and/or procedures.

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Overview of International Frameworks and Protocols for the Safe Provision of Foods

GMP ( Good Manufacturing Practices)

PAS (Publicly Available Specification)

FSSC 22000:2010 (Food Safety System Certification)

SSOP (Sanitation Standard Operating Procedure

HACCP

ISO 22000:2005

Food Safety Management Systems- Requirements for any organization in the food chain

Overview of International Frameworks and

Protocols for the Safe Provision of Foods

RVA Scheme (Dutch HACCP) – HACCP accredited

SQF, American (FMI) Scheme – based on HACCP and ISO 9001:2000

2 schemes – SQF 1000 for primary producers

SQF 2000 for manufacturers and distributors

BRC – British Retailers Scheme

IFS – French/German Retailers’ Scheme

HACCP - A system which identifies, evaluates, and controls hazards which are significant for food safety Based on Codex Alimentarius Guidelines, USDA 21 CFR Part 110,123, Singapore Standard (SS 444) , Canadian Food Inspection Agency’s Food Safety Enhancement Program

Overview of International Frameworks and

Protocols for the Safe Provision of Foods

• EurepGAP is a common standard for farm management practice created in the late 1990s by several European supermarket chains and their major suppliers. GAP is an acronym for Good Agricultural Practices

• The aim was to bring conformity to different retailers' supplier standards, which had been creating problems for farmers. It is now the world's most widely implemented farm certification scheme.

• Most European customers for agricultural products now demand evidence of EurepGAP certification as a prerequisite for doing business.

• Eurepgap (Globalgap) accredited for vegetables and seafoods

SSOP (Sanitation Standard Operating

Procedures) Scope

• Written procedures that an establishment develops and implements to

prevent direct contamination or adulteration of product. Prerequisite

program for HACCP.

• Components of GMPs emphasizing sanitation procedures.

Scope:

Safety of water

Condition of cleanliness of food contact surfaces

Prevention of cross contamination

Maintenance of handwashing, hand sanitizing and toilet facilities

Protection of food, food packaging materials and food-contact

surfaces from adulteration

Proper labeling, storage and use of toxic compounds

Control of employee health conditions

Exclusion of pests

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Publicly Available Specification (PAS)

Focuses on the prerequisite program (PRP)

elements & sets out detailed requirements (similar to

North American- based GMPs)

Required to pass each element within an FSSC

22000:2010 audit (similar to ISO 22000 but can be

Applicable to food manufacturers (ISO/TS 22002-1)

Applicable to packaging manufacturers – PAS

223:2011

Applicable to food retailers – PAS 221:2013

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PAS SCOPE

• Construction and layout of buildings and

associated utilities;

• Layout of premises, including workspace and

employees facilities;

• Supplies of air, water, energy and other utilities;

• Supporting services, including waste and

sewage disposal

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PAS Scope

• Suitability of equipment and its accessibility for

cleaning maintenance and preventive

maintenance

• Management of purchased materials

• Measures for the prevention of cross

contamination

• Cleaning and sanitizing

• Pest control

• Personal hygiene

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PAS Scope

Additional aspects relevant to manufacturing operations:

• Rework

• Product recall procedures

• Food defense, biovigilance and bioterrorism

• For food packaging manufacturers: additional Clause 19: Food packaging design and development

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Codex Alimentarius Commission

A subsidiary body of the Food and

Agriculture Organization and the World

Health Organization of the United Nations.

(Commission du Codex Alimentarius)

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General Principles of Food Hygiene (CODEX

ALIMENTARIUS)

• Identify the essential principles of foodhygiene applicable throughout the food

chain.

• Provide a guideline for specific codes

which my be needed for sectors of the

food chains, processes, or commodities to

amplify the hygiene requirements specificto those areas.

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Regulating Food Safety

• Main purpose of food safety regulation is to safeguard public health by ensuring that food offered to the consumers is:

safe

Unadulterated

Honestly prepared

Regulatory Bodies

Functions may include:

• Regulating the processing, manufacturing and shipping and sale of food

• Setting standards for the composition, quality, safety and labeling of food and food additives

• Issuing a recall of food that may cause a risk to health

• Issuing permits to operate

• Providing advice on all aspects of food safety

• Conducting inspection and audits of food establishments

• Enforce the regulation

Regulatory Bodies

• National – FDA ( statutes, laws, regulations )

• LTO (License to Operate or Permit to Operate)

• Product Registration

• Regulatory standards for products

• Local – municipal ( ordinances)

• Ex. Sanitary Permit

Microbiological Analysis of Purified Water

Annual Medical Examination of Food Handlers

• Voluntary standard by food industry organizations , scientific organizations , professional societies (IFT)

Examples of Regulatory Standards on Products Raw

Materials and Packaging Materials

• 21 CFR 182.1745 CMC Sodium carboxymethylcellulose

• Food Grade Lubricant 21 CFR 178.3570

• 21 CFR 172-878 FDA Mineral Oil

• Commission Directive 2007/42/EC Relating to materials and articles made of regimented cellulose film intended to come into contact with foodstuffs

• Commission Regulation(EU) No. 10/2011 Commission Regulation on Plastic Materials and Articles to come into contact with Food

• 21 CFR177.1520 – Resin

• 9 CFR 317.24 – deals with chemical hazard from packaging materials

• 9 CFR 318.7 - Chemicals used are approved for the

intended use and at appropriate amounts

• SIS Directive 7310.4 Rev. 2 - Metal contamination >1/32" must be

removed from product

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Cambodia Regulations Relating to Food Safety

• Inter-Ministerial Prakas no. 868 dated 22 Oct 2010

• Royal Decree No. NS/RKM/0607/013 dated 24 June

2007 promulgating the Law on Standards of

Cambodia

• Royal Decree No. NS/RKM/0608/018 dated 23 June

2006 promulgating the Law on Administration of

Factory and Handicraft

• Royal Decree No. NS/RKM/0607/013 dated 24 June

2007 promulgating the Law on Standards of

Cambodia

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Cambodia Regulations Relating to Food Safety

• Royal Decree No. NS/RKM/0506/011 dated

21 June 2006 promulgating the Law on

Fisheries

• Royal Decree No. NS/RKM/0600/001 dated

21 June 2000 promulgating the Law on

Quality and Safety of Products and Services

• Sub-Decree No. 209/ANKr.BK dated 31 Dec

2007 – Use of Prohibited and Restricted

Goods

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Cambodia Regulations Relating to Food Safety

• Sub-Decree No. 108/ANKr.BK dated 24 Aug 2007 – Slaughtering and Management and Sanitary Inspection on Animals, Meat and Animal Products

• Sub-Decree No. 47/ANKr.BK dated 12 June 2003 – Sanitation of Foods for Human Consumption

• Sub-Decree No. 209/ANKr.BK dated 31 Dec 2007 – Use of Prohibited and Restricted Goods

97

Cambodia Regulations Relating to Food Safety

• Sub-Decree No. 16/ANKr.BK dated 17 March 2003 –

Sanitary Inspection on Animals and Products from

Animals

• Sub-Decree No. 15/ANKr.BK dated 13 March 2003 on

Phytosanitary Inspection

98

GMP : Introduction

SESSION 04

99

Good Manufacturing Practices (GMP) Collection of generally recognized rules, procedures and practices that

provide a code stating what is acceptable and what is not acceptable

in the food industry to ensure production of quality and safe foods.

Companies usually develop procedures and are usually termed SOP

or Standard Operating Procedures

Per Codex Alimentarius, the following are the scope of GMP/GHP:

Primary Production

Design and Facilities

Control of Operation

Maintenance and Sanitation

Personal Hygiene

Transportation

Product Information and Consumer Awareness

Training

100

Prerequisite Programme

• PRP ( prerequisite programme) – food safety basic conditions and activities that are necessary to maintain a hygienic environment throughout the food chain suitable for the production, handling and provision of safe end products and safe food for human consumption

• The PRPs depend on the segment of the food chain in which the organization operates and the type of organization

Objectives

General Principles of Food Hygiene

– Identify the essential principles of food hygiene applicable throughout the food chain.

– Recommend a HACCP-based approach as a meansto enhance food safety

– Provide a guideline for specific codes which my be needed for sectors of the food chains, processes,or commodities to amplify the hygiene requirements specific to those areas.

Scope & Use

Scope

– The food chain : From primary production to the final consumer

Roles of Governments

– Protect consumers

– Provide assurance that food is suitable for human consumption

– Maintain confidence in internationally traded food

Scope & Use

Roles of Industry

– Provide food which is safe and suitable for consumption

– Ensure that consumers have clear and easily-understood information

– Maintain confidence in internationally traded food

Consumers

– Recognize their role by following relevant instructions and apply appropriate food hygiene measures

Use

– In deciding whether a requirement is necessary or appropriate, an assessment of the risk should be made

Terms and Definitions

• Cleaning - the removal of soil, food residue, dirt,

grease or other objectionable matter

• Contaminant – any biological or chemical agent,

or other substances not intentionally added to

food which may compromise food safety or

suitability

105

Terms and Definitions

• Contamination- the introduction or occurrence of

a contaminant in food or food environment

• Disinfection – the reduction, by means of agents

and/or physical methods, of the number of

microorganisms in the environment, to a level

that does not compromise fppd safety or food

suitability

106

Terms and Definitions

• Establishment – any building or area in which

food is handled and the surroundings under the

control of the same management

• Food hygiene – all conditions and measures

necessary to ensure the safety and suitability of

food at all stages of the food chain

107

Terms and Definitions

• Hazard – a biological, chemical or physical

agent in, or condition of, food with the

potential to cause an adverse health effect

• HACCP – a system which identifies,

evaluates, and controls hazards which are

significant for food safety

108

Terms and Definitions

• Food handler – any person who directly handles

packaged or unpackaged food, food equipment

and utensils, or food contact surfaces and is

therefore expected to comply with food hygiene

requirements

• Food Safety – assurance that food will not cause

harm to the consumer when it is prepared and/or

eaten according to its intended use

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Terms and Definitions

• Food Suitability – assurance that food is acceptable for

human consumption according to intended use

• Primary production – those steps ion the food chain up

to and including, for example, harvesting, slaughter,

milking, fishing

110

Primary Production

SESSION 05

111

1.0 Primary Production

• Those steps in the food chain up to and

including, for example harvesting, slaughter,

milking and fishing

112

1. Primary Production

• Objectives:

– Avoid the use of areas where the environment poses a threat to the safety of food;

– Control contaminants, pests and diseases of animals and plants in such a way as not to pose a threat to food safety

– Adopt practices and measures to ensure food is produced under appropriately hygienic conditions

Raw Materials

Feed Mill

Grower

Processing

Consumers - Retails

1. Primary Production

1. Primary Production

• 1.1.1 Environmental hygiene– Potential sources of contamination from the

environment should be considered

• 1.1.2 Hygiene production of food sources– Control contamination from air, soil, water, feedstuffs,

fertilizer, pesticides, veterinary drugs, etc.

– Control plant and animal health

– Protect food sources from faecal and other contamination

1. Primary Production

• 1.1.3 Handling, Storage and Transport– Sort food and food ingredients to segregate material which is evidently

unfit for human consumption

– Dispose of any rejected material in a hygienic manner

– Protect food and food ingredients from contamination by pest, or by chemical, physical or microbiological contaminants

• 1.1.4 Cleaning, Maintenance and Personnel hygiene at primary production– Cleaning and maintenance is carried out effectively

– Any appropriate degree of personal hygiene is maintained

2.1 Location

2.1.1 Location should normally be located away from

– Environmentally polluted areas;

– Areas subject to flooding unless sufficient safeguards are provided;

– Areas prone to infestations of pests;

– Areas where wastes, either solid or liquid, cannot be removed

2.1.2 Equipment– Permits adequate maintenance and cleaning;

– Functions in accordance with its intended use;

– Facilitates good hygiene practices, including monitoring

Establishment: Design and Facilities

SESSION 06

118

2. Establishment: Design & Facilities

• Objectives:– Contamination is minimized;

– Design and layout permit appropriate maintenance, cleaning and disinfections and minimize air-borne contamination;

– Surfaces and materials are non-toxic, suitably durable, and easy to maintain and clean;

– Suitable facilities are available for temperature, humidity and other controls;

– Effective protection against pest access and harbourage

Plant Schematic of fabrications layout

120

Service entrance for administrative personnel

Administrative facilities

Toilet Toilet

Cloak room

Cloak room

Entrance for

production

personnel

Hygiene barrier

Acceptance of raw material

Storage of raw material

Preparation for processing

Waste

Manufact-uring

Storage of packaging material

Packaging

Storage of Finished product

2.1 Location

2.1.1 Location should normally be located away from

Environmentally polluted areas;

Areas subject to flooding unless sufficient safeguards are provided;

Areas prone to infestations of pests;

Areas where wastes, either solid or liquid, cannot be removed

121

2.1 Location

2.1.2 Equipment

Permits adequate maintenance and cleaning;

Functions in accordance with its intended use;

Facilitates good hygiene practices, including monitoring

122

Examples of Non-compliance

123

2.2 Premises & Rooms

2.2.1 Design and Layout

Permit good hygiene practices

2.2.2 Internal structures and Fittings

Should be soundly built of durable materials

Be easy to maintain

Be easy to clean

124

Example of fabrications layout

125

Service entrance for administrative personnel

Administrative facilities

Toilet Toilet

Cloak room

Cloak room

Entrance for

production

personnel

Hygiene barrier

Acceptance of raw material

Storage of raw material

Preparation for processing

Waste

Manufact-uring

Storage of packaging material

Packaging

Storage of Finished product

2.2 Premises & Rooms

• Floor- Impervious materials with no toxic effect in intended use

• Walls- Smooth surface

• Windows- Easy to clean, fitted with removable and cleanable insect-proof screens

• Door - Easy to clean, fitted with removable and cleanable insect-proof screens

• Working Surfaces -Durable, easy to clean, maintain and disinfect

126

127

Layout of Premises & Workspace

• Walls/floors shall be washable or cleanable, as

appropriate for process/product risk – materials

withstand cleaning (recommend rounded

wall/floor junctions – coving in process areas)

Zoning

128

2.2 Premises & Rooms

2.2.3 Temporary / Mobile premises and Vending machines

Should be sited, designed and constructed to avoid contamination

Avoid harbouring pests

129

2.3 Equipment

2.3.1 General

Equipment used to cook, heat, cool, freeze food etc. should

be designed to achieve the required food temperaturerapidly

be designed to allow temperature to be monitored and controlled

have effective means of controlling and monitoring humidity, airflow etc

130

2.3 Equipment

2.3.1 Food control and Monitoring equipment

Equipment used to cook, heat treat, cool, store or freeze food should be designed to achieve the intended use

Requirement

Harmful micro-organisms or toxins are eliminated or reduce to safe level;

Critical limits established in HACCP-based plans can be monitored;

Temperature and other conditions necessary to food safety can be rapidly achieved and maintained

131

2.3 Equipment

2.3.3 Containers for waste and inedible substances

Identifiable, suitably constructed

Made of impervious material

Be lockable to prevent malicious or accidental contamination of food

132

Maintenance and Calibration

• Effective maintenance and calibration programs should be in place

to ensure that all equipment (including specialized instrumentation)

and utensils function as per their intended purpose

• there is no potential for introducing biological, chemical or physical

hazards

Examples: count tools before and after use,

clean and sanitize area following maintenance and

calibration activities

133

Maintenance and Calibration

• The operator should implement written maintenance and calibration programs, which include:

• a list of equipment and utensils (with their location) requiring regular maintenance and calibration;

• instruction on how to perform the maintenance and calibration activities;

• the maintenance and calibration frequencies;

• identification of the person(s) who is assigned the responsibility for the maintenance and calibration procedures; and

• where applicable, the name(s) of an external company or companies conducting maintenance and/or calibration activities.

134

Maintenance and Calibration

• Maintenance and calibration of equipment

should be done according to the

manufacturer's instructions/manual and be

completed by trained personnel.

135

Workshop 2. Preventive Maintenance (PM)

and Calibration of Equipment

• Group the participants into 2 teams

• Group 1 – PM Program of Equipment and

Food Manufacturing Facility

• Group 2 – Master Calibration Program of

Equipment

• List all the items in the food manufacturing

operations that require PM and Calibration

• Time: 15 min

136

Workshop 2 Template: Preventive Maintenance

Program

Area/ Location

Item/Equipment

Frequency /Schedule

Internal External Responsibility

Records

137

Workshop 2 Template: Calibration Program

Area /Location

Item/Equipment to beCalibrated

Frequency/Schedule

Internal External Responsibility

Records

138

2.4. Facilities

2.4.1 Water supply

Adequate supply

Non-potable water system shall not be connected with potable water system

Non-potable water system shall not allow reflux into potable water

2.4.2 Drainage and Waste disposal

Adequate drainage and disposal systems

Avoid the risk of contaminating food or potable water

139

2.4. Facilities

2.4.3 Cleaning

Adequate facilities, suitably designed should be provided for cleaning food, utensils and equipment

Adequate supply of hot and cold potable water where appropriate

140

2.4. Facilities

2.4.4 Personnel hygiene facilities and toilets

Hygienically washing and drying hands including wash basin and a supply of hot and cold water;

Lavatories of appropriate hygienic design;

Adequate changing facilities for personnel

141

2.4. Facilities

2.4.6 Air Quality and Ventilation

Minimize air-borne contamination of food

Control ambient temperature

Control odour which might affect the suitability of food

Control humidity to ensure the safety and suitability of food

142

2.4. Facilities

2.4.7 Lighting

Adequate natural or artificial lighting to enable the undertaking to operated in a hygienic manner

Adequate intensity to the nature of the operation

Be protected to ensure that food is not contaminated by breakages

143

Unprotected lighting unit

144

Lighting Cover

145

2.4. Facilities

2.4.8 Storage

Permit adequate maintenance and cleaning;

Avoid pest access and harbourage;

Protected from contamination during storage;

Provide an environment which minimizes the deterioration of food (e.g. by temperature and humidity control)

146

147

Screened Door

148

149

Doors kept open, uncemented sides of building

Control of Operation

SESSION 07

150

3.0 Control of Operation

Objectives

Formulating design requirements with respect to

raw materials, composition, processing, distribution,

and consumer use to be met in the manufacture and handling of specific food items;

Designing, implementing, monitoring and reviewing

effective control system

151

3.1 Control of Food Hazards

Identify any step which are critical to the safety of food

Implement effective control procedure

Monitoring control procedures to ensure continuing effectiveness

Review control procedure periodically, and when the

operations change

152

3.2 Key aspects of hygiene control systems

3.2.1 Time and temperature control

Temperature control system should taken into account:

Nature of food : Aw, pH, and likely initial level and types of micro-organism;

Intended shelf-life of the product;

Methods of packaging and processing;

Intended to be used, e.g. further cooking/processing or ready-to-eat

Tolerable limits for time and temperature variation / record

153

3.2 Key aspects of hygiene control systems

3.2.2 Specific process steps, for example:

Chilling

Thermal processing

Irradiation

Drying

Chemical preservation

Vacuum or modified atmospheric packaging

154

3.2.3 Microbiological and Other Specifications

Specification should be based on sound scientific principles

3.2.4 Microbiological Cross-contamination

Raw, unprocessed food should be effectively separated from ready-to-eat foods

Access to processing areas may need to be restricted or controlled

Personnel may need to be required to put on clean protective clothing including footwear and wash their hands

155

3.2 Key aspects of hygiene control systems

Packing rice- good practices

156

Noncompliant practices

157

3.2 Key aspects of hygiene control systems

3.2.5 Physical and Chemical contamination

System should be in place to prevent

contamination of foods by foreign bodies such as

glass or metal shards from machinery, dust, harmful fumes and unwanted chemicals

Suitable detection or screening devices should be used

158

Specifications should be identified and applied

Inspected and sorted before processing

(Where necessary) laboratory tests should be made to establish fitness for use

Effective stock rotation

159

3.3 Incoming Material Requirements

3.3 Incoming Material Requirements

Specifications should be identified and applied

Inspected and sorted before processing

(Where necessary) laboratory tests should be made to establish fitness for use

Effective stock rotation

160

161

Management of Purchased Materials

Delivery vehicles checked prior to /during unloading to verify (e.g.

seals intact, free from infestation, temperature records)

Materials inspected, tested or covered by COA to verify conformance

to specified requirements prior to acceptance and use – method

documented

3.4 Packaging

Adequate protection for products to minimize

contamination, prevent damage and accommodate

proper labelling

Non-toxic and not pose a threat to safety and

suitable of food

Reusable packaging should be durable, easy to

clean and where necessary, disinfect

162

3.5. Water

3.5.1 In contact with food

Potable water should be used in food handling andprocessing

3.5.2 As an ingredient

Avoid food contamination

3.5.3 Ice and Steam

Made from potable water or should not constitute athreat to the safety and suitability of food

Protected from contamination, maintain and disinfect

163

Depend on the size of the business, the nature of activities and types of food involved

Managers and supervisors - enough knowledge of food hygiene principles and practices to be able to judge

Potential risks

Appropriate preventive and corrective actions

Effective monitoring and supervision

164

3.6 Management and Supervision

3.7 Documentation and Records

Kept and retained for a period that exceeds the shelf-life of product

Enhance the credibility and effectiveness of the food safety control system

165

3.8. Recall Procedures

Effective procedure

Tested through mock recall

Recalled product - held under supervision

Determine to be safe for human consumption

Re-process in a manner to ensure safety

166

Legal Requirements

EU Food and Feed General Food Law -

Regulation (EC) 178/2002

• Article 19

– If a food business operator considers or has

reason to believe that a food which it has

imported, produced, processed, manufactured or

distributed is not in compliance with the food

safety requirements, it shall immediately initiate

procedures to withdraw the food in question

from the market

167

Workshop 3

Flow Diagram/Plant Schematic

A. Flow Diagram

Each company will prepare a flow diagram for their specific product

The process flow diagram will identify the important process steps

(from receiving to shipping)

Each process step should be considered in detail and the information

expanded to include all relevant process data:

- all ingredients and packaging used

- sequence of all process operations (including raw material

addition)

- time/temperature history of all raw materials and intermediate

and final products including the potential for delay

- flow conditions of liquids, solids and air

- equipment design features

168

Workshop 3 Cont.

Plant Schematic

A plant schematic must be developed to show product flow and employee traffic patterns within the plant for the specific product.

_ the diagram should include the flow of all ingredients and packaging materials from the moment they are received at he plant, through storage, preparation, processing , packaging, finished product holding ad shipping.

- The personnel flow should indicate employee movement through the plant, including changing room, toilets and lunchroom. The location of handwashing facilities and food baths (if applicable) should be noted.

Time : 30 min

Team Presentation: 30 min

169

Establishment: Maintenance and Sanitation

SESSION 08

170

Objectives

Ensure adequate and appropriate maintenance and cleaning;

Control pests;

Manage waste;

Monitor effectiveness of maintenance and sanitation procedurres

4.1 Maintenance and Sanitation

4.1.1 General

Facilitate all sanitation procedures

Function as intended, particularly at critical steps

Prevent contamination of food, e.g. metal shards, flakingplaster, debris and chemicals

4.1 Maintenance and Sanitation

4.1.2 Cleaning procedures and methods

Cleaning procedures will involve, where appropriate;

Removing gross debris from surfaces;

Applying a detergent solution to loosen soil and bacterial film and hold in solution or suspension;

Rinsing with water to remove loosened soil and residues of detergent;

Dry cleaning or other methods for removing and collecting residues and debris;

Where necessary, disinfection

4.1 Maintenance and Sanitation

Appropriate clean, and should include the cleaning of cleaning equipment / tools

Continually and effectively monitored for suitability

and effectiveness and where necessary, documented should specify:

Areas, item of equipment and utensils to be cleaned;

Method and frequency of cleaning

Monitoring arrangement

4.2 Cleaning Programmes

4.3.1 General

Good hygiene practice

Good sanitation, inspection of incoming materials

Good monitoring

4.3.2 Preventing access (EXCLUSION)

Kept in good repair and condition to prevent pest access and to eliminate potential breeding sites

Wire mesh screens on open window, doors and ventilators

Animals should be excluded from the ground and food processing plants

4.3 Pest Control Systems

4.3.3 Harbourage and Infestation

Potential food sources - stored in pest-proof containers and/or stacked above ground and away form walls

Areas both inside and outside food premises should be kept cleaned

(Where appropriate) Refuse - stored in covered, pest-proof containers

4.3 Pest Control Systems

4.3.4 Monitoring and Detection

Regularly examined for evidence of infestation

4.3.5 Eradication

Treatment with chemical, physical or biologicalagents - without posing a threat to the safety orsuitability of food

4.3 Pest Control Systems

178

Pest Control

• Programs documented- address, plans , methods,

schedules, control procedures and training

• Programs include a list of chemicals approved for

use in specified areas of the facility

• Material Safety Data Sheet (MSDS) of all pesticides

should be available.

Suitable provision must be made for the removal and storage of waste

Waste stores must be kept appropriately clean

4.4 Waste Management

Monitored for effectiveness, periodically verified

Microbiological sampling of environment and food contact surfaces

Regularly reviewed and adapted to reflect changed circumstances

4.5 Monitoring effectiveness

Workshop 4 SSOP Procedure Writing - 2 persons working per item

• Write a procedure for each of the eight (8) key areas for

SSOP

1. Safety of Water - Team 1

2. Condition/Cleanliness of Food Contact Surfaces -Team 2

3. Prevention of Cross- Contamination - Team 3

4. Handwashing, Sanitizing Facilities Team 4

5. Protection from food adulteration – Team 5

6. Proper labeling and Storage –Team 6

7. Control of Employee Health Conditions - Team 7

8. Exclusion of Pests - Team 8

181

Workshop 4

The Procedure needs to give reference to the following:

Purpose /scope of the procedure

Who (responsibility)

Where (Area/location)

When (frequency)

Activity/Action

Reference

Records

Time allotted: 30 min with sample presentation from 2 teams.

182

Sample Template for SSOP Documentation

COMPANY NAME SSOP MANUAL

Procedure #: SSOP01

Page no: 1

Revision No: 0

SAFETY OF WATER Date: May 15, 2007

Prepared by: Reviewed by: Approved by:

Purpose/ Scope: Water to be used during processing and those that will come in contact with food

and food contact surfaces shall be potable and safe for consumption.

Who Where When Action Reference Records

Maint.

Boiler Room Area

Monthly 1. Draining, application of detergent soap, and scrubbing of water storage tank is done to wash-out any build up

of dirt. A 100 ppm chlorine rinse finishes off the rinsing process.The tank and pump shall be inspected for leaks

and condition of repair by the Production Supervisor and the results recorded on the Daily Sanitation

Checksheet

Work Instruction Manual (page CP-6) Daily

Personnel Sanitation

Checksheet.

Maint.

Boiler Room Area

Monthly 2. Draining and flushing of pressurized Work Instruction Manual (page CP-6) Daily

Personnel water tank Sanitation

Checksheet.

Production All area Daily 3. Water pipes and faucets shall be inspected for leaks and condition of repair by the Production Supervisor and

results recorded on the Daily Sanitation Checksheet Daily

Supervisor with Sanitation

pipelines Checksheet

QA Production Annually 4. Microbiological, physical, and chemical BFAD Q.A Files

Personnel area analysis of water is done annually by Standards

submission of product samples by Quality

Assurance Personnel to Private Laboratory

Testing center.

QA All Quarterly 5. In-house microbiological analysis of water to test or verify potability or safety for use in production or for

drinking.BFAD Q.A Files

Personnel waterlines Standards

183

Workshop 5: Cleaning Program

1. Group the participants into 2 persons per team

2. Develop a Master Cleaning Program for the following areas:

Outside Premises and Toilets – Team 1

Warehouse/Storage Area (RM, Packaging and FG) –

Team 2

Staging Area- Team 3

Processing area - Team 4

Packing Area –Team 5

Change Room and Locker rooms – Team 6

Eating Area Team 7

Cleaning equipment Team 7

184

Workshop 5

3. Areas , items of equipment and utensils to be cleaned

4. Responsibilities for particular tasks

5. Method and frequency of cleaning, and

6. Monitoring arrangements

Time: 30 min

Presentation by 2 teams

185

Master Cleaning Program

186

Area Items to be cleaned

Responsibility Method of cleaning

Frequency Verification Records

Establishment:

Personal Hygiene

SESSION 09

187

5.0 Personal Hygiene

Objectives

Maintaining an appropriate degree of personal cleanliness

Behaving and operating in an appropriate manner

188

5.1 Health Status

• People known, or suspected, to be suffering from, or to

be a carrier of a disease or illness - should not be allowed to enter any food handling area

189

Health status Employees with signs of diseases and bacteria carriers

are not permitted to work :

190

5.2 Illness and Injuries

• Jaundice

• Diarrhoea

• Vomitting

• Fever

• Sore throat with fever

• Visibly infected skin lesions (boils, cuts,etc.)

• Discharges from ear, eye or nose

191

5.3 Personal Cleanliness

Where appropriate) wear suitable protective clothing, head covering, and footwear

Wash hands when -

At the start of food handling activities;

Immediately after using the toilet;

After handling raw food or any contaminated material

192

When to wash hands

Every time entering to a GMP area

Whenever your hands are visibly dirty

After touching non contact product zone

Every time you touch your mouth, nose or eyes.

After using the bathroom

After coughing or sneezing

After touching high-hand contact surfaces such: door knobs, elevator buttons, railings etc.

193

194

Handwashing Procedure

From: University of Georgia

Removal of bacteria from hands and gloves: A demonstration

195

Unwashed Rinsed hand

Washed 20 sec using soap and

water

Washed 20 sec and then

sanitized

Removal of bacteria from hands and gloves: A demonstration

From: University of Georgia

5.4 Personal Behaviour

Refrain from behaviour which could result in

contamination of food-

Smoking;

Spitting;

Chewing or eating;

Sneezing or coughing over unprotected food

Jewellery, watches, pin or other items should not be worn

197

5.5 Visitors

• Should wear protective clothing and adhere to the other personal hygiene provisions in this section

198

Transportation

SESSION 10

199

6. Transportation

Objectives

Protect food from potential sources of contamination;

Protect food from damage likely to render the food unsuitable for consumption;

Provide an environment which effectively controls the

growth of pathogenic or spoilage micro-organisms and the production of toxins in food

200

6.1. General

Products are adequately protected during

transport

Type of conveyances or containers depends on

the nature of food and conditions under which it

has to be transported.

201

6.2. Requirement

Where necessary) conveyances and bulk containers should be designed and constructed so that they;

Do not contaminate foods or packaging

Can be effectively cleaned, disinfected

Permit effective separation of different foods or foods fromnon-food items (where necessary) during transport;

Effective protection from contamination, including dust and fumes;

Allow any necessary temperature, humidity and other conditions to be checked

202

6.3. Use and Maintenance

Kept in an appropriate state of cleanliness, repair and condition

Effective cleaning and where necessary, disinfection should take place between loads

Be designated and marked for food use only

203

Product Information and Consumer

Awareness

SESSION 11

204

Objectives

Products

Adequate and accessible information: Handle, store, process, prepare and display

Lot or batch can be easily identified and recalled if necessary

7. Product Information and Consumer Awareness

Objectives

Consumer

Understand the importance of product information;

Make informed choices appropriate to the individual;

Prevent contamination and growth or survival of foodborne pathogens by sorting, preparing and using it correctly

Industry or trade users

Clearly distinguishable from consumer information, particularly on food label

7. Product Information and Consumer Awareness

Essential in product recall

Effective stock rotation

Each containers of food should be permanently marked to identify the producer and the lot

7.1 Lot Identification

All food products should be accompanied by or bear

adequate information - Handle, display, store and prepare and use the product safely and correctly

7.2 Product Information

Clear instructions - Handle, display, store and use the product safely

7.3 Labeling

210

Product Information/Consumer Awareness

Information may be provided by labeling or other

means, such as company websites &

advertisements, & may include storage,

preparation & serving instructions applicable to

the product

Enable consumers to understand the importance of any product information

Temperature control

Time control

Food borne illness

7.4 Consumer Education

Training

SESSION 12

212

8.Training

Objectives

Those engaged in food operations who come directly

or indirectly into contact with food should be trained,

and/or instructed in food hygiene to a level

appropriate to operations they are to perform

213

All personnel should be aware of role and responsibility in protecting food from contamination or deterioration

Food handles should have the necessary knowledge and skills to handle food hygienically

Who handle strong cleaning/hazardous chemicals should be instructed in safe handling techniques

8.1 Awareness and Responsibilities

Factor / Level of training required included:

Nature of food;

Manner in which food is handled and packed;

Extent and nature of processing or further preparation before consumption;

Condition under which the food will be stored;

Expected length of time before consumption

8.2 Training Programmes

Periodic assessments of the effectiveness of training programmes should be made

Manager and supervisors should have the necessary

knowledge of food hygiene principles and practices to

be able to judge potential risks and take the necessary action to remedy deficiencies

8.3 Instruction and Supervision

Routinely reviewed and updated where necessary

Food handlers remain aware of all procedures

necessary to maintain the safety and suitability of

food

8.4 Refresher Training

Training Needs Analysis

• Training needs analysis identifies training

needs at employee, departmental or

organisational level in order to help the

organisation to perform effectively.

218

Objective of Training Needs Analysis

To ensure that training addresses existing

problems, is tailored to organizational

objectives, and is delivered in an effective

and cost-efficient manner.

219

Proper Facilities, Education and

Training, Training, Training

220

Specifications

SESSION 13

221

Definition

• A document that explicitly states

essential technical

attributes/requirements for a product

and procedures to determine that the

product's performance meets its

requirements/attributes.

222

The Reason for Specifications

• Contractual agreement between you and your

suppliers

• Contractual agreement between you and your

customers

• Confirms understanding

• Provides clarity and transparency between

partners

• Provides protection

• Forms part of a legal defence system

223

Content and Format

Minimum contents

• General product information- name of product, size of product

• General supplier information- name of company, production site

details, date of specification issue and other information

• Food safety legal requirements for country of production -

compositional, process, microbiological and quantity

• Food safety legal requirements for the country of sale -

compositional, process, microbiological and quantity

• Quality standards/attributes

• Shelf life

224

Comprehensive Finished Product

Specifications

• Product Details

• Formulation

• Raw materials, ingredients

and requirements to them

• Packaging

• Quality and safety data,

and reference to regulatory

requirements Nutritional

Data

• Dietary Statements

• Term and storage

conditions

• Distribution methods

• Production process

requirements

• Product control periodicity

and methods

• Information which should

be included in the labels

• Safety labelling and/or

instruction on treatment,

cooking and use

• Use warning and sensible

groups of consumers

225

Legal and Customer Requirements

• Always check and review legal requirements by

obtaining the actual legislation from official

websites or hardcopy from official sources

• Legislative requirements will change significantly

over a period of time

• Seek advice from reliable sources e.g. country’s

embassy, Government websites

• Consider packaging as part of the specification as

this has its own legal requirements

• Work with your customer on their own finished

product specification and confirm and clarify the

requirements before completion

226

Control of Specifications

• Specifications shall always be concise, accurate

and explicit

• With respect to the specification from your

suppliers you should specify the information and

data to be provided

• With respect to specification issued by your

customers you should ensure the information

provided is accurate and can be consistently

achieved

227

Using specifications in hazards analysis

• Product’s characteristics

- raw materials, ingredients and materials in

contact with food

- finished products characteristics

- Intended use

• The process flow chart, its stages and

management tools

228

Raw materials description

• Descriptions of raw materials, ingredients and materials in

contact with products should include the information on:

• Biological, chemical and physical characteristics,

• Contents of multi component ingredients, including additives

and supporting materials,

• Origin,

• Production method,

• Packaging and transportation methods,

• Storage conditions and expiry date,

• Preparation and/or operation before use or processing,

• Eligibility criteria related to food safety, or specifications of

the materials and ingredients procured related to their

intended use

229

Finished Product Description

• Finished products descriptions should

include the following:a) Product name or a similar identification;

b) Contents;

c) Biological, chemical and physical characteristics related to food

safety;

d) Storage life and storage conditions;

e) Packaging;

f) Food safety labeling and/or instructions on treatment, cooking,

and use;

g) Method(s) of distribution.

230 230

Finished product description

• It is necessary to determine regulatory requirements on

food safety, applicable to what is included in the

description

• Descriptions have to be updated

• Storage life – is a period, when a product’s

microbiological safety and its consumption suitability

shall be retained under defined storage conditions,

shown in the labeling or other storage instructions

231 231

Workshop 6: GMP Checklist

Group the participants into 6 groups

Make a GMP Checklist for the different areas and suggest a rating system :

Receiving/ Testing of Raw Materials - Team 1

Warehouse for RM, Packaging Materials and Finished Goods -Team 2

Processing Area – Team 3

Packing Area – Team 4

Outside Premises – Team 5

Lockers/Changing Room and Toliets – Team 6

Time Limit: 30 minutes

Presentation of Results

232

Open Forum

SESSION 14

233

Sharing of Experiences on Consultancy

• Opportunities for Local Consultants

• Tips on Consultancy

234

Questions and Answers

• Participants can ask questions to the

trainer and local consultants on

consultancy.

• Questions can be asked verbally or written

and submitted to the Trainer.

• Local Consultants and Trainer will answer

the questions

235

GMP Program

Activities Responsibility

Training Whole Organization

Assembly of GMP Team Top Management

Documentation for GMP Program Process Owners /GMP Team

Walk thru of the GMP Documents –

Awareness Training ( Cascading)

Process Owners

Implementation of GMP Whole Organization

Planning for Internal Audit GMP Team

Conduct of Internal Audit GMP Team/ Internal Audit Team

Reporting of Audit Findings GMP Team Leader

Corrective/Preventive Actions Process Owners

Review of GMP Program Top Management, GMP Team

Improvement of GMP Program Whole Organization236

References

237

Codex Alimentarius Recommended International

Code of Practice General Principles of Food

Hygiene (CAC/RCP 1-1969, Rev. 4 2003)

IFC Global Market Presentation Materials

GFSI (http://www.fskntraining.org, )

http://www.healthline.com/health-

slideshow/worst-foodborne-illness-outbreaks#11

Post Test ( 15 min)

and

Evaluation of GMP Seminar

238

ANNEX 1

Codex Alimentarius Commission’s

Recommended International Code of

Practice: General Principles of Food

Hygiene

239

ANNEX 2

Powerpoint Presentation Materials on

GMP: Training the Trainers

240

241

THANK YOU

THANK YOU.