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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
5
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
8
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.
9
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.
10
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.
11
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.
12
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
13
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.
22
Biological Hazards
o Bacteria
o Fungi ( molds and yeasts)
o Viruses
o Parasites
23
Examples of Biological Hazards
• Salmonella species
• Clostridium perfringens
• Clostridium botulinum
• Bacillus cereus
• Staphylococcus aureus
• E. coli
• Hepatitis A
• Norwalk
• Vibrio
• Trichinella spiralis
• Giardia lamblia
24
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
66
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
67
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
68
69
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
70
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
71
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
72
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
.
73
Workshop 1: Food Safety Hazards
BIOLOGICAL /CHEMICAL /PHYSICAL HAZARD
SOURCE(S) CONTROL MEASURE
74
Introduction to Food Safety Frameworks Relating
to GMP (Prerequisite Program - PRP)
SESSION 03
75
GMP/ SSOP provide the basic foundation for the development of a HACCP system.
76
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.
78
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.
79
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.
80
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
84
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
85
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
86
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
87
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
88
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)
89
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.
90
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
94
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
95
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
96
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
109
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.
