GMP & HYGIENE

………WAY TO GOOD FOOD, GOOD LIFE

Written By: Athar N. Butt

(Market GMP Coordinator)

Sponsored By: Corporate Quality Assurance

1

CONTENETS

No. TOPIC PAGE Index 2 1 Hygiene & Quality Assurance 3 2 Hygiene & Microbiological Risks 4 3 Personal Hygiene 5 3.1 Entering the Processing Area 6 3.2 Hand Wash 7 3.3 Shoe Change / Foot Wear 8 4 Colour definitions of Hygiene Zones 9 5 Three Zones and Three Cleaning Systems 9 6 Colour coding of Cleaning Tools 10 7 Manual Cleaning 10 8 General Poor Personnel Practices 11

2

HYGIENE & QUALITY ASSURANCE The Hygiene of the enterprise, personal hygiene and the quality of the products are very dependent. In food industry, non-compliance with the rules of hygiene during processing and manufacturing is most of the time main reason to number of problems related to Quality. As part of Nestle Family ensuring and providing consistent Quality Product is our goal. In order to achieve this goal, it is necessary to be aware of all the dangers, so that strong proactive measures are in place to account for these issues before they can happen. Hence this makes your involvement and knowledge very important. What are Hygiene, Food Hygiene and Food Safety? Hygiene is the science of maintaining cleanliness leading to good health however, Maintaining all conditions and measures necessary to ensure safety and suitability through out the supply chain is Food Hygiene & Assuring that the product will not cause any harm to the customer when prepared and or eaten as per its intended use is Food Safety. Do you know what are Food Contaminants & their types? All reasons and / or occurrences (biological, chemical, foreign matter) that are harmful & are a concern to food safety and suitability, which are not added intentionally, are termed as Food Contaminants. There are four major classes of Food Contamination.

1. Physical - glass pieces, human hair, brush bristles etc 2. Chemical - cleaning or disinfection chemical residues etc 3. Microbiological - yeast, mould, bacteria etc 4. Allergen - gluten, fish, eggs, peanuts etc

3

HYGIENE & MICROBIOLOGICAL RISKS Hygiene is directly dependant on cleanliness. Cleanliness itself is a direct measure of

dirtiness. There are two types of dirtiness – Visible & Invisible. It’s the invisible

dirtiness that is a cause of high concern and requires 100% commitment

. What do we mean by invisible dirtiness? - It’s the microorganisms.

They are tiny living organisms, which cannot be seen

with naked eye & are more commonly known as

Germs. They are present everywhere in: air, water,

soil, moist surfaces, human skin, nose, mouth,

animals, birds, insects, dirty equipment & utensils etc.

They are tiny but can be very dangerous.

4

PERSONAL HYGIENE – ENTERING THE PROCESSING AREA

5

HAND WASHING – ENTERING THE PROCESSING AREA

The hygiene of the hands is of primary importance in food industry. The correct

washing of the hands is the first duty of each employee.

Every employee should wash hands when entering the processing area

with Soap and excess water specially:

o before starting / resuming work.

o after coming back from the break

o after using toilet.

o after handling raw material / waste materials.

Wash hands at the designated areas only.

6

ENTRY PROCEDURE INTO HIGH HYGIENE CONTROL AREA

(1) Take a hair

cover from the designated

area.

(2) Ensure that the

hair cover is worn correctly.

(3) Take a pair of

new clean shoe covers, from

the designated container.

(4) Wear a clean shoe cover

over one shoe.

EXIT PROCEDURE INTO HIGH HYGIENE CONTROL AREA

(5) Without

touching the dirty side of

the floor, cross your leg to the clean side of shoe change

bench.

(6) Then put on

another clean shoe cover

over the other foot.

(7) Without

touching the dirty side of

the floor, cross your second leg to clean side of the

shoe change.

(8) Before

entering the clean area

disinfect the hands with

disinfectant.

(1) Exit to the low hygiene side of

the shoe change area with shoe

covers still on your shoes.

(2) Remove the shoe covers

from both your feet after

moving to the basic hygiene

side of the shoe change.

(3) Place the used shoe covers in the designated

GREY container.

(4) Ensure that the Grey container

is properly closed before leaving the shoe change

area.

7

COLOR DEFINITION OF HYGIENE ZONES

High Hygiene Area

Medium Hygiene Area

Basic (Low) Hygiene Area

CLEANING TOOLS COLOUR CODING BASED ON NEED AND ZONES

HIGH HYGIENE AREA RED Inside processing area: where product

is in contact with equipment

GREEN Outside the processing area

YELLOW Floor

MEDIUM HYGIENE AREA BASIC HYGIENE AREA WHITE Inside processing area: where product

is in contact with equipment

GREY Outside the processing area

BLUE Floor

&

8

MANUAL CLEANING

Manual Cleaning routines are designed according to the equipment.

Avoid use of jets to ensure proper manual cleaning.

Manual wet cleaning routine should follow the below mentioned steps:

o Use normal water to remove large food residues and soil particles

o Apply detergent with friction / brushing to clean

o Rinse

o Disinfect

o Rinse

o Dry if possible

Workbench / floor where manual cleaning to be performed must be clean prior to

equipment.

Clean the floor again after the equipment cleaning.

Visual inspection after thorough cleaning must be done.

Drains must be regularly cleaned and disinfected.

Do not allow stagnant water or wet floors after washing.

Make sure the drain covers are properly placed before and after cleaning.

Always take guidance and respect the rules of cleaning based on the specific area.

Keep the cleaning tools properly at their designated places.

Do not let water run to waste without need.

Drain & roll the cleaning hose back on its hanger after use.

Before using chemicals ensure proper safety / personal protective equipment is

worn.

9

GENERAL POOR PERSONNEL PRACTICES

Ignoring / hiding poor personal health conditions.

Spitting on the floor.

Picking nose, ear and teeth.

Sneezing on the line.

Leaving change (locker) rooms in untidy condition.

Untidy or unhygienic washrooms.

Untidy personal hygiene and uniform.

Smoking in toilets.

Combing hair in the plant.

Eating food in processing area.

Eating chewing gum in the plant and process areas.

Poor housekeeping and littering.

Sitting or lying, putting soiled feet, tools and / or materials on process equipments

and / or job floors.

Uncovered wounds.

Ignoring personal safety on line and in processing area.

Working without personal protective equipment.

Ignoring minor leaks of steam, water or air without notice.

10

11