HACCP_lengkap

HACCP isPreventive, not reactiveA management tool used to protect the food supply against biological, chemical and physical hazardsPioneered in the 1960sFirst used when foods were developed for the space programAdopted by many food processors and the U.S. governmentOrigins of HACCP

HACCPHACCP is not a zero-risk system.It is designed to minimize the risk of food safety hazards.The HACCP approach be adopted by all regulatory agencies and that it be mandatory for food processors.1985 National Academy of SciencesRecommendation:National Academy of Sciences recommendation led to formation of the National Advisory Committee on Microbiological Criteria for Foods (NACMCF).

HACCP InspectionsHACCP inspections complement traditional inspection methodsHACCP:Emphasizes process controlConcentrates on the points in the process that are critical to the safety of the productStresses communication between the regulator and industryTraditional Inspection Methods for Food-Safety ControlversusThe HACCP Approach

HazardsIn HACCP, hazards refer to conditions or contaminants in foods that can cause illness or injury. It does not refer to undesirable conditions or contaminants such as:InsectsHairFilthSpoilageEconomic fraud andViolations of regulatory food standards not directly related to safetyA biological, chemical or physical agent that is reasonably likely to cause illness or injury in the absence of its control

Many pathogenic microorganisms reproduce by dividing in two

When they grow, microorganisms produce by-productsYeast - bread, beverages, fruitLactic acid bacteria - yogurt, cheese, meatsStaphylococcus aureus - enterotoxinMost spoiled foods do not present a health risk, and not all food that appears normal is safe to consumeFood spoilage or decomposition that can result in a food safety problem should be prevented or controlled by a HACCP program

Bacterial HazardsFood infection and food intoxicationSporeforming and nonsporeforming bacteriaSporeforming Bacteria (Pathogens)Clostridium botulinumProteolyticNonproteolyticClostridium perfringensBacillus cereus

Nonsporeforming BacteriaBrucella abortis, B. suisCampylobacter spp.Pathogenic Escherichia coli (e.g., E. coli O157:H7)Listeria monocytogenesSalmonella spp. (e.g., S. typhimurium, S. enteriditis)Shigella spp. (e.g., S. dysinteriae)Pathogenic Staphylococcus aureus (e.g., coagulase positive S. aureus)Streptococcus pyogenesVibrio spp. (e.g., V. cholerae, V. parahaemolyticus, V. vulnificus,)Yersinia enterocolitica

Viral HazardsVery small particles that cannot be seen with a light microscopeDo not need food, water or air to surviveDo not cause spoilageInfect living cells and are species specificReproduce inside the host cellSurvive in human intestines, water or food for monthsTransmission usually by fecal-oral route and related to poor personnel hygiene

Parasites in FoodsParasites are organisms that need a host to surviveThousands of kinds exist worldwide, but only about 100 types are known to infect people through food contaminationTwo types of concern from food or water:Parasitic worms [e.g., roundworms (nematodes), tapeworms (cestodes), flukes (trematodes)]ProtozoaRole of fecal material in transmission of parasites

Parasitic Protozoa and WormsRoundworms (nematodes)Anisakis simplexAscaris lumbricoides Pseudoterranova dicepiensTrichinella spiralis Tapeworms (cestodes)Diphyllobothrium latumTaenia solium, T. saginataFlukes (trematodes)ProtozoaCryptosporidium parvumEntamoeba histolytica Giardia lamblia

Chemical HazardsNaturally OccurringIntentionally addedUnintentionally addedMycotoxins (e.g., aflatoxin)ScombrotoxinCiguatoxinShellfish toxinsParalytic shellfish poisoning (PSP)Diarrhetic shellfish poisoning (DSP)Neurotoxic shellfish poisoning (NSP)Amnesic shellfish poisoning (ASP)/Domoic AcidTypes of Naturally Occurring Chemical Hazards

Unintentionally or Incidentally Added ChemicalsAgricultural chemicals e.g., pesticides, fungicides, herbicides, fertilizers, antibiotics and growth hormonesProhibited substances (21 CFR, Part 21.189)Toxic elements and compounds e.g., lead, zinc, arsenic, mercury, cyanideSecondary direct and indirecte.g., lubricants, cleaning compounds, sanitizers, paint

Intentionally Added Chemicals - Food AdditivesDirect (allowable limits under GMPs)Preservatives (e.g., nitrite and sulfiting agents)Nutritional additives (e.g., niacin, vitamin A)Color additives (e.g., FD&C Yellow No. 5)Intentionally additive in Meat and Poultry Nitrate agents (red meat)Growth hormones (livestock)Growth promoting drugs (poultry)Unintentionally addedAflatoxins, pesticides (feed)Cleaners, sanitizing agents (meat and poultry)

Control of Chemical Hazards Approved and legal chemicals (cleaners, sanitizers, hormones, pesticides) Use a safe levelLetters of guarantee and vendor certificationProper procedures and rinsing (cleaners and sanitizers)Storage of feed (aflatoxin)Storage and labeling for ingredients and raw materials

Physical HazardsPhysical hazard: a hard foreign object that can cause illness or injury

Inherent to the food or ingredientContaminant during processing

Examples of Physical HazardsIn the food or ingredientsBone fragments (ground beef)Feathers from animal carcass (turkey)

Contamination during processingStones, rocks, dirt in vegetablesMetal from processing equipment (ground beef)Jewelry, fingernails (food handler)

Control of Physical HazardsSeparate and remove physical objectsFilter or sieve (meat grinder)Water bath (vegetables)Metal detector (all foods)Good employee practices (jewelry)Good sanitation and quality control programs

Procedures, including GMPs, that address operational conditions providing the foundation for the HACCP systemHACCP System

Good Manufacturing PracticesGMPs are minimum sanitary and processing requirements necessary to ensure the production of wholesome food.

Prescribed requirements forpersonnelbuilding and facilitiesequipment and utensilsproduction and process controls

GMPs: PersonnelKnowing how and when to wash handsUnderstanding the importance of clean uniformsProper use of hair and beard netsPolicy on jewelry Policy on chewing tobacco, smoking, and eating

GMPs: Building and FacilitiesHandwashing stationsStorage of ingredients (refrigerated and on pallets) Separation of raw ingredients from processed foodsPest management program

GMPs: Equipment and UtensilsEasily cleaned and sanitizedEasily maintainedMeet food grade standards

GMPs: Production and Process ControlsTime/temperature control chartsRecords on food ingredientsLot identification and codingProduct weight controls

Good Manufacturing Practices

Examples OfGMPs

Why is this Important?

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Standard Operating ProceduresStandard Operating Procedures (SOPs) are established or prescribed methods to be followed routinely for the performance of designated operations or in designated situations.

Standard Operating ProceduresSOPs relate to specific tasks and should address the following:the purpose and frequency of doing a taskwho will do the taska description of the procedure to be performed that includes all the steps involved the corrective actions to be taken if the task is performed incorrectly

Eight Key Sanitation Conditions and Practices:Safety of waterCondition and cleanliness of food-contact surfacesPrevention of cross-contaminationMaintenance of hand-washing, hand-sanitizing and toilet facilitiesProtection from adulterantsLabeling, storage and use of toxic compoundsEmployee health conditionsExclusion of pests

Standard Operating Procedures

Examples OfSOPs

Sanitation SOPsSanitation Standard Operating Procedures (SSOPs) are prescribed methods specifically for cleaning and sanitizing.

Sanitation SOPs

Examples OfSanitationSOPs

Cleaning and SanitizingCleaning and sanitation programs are keys to successful GMPs and SSOPs.

Cleaning Cleaning is the chemical or physical process of removing dirt or soil from surfaces.

Cleaning removes 90-99% of the bacteria, but thousands of bacteria may still be present.

SanitizingSanitizing is the process that results in reduction/destruction of microbes.

Different sanitizers will be used for different food products. Chlorine, iodophors, and quaternary ammonia compounds are the most common sanitizers used.

Sanitation ProgramsBuildings and groundsRaw material handling and storageProcessing hygiene and handling finished goodsPest controlWaste disposalEmployee hygiene and facilitiesFinished product storageTransportation

Why is this Important?

Prerequisite Programs and Preliminary Steps Procedures, including GMPs, that address operational conditions providing the foundation for the HACCP system

Examples of Common Prerequisite ProgramsFacilitiesProduction equipmentStandard operating proceduresSupplier controlsProduction specificationPersonnel policiesTraceability and recalls

Preliminary StepsHACCP team assemblyDescription, food and distributionIdentify intended use and consumers of foodDevelop flow diagramVerify flow diagram

HACCP PrinciplesConduct a hazard analysisDetermine the Critical Control PointEstablish critical limitEstablish CCP monitoring procedureEstablish corrective actionEstablish verification procedureEstablish record-keeping and documentation procedure

Hazard AnalysisConduct a hazard analysis Likelihood of occurrence Severity

Principle 1

Considerations for the HACCP Team Safety concerns must be differentiated from quality concerns.Hazard AnalysisHazard identificationHazard evaluation

Hazard IdentificationList potential hazards at each operational step in the process from receipt of raw materials through release of the finished productAll potentially significant hazards must be considered

Hazards ListBiological HazardsPathogenic microorganisms (e.g., bacteria, viruses)ParasitesChemical HazardsNatural toxinsChemicalsPesticidesDrug residuesUnapproved food and color additivesDecomposition (safety only, e.g., histamine)Physical HazardsMetal, glass, etc.

Hazard AnalysisA hazard must be controlled if it is:Reasonably likely to occur, andLikely to result in an unacceptable risk to consumersHazard-Analysis WorksheetColumn 1. Processing stepColumn 2. Results of hazard identificationColumn 3. Results of hazard evaluationColumn 4. Justification for accepting or rejecting the potential hazard

Control MeasuresActions and activities that can be used to prevent or eliminate a food safety hazard or reduce it to an acceptable levelTime/temperature controlHeating and cooking processesCooling and freezingFermentation and/or pH controlAddition of salt or other preservativesDryingSource controlControl Measures: Bacterial Hazards

Control Measures: Viral HazardsCooking processesControl Measures: Parasite HazardsDietary controlInactivationHeating Drying FreezingRemoval

Control Measures: Chemical HazardsSource controlProduction controlLabeling controlControl Measures: Physical HazardsSource controlProduction control

Determine theCritical Control PointsPrinciple 2

Critical Control PointA point, step or procedure at which control can be applied and is essential to prevent or eliminate a food-safety hazard or reduce it to an acceptable level

Points may be identified as CCPs when hazards can be preventedIn some products and processes, the following may be true:Introduction of pathogens or drug residue can be prevented by control at the receiving step (e.g., supplier declaration)A chemical hazard can be prevented by control at the formulation or ingredient-addition stepPathogen growth in the finished product can be prevented by control at the formulation or ingredient-addition step (e.g., pH adjustment or addition of preservatives)Pathogen growth can be controlled by refrigerated storage or chilling

Points may be identified as CCPs when hazards can be eliminatedIn some products and processes, the following may be true:Pathogens can be killed during cookingMetal fragments can be detected by a metal detector and eliminated by removing the contaminated product from the processing lineParasites can be killed by freezing (e.g., Anisakis in fish destined for raw consumption)

Points may be identified as CCPs when hazards are reduced to acceptable levelsIn some products and processes, the following may be true:The occurrence of foreign objects can be minimized by manual sorting and automatic collectorsSome biological and chemical hazards can be minimized by obtaining shellfish from approved waters

CCPs vs. Control PointsControl PointsPoints where quality factors can be controlledPoints where non-HACCP regulatory requirements can be controlledCCPsPoints where food-safety hazards can be controlled

Multiple CCPs and HazardsA CCP can be used to control more than one hazardA refrigerated storage CCP may control pathogen growth and histamine formationMore than one CCP may be needed to control a hazardThe cook step and patty-forming step are CCPs in controlling pathogens in cooked hamburger patties

CCPs are Product- and Process- SpecificThey may change with differences in:Plant layoutFormulationProcess flowEquipmentIngredient selectionSanitation and support programs

CCP Decision TreeQ1: Does a control measure(s) exist at this step or subsequent steps in the process flow for the identified hazard?

Q2: Does this step eliminate or reduce the likely occurrence of a significant hazard to an acceptable level?

Q3: Could contamination with an identified hazard or hazards occur in excess of acceptable levels, or could these increase to unacceptable levels?

Q4: Will a subsequent step eliminate the identified hazard(s) or reduce the likely occurrence to an acceptable level?

CCP Decision Tree Table for IQF Cooked ShrimpProcess Step/HazardQ1Q2Q3Q4CCPReceiving fresh shrimpBacterial pathogensYesNoYesYesNoSulfiting agent YesNoYesYesNoReceiving frozen shrimpBacterial pathogensYesNoYesYesNoSulfiting agentYesNoYesYesNoThawingBacterial pathogensYesNoYesYesNo

CCP Decision Tree Table for IQF Cooked ShrimpProcess Step/HazardQ1Q2Q3Q4CCPCold storageBacterial pathogensYesNoYesYesNoCookerPathogen survivalYesYes--YesWeigh/Pack/LabelSulfiting agent YesYes--Yes

Establish Critical LimitsPrinciple 3

Critical LimitA maximum and/or minimum value to which a biological, chemical or physical parameter must be controlled at a CCP to prevent, eliminate or reduce to an acceptable level the occurrence of a food-safety hazard

Examples of Critical LimitsHazardCCPCritical Limitbacterialpasteurizer161oF for 15pathogens seconds(biological)for elimination ofpathogens from milk

Examples of Critical LimitsHazardCCPCritical Limitbacterialdryingdrying schedule:pathogensovenoven temperature: 200oF(biological)drying time: 120 min.air flow rate: 2 ft3/min.product thickness: 0.5 inches(to achieve aw 0.85 to controlpathogens in dried foods)

Examples of Critical LimitsHazardCCPCritical LimitbacterialacidificationBatch schedule:pathogensproduct weight: 100 lbs.(biological)soak time: 8 hoursacetic acid concentration: 3.5% volume: 50 gallons(to achieve maximum pH of 4.6 to control Clostridium botulinum in pickled foods)

Sources of Information on Critical LimitsGeneral SourceExamplesscientific publicationsjournal articles, food science texts, microbiology textsregulatory guidelinesstate and local guidelines, tolerances and action levels; USDA guidelines, tolerances and action levels; FDA guidelines, tolerances and action levels

Sources of Information on Critical LimitsGeneral SourceExamplesexpertsNACMCF (National Advisory Committee on Microbiological Criteria for Foods), thermal process authorities; consultants, food scientists/ microbiologists, equipment manufacturers, sanitarians, university extension, trade associationsexperimental studies In-house experiments; contract labs

Options for Controlling HazardsOften a variety of options exist for controlling a particular hazardThe selection of the best control option and critical limit is often driven by practicality and experience

Monitoring for Pathogens at a Cook StepOption No. 1: Monitoring for PathogensHazardpresence of pathogens (microbiological)CCPfryerCritical Limitno pathogens detected

Monitoring for Pathogens at a Cook Step Option No. 2: Monitoring Internal TemperatureHazardpresence of pathogens (microbiological)CCPfryerCritical Limitminimum internal temperature of 150oF for 1 minute

Monitoring for Pathogens at a Cook Step Option No. 3: Monitoring Factors That Affect Internal Temp.Hazardpresence of pathogens (microbiological)CCPfryerCritical Limitsminimum fryer oil temperature of 350oFmaximum patty thickness of 1/4 inchminimum cook time in the oil of 1 minute

Operating LimitsCriteria that are more stringent than critical limits and that are used by an operator to reduce the risk of a deviationOperating limits may be selected for various reasons:For quality reasonsTo avoid exceeding a critical limitTo account for normal variabilityAn action taken by the firm to bring the process back within operating limitsProcess Adjustment

Operating Limit/Process Adjustment ExampleCooker TemperatureCorrective ActionRequiredLot 1Process Adjustment NeededOperating LimitCritical LimitLot 2Lot 3Lot 4Lot 5Degrees F

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Establishment of Critical LimitsCritical Control PointCritical LimitsCCP CookerCook at 212oF for 3 minutesCCP - Weigh/Pack/LabelAll product containing sulfiting agent must declare presence

HACCP Plan Form: Critical Limits

1.CCP2.Hazard3.CriticalLimits

What How Frequency WhoMonitoring4.5.6.9.Verification8.CorrectiveAction(s)10.Records7.

Principle 4Establish CCP monitoring procedures

Purpose of MonitoringTo track the operation of the process and enable the identification of trends toward a critical limit that may trigger process adjustmentsTo identify when there is loss of control (a deviation occurs at a CCP), and To provide written documentation of the process control systemTo conduct a planned sequence of observations or measurements to assess whether a CCP is under control and to produce an accurate record for future use in verificationMonitoring

HACCP Plan Form: Monitoring



MonitoringWhat: Usually a measurement or observation to assess if the CCP is operating within the critical limitHow: Usually physical or chemical measurements (for quantitative critical limits) or observations (for qualitative critical limits). Needs to be real-time and accurate.When (frequency): Can be continuous or intermittentWho: Someone trained to perform the specific monitoring activity

What will be Monitored?Measuring a characteristic of a product or process to determine compliance with a critical limitCold-storage temperaturepH of an acidifying ingredientLine speed

What will be Monitored?Observing if a preventive measure at a CCP is being performedChecking a vendors certificateChecking shellfish tags for harvest area

How Critical Limits and Preventive Measures will be MonitoredMust provide rapid resultsMicrobiological testing is seldom effectivePhysical and chemical measurements are preferred monitoring methodsTime and temperatureWater activityAcidity (pH)Sensory examination

How Critical Limits and Preventive Measures will be MonitoredExamples of monitoring equipmentThermometersClockspH metersWater activity metersChemical analytical equipment

Continuous MonitoringContinuous monitoring is preferredContinuous monitoring procedures:Temperature recording chartMetal detectorDud detectorContinuous records need to be observed periodicallyMonitoring FrequencyContinuousNoncontinuous

Noncontinuous MonitoringNoncontinuous monitoring must be used when continuous monitoring is not possibleFrequency of noncontinuous monitoringHow much does the process normally vary?How close are normal values to the critical limit?How much product is the processor prepared to risk if the critical limit is exceeded?

Noncontinuous MonitoringExamples of noncontinuous monitoring:Temperature checks of batter on a breading line at specified intervalsRoutine, daily checks for properly iced fishPeriodic sensory examination for decomposition in histamine-forming seafood

Who will Monitor?Monitors can be:Line personnelEquipment operatorsSupervisorsMaintenance personnelQuality-assurance personnel

Who will Monitor?Those responsible for monitoring should:Be trained in CCP monitoring techniquesFully understand the importance of CCP monitoringHave ready access to the monitoring activityAccurately report each monitoring activityImmediately report critical limit infractions so that immediate corrective actions can be taken

Principle 5Establish corrective actions

Corrective Action Options Include:Isolating and holding product for safety evaluationDiverting the affected product or ingredients to another line where deviation would not be considered criticalReprocessingDestroying productCorrective ActionProcedures to be followed when a deviation occurs

Corrective Action ComponentsTo correct and eliminate the cause of the deviation and restore process controlBring CCP back under controlDetermine cause of deviation to prevent future recurrenceTo identify the product that was produced during the process deviation and determine its disposition

Product Disposition Step 1: Determine if the product presents a safety hazard based on expert evaluation or on physical, chemical or microbiological testingStep 2: If no hazard exists based on the evaluations in Step 1, the product may be releasedStep 3: If a potential hazard exists (based on the evaluations in Step 1), determine if the product can be reworked/reprocessed, or diverted for a safe useStep 4: If potentially hazardous product cannot be handled as described in Step 3, the product must be destroyed. This is usually the most expensive option and is usually regarded as the last resort

Corrective Actions: ExampleDeviationTemperature of milk at pasteurizer drops below critical limitCorrective ActionMilk flow is diverted until temperature recovers. Diverted product is repasteurized. Check the operation of the heating/cooling units to determine the reason for the temperature deviation that caused the flow diversion. Repair if necessary, re-establish control and resume production

Corrective Actions: ExampleDeviationProduct (e.g., hot-smoked fish) does not reach required internal temperature for the required timeCorrective ActionRecook or destroy product

Corrective Actions: ExampleCorrective ActionDeviationMahi-mahi held at elevated temperature for excess time period (temperature limit exceeded, possible elevated histamine level).Bury product in ice, place on hold and conduct sensory analysis and histamine test. Determine the reason for the process delay. Prevent further occurrences.

HACCP Plan Form: Corrective Actions



Principle 6Establish verification procedures

VerificationThose activities, other than monitoring, that determine the validity of the HACCP plan and that verify the system is operating according to the plan

Trust What You VerifyVerification provides a level of confidence that the HACCP plan:is based on solid scientific principles, is adequate to control the hazards associated with the product and process, andis being followed

Elements of VerificationValidationCCP verification activitiesCalibration of monitoring devicesCalibration record reviewTargeted sampling and testingCCP record reviewHACCP system verificationObservations and reviewsMicrobiological end-product testingRegulatory agencies

ValidationThe element of verification focused on collecting and evaluating scientific and technical information to determine if the HACCP plan, when properly implemented, will effectively control the hazards

Validation FrequencyInitiallyWhen factors warrant, e.g.,Changes in raw materialsChanges in product or processAdverse review findingsRecurring deviationsNew information on hazards or control measuresOn-line observationsNew distribution or consumer handling practices

Examples of Validation Activities:Cooked hamburgersCollect data to establish that critical limits for maximum patty thickness, maximum belt speed, and minimum oven temperature will ensure that the internal temperature of every patty reaches the minimum requirementCooked shrimpVerify that the internal temperature of the shrimp reaches the required temperature for the required timeValidate that adequate temperatures are delivered throughout the cooker during processing

Examples of Calibration ActivitiesA MIG thermometer used to monitor temperature at a cook CCP may be checked for accuracy by comparing it against a certified thermometer in a hot-water bathThe continuous temperature chart recorder on a pasteurizer may be compared during each batch against a certified accurate thermometerA pH meter is calibrated against pH buffer standards of 7.0 and 4.0 when it is used to test products with a final pH of 3.8 to 4.2

Verification Activities of the HACCP SystemCheck the accuracy of the product description and flow chartCheck that CCPs are monitored as required by the HACCP planCheck that processes are operating within established critical limitsCheck that records are completed accurately and at the time intervals required

HACCP Plan Form: Verification



Principle 7Establish record-keeping and documentation procedures

Four Kinds of HACCP Records1. HACCP plan and support documentation used in developing the plan2. Records of CCP monitoring3. Records of corrective action4. Records of verification activities

HACCP Plan Form: Records



************Chemicals that are added to a food intentionally (ingredient) or non-intentionally (cleaner and sanitizer residues) must be: Approved, legal and safe for use in foods Used at safe levels

A food company will often require letters of guarantee or vender certification to help control the quality of incoming raw materials.

Cleaner and sanitizer residuals are controlled though proper sanitation procedures and good rinsing.

Non-food products should be stored separately from food products. Food ingredients should be stored in a cool, dry place in a sealed container. This helps to prevent growth of molds that can produce aflatoxins.

A physical hazard is a hard foreign object (bone, metal, glass) that can be harmful to a persons health. Physical objects can cause illness, induce choking, break teeth, damage the digestive tract, etc.

Physical hazards can be part of the food or added as a food ingredient. Just like chemical hazards, there is an acceptable limit (size) for a physical object.

Physical hazards can also be introduced during harvesting, distribution, and processing.Many types of physical hazards can be present in foods.

Physical hazards that are associated with the food include bone fragments or feathers from animal products.

Stones, rocks and dirt are commonly found in foods that are grown close to the soil like fruits and vegetables.

Metal is a common physical hazard that can be introduced during processing in cutting, slicing, or grinding operations.

Physical hazards can be introduced from anything that comes in contact with the food. Physical hazards can come from the person that handles the food. Jewelry and fingernails are common physical hazards that may be present due to poor food handling.The key to controlling physical hazards is to be able to find them if they are present and remove them. Physical objects are best removed by some kind of separation technique. Separation can be done in many ways: A filter or sieve can be used to remove physical objects such as in a meat grinder. The sieve plate allows small particles to pass and removes larger objects. A water bath can be used to remove debris such as rocks, stones, and dirt from fruits and vegetables. Heavy objects like stones and rocks fall to the bottom of the bath where they can be removed. When metal is a concern, a metal detector can be used. A metal detector can identify a food that contains a metal object so that food can be examined more closely.Good food handler training is needed since the food handler is an important source of physical hazards. Food handlers should be aware of the physical hazards that could be on their clothing or hands (such as jewelry and fake fingernails) and other items that could end up in food.A good sanitation program includes good procedure for cleaning and sanitizing equipment. Good sanitation also helps to reduce the possibility of physical hazards in the food.*Good manufacturing practices are required by law for all food manufacturing companies. Information on GMPs is contained in section 21 of CFR, part 110.

GMPs are requirements that must be performed during processing to ensure production of safe and wholesome food of high quality.

GMPs are prescribed for 4 main areas of food processing personnel building and facilities equipment and utensils production and process controls

GMPs are the foundation and prerequisites for all food safety and food quality programs.There are many examples of GMPs that are important in the food processing plant that you work in. Some examples are procedures for handwashing, clean uniforms, policies regarding smoking and eating, proper use of hair nets, and policy on wearing jewelry.

There are specific procedures in place for GMPs and personnel. It is important that procedures are followed to prevent the food from becoming contaminated and to ensure that the food processing plant is maintained in a sanitary condition.The food processing building also needs to meet certain requirements before food can be processed. For example, handwashing stations must be provided for all food workers. There should also be storage facilities that permit separation of raw food ingredients and processed foods. A good Pest Management Program ensures that pests (like rats and mice) are kept out of the food processing plant. Pests can be a significant source of food contamination.Equipment and utensils are also covered under GMP policies. Equipment and utensils should be approved for use in food processing environments and should be easily cleaned, sanitized, and maintained.Production and processing controls are important for all food safety and food quality programs. Keeping food records of time/temperature will help to ensure a high quality, safe product. Records should be kept when all raw ingredients are received. You also need to have a method of tracking your product. Lot identification and product coding can be used to identify when and where the product was produced.Present examples of procedures for GMPs in your food processing plant.Handwashing is important because it helps to prevent contamination of foods that are handled by human hands. Think of all the places a hand is during the course of a day: it takes out the trash, covers a sneeze, and wipes hair from the face. Employees need to know when and how their hands should be washed.

Review handwashing policies in your plant.Hair nets are important for two reasons. They help keep hair out of food and help keep human hands away from hair. Both help to reduce the chance of food contamination.

Review your policies on use of hair and beard nets.The human mouth is a great place for bacteria to hide. Since hands may be contaminated, instruct employees to wash their hands before continuing work.

The employee is touching his mouth during smoking. Since the human mouth is a great place for bacteria to hide, instruct the employee to wash their hands before continuing work.

Review your policies on smoking and eating.

Jewelry should be limited to a plain wedding band. Jewelry can be a physical hazard and can be heavily contaminated with bacteria. Wearing jewelry can also be dangerous to the employee. For example, a necklace could get caught in a mixing machine and cause harm to the operator.

Standard Operating Procedures (SOPs) are established or prescribed methods to be followed routinely for the performance of designated operations or in designated situations.

SOPs are simply a set of step-by-step directions for doing a job correctly.

Have you ever seen SOPs written for your plant?SOPs are specific step-by-step directions that need to answer five main questions: What is the purpose of doing the task? How often should the task be done? Who is responsible for doing the task? What are the specific steps needed to get the job done correctly? What should be done if the task is not done correctly?

Present examples of procedures for SOPs in your food processing plant.

These are the step-by-step directions to be followed to do the job properly.There are specific types of SOPs called Sanitation Standard Operating Procedures, or SSOPs.

SSOPs are specific step-by-step procedures needed for processes related to sanitation.

Have you ever seen SSOPs written for your plant?Present examples of procedures for SSOPs in your food processing plant.Cleaning and sanitizing are part of food plant sanitation programs that are included in GMPs.

Cleaning and sanitizing are mainly done for food contact surfaces (equipment) and for the areas of the food processing facility.

A good cleaning and sanitizing program can greatly improve the safety and quality of food.

The specific processes for cleaning and sanitizing may be contained in SSOPs.

Cleaning and sanitizing are very different processes. BOTH need to be done correctly to expect the safest and highest quality products.Cleaning is the first step in the process. Cleaning removes the visible dirt and most of the bacteria that may be present on the surface.After a surface has been properly cleaned, it is ready to be sanitized.

Sanitizing is the step that destroys many of the remaining bacteria still present on a surface after cleaning.Good cleaning and sanitizing programs are important in all areas of food receiving, production, storage, and transportation. Good sanitation programs must be established for: Buildings and grounds Raw material handling and storage Processing hygiene and finished product handling Pest control Waste disposal Employee hygiene and facilities Finished product storage TransportationCleaning is important because it removes the visible dirt.

Sanitizing is important because it destroys microorganisms left on a properly cleaned surface.

A foot bath is used to prevent contamination from shoes or boots from one area of a food processing plant to another. A foot bath will contain a sanitizing solution that comes in contact with the shoe or boot.

Are there any foot baths in your food processing plant? Where and why?

Any kind of pest can bring harmful microorganisms with them into your plant. Rats, mice, bugs and insects should be kept out of a food processing plant. If you keep pests out, you eliminate the chance of contamination.

How do you keep pests out of your plant?

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