The document discusses good manufacturing practices (GMP) and food safety. It defines GMP as quality assurance to ensure food meets quality and safety standards required for its intended use. GMP covers all aspects of manufacturing from processes and facilities to personnel, documentation, and product tracing. Food plants must implement pest control and maintain sanitary facilities, equipment, and employee hygiene practices. Buildings should be designed for cleanability, segregation of raw and finished goods, and protection from pests. The Codex Alimentarius Commission establishes international food safety standards including GMP and Hazard Analysis and Critical Control Point programs.
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1.
2.
3. What is GMP ?
• WHO defines Good Manufacturing Practices (GMP) as
“quality assurance which ensures the quality standards
appropriate to their intended use and as required by the
marketing authorization.”
• GMP covers all aspects : defined manufacturing
process; validated critical manufacturing steps; suitable
premises, storage, transport; qualified and trained
production and quality control personnel; adequate
laboratory facilities; approved written procedures and
instructions; records to show all steps of defined
procedures have been taken; full traceability of a
product through batch records and distribution records;
and systems for recall and investigation of complaints.
4. Pest control
• Food plants must have structures to control
insects, rodents, birds, cats and other animals.
• Doors, windows and other openings must be
secured.
• Openings that are typically left open for
ventilation should be screened. Installation of air
curtains, fans and electrocutors at strategic
locations will be extremely helpful.
• Snap traps, glue boards and bait stations must
be placed around the immediate building
exterior and interior walls.
5. Building design and construction
• The ground selected should be above the road level and water
drainage system.
• The building should be a few feet above ground level for cleaning
water to flow out.
• Adequate protection should be provided against rain and dust
storms.
• Areas for incoming raw material and outgoing finished goods
should be segregated.
• Lighting and ventilation systems should be adequate for visibility
and safety.
• All entry points to the building should be secured against insects,
rodents and other animals.
• The doors, windows, walls, floors and ceilings should be made of
smooth surfaces that can be easily wiped and cleaned.
• Materials used in construction of floors and walls should be
nontoxic.
6. Sanitary, Facilities And Control
• Toilets and hand-washing facilities must be provided
inside the processing centre;
• Toilet tissue must be provided;
• Toilets must be kept sanitary and in good repair;
• Toilet rooms must have self-closing doors;
• Hand-washing facilities must provide:
o Running water at a suitable temperature;
o Effective hand-cleaning and hand-sanitizing preparations;
o Clean towel service or suitable drying devices;
o Easily cleanable waste receptacle;
o Water control valves designed and constructed to protect
against recontamination of clean, sanitized hands;
7. Equipment and Utensils
• Equipment and utensils
must be designed for
easy cleaning and
sanitation.
• Equipment and utensils
must be made from
non-corrosive materials.
9. Raw material, Ingredient and Storage
• Raw product and
finished product must be
stored in segregated
areas under conditions
that prevent
contamination and the
growth of undesirable
microorganisms.
• Product flow zones must
be protected from all
sources of
contamination.
11. Codex Alimentarius Commision
(CAC)
• Codex standard
• The reference for international food safety
requirements
- Code of practice – General Principles of
Food Hygiene
- Hazard Analysis and Critical Control Point
(HACCP)
GMP Codex (Good Manufacturing
Practice) : a pre-requisite program of
HACCP
12. CAC/RCP 1-1969, Rev.4 - 2003
I : Objective
II : Scope, Use and Definition
III : Primary Production
IV : Establishment : Design and Facilities
V : Control of Operation
VI : Establishment : Maintenance and Sanitation
VII : Establishment : Personal Hygiene
VIII: Transportation
IX : Product Information and Consumer
Awareness
X : Training
13. SECTION I - OBJECTIVE
• Identify the essential principle of food
hygiene applicable throughout the food
chain
• Recommend a HACCP-based approach
as a means to enhance food safety
• Indicate how to implement those principles
• Provide a guidance for specific codes
which may be needed for – sectors of the
food chain
14. SECTION II – SCOPE, USE AND
DEFINITION
• Scope : Food Chain, Roles of Government,
Industry and Consumer
• Use :
– Each section indicates both the objectives to be
achieved and the rationale behind those
objectives in terms of the safety and suitability of
food
– What is necessary and appropriate on the ground
of the safety and suitability of food for
consumption ?
– “Where necessary” and “where appropriate”
15. Problems in food supply chain
• Transparency and geographycal location
• Analysis and control of risk
• Co-operation/openness in supply chain
• Define, translate and control requirements
finished products throughout the chain
• Validation / control changes
• Control suppliers
16. Communication along the supply chain
Crop produsers
Feed producers
Primary food producers
Food processors
2nd food processors
Wholesalers
Retailers
Consumer
Producers of pesticides,
Fertilizers and veterinary drugs
Food chain for the production
Of ingredients and additives
Transport and storage
operators
Producers of equipment
Producers of cleaning agents
Producers of packaging
materials
Service providers
Other supplying food chain
RegulatoryAuthorities
17. SECTION III – PRIMARY
PRODUCTION
• Objectives : primary production should be
managed in a way that ensures that food is
safe and suitable for its intended use.
• Where necessary, this will include :
– Avoiding the use of areas where the environment
poces a threat to the safety of food
– Controlling contaminant, pests and diseases of
animals and plants in such a way as not to pose
a threat to food safety
– Adopting practices and measures to ensure food
is produced under appropriately hygienic
conditions
18. SECTION IV – ESTABLISHMENT :
DESIGN AND FACILITIES
• Objectives : Depending on the nature of the
operations, and the risks associated with them,
premises
• Equipment and facilities should be located,
designed and constructed to ensure that
– Contamination is minimized
– Design and layout permit appropriate maintenance,
cleaning and disinfections and minimize air-borne
contamination
– Surfaces and materials, contacted with food, are non-
toxic, suitable durable and easy to maintain and clean
19. SECTION V – CONTROL OF
OPERATION
• Objective : to produce food which is safe
and suitable for human consumption by :
– Formulating specific design requirements for
raw materials, composition, processing,
distribution and consumer
– Designing, implementing, monitoring and
reviewing effective control systems
20. SECTION VI – ESTABLISHMENT :
MAINTENANCE AND SANITATION
• Objective :
– To establish effective systems to : ensure
adequate and appropriate maintenance and
cleaning :
• Control pests
• Manage waste
• Monitor effectiveness
of maintenance and
sanitation procedures
21.
22. DEFINITION
Sanitation Standard Operating Procedures is
the common name give to the sanitation
procedures in food production plants which are
required by the Food Safety and Inspection
Service of the USDA and regulated by 9 CFR part
416 in conjunction with 21 CFR part 178.1010. It is
considered one of the prerequisite programs of
HACCP
Sanitation Standard Operating Procedures —
SSOPs — are the specific, written procedures
necessary to ensure sanitary conditions in the
food plant. They include written steps for cleaning
and sanitizing to prevent product adulteration.
23. SSOP’s can be very simple to extremely
intricate depending on the focus.
Food industry equipment should be
constructed of sanitary design; however some
automated processing equipment by necessity
is difficult to clean.
An individual SSOP should include:
1.The equipment or affected area to be cleaned,
identified by common name,
2.The tools necessary to prepare the equipment
or area to be cleaned
3.How to disassemble the area or equipment
4.The method of cleaning and sanitizing
24. Pre-operational SSOPs
• Describe the daily, routine sanitary procedures
that occur before processing begins.
• the cleaning of product contact surfaces of
facilities, equipment, and utensils to prevent direct
product contamination or adulteration.
• These might include:
1.) Descriptions of equipment disassembly,
reassembly after cleaning, use of acceptable
chemicals according to label direction, and
cleaning techniques.
2.) Application instructions, including concentrations,
for sanitizers applied to product contact surfaces
after cleaning.
25. Established procedures during operations
might include, where applicable:
1) Equipment and utensil
cleaning/sanitizing/disinfecting during
production, as appropriate, at breaks, between
shifts, and at mid-shift cleanup.
2) Procedures for employee hygiene, such as
cleanliness of outer garments and gloves, hair
restraints, handwashing, health, etc.
3) Product handling in raw and in cooked product
areas.
26. • SAFE WATER--SSOP item 1
Safety of the water that comes into contact with food or
food contact surfaces, or is used in the manufacture of
ice; Existing Conditions:
• CLEAN FOOD CONTACT SURFACES: SSOP item 2
Condition and cleanliness of food contact surfaces,
including utensils, gloves, and outer garments
• PREVENT CROSS-CONTAMINATION - SSOP item 3
Prevention of cross-contamination from insanitary
objects to food, food packaging material, and other food
contact surfaces, including utensils, gloves, and outer
garments; and from raw product to cooked product;
• EMPLOYEE HYGIENE - SSOP item 4
Maintenance of hand washing, hand sanitizing, and toilet
facilities;
27. ADULTERATION - SSOP item 5
Protection of food, food packaging material, and
food contact surfaces from adulteration with
lubricants, fuel, pesticides, cleaning compounds,
sanitizing agents, condensate, and other
chemical, physical, and biological contaminants;
TOXIC COMPOUNDS - SSOP item 6
Proper labeling, storage, and use of toxic
compounds.
EMPLOYEE HEALTH - SSOP item 7
Control of employee health conditions that could
result in the microbiological contamination of
food, food packaging materials, and food contact
surfaces.
28. The person in charge shall
demonstrate this knowledge by :
a) Complying with this Code by having no critical
violations during the current inspection;
b) Being a certified food protection manager who
has shown proficiency of required information
through passing a test that is part of an
accredited program; or
c) Responding correctly to the inspector’s
questions as they relate to the specific food
operation. The areas of knowledge include:
1) Describing the relationship between the
prevention of foodborne disease and the personal
hygiene of a food employee;
29. 2) Explaining the responsibility of the person in
charge for preventing the transmission of
foodborne disease by a food employee who has
a disease or medical condition that may cause
foodborne disease;
3) Describing the symptoms associated with the
diseases that are transmissible through food;
4) Explaining the significance of the relationship
between maintaining thetime and temperature of
potentially hazardous food and the prevention of
foodborne illness;
5) Explaining the hazards involved in the
consumption of raw or undercooked meat,
poultry, eggs and fish;
30. 6) Stating the required food temperatures and times
for safe cooking of potentially hazardous food
including meat, poultry, eggs, and fish;
7) Stating the required temperatures and times for the
safe refrigerated storage, hot holding, cooling, and
reheating of potentially hazardous food;
8) Describing the relationship between the prevention
of foodborne illness and the management and
control of the following:
a) Cross contamination,
b) Hand contact with ready-to-eat foods,
c) Handwashing, and
d)Maintaining the food establishment in a clean
condition and in good repair;
31. 10) Explaining correct procedures for
cleaning and sanitizing utensils and
food-contact surfaces of equipment;
11) Identifying the source of water used
and measures taken to ensure that it
remains protected from
contamination such as providing
protection from backflow and
precluding the creation of cross
connections;
12) Identifying poisonous or toxic
materials in the food establishment
and the procedures necessary to
ensure that they are safely stored,
dispensed, used, and disposed of
according to law;
32. Continued…
13) Identifying critical control points in the
operation from purchasing through sale or
service that when not controlled may
contribute to the transmission of foodborne
illness and explaining steps taken to ensure
that the points are controlled in accordance
with the requirements of this regulation;
14) Explaining the details of how the person in
charge and food employees comply with the
HACCP plan if a plan is required by the
law or an agreement between the regulatory
authority and the establishment;
33. SECTION VII – ESTABLISHMENT :
PERSONAL HYGIENE
• Objective : to ensure that
those who come directly or
indirectly into contact with
food are not likely to
contaminate food by :
– Maintaining an appropriate
degree of personal
cleanliness
– Behaving and operating in
an appropriate manner
34. Conditions and the
efforts necessary to
prevent food from
possible contamination
of biological, chemical
and physical objects
which can be
annoying, harmful and
dangerous to human
health.
Food Safety
35. 1. Food sanitation
2. Use of food additive
3. Genetic engineering
4. Irradiation of food
5. Food packaging
6. Quality assurance of
food
7. Food contaminated
8. Expired food
37. Prevention of contamination
1. Protection from Bacterial Contamination
Food providing from safe origin
Contaminated prevention by minimum hand
contact, food covering, raw and cooked
food separation, waste bin covering and
animal prevention
Prevention of contamination channels;
single usage of knives and spoons, contact
surface cleaning with disinfectants and
equipment separation
38. 2. Prevention of the bacterial growth
Factors on bacteia growing in food :
48. 1. Food as Vectors of Pathogens
• Food or waters may act merely as vectors of a
pathogenic species, there is no requirement for
the pathogen to grow or multiply in the food.
• Only a very small number of the pathogen cells
(<100) need to be consumed to bring about a
consumer response or reaction
• These include : typhoid (Salmonella typhi),
Dysentry (Shigella dysenteriae), Cholera (Vibrio
cholerae) and Tuberculosis (Mycobacterium)
49. 2. Food as Substrates for Pathogen Growth
• Food act as substrates for the growth and
multiplication of pathogenic species,
which, when developed high enough
numbers, cause illness on human
consumption.
• These are the classical cases of microbial
based food poisoning.
• Two sub-groupings may be recognize :
a. Consumer infection
b. Consumer intoxication
50. a. Consumer Infection
• Upon consumption the pathogenic species
concerned multiplies in the alimentary
tract thereby bringing about consumer
response or reaction.
• Consumer symptoms are generally felt
after an incubation period of 12-24 hours
• Ex : Salmonella sp, Clostridium
perfringens, Vibrio parahaemolyticus,
enteropathogenic Escherichia coli strains
and Shigella sp.
51. b. Consumer Intoxitation
• In this case it is the consumption of a toxic
product previously produced in the food by
microbial growth which brings about a
consumer response.
• Symptoms are generally felt much sooner
(3-12 hours) after food consumption.
• Ex : Staphylococcus aureus and
Clostridium botulinum
52. Causative Organisms of Food-borne Disease
1. Salmonella sp.
• Salmonella food poisoning is mainly
associated with freshly cooked meat and
poultry products which is have in some way
been undercooked and mishandled before
consumption.
• The cycle of Salmonella food poisoning
transmission may be summarised as follow :Animal Bird
Wast
e
Animal Food
Food Man
Faeces
53. 2. Clostridium perfringens
• C. perfringens occurs widely in the
environment and is perhaps the most
widely distributed of all bacterial
pathogens.
• It is natural inhabitant in the intestines of
many healthy humans, animals and birds
• Meat and poultry products are frequently
contamined with this organisms.
54. 3. Staphylococcus aureus
• S. aureus is closely associated with
humans and other animals-in particular
skin, nose cooked food product.
4. Vibrio parahaemolyticus
• They are found mostly in estuarine and
near coastal waters and therefore
naturally contamine most seafood
products
55. 5. Bacillus cereus
• Survey on the incidence of this organism
in foods show a high frequency of
incidence in dried foods, such as cereals,
spices and powdered milk.
6. Clostridium botulinum
• It occurs in soils, waters and marine
sediments an may contaminate a wide
variety of products such as fruits,
vegetables, meats, seafoods, from home
preserved food products (canned/bottled
fruits and vegetables)
56. 7. Escherichia coli
• The organism enters kitchen and food
preparation areas in many raw foodstuffs and
readily passes to cooked foods by usual means
of hands, surfaces, containers, and other
equipment
8. Shigella sp.
• Milk and oysters have been incriminated in
shigellosis outbreaks in the past, and because
are also considered of the low infective dose of
these species, contaminated water supplies are
also considered as important causes of this
disease
57. SECTION VIII -
TRANSPORTATION
• Objective : measure should be taken
where necessary to :
– Protect food from potential sources of
contamination
– Protect food from damage
– Provide an environment which effectively
controls the growth of pathogenic or spoilage
micro-organisms and the production of toxin
in food
58. SECTION IX – PRODUCT INFORMATION
AND CONSUMER AWARENESS
OBJECTIVES
• Products should bear appropriate information to
ensure that :
– Adequate and accessible information is available to the
next person in the food chain to enable them to handle,
store, process, prepare and display the product safely
and correctly
– The lot or batch can be easily identified and recalled if
necessary
• Consumers should have enough knowledge of food
hygiene to enable them to :
– Understand the importance of product information
– Make informed choices appropriate to the individual
– Prevent contamination and growth or survival of
foodborne pathogens by storing, preparing and using it
correctly
59. SECTION X - 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 the
operations they are to perform
60.
61. Food Safety
an HACCP Approach
Hazard Analysis Critical Control Point
Is a systematic approach to be used in food
production as a means to ensure food
safety.
The first step requires hazard analysis, an
assessment of risks associated with all
aspects of production from growing to
consumption.
62. Why HACCP
• Because HACCP is the
only practical approach (currently tested)
• However, HACCP is not
without risk, HACCP minimize the risk
ofharm (physical, chemical and biological)
63. How HACCP prevents contamination..??
• Identify sources
of potential contamination (proactive)
• Take action to prevent (preventive)
• Monitoring measures to ensure the
effectiveness of (effective)
• Dynamics that always follow the
development of HACCP(anticipatory)
64. HACCP refine the
traditional examination system
• HACCP system is more emphasis on the
production process
• HACCP focuses on each stage
of the critical points that affect thesafety of
products
• HACCP in the importance of
communication between the industry,betw
een industries and policy makers
65. HACCP benefits for the industry
• Security system (safety) are accepted regi
onally and internationally
• Bring more information and a better
understanding of products and processes
• Participation and a better understanding of
food safety programs(food safety)
• Reduce the level of non-conformity
As a support to the implementation
of TQM
66. A Sequence steps to implement
HACCP
Assemble the HACCP team and Training
Set-up company’s Food safety Policy
Describe the product description
Identify intended use
Construct flow diagram
On site verification of flow diagram (pre-requisite)
Follow the seventh HACCP Principles
Product identification and traceability (Recall
Product)
Establish procedure for consumer complaint
Validation for implementation
67. The Seventh Principles of HACCP
• Principle 1: Conduct a hazard analysis.
• Principle 2: Identify critical control points.
• Principle 3: Establish critical limits for each critical
control point.
• Principle 4: Establish critical control point monitoring
requirements.
• Principle 5: Establish corrective actions.
• Principle 6: Establish record keeping procedures.
• Principle 7: Establish procedures for verifying the
HACCP system is working as intended.
72. COMPREHENSIVE PRODUCT CONTROL
LOW SAFETY RISKHIGH SAFETY RISK
HACCP QC / TQC
Biological
CCP’s
Physical
CCP’s
Chemical
CCP’s
Sanitation
CP’s
GMP
CP’s
Equipment
CP’s
Product
CP’s
Regulatory
CP’s
Relationship between high risk and low
risk concerns for a food product
73. CCP and CP Decision tree
QUESTION :
IF I LOSE CONTROL, IS IT LIKELY THAT A
HEALTH RISK WILL OCCUR
CONTROL POINTCRITICAL CONTROL POINT
CCP or CP ?
NOYES
Examples :
•Pasteurization of milk
•Thermal process for canned foods
•Refrigerations of minimally processed
chilled foods
•Metal detector on ground beef line
Examples :
•Food bath in canning facility
•Hand wash station in a frozen
vegetable plant
•Chloranation of mixing kettles in a
canned food operation
•Pest control in a cheese plant
74. CCP Decision Tree
Yes
Yes
Modify step, Process
or Product
Is control at this step
necessary for safety
Q1. Do preventive measure(s) exist
or sub-sequent step for the
identified hazard ?
Q2. Does this step eliminate or
reduce the likely occurance of a
hazard to an acceptable level ?
Q3. Could the hazard increasae to an
unacceptable or could contamination
increase to unacceptable level ?
Q4. Will a subsequent step eliminate
identified hazards or reduce likely
occurrence to an acceptable level ?
Critical Control Point
Not a critical
Control Point
No
Yes
Yes
Yes
No
No
No
No
75. 3. Process Flow Charts
• Creation of accurate process flow charts is
one step in developing understanding.
• Once the chart has been developed, and
the risk assessment are completed, the
“HACCP Team” may begin to assign Critical
Control Points.
76. Canned mushroom
(production and processing)
2-M
Receiving
Grading and Weighing
Packing
Transport
Perforated Bags
And/or Plastic boxes
Collection Station
4-M
Compost
Sterilization
Mushroom Beds in Huts
Colonize Compost
Harvest Hand Operation
Spawn
(A.bisporus)
Casing Oil
1. Rice Straw 47%
2. Animal Waste 47%
3. Bean curd 2,5%
4. Urea 0,07%
5. Minerals
Heat and Chemical
Water
Control R.H
Temperature
Several flushes
Plastic pails
≥ 15 cm deep
From field
Light
Industry
1-MC
3-M
TRANSPORT
Trucks- -No Refrigerator
M =
Microbiological
C = Chemical
P = Physical
S = Sanitation
77. Continued….
Flume and Bucket Lift
Blancher Tunnel
or Screw
Cooling Canal
Sorting Belt
Sizers (18 - 40 mm)
Collection Pans
Grading Tables
Weighing
Filling (Hand Operation)
6-8’; 995 – 100 C 8-M
11-M
Slicer
Rejects
Acceptable (pans)
9-MPC (S)
10-M
Rejects
Can Washer
13-M
Can Manufacture
12-M
M =
Microbiological
C = Chemical
P = Physical
S = Sanitation
78. Continued…
Boxing
Incubation
Box Unloading
Labelling
(Hand Operation)
Casing
(Hand Operation)
Monitor for Swells
22-M
Fiber
Drying
Rejects, Test to Determine
Cause for Rejection
Dud Detection Tap Tone
23-M
New Fiber
Cude Cases with Can Code,
Swells/Low Vacs
(Rejects)
Retort Loading
Retorting
Cooling
Basket Unloading
0,5 ppm Discharge
19-M
Monitor & Control Critical Factors
(IT Fill, Process Time & Temp.
Vent Schedule
Chlorinated Water
20-M
Handle to Prevent Abuse
20-M
M =
Microbiological
C = Chemical
P = Physical
S = Sanitation
79. THE HAZARD ANALYSIS PROCESS
The hazard analysis process consists of asking a series
of questions at each operational step in the processing of
the product as it flows through the plant.
The analysis examines the effect of a variety of factors
upon the safety of the food. Sample questions are given
below.
1. INGREDIENTS
• Do the produce contain any sensitive ingredients that are
likely to present microbiological hazards
• What is the normal microbial content of the food stored
under proper conditions?
• Does the microbial population change while the food I
stored before consumption?
• Does that change in microbial population alter the safety of
the food?
80. 2. FACILITY DESIGN
Does the layout of the facility provide an adequate
separation of raw materials from ready-to-eat foods?
Is positive air pressure maintained in product packaging
areas? Is this essential for product safety?
Is the traffic pattern for people and moving equipment a
potentially significant source of contamination?
3. EQUIPMENT DESIGN
Will the equipment provide the time and temperature
control that is necessary for safe food?
Is the equipment properly sized for the volume of produce
that will be package?
Can the equipment be sufficiently controlled so that the
variation in performance will be within the tolerances
required to produce a safe food?
Is the equipment reliable or is it prone to frequent
breakdowns?
81. Is the equipment designed so that it can be cleaned and
sanitized?
Is there a chance for product contamination with hazardous
substances?
What product safety devices, such as time and temperature
integrators, are used to enhance consumer safety?
3. PACKAGING
Does the method of packaging affect the multiplication of
microbial pathogens and/or the formation of toxins?
Is the packaging material resistant to damage, thereby preventing
the entrance of microbial contamination?
Is the package clearly labeled “Keep Refrigerated” if this is
required for safety?
Does the package include instructions for the safe handling and
preparation of the food by the consumer?
Are tamper-evident packaging features used?
Is each package legibly and accurately coded to indicate
production lot?
Does each package contain the proper label?
85. Application of HACCP
• Participant should be divided into 5 group
consisting for 4 people
• Each group choose 1 of the following
comodities and processing (strelization,
drying, fermentation)
d. Corn
e. Citrus
f. Soy bean
a. Cassava
b. Banana
c. Mango
Discussfully the HACCP process and
determine the Critical Operation (CP),
Potetial Risk (PR), Control Point (CP) and
Critical Control Point (CCP)