3rd party Training Material.pptx

Basic cGMP and
HACCP Prerequisites Programs

ISO 22000:2005
FOOD SAFETY MANAGEMENT
SYSTEM
specifies requirements for a food safety
management system where an organization in the
food chain needs to demonstrate its ability to
control food safety hazards in order to ensure that
food is safe at the time of human consumption.

HACCP: HAZARD ANALYSIS and
CRITICAL CONTROL POINTS
systematic preventive approach to food
safety that identifies physical, chemical, and
biological hazards in production processes
that can cause the finished product to be
unsafe, and designs measurements to reduce
these risks to a safe level.

cGMP: current GOOD
MANUFACTURING PRACTICES
Procedures that must be implemented to
prevent food adulteration caused by food
hazards, contaminants, or unsanitary
conditions

 Prevent injury to consumers
 Prevent adverse and negative publicity and
product recall
 Ensure continued patronage
 Ensure brand loyalty and company
profitability
 Provide continuing advantage on brand image
 Reduce costly rework
 Avoid costly litigation and public backlash
 Ensure our job security
Why Food Safety?

Food Process Distribution
Chain
Receiving/
Storage
Farm/
Ingredient
supplier
Transport Process
Storage/
Distribution
Supermarket
Home

FOOD SAFETY HAZARDS
A biological, chemical or physical agent in, or
condition of, food with the potential to cause
an adverse health effect.

 Biological
 Chemical
 Physical
Categories of Foodborne
Hazards

 Intoxication or poisoning due to chemical
contamination of food
 Poisoning depends on the type of poison,
person, dose, and the effect on the person
 Poisons effects may be
 Acute effect (vomiting, gastroenteritis,
etc.)
 Chronic, long term effect (cancer,
muscle dystrophy, etc.)
Chemical Hazards

 Unintentionally/incidentally
added substances
 Naturally occurring substances
 Intentionally added substances
Categories of Chemical
Hazards

Unintentional/ Incidental
Chemical Hazards
Pesticide residues
Agricultural chemicals
Cleaning agents
Industrial by-products
Antibiotics (animals)
Metal or equipment residues

Naturally Occurring
Chemical Hazards
Toxic plant species
 Mushrooms
 Certain species contains neurotoxins that can hardly
be differentiated from non-toxin species
 Cassava
 Contains amino acid-derived cyanogenic glucosides,
some more than others, and must be thoroughly
cooked to remove toxic levels.
 Eaten raw, the human digestive system will convert
part of it into cyanide. Two cassava roots contain
enough to be fatal.
 Aflatoxins from molds

Naturally Occurring
Chemical Hazards
Toxic animal
 Sea food red tide algae
 Diarrheic or neurotoxins produced by
accumulated poisonous algae in
shellfish and mollusks
 Scombrotoxin
 Toxin formed on certain fish (tuna,
bluefish, “mahi mahi”) species when
enzyme producing bacteria grows due
to poor storage and reacts with fish
protein to produce histamine, causing
severe allergic reaction
Blue green algae

 variant Creutzfeldt-Jakob (vCJD)/ Bovine Spongiform
Encephalopathy (BSE) )
 Prions are normal proteins of animal tissues that
may be involved in cell-to-cell communication that
can misfold and become infectious, causing
neurodegenerating disease
 Associated with the use of animal wastes (brains,
entrails) as feed protein source
 Bovine and human share the same characteristics
and believed transmissible
 Not known to be spread through milk consumption
Schematic diagram
of a prion
Naturally Occurring
Chemical Hazards
Toxic Animal (Mad Cow Disease)

 Intentionally added during growth, processing,
storage or distribution of food
 Dangerous in high amounts, improper usage,
or may be allergens
 Regulated by government GRAS (Generally
Regarded As Safe) classification
 Examples of improper amounts are
 Color additives (FDC Yellow No. 5)
 Preservatives (nitrites)
 Nutritional additives (Vit A)
Intentionally Added
Chemical Hazards
Food Processing Ingredients

Intentionally Added
Chemical Hazards
Allergens
 Foods that cause antigenic reaction on
certain individuals
 Examples are Soy, nuts, milk, eggs, fish,
crustaceans, wheat, lactose
 Also now considered a food hazard

Physical Hazards
 Includes any potentially harmful
extraneous matter not normally found in
foods. Involve injuries caused by
chewing or ingesting foreign objects in
food

 Common sources
 Raw material contaminants or packaging
 Unsecured equipment openings or processing
 Food handlers
 Faulty equipment or equipment parts
 Environment
 Examples: bone fragments, metal shavings packing
staples, tacks, and pins, glass, hair, fingernails,
wood, stones, toothpicks, among others
Physical Hazards

 USDA FSIS
 < 1cm not a safety hazard
 1 – 2 cm low risk
 > 2 cm potentially a hazard and may cause injury
 US FDA
 Criteria for recommending legal action
 7 – 25 mm and requires additional preparation
 < 7 mm and intended for special risk group
 > 25 mm in length
 Criteria for seizure
 Hard object 7 – 25 mm in RTE foods
 US Consumer Product Safety Commission
 Dangerous to children under 3 years old
 Spherical objects >1.75 mm diameter
Physical Hazards:
Bone Particle Size Standards

Most significant threat, accounting for
at least two thirds of
foodborne illnesses
Biological Hazards

Bacteria
 Living, single-celled
 Carried by food,
water,
humans and insects
 Can reproduce rapidly
 Reproduce by binary
fission

Bacteria
 Some survive freezing
 Some form heat resistant spores
 Some spoil food; others cause
disease
 Some cause illness by producing
toxins

Bacterial Size
A single dot in your
manual can contain
millions of bacteria.
Bacteria
on the tip
of a needle
point

Organism Size (in μm)*
Protozoa 5 – 200
Fungi (Yeast
and Molds)
5 – 10
to meters
Bacteria 0.5 - 5
Viruses .015 - .02
Size of Microorganisms
*1 μm = 0.001 mm
1 cm = 10 mm
1000 mm = 1 meter

Shapes of Bacteria
Bacilli
Rod-shaped
Cocci Spirochetes
Round-shaped Spiral-shaped
Gram Stain Characteristics
Gram positive cells
are blue or purple.
Gram negative cells
are red.
Bacterial Characteristics

Ability to Form Spores
Spore formers Non-spore formers
• Some bacteria develop resistant forms in
response to adverse environmental
conditions, called spores
• Spores are of food safety importance
because of their heat resistance
Bacterial Characteristics

Bacterial Growth
 Bacteria multiply by dividing into two (binary
fission)
 One growth cycle is the time to produce one
generation
Time 10 min 20 min 40 min 1 hour 1 hr 20 min 10 hrs
No. of
Cells
1 2 4 8 16 > 1 billion

Bacterial Growth Curve
Number
of
organisms
(log
cells/g)
Incubation time
A
B
C
D
A : Lag Phase
B : Logarithmic Phase
C : Stationary Phase
D : Death Phase

Role of Bacteria in Foods
 Spoilage agents
 Causes souring, off odors and off flavor in food
 Production aid
 Imparts unique flavor and desired taste in
fermentation (yogurt, cheese, fish sauces and
condiments)
 Disease agents
 Because growth conditions are available, disease
causing bacteria can grow and multiply

Growth Factors
 Food (Nutrients)
 Acidity (pH)
 Temperature
 Time
 Oxygen
 Moisture (Water)
O2
O2
O2
O2
O2

Food as Growth Environment
• Microorganisms require nutrients to grow
– Proteins
– Carbohydrates
• Spoilage occurs as a result of microbial
growth
• Finished products tend to have fewer micro
flora than raw products.
• Foods can serve as a vehicle for disease
transmission

pH (Acidity)
• pH is a measure of acidity or alkalinity
• pH values range from 0 - 14
• For regulatory purposes, foods are divided into
two groups based on pH
• Low acid foods (pH  4.6)
• High acid foods (pH  4.6)

• Pathogenic bacteria grow well at a
pH of 4.6 to 7.5
Butter
6.0-6.8
Raw Chicken
5.5-6.4
Egg Yolks
6.0-6.3
pH (Acidity)

Approximate pH Growth Ranges for Some
Foodborne Organisms
Molds
0 1 2 3 4 5 6 7 8 9 10 11 12 13
14
Yeasts
Lactic acid bacteria
Staphylococcus aureus
Salmonella spp.
Escherichia coli
Clostridium botulinum
Bacillus cereus
Vibrio parahaemolyticus
Campylobacter spp.
Vibrio spp.

Temperature
 Different bacteria (or
microorganism) grows at different
temperatures ranges
 Most microorganisms grow well in
the
Temperature Danger Zone (TDZ)
which is
5oC to 60oC

Temperature
• Thermophile (50 – 70°C)
• Mesophile (10 – 55°C)
• Psychrophile (0 – 20°C)
DANGER
ZONE
Some bacteria grow
outside the TDZ

 Growth cycle time are faster at optimum
growth temperatures
 Pathogenic microorganisms can grow to high
levels if they remain in the TDZ from two to
more than four hours
 Specific temperature over time ensures
destruction of microorganism (Minimum
cooking time)
Time
Time/temperature relationship is a critical
factor to always consider

Oxygen
 Microorganisms have different oxygen needs for
growth
 Types of bacteria by oxygen requirements
 Aerobic bacteria needs oxygen to grow
 Anaerobic bacteria grows only in the absence of
atmospheric oxygen
 Facultative anaerobes grow both with or without
oxygen
O2
O2
O2
O2
O2

 Moisture enables bacteria to
assimilate food
 In food, available moisture is
expressed as water activity
 Food with water activity of .85 or
above are considered potentially
dangerous food
Water (Moisture)

Approximate aw Values
Food Group aW
Fresh meats, fish, fresh fruits, vegetables, milk, beverages 0.96
Evaporated milk, tomato paste, Lightly salted fish, pork, beef
products, canned cured meats, fermented sausages (not
dried), processed cheese
0.93-0.96
Dry or fermented sausage, dried beef, raw ham, aged
cheddar cheese, sweetened condensed milk
0.85-0.93
Intermediate moisture foods, dried fruit, flour, cereals, jams
and jellies, molasses, honey, heavily salted fish, some aged
cheese, nuts
0.60-0.85
Confectionery, chocolate, noodles, biscuits, crackers, potato
chips, dried egg, milk and vegetables 0.60
No microbial growth < 0.60

Controlling Bacterial Growth
 Make food unavailable to bacteria
through cleaning and sanitation
 Make the food more acidic
 Keep hot food hot and cold food cold
and lessen the time in the TDZ
 Cook food properly
 Provide modified atmosphere if viable
 Lower the water activity or reduce
moisture available
F
A
T
T
O
M
O2
O2
O2
O2
O2

Bacteria As Disease Agents
 Infection – establishment of an infective
agent in a suitable host
 Intoxication – disorder caused by
bacteria or by products
 Toxico-infection – establishment of an
infective agent and subsequent formation
of toxin or by products
Bacteria is known to cause all three types of
microbial diseases

Classification of Foodborne Diseases
Foodborne Disease
Mycotoxins
(Fungal
Toxins)
Algal
Toxins
Bacterial
Toxins
Intoxication Infection
Toxicoinfection Invasive Infection
Chemical
Poisoning
Poisonous
Plant
Tissues
Poisonous
Animal
Tissues
Microbial
Intoxication
Neurotoxin
Other
Enterotoxin
Intestinal
Mucosa
Systemic
Other Tissues or
Organs (Muscle,
Liver, Joints, Fetus,
Other)

Salmonella
 Morphology
 Rod shaped, Gram(-), motile (flagellated)
facultatively anaerobic. 1,400 serotypes
 Opt. temp: 35 – 37 C, range 5 – 47C, aw: >0.93,
<3% NaCl, pH: 6.5 – 7.5, 4 - 9 range
 Infection causes typhoid fever, nausea, vomiting, loose watery
diarrhea with blood and mucus, abdominal cramps, fever,
head ache.
 Onset may come within 6 to 48 hours, last 1 – 2 days
depending on host, dose and strain.
 All age groups are susceptible.

Salmonella
 Refrigeration does not kill the bacteria
 Typically associated with poultry and swine, human and
animal carriers.
 Causes of outbreak are cross contamination of raw and
cooked food, unclean utensils, temperature abuse,
contamination through water, soil, feces, raw meats, sea
foods and poultry, eggs, milk, dairy products, among
others.
 Environmental sources may come from sewage, water,
among others

Pathogenic E. coli
Morphology
 Gram (-) rods, non-spore forming, facultative
anaerobes
 Opt. temp: 10 - 35C, < 8 - 10% NaCl,pH: > 5
 Ubiquitous, wide family and resistant. Typically associated with
contaminated water, food through food handles or equipment
 Classified by type of infection (EPEC, EIEC, ETEC, EHEC,
O157:H7)
 Commonly found in sewage and used as an indicator for
hygiene
 Cooking of food at least 70 C for 15 seconds internal
temperature suffice to make food safe

Campylobacter jejuni
Morphology
 Gram (-) bacilli, thermophilic, obligate micro
aerophilic
 Opt. temp: 42C, range: 25 - 43C, >5% O2, aw :
0.83- 0.99, <2%% NaCl, pH: 5.5 – 8
 Infection causes acute diarrhea, abdominal pain, fever,
nausea. Occurs 2 – 5 days after ingestion and lasts for 7 – 10
days. Cannot grow below 30 C. Present in gut of healthy
poultry, animals, streams
 Proper food handling, clean and health meat source, clean
water and proper cooking are a primary means of control

Clostridium botulinum
Morphology
 Gram (+), anaerobic rods, spore forming
 Opt. temp: 4 – 14 C, max: 42C, aw: 0.93, 5 – 10% NaCl,
pH: 4.6 - 5, max 9
 Produces enterotoxin, typically associated with canned and
fermented foods, processed meats. Causes diarrhea, vomiting,
headache, nausea, muscle paralysis, respiratory failure. Heat
resistant but poor competitor.
 Found in soil, water sediments. Environmental sources may
come from environment, poor raw materials, raw food, among
others
 Can grow toxin on cold storage

Clostridium perfringens
Morphology
 Gram (+), anaerobic rods, spore forming, thermophilic
 Opt. temp: 41- 45C, range: 10- 52C, aw: >0.95, <5%
NaCl, pH: 5.5 – 8, max 9
 Poisoning causes intense abdominal cramps, diarrhea. In
worst cases, “gas gangrene", necrotic enteritis
 Typically associated with temperature abuse of food
products, where large food is prepared early prior to
consumption.
 Forms thermophilic spore which presents problems after
processing. Additionally, spore generation critical for
growth after processing.

Clostridium perfringens
 Environmental contamination are
expected due to wide distribution of
spores in the environment but food
cooking, handling, storage are a
primary means of control.
 Appropriate cooking, cooling and
storage of food prevents spore
formation and toxin production

Morphology
 Gram (+) cocci, facultative anaerobes
 Opt. temp: 35 - 37, range: 7 - 45C, aw: 0.83- 0.99, 7–
7.5% NaCl, pH: 4.5 – 9.5
 Ingestion of toxin cause gastroenteritis, nausea,
vomiting, abdominal cramps, prostration.
 Typically associated with food handling after cooking,
storage at slightly elevated temperatures after
preparation due to heat resistant toxins
 Poor competitor, and typically grows on contaminated
cooked food where competitors are not present
Staphylococcus aureus

S. aureus
 Commonly found in human skin and
orifices, among food handlers
intoxication. May be the most
widespread but widely
underestimated.
 Control is avoiding contamination
during handling of cooked food,
particularly of leftovers for re-
cooking, or refrigeration o cooked
food when not to be consumed

Bacillus cereus
Morphology
 Gram (+), aerobic rods, spore forming
 Opt. temp: 30C, range: 5 - 50C. pH: 5 – 9aw: >0.95
 Toxico-infection causes watery diarrhea, abdominal pains and
spasm, nausea, vomiting hours after ingestion of bacteria.
 Typically associated with spores-laden raw materials, poor post-
cooking storage with heat resistant spores which may come from
poorly handled raw milk source, farinaceous foods,
 Control comes with keeping warm food warm, and cooling or food
when not to be consumed

Listeria monocytogenes
Morphology
 Gram (-) flagellated, motile rods, non-spore forming,
aerobic, thermo resistant
 Opt. temp: 30 - 37C, range: 0 - 45C, 5 - 10% NaCl, aw:
>0.92, pH: 4.4 – 9.4
 Infection causes diarrhea, vomiting , fever, convulsions. In severe cases
bacteremia, as neonatal meningitis, adult listeriosis to
immunocompromised or aged persons, and listeric abortion
 Thermoresistant, usually comes from infected cow’s milk, dairy
products, cold meats and salads, raw and cooked poultry. Environmental
sources may come from sewage, water, plant environment, animals
 Emerging pathogen, targets are immunocompromised, pregnant
women, children, elderly, cancer patients

Shigella
Morphology
 Gram (-), non-motile, non-sporeforming aerobic rods
 Optimum temp. growth: >8 - < 42C, pH range ? – 9-
11
 Bacillary dysentery infection, nausea, vomiting, diarrhea,
abdominal cramps, fever, head ache. Onset within 6 to 48
hours. Is known to become antibiotic resistant
 Typically associated with over crowding and poor personal
hygiene, as in institutions, food and water contaminated by
human feces

Vibrio cholerae
Morpohology
 Gram (+) rods, flagellated, non- spore forming
 Opt. temp. Range 8 - 42C, aw: >0.95, pH range
6 – 9.6
 Causative agent of cholera, known as El Tor. Characterized by rapid
onset of dehydrating diarrhea known as “rice-water” stools
 Associated with contaminated water and consumption of shellfish or sea
food, due to cross contamination or raw consumption
 Control is therefore ensuring clean water source and proper cooking and
food handling
 Treatment is primarily intravenous and oral rehydration

Relevant Bacterial Pathogens
Yersinia enterocolitica
 Infection causes diarrhea, vomiting, headache, fever.
Can mimic appendicitis.
 Associated with wild and domestic animal intestines,
shellfish and mollusks, and typically associated with
meat and milk products. As with Campylobacter, this is
also an “emerging” pathogen
V. parahemolyticus
 Linked exclusively to consumption of contaminated
seafood. Illness usually begins with an explosive
diarrhea with cramping abdominal pain, 8 to 72h after
ingestion. Similar to S. aureus, although heat labile, it
produces heat stable toxin

Aeromonas hydrophila
 Associated with shell fish, seafoods and crustaceans, as
well as contaminated water.
 Eating raw contaminated food, inadequate cooking, poor
food handling, cross contamination during cold storage
are primary causes.
 Proper cooking, segregation of cooked from raw are
controls.

E. sakazakii
 Associated primarily with neonates and
immunocompromised, causes meningitis,
necrotizing enterocolitis, neurologic disorder.
 Associated with hospital setting, environment
in infant formula production.
 Has better tolerance to high processing
temperatures. Ubiquitous, little known as to its
epidemiology and source.

 Bacteria
 Algae
 Viruses
 Fungi (Yeast and Molds)
 Protozoa and Parasites
Broad Groups of
Microorganisms

 Various food poisoning due to consumption of fish,
shellfish and mollusks with accumulated algal toxins in
their bodies brought about by various toxin-producing
algae.
 Poisoning occurs during various seasonal changes that
favor toxic algal growth
 Toxin produced are not heat labile
 The types of poisons produced are
 Paralytic shellfish poisoning
 Diarrheic poisoning
 Ciguatera
 Amnesiac shellfish poisoning
Algae: Algal Poisoning

 Smaller than bacteria and normally made up of
proteins and genetic materials
 Require a living host (animals or humans) to
grow and reproduce; Cannot multiply in foods
 Infect humans through fecal-oral route or use of
unsanitary water
Viruses: Viral Characteristics
Mode of Viral Multiplication

 Viruses can generally survive in dry conditions,
water, food or long periods
 Inactivated at room temperature, destroyed
readily by heat, by strong oxidizing agents but
generally acid resistant
 Viruses of importance in foods are:
 Hepatitis A virus
 Norwalk virus group
 Rotavirus
 H5N1 “Bird flu”
Viruses: Viral Characteristics

Viral Gastroenteritis
 Caused by rotaviruses, Norwalk
agent, adenoviruses and
enteroviruses infection
 Causes vomiting, diarrhea, fever,
head ache.
 No specific therapy except fluids
and electrolyte replacement

Hepatitis A Gastroenteritis
 Causes low grade fever,
malaise, nausea, jaundice and
abdominal paint. May be mild
and can occur unnoticed.
 Caused by hepatitis A virus
infection
 No specific therapy except fluids
and electrolyte replacement,
and if available, vaccines.

 Highly pathogenic bird Type A strain of
influenza
 If infected, can cause mild illness to
sudden severe respiratory illness (fever,
sore throat, cough, sever respiratory stress
secondary to pneumonia) and rapid death,
resulting to 100% pathogenicity
 Widespread to Asia and Europe. Other
versions (H7N7, H9N2) have already
caused deaths. Commonly found on wild
birds
 In human infection, can spread through
cough and bodily secretions. Can survive
at 4 C for 35 days and 7 days in 37C.
Avian Flu (Influenza H5N1)
Sub-microscopic
H5N1 virus

Avian Flu Challenges
 Highly pathogenic to birds, which
are a large part of human food and
activity. Virus is a near relative to
human flu virus but largely
unrecognized by the host if infected.
 Has unique characteristic of
“jumping” specie barriers to hogs,
domestic pets, and ultimately to
humans, and may cause pandemic.
 This is due to rapid mutation and
the propensity to acquire genes
from other infective viruses
(antigenic drift)

Avian Flu Challenges
 Mild pathogenic version can spread without detection,
and subsequent mutation to highly pathogenic strain can
cause widespread infection and ultimately pandemic
 Ease of spread as feces and bodily secretions can
cause spread throughout from animals to humans.

Avian Flu (Influenza H5N1)
Control Measures
 No known human to human contact or transmission as
yet known
 Halting spread through poultry population by culling of
affected birds to prevent pandemic
 Vaccination using current human influenza vaccines
 Development of vaccines though limited
 Protection of workers culling known infected poultry
and animals
 As with other viruses, easily heat labile

Viral Control
 Good sanitary and personal hygiene practices
 Home slaughter of sick or dead poultry is not
advisable
 Prevent cross contamination of raw with cooked
food, particularly raw food with cooked food, food
utensils, food handling surfaces, knives and handlers
 Proper cooking
 Avoid eating raw poultry, raw eggs
 Conventional cooking remains a safe practice
(cooking above 70C)
 Combined control mechanisms often necessary

Unicellular, oval in shape
• Frequently found in the environment
• Used as food supplement, used in alcohol
production
• Generally food spoilage organism for high acid
food
• Not known as a foodborne invasive pathogen
Yeasts Characteristics

Yeast as Spoilage Agents
Food Yeast(s) Responsible for
Spoilage
Pickles Saccharomyces bailii
Salad dressing Various yeasts; predominantly
Saccharomyces bailii
Fruit juices Various yeasts
Preserves Saccharomyces rouxii
Syrups Saccharomyces rouxii

 Multicellular, with many
distinctive shapes
 Always found in the environment
and responsible for the
decomposition of many materials
 Can cause disease due to toxin
production
 Generally food spoilage organism
for high acid food
Characteristics of Molds
Sporangiospores
Conidiospores

Molds as Spoilage Agents
Mold species Food
Alternaria Apples, citrus fruits, cabbage, tomato, beef, bacon
Aspergillus spp.
Citrus fruits, vegetables, hams, salami, cooking
oils
Botrytis Apples, stone fruits, vegetables, bacon
Cladosporium
Stone fruits, cucumber, pumpkin, beef, butter,
margarine
Fusarium spp. Citrus fruits, vegetables, meats, figs
Geotrichum Citrus fruits, vegetables, chicken, sausage, cream
Monilia Blueberries, bacon, barley
Penicillium spp.
Citrus fruits, potatoes, various meat and grain
products
Rhizopus spp.
Apples, pears, vegetables, bacon, beef

 Some molds produce secondary
metabolites during growth and/or
sporulation that cause toxicity on
humans; these metabolites are
referred to as “mycotoxins”
Molds In Food

 Some molds produce mycotoxins that cause toxicity
on humans
Molds In Food
Mycotoxin Mold Principal Toxic Effects
Aflatoxin
Islanditoxin,
Luteoskyrin
Aspergillus
Pencillium
Liver damage, cancer
hemorrhaging
Diacetoxyscripenol,
T-2 toxin, Butenolide
Fusarium Diarrhea, weight loss
Deoxynivalenol Fusarium Nausea, vomiting,
somnolence
Ochratoxins Aspergillius Fatty liver

USFDA Aflatoxin Maximum Acceptable Levels
Aflatoxin action
level (ppb)
Commodity Species
0.5 (M1) Milk Humans
20 Any food except milk Humans
20 Feed All species
Exceptions
300
Cottonseed meal used
in feed
All species
300 Corn Finishing beef cattle
200
Corn Finishing swine
(>100 lbs.)
100 Corn Breeding cattle, swine, poultry
Molds In Food

Parasitic Worms
 Can cause malnutrition due to anemia,
loss of Vitamin A, loss of appetite and
subsequent poor growth and reduced
learning.
 Mostly transmitted through fecal-oral
route, contaminated meat, or
contaminated water and prevalent in
the tropics and third world countries
 Prevalent are Ascariasis, Trichuriasis,
Taeniasis, Amoebiasis, among others

Control of Parasitic Worms
 General improvement of sanitary habits, sanitary
facilities, water sources
 Removal of vectors and carriers
 Mass screening and treatments

 Protozoa are unicellular, small aquatic animals
 Eukaryote (genetic material encased in a nuclear
membrane, unlike bacteria and viruses)
 Can ingest solid food particles
 Generally not food spoilage organism
 Require a living host to reproduce; does not grow
in foods nor nor multiply in food or water
Amebiasis organism
Protozoan Characteristics

• Caused by consumption of
– Food or water contaminated with human or
animal wastes
– Raw or poorly cooked meats, fish or crustaceans
carrying larval or cystic stages of parasites
• Cyst stage is the infective stage, while the
trophozoite stage is the infestation stage
Protozoan Parasites

Amoebiasis (Entamoeba histolytica)
 Acute infection of causes amebic
dysentery (bloody, mucousy diarrhea,
fever, abdominal pain, fever). Chronic
amebiasis may cause liver abscess,
or carrier state.
 Transmitted through fecal-oral route,
contaminated water or food. Raw or
poorly cooked meats, fish or
crustaceans carrying larval or cystic
stages of parasites
 Prevalent in the tropics. Locally,
associated with water supply
Flask shaped colonic ulcer
typically associated with
amoebiasis

• Implicated in foodborne outbreaks
– Flagellates
• Giardia lambdia
• Toxoplasma hominis
– Ciliates
• Balantidium coli
• Toxoplasma gondii
– Sporozoa
• Cryptosporidium
• Cyclospora
Other Protozoan Parasites
Giardia parasite

Control of Food Hazards
HOW DO YOU CONTROL OR
ELIMINATE THE FOOD
HAZARDS?

Overview of EKPI
9 HACCP Prerequisite Programs
1. Facility Sanitation Systems
2. Pathogen Environmental Hygiene Monitoring
Programs
3. Extraneous Material Control Systems
4. Preventive Maintenance and Calibration Systems
5. Compliance With Current Good Manufacturing
Practices
6. Hygienic Zoning of Production Facilities
7. Chemical Management Systems
8. Integrated Pest Management Systems
9. Allergen Control and Management

Components
 Master sanitation schedules
 Sanitation matrices (allergen and
product compatibility)
 Sanitation standard operating
procedures
 Initial and periodic qualification of
sanitation practices
Facility Sanitation Systems

Components
 Routine verification of sanitation practices
 Training of personnel responsible for
sanitation
 Management of sanitation compounds and
utensils
 Sanitation techniques
 Requirements for COP and CIP systems
Facility Sanitation Systems . . .

1. Secure, Dry Clean, and Disassembly
2. Pre-rinse
3. Soap and scrub
4. Post Rinse
5. Cleaning and Assembly
6. Pre-operational Inspection
7. Disinfect and Sanitize
7 Steps of Sanitation

1. No Off Foreign Materials
2. No Off Color
3. No Off Odor and/ or Flavor
4. No Micro organisms
5. No allergens
How to determine if already
clean?

 Glass and brittle plastic control (used in
structural, laboratory, and packaging
applications)
 Fibrous material control (structural,
pallets, etc.)
 Control of debris from packaging
materials (bag stripping, sieving,
filtration, etc.)
 Control of debris from maintenance and
construction activities
 In-line detection systems (metal
detectors )
Foreign Material Control Systems

Foreign Material Control Systems

HYGIENE RESTRICTED AREAS AT EKPI- ZONING
1. Maximum Hygienic Restricted Area
2. Medium Hygienic Restricted Area
3. Minimum Hygienic Restricted Area

HYGIENE RESTRICTED AREAS AT EKPI
- defined as those covered by the Manufacturing Area of the Foods
Division, from the Engineering and Maintenance building bridge way
entrance to the Quality Assurance (QA) hallway entrance.
- Areas: Batching Area (including Kraft Batching Room), Grinding Room,
Oil Room, Dry Blends Mild and Strong Areas, Calumet Loading and
Unloading Rooms, Tang Loading and Unloading Rooms, Komatsu
Loading and Packing Rooms, Panko Area, Chiller and Freezer Rooms,
BID Rooms

- Required uniforms:
a. Prescribed polo and/ shirt and pants (no zippers and/or buttons
with single pockets);
b. Cotton head caps;
c. Hair nets are required when hard hats are worn instead of cotton
head caps;
d. Cotton face masks and or dust masks
e. Safety rubber boots or safety shoes
f. Aprons, whenever necessary – except for company guests and
visitors
- Visitors and Guests – white laboratory gowns
- Engineering visitors – blue laboratory gowns
- Casual employees – as prescribed and provided by the agency

- defined as those covered by the laboratories and offices of QA and Food
and Beverage Innovation Center (FBIC) of all food-related departments
under the Edward Keller (Philippines), Inc.

a. Prescribed polo and pants (no zippers and/or buttons with single
pocket)
b. or White laboratory gowns (no zippers and/or buttons, with
inside pocket only)
c. Cotton face mask or dust mask, whenever necessary
d. Cotton head caps – as necessary
e. White rubber boots, working shoes or safety shoes
f. Aprons, whenever necessary

- defined as those NOT covered by the maximum and medium hygienic
restricted areas
- Areas: All main building offices, Engineering and Maintenance building,
warehouses (RM and FG), Canteen, Company facilities other than the
maximum and medium hygienic restricted areas

a. Prescribed office / working uniforms
b. Hair nets and aprons – for canteen concessionaires
c. Minimum Dress Code as required by HRD
IMPORTANT: Rubber slippers, haltered
sleeved clothes (sando-type) and short pants
of any kind, except when worn as part of a
business suit, are STRICTLY PROHIBITED
within the buildings and facilities of the
company

PERSONNEL HYGIENE
Disease Control
• Food handling personnel must normal pass
medical examination, first as a condition of their
engagement and then regularly during their
employment
 No person known or suspected to be suffering from, being a carrier of a
disease likely to be transmitted through food, or to be afflicted with boils,
sores, skin infection or diarrhea, shall be allowed to have contact with
exposed food or work in an area where exposed food is present
 No person having wound shall continue to handle food or food-contact
surfaces until the injury is properly cleaned and protected by a firmly secured
waterproof dressing of prescribed type.

PERSONNEL HYGIENE
1. Control of diseases
a. New Hires
b. Annual PE
c. Current health condition
Body Parts What to check Security Team Shift Supervisors
Eyes Soreness, Redness, Excessive
Discharge
X X
Nose Discharge X X
Mouth Sores (External) X X
Face Severe acne X X
Ears Excessive discharge X X
Neck Rashes with abrasions n/a X
Hands Open wounds, skin problems n/a X
Arms Open wounds, skin problems n/a X

PERSONNEL HYGIENE
Hair Restraint
 All male employees shall sport short hair that is well
groomed and without sideburns, and must wear the
prescribed head caps as hair restraint. For
Manufacturing male personnel, hair must not touch
or go beyond the upper eyebrow when let down,
and the entire hairline must be covered by the head
caps .
 All manufacturing employees must wear the
prescribed head caps, with all the hair entirely
covered by the head caps.

PERSONNEL HYGIENE
 All male employees are allowed to maintain only trimmed moustache.
However, maintaining beard is strictly prohibited.
 All manufacturing employees must maintain only clean, short and
unpolished fingernails.
 Taking a bath is a must for everybody.
 Use foot dip/bath every time you enter the Production Areas

PERSONNEL HYGIENE
 Appropriate degree of personal cleanliness
A. Clothing
a. Hair Restraint
b. Facial Masks
c. Apron and Uniform
d. Footwear
B. Cleanliness
a. Personal Cleanliness
b. Clean hands
c. Personal Behavior

PERSONNEL HYGIENE
 Clothing, uniforms and personal belongings must only be kept or stored at
the respective lockers.
 Wearing of jewelry and similar accessories shall be prohibited in the
MEDIUM and MAXIMUM hygienic restricted areas.
 Wearing of any hanging objects and/ or tools shall be STRICTLY PROHIBITED
in the MEDIUM and MAXIMUM hygienic restricted areas.
 Wearing of any make-up (facial or body) shall be prohibited in the
MAXIMUM hygienic restricted areas. Exempted are the official company
visitors and/ or guests.

PERSONNEL HYGIENE
Handwashing Protocol
1. Moisten hands under potable running water
2. Soap thoroughly with liquid soap and build a good lather.
Lather to elbow.
3. Scrub thoroughly. Use brush for nails.
4. Rub hands together for 20 seconds
5. Rinse thoroughly under running water.
6. Dry hands under hands-free operated blow drier or clean paper towel.
7. Disinfect hands with 70% ethanol

PERSONNEL HYGIENE
Frequency of Handwashing
 Before starting work.
 Before handling product.
 After coughing, sneezing or blowing.
 After touching trash, floors or soiled objects.
 After touching head, hair, mouth, nose, ears, wounds, sores or any
part of the body.
 After handling cleaners or chemicals.
 After visiting rest room or locker rooms
 After breaks or any absence from work areas.

PERSONNEL HYGIENE
Before Handwashing

PERSONNEL HYGIENE
Washed with water

PERSONNEL HYGIENE
Washed with soap and water

PERSONNEL HYGIENE
Washed with soap and water; used alchohol

OUTER GARMENT POLICY
 Prescribed uniforms for Production Personnel should not be worn outside
the plant.
 Street clothes and footwear are STRICTLY NOT WORN within
the manufacturing areas
 The protective outer garments or prescribed uniforms for the maximum and
medium hygienic restricted areas must be clean at the start of the shift.

DINING AND PANTRY AREAS
 It shall be mandatory for ALL EMPLOYEES to take their meals and/or
meriendas at the designated Company Canteen.
 The duly designated Pantry shall only be used for coffee, milk or tea
drinking
 Candies, gums, cookies, all other beverages, ‘kakanin’ and all other similar
consumable food shall not be kept and eaten at the respective workplaces
or lockers.

CHEMICAL CONTROL
 Use of correct concentration of sanitizers
Food Contact Surfaces: 150 – 200ppm
Non-food Contact Surfaces: 800 – 1000ppm
 Use of correct Pesticides
 Use of food grade lubricants
OBSERVE PROPER CONCENTRATION AND STORAGE

4 Prong Strategy
 Exclusion (Do not allow to enter)
 Deprivation (Do not allow to proliferate
and be near food)
 Clean (Prevent sources of food and
opportunities to food)
 Exterminate
Integrated Pest Management
Systems

Integrated Pest Management
Systems

Strategies for Allergen Control
 Product Scheduling and Sequencing
 Cleaning and Sanitation program
 Process Controls
 Rework Management
 Ingredients and Formula Management
 Correct Labels and Packages
Allergen Control

 Raw Material Segregation
Material Labeling
Designated Storage
Designated Scoops and Utensils
A
Prevention and Elimination Strategy

 All changes made to existing systems
and/or procedures, processes, equipment,
buildings, etc. must be reviewed prior to
implementation.
 Changes with potential impact on the Food
Safety program must be assessed by the
HACCP team prior to implementation.
Review and Change Control

RESTRICTIONS
 Eating inside the Production areas and other areas except at the canteen is
STRICLY PROHIBITED!
 Spitting, blowing of nose, sneezing and coughing over unprotected food and
similar habits that can lead to food contamination is STRICTLY PROHIBITED
inside the manufacturing facility.
 Scratching of face, nose, ears and other parts of the body when handling any
product is STRICLTY PROHIBITED!
 Placing of raw materials, finished goods and utensils directly on the floor
with/without cover.
 Use of production utensils for personal use is STRICLTY PROHIBITED!

RESTRICTIONS
 Use of packaging materials other than its intended use is prohibited.
 Only retractable ballpen can be used inside the Production area
 Use of strong perfumes and other scents is not allowed inside the Production
Area

RESTRICTIONS
 Drinking and/or bringing within the plant premises of any form of
intoxicating drinks or under the influence of such.
 Use and/or bringing within the plant premises of any form of illegal drugs
and/or under the influence of such.
 Loitering and playing around with fellow workers during actual operations
which may result to accidents or hamper process.
 Mixing and blending products near packaging materials or any other
products which may be contaminated.
 Operating of any equipment without the consent from respective managers.

RESTRICTIONS
 Smoking is not allowed within the premises of EKPI
 Using of cellular phone is not allowed inside the
Processing areas.

Structure/Chapter
Thank you!
Questions?

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