GAP

1. GOOD PRACTICES
IN FOOD INDUSTRIES

2. GOOD
MANUFACTURING
PRACTICES
Range of Processor-Level Problems
by Type of Food Safety HazardPosed
Microbiological Safety •Inefficient employee hygiene practices
•Ineffective training of employees
•Biofilms
•Plant renovations
•Ineffective use of cleaning agents/disinfectants
•Lack of sanitary equipment design
•Reactive instead of routine maintenance
•Contamination of raw materials
•Post-processing contamination

3. GOOD
MANUFACTURING
PRACTICES
Chemical Safety •Raw material contamination with pesticides
•Spillage of pesticides
•Adding too much of an approved ingredient
•Raw material contamination with an allergen
•In-line cross-contamination with an allergen
•Cross-contamination from maintenance tools,
conveyor belts
•Older equipment (more difficult to clean)
•Raw material contamination with natural toxins
•Mycotoxin infestation due to drought, insect
damage, delayed harvesting, mechanical damage
•Corrosion of metal containers/equipment/ utensils
•Contamination with cleaner/sanitizer residue

4. GOOD
MANUFACTURING
PRACTICES
Physical Safety •Foreign matter in raw materials
•Poorly maintained equipment/lines
•Light fixture breakage
•Foreign matter introduction during storage

5. GOOD
MANUFACTURING
PRACTICES
Prerequisites for Food Safety:
 Good Agricultural Practices (GAPs)
 Good Manufacturing Practices (GMPs) or
 Good Hygiene Practices (GHPs)
 Other GPs (GTP, GDP, GRP, etc)
GHP
GAP GMP
Other
GPs

6. GOOD
MANUFACTURING
PRACTICES
Good Agricultural Practices
 A collection of principles to apply for on-farm
production (pre-planting, planting, harvest) and
post-harvest (sorting, packing and storage
operations), resulting in safe and healthy food
and non-food agricultural products, while taking
into account economical, social and
environmental sustainability.

7. Good Agricultural Practices
 GAPs may be applied to a
wide range of farming system
and at different scales.
 They are applied through
sustainable agricultural
methods, such as
 Integrated pest
management
 Integrated fertilizer
management
 Conservation agriculture.

8. Good Agricultural Practices
 GAPs rely on four principles:
 Economically and efficiently
produce sufficient (food
security), safe (food safety)
and nutritious food (food
quality);
 Sustain and enhance natural
resources;
 Maintain viable farming
enterprises and contribute to
sustainable livelihoods;
 Meet cultural and social
demands of society.

9. GOOD
MANUFACTURING
PRACTICES
GAPs focus on:
 Soils
 Maintaining “clean soil” reduces the risk of contaminating
produce with illness-causing microorganisms found in soil
during stages of growth and harvesting.
 Improper manure management and application can cause
an increase in risks of product contamination.
 Although manure is a good fertilizer, all manure contains
pathogens.

10. GOOD
MANUFACTURING
PRACTICES
 Water
 Water used for irrigation, cooling, processing, or for
cleaning equipment and facilities should be free of
microbial contaminants.
 Water quality and safety can be dependent on water
sources.
 Regularly testing water sources provides documentation
that the water is not a source of contamination.
 The method and timing of water use also has an effect on
its contribution to product contamination.
 Water quality becomes more important as harvest
approaches and water contact with the product occurs or
increases.

11. GOOD
MANUFACTURING
PRACTICES
 Hands
 Having “clean hands” refers to the human element
involved in food safety during production and processing.
 The food producer and handler each have an important
role in ensuring the safety and quality of foods grown and
processed.
 Poor hygiene and health, unclean clothing or shoes, or
unsafe practices on the part of workers can threaten food
safety.
 Providing clean and appropriately stocked restroom and
hand-washing facilities to field and processing employees
helps prevent product contamination.

12. GOOD
MANUFACTURING
PRACTICES
 Surfaces
 Produce items will have physical contact with many
surfaces during harvest and processing.
 These may include harvest equipment and containers,
transport bins, knives and other utensils, sorting and
packaging tables, product packaging, and storage
areas.

13. GAP implementation covering:
 Water quality
 Land history and
surrounding properties
 Soil amendments
 Field sanitation
 Pest control
 Agricultural chemicals
 Worker sanitation
facilities
 Worker health and
hygiene
 Tools and equipment
 Container and
packaging materials
 Transport
 Post-harvest cooling
 Storage
 Product traceability
(Sperber, 2005)

14. Good Manufacturing Practices (GMPs)
GMPs describe the methods,
equipment, facilities, and
controls for producing
processed food.
 GMPs are applied as criteria
to determine whether a food
is adulterated .

15. GOOD
MANUFACTURING
PRACTICES
GMPs Contd…
 “Good Manufacturing Practices (GMP) are the
part of quality assurance that ensures that
products are consistently produced and
controlled in such a way to meet the quality
standards appropriate to their intended use”.

16. GOOD
MANUFACTURING
PRACTICES
GMPs Contd…
 GMP are concerned with both production and
quality control. Their basic requirements are as
follows:
 Manufacturing processes are clearly defined and
controlled. All critical processes are validated to
ensure consistency and compliance with
specifications.
 Manufacturing processes are controlled, and any
changes to the process are evaluated. Changes that
have an impact on the quality of the product are
validated as necessary.

17. GOOD
MANUFACTURING
PRACTICES
GMPs Contd…
 All necessary key elements for GMP are provided,
including the following:
- qualified and trained personnel
- adequate premises and space
- suitable equipment and services
- correct materials, containers and labels
- approved procedures and instructions
- suitable storage and transport

18. GOOD
MANUFACTURING
PRACTICES
GMPs Contd…
 Instructions and procedures are written in clear
and unambiguous language;
 Operators are trained to carry out and
document procedures;
 Records are made, manually or by instruments,
during manufacture that demonstrate that all
the steps required by the defined procedures
and instructions were in fact taken and that the
quantity and quality of the product was as
expected. Deviations are investigated and
documented;

19. GOOD
MANUFACTURING
PRACTICES
GMPs Contd…
 Records of manufacture (including distribution)
that enable the complete history of a batch to
be traced are retained in a comprehensible and
accessible form;
 The distribution of the products minimizes any
risk to their quality;
 A system is available for recalling any batch of
product from sale or supply;

20. GOOD
MANUFACTURING
PRACTICES
GMPs Contd…
 Complaints about marketed products are
examined, the causes of quality defects are
investigated, and appropriate measures are
taken with respect to the defective products
and to prevent recurrence.

21. GOOD
MANUFACTURING
PRACTICES
GMPs Contd…
 Thus GMPs are guidelines for the production of safe food
products.
 The GMPs address the basic sanitary requirements for
food processing, handling and storage
 The GMP regulations are generally principles identifying
the problem areas of sanitation in the food industry.
 For performing GMPs, Standard Operating Procedure
(SOP) and Sanitation Standard Operating Procedure
(SSOP) are required.

22. GOOD
MANUFACTURING
PRACTICES
GMPs Contd…
 Most of these GMPs are used by many national
governments worldwide for monitoring the safety of
consumer foods and for inspection of establishments that
process, package, handle, and store foods.

23. GOOD
MANUFACTURING
PRACTICES
GMPs ARE:
 Preventative measures to ensure food safety
 Based on practical experience over a long period
of time
 The foundation on which to build a HACCP
program
Good Management Practices Dec-07 23

24. GOOD
MANUFACTURING
PRACTICES
GMP – Food Industry

25. GOOD
MANUFACTURING
PRACTICES
 Example of equipment design

26. GOOD
MANUFACTURING
PRACTICES
SOPs
 A set of written instructions to document a routine
activity used by an organization.
 SOPs detail the work processes that are to be conducted.
 They document the way activities are to be performed to
facilitate consistent performance to safety and quality
system requirements.
 SOPs are intended to be specific.
 They assist an organization in maintaining their safety
and quality control and in ensuring compliance with
regulations.

27. GOOD
MANUFACTURING
PRACTICES
SOP’s ALLOW YOU TO:
1. SAY what you do
2. DO what you say
3. PROVE it
Good Management Practices Dec-07 27

28. GOOD
MANUFACTURING
PRACTICES
SSOPs
 Are the procedures that must be followed in order to
make sure that cleaning and sanitation activities are
performed correctly.
 SSOPs is a key component of a safety plan.
 Involve the development of detailed descriptions of
the cleaning procedures and sanitation operations
that must be performed to prevent contamination or
adulteration of the product.
 SSOPs also describe the frequency with which each
procedure is to be conducted and identify the
employee(s) responsible for the implementation and
maintenance of each procedure.

29. GOOD
MANUFACTURING
PRACTICES
 An SSOP usually includes:
o Activity name
o Place where it is performed
o List of the equipment and material necessary to perform it
o Frequency of performance
o Approximate time to perform it
o Responsible individual
o Description of every step necessary to perform the procedure

30. GOOD
MANUFACTURING
PRACTICES
Good Hygiene Practice
 GHP is prerequisite for GMP implementation.
 A guide for food manufacturers on compliance
with food safety regulations (general food
hygiene).

31. GOOD
MANUFACTURING
PRACTICES
GHP – Food Services

32. GOOD
MANUFACTURING
PRACTICES

33. GOOD
MANUFACTURING
PRACTICES
Retail

34. GOOD
MANUFACTURING
PRACTICES
Plant Management’s
Responsibility
 To ensure:
 Disease Control
 Cleanliness
 Education andTraining
 Supervision

35. GOOD
MANUFACTURING
PRACTICES
Disease Control
 Person having or appear to have:
 Illness
 Open lesion
 Boils, sores, infected wounds
 Other sources of microbial contamination
 Be excluded from operation till recovery
 Chance of contamination of:
 Food, food contact surface, packaging material

36. GOOD
MANUFACTURING
PRACTICES
Cleanliness….
 All persons working in direct contact with
food, food contact surfaces, or food
packaging material shall conform to hygienic
practices while on duty to protect against
contamination of food

37. GOOD
MANUFACTURING
PRACTICES
….Cleanliness….
 Wearing outer garments suitable to
operations
 Maintaining adequate personal cleanliness
 Washing hands (at least for 30 sec)
 Before starting work
 After each absence from work station
 At any other time when the hands may have
become soiled or contaminated

38. GOOD
MANUFACTURING
PRACTICES
….Cleanliness….
 Removing jewellery and other objects which
may fall into
 Food, equipment or containers
 Remove hand jewellery that
 Cannot be adequately sanitized during periods in
which food is manipulated by hands
 If it cannot be removed it be covered by material
which can be maintained in an intact clean and
sanitary condition

39. GOOD
MANUFACTURING
PRACTICES
….Cleanliness….
 Maintaining gloves
 Be in an intact clean and sanitary conditions
 Be of an impermeable material
 Wearing where appropriate
 Hair nets, headbands, caps, beard covers or other
effective hair restraints

40. GOOD
MANUFACTURING
PRACTICES
….Cleanliness….
 Store clothing or other personal belongings
 In areas other than where food is exposed or where
equipment or utensils are washed
 Confining the following to other areas
 Eating food, chewing gums, drinking beverages, or
using tobacco

41. GOOD
MANUFACTURING
PRACTICES
….Cleanliness….
 Taking other necessary precautions to protect
 Food, food contact surfaces, or food packaging
material from
 Micro organisms
 Foreign material; perspiration, hair, cosmetics,
tobacco, chemicals and medicines applied to the skin

42. GOOD
MANUFACTURING
PRACTICES
Education and Training
 Personnel responsible for identifying sanitation
failures or food contamination
 should have a background of education and/or experience
necessary for production of clean and safe food
 Food handlers and supervisors should receive
appropriate training in
 Proper food handling techniques
 Food protection principles
 Be informed of the danger of poor personnel hygiene and
unsanitary practices

43. GOOD
MANUFACTURING
PRACTICES
Supervision
 Competent supervisory personnel be
assigned the responsibility for assurance of
compliance by all personnel with all
requirement with this part

44. GOOD
MANUFACTURING
PRACTICES
KEY CONCEPTS OF A HACCP PLAN
 Good Manufacturing Practices (GMPs)
 Standard Operating Procedures (SOPs)
Good Management Practices Dec-07 44

45. GOOD
MANUFACTURING
PRACTICES
PREREQUISITE PROGRAMS
A. Premises (including water supply)
B. Transportation, Receiving and Storage
C. Equipment Design, Installation and Maintenance
D. PersonnelTraining
E. Sanitation & Pest Control
F. Recall
Good Management Practices Dec-07 45

46. GOOD
MANUFACTURING
PRACTICES
PREREQUISITE PROGRAM: PREMISES
 Building Exterior
 Building Interior: Design, Construction, Lighting,
Ventilation, Waste Disposal, Inedible Areas
 Sanitation Facilities: Employee Facilities,
Equipment Cleaning & Sanitizing Facilities
 Water/Ice Quality and Supply
Good Management Practices Dec-07 46

47. GOOD
MANUFACTURING
PRACTICES
PREREQUISITE PROGRAM: PREMISES
 Premises SOP
 Monitoring Procedure: part of internal audit
procedures
Good Management Practices Dec-07 47

48. GOOD
MANUFACTURING
PRACTICES
PREREQUISITE PROGRAM: TRANSPORTATION,
RECEIVING & STORAGE
 Receiving: Food Carriers,Temperature Control,
Approved Suppliers
 Storage: Ingredient, Allergen, Finished Product and
Chemical Storage
 Transportation: Food Carriers,Temperature Control
Good Management Practices Dec-07 48

49. GOOD
MANUFACTURING
PRACTICES
PREREQUISITE PROGRAM: TRANSPORTATION,
RECEIVING & STORAGE
 Transportation Receiving and Storage SOP
 Monitoring Procedures: check each shipment,
 CAR: example
 Allergen Program
 Approved Suppliers Program
Good Management Practices Dec-07 49

50. GOOD
MANUFACTURING
PRACTICES
PREREQUISITE PROGRAM: EQUIPMENT
 Equipment Design and Installation
 Equipment Maintenance and Calibration
 Equipment SOP
 Temperature Monitoring Log
 Thermometer Calibration
Good Management Practices Dec-07 50

51. GOOD
MANUFACTURING
PRACTICES
PREREQUISITE PROGRAM: PERSONNEL
 Training: Hygiene andTechnical
 Hygiene and Health Requirements
 Personnel SOP
 Employee Sanitation SOP
 Visitor Log Book
Good Management Practices Dec-07 51

52. GOOD
MANUFACTURING
PRACTICES
PREREQUISITE PROGRAMS: Sanitation &
Pest Control
 SANITATION
 PEST CONTROL
 SOP
 PREOPS CHECKLIST
 TRUCK CLEANING LOG
Good Management Practices Dec-07 52

53. GOOD
MANUFACTURING
PRACTICES
PREREQUISITE PROGRAM: RECALL
 The Recall System
 Complaints Log
 Complaints Log SOP
 RecallTemplate
 Recall Notice
 Allergen Alert Notice
Good Management Practices Dec-07 53

54. GOOD
MANUFACTURING
PRACTICES
CRITICAL LIMITS
 Is a value which separates acceptability from
unacceptability
 Critical Limits must meet or exceed government
regulations
 One or more critical limit must be met to ensure
a CCP is controlling the hazard
Good Management Practices Dec-07 54

55. GOOD
MANUFACTURING
PRACTICES
CRITICAL LIMITS
 Temperature /Time
 pH
 Aw (available water)
 Preservatives
 Available chlorine
 Sensory observations
Good Management Practices Dec-07 55

56. GOOD
MANUFACTURING
PRACTICES
SOURCES OF CRITICAL LIMITS
 Regulatory Standards
 Company Standards
 Literature Surveys
 Experimental Studies
 ExpertAdvice
Good Management Practices Dec-07 56