good manufacturing practices

1. Lecture 3: Preventive Measures and
Control Methods to Minimize Hazards
and Maintain Quality of Foods – GMP
and PRP
Assoc. Prof. JOANN DAVID DAR
Dept. of Food Science and Technology, CHSI, CLSU
PGS Food Safety, QA Systems and Risk Analysis, Universiteit Gent-Belgium
M.Sc. Food Science and Technology, ENSIA-SIARC - France
BS Food Technology, CLSU-Philippines

2. Topical Outline
1. Good Manufacturing Practices (GMP)
2. Pre-Requisite Programs

3. GOOD MANUFACTURING PRACTICES (GMP)
• package of requirements and procedures by which the work methodology
takes place under controlled conditions and by which surroundings
conditions are created that allows the production of hygienic and safe
products
• Aim is to prevent or reduce the contamination to a minimum
• Implemented on different levels in a food company.
The environment;
The process and product;
The personnel.

4. GMPs
GMP 1: clearing and disinfection;
GMP 2: pest control;
GMP 3: water and air quality;
GMP 4: temperature control;
GMP 5: personnel (facilities,
hygienic way of working, health,
education);
GMP 6: structure and infrastructure
(surrounding area, building,
materials, equipment)
GMP 7: technical maintenance;
GMP 8: waste management;
GMP 9: control of raw materials;
GMP 10: work methodology.

5. 2. PRE-REQUISITE PROGRAM (PRP)
• define as every specific and documented activity or facility that is implemented corresponding to
the ‘Codex General Requirements of Food Hygiene’, the ‘Good Manufacturing Practices’ and the
legislation
• purpose to create basic requirements that are necessary for the production and processing of safe
foods in all stages of the food chain.
• covers GHP (Good Hygienic Practices), GMP and the legislation
• The term ‘program’ refers to the fact that PRP’s are more than a working instruction, a plan or
regulation. They are “general control measures”, that need to be verified on their effectiveness on
a regular basis.

6. PRPs are divided into 14 groups:
PRP 1: cleaning and disinfection;
PRP 2: pest control;
PRP 3: water and air quality;
PRP 4: temperature control and registration;
PRP 5: personnel (facilities, hygienic way of
working, health, education);
PRP 6: structure and infrastructure
(surrounding area, building, materials,
equipment)
PRP 7: technical maintenance and calibration;
PRP 8: waste management;
PRP 9: control of raw materials;
PRP 10: traceability, recall, good returned,
rejections/non-comfort products;
PRP 11: allergens;
PRP 12: physical and chemical
contaminations;
PRP 13: management of product information;
PRP 14: work methodology.
*PRPs in yellow font color are absent in GMP

7. PRP 1: cleaning and disinfection
• Best measure to keep pests outside and to prevent accumulation
of pathogen and spoilage microorganisms
• Every company needs an elaborated :Cleaning and Disinfection
Plan”
CLEANING – processes elaborated to remove dirt; after cleaning, the
surfaces are visual clean but microorganisms can still be present
DISINFECTION – processes elaborated to kill the remaining
microorganisms after cleaning

8. PRP 1: cleaning and disinfection……continuation
PRP1.1 Cleaning and Disinfection Plan
The cleaning and disinfection plan must contain the following aspects:
WHAT needs to be cleaned and disinfected?
HOW this has to be done? (which activity and which equipment has to be
used?) – a reliable procedure needs to be used
WHEN the cleaning and disinfection needs to be carried out?
WHO is responsible?
a REGISTER or REGISTRATION/RECORD of the executed cleaning and
disinfection activities has to be kept up to date
Note: Cooling elements and evaporators – must be included

9. PRP 1: cleaning and disinfection……continuation
PRP 1.2 Material
• Cleaning chemical to be used must be approved as biocide
• Detergents- no odour and non-corrosive
• Various disinfectants must be used- to prevent build up of
resistance among microorganisms
• Company must have Material Safety data Sheet (MSDS) for every
chemical – safety and how to use
• Detergents and disinfectants- must only be present in production
room during cleaning and disinfection- must be in proper storage

10. PRP 1: cleaning and disinfection……continuation
PRP 1.2 Material …. continuation
• Cleaning material(brush, wiper, etc) – has to be synthetic and not a cause of contamination;
- has to be resistant against corrosion and the use of chemicals
- has to be cleaned and disinfected regularly and included in the cleaning and
disinfection plan
- separate clean
ing materials (different colors) needs to eb used for the cleaning and disinfection of
a. Sanitary fittings
b. Low care area (area where contaminated foods are handled i.e. raw foods)
c. High care area (area where every contaminant that comes into the food, will be present in
the end product. The product does not undergo a treatment that can eliminate present
contaminants i.e. cooked foods)

11. PRP 1: cleaning and disinfection……continuation
PRP 1.3 Execution of cleaning and disinfection – the followings steps are used:
a. Preparation – visible dirt is removed with a brush or water; when necessary,
machines and apparatus need to be disassembled
b. Cleaning – rinse with water; carry out the real cleaning with an appropriate
detergent. With this step, fat and other visible dirt is removed and it is visual
clean
c. Rinsing –witn water to remove dirt and detergent; If there is a large amount of
accumulated water, this should be removed as it can dilute the disinfectant
d. Disinfection – remaining microorganisms are killed during disinfection; only
effective if proper cleaning was carried out properly
e. Rinsing – to avoid food contamination with disinfection, everything is rinsed with
potable water.
*CLEANING-IN-PLACE – use a similar methodology without dismantling the equipment

12. PRP2. Pest Control
• Effective measures need to be in proper place to keep pests away from
the processing/production site/area;
• Someone needs to responsible for Pest Control
• Measures should put more emphasis on prevention- i.e. avoid the
entrance of pests and pay attention to the following points
a. Exterior walls may contain as less as possible cracks and chinks
b. Pipes and grids need to be accessible for cleaning
c. Exterior windows need to be provided with screen
d. Loading and unloading gate has to be closed immediately after loading
and unloading

13. PRP2. Pest Control……continuation
e. the company and its surrounding should be kept neat and clean
f. apparatus and rooms which are not being used need to be cleaned
g. Prolonged staying of a pool of water has to be avoided
h. Presence of a pest control plan is indispensable – need to focus on rodents,
crawling and flying insects
- presence of baits /traps is a preventive measure (early detection of pests);
hiring of a pest control (specialized and professional) company is recommended but
not required
- installation of baits need to be indicated on a floor plan and must be
numbered for monitoring
- insect killers need to be installed in rooms where it is necessary (i.e.
loading, unloading bays, or other rooms with direct entrance to outside, cleaning
area)

14. PRP2. Pest Control……continuation
h. Presence of a pest control plan …………….
- UV lamp need to be replaced at least once a year or as per
manufacturer’s instructions; the bin used to collect the insects must be
broader than the lamp or the system of electrocution must ne provided
with adhesive tape to avoid insects falling out of the bin; these bins must
be emptied and cleaned on a regular basis; the cleaning of these
recipients must be included in the Cleaning and Disinfection Plan or can be
included in the contract of the company responsible for pest control
- When there is a problem on pests- need to determine the cause
- Pesticides – must be put in proper storage/room with limited access and
must be acknowledged as biocides; may not have contact with foods,
contact surfaces or packaging materials

15. PRP3. Water and Air Quality
PRP 3.1 Water quality