Buttercup Bakery Adapted from http://www.fskntraining.org
All staff are to complete this training BEFORE their FIRST shift.This forms part of Level 1 Training - INDUCTION
GFSI Basic Level The organization shall ensure there are adequate control measures in place to prevent cross contamination of allergens. All ingredients known to cause food allergies in the product shall be clearly identified and communicated to the customer.
The importance of allergens The handling and control of allergens
A food allergy is a reproducible adverse reaction to a particular food that involves the immune system. Nearly all allergens are proteins. A food allergen is defined as a form of food intolerance associated with a hypersensitive immune response mediated reaction in which antibodies are formed. A food intolerance is defined as a reproducible reaction to a food which occurs without a hypersensitive immune response.
Allergen lists differ from region to region. On a global basis approximately 1 – 2% of adults and 5 – 8% of children suffer from food allergy. Death and serious health problems can result from allergic reactions. In some cases 1mg can trigger a reaction and even death (1 mg is 1000 times smaller than 1g) Approximately 100 deaths due to peanut allergy in 2006.
Respiratory reaction e.g. asthma Gastrointestinal reaction e.g. vomiting, diarrhea Skin reaction e.g. dermatitis Anaphylactic shock – drop in blood pressure, severe constriction of airways, multiple organ failure and death
SANS 10049; R146 Allergen Risk Analysis required Which allergens are used in this facility Which raw materials are they found in? Do the suppliers control allergens in their own facilities? Allergen Risk must be managed Where and how are they stored? Where and how are they processed? What equipment is used? Is it shared? Do the cleaning SOP’s take into account allergens (in all areas, e.g. receiving, storage, processing, packaging)? Are employees aware of the risk? Allergen Risk must be communicated To staff To consumers (via label) Allergen Risk must be reviewed Internal Audits
Wheat Gluten Egg Milk Sesame Seeds Soya Tree nuts (pecan nuts) Peanuts Celery Fish & Seafood
Packaging People Allergen ManagementCleaning Raw Materials & Supply Chain Manufacturing Premises, Equipment & Processes
Staff awareness by product identification and recipe control Hand washing Clothing Rework control Waste control Use of utensils Control of food consumption Peanut butter sandwiches, fish etc
Known status of ingredients from suppliers i.e. possible cross contamination Ingredient Specifications Clear labeling & identification Transported responsibly Good packaging integrity Stored correctly (separately, tightly sealed containers)
Correct packaging control Packaging line change – correct cleaning after packing product containing allergens Products with and without allergens kept separate – not packed on the same table Applying correct label – problems with “mislabeling” e.g. using label for plain hamburger on seeded hamburgers…
Effective cleaning to reduce the risk of cross contamination Dedicated cleaning equipment Cleaning schedules Cleaning of spillages Dismantling of equipment
Different parts of the factory Physical barriers Dedicated equipment Minimize movement of materials Scheduling of production runs with appropriate cleaning between production runs Control of rework