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Good Manufacturing Practices Training by International Food Safety Consultancy

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Good Manufacturing Practices Training by International Food Safety Consultancy

  1. 1. PART II GOOD MANUFACTURING PRACTICES (GMP)
  2. 2. GMP Prerequisite programs which will provide the basic environmental and operating conditions that are necessary for the production of safe and wholesome food.
  3. 3. SSOP Sanitation Standard Operating Procedures
  4. 4. According to FDA, the SSOP should include: * General maintenance * Substances used in cleaning and sanitizing; * storage of toxic materials * Pest control: * Sanitation of food-contact surfaces * Storage and handling of clean portable equipment and utensils * Rubbish disposal
  5. 5. The SSOP adopted by FSIS cover the pre-operational and operational sanitation procedures that an establishment shall implement to prevent direct contamination or adulteration of products
  6. 6. FOOD SAFETY ON PRIMARY PRODUCTION
  7. 7. DEFINITION Covers all steps of the food chain, from production to harvest, slaughter, milking or fishery
  8. 8. OBJECTIVE Ensures that food is safe and suitable for its intended use
  9. 9. CHALLENGE The integration of government agencies with primary producers.
  10. 10. IMPORTANT ASPECTS • ENVIRONMENTAL HYGIENE – Water – Land • HYGIENIC PRODUCTION OF FOOD • HANDLING, STORAGE AND TRANSPORTATION • CLEANING, MAINTENANCE AND PERSONNEL HYGIENE
  11. 11. ENVIRONMENTAL HYGIENE – Water: irrigation, application of pesticides and fertilizers, cooling, frost control, drinking water, cleaning of buildings, personal hygiene, etc – Has the potential to be a direct source of contamination and a vehicle for spreading contamination – Irrigation water source and supply
  12. 12. HYGIENIC PRODUCTION OF FOOD • Control contamination from air, soil, water, foodstuffs, fertilizers (including natural fertilizers), pesticides, veterinary drugs or any other agent used in primary production; • Control plant and animal health so that it does not pose a threat to human health through food consumption, or adversely affect the suitability of the product;
  13. 13. • Protect food from fecal and other contamination; • Manage wastes, and store harmful substances appropriately.
  14. 14. HANDLING, STORAGE AND TRANSPORTATION Procedures should be in place to: - Sort out food and food ingredients from material which is clearly unfit for human consumption; - Dispose of any rejected material in a hygienic manner; and;
  15. 15. - Protect food and food ingredients from contamination by pests, chemical, physical or microbial contaminants or other objectionable substances during handling, storage and transportation.
  16. 16. CLEANING, MAINTENANCE AND PERSONNEL HYGIENE Appropriate facilities and cleaning procedures
  17. 17. ESTABLISHMENT: DESIGN AND FACILITIES
  18. 18. OBJECTIVES - Minimize contamination; - Permit appropriate maintenance, cleaning and sanitizing
  19. 19. BUILDING Establishments should be built away from  Polluted areas and industrial activities which pose a threat for contamination of food ;  Areas subject to floods, unless sufficient safeguards are provided;  areas prone to infestations by pests;  Areas where waste (solid or liquid) cannot be removed effectively.
  20. 20. MAINTENANCE – Maintain roads, yards, and parking to avoid contamination of areas where food is exposed; – Adequately drain areas that may contribute to contamination of food by foodborne filth, or provide conditions for nesting and breeding of for pests; – Operate systems for waste treatment and disposal in an adequate manner.
  21. 21. PREMISES AND WORKING AREAS • Design and layout - protect against cross-contamination - control process flow
  22. 22. Internal structures and fittings  Walls and floors;  Ceilings and overhead fixtures; Windows;  Doors;  Working surfaces; Establishments;  Sewage lines.
  23. 23. EQUIPMENT Sanitation and maintenance to avoid contamination: – Construction material – Durability – Maintenance, Sanitation, Monitoring
  24. 24. Program of preventive maintenance -List of equipment requiring regular maintenance. -Procedures and frequencies of maintenance are based on instructions from the manufacturers or on operating conditions.
  25. 25. FACILITIES • • • • • • • • • Water supply Drainage and waste disposal Cleaning Facilities for personnel hygiene Toilets Temperature control Air quality and ventilation Lighting Storage
  26. 26. CONTROL OF OPERATIONS
  27. 27. Objectives Production of safe and suitable food for human consumption ensuring: requirements for raw materials, composition, processing, distribution, and consumer use; designing, implementing, monitoring and reviewing control systems.
  28. 28. Control of Food Hazards
  29. 29. identify any points in the operations which are critical to the safety of food; implement effective control procedures; ensure effectiveness of procedures; review procedures periodically.
  30. 30. Examples of general procedures Product composition current written composition details of formulation
  31. 31. Food additives Manufacturer should guarantee that all additives in use:  are approved for the food being produced;  comply with the specific laws and regulations;  are pure;  provide certifications for each lot  comply with legal limits.
  32. 32. Label accuracy The manufacturer should ensure that the label provides: • accurate information of net contents; • manufacturer’s, packer’s and/or distributor’s names and addresses; and • instructions for proper handling by the consumer
  33. 33. Time and temperature control
  34. 34. Time and temperature control Such controls include time and temperature of:  Cooking  Cooling  Processing  Storage
  35. 35. Temperature control systems should take into account:  nature of the food  intended shelf-life of the product  method of packaging and processing  intended use
  36. 36. Specify limits for time and temperature variation Calibration and verification of equipment and instruments
  37. 37. Metrologic verification Set of operations needed to assure that a measuring equipment complies with standards and requirements for the intended use.
  38. 38. Specific process steps
  39. 39. • • • • • • chilling thermal processing irradiation drying chemical preservation packaging in vacuum or modified atmospheer
  40. 40. Microbiological cross contamination
  41. 41. Pathogens can be transferred from one food to another, either by direct contact, by food handlers, through common contact with surfaces, or through the air.
  42. 42. Chemical and physical contamination
  43. 43. Contamination of food by foreign matters such as glass or metal particles, dust, harmful fumes and unwanted chemicals.
  44. 44. RAW MATERIAL AND INGREDIENTS
  45. 45. Reception: – Manufacturer – Specifications – Chemicals – Inspection of raw material
  46. 46. PACKAGING
  47. 47. • Packaging materials • Protection of food • Prevent recontamination
  48. 48. WATER
  49. 49. • Water Quality • Chlorine • Analysis • Cleaning of reservoirs
  50. 50. • Ice making • Steam production • Drainage • Plumbing
  51. 51. Aspects to be considered: adequate source appropriate temperature and pressure separated system according to use allowed disinfecting agents control of drinking water
  52. 52. • • • • Monitoring Correcting deviations Records Water standards: WHO
  53. 53. MANAGEMENT AND SUPERVISION
  54. 54. • The type of control and supervision needed will depend on the size of the business, the nature of the activities and the types of food being produced. • Managers and supervisors should have enough knowledge of principles of food hygiene
  55. 55. DOCUMENTATION AND RECORDS
  56. 56. Monitoring time Legibility Revising and updating records
  57. 57. RECALL PROCEDURES
  58. 58. Recall information should include the following: - Amount of product produced, in inventory and distributed. - Name, size, code or lot numbers of food recalled - Area of distribution - Reason for the recall - Final disposition of the product (rework, discharge, etc.)
  59. 59. Storage
  60. 60. • Temperature conditions • Relative humidity • Air velocity • FIFO (First In First Out)
  61. 61. BUILDING MAINTENANCE AND SANITATION
  62. 62. OBJECTIVES To establish effective systems to ensure appropriate maintenance and clean ing, pest control, waste management and effective monitoring.
  63. 63. Biofilm: • • • Adhesion Protection Resistance
  64. 64. CLEANING PROCEDURES AND METHODS
  65. 65. Cleaning and sanitizing normally require the following steps: 1. Dry clean 2. Pre-rinse 3. Detergent application (may include scrubbing) 4. Post-rinse; and 5. Sanitizer application.
  66. 66. CLEANING PROGRAMS
  67. 67. Where written cleaning programs are used, they should specify: - areas, items of equipment and utensils to be cleaned - responsibility for specific tasks - method and frequency of cleaning - monitoring
  68. 68. CLEANING OF EQUIPMENT
  69. 69. • CIP (clean-in-place). • manual • automatic • immersion • drying
  70. 70. CLEANING OF PREMISES
  71. 71. • areas to be cleaned; • methods of cleaning; • person responsible; and • frequency of the activity
  72. 72. DETERGENTS
  73. 73. • General use • Alkaline or chlorinated detergents • Acid detergents • Enzymatic detergents
  74. 74. Cleaning effectiveness will depend upon several basic factors: • Contact time • Temperature • Physical disruption of the soil (scrubbing) • Water chemistry
  75. 75. SANITATION AGENTS
  76. 76. • Chlorine • Quaternary Ammonium Compounds • Iodophors, • Acid sanitizers including acidanionium,carboxylic and peroxyacetic acid types • Ozone • Ultraviolet(UV) irradiation • Hot (hot water)
  77. 77. PEST CONTROL
  78. 78. Preventing access
  79. 79. • Entrance sites • External and Internal inspection • Assess the facility’s capacity for excluding pests.
  80. 80. Harborage and infestation
  81. 81. • Availability of food and water • Effectiveness of cleaning and sanitation procedures
  82. 82. Monitoring and detection
  83. 83. • Observations of the presence • Evidence of the presence
  84. 84. Eradication
  85. 85. Agents: • • • Chemical Physical Biological
  86. 86. Waste Management
  87. 87. • Storage Areas • Waste bins, tubs and dumpsters • Proper cleaning and sanitizing
  88. 88. SANITATION MONITORING EFFECTIVENESS
  89. 89. Sanitation systems program periodically verified – Audit pre-operational inspections, – Microbiological sampling of environment and food contact.
  90. 90. PERSONAL HYGIENE
  91. 91. Objective To ensure that those who come directly or indirectly into contact with food are not likely to contaminate it.
  92. 92. HEALTH STATUS
  93. 93. • Illness • Injuries • Individual Health Card
  94. 94. PERSONAL CLEANLINESS
  95. 95.  Personal effects  Hand washing  Use of antiseptic on hands
  96. 96. UNIFORM
  97. 97. • Uniform – Uniforms should be kept clean and in good condition. • Masks and gloves – should be used when a ready-to-eat food is prepared
  98. 98. PERSONAL BEHAVIOR
  99. 99. • Trained to be conscious of the importance of GMP • Unacceptable Action
  100. 100. VISITORS
  101. 101. Adhere to the same personal hygienic provisions described for food handlers.
  102. 102. TRANSPORTATION
  103. 103. OBJECTIVES • To protect food from potential sources of contamination and from damage likely to render food unsuitable for consumption; • To provide an environment which limits growth of pathogenic or spoilage microorganisms and the production of toxins.
  104. 104. Requirements • • • • • • design and construction clean and/or disinfect separate foods from non-food items maintain temperature verification of temperature prevent contamination
  105. 105. VERIFICATION - Inspection of vehicle - Program describing effective cleaning and sanitation procedures - Restrain transportation of non-food items - Loading/unloading - Design and construction of tank vehicles - Materials used in vehicles for food transportation
  106. 106. PRODUCT INFORMATION AND CONSUMER AWARENESS
  107. 107. OBJECTIVES – All products should be labeled with sufficient information to ensure that the person in the next step of the food chain will understand how to handle, store, process, prepare and display the product safely and correctly ; – This information should contain a clear identification of the lot or batch in order to facilitate any necessary recall.
  108. 108. Lot identification
  109. 109. A lot is a defined quantity of a commodity produced under the same conditions . Lot identification is essential to product recall and also contributes to effective stock rotation.
  110. 110. Product information
  111. 111. Adequate label information on food products enables the next person in the food chain to handle, display, store, prepare and use the product safely and correctly.
  112. 112. Labeling
  113. 113. “Codex of General Standard for the Labeling of Prepackaged Foods” (CODEX STAN 1-1985).
  114. 114. The minimum information required on prepackaged labels is:  Name of the food  Ingredients  Net contents and drained weight
  115. 115.  Name and address of manufacturer, packager, distributor, importer, exporter or vendor of the food  Country of origin;  Lot identification;  Date and storage instructions;  Instructions for use.
  116. 116. Consumer education
  117. 117. • Health education programs should cover general food hygiene; • Helping consumers to understand the importance of reading labels, following instructions for use, and making correct choices; • Information on the relationship between time/temperature control and foodborne diseases
  118. 118. TRAINING
  119. 119. • Awareness and responsibilities • Training programs • Instruction and supervision • Refreshing training • Minimum program for GMP training courses • Code of Hygyenic Practices - Codex Alimentarius Commission
  120. 120. Minimum program for GMP training courses • • • • Primary production; Design of plant and facilities Control of operations; Plant maintenance and sanitation;
  121. 121. • Transportation; • Product information and consumer awareness; • Training; • GMP evaluation.
  122. 122. GOOD MANUFACTURING PRACTICE EVALUATION
  123. 123. Verification Audit

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