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Good manufacturing practices_pp
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- 2. Agenda • Basic FoodSafety • cGMP • Food Handling Practices
- 3. Food Safety - isa scientific discipline describing handling, preparation, and storage of food in ways that prevent food-borne illness.
- 4. Food Safety •Food cantransmit pathogens which can result in the illness or death of the person or other animals. The main mediums are bacteria, viruses, mold, and fungus. It can also serve as a growth and reproductive medium for pathogens. In developed countries there are intricate standards for food preparation, whereas in lesser developed countries there are less standards and enforcement of those standards.
- 5. Food Safety Act •THE IMPLEMENTING RULES AND REGULATIONS OF REPUBLIC ACT NO. 10611, “AN ACT TO STRENGTHEN THE FOOD SAFETY REGULATORY SYSTEM IN THE COUNTRY TO PROTECT CONSUMER HEALTH AND FACILITATE MARKET ACCESS OF LOCAL FOODS AND FOOD PRODUCTS, AND FOR OTHER PURPOSES” OTHERWISE KNOWN AS THE “FOOD SAFETY ACT OF 2013.”
- 6. Food Safety Act •Section 15, Article II of the 1987 Philippine Constitution declares that the State shall protect and promote the right to health of the people and instill health consciousness among them. Furthermore, Section 9, Article XVI provides that the State shall protect consumers from trade malpractices and from substandard or hazardous products. Toward these ends, the State shall maintain a farm to fork food safety regulatory system that ensures a high level of food safety, promotes fair trade and advances the global competitiveness of Philippine foods and food products.
- 7. 5 key principlesof food hygiene 1. Prevent contaminating food with pathogens spreading from people, pets, and pests. 2. Separate raw and cooked foods to prevent contaminating the cooked foods. 3. Cook foods for the appropriate length of time and at the appropriate temperature to kill pathogens. 4. Store food at the proper temperature. 5. Do use safe water and safe raw materials.
- 8. GMP “Good ManufacturingPractices” • Good manufacturing Practices are those activities and practices that we do to prevent hazards or contamination from entering food products. • Always improving and changing (that is why they are called “current”)
- 9. cGMP Violations -- SevereConsequences • Product is “adulterated” • Shutdown of manufacturing facility • Seizure of product • Recall product • Front page press coverage • Competitive disadvantage
- 10. Good Manufacturing Practices Dealwith contamination • by people • by food materials • by packaging materials • by hazardous materials • by miscellaneous materials
- 11. Contamination •Contamination is thepresence of an unwanted material in a product, physical body, natural environment, workplace, etc. Contaminants are biological, chemical, physical substance •Any behavior that could result in food adulteration such as eating, use of tobacco, chewing gum or other unhygienic practices, is not allowed in food handling areas
- 12. Hazards •Physical hazard - chippedoff glass, plastic, wood, stone, etc •Chemical hazard - oil, lubricants, detergent, etc. •Biological hazard - bacteria, fungi, virus
- 13. Prevent contamination Careless employeepractices can cause product contamination. The best way to avoid contamination is to prevent it.
- 14. How do weprevent contamination? GMP!
- 15. Good Manufacturing Practices •Personnel Hygiene • Building and Facilities • Tools and Equipment • Food Handling Practices • Raw materials / ingredients • Cleaning & Sanitation Program • Pest Control Program
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- 17. Hygiene All employees workingin direct contact with food, food contact surfaces and food packaging must conform to hygienic practices. This protects against food contamination by microorganisms or unwanted material.
- 18. Hygiene and CommunicableDiseases • clothing • hair • personal habits • hand washing • personal effects and jewelry • illness and disease • injuries • visitors • training
- 19. Production employees • Bathedaily • No perfume, aftershave, fragrant creams • No jewellery • No false nails or nail polish • Fingernails should be trimmed short • Use metal detectable bandages covered with gloves • No eating, drinking or chewing gum
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- 22. Clothing • Everyone mustwear pants and covered sleeves. • Separate shoes (no open toes or high heels) are to be worn in the factory. • Personal belongings and street clothing must be stored in locker rooms.
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- 25. Illness • Doctor’s certificateon hiring • Inform your supervisor or HR if you are ill with symptoms that could contaminate ingredients or products • No medication allowed in factory • Ensure that a clean bandage covers any open wounds
- 26. Hand washing All employeesmust wash their hands thoroughly: • when they enter food handling areas • before starting work • after handling contaminated materials • after breaks • after using toilet facilities
- 27. Hand washing Procedure •Rinse • Clean • Rinse • Sanitize • about 20 secs or just sing the happy birthday song
- 28. Building & Facility •Separate or defined areas as are necessary to prevent contamination or mix-ups • Building will be adequately sized for proper storage of equipment and material • Operations will be performed in specific areas • Raw materials received will be placed in quarantine until tested • Rejected material will be separated
- 29. Building & Facility •Therewill be adequate lighting – Should be provided with shatter shield to prevent contamination when broken •Should have adequate ventilation
- 30. Building & Facility •Sewageand trash will be stored and disposed of in a safe and sanitary manner – Color coded trash bin for biodegradable, non-biodegradable and recyclable wastes •Adequate washing and toilet facilities will be available – hot and cold water – single service towels – soap
- 31. Building & Facility •Buildingwill be maintained in a clean and sanitary manner •There will be cleaning schedules with approved cleaning agents – SOPs on cleaning •Buildings in a good state of repair •Buildings maintained pest and rodent free • Written procedures and approved rodentcides, insecticides and fungicides – will not affect product
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- 33. Tools & Equipment •Mustbe made with stainless material or plastic that is food grade (direct contact) •Wooden tools is not allowed •In good repair •Must be easily cleaned • Lubricants must be food grade or has MSDS certificate
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- 35. Personnel • Do notleave gloves, masks, etc. lying around while on break or at shift end. • Crates, boxes, containers or buckets must not be placed directly on the floor. • Store brooms and dust pans at stations provided.
- 36. Product • Keep handcontact with ingredients to a minimum. • Check ingredients for expiration dates to ensure that fresh ingredients are used. • Cooling product should always be kept covered.
- 37. Equipment, containers andutensils • Use white or brown containers to store ingredients and rework. • Use gray containers for garbage. Garbage containers must be kept covered. • Ensure that all containers, including those holding rework, are properly labelled and are kept covered.
- 38. Equipment, containers andutensils
- 39. Cloths Use white clothsto wipe hands regularly and dispose of soiled cloths immediately. No moist cloths are to be left in the production area. Use yellow cloths to clean the floor and objects (e.g. step stools) that come into contact with the floor.
- 40. Utensils •Production equipment/utensils mustbe thoroughly cleaned and sanitized after use. •Kept and arranged on a clean sanitary place
- 41. Premises • Keep unscreeneddoors and windows closed. • Report any pests or evidence of pests such as flies, insects, mice droppings.
- 42. Equipment • Return toolsand attachments to their proper place after use. • Check product surfaces before starting equipment. Remove any foreign objects or dirt. • Replace brushes that lose bristles.
- 43. Personnel Practices • Donot lean, sit or step on product surfaces. • Do not handle ingredients or products with either cut or infected hands. • Do not engage in horseplay. • Keep hand contact with ingredients and product to a minimum.
- 44. Sanitation • Keep contactsurfaces clean and free of contamination from tools, cords, cleaning utensils, machine parts, lubricants and paper. • Clean all spills promptly. • Keep everything off the floor and the area clean and floors swept.
- 45. • Work areasshould be cleaned regularly throughout the shift. • Keep your immediate working area swept or dust mopped. Wipe or mop up spilled liquids promptly. • Scrape the floor around the work area after completing a job. • Leave your work area clean at the end of your shift. Sanitation
- 46. • Rinse • Clean(soap) • Rinse • Sanitize Sanitation
- 47. • Use foodgrade chlorine with Material Safety Data Sheet • Dilute to appropriate concentration –Hand dip – 30-50ppm –Foothbath – 200ppm –Tools & equipment – 50-100ppm Sanitation
- 48. Receiving and Storage •Raw materials are properly arranged and labelled accordingly. • Inspect torn bags and boxes and then repair if appropriate. • Brush off bags and boxes before opening them. • Store ingredients and products at the appropriate temperature.
- 49. Receiving & Storage •Use ingredients in the proper rotation (FIFO - oldest stock first) • Handle ingredients or products carefully to avoid spilling • Do not return products or ingredients to the production line after they have touched the floor or any other surface that is not clean.
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- 51. Maintenance and Repairs •Ensure area is segregated from production by use of tarps. • Do not leave maintenance supplies in the product zone. • Return all tools and attachments to their proper place after use. • Ensure the production area is clear of all tools and hazards before production starts
- 52. Retail store • Monitorand maintain proper temperatures • Rotate ingredients using FIFO and check for expired items. • Check best before dates and the quality of the food before using. • Refrigerate cold foods immediately upon receipt. • Sanitize equipment, cutting boards, work surfaces and utensils. • Always wash hands after handling money.
- 53. Visitors to ProductionAreas • Should always be accompanied. • Must be appropriately dressed - hair coverings, booties over street shoes, gloves, sleeve covers, etc.
- 54. Quiz Spot the Hazards: GoodManufacturing Practices
- 56. On the job..... •Thinkabout food safety as you work •Watch for hazards and remove any that you find Questions ?
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