Safe Food Realization Through Ipleetatio of Iteatioal Reuieets - PowerPoint PPT Presentation

Best in Class Personal Hygiene Practices for Safe Food Realization Through I�ple�e�tatio� of I�te��atio�al Re�ui�e�e�ts …. Contents …  International References  Trends in Food borne Illness  Personnel Hygiene  Access Control  Hygiene Station  Hand washing requirements  Location Selection  Layout & Zoning  Building  Material Receipt & Movement  Bore-well Head Protection  List of Food Handlers medical test & controls Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 1

International References • CODEX Alimentarius • FSSAI • EHEDG : European Hygienic Engineering Design Group • FDA : US Food and Drug Administration • NSF: National Science Foundation • FSSC 22000: Food Safety System Certification • AIB : AIB International • Canadian Food Inspection Agency • University of Guelph Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 2

Trends in Food borne Illness in USA, 1996 – 2010 Fig : Changes in incidence of laboratory-confirmed bacterial infections, United States, 2010 compared with 1996 – 19981 Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 3

Integrated Disease Surveillance Project (IDSP) Integrated Disease Surveillance Project (IDSP), launched by Union Minister of Health & Family Welfare, India in November 2004 2000 3000 1964 2636 1675 1667 1584 1585 2500 1500 2000 No. Of Outbreaks NO Of Deaths 990 1000 1500 799 1108 901 810 1000 553 500 500 120 95 77 50 0 0 2015(Till 21 2008 2009 2010 2011 2012 2013 2014 Nov'2015) No. of Outbreaks 553 799 990 1675 1584 1964 1585 1667 Death 50 120 95 77 1108 901 810 2636 Source: http://www.idsp.nic.in Geometric increase in number of Food Borne Cases from as well as deaths in India Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 4

Personnel Hygiene: USFDA Key Requirements Personnel hygiene is a very vast term which includes following: Disease Cleanliness Wearing personal Hand control outer cleanliness Washing garments Storing clothing Wearing hair nets, Jewellery Maintaining headbands, caps, Removal gloves beard covers Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 5

Hand washing requirements • Wet hands & arms up to the elbows with warm Step 1 water • Apply small amount of soap Step 2 • Wash thoroughly (rub) for at least 20 sec Step 3 • Brush nails with the nail brush • Rinse brush and keep in container with sanitizer Step 4 • Rinse well with warm water having temperature at least 43°C (110°F) for at least 10 sec Step 5 • Dry with paper towel or dryer Step 6 • Put on the approved food grade sanitizer gel and thoroughly (rub) Step 7 Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 6

Access Control Site security should be reviewed, and the need for CCTV, and/ or security guards should be considered as pert of a food defence programme. In particular, material storage tanks, silos, and line hook ups should be provided with adequate enclosure, security, drainage, space and spill control. Protection of products against potential acts of sabotage etc. Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 7

Hygiene Station A Hygiene station consists of: 1. Hand wash station. 2. Foot wash station 3. Access controlled flap gate or tripod turnstile. 4. Hygiene Watch System 5. Disinfectant solution. Hygiene Station with Access Control Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 8

Hygienic Aspects of Locker Area, Toilet & Cubical  Lockers with sloped roof top and step over bench in front  All Junction with the floor are covered. Toilet & Cubical devices to be mounted from the wall to facilitate suitable cleaning . Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 9

Suggested number of lavatories, Urinal stall & Hand wash basins/ number of employees Staff Member Number of sanitary conveniences MEN WOMEN Lavatories Urinals Wash basins Lavatories Wash basins 10 1 1 1 1 1 20 1 2 2 2 2 40 2 3 2 3 3 60 3 3 2 4 4 80 4 4 3 6 5 100 4 4 3 8 6 120 5 5 4 9 7 140 5 5 4 10 8 180 5 6 5 11 8 Add 1 lavatory, 1 urinals and 1 wash basin for Add 1 lavatory, and 1 wash every 70 persons in excess of 280 persons basin for every 35 persons in excess of 280 person Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 10

Hazard Prevention from external to internal environment When ever possible, factories should be located away from or protected against:  Environmentally polluted or remediation areas  Industrial activities which pose a serious threat of contaminating food (e.g. Incinerators, landfills, junkyards etc).  Areas where wastes, either solid or liquid, cannot be removed effectively. Schematic site plan indicating potential to and from the food manufacturing plant Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 11

Hygienic Building Layout A building layout locating production areas, services areas, storage areas (e.g. Chemicals), surrounding areas and main air intake/ outlet locations. Schematic of Hygienic layout of a building Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 12

Zoning Food production areas must be segregated from non-food production areas e.g. Locker rooms, canteens/restaurants, smoking areas, boiler rooms, workshops, living accommodation etc. Food Manufacturers should undertake a hazard analysis to determine how many processing areas or zones are appropriate for the safe manufacture of their product range. Hazard analysis consider:  Hazard present in Raw Material.  Hazard present in the processing environment.  The potential for product microbial spoilage. Etc Hygienic design criteria for Zones  Food Production areas  Basic Hygiene areas  Medium Hygiene areas  Ingredient preparation area  General processing area  High Hygiene area  Aseptic area Schematic separation of non-microbiological hazard Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 13

Access control during High Hygiene & Low Hygiene Area Dedicate d Foot bath High maintena Different & Foot Flow of hygiene nce tools Foot colour washers waste footwear are to be wares & code to should be from High should be used for Aprons be given used only Hygiene captive to High shall be to the in low Zone to high Hygiene changed. tools. hygiene Low hygiene. & Low area. Hygiene areas. Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 14

Building: Pest proofing measure to prevent entry through foundations Foundation are one of the most important structural members. Foundations shall be designed to guarantee stability and structural safety of the entire building structure and should be concrete based (avoid wood, brick and block foundations). Pest proofing measure to prevent entry through foundations Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 15

Roof Drainage  Roofs should be sloped to a minimum of 1-2% to ensure positive drainage.  For Flat roofs, water can be transported in channels on the roof over the hygienic areas and then lead into a gravity or vacuum/ siphonic system outside the hygienic areas. Sloped Roof to ensure positive drainage Rat Stop for preventing Rodent entry through Roof Drainage Downpipe Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 16

Hygienic Flooring Floors Floors provided the foundation for safe, hygienic food production in factories. The hygienic design and installation of floors to ensure a correct level of ongoing hygiene . Floors are critical areas, for example they are places where listeria monocytogenes are likely to be found and where the bacteria could persist despite cleaning and disinfection. Slipping correspond to around 20% of work place injuries. Floor sloped towards the drain Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 17

Hygienic challenges during Flooring Hygienic challenges during Flooring Bubbles holes in Heavy duty Electronic microscopic pics on an epoxy raisin floor Polyurethane floor Lose tile at discharge point due to discharge of Hot & Cleaning Chemicals Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 18

Hygienic design drains Drains: Areas with CIP System Water should be directed into the drainage system by a pipelines. Nevertheless to avoid waste water backflow and to protect line hygiene, air gaps are necessary. The volume and temperature of water must be considered when selecting the product. The drainage products shall includes following features:  Continuous welding of joints  Radiused and rounded corners  Drain ability  No crevices or dead spaces Drains design Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 19

Building: Hygienic Lighting Placements Lighting: All areas where food is examined processed or stored, and where equipments or utensils are cleaned and in personnel changing areas, must have adequate natural and/or artificial lighting for the activities conducted.  Lightening should be suitably sealed to the ceiling or walls in a way that avoid any projection where dust can accumulate or spaced off them to give easy access for inspection and cleaning with the top of the light fittings sloped to 45°C to enable cleaning. Sloped body light, integrated in the ceiling flush with that ceiling Date: 2 nd Dec 15 Mother Dairy- Delhi Slide No: 20