Gaziantep University FE 322 FOOD PRODUCTION MANAGEMENT Basics

Gaziantep University FE 322 FOOD PRODUCTION MANAGEMENT Basics of HACCP and Prerequisite Programs Part I ALİ COŞKUN DALGIÇ

Introduction to HACCP Hazard Analysis and Critical Control Point (HACCP) is an internationally recognized system for reducing the risk of safety hazards in food. A HACCP System requires that potential hazards are identified and controlled at specific points in the process. • Biological • Chemical • Physical Any company involved in the manufacturing, processing or handling of food products can use HACCP to minimize or eliminate food safety hazards in their product.

Introduction to HACCP What HACCP is not: • HACCP is not a Quality Control system • HACCP is not a government program (although there are regulatory requirements for companies to have a HACCP program in place. Visit FDA. gov for information)

Building a HACCP System Implementing a HACCP System requires that both Prerequisite Programs and HACCP Plans are implemented. • Prerequisite programs are programs that are put in place in the facility to control hazards in the environment, preventing contamination of the product. Prerequisite programs ensure a hygienic environment, and good manufacturing processes for personnel that reduce the risk of contamination of the food product. • HACCP Plans are prepared for each process or product, and identify possible hazards and controls in place to make sure the hazards are eliminated or controlled to ensure acceptable levels in the food product.

Prerequisite Programs Introduction Prerequisite Programs are programs and practices that are put in place to maintain a sanitary environment and minimize the risk of introducing a food safety hazard. • Provide suitable building and equipment design and construction • Plan and Implement Pre-requisite programs

Prerequisite Programs Building and Equipment Design and Construction Detailed requirements for the building and equipment construction and design requirements • Site Requirements and Approval • Food Handling Areas • Water and Ice Supply • Storage Facilities • Separation of Functions • On-site Laboratories • Staff Amenities • First Aid Facilities • Waste Disposal • Exterior

Building and Equipment Design and Construction Site Requirements and Approval Your facility and site must be located so that other operations nearby do not jeopardize the safe and hygienic operations at your facility.

Building and Equipment Design and Construction Exterior Make sure that grounds surrounding the facilities are well maintained • Minimize dust • Free of waste and debris • Limit harborage for pests and vermin • Keep paths, roadways, loading areas maintained

Building and Equipment Design and Construction Site Requirements and Approval Weeds and unused equipment around buildings provide harborage sites for pests http: //www. edisaurus. com/trains/pix/wf_recent/058 -27. jpg

Building and Equipment Design and Construction Interior layout and environment Poor Better Best

Building and Equipment Design and Construction Food Handling Areas Use surface materials that do not contribute a food safety risk, are smooth, easy to clean, and not damaged by cleaners: • Product contact surfaces • Walls • Ceilings • Floors Cleanable, durable, impervious to moisture n

Building and Equipment Design and Construction X Food Handling Areas Use surface materials that do not contribute a food safety risk, are smooth, easy to clean, and not damaged by cleaners: • Product contact surfaces • Walls • Ceilings • Floors No false ceilings – loosene panels allow dust to enter facility n n Should be impervious to moisture, cleanable

Building and Equipment Design and Construction Food Handling Areas Use surface materials that do not contribute a food safety risk, are smooth, easy to clean, and not damaged by cleaners: • Product contact surfaces • Walls • Ceilings • Floors n Also the floors should ideally be impervious to spillage of product, water and disinfectants, durable to impact, resistant to disinfectants and chemicals used, slip resistant, non-toxic, non-tainting and of good appearance and easy repairable. Expansion joints should be filled and sealed

Building and Equipment Design and Construction Food Handling Areas Use surface materials that do not contribute a food safety risk, are smooth, easy to clean, and not damaged by cleaners: • Product contact surfaces • Walls • Ceilings • Floors Wooden wall bumper provides an ideal environment for growth of bacteria and mold n

Building and Equipment Design and Construction Food Handling Areas Use surface materials that do not contribute a food safety risk, are smooth, easy to clean, and not damaged by cleaners: Doors • Product contact surfaces • Walls • Ceilings House Mouse • Floors Doors should be adequately constructed with spaces between the jam and the door sealed properly.

Building and Equipment Design and Construction Doors Food Handling Areas Use surface materials that do not contribute a food safety risk, are smooth, easy to clean, and not damaged by cleaners: • Product contact surfaces • Walls • Ceilings • Floors Exterior doors should be self-closing or have an insect screen or air curtain installed. ”

Building and Equipment Design and Construction Floors, Drains and Waste Traps Floors in food handling areas must be: • Smooth • Impact resistant • Graded and drained • Impervious to liquids • Easily cleaned • Drained

Building and Equipment Design and Construction Floors, Drains and Waste Traps Floors in food handling areas must be: • Smooth • Impact resistant • Graded and drained • Impervious to liquids • Easily cleaned • Drained

Building and Equipment Design and Construction Norway Rat Ducting, Conduits and Pipes Prevent contamination from dust or material buildup on pipes by: • Recessing into walls or ceilings, or • Mounting far enough away from surfaces to allow for effective cleaning Should be constructed or renovated to prevent rodents from climbing into the building Galvanized metal or smooth, hard plastic board >36 in 12 in

Building and Equipment Design and Construction Doors, Hatches and Windows Requirements are that: • Doors and hatches must be solid • Windows must be shatterproof glass in processing or food handling areas • Pest and fly proof windows • Ceilings must be in place to prevent contamination of product Best window Next best window Worst window Unbreakable, Sealed, & unopenable (no window) Breakable glass, screened, poorly sealed, & openable

Building and Equipment Design and Construction Lighting and Light Fittings When in food handling areas: Lighting must be sufficient, and appropriate intensity for people to carry out tasks “Safety-type light bulbs that prevent contamination of mushrooms with glass should be used and regularly cleaned. ” Lighting should be adequate to carry out plant operations and protected so that broken glass will not be a potential hazard.

Building and Equipment Design and Construction Inspection Area Provide a suitable area if inspection of product in the processing area is needed: • Easy access to hand washing facilities • Sufficient lighting for the inspection of product Dust, Fly and Vermin Proofing Prevent access by: • Making sure openings are effectively sealed when closed • Providing personnel access doors fitted with self closing device and fly proofed • Fly proofing external doors • Locating pest control devices so they do not pose a risk of contamination

Building and Equipment Design and Construction Ventilation Provide adequate ventilation • In enclosed processing and food handling areas • In cooking areas • Use extractor fans and canopies where large amounts of steam are generated Positive air flow minimizes airborne bacter and mold spores Proper ventilation is basic to good food plant sanitation. This will control condensation and help to eliminate any mould growth. Intake air should be filtered and positive air pressure maintained in the finished product area.

Building and Equipment Design and Construction Air flow countercurrent to product flow Air flow Dump tank Wash Product flow Pack

Building and Equipment Design and Construction Equipment, Utensils and Protective Clothing Minimize the risk of contamination from equipment: • Equipment • Design and construct of appropriate materials, and make them easy to clean, dismantle and properly maintain Equipment used in all operations should be designed and maintained to allow adequate cleaning and sanitizing and to prevent contamination with microbial, chemical, and physical hazards.

Building and Equipment Design and Construction Equipment should be designed so that: – it does not bruise or damage the product – it can be taken apart for cleaning – outside surfaces do not allow soil, pests, and microbes to accumulate – food is protected from contamination Surfaces that touch food – should be of materials that do not chemically react with the food – Smooth and nonporous – few crevices or pockets where soils may accumulate

Building and Equipment Design and Construction

Building and Equipment Design and Construction Drip or condensate from fixtures, ducts and pipes in packing facilities should not be allowed to contact food, food-contact surfaces, or food-packaging materials.

Building and Equipment Design and Construction Cleaning of Processing Equipment, Utensil and Protective Clothing Provide for effective cleaning: • Processing Equipment, utensils and clothing • Make sure there is a suitable area, properly equipped for cleaning operations • Provide racks to store cleaned items

Building and Equipment Design and Construction

Building and Equipment Design and Construction Personel Hygiene • Proper handwashing • Removal of exposed jewelry and other objects • Restraining hair • Wearing clean work clothes • Storing food, clothes, and personal belongings away from food production areas • Restricting movement of workers Hand Washing Facilities Provide hand washing signage and facilities at all personnel Access points and near processing areas as required. Hand basins must be non-corrodible and supplied with: • Potable water • Liquid soap in dispenser • Paper towels • Waste container for paper towels

Building and Equipment Design and Construction Protective Clothing Racks Keep racks for storage of protective clothing near personnel Access doorways • To provide temporary storage when staff leaves the area

Building and Equipment Design and Construction Water and Ice Supply Water and air often come in contact with product and must be controlled to prevent introducing contaminants. • Provide clean potable water for processing, for use as an ingredient and for cleaning purposes • Make sure that supplies of hot and cold water are sufficient to meet requirements • Do not allow cross contamination of potable and nonpotable lines • Clearly identify non-potable lines • Use non-return devices on non-potable lines • • • Drench treatments Transporting product Washing product Cleaning and sanitizing Delivery of fungicides and wax coatings Drinking and handwashing

Building and Equipment Design and Construction Storage Facilities Cold Storage, Freezing and Chilling of Foods • Confirm performance of freezing and chilling • Design to allow for hygienic refrigeration • Make areas easily accessible for inspection and cleaning • Provide sufficient capacity • Meet requirements for walls, ceilings, floors and light fittings • Defrost and condensate lines must be controlled and discharge into drainage system • Monitor conditions, use temperature recording devices • Design loading and unloading docks to protect product Dry Ingredient and Shelf Stable Goods Storage • Locate away from wet areas • Designed to protect product from contamination and deterioration • Light fittings must comply with requirements where product is not enclosed or cased

Building and Equipment Design and Construction Storage Facilities Hazardous Chemicals and Toxic Substances • Store securely to prevent hazards to staff, product, packaging, product handling equipment or areas • Separate pesticides, fumigants and insecticides from sanitizers and detergents • Store chemicals in original containers Waste Disposal Waste materials should be identified, collected and removed to prevent introducing or spreading contaminants: • Dry waste • Liquid waste

Building and Equipment Design and Construction Pest Control Program Develop an effective written Pest Control Program that sets out: pest control procedures for the exterior and interior of the establishment including: - personnel responsible for particular tasks, - the activities to be performed, - the chemicals required, - the methods for proper handling and application of pest control chemicals to ensure that maximum residue limits are not exceeded, - the type and location of pest control devices (e. g. live traps insect devices), - documentation requirements, and - methods to prevent or minimize cross-contamination; and pest control schedule or frequency of activities http: //www. animaltraps. com/endtunnel. htm

Prerequisite Programs The processing plant • Plant location, physical environment and infrastructure • Buildings, construction and layout • Facilities • Utensils and equipment Operational conditions including GHP • Safety of water and ice • Cleanliness of food contact surfaces • Prevention of cross-contamination • Maintenance of facilities for personal hygiene • Protection of food from adulterants • Proper labelling, safe storage and use of toxic compounds • Control of employee health conditions • Pest control • Waste management • Storage and transportation • Traceability and recall procedures • Training

Prerequisite Programs

Prerequisite Programs

Prerequisite Programs