4) FAAS 608 - Week 6 7

Basic Concepts in the Implementation of the Food Safety
Management System:
ISO 22000: 2005
Practical implementation of GHP, GMP, HACCP, ISO 22000
Dr. Nada EL DARRA, Associate Professor of Food safety & Technology
Spring 2019-2020
Week number 6 & 7
04/04/2020 Dr. NADA EL DARRA 1
7. Planning and Realization of safe products

1. General
• The organization shall plan and develop the processes needed for the realization
of safe products.
• The organization shall implement, operate and ensure the effectiveness of the
planned activities and any changes to those activities.
- This includes PRP (s) as well as operational PRP (s) and/ or the HACCP plan.

2. History of HACCP
• Synonymous with food safety.
• Worldwide-recognized systematic and proactive approach that
addresses hazards through prevention, rather than through end-product
Testing.
• Pioneered in the 1960s by the Pillsbury Company, for the production
of safe food for NASA.
• Emphasized control of the process as far upstream in the processing system
as possible.
• Concept presented publicly in 1971.
• Recommended in 1985, by the United States National Academy of Science to
ensure food safety and more recently, by the International Commission on
Microbiological specifications for foods (ICMSF), the International Association
of Milk, Food and Environmental Sanitarians (IAMFES)
Why to use HACCP
• Management of Product Safety
• Recognized globally
• Limitations of traditional quality control
• External pressures, government mandates
• Risk-based, preventive approach.
Foundation for the development of effective product quality management

systems.

Benefits of HACCP
• Saves your business money in the long run.
• Avoids poisoning your customers.
• Food safety standards increase
• Ensures your are compliant with the law
• Food quality standards increase
• Organizes your process to produce safe food
• Organizes your staff promotion teamwork and efficiency
• Due diligence defence in court

Benefits of HACCP
To the consumer To the company To government
- Less risk of illness - Production of safer food lower business risk -Facilitating food safety
inspection / more
- Improved quality of life - Improved / maintained reputation
efficient food control
- Greater confidence in food - Compliance with legislation
- Improved public health
- Staff have clearer ideas of food safety requirements and / reduced health care
practices cost
- Demonstrates company commitment to food safety - facilitate international
trade
- Better staff organization / use of time
- Long term reduction in wastage
- Less likely to receive customer complaints
- Possible increase of the market access

Costs of implementing HACCP
1. Initial/ start up costs: 2. Implementation cost
• Formal meetings/ management costs

• Time spent on monitoring
• Preparation of background information
• Cost of monitoring
• Staff training
• Time/ money spent on cleaning
• External consultant fees
• Cost of corrective actions
• Overtime / pay costs
• Ongoing staff training
• Possible equipment costs
• Increased maintenance cost
• Increased costs of documentation
• Time spent on record keeping
Shared responsibility :
Farmers Manufacturers Consumers
Effectiveness of HACCP
Overview of major incidents
Microbiology Food safety basics
Microbiology basics
External Factors:
• Temperature.
• Oxygen Requirements.
• Interaction between microbes
• Time.
Intrinsic Factors:
• pH
• Water activity
• Nutrition
• Redox Potential
Where do they come from?
Where are sensitive ingredients?
Some ingredients have a historic association with particular foods and have cause outbreaks
in the past, examples are:
Salmonella- fluid and dry milk products, red meat, poultry and eggs,
Chocolate and cocoa, coconut and peanuts
Listeria- raw and fluid dairy products, raw meat and poultry, soft ripened
cheeses, cured meats, cooked meats and seafood.
Pathogens of concern
Staphylococcus aureus
Key points to remember:
• Produces a heat-stable toxin
• Common on people’s skin and in nose
• Growth (toxin production) parameters:

• pH 4 to 10
• Temp 4 to 46⁰C
• Minimum aw: 0.83 (0.87)
• Nature of illness
• Typically, 30 minutes to 2 hours after ingestion
• Nausea, vomiting, abdominal cramping
• Infective dose
• Toxin formed with greater than 100,000 cells per gram
Salmonella
• Survives in dry foods
• A few cells can cause illness in some people
• Animals are common carriers
• Growth parameters:
• pH 3.8 to 9.5
• Temp 45.2to 46.2⁰C
• Minimum aw: 0.94
• 6-72 hours after ingestion
• Nausea, vomiting, abdominal cramping, diarrhea, fever, headache, arthritis, can cause death
• Infective dose
• As low as one cell, depending on age and health of host and strain of salmonella.
Listeria monocytogenes
• Grows at refrigerated temperatures
• 20% of cases result in death
• FDA_zero tolerance in food.
• pH 4.39 to 9.4
• Temp -0.4 to 45⁰C
• Can progress to septicemia, meningitis, encephalitis, stillbirth: onset 3 days to 3 months
• Susceptible populations= young, old, immunocompromised, pregnant
• Infective dose
• Less than 1000 cells
E. Coli O157:H7
• Acid-tolerant, produces a toxin
• Infection can HUS
• Cattles are the main carriers
• pH 4.4 to 9.0
• Temp 8 to 45⁰C
• Typically 3 to 4 days after ingestion
• Severe cramping, diarrhea (bloody), hemolytic uremic syndrome (HUS) causing kidney failure
• Infective dose
• Unknown (could be as little as 10 cells).
Outbreaks
E.Coli O157 in South Wales
• Outbreak of E.coli O 157 bacterium in South Wales in 2005.

• Largest outbreak in Wales and the second largest in the UK.
• The outbreak was traced to meat supplied by John Tudor’s & Son.
• Cross contamination due to inadequate cleaning.
• One vacuum packing machine was used for both raw and cooked meat
• 157 cases were identified in the outbreak, 31 people were hospitalized

and one child died.
Outbreaks
Samonella in Ice Cream, 1994
• Schwan’s Ice Cream mix was transported in a tank truck previously used
to haul raw liquid eggs.
• Minnesota Department of Health informed the Schwan Food Company that 67 people in
Southern Minnesota had been infected with Salmonella Enteritidis and that there was a
strong statistical link between the illnesses and the ice cream consumption.
• Schwan’s quickly halted the production and sale of the company’s ice cream and began a
public awareness campaign asking people not to eat their ice cream products.
• Over 200,000 people ill.

Outbreaks
Botulism and Hazelnut Yogurt, UK 1989
• Largest outbreak of foodborne botulism in the UK.

• 27 people ill and one death.
• Yogurt made with cans of hazelnut puree, the source of the toxin.
• pH > 4.5
• The heat process was insufficient to destroy spores of C.botulinum.
• Sugar had been replaced by aspartame, leading to an increase in water activity.
• Recall affected ALL hazelnut yogurts, not just the brand with the issue.
Outbreaks
Chinese Milk Incident, 2008
• Almost 300,000 victims; 54,000 babies hospitalized, 6 infant deaths.
• Involved Milk and infant formula
• Adulterated milk with melamine
• Added so it would appear to have a higher protein

Outbreaks
Canada Listeriosis outbreak, 2008
• 57 confirmed cases; 23 people died.
• Listeria Monocytogenes
• Sliced luncheon meat
• Contamination traced to slicing equipment
• Cleaning procedure did not cover niche in the equipment, allow listeria to grow.
HACCP, a shift in responsibility
• Today, the food industry is not only responsible for producing safe food
but must also show, in a transparent manner, it has planned for food
safety.
Moving to a Focused Food Safety Management Strategy
Testing is inadequate
Reactive approach has been evident
Preventive approach is needed

HACCP is not a stand-alone system
There are certain points

that should be considered
before implementation of
the HACCP plan
PRE -REQUISITE PROGRAM (PRP)

Every specific and documented activity or facility corresponding to the ‘codex general requirements of
food hygiene with the purpose to create basic requirements that are necessary for the production and
processing of safe foods in all stages of the food chain
PRP covers GMP/ GHP/ SOP and legislation

Prerequisite Programs (PRPs) as defined by ISO 22000: 2005
PRP Prerequisite Programs: Basic conditions and activities that are necessary to
maintain a hygienic environment throughout the food chain suitable
7.2. Prerequisite Programmes (PRPs)
“Practices and conditions needed prior to and during the implementation of
HACCP and which are essential for food safety” (WHO)
• Foundation for an effective HACCP system.

• Often facility-wide programs rather than process or product specific
• They reduce the likelihood of certain hazards

HACCP and Prerequisite Programmes (PRPs)
PRPs:
- Should be assessed during the design and implementation of each HACCP plan
- Should be documented and regularly audited.
- PRP established and managed separately from the HACCP plan.

7.2.Prerequisite Programmes (PRPs)
PRPs deal with the “good housekeeping” concerns of the establishment, whereas,
HACCP manages specific process hazards.
The plant must provide all documentation including the written program, records and
results for all PRPs which support their HACCP system.
PRPs are outside the HACCP plan but still within the HACCP system.
What is the difference between a CCP in the establishment's HACCP plan and a
prerequisite program?
A CCP is designed to control a food safety hazard that has been determined to be
reasonably likely to occur/ a PRP may prevent a food safety hazard from occurring.

Can HACCP be implemented here?









7.2.Prerequisite Programmes (PRPs)
• Establishments should revise their PRPs, as necessary, to ensure their effectiveness
and should take appropriate corrective actions when they determine that their
PRPs may have failed to prevent contamination of product.
• PRPs must be implemented and have records to verify implementation.
• Repeated failures may indicate that PRP does not support the decisions made in the
hazard analysis.

7.2.Importance of PRPs
HACCP programs have often focused on the process of manufacturing and

Traditionally not focused on the environment where the process is located.
One must also consider:
- Facility design
- Equipment design
- Ingredient and product movements
- People traffic patterns
- Contamination sources and vectors
- These are part of the prerequisite programs that are the foundation of HACCP

Control of microorganism in the process environment





Examples of PRPs:
- Good Manufacturing Practices (GMPs)
- Good Hygiene Practices (GHP)
- Standard Operating Procedures (SOPs)
- Sanitation Standard Operating Procedures (SOPs)
- Design and construction of premises
- Supplies of water
- Waste control
- Equipment suitability _ cleaning and maintenance
- Measures for the prevention of cross-contamination
- Supplier control and management of purchased materials
- Cleaning and sanitizing
- Pest Control
- Personal Hygiene
- Training
- Transportation
- Traceability systems
- Recall procedures

7.2. PRPs
When choosing and developing PRPs, it is essential to consider information

from the following sources:
- Statutory and regulatory requirements
- Industry standards and codes of practices
- Codex Alimentarius principles
- International food safety standards
- Customer requirements
- Historic date (Audit reports ad customer complaints)

7.2. PRPs
The PRPs shall:

- Be appropriate to the organizational needs with regard to food safety
- Be appropriate to the size and type of the operation and the nature of the
products being manufactured
- Be implemented across the entire production system
- Be approved by the food safety team

GMP: Good Manufacturing Practices
Good manufacturing Practices are minimum common sense sanitary &

processing requirements which should apply to all food processing
establishment.
GMP generally relates to good house keeping practices concerning food

safety & quality.

GHP: Good Hygiene Practices
GHPs lay a form foundation for ensuring food hygiene. They follow the food from primary
production through to the final consumer, highlighting the key hygiene controls at each
stage.

1.PRPs: Food Establishment Design

Assessment of Plant starts by considering:
✓ The Environment ( site)

✓ Building ( design construction and sanitation
✓ Food handling equipment ( design, construction, sanitation, installation
and maintenance)
✓ Ingredients
✓ Process control ( manufacturing, filling)
✓Packaging
✓ Storage
✓ Distribution

To assess the site you may ask:
Are there any nearby source of contamination?

What are the fence conditions ?
What are the site conditions ? Weeds, wreckages, roads, water, etc.
Are doors and windows closed?
Is there an effective pest control at exterior of building ?

Food Establishment Design
Premises, equipment, surfaces and facilities should be located,
Designed and constructed to ensure:
- Minimum contamination
- Proper maintenance, cleaning, disinfection
- Protection against Pests

Food Establishment Design
Evaluation of the premises takes into account
- Location
- Equipment
- Facilities: water, air, Lightning, storage

Building: construction and design
Sanitary considerations of:
• Frames • Lightning
• Walls • Ventilation
• Windows • Insulation
• Doors and Docks
• Ceilings
• Floors
• Drains
• Stairs
• Elevators

Building: construction and design
Frames
External walls that represent the skin protecting internal tools, personnel and activities
Frames may be:

• Reinforced concrete with rods in beams & columns
• Composite structure with H or I beams
• Steel framing with H and/or I beams & columns

Walls
They should be water, insect and rodent
External walls
proof
Remember rodent may:
• Gain entrance through 6.4 mm (mice) and 12.7 mm (rats)
• Walk along vertical wires

• Climb outside vertical pipes not more than 76 mm
• Climb inside vertical pipes < 102mm and >38 mm diameter
• Jump 660 to 915 mm vertically and horizontally
• Drop from 15 to 25 m without being killed
• Burrow vertically in earth about 1.2 m

Walls
They should be smooth, flat, resistant to water
Internal walls and corrosion, impervious, easily cleanable and
white or light colored.
• Sanitary specifications are normally developed

according to individual requirements
• Surfaces in wet areas should be impervious to
moisture and stand up harsh action of cleaning
chemicals
• Dry, dusty areas require hard and smooth finish
free of pits, slits and cracks
Inconvenient wall finish may result in

contamination of the product

Walls
When choosing the wall finish underline
Internal walls maintenance cost
• Correct grade of ceramic glazed tile

properly applied has been proved cost
effective
• Metal walls may present a sanitary
problem of expansion and contraction
• Wall angles, corners and junctions of
walls and floor should be imperviously
sealed and, for ease of cleaning, be round
Contradiction between internal wall

finish and other practices

Windows
Windows deserve more attention than they actually receive, requiring both cleaning and maintenance
Where appropriate, glass used in windows

should be unbreakable e.g laminated,
reinforced, or polycarbonate sheet Screening
Inside sills and ledges should be minimized and • Woven wire cloth (6x6mm)
sloped (20 to 45o)
• Perforated metal <6mm
External windows should be screened to prevent
insects, dusts and birds getting into the plant •Stain less steel 18x18 mesh 0.23 mm
• Aluminum, bronze or galvanized

Steel 18x16, 18x14, 0.28 mm

Doors and Docks
• The major purpose of doors and docks is to

prevent the entry of pests and dusts and any
other form of contamination
Thus:
Metal door at top of stair
• Doors must be close fitting with maximum prevents rodent access
clearance of less than 6mm & preferably less
than 3mm
• Door jambs (frames) must be metal and rust
resistant in wet area
• Doors should open to the outside and have a
self closing mechanism
• Doors for personnel are of hollow metal with
Rodent proofing of dock stair
good tight spot-welded seams since loose
fittings may allow the entry of insects

Ceilings
Ceilings should be non-porous, easy to clean and light-colored. These tends to

accumulate dusts, condensate, and droplets from manufacturing processes which may
host various germs.
Ceilings may be formed of:

Effective when there is serious problems with dust, flaking paints etc.
Suspended from above. Required for high-hazard operations
Corrugated metal Cavities formed by the corrugation at supporting beams are difficult
to clean and may present a condensation problem
Concrete Formed and poured in place concrete are preferred in production

area to avoid caulking damages in case of precast concrete panels

Building: construction and design: Floors
Floors are important part in plant operation, sanitation and costs. Choosing the right floor
materials is dependant on the type of operations, process, and materials used in the
manufacturing processes
Ideally, floors should be:

• Impervious to spillages of product and other
fluids Remember that floor has to
•Durable i.e. resistant to impact or scuffing by withstand use, cleaning and
containers, equipments, pipe work etc. abuse. Cleanliness results from
• Slip resistant to personnel and traffic the ability to remove surface
contamination quickly and easily.
• Non-toxic and non-tainting
• Easy to clean and disinfect
• Good appearance
Floors should be sloped to drains to avoid
•Repairable formation of residual pools.

Floors
To choose floor materials, knowledge of manufacture conditions, selection of floor
finish, preparation of sub-floor, and application of surface finish, is required
Epoxy is one of the materials recommended for floor
Floor materials may be:
Concrete : Not convenient for acid split, water, traffic, alkali etc
Metal Plate: Used for heavy use e.g. severe impact, traffic,
Wood : Used in dry areas only and where operators stand for long period
Vinyl : not suitable for processing areas
Asphalt : Used for interior rail road, unloading docks etc.
Chemical resistant: Require sound sub-floor prepared properly for surface finish
Brick/pavers/tile: Popular in wet processing areas

Drains
Drains main purpose is to remove process waste
Sanitary sewers and plant drains should not be cross-connected
Drain spot can be breeding spot

for pathogens
Coved angle
One drain every 37 SQM Coved base
Design of floor drain – adequate Floor opening for pipe work,

installation assure proper drainage equipment, etc. should be curbed

Drains
Floor drains should be set so that the top of the grating is 3mm below the level of the floor.
Full “S” traps, bell traps and crown-vented traps should not be used
Coved tile
Water proof
membrane
Drains should have smooth 150-203mm
vertical walls, rounded or

Coved
coved bottoms and a
minimum slope of
1 in 100.
Round

Stairs should not only be safe to use but easy to clean and designed in such a way
Stairs to prevent cross-contamination
A : Decking should be made from solid

plate
B: Kick plate minimizes contamination
C: Stair case risers above product flow
Design for stair and platform over open food

Elevators
The most significant sanitary aspect of elevators is

the well or “foot” which is at the base of the
shaft. It is often poorly lit and harbors debris
which can feed pests.
Inspection at least twice a year and regular
cleaning is advised.

Lighting
Lighting should:
• Be sufficient for work or function
• Be of suitable color
• Avoid contamination
• Be insect and dust-tight
• Provide suitable contrast
Section
Emergency lighting
Used when normal system fails
This include Escape and Standby lightings Good design features of light fitting

Ventilation
Ventilation is the exchange of unwanted air for a controlled and

conditioned supply of healthy fresh air.
Removes odor, heat and moisture

General air Introduce fresh air
supply
Provide comfortable environment
Specific air
Provides a safe local environment for a high risk product
supply

Insulation
Insects can live in almost all types of insulating materials and must be sealed out by the
insulation jacket’ –apply widely
Curtain wall of sheet metal

prevent rodent burrows under
Before
building foundation
After

Maintenance and Alterations
“Prevention is better than cure”
Building maintenance involves timely
repair of building materials as the need
occurs
Deferring building maintenance can

compound sanitary problems
• Vermin gain access through and harbor in wholes and cracks in the structure
• Structure damage readily supports dust and dirt and creates areas difficult to clean
• Increase the risk of direct contamination from things like peeling paint, torn insulation and broken
light fixtures

As an example of a practical approach the following questions may be prompted:
• What can go wrong?

• Why?
• What systematic and regular inspection and tests should be made to trigger action?
• What remedial action(s) can be pre-planned?

Example of floor trouble point checking and suggested frequencies
Acid-proof brick or tile floor Insp. inter
Monolithic floors Insp. inter
Expansion joints 3 month
Expansion joints 2
Drains and pipes 3
Drains 2
Trenches, walls and bottoms 3
Pump bases 4
Pump bases 6
Vertical walls 4
Equipment foundations 6
Equipment foundation 4
Juncture points between floor 6
and trench wall Areas adjacent to heat sources 6
Changes in directions-corners, 12 Very wet areas 6
curbs, etc
Juncture joints of floor and 6
Low points in floor areas 12 trenches
High points 12 Low points 12
Wheeled traffic lanes 12 Balance of the floor 12
Balance of the floor 12

Painting
Has contamination risks of:

• Paint flaking falling into open
ingredients
• Sandblasting
• Toxic materials
• Odors
• Use drop clothes or plastic sheets
When applying paint remember to protect
• Before applying, remove residues e.g.
• Food contact surfaces
grease, oil, scales etc.
• Processing equipment
• Select appropriate paint
• Controls, gauges, Instruments..

Alterations Alterate existing establishment
Rules for sanitation:

• Use only waste containers not drains
• Go to work area by most direct route
• Dispose waste immediately
• Cover equipments with dust-proof route
•Notify company incase of incidents
• Enclose work area with dust-proof sheets
• Contact company when job can’t be done
• Insulate to the most adjacent work area
• Do not use food containers for other purposes
• Materials that come in contact with ingredients
should be food grade • Always take safety precaution measures
necessary for the job
• All materials used should be company approved
• Replace trunking covers after use

Personal standards including contractors and their employees

Alterations
• Be clean, tidy and work safely • Contractors must not handle food
•Maintain high standard of cleanliness • Obey any specific hygiene requirements.
• Cover hand wounds with colored plaster
• Report all injuries
• Leave the work if you are sick
• Wear protective clothing
• No jewelry or watches
• Spitting is forbidden
• Smoke, eat, in specified areas
• Misuse of equipment is forbidden

Personal standards including contractors and their employees

Alterations
• Company employees must challenge contactors employees when breaking rules
• Company management have primary responsibility

• A record of all non-compliance should be maintained
• Ingredients, equipments, packaging materials must be removed or covered
• Good communications between parties must be maintained to ensure sanitation
standards

2. Sanitary Design of Equipment
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Sanitary Design
• Plant Design
• Manufacturing layout
• Sanitary design of equipment
• Foreign material control
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Plant design
Administrative
The ideal plant Raw

materials
layout integrates the Employee amenities
departmental areas
in a logical way to
provide for a smooth
flow of materials and Production area
services
LAB
Final Products
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A-Process:
Combining numerous
raw materials
through multiple
production steps into
a limited number of
end products.
(Example: ready made
foods)
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T-Process: Parallel non-related production lines
(Example conserve)
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V-Process: Production of a large number of specific items through multiple
production steps using limited set of raw materials. (Example roastery)
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I-Process: Combining numerous raw materials
through a single production sequence into a large
number of end products. (Example: Bakeries, breweries)
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Sanitary design of equipment
“ Good Design is Intelligence Made Visible”
Sanitary design must deliver:

• Efficient performance of the intended task
• No additional contamination of the product
• Maximum protection from external contamination
• Cost effective as installed
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Basic Principles of Sanitary Design of Equipments (1)
All surfaces with contact with food:

• Must be inert, must not migrate, absorbed or adsorbed.
• Must be smooth and non-porous.
•Must be visible for inspection or readily disassembled for
cleaning
• Must be accessible for manual cleaning or CIP.
• Must be self-emptying or self-draining
• Protect product from contamination
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Basic Principles of Sanitary Design of Equipments (2)
• Exterior surfaces must not harbor dust,

bacteria or any sort of contamination
• Avoid dead spaces which trap food
• Must be guarded to insure safety in
operation
• Noise suppression conditions to provide
acceptable environment
• Mechanically secured to avoid
Dead spaces could represent
contamination of the product
major defaults in equipment
design
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Sanitary Design – Installation Principles (1)
1. There should be sufficient height to allow adequate access for

cleaning, inspection and maintenance of equipment and cleaning
floor
2. Sufficient distance from wall ( about 1 meter)
3. Ancillary equipment, control system and services connected to the
process should be located as to allow access for inspection and
cleaning
4. Supporting framework, wall mountings and legs should be kept to
minimum
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Sanitary Design – Installation Principles (2)
5. Base plates used to support equipments should have smooth, continuous and
slopping surfaces to aid drainage
6. Pipe work and valves should be mounted independently of other equipment to
avoid strain and damage
7. Avoid draining directly over the floor
8. Avoid installation practices that introduce ledges and soil traps
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Establishment: Personal Hygiene
To prevent food from being contaminated by the people who come in contact with it,
personnel must receive clear instruction on the following:
➢ Health status
➢ Illness and injuries
➢ Personal cleanliness
➢ Personal behavior
https://youtu.be/KBvU4Bmu5O0
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Areas examined under GHP
1. Primary production
2. Establishment: design and facilities
3. Control of operation
4. Establishment: sanitation
a) Water supply
b) Cleaning and disinfection
c) Pest control
d) Waste management
5. Personal hygiene
6. Transportation
7. Training
Personnel hygiene
Food poisoning bacteria can be present on the
skin and in the nose of healthy people.
Hand washing
Hand must be washed:
➢ before working
➢ before preparing food
➢ after going to toilet All food handlers must maintain
➢ after handling raw food high standard of food hygiene
and cleanliness in order to avoid
transferring food poisoning
bacteria
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Washing hands…..
✓ after licking fingers, coughing, sneezing, eating

drinking or smoking
✓ after touching ears, hair, nose or other bare body
parts
✓ after touching pimples or sores
✓ after handling waste
✓ after carrying out cleaning duties
✓ after changing soiled clothes
✓ after handling animals
✓ after handling any unhygienic practices
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This procedure is a basic requirement for food safety plan
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Hand Care
▪ Keep fingernails short and clean
▪ Cover all wounds on hands by bright colored water proof strips
▪ Wear disposable gloves if there is a wound on hands
▪ Change both gloves and wound strip regularly
Clothing and Appearance
▪ Uniforms should be clean at the beginning of a work shift

▪ Wear a hair restraint (hat or hairnet)
▪ Avoid wearing jewellery while handling and preparing food
▪ Avoid using strong perfumes
▪ Do not wear uniforms outside food preparation area
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Personal hygiene practices while handling food
▪ Avoid touching nose, mouth, hair and skin during food
preparation
▪ Do not smoke in food premises
▪ Do not cough or sneeze directly onto food. Wash hands
afterwards
▪ Wash hands after blowing nose
▪ Use disposable tissues to wipe hands Oh...
Infection
▪ Food handlers should be free from any illnesses such
as gastroenteritis or flu
▪ Cease working and report to the manager when feeling
ill
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• Blow into bag
• Lick fingers
• Smoke
• Spit
DO NOT •
•
Eat sweets/gum etc
Wear excessive jewellery
• Wear false nails
• Wear nail varnish
• Wear watches
• Touch mouth
• Pick nose
• Wear stong aftershave/perfume.

• Keep hands clean
• Keep nails clean
• Keep nails short
• Wear waterproof dressings
• Replace dressings when loose
DO •
•
Change soiled overclothing
Use tasting spoons only once
• Shower regularly
• Keep hair clean
• Wear head covering.

Food employees Health certificate
routine examination (6 months)
‫الفحوصات الطبية للعاملين في خدمات الطعام‬
‫ اشهر) الحصول على الشهادة الصحية‬6 ‫( تجدد كل‬

‫الحصول على الشهادة الصحية ½‬
‫‪Lebanese required health examinations‬‬
‫اجراء الفحص الطبي الشامل قبل التوظيف‬
‫المرسوم الصحي رقم ‪17376‬سنة ‪ 1964‬معدل ‪67‬‬
‫• الفحص السريري لألمراض السريرية مرة كل ستة أشهر‪.‬‬

‫‪Clinical examinations and medical lab analysis‬‬
‫• فحص عينة من البراز للسالمونيال ( ‪ ،(Salmonella sp‬الشيجيال )‪،(Shigella‬‬
‫• فحص الطفيليات )‪ (Parasites Stool test‬والديدان المعوية مرة كل ستة أشهر ‪.‬‬
‫• فحوصات أشعة للصدر مرة كل سنتين للسل الرئوي في الحاالت التي يراها الطبيب ضرورية إلعطاء‬
‫الشهادة المطلوبة‪Chest X ray / cont dis. .‬‬
‫• فحوصات التهاب فيروس الكبد (‪.Hepatitis (A) (C‬‬
‫• عمل أية فحوصات إضافية يراها الطبيب ضرورية إلعطاء شهادة ( خالية من األمراض السارية‬
‫والمعدية)‪.‬‬
‫‪04/04/2020‬‬ ‫‪Dr. NADA EL DARRA‬‬ ‫‪108‬‬

3. Cleaning and Sanitation
4-Apr-20 109
Why Cleaning is Important?
• Dirt, food waste and other debris are a significant potential source of
microbiological and physical hazards and will attract pests that can
contaminate the production environment.
• Micro-organisms such as Salmonella can grow rapidly on organic material
such as meat and dairy.
4-Apr-20 110
What Does “Clean” Mean?
• Clean means: Free from dirt, marking or soiling. Visibly clean surfaces
look, smell and feel clean
Surfaces in contact with food should be:
• Physically clean: all visible dirt/soil/residues have been removed

• Chemically clean: all cleaning material residues have been removed
• Microbiologically clean: nb of organisms has been reduced to level
acceptable for human health
4-Apr-20 111
Sanitization / Disinfection: is the reduction of harmful microorganisms to an acceptable level/
safe level not harmful to humans.
❖This is usually done by the use of chemicals (Sanitizer/Disinfectant), or by heat (hot water at
around 82°C or steam).
❖For food contact surfaces is a process which reduces the contamination level by 99.999% in
30 sec.

Effective Cleaning
Effective cleaning depends on: removal of gross physical contamination followed by the
correct use of chemical agents.
Cleaning chemicals may be:
Detergents: Chemical used to dissolve grease and remove dirt and soil
• Disinfectants: reduce bacteria
• Surfactants: improve wetting
• Sequestrants: improve suspension
• Stabilizers: Stabilize disinfectant
• Alcohols: decrease drying time
4-Apr-20 113
General principles
➢ The purpose of cleaning is to remove food residues and dirt.
➢ The purpose of disinfection is to reduce the numbers of living microorganisms
➢ Disinfection does not usually kill bacterial spores.
➢ To be effective, disinfection must be preceded by thorough cleaning
4-Apr-20 114
Biofilms
➢ Some microorganisms secrete polysaccharides.
➢ Polysaccharides combine with hard water salts to create biofilms on surfaces
➢ Biofilms are tenacious and difficult to remove
➢ This problem is important for the food manufacturing industry, not for the home
4-Apr-20 115
Cleaning Compounds (Detergents)
Cleaning compounds ( Detergents) are generally complex mixtures of

chemicals that achieve a specific purpose. The major function cleaning compounds is to
lower the surface tension of water so that soils may be loosened and flushed out.
116
117
118
Cleaning Procedure
“Keep food premises, as well as vehicles and containers used to transport foodstuffs,
clean”
Follow these steps to clean:
1. Pre-clean – remove physical dirt, followed by pre-rinse

2. Main clean – use diluted detergent to remove grease, especially ”elbow grease”, this is the
most important part of cleaning programme
3. Intermediate rinse – rinse with clean water to remove detergent
4. Disinfection – use disinfectant to reduce or kill microorganisms
5. Final rinse – rinse with potable water to remove disinfectant (if rinsing is included in the
instructions on the label)
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120
121
122
123
124
Ideal detergent should fulfill the following properties:
❖Act as a wetting agent (i.e., effectively wet the dirt)

❖Break-up and lift greasy dirt
❖Hold the dirt in suspension (i.e., wash the dirt away)
❖Be soluble in cold water
❖Be effective in hard water
❖Not produce excessive foam
❖Rinse away easily without streaking
❖Be harmless to user and surfaces i.e. non toxic
❖Non corrosive
❖Stable during storage
❖Cost effective
125
Selecting a Detergent
There are different types of detergent, which are each suited to

certain uses. They are not adequate for all equipment and areas to be
cleaned. Selection of a detergent , however, depends on :
❖ Soil type (fat, protein, raw, baked on, chemical scale, etc.)
❖ Quantity of soil
❖ Type of surface to be cleaned (solid, mesh, stainless, galvanized,
etc.)
❖ Quality of water (hard, soft)
❖ Method applied for cleaning (spray, foam, manual, etc.)
❖ Temperature at which cleaning can be carried out
126
Types of Detergents
Physically active ingredients alter physical characteristics such as solubility or

colloidal stability.
❖Alkaline (anionic) detergents are used for organic materials (soils):
- Fats/oils
- Proteins
- Carbohydrates
❖ Acidic (Cationic) detergents are used for inorganic materials (soils):

- Scale from hard water (Calcium, magnesium)
- Other mineral films (iron, sulphates)
127
Choice of Detergent
4-Apr-20 128
Detergents
Surface active compounds which have:
- A polar head (hydrophilic)
- A non-polar tail (hydrophobic)
4-Apr-20 129
Surfactants: are wetting agents that lower the surface tension of a
liquid, allowing easier spreading, and lower the interfacial tension
between two liquids.
It is a substance that, when dissolved in water, gives a product the

ability to remove dirt from surfaces such as the human skin,
textiles, and other solids.
Each surfactant molecule has a hydrophilic

(water-loving) head that is attracted to water
molecules AND a hydrophobic (water-hating)
tail that repels water and simultaneously
attaches itself to oil and grease in dirt
130
How do surfactants work in detail?
Surfactants can work in three different ways:
a_ roll-up,
b_ emulsification, and
c_ solubilization.
A_ Roll-up mechanism
The surfactant lowers the oil/solution and
fabric/solution interfacial tensions and
in this way lifts the stain of the fabric.
B_ Emulsification
The surfactant lowers the oil-
solution interfacial tension and
makes easy emulsification of
the oily soils possible.
C_ Solubilization
Through interaction with the micelles of a surfactant in a
solvent (water), a substance spontaneously dissolves to
form a stable and clear solution.
SANITIZATION
❑One important point is that for your sanitizer to be effective, the surface being
sanitized must be clean i.e. apply sanitizer immediately after cleaning. Applying
sanitizer prior proper cleaning the surface is a waste of time and money. you can not
sanitize a dirty surface.
❑There are two acceptable methods of sanitizing :

❖ Thermal Sanitization involves the use of hot water or steam for a specified
temperature and contact time.
❖Chemical Sanitization involves the use of an approved chemical sanitizer at a

specified concentration and contact time.
134
Thermal Sanitizing
Steam
Has limited application. It is generally expensive compared to

alternatives, and it is difficult to regulate and monitor contact
temperature and time. Further, the by products of steam condensation
can complicate cleaning operations.
135
Thermal Sanitizing
Hot Water
Hot-water sanitizing--through
• spray (dishwashers)
• circulating systems. OR
• immersion (small parts, knives, etc.),
❖ This method of sanitizing involves the use of hot water and a three
compartment sink.
❖ Items to be sanitized are soaked in hot water at a temperature of 170°F for at
least 30 seconds.
❖ A long handled mesh basket is needed to soak utensils.
• A thermometer must be used to determine temperature readings.

• The time required is determined by the temperature of the water.
136
Thermal Sanitizing
Hot Water
Advantages Disadvantages
❖relatively inexpensive ❖slow process which requires come-

up and cool-down time
❖easy to apply and readily available
❖can have high energy costs
❖generally effective over a broad
range of microorganisms, ❖has certain safety concerns for
employees.
❖relatively non-corrosive
❖forming or contributing to film
❖penetrates into cracks and crevices. formations, and
❖shortening the life of certain

equipment or parts there of (gaskets,
etc.).
137
Chemical Sanitizing
This method requires even more precise knowledge and greater

controls than the hot water sanitizing method since the effectiveness
of the sanitizer is dependant upon exact amounts of chemicals used.
138
Chemical Sanitizing
The ideal chemical sanitizer should be :

❖Approved for food contact surface application
❖Have broad spectrum activity i.e. Effective against all kinds of
bacteria, yeast, molds and viruses.
❖Biocidal ( kill organisms ) at use concentration rather than biostatic
( control organisms )
❖Stable under all types of conditions.
❖Tolerant of a broad range of environmental conditions.
❖Readily solubilized and possess some detergency.
❖Non toxic
❖Non corrosive to equipment surfaces.
❖Inexpensive.
139
Chemical Sanitizing
Specific Types of Chemical Sanitizers
In food-handling operations, these are used as rinses, sprayed onto

surfaces, or circulated through equipment in CIP operations.
❖ Chlorine (maximum concentration 200 ppm
❖ Iodine
❖ Quaternary Ammonium Chloride Compounds (maximum
concentration 200 ppm)
❖ Acid Anionics
❖ Peroxides (Hydrogen peroxide + Acetic acid)
140
Ware Washing
Manual washing and sanitizing Facilities
Restaurants and institutions are required to have a three/four-
compartment sink.
❖The first compartment is used to rinse off large particles of

adhering soil.
❖ The second compartment is used to apply the detergent in 120° to
140°F water.
❖The third compartment is used to rinse and
❖the fourth to sanitize.
141
Ware Washing
Manual washing and sanitizing Facilities
The sink compartments must be large enough to accommodate the

largest piece of equipment or utensil to be cleaned.
142
Ware Washing
Manual Ware washing 6 Steps
1.Pre-clean (Remove debris) remove excess food waste by
❖ Scraping
❖ Pre-soak/pre-rinse all eating utensils and equipment
❖ Use hot soapy water
2.Main Wash loosen surface waste and grease using a detergent. :
3.Rinse remove loose food waste, grease and detergent, using
clean hot water
4.Sanitize :
❖ Use 50-200 ppm chlorine; mix with cool water or
❖ 200ppm quaternary ammonia; mix with 75°F (23°C) water
❖ Immersion time is 7 seconds
❖ Use appropriate test strips to check concentration
5.Final rinse remove the disinfectant.
6.Air Drying remove all moisture.
143
Drying Facilities
❖ Adequate facilities must be provided to air dry washed utensils

and equipment.
❖Adequately sized drain boards, or easily moveable dish tables,

and separate for soiled and cleaned utensils should be provided.
❖The drain boards and dish tables should be pitched a minimum

of 1/8 inch per foot and drainage directed into a sink so as to prevent
contamination of other areas of the dish table or drain board.
❖Drain boards may generally be at least 36 inches (91 cm) to

48 inches long and 30 inches (121 cm) wide.
144
Cleaning schedule
A cleaning schedule is probably the simplest way of organizing routine

cleaning. These schedules should state :
•What is to be cleaned? A list of all items which need to be cleaned
•When is it to be cleaned?
•Frequency of cleaning. How often each item should be cleaned
•Method of cleaning. Including the material and equipment to be used
•Type, and amount of chemical to use.
•Person responsible for cleaning.
•The precautions to be taken
•Any special notes or in formation.
Having written your cleaning schedule, prepare charts of the schedules

so that they can be displayed in each room or area.
145
CLEANING SCHEDULE EXAMPLE Issued by (name/date)
Cleaning of Method, time Equipment PPE Frequency Notes

chemicals
Room/area X + Disinfect Daily
Machine XYZ
Vehicle ZVW
4-Apr-20 146
Cleaning Practices
Clean and disinfect at a frequency sufficient to

avoid any risk of contamination
Food contact surfaces more than once a day
Deep clean Twice a year
Instruct production staff Clean as you go
4-Apr-20 147
4-Apr-20 148
4-Apr-20 149
Chlorine-based disinfectants are amongst the most useful of
disinfectant used for food hygiene. They are termed chlorine-
bleaches and hypochlorites. Strength is expressed in ppm.
Available chlorine
Dilution of
Uses
stock solution
% ppm
Disinfection of
soiled surfaces 1/100 0.1 1000
Infant and other

feeding utensil 1/800 0.0125 125
Uncooked fruits
and vegetable 1/1600 0.0065 60 - 90
4-Apr-20 150
Chlorine-based disinfectant
Advantages: Wide microbial range, rapid action,
very low toxicity, negligible taint,
cheap, dry powders abd tablets
stable on storage.
Disadvantages: Corrosive to some metals, liquid

preparations and use-dilutions unstable
4-Apr-20 151
Quaternary-ammonium compounds
Are surface active molecules and therefore detergent. They
have surfactant property i.e. if combined with materials-
attractant surfactants become ineffective.
Advantages: Easy to use, stable, little corrosion, non
toxic.
Disadvantages: Easily inactivated, smaller microbial

range than hypochlorite.
4-Apr-20 152
How does peracetic acid disinfection work?
Peracetic acid as a disinfectant oxidizes the outer cell membranes

of microorganisms. The oxidation mechanism consists of electron
transfer. When a stronger oxidant is used, the electrons are
transferred to the microorganism much faster, causing the
microorganism to be deactivated rapidly.
Table 1: oxidation capacity of various disinfectants

Disinfectant EV (electronic volts (
Ozone 2,07
Peracetic acid 1,81
Chlorine dioxide 1,57
Sodium hypochlorite 1,36
4-Apr-20 153
• Proper storage of Toxic
Compounds
Room with limited
access;
segregate food grade
from non-food grade;
and
keep away from food
equipment, utensils, and
other food contact items
154 4-Apr-20
• Containers used to hold
cleaners and sanitizers
must not be food
containers that could
inadvertently be used to
pack a food product.
4-Apr-20 155
• Employees bring in
additives in their
personal items
• Personal items should
not be stored in food
storage or processing
area
156 4-Apr-20
Cleaning in all food premises
To Summarize:
1. Food premises are to be kept clean
2. The layout, design, construction, sitting and size are to:
a. permit adequate maintenance, cleaning and/or disinfection
b. avoid or minimize air borne contamination
c. allow for the hygienic performance of all operations
3. In rooms where food is prepared, treated or processed.. the design and layout are to
permit good food hygienic practices, including protection against contamination
between and during operations. In particular: floor, walls, windows, equipment
surfaces etc.
4. Conveyances and/or containers used for transportation are to be kept clean
4-Apr-20 157
Cleaning in all food premises
5. All articles, fittings and equipments with which food comes into contact are to:
a. Be effectively cleaned, and where necessary disinfected,
b. Cleaning and disinfection are to take place at a frequency sufficient to avoid any risk
contamination,
c. Be so constructed, and be kept in such good order repair and condition.
6. Containers (food waste, non-edible by-product or other refuse) are to be of an
appropriate construction, kept in sound condition, be easy to clean and, where necessary,
to disinfect.
7. Refuse stores are to be managed in such a way as to enable them to be kept clean.
Refer to GMP – sanitary design of equipment and premises
4-Apr-20 158
4. Food Transportation, Product information and Training
4/4/2020 159
Transportation
Measures should be taken to:

➢ Protect food from: i) contamination sources
ii) damage likely to render the food unsuitable for consumption
➢ Provide an environment which controls the growth of pathogenic or spoilage

microorganisms and the production of toxins in food
4/4/2020 160
Product information and consumer awareness
➢ Lot identification
➢ Product information
➢ Labelling
➢ Consumer education
4/4/2020 161
Training
➢ Awareness and responsibilities

➢ Training programmes
➢ Instruction and supervision
➢ Training offers food handlers a better understanding of how food can become contaminated, and how
foodborne illnesses can be avoided through proper food
handling procedures.
Each food business must decide what training their food handlers need by identifying the areas of their work
most likely to affect food hygiene and safety.
Examples of basic knowledge in food safety:

1- Main contributors factors to outbreaks
2- Temperature control of potential hazardous food
3- Proper ways of using equipment (skills of using thermometer etc.)
4/4/2020 162
Consumer information
➢ Consumers should know enough about food hygiene to be able to:

- Understand the importance of product information
- Make informed choices appropriate to the individual
- Prevent contamination and growth or survival of foodborne pathogens by storing,
Preparing and using it correctly.
4/4/2020 163
Handling customer complaints
➢ Customer complains should be handled carefully because they help reflect possible
problems that may be overlooked by the management during food production.
➢ Depending on the results of investigation, action should be taken.
➢ Establish complaint handling procedures.

➢ Document all customer complaints
➢ Records details including the date, customer details, reasons for complaining and action
taken
4/4/2020 164
Waste disposal
➢ Waste can be regarded as any item of foods, ingredients, packaging materials
etc., which is not suitable for further use and intended to be disposed of.
➢ Waste disposal bins should be placed near the working area of food preparation rooms
and positioned conveniently to operating staff.
➢ Waste disposable bins should be clearly distinguishable from other storage bins
➢ A defined area should be allocated for the storage of waste pending disposal.
➢ When food waste is removed from food preparation area pending disposal, it must be
placed in a tightly covered waste storage bin.
➢ Plastic liners should be used in waste disposal and storage bins
➢ They should be emptied when full or on a regular basis.
➢ Waste bins should be cleaned and sanitized daily than place upside down and off the
floor to drain overnight.
4/4/2020 165
Incident management and Trace/Recall Procedures

Recall of products
Definition : Firm’s removal of marketed product that the Food & Drug Administration considers to be
in violation of the law it administers and against which the agency would initiate legal action; e.g.,
seizure.
Recall Policy
Recall system is an effective method of
removing or correcting consumer products
that are in violation of law
Recall is a voluntary action that takes

place because manufacturers and
distributors are responsible for the
protection of public health from products
that present a risk of injury or gross
deception or are otherwise defective
4/4/2020 167
Recall Strategy (1)
Strategy should be based on:

A- Class of recall - may be classified into:
1. Class I: Situation where use of product
may present serious adverse health
consequencies or death e.g. Cl
butilinum
2. Class II: Situation where use of product cause

temporary illness e.g. pathogens other than Cl
botulinum.
3. Class III: Situation where use of product does not
cause illness
4/4/2020 168
Recall Strategy
B. Depth of recall: Depending on the degree of hazard and the extent of distribution,
the recall must specify the extent to which the recall shall extend e.g. wholesalers,
retailers, consumers..
C. Public warning: The purpose is to alert the public that the product present a serious
hazard to health
D. Effectiveness checks: This is to verify that all persons who received or used the
product, have received notification about the recall and have taken the appropriate
actions.
4/4/2020 169
Recall Communication
A recall communication should be written with the following guidelines:

a. Be brief and to the point
b. Clearly identify the product, its size, lot number, consumers, customers,
etc.
c. Explain concise reasons for the recall and hazards involved
d. Provide easy, dedicated and clear means and channels for feedback.
4/4/2020 170
Recall Status Report
The recalling firm must produce

periodic recall status report which
must willingly be provided to the
official government offices or other
concerned parties such as hospitals
and others working to control the
damage.
4/4/2020 171
GMP: Storage in the Food Industry
4/4/2020 172
Keeping Food Safe in Storage
CONCEPTS
Refrigerated storage: Storing potentially hazardous food at internal
temperature of 5 C or less (Check regulations)
Frozen Storage: Storing potentially hazardous food at -18 C or lower
Dry storage: Store to hold food at between 10 and 21 C and a relative
humidity of 50 – 60 %
First-in-First-out (FIFO): A method of stock rotation
Shelf-life: Recommended period of time during which food can be stored and
remained suitable for use
Hygrometer: Instrument used to measure relative humidity
4/4/2020 173
General storage guidelines
Storage areas should be positioned to

prevent contamination
Keep potentially hazardous food out of the

temperature danger zone
Follow the first-in-first-out (FIFO method
Never place hot food in a refrigerator

To hold food at a specific temperature in
Store raw meat, poultry and raw fish
freg. must usually be kept 1 C lower
separately from ready-to-eat food to
prevent cross contamination
Wrap food properly
4/4/2020 174
Monitor food temperature

regularly
Do not overload the

refrigerator
Refrigerated ready-to-eat
food should be discarded
within 7 days of
preparation
Keep all storage areas
clean and dry
4/4/2020 175
Products should be
stored in clean,
covered containers
that are clearly
marked
4/4/2020 176
Keep storerooms cool, dry and

well ventilated
Store food in its original package

if possible
Store food at least six inches off

the floor and away from walls
Dry storage temperature should be between 10
and 21 C, and RH between 50 and 60 %
4/4/2020 177
Follow FIFO
Shelve food based upon
use-by or expiration dates,
so older food is used first
4/4/2020 178
• Chemical Handling
• Key Elements of Chemical Safety Code

✓Follow manufacturer's instructions
✓Wear protective clothing
✓Never mix chemicals without the supervision of a
qualified person
✓Store chemical safely
✓Clean up any spillage immediately
✓Quick medical treatment
✓Use common sense
4/4/2020 179
Manufacturer’s Instructions
✓Read product information data sheets and product make up instructions

✓Read material safety data sheet (MSDS) for precautions to be taken for handling
✓Compatibility of the product with materials of construction of equipment where it
is to be used. (e.g. Caustic soda products are not suitable for Aluminum or Zinc).
✓Follow the warning signs
✓Read label
4/4/2020 180
Chemicals must be clearly labeled
Chemicals must be separately

stored
Where legitimate sign of “danger”

must easily recognized
4/4/2020 181
Pest Control
4 April 2020 182

Pest-control and Disinfection
The Pests
Most dangerous since they live within the food stuffs
Permanent reproduce extremely fast and capable of causing substantial
damage
Casual visitors, do not colonize the foodstuffs but establish

Occasional
themselves in production or storage premises.
There is constant transmigration of infestant throughout,

Note and they well adapt to hostile environment
4 April 2020 183

Pest-control and Disinfection
• There are 4 types of infestants must be known to food processors:
Insects: Permanent e.g. beetles, butterflies and moths

Occasional e.g. cockroaches and crickets
Arachnids: Acarids such as mites
Mammals: Rodentia e.g. rats and mice
Birds
• Domestic animals e.g. cats, dogs, are also considered infestants.
4 April 2020 184

Exclusion and eliminations of infestants
When developing a pest control program it is essential:
• To have expert advise

• To put the program in writing
• To record results in details so as to permit analysis
• To review the program at appropriate frequencies
Effective approach is the perfect application of preventive measure
4 April 2020 185

Guidelines for the exclusion and elimination of infestants
External Measures
Outer Boundaries: Walls surrounded by paved path 7 – 8 m wide/clean

Windows: Protected by anti-insect netting
Air intake : (Vents)
Ventilation of premises: Condensation problems
Lighting: Attract insects
Doorways: Leading to the production area
4 April 2020 186

Guidelines for the exclusion and elimination of infestants
Internal Hygiene
Production premises: Kept tidy

Unused space: Every day check and clean
Refuse and Waste
Walls and Floors: Kept clean and intact
Junctions between walls and pavements
Electric control panels and wire ways
Drainage channels
Roof corners and side ways
Internal Hygiene is a key issue in the
Damaged materials of products
exclusion of infestants
Production machinery and equipment
4 April 2020 187

Monitoring of infestants
What to monitor?
Materials entering the factory

• Materials entering the factory 1. Raw materials:
• Outside areas Sacks or bags:
• Inside areas • Look for signs of insects or rodents

• Examine the folds of the sacks
• Leave sacks open for about 15 minutes
• Use appropriate sieves
• Examine the presence of mites
Tanker:
• Inspect the upper loading hatches for live insects
• Take appropriate sample for examination
Search for insects and rodents residues
4 April 2020 188

Tests depends on whether the substratum being examined is:

2. Filth test • Completely soluble in water
• Insoluble in water
• Chemical tests (AOAC), 44 001 – 44,225

• Use of X-ray (expensive, rather used for research) Radiography makes it possible to
discover:
•The extent of infestation
• The development stages of insects
• Their degree vitality
• Use of Scanning Electronic Microscopy (SEM). This is to identify species from residues
of insects and rodents
4 April 2020 189

3. Packaging and miscellaneous materials
The items to inspect upon arrival of packaging materials basically are:

✓Vehicles used to deliver goods
✓Outer packaging of materials
✓The materials themselves
A careful examination must be made of the pallets supporting the materials, they are often a nesting place for
insects.
4 April 2020 190

Monitoring of infestants Outside area
Monitoring of outside areas surrounding building must be performed systemically on an ongoing basis. The
following types of devices can be positioned around the buildings for insects and mice:
Insects Rodent
•Poisonous baits for air-borne insects
• Mechanical traps
• Baited traps
• Poisonous bait traps
• Light traps
• Glass-jar traps
• Electrocuters
• Pheromone traps (glue)
• Cockroach traps
Example of birds trap
4 April 2020 191

Inside area
• Examination of dust residues

• Analysis of traces of infestation
• Use of food traps and baits
• Use of light and pheromone traps
Carrying out appropriate Preventing the entry of infestation

cleaning procedures
4 April 2020 192

Pests can be controlled by taking the following measures:
1.Exclusion and restriction (preventing access and denying
harbourage)
•Check incoming food and supplies for sign of pests before storing it.
•Eliminate cracks and crevices in food storage and handling areas by

proper sealing all gaps around fittings or in walls or floors .
• Make all food handling and storage areas accessible to routine

cleaning.
❖Seal cabinets and kitchen equipment to the wall or floor, or
have at least six inches of clearance to allow adequate cleaning.
❖Kitchen equipment one to two inches off the floor or ¼ inch from the wall, is very
difficult to keep clean and is usually an attractive site for cockroaches and other pests.
193
harbourage)
• Keep all doors and windows tight fitting and fit windows and doors open directly into food
preparation areas with screens (with apertures of 2mm square or less) to keep insects out.
•Screened doors should open to the outside and should be closed at all times.
•Cover ventilation ducts and floor drains.
•Food handling and storage areas should be rodent proof and bird proof. Remember, mice can
enter openings less than ¼ inch (0.635 cm), and rats can enter openings less than ½ inch (1.27 cm)
in diameter.
•Clean up all debris and trash.
194
harbourage)
• Remove cartons, newspaper, etc. that may attract and harbour pests.
•Place garbage and food waste in enclosed containers that are emptied regularly ( in sealed plastic
bags and inside tightly covered refuse bins).
•Remove waste food or garbage to proper storage or disposal sites regularly at least daily.
•Keep toilets cleaned and sanitized .
•Slope the grounds properly for adequate drainage. Poor drainage around buildings provides
breeding places for insects and microorganisms.
195
harbourage)
•The outside of the building presents the first impression of your operation to the public.
o Keep grass short, and clean paved access ways.
o Maintain proper drainage to reduce shelter areas for pests.
•Inspect regularly (e.g. weekly) for sign of pests °V both outside and inside.
•Store food and supplies properly
•Cats, dogs or any animals are forbidden on the site.
196
2.Destruction
• Use chemical, physical or biological means.

o Physical pest traps are allowed o Poisons for
pest eradication are forbidden in the raw material and production areas
o Poisons for pest eradication are allowed outside the factory provided they are
controlled.
o Insecticides used inside the factory, restaurants, storage, offices must be of low toxicity
and approved for targeted pests.
•Use a zapper or insecticutor to capture and kill flying insects.

Ensure zappers are not above or within 3 metres of a food preparation or storage area. Avoid
spraying insecticide over food preparation surfaces.
•Hire a professional pest control company if necessary.
197
The Contractor Selection (Pest Control Company)
• Most food businesses rely on the expertise of a pest control company, or the local authority, to ensure their
freedom from infestations. The final decision on whom to choose normally depends on the type of pest and
the methods required for its control
• The destruction of pest observed in the premises is not sufficient; regular inspections should be carried out
to ensure the complete absence of pests from the immediate surrounding area.
• However, food authorities should consider the attitude of, and precautions taken by, companies when
deciding whether or not to institute proceedings, and the court will also taken these factors into account
when considering a “due-diligence” defence or the level of fine.
• The following matters should be considered when selecting a contractor:
❖ the ability to undertake a complete survey and provide a clear report of recommendations and
action required;
❖ the experience of pest control in restaurants;
❖ the adequacy of appropriate insurance cover with regard to product, public and employer’s liability
together with evidence of financial viability;
❖ the contractor must have sufficient resources in terms of trained/qualified staff and the necessary
equipment to carry out proper pest control services;
❖ clear reporting procedures and accountability must be established;
❖ the methods and materials used for pest control treatment have to be approved under the Control of
Pesticides Regulations;
❖ the ability of the company to provide a complete service, including preventive measures.
• Action points should then be agreed and follow-up visits made to ensure the remedies are carried out.
• Whichever firm is chosen, to ensure successful control, it will need the full cooperation of the client and the
contractor should be recorded.
The Role of Management in Pest Control
• The role of supervisors and managers will depend on the size of the operation and the pest control strategy
employed. However, responsibilities may include:
❖ ensuring the provision of proactive pest control management to assist a due-diligence defense, if
required;
❖ arranging for the instruction of staff, especially cleaners to recognize pests or signs of pests;
❖ routinely inspecting vulnerable areas for pests, signs of pests and poor maintenance or proofing;
The Role of Management in Pest Control
❖ arranging for defects and poor housekeeping to be remedied and for contact surfaces are to be
requested to deal with any infestation;
❖ ensuring that any contaminated food is destroyed;
❖ ensuring that the contractor does not expose food to risk of contamination during treatment;
❖ ensuring that any food-contact surfaces that may have been contaminated;
❖ Knowing how to deal with boxes and dead bodies.

WATER SUPPLY
Aspects to consider in the dairy industry
4-Apr-20 204
Why is the Quality of the
Water Supply Important
• Water is an important potential source of microbiological and chemical
hazards.
• Water supplies can become polluted with human sewage or agriculture
waste containing faecal contamination from animals.
• Bacteria are able to multiply in water distribution systems, even when the
income water supply is not contaminated, the problem will be greater if
the water system is not kept clean.
• Water supplies can also be a source of chemical contaminants, such as
heavy metals, pesticides, nitrates, and industrial pollutants.
4-Apr-20 205
Water Supply
• There is to be an adequate supply of potable water, which is to be used

whenever necessary to ensure that foodstuffs are not contaminated
• Private supplies – where water is drawn from a private supply it may
require disinfection treatment (e.g. filtration ultra – violet light
chlorination). Consult a water treatment specialist to help identify the
most effective method.
• Capacity- make sure that the water distribution system has sufficient to
meet demand at peak times (e.g. during cleaning).
4-Apr-20 206
Water Supply
• Water storage tanks – should be made of inert material to avoid chemical

contamination of water and corrosion. Keep tanks covered and secured to
prevent contamination.
• Plans –Detailed plans will help to identify any redundant pipe work that
could act as a reservoir of microbiological contamination and to define an
area to be isolated if contamination occurs. Keep an accurate and dated
plan of the potable and any-non potable systems, including pipe work, point
of entry of water into the premises and numbered outlets.
4-Apr-20 207
Cleaning and Maintenance
• Cleaning – clean tanks regularly to prevent any build up of organic or
mineral material that could act as a source of microbial growth and
contamination and when a contamination incident occurs.
• Maintenance – keep water distribution systems in good condition and

maintained so that water does not become contaminated. Carry out regular
inspections for signs of damage, corrosion, leaks etc. (once a month may be
sufficient for well designed premises that are kept in good order).
4-Apr-20 208
Cleaning and Maintenance
• Disinfection systems – if used, treat filtration and other disinfection

systems with ultra-violet light. They require maintenance e.g. filter systems
need to be cleaned and/or changed regularly to maintain performance.
• Chlorine – if added to disinfect private supplies, seek specialist advice.

• Water softening – in hard water areas water softening may be applied to
prevent the build up of scale and reduce the use of detergents.
4-Apr-20 209
Training, Instruction & Supervision
• Instruct staff (and any contract cleaners) about the need to use potable
water (including ice and steam if appropriate), to use only water from the
correct outlets and reports problems promptly. Staff who take or test
water samples need to be adequately trained so that results are reliable.
• Where non-potable water is used, e.g. for fire control, steam production.
Refrigeration and other similar purposes, it is to circulate in a separate,
duly identified system. Non- potable water is not to connect with, or allow
reflux into, potable-water systems.
4-Apr-20 210
Recycled Water
If recycled or re-circulated water is used, carry out daily tests to check its
quality, keeping a record of the results. Take appropriate action if quality
standards are not being met.
4-Apr-20 211
Use of Ice
Keep ice storage containers covered. Clean and

periodically disinfect to be sure that they do no become
contaminated
Use of Steam
Include the potable water outlet used to

feed the steam supply in the sampling
program.
4-Apr-20 212
Water Testing-Microbiological Parameters
• Total viable count (TVC) at 22 C after 72 hours

• Total viable count (TVC) at 37 C after 48 hours
• Coliform bacteria (total coliforms)
• E.coli
• Enterococci
• Clostridium perfingens (including spores) – if
water originates from, or is influenced by
surface water.
4-Apr-20 213
Private supplies or Main Supplies
• Storage – in these cases microbiological parameters should be monitored

to check that the water being used is of potable quality and that
contamination is not occurring after the water enters the premises:
• Testing Frequency- TVCs and Coliforms should be measured monthly and
used to indicate when further investigation is required.
All microbiological parameters should be checked at least annually and as part if any follow-up
investigation when the TVCs and/or Coliform levels exceed the guidelines.
4-Apr-20 214
Interpretation of Results
Total viable count (TVCs) – the results of TVC tests can be used to assess
the water quality around the plant.
Guideline figures for acceptable TVC values are:
• TVC at 22C after 72h – up to 100 per ml
• TVC at 37 C after 48h – up to 20 per ml
Regular samples from the same points on the system can indicate a
developing contamination problem. Any increase in counts above these
guideline figure should be classified as a low level positive.
4-Apr-20 215
Coliform Bacteria (total coliforms)
Expected levels are less than 1 per 100ml.

Presence should be considered as a low level
positive and must be re-sampled. If coliform
bacteria are found at levels above 3 per 100 ml
of water, in two consecutive samples, or in
more than 5% of samples taken within a year,
this may indicate contamination in the water Illustration of E. Coli
distribution system, and urgent action must be
taken
4-Apr-20 216
• E.coli – if E.coli is detected in water, this is evidence of contamination by
animal or human feces. This is a serious food safety risk and urgent action
must be taken.
• Enterococci – and Clostridium prefingens are also indicative of fecal

contamination and urgent action must be taken
• Chlorine – British standards 12671:2000 Chlorine dioxide – the combined

concentration of chlorine dioxide, chlorite and chlorate should not exceed
0.5mg/litre as chlorine dioxide in the water entering supply.
-
4-Apr-20 217
Follow up Actions – Low Level Positives
• Re –sample and test for all faecal indicators. If a

further low level positive result is obtained, but
there is no evidence of faecal contamination,
investigate the source of the problem.
4-Apr-20 218
Follow up Action – High Level Positives
• Do not use the water outlet or tank from which the

sample was taken (and associated outlets if
necessary) until the contamination has been
investigated and eliminated
4-Apr-20 219
Corrective Action: Contamination within Premises
If contaminated water comes into contact with food, take urgent

corrective action to ensure food safety.
Corrective action may include:
• isolating appropriate water outlets/tanks until satisfactory
microbiological test results are obtained
• stopping production where no potable supply can be provided.
• Dealing with any product that has been contaminated, including
removing it from the market if necessary.
4-Apr-20 220
Corrective Action: Contamination within Premises
• Establishing the underlying cause and

what needs to be done to prevent
similar contamination incidents in
the future
• Reviewing sampling and testing
procedures
• Improving staff instructions and
training.
4-Apr-20 221
Supplier Quality Assurance
-Approved Suppliers & locations
-Specifications
• Continuing Guarantees
• Certificates of Analysis
-Auditor programs
▪ Auditor Training & Calibration
▪ Third party audits to the supplier
▪ Second party audit on the supplier
-Review of Suppliers
HACCP and PRP programs
Foreign supplier verification program (FSMA)

Foreign Material Management
-Meant to control foreign material in products

Magnets
Screens/filters/ sifters
Metal detectors
X-ray

Chemical control
-A chemical control program must control and monitor the purchase, use, storage and disposal of
chemicals


4) FAAS 608 - Week 6 7

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4) FAAS 608 - Week 6 7

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Basic Concepts in the Implementation of the Food Safety

Practical implementation of GHP, GMP, HACCP, ISO 22000

Dr. Nada EL DARRA, Associate Professor of Food safety & Technology

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Foundation for the development of effective product quality management

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1. Initial/ start up costs: 2. Implementation cost

• Formal meetings/ management costs

• Growth (toxin production) parameters:

• Outbreak of E.coli O 157 bacterium in South Wales in 2005.

• 157 cases were identified in the outbreak, 31 people were hospitalized

• Over 200,000 people ill.

• Largest outbreak of foodborne botulism in the UK.

• Almost 300,000 victims; 54,000 babies hospitalized, 6 infant deaths.

• Involved Milk and infant formula

• Adulterated milk with melamine

• Added so it would appear to have a higher protein

• 57 confirmed cases; 23 people died.

• Sliced luncheon meat

• Contamination traced to slicing equipment

Preventive approach is needed

There are certain points

PRE -REQUISITE PROGRAM (PRP)

PRP covers GMP/ GHP/ SOP and legislation

• Foundation for an effective HACCP system.

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- Should be documented and regularly audited.

- PRP established and managed separately from the HACCP plan.

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• PRPs must be implemented and have records to verify implementation.

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HACCP programs have often focused on the process of manufacturing and

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When choosing and developing PRPs, it is essential to consider information

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The PRPs shall:

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Good manufacturing Practices are minimum common sense sanitary &

GMP generally relates to good house keeping practices concerning food

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✓ The Environment ( site)

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Are there any nearby source of contamination?