Hygienic and Sanitary

Practices for
Bakery – Basic Level
 Learning Outcome
This manual is for basic manufacturing outlets including small canteens, caterers, bakeries etc.

This manual explains General Requirements on Hygienic and Sanitary Practices to be followed by all Food Business
Operators engaged in catering/food service establishments, as per Food Safety & Standard Act, 2006.

This manual presents bare minimum requirements of Food Safety and hygiene to be followed by Food Business Operators
along with Industry best practices.

The objective of this manual is to train the Food Safety Supervisors about GHP requirements that should be followed in a
catering business. The FSS may interpret these requirement according to the size and type of their establishment.

The desired outcome of this manual is better understanding of food safety and hygiene requirements and high standards
of food safety.

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 Modules

1. Introduction to Food Safety

2. Food Safety in Bakery Practices
3. Good Hygiene (GHP)and Good Manufacturing
Practices(GMP) in Bakery
4. Regulation and Technical Skills in Bakery

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Module I - Introduction to
Food Safety

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Food Safety
Food Safety can be defined as the assurance that food will
not cause harm to the consumer when it is prepared or
eaten according to its intended use .

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Why Food Safety Is Important?
Loss of Customer &
Sale

Loss of prestige &

reputation

Embarrassment

Legal action by
Authority

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 What’s Wrong?

Sources of Food Contamination Food Contamination Food Spoilage

Food Poisoning

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 Food Contamination

A food contaminant has been defined as any substance not intentionally added to food, which is
present in such food as a result of the production, manufacture, processing, preparation, treatment,
packing, transport or storage of such food as a result of environmental contamination.

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Sources of Contamination From Farm to Table

Vehicle
emission
Crops Processin
g
Agricultural
practices
Cooking
Livestock
Landfills Retail
Storage

Industrial emissions
Seafood
and effluents
Distribution

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Types of Food Contamination

Food
Contamination
 Physical Contamination

Jewellery, Hair and

fingernails

Pest droppings, fur,

dust
and dirt

Paper, Cardboard,
threads

Wood, glasses, bits of

equipments
Chemical Contamination

Cleaning
Agents

Pesticides Residues

Non-permitted
Food
Additives

Machinery Grease
Biological Contamination

Bacteria

Viruses

Yeast & Molds

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Food Allergens in Bakery

Gluten
Milk Eggs

Soybean Pea Nuts Tree Nuts

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Contributing Factors to Food
Contamination
Poor
No Improper
Personne
Pest storage and
l Hygiene
Contro temperatur
l e

Improper Cross
Cleaning Contaminatio
and n
Sanitatio
n

Bad
Uncovere
Storage Expiry
d Food
date
 Danger Zone
Checking internal temperature of cooked food

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 Food Poisoning
• Food poisoning is an acute illness, which usually occurs within 1 to 36
hours of eating contaminated or poisonous food.

• Symptoms normally last from 1 to 7 days and include one or more of the following
abdominal pain
diarrhea vomiting fever collapse
Food Poisoning!
 Food Safety Programs
Food Safety Programs are procedural measures that reduce
the likelihood of a food safety or a food quality hazard
occurring, but one that may not be directly related to activities
taking place during production.

Different Food Safety Programs:

❖GMP - Good Manufacturing Practices
❖GHP - Good Hygiene Practices
❖HACCP - Hazard Analysis and Critical Control Point
Module II - Food
Safety in Bakery

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 Introduction

• Bakery businesses are food processors of largely wheat based products

cooked in insulated heated space, the bakery ovens.
• Baking includes the production of such items as bread, cake, pastry, biscuits,
crackers, cookies, and pies where flour is the essential and principal
ingredient for the base product
 Bakery Premises - Location
Establishments should be built away from:

✓Polluted areas and industry activities

✓Areas subjected to floods
✓Areas prone to infestation by
pests
✓Areas where waste cannot be removed
effectively
 Design and Layout
✓ Premises and Rooms
Facilities: appropriate
maintenance, cleaning and
disinfections

✓ Minimizes contamination:
Walls, Floors, Partitions,
ceilings, windows - well
designed and constructed for
easy maintenance and cleaning
Facilities
• Portable water- for manufacturing
and hand washing
• Non portable water can be used for
fire control or steam. However lines
used be clearly marked
• Drainage and waste disposal
• Personal hygiene facilities, lavatories
and changing facilities with hot Waste
water (> 40⁰C) Bin with
• Natural and mechanical ventilation foot
operated
• Proper ventilation and temperature
lid
control mechanism.
• Natural or artificial lighting
Equipments
• Proper procedures should be
available for each equipment like
Oven, Mixers, Proofer etc.
• Easy to dismount, Smooth edges
and easily accessible for cleaning,
free from dust and pest activity
• Covered or protected to prevent
contamination
• Cleaned and disinfected after every
maintenance procedure
• All interior surface in contact with
the product must be emptying

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Keep Bakery Equipments Clean
Proper placing of Tools/ Equipments
Bakery Process Flow
Pre Mixing Mixing

Dividing

Dough Moulding

Non
Fermentation Fermentation

Proofing

Baking

Cooling

Packing
 Raw Material
•All material should be procured from
vendors who have obtained FSSAI license
•All material should be clean and
uncontaminated, and safe
•All material should be examined at point
of receiving for
➢Damage or signs of
contamination
➢External dirt on packages
➢Labeling, Product name,
Manufacturers name and address,
date and code, and all information
required by packaging Rules.
➢Material should be easily
traceable
to its source.
 Storage
• Raw materials, process materials and products are
stored separately at ideal conditions of temp, R.H
and air velocity

• Chemicals, bagged raw materials should

be stored on sound pallets

• Storage area must be free from pests and other

contaminants

• Raw material and finished products must be rotated

in First In First Out (FIFO) and First Expiry First Out
(FEFO) basis.
 Raw Material Storage

No Stacks Proper Stacks

 Mixing
• All dry material must be sifted, and liquids must be
filtered before use.
• Vessels should be clean, and of stainless or non
rusting material.
• Formulas and Recipes should be strictly followed and
quantity of additives must be within limits.
• Any bit of dough that falls to the floor should not be
re-mixed, as it can pick up bacterial contamination.
• All hand tools, spatula, spoons and scoops should be
clean and be kept on hygienic surfaces like trays, and
clean working table tops.
Dividing
• From bulk dough, unit dough piece or
batter is separated for processing before
baking.
• High speed machines, Semi-automatic
equipment, and hand work may be
involved.
• Dough bits, dusting flour, and oil if
allowed to gather for long, will go
rancid, allow bacteria to grow, and
encourage fungal growth.
Dividing
•Food should be prepared at
steady pace and not allowed
to stand more than necessary
for process.
•Temperature control should
be maintained as needed by
process.
Baking and Cooling
• Oven area should be segregated, to avoid
cross contamination with fumes and smoke.
• Controls should be maintained on
temperatures, humidity, and timing of
baking.
• Cooling should be done in as clean an
environment as possible.
• Finishing, cutting, and decorating should be
done with all precautions.
Packaging
•Packing material can have unwanted
smell from paper or inks. These will
get picked up by food.
•All packs must carry codes to allow
quick tracing of material in event of
any issue.
•Internal records should be
accurately kept.

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 Packaging of End Products
No Packaging Proper Packaging
Transportation
• Requirement of safe and proper transportation of foods
 Design and construction of vehicle
 Clean and/or disinfect
 Separates food from non food item
 Maintain temperature
 Prevents contamination
 Training of carrier personnel
 Maintenance of records of written procedures,
agreements and training (required of carriers)

• Verification Procedure
 Inspection of vehicle
 Programs describing effective cleaning
– and sanitation
 Loading/unloading
 Materials used in vehicles for food transportation
Module III – Good Hygiene
and
Manufacturing Practices
 Personal Hygiene - A healthy human is covered with microorganisms

on hair (incl. beards in the nose

and mustaches)

in the mouth

on the skin

under the nails

The human gastro-intestinal tract excretes microorganisms

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 Only minute amount of certain pathogens can cause
infections in humans

Infections occur easily when just

one food handler does not
observe hand hygiene rules.

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Before you get to work
• Take a shower
Wash off dead skin and bacteria
• Put on clean clothes and footwear
Clothes and footwear can carry bacteria into
the plant
• Keep fingernails clean, trimmed and without
polish
Polish or artificial nails can fall off

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Personal Hygiene -
Do’s and Don'ts
Hands need to be washed regularly and
immediately
•before working with food
•after using toilet
•after handling rubbish/waste
•after smoking, coughing, sneezing, using
tissue, eating, drinking, smoking
•after touching hair or scalp or mouth

Sanitizers do not replace hand washing

Steps of proper hand washing

Washing hands
the right way only
require three
elements:
•running water,
•soap,
•and something to dry
hands with.

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 Use clean facilities
Dirty facilities

Clean facilities

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Maintain Correct Food Temperature

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Correct Food Storage

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Check Expiry dates and Label Foods

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 Pest Prevention and control
• Holes, drains and places must be sealed
• Food sources should be kept away from the
walls and above the ground
• Doors should have self closing facility
• Use of poisons are strictly prohibited in
the raw materials and production area
• Insecticides and pesticides used should be of low
toxicity and should be approved by the regulatory
body
• Plant inspectionand surveillance program
must be conducted and documented.

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Pest Control Measures -Fumigation
✓ Periodic fumigation to be ensured.

▪Method of fumigation should be

approved (like use of Aluminium
phosphate which is an approved
fumigant)
▪Fumigation is recommended to practice
minimum Once in a year.
▪Should be carried by an approved third
party
(expert and experienced)
▪Post fumigation, the area should be
inspected and verified for non-
presence of any fumigant residue.

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Pest control in Bakery

Ultraviolet Rodent
Traps

Sticky fly Papers Mist Net 52

Pest control measures in Bakery

Strip Curtain Air Curtain

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Pest Control Measures -Good House keeping
• Premises and refuse areas kept in clean and
tidy condition
• Waste bin should be washed after emptying
• Waste must not be allowed to accumulate
• Spillages are cleared away promptly
• Food should be covered
• Drains are kept clean and good conditions
• Sightings of pests or pest damage are
reported to management immediately
• Stock should be checked regularly
and damaged stock removed

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 Cleaning and Sanitation
• Procedure and frequency must be
documented
• Cleaning products- recommended for food
industry
• Labelled and kept outside the production area
• Litter bins should be covered and fitted with
plastic
insert
• Silos must be capable of totally emptied and
cleaned
• Adequate preventive and corrective
maintenance to facilitate cleaning operations

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Forbidden behaviour in a food-handling environment

No Eating in processing
area

No NO SNEEZING
Jewellery,
Mobile 57
Wear hair nets/
beard nets
No beard Net Proper Beard Net

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Forbidden behaviour in a food-
handling environment
No gloves Wearing Gloves

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Stop Cross Contamination

Colour coding of chopping board

Steps to Serving Safe Food

1. Wash hands with soap and 6. Cold foods should be

clean water before serving
food.
2. Keep food covered prior to
serving
3. Serving plates and utensils
should be cleaned and air
dried
4. Do not reuse and reheat
food in disposable wares
5. Eat freshly baked food as far
as possible
served chilled and
stored in fridge
(below 5°C)
7. Hot food should be
served and kept
above 60°C
8. Wash crockery and
cutlery after use
9. Do not serve food
pr put ice in a glass
with bare hands
10.Use a spoons, tongs
or gloves while
serving food
Safe Serving Materials (Do’s and Don'ts)
 Use Stainless steel utensils
 Use Copper utensils
 Use food grade glass, ceramics or
 porcelain
 Use Safe disposable wares or single
service items
× Do not use any kind of plastic wares to serve
food
× Do not use newspaper to serve food
× Do not serve anything sour in non-tinned
copper and brass utensils, or aluminum
utensils
Power Outages and Food Safety
During a Power Outage
•Keep refrigerator and freezer doors closed.
•The refrigerator will keep food safe for up to 4
hours.
• If the power is off longer, you can transfer
food to a cooler and fill with ice or frozen gel
packs.
•Keep the freezer full. Fill empty spaces with
frozen plastic jugs of water, bags of ice, or gel
packs.
• A full freezer will hold the temperature for
approximately 48 hours (24 hours if it is half
full).
After a Power Outage
•Never taste food to determine its safety.
When In Doubt, Throw It Out!
•Discard food like milk, cream, fillings, cut
fruits , cooked vegetables, pies if your
refrigerator has been without power for
more than 4 hours:
•Discard any foods like bread or salad
greens that may have become
contaminated by juices dripping from raw
meat, poultry, or fish.
•In general, if any food has an unusual
odor, color, or texture, throw it out.
 Do’s and Don’ts
✓ Keep food covered
✓ Wear gloves while handling and
serving the food
✓ Wear a hair restraint when working
with food
✓ Clean and sanitize equipment on a
regular basis
✓ Hand basins should be located
conveniently and used for hand
washing only
✓ Prevent cross-contamination
× Never cough or sneeze over food
× Toilets should not open directly into
any room where food is handled.
× Do not wear jewelery/ nail polish
while preparing/serving food
× Cold foods should never be stored on
top or near hot food storage
× Waste shall not be permitted to
build up in food areas
× Never prepare the food with open
cut/ wound
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Before and After Training

Training

Controls

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Keep Bakery clean

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Correct people BUT ALSO praise
A personal thankyou from a supervisor for correct behaviour do wonders.

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Module IV - Regulation and
Technical Skills in Bakery

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Food Laws in India - FSSAI
• Food Safety and Standards Authority of India (FSSAI) implements a complete law to control
food businesses and ensure food safety.

• It lays down standards on all food categories and guidelines for Good
manufacturing practices that need to be followed.

FOOD SAFETY AND STANDARDS ACT, 2006 is applicable on all who are handling food,
uniformly across the country.

• FSSAI is the single authority for

• Scientific development of Standards
• Ensuring uniform implementation on who handles food, in manufacture,
sale or transportation of all food.
• Encouraging food Business operatives to be responsible for food
safety
• Encouraging food safety management systems
• Providing stringent penalties for deliberate or negligent acts that would make food
unsafe.

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Food Safety
• Food article made in a bakery can become unsafe if strict controls are not followed
during processing.

• FSSAI defines UNSAFE FOOD as an article of food whose nature, substance or quality is
such as to make it injurious to health.
• The article itself, or its package should not be of poisonous or deleterious
substance
• The article should not have any filthy, rotten, or decomposed substance
• Food should not be prepared under unhygienic processing
• Food should not have an ingredient which is not permitted
• Food article should not be coloured, flavoured, coated, or treated as to damage
the article or to make it appear better or of greater value than it really is.

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 Registration Licensing

Filing of an Filing of a completed

Application Application
Application
Form A Fees
Rs 100/-
Acknowledge application & Applicatio
Processing grant unique application
of no. n form
Application B

Scrutiny, notice on any additional

Within 7 information required or 15
Grant Registration incomplete Application if any
Certificate if ok or days of days
reject or Issue receipt of
notice for
inspection
application
30 FBO files additional
days required FBO
information may
Conduct inspection – start
Within a
suggest the
improvement if period of Inspection of premises & issue
No busines
necessary 30 days inspection report, improvement
notice inspectio s after
n 60 days

After Inspection and Food Business Either grant or reject the license
satisfied with Within 60 days of receipt of
improvement grant
operator may
completed application or within
registration or start business 30 days of inspection
reject
 Factors affecting Quality of Baked Goods
• Method of preparation
• pH
• Specific Gravity of batter
• Temperature of batter/ dough
• Scaling and Leveling
• Baking
• Water Activity
• Food safety measures

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Process Control Points – Breads & Biscuits
• Weighing balance should be calibrated correctly
• Raw material temperature like flour and water
temperature
• Dough / batter temperature, pH
• Mixing time
• Proofing time
• Proofing temperature and Relative Humidity
• Oven Temperature
• Baking Time

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Process Control Points in Cake
• Mixing time
• Mixing Aeration
• Amount & type of sprayed greasing oil/fat
• Temperatures of the different zones of the oven,
balance between upper and lower heat,
• Baking Humidity (level of the chimneys)
• Baking time, etc.
• Solid ,Liquid/Recipe Balancing
• Balance of Sugar against flour.
• Type of Shortening and its balance against eggs.
• If Milk is used total weight of egg and milk is
balanced against sugar.

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Conclusion

IN PROCESSING OF BAKERY PRODUCTS, FOOD HANDLERS

MUST
ENSURE THAT ALL HAVE BEEN TAKEN TO
PRECAUTIONS
AS HEALTH
FOLLOW REGULATORY CONTROL OF THE
CONSUMERS IS PRIMARY CONCERN FOR ANY FOOD OPERATION
!

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