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OAS REGIONAL PROJECT

OAS REGIONAL PROJECT. QUALITY MANAGEMENT MODULE 2. Presenter: Marcia Henry Manager, Project & Quality Management Systems Scientific Research Council. GOOD MANUFACTURING PRACTICES. Definition : Practices or Procedures in a Factory Which Guarantee the Safe Production of Food.

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OAS REGIONAL PROJECT

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  1. OAS REGIONAL PROJECT QUALITY MANAGEMENT MODULE 2 Presenter: Marcia Henry Manager, Project & Quality Management Systems Scientific Research Council OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  2. GOOD MANUFACTURING PRACTICES Definition: Practices or Procedures in a Factory WhichGuaranteethe Safe Production of Food OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  3. GOOD MANUFACTURING PRACTICES • Documentation and Records: • Preparation of process documents • Productive Process Plan (HACCP) • Generate, file, conserve and store process records OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  4. GOOD MANUFACTURING PRACTICES • Production and Process Control: • Food risks control • Requirements of raw material - relationship with suppliers & conservation of raw materials • Production process control - control of the processes of production • Storage and distribution control OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  5. GOOD MANUFACTURING PRACTICES • GMP is based on the processing activities of the enterprise. • Taking as a reference the Recommended General Principles of Food Hygiene of Codex Alimentarius (FAO/OMS): CAC/RCP 1-1969, Rev. 3 (1997) • Follows the Systems Focus • Follows the Continuous Improvement Route OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  6. GENERAL GUIDELINES FOR GOOD MANUFACTURING PRACTICES OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  7. WATER • Adequate supply of potable water with appropriate facilities for its storage and distribution to ensure the safety and suitability of food. • Potable water should be as specified in the latest edition of WHO Guidelines for Drinking Water Quality, or water of a higher standard. • Non-potable water shall have a separate system & shall be identified and shall not connect with, or allow reflux into, potable water systems. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  8. LIGHTING • Lighting must be adequate for the operation. • All lights in the production and warehouse areas should be shielded. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  9. AIR QUALITY & VENTILATION • Natural or mechanical ventilation are provided to: • minimize air-borne contamination of food; • control ambient temperatures; • control odours which might affect the suitability of food; and • control humidity, where necessary, to ensure the safety and suitability of food. • Ventilation systems are designed and constructed to prevent air flow from contaminated areas to clean areas • Ventilation Systems are adequately maintained and cleaned. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  10. GROUNDS • All external areas within the confines of the plant must be free from waste, refuse and redundant equipment. • The facility should not be in the vicinity of any establishment that generates objectionable odours, smoke, dust or contaminants. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  11. GROUNDS • Structures that could attract or harbour insects or rodents (rats) should be removed. • Grass should not be left uncut for long periods. • Roads, yards or parking lots should not be excessively dusty. • The site should be properly drained. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  12. PLANT CONSTRUCTION AND DESIGN The plant should be suitable in size and design to: • Provide the Proper Environmental Conditions • Provide Adequate Space for Satisfactory Performance of All Operations OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  13. PLANT CONSTRUCTION AND DESIGN • Permit Adequate Cleaning and Sanitation • Minimize Contamination by Extraneous Materials • Prevent Access by Pests OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  14. PLANT MAINTENANCE • Plants should also be properly maintained. • A preventative maintenance plan should be implemented OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  15. WORK SURFACES Work SurfacesShould Be: • Non-absorbent & Non-toxic • Smooth • Durable (able to withstand repeated cleaning and sanitizing) • Unaffected By Food • Easy to Clean, Maintain and Disinfect OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  16. WALLS • Constructed of material that is durable, smooth and cleanable. • Impervious (unable to absorb odours etc) and light coloured. • Well joined to prevent contaminants from being trapped in the crevices. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  17. CEILINGS • Have Smooth Surfaces • Made of Materials that are Cleanable, Durable and Fire Resistant • Made of Materials that Prevent the Shedding of Particles • Have Joints That Are Sealed OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  18. FLOORS • Constructed of Material That Is Smooth and Impervious • Able to Withstand Machinery Movement, and Cleaning • Have Surfaces That Are Safe, Easy to Clean and Waterproof • Sloped for Proper Drainage OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  19. DRAINS • Be Adequate and Have Sufficient Capacity to Cope With Process Requirements • Be Properly Located to Prevent Pooling of Water • Have Traps That Are Well Fitted and Easily Removed for Cleaning • Have Channels That Are Well Constructed to Prevent Backflow and Contamination of Food, Food Products & Potable Water. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  20. DOORS • All Doors Should Have Smooth, Non-absorbent Surfaces and Be Close Fitting • External Doors Should Be Screened • Easy to Clean and, Where Necessary, Disinfect OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  21. WINDOWS • Windows Used for Ventilation should be Screened with Insect-proof Screens. They should be easily Removed for Cleaning. • All Windows should be Well Fitting, Fixed and Kept Clean. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  22. CLEANING & SANITATION • Adequate facilities should also be provided for cleaning and sanitizing equipment. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  23. EQUIPMENT • Situated off the Floor and Away From the Wall to Allow for Proper Cleaning • Designed to Allow for Adequate Cleaning • Made From Material That Can Be Adequately Cleaned • Installed so as to Facilitate Cleaning OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  24. EQUIPMENT FOR PROCESSING • Designed to achieve the required food temperatures as rapidly as necessary & to maintain the required temperatures • Designed to allow temperatures to be monitored and controlled • Properly Maintained OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  25. INFESTATION CONTROL • Pest prevention measures must be taken to ensure that the factory is free of rodents, birds and all other pests. • An approved company should provide pest control services but plant personnel may be trained and assigned the responsibility. • Fogging, spraying and other such treatments must not be carried out during production hours OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  26. ERADICATION • Continued surveillance must be done in order to detect signs of pest infestation. • Holes, drains and other places where pests are likely to gain access should be kept sealed. • Animals should, wherever possible, be excluded from the grounds of factories and food processing plants. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  27. WASTE MANAGEMENT • By-products resulting from processing must be removed continuously during the processing period and stored where they cannot come into contact with in-process materials • Waste should be collected in suitable lidded receptacles, situated away from production entrances and windows OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  28. WASTE MANAGEMENT • Waste and rework materials should be separated and easily identified • Areas where waste containers are placed should be kept clean at all times and spillages should be removed immediately. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  29. WASTE MANAGEMENT • Daily, waste should be removed from the premises. Where this is not possible, bins that cannot be disturbed by animals and which will particularly prevent entry by rodents (rats) must be used. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  30. STORAGE • Adequate space for safe storage of food and other raw materials. • Separate storage areas for raw and processed foods. • Cleaning materials should be stored away from food and off the floor. They should be stored in a separate area. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  31. STORAGE • Foods must be kept safe and at the right temperature to avoid contamination and waste. Storage conditions and storage time depend on the type of food and the way it has been processed. • Food should be stored off the floor. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  32. CLEANING • A disinfection /sanitization plan should be implemented. • Work areas, equipment and work surfaces must be cleaned before and after use • Important to clean as work progresses. All work areas and equipment should be left tidy, clean and sanitary at the end of each working day. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  33. CLEANING • Always clean from the cleanest area to the dirtiest area to avoid contamination • Always follow manufacturer's instructions on the use of sanitizers and other cleaning chemicals • Sanitizers must be left on surfaces long enough to work properly OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  34. PERSONNEL FACILITIES • Changing facilities and bathrooms must be adequate for the number of personnel employed. • Bathrooms, lunchrooms and changing rooms should not open directly into the plant floor but should be enclosed behind a wall. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  35. PERSONNEL FACILITIES • Processing areas should contain a sufficient number of conveniently located hand washing facilities. Remote controlled foot, knee and hand washing stations are preferable • First aid facilities and adequate first aid equipment should be available OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  36. TRAINING • Necessary for systematic detection of contamination caused by biological, physical and chemical contaminants • Planned Training in Food Hygiene - education and training are important elements in developing and implementing a good food hygiene programme OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  37. TRAINING • Personnel responsible for identifying sanitation failure or food contamination should have a background of education or experience, or a combination thereof, to provide a level of competency necessary for production of clean and safe food. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  38. TRAINING • Food handlers and supervisors should: • Receive appropriate training in proper food handling techniques and food-protection principles and • Be informed of the danger of poor personal hygiene and unsanitary practices OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  39. SUPERVISION • Responsibility for assuring compliance by all personnel with all requirements of good manufacturing practices shall be clearly assigned to competent supervisory personnel OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  40. SANITATION PLAN FOR: • Food Contact Surfaces • Floors • Equipment & Utensils OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  41. STAFF HYGIENE • Disease Control: Health condition of personnel ensuring that no communicable infections, infected lesions and other source of microbial contamination occur • Cleanliness: • Hand washing before start of work, after each absence from the workstation and after hands are soiled or contaminated • Maintaining adequate personal cleanliness OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  42. CLEANLINESS • Appropriate Clothing, Suitable to the Operation in a Manner That Protects Against Contamination of Food, Food-contact Surfaces or Food Packaging Materials. This Includes Gloves, Boots, Aprons, Hair Restraints, No Jewelry or Other Objects That May Fall Into the Product • Designated Eating & Smoking Areas - Outside of Production Area • Designated Storage Area for Clothing and Personal Belongings OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  43. MONITORING EFFECTIVENESS • Sanitation systems should be: • Monitored for effectiveness; • Periodically verified by means such as: • audit pre-operational inspections or, • where appropriate, microbiological sampling of environment and food contact surfaces and • Regularly reviewed and adapted to reflect changed circumstances. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  44. Good Manufacture Practices FOOD INDUSTRY • Control of measuring devices: • Equipment Control, Maintenance and Calibration • Traceability of calibrated equipment • Identification and traceability of products: • Processes identification and traceability of product at all stages of production and delivery. • Mechanisms for Recall: to remove products from the market when necessary. OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  45. Prerequisite Programmes • When Sanitation Standard Operating Procedures (SSOPs) are well designed and fully and effectively implemented they are valuable in controlling hazards • With SSOPs in place, HACCP can be more effective since they would concentrate on controlling hazards associated with the food or processing and not on the processing plant environment OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

  46. Prerequisite Programmes • GMP and Sanitation Procedures Affect the Processing Environment and Should Be Considered Prerequisite Programs to HACCP • Prerequisite Programs Are Procedures Including GMP, that Address Operational Conditions Providing the Foundation for the HACCP System OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

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