The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

1. Module 3.4 The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

2. Introduce trainees to the importance of maintenance, sanitation and personal hygiene programmes in assuring food hygiene Relate general principles of maintenance, sanitation and personal hygiene programmes to good practices in coffee processing and handling Objectives Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

3. Scope, outline and objectives of Section VI of Codex General Principles of Food Hygiene, “Establishment: maintenance and sanitation” Designing and implementing maintenance programmes – application to coffee Designing and implementing cleaning programmes – application to coffee Pest control and waste management in coffee processing General personal hygiene issues Content Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

4. Objective of Section VI Establish effective systems to • Ensure adequate and appropriate maintenance and cleaning of the establishment and equipment • Control pests • Manage waste • Monitor effectiveness of maintenance and sanitation procedures To facilitate the continuing effective control of food hazards, pests and other agents likely to contaminate food Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

5. Outline of Section VI Codex GPFH Establishment: maintenance and sanitation • 6.1 - Maintenance and cleaning • General principles underlying maintenance and cleaning programmes and scope of cleaning procedures • 6.2 - Cleaning programmes • Outlines the scope of cleaning programmes and practical guidance for their establishment • 6.3 - Pest control systems • Outlines main aspects of effective pest control programmes • 6.4 - Waste management • 6.5 - Monitoring effectiveness Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

6. Maintenance programmes • Establishments and equipment should be kept in an appropriate state of repair to • Facilitate cleaning and sanitation • Ensure that equipment functions as intended (particularly at critical steps) • Prevent introducing hazards into food Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

7. Maintaining the establishment • Prepare checklist to guide periodic inspection of the establishment • During each inspection notes should be taken of observations • Results of the inspection should be evaluated and recommended actions prioritised according to associated risks • Records should be kept of actions taken to address problems found during inspections Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

8. Inspection of the physical plant • Inspection should include • Immediate environs of the facility • External walls, windows, doors and roof • Internal walls • Ceiling fixtures • Floors Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

9. Equipment maintenance programmes • Processors should keep a list of all equipment used in the facility • Programme of preventative maintenance should be documented including procedures and frequencies of maintenance • Based on equipment manufacturers’ instructions • Production experience • Operating conditions that could affect condition of equipment Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

10. Harvester, bags, baskets Hopper, channels Pulper Fermentation vats Washer Elevators Drying surfaces, tables Huller / polisher Conditioning bins De-stoner De-huskers Extractor fans Air buoyancy separators Winnowers Gravity tables Grader Colour sorter Generator Equipment in coffee processing Some processing equipment used in the production of green coffee Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

11. Maintenance of equipment • Programme of preventative maintenance should be adhered to • Equipment should be maintained to ensure absence of potential physical and chemical hazards (metal shards, flaking paint, lubricants, etc. • Equipment must function properly particularly if involved in a hygiene control step (removal of husk) Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

12. Make routine checks on machine performance: frequency of cherries in output, husk fragments, broken beans, - readjust as indicated • Cherries are sometimes husked at moisture above 15% which causes heating and exceptional wear • Air-borne contamination occurs during hulling Maintenance of equipment –example of hullers Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

13. Maintenance of equipment • Equipment for control and monitoring along the coffee chain • Moisture measuring devices • Water activity meters • Maintenance and calibration of equipment should be performed by appropriately trained personnel Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

14. Maintenance and calibration records Records of maintenance and calibration of equipment must be kept Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

15. Cleaning programmes - general • Cleaning is required to ensure that food residues and dirt, which may be a source of contamination, are removed from all parts of the establishment including equipment • Appropriate cleaning methods and materials depend on the nature of the business • Cleaning chemicals should be handled and used carefully and stored in accordance with manufacturers’ instructions Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

16. Cleaning methods and procedures • Separate or combined methods can be used • Physical methods - heat, scrubbing, turbulent flow, vacuum cleaning • Chemical methods - detergents, alkalis, acids • Cleaning procedures involve: • Removing gross debris from surfaces • Applying detergent solutions to loosen soil & bacterial films • Rinsing with water to remove residues • Dry-cleaning and other similar methods • Where necessary disinfection Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

17. This amount of residue could support significant fungal growth Cleaning programme – example of hygiene implications in coffee • Dry pulp remaining on the machine could cause contamination by undesirable fungi • Although fermentation presents a hurdle for development of OTA-producers, addition of any undesirable inoculum must be minimized • Unfermented parchment routes such a descascado or split cherry drying would present further risk of fungal development from such a source Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

18. Cleaning programmes • Cleaning and disinfection programmes should be documented and monitored • Cleaning programmes should specify • Areas, items of equipment and utensils to be cleaned • Responsibility for particular task • Method and frequency of cleaning • Monitoring arrangements Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

19. Cleaning programmes • Establish appropriate cleaning procedures for each piece of equipment • Cleaned out of place (COP) • Cleaned in place (CIP) • For equipment, disassembly & re-assembly instructions as required for cleaning and inspection Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

20. Programme for weekly cleaning of pulper • Procedures: • Unscrew supports of disks and blades • Remove disks • Rinse disks, blades and chassis with clean water, wash • with detergent, rinse with clean water • Reassemble disks and blades • Tighten the bolts firmly • Supervisor: Mr Peter Documenting cleaning programmes • Cleaning procedures for the equipment • Institute appropriate daily cleaning procedures • Institute more thorough procedures when operation of equipment will be suspended Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

21. Cleaning programmes Cleaning of premises: written cleaning and disinfection programmes for preparation, processing, storage areas Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

22. Pest control systems - general • Pests pose a major threat to the safety and suitability of food • Pests infestation can occur where there are breeding sites and supply of food • Good hygiene practices should be employed to avoid creating an conducive environment • Good sanitation, inspection of incoming materials and good monitoring can minimise risks of infestation Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

23. Pest control systems Preventing access • Buildings should be kept in good repair and condition to prevent pest access and to eliminate potential breeding sites • Use of wire mesh screens on windows, doors, ventilators • Holes and drains kept sealed Harbourage and infestation • Availability of food and water encourages pest harbourage and infestation: • Potential food sources should be stored in pest-proof containers or • Stacked above the ground and away from walls Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

24. Pest control systems Monitoring and detection • Establishments and surrounding areas should be regularly examined for evidence of infestation Eradication • Pest infestations should be dealt with immediately and without adversely affecting food safety or suitability • Treatments with chemical, physical or biological agents should be carried out without posing a threat to the safety of food • Pesticides used should be acceptable to the food control regulatory authorities • Where applicable, name of the pest control company or any person contracted for the pest control programme Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

25. Waste management • Waste stores and containers must be kept clean • Suitable provision must be taken for the removal, storage and handling of waste • Waste must not be allowed to accumulate in food handling, food storage, and other working areas and adjoining environment Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

26. Waste from coffee production • Coffee processors must plan for proper handling of wastes produced from their operations • 1 ton dry cherries = 500 kg husk • 1 ton of parchment coffee = 200 kg parchment • 1 ton fresh cherries = 610 kg pulp • 1 ton unsorted beans = 5 - 10 kg of rejects Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

27. Monitoring effectiveness Sanitation systems should be • Monitored for effectiveness • Periodically verified through • Audit pre-operational inspections • Microbiological inspections • Regularly reviewed • Adapted to reflect changed circumstances Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

28. Personal hygiene • Ensure that those who come directly or indirectly into contact with food are not likely to contaminate food by • Maintaining an appropriate level of personal cleanliness • Behaving and operating in an appropriate manner Remember that these are general principles to guide all food establishments - some provisions may not be pertinent in the production of green coffee beans Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

29. Personal cleanliness and behaviour • Food handlers should wear suitable protective clothing • Personnel should always wash their hands when personal cleanliness may affect food safety (for example, after handling contaminated material) • Personnel should refrain from behaviour that could result in food contamination (for example, smoking, spitting, chewing/eating) • Personnel should not use perfumes and other highly scented substances that could taint the coffee • Personal effects such as jewellery, watches, etc. should not be brought into food handling areas Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene

30. Next steps… • Which coffee processing operations that you are familiar with have documented and effective cleaning and maintenance programmes in place? • What can you do to ensure that adequate cleaning and maintenance programmes are implemented by coffee processors? • Next module - Transportation Module 3.4 – The Codex General Principles of Food Hygiene – Maintenance, sanitation and personal hygiene