Safe Food Realization Through Ipleetatio of Iteatioal Reuieets - - PowerPoint PPT Presentation

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 1

Best in Class Personal Hygiene Practices for Safe Food Realization

Contents …

 International References  Trends in Food borne Illness  Personnel Hygiene  Access Control  Hygiene Station  Hand washing requirements  Location Selection  Layout & Zoning  Building  Material Receipt & Movement  Bore-well Head Protection  List of Food Handlers medical test & controls

Through Ipleetatio of Iteatioal Reuieets ….

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 2

International References

• CODEX Alimentarius
• FSSAI
• EHEDG : European Hygienic Engineering Design Group
• FDA : US Food and Drug Administration
• NSF: National Science Foundation
• FSSC 22000: Food Safety System Certification
• AIB: AIB International
• Canadian Food Inspection Agency
• University of Guelph

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 3

Trends in Food borne Illness in USA, 1996–2010

Fig : Changes in incidence of laboratory-confirmed bacterial infections, United States, 2010 compared with 1996–19981

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 4

Integrated Disease Surveillance Project (IDSP)

Source: http://www.idsp.nic.in

2008 2009 2010 2011 2012 2013 2014 2015(Till 21 Nov'2015)

• No. of Outbreaks

553 799 990 1675 1584 1964 1585 1667 Death 50 120 95 77 1108 901 810 2636

553 799 990 1675 1584 1964 1585 1667 50 120 95 77 1108 901 810 2636

500 1000 1500 2000 2500 3000

500 1000 1500 2000

NO Of Deaths

• No. Of Outbreaks

Geometric increase in number of Food Borne Cases from as well as deaths in India Integrated Disease Surveillance Project (IDSP), launched by Union Minister of Health & Family Welfare, India in November 2004

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 5

Disease control Cleanliness Wearing

• uter

garments personal cleanliness Hand Washing

Personnel Hygiene:

USFDA Key Requirements

Personnel hygiene is a very vast term which includes following:

Storing clothing Wearing hair nets, headbands, caps, beard covers

Jewellery Removal Maintaining gloves

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 6

Hand washing requirements

Step 1

• Wet hands & arms up to the elbows with warm

water Step 2

• Apply small amount of soap

Step 3

• Wash thoroughly (rub) for at least 20 sec

Step 4

• Brush nails with the nail brush
• Rinse brush and keep in container with sanitizer

Step 5

• Rinse well with warm water having temperature at

least 43°C (110°F) for at least 10 sec Step 6

• Dry with paper towel or dryer

Step 7

• Put on the approved food grade sanitizer gel and

thoroughly (rub)

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 7

Access Control

Site security should be reviewed, and the need for CCTV, and/ or security guards should be considered as pert of a food defence programme. In particular, material storage tanks, silos, and line hook ups should be provided with adequate enclosure, security, drainage, space and spill control.

Protection of products against potential acts of sabotage etc.

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 8

Hygiene Station

A Hygiene station consists of: 1. Hand wash station. 2. Foot wash station 3. Access controlled flap gate or tripod turnstile. 4. Hygiene Watch System 5. Disinfectant solution. Hygiene Station with Access Control

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 9

Hygienic Aspects of Locker Area, Toilet & Cubical

Lockers with sloped roof top and step

• ver bench in front

All Junction with the floor are covered.

Toilet & Cubical devices to be mounted from the wall to facilitate suitable cleaning .

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 10

Suggested number of lavatories, Urinal stall & Hand wash basins/ number of employees

Staff Member Number of sanitary conveniences MEN WOMEN Lavatories Urinals Wash basins Lavatories Wash basins 10 1 1 1 1 1 20 1 2 2 2 2 40 2 3 2 3 3 60 3 3 2 4 4 80 4 4 3 6 5 100 4 4 3 8 6 120 5 5 4 9 7 140 5 5 4 10 8 180 5 6 5 11 8 Add 1 lavatory, 1 urinals and 1 wash basin for every 70 persons in excess of 280 persons Add 1 lavatory, and 1 wash basin for every 35 persons in excess of 280 person

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 11

Hazard Prevention from external to internal environment

When ever possible, factories should be located away from or protected against:

 Environmentally polluted or remediation areas  Industrial activities which pose a serious threat of contaminating food (e.g. Incinerators,

landfills, junkyards etc).

 Areas where wastes, either solid or liquid, cannot be removed effectively.

Schematic site plan indicating potential to and from the food manufacturing plant

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 12

Hygienic Building Layout

A building layout locating production areas, services areas, storage areas (e.g. Chemicals), surrounding areas and main air intake/ outlet locations. Schematic of Hygienic layout of a building

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 13

Zoning

Food production areas must be segregated from non-food production areas e.g. Locker rooms, canteens/restaurants, smoking areas, boiler rooms, workshops, living accommodation etc. Food Manufacturers should undertake a hazard analysis to determine how many processing areas or zones are appropriate for the safe manufacture of their product range. Hazard analysis consider:

 Hazard present in Raw Material.  Hazard present in the processing environment.  The potential for product microbial spoilage. Etc Hygienic design criteria for Zones  Food Production areas  Basic Hygiene areas  Medium Hygiene areas  Ingredient preparation area  General processing area  High Hygiene area  Aseptic area

Schematic separation of non-microbiological hazard

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 14

Access control during High Hygiene & Low Hygiene Area

High hygiene footwear should be captive to high hygiene. Dedicate d maintena nce tools are to be used for High Hygiene & Low Hygiene areas. Different colour code to be given to the tools. Foot wares & Aprons shall be changed. Foot bath & Foot washers should be used only in low hygiene area. Flow of waste from High Hygiene Zone to Low

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 15

Building: Pest proofing measure to prevent entry through foundations

Foundation are one of the most important structural members. Foundations shall be designed to guarantee stability and structural safety of the entire building structure and should be concrete based (avoid wood, brick and block foundations).

Pest proofing measure to prevent entry through foundations

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 16

Roof Drainage

 Roofs should be sloped to a minimum of 1-2% to ensure positive drainage.  For Flat roofs, water can be transported in channels on the roof over the hygienic areas and then

lead into a gravity or vacuum/ siphonic system outside the hygienic areas.

Sloped Roof to ensure positive drainage

Rat Stop for preventing Rodent entry

through Roof Drainage Downpipe

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 17

Hygienic Flooring

Floors

Floors provided the foundation for safe, hygienic food production in factories. The hygienic design and installation of floors to ensure a correct level of ongoing hygiene . Floors are critical areas, for example they are places where listeria monocytogenes are likely to be found and where the bacteria could persist despite cleaning and disinfection. Slipping correspond to around 20% of work place injuries.

Floor sloped towards the drain

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 18

Hygienic challenges during Flooring

Hygienic challenges during Flooring

Bubbles holes in Heavy duty Polyurethane floor Electronic microscopic pics on an epoxy raisin floor Lose tile at discharge point due to discharge of Hot & Cleaning Chemicals

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 19

Hygienic design drains

Drains: Areas with CIP System

Water should be directed into the drainage system by a pipelines. Nevertheless to avoid waste water backflow and to protect line hygiene, air gaps are necessary. The volume and temperature of water must be considered when selecting the product. The drainage products shall includes following features:

 Continuous welding of joints  Radiused and rounded corners  Drain ability  No crevices or dead spaces

Drains design

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 20

Lighting: All areas where food is examined processed or stored, and where equipments or utensils

are cleaned and in personnel changing areas, must have adequate natural and/or artificial lighting for the activities conducted. Lightening should be suitably sealed to the ceiling or walls in a way that avoid any projection where dust can accumulate or spaced off them to give easy access for inspection and cleaning with the top of the light fittings sloped to 45°C to enable cleaning.

Sloped body light, integrated in the ceiling flush with that ceiling

Building: Hygienic Lighting Placements

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 21

Design of Stairs passing over production line & Platform upstairs

 Floors, Stairs, Catwalks, bridges over production lines shall be sealed  Design shall preclude contamination of area below.  They should be constructed with impervious, non corrodible, easy to clean etc.

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 22

All ceiling throughput for piping should be well sealed with sealant or a colar

Proofing of Ceiling – Pipeline entry points

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 23

Clea Coept Ai Hadlig Uits

Traditional Metal Ductwork for Air Distribution

• Pest scrolling over the duct is likely
• Un-Even Air Distribution throughout

entire length

• Considerably heavy Structural Load on

building with simpler suspension system

• Higher probability of dirt / dust

contamination

• Reduced Distribution & Blending of the

conditioned air in a given space

• Uale “upply ai elo the De

Poit

• Higher Maintenance

Textile duts for Air Distriution

 Pest scrolling over the duct is prevented

 Designed for Even Air Distribution throughout entire length  Reduced Structural Load on building with simpler suspension system  Compactable with disposable HVAC filtes etified to eet the Food “afe F7/F9 standards.  Dirt / Dust contamination is prevented  Enhanced Distribution & Blending of the conditioned air in a given space  “upply ai elo the De Poit  Less Maintenance

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 24

Clea Coept Ai Hadlig Uits

Traditional Metal Ductwork for Air Distribution Textile duts for Air Distribution

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 25

Material Movement: Control Measures to Prevent Pathogens into Plant

 This type of sanitizing equipment is often known as a aie tuel or

saitizig tuel.

 The tunnel is a belt-driven, conveyor system that sprays a mixture of water and a

sanitizing agent to disinfect the containers before they are sent into the food processing plant and opened.

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 26

Material Movement: Transport Dock  Loading dock should be solid structures,

 built to match the height of the loading bed of transport vehicle.  Dock doors may be vertical lift doors, garage type up-and-oe overhead doors

• r roller shutter type doors.

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 27

Bore-well Head Protection

Well Casing or Lining: All that part of the suction pipe or drop pipe of any well within 3 meters (10feet) of and below the ground surface shall be surrounded by a watertight casing pipe extending above the ground, platform or floor surface, as the case maybe, and covered at the top as herein provided.

Bore-well Head Protected with Solid Concrete

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 28

Initial & Periodic Medical Tests for Food Handlers

Pre-Employment Medical Screening- Annual Medical check up

 General health check-up  General health check-up  Urine test (Routine)  Blood test (HB, CBC, ESR, RBS)  Vision test  Urine test (Routine)  Blood test (HB, CBC, ESR, RBS)  ECG  Vision Test  Audiogram Testing

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 29

Innovations in Analytical Techniques

• Analysis without time-consuming sample preparation
• Perform up to 112 different diagnostic tests on a 10

microliter (half a drop) biological sample

• Sample is placed into the atidge’s port and the

cartridge is docked with the Data Communicator

• Light generating bio-luminating molecules are attached

with DNA strands fixed on the base

• These DNA strands are complementary with antibodies

and DNA of Pathogens (Bio-markers)

• When these DNA capture strands binds with respective

biomarkers produces light spots

• Extremely sensitive light sensor detect the light spots

Using bio-luminating molecules

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 30

Recent Emphasis on Food Security & Bio-Terrorism

Beware of New Employees/ Suppliers/ Security Personnel/ Drivers etc

Date: 2nd Dec 15 Mother Dairy- Delhi Slide No: 31

Thank You