1. OAS REGIONAL PROJECT QUALITY MANAGEMENT MODULE 2
Presenter: Marcia Henry
Manager, Project & Quality Management Systems
Scientific Research Council
9/20/2018
OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

2. GOOD MANUFACTURING PRACTICES
Definition:
Practices or Procedures in a Factory Which Guarantee the Safe Production of Food
9/20/2018
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
9/20/2018
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
9/20/2018
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 , Rev. 3 (1997)
Follows the Systems Focus
Follows the Continuous Improvement Route
9/20/2018
OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

6. GENERAL GUIDELINES FOR GOOD MANUFACTURING PRACTICES
9/20/2018
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.
An adequate supply of potable water with appropriate facilities for its storage, distribution and temperature control, should be available whenever necessary 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 (for use in, for example, fire control, steam production, refrigeration and other similar purposes where it would not contaminate food), shall have a separate system. Non-potable water systems shall be identified and shall not connect with, or allow reflux into, potable water systems.
9/20/2018
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.
Adequate natural or artificial lighting should be provided to enable the undertaking to operate in a hygienic manner. Where necessary, lighting should not be such that the resulting colour is misleading. The intensity should be adequate to the nature of the operation. Lighting fixtures should, where appropriate, be protected to ensure that food is not contaminated by breakages
9/20/2018
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.
AIR QUALITY AND VENTILATION
Adequate means of natural or mechanical ventilation should be provided, in particular to:
- minimize air-borne contamination of food, for example, from aerosols and condensation droplets; - 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 should be designed and constructed so that air does not flow from contaminated areas to clean areas and, where necessary, they can be adequately maintained and cleaned.
9/20/2018
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.
9/20/2018
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.
9/20/2018
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
Where appropriate, the internal design and layout of food establishments should permit good food hygiene practices, including protection against cross-contamination between and during operations by foodstuffs
9/20/2018
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
Structures within food establishments should be soundly built of durable materials and be easy to maintain, clean and where appropriate, able to be disinfected.
9/20/2018
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
9/20/2018
OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

15. WORK SURFACES Work Surfaces Should Be: Non-absorbent & Non-toxic
Smooth
Durable (able to withstand repeated cleaning and sanitizing)
Unaffected By Food
Easy to Clean, Maintain and Disinfect
working surfaces that come into direct contact with food should be in sound condition, durable and easy to clean, maintain and disinfect. They should be made of smooth, non-absorbent materials, and inert to the food, to detergents and disinfectants under normal operating conditions.
9/20/2018
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.
the surfaces of walls, partitions and floors should be made of impervious materials with no toxic effect in intended use; - walls and partitions should have a smooth surface up to a height appropriate to the operation;
9/20/2018
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
ceilings and overhead fixtures should be constructed and finished to minimize the build up of dirt and condensation, and the shedding of particles
9/20/2018
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
floors should be constructed to allow adequate drainage and cleaning;
9/20/2018
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.
Adequate drainage and waste disposal systems and facilities should be provided. They should be designed and constructed so that the risk of contaminating food or the potable water supply is avoided
9/20/2018
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
doors should have smooth, non-absorbent surfaces, and be easy to clean and, where necessary, disinfect
9/20/2018
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.
windows should be easy to clean, be constructed to minimize the build up of dirt and where necessary, be fitted with removable and cleanable insect-proof screens. Where necessary, windows should be fixed
9/20/2018
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.
9/20/2018
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
Equipment and containers (other than once-only use containers and packaging) coming into contact with food, should be designed and constructed to ensure that, where necessary, they can be adequately cleaned, disinfected and maintained to avoid the contamination of food. Equipment and containers should be made of materials with no toxic effect in intended use. Where necessary, equipment should be durable and movable or capable of being disassembled to allow for maintenance, cleaning, disinfection, monitoring and, for example, to facilitate inspection for pests.
9/20/2018
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
In addition to the general requirements in paragraph 4.3.1, equipment used to cook, heat treat, cool, store or freeze food should be designed to achieve the required food temperatures as rapidly as necessary in the interests of food safety and suitability, and maintain them effectively. Such equipment should also be designed to allow temperatures to be monitored and controlled. Where necessary, such equipment should have effective means of controlling and monitoring humidity, air-flow and any other characteristic likely to have a detrimental effect on the safety or suitability of food. These requirements are intended to ensure that:
- harmful or undesirable micro-organisms or their toxins are eliminated or reduced to safe levels or their survival and growth are effectively controlled; - where appropriate, critical limits established in HACCP-based plans can be monitored; and
- temperatures and other conditions necessary to food safety and suitability can be rapidly achieved and maintained.
9/20/2018
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
Pests pose a major threat to the safety and suitability of food. Pest infestations can occur where there are breeding sites and a supply of food. Good hygiene practices should be employed to avoid creating an environment conducive to pests. Good sanitation, inspection of incoming materials and good monitoring can minimize the likelihood of infestation and thereby limit the need for pesticides.
9/20/2018
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.
Pest infestations should be dealt with immediately and without adversely affecting food safety or suitability. Treatment with chemical, physical or biological agents should be carried out without posing a threat to the safety or suitability of food.
9/20/2018
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
Adequate drainage and waste disposal systems and facilities should be provided. They should be designed and constructed so that the risk of contaminating food or the potable water supply is avoided
9/20/2018
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.
Suitable provision must be made for the removal and storage of waste. Waste must not be allowed to accumulate in food handling, food storage, and other working areas and the adjoining environment except so far as is unavoidable for the proper functioning of the business.
Waste stores must be kept appropriately clean
9/20/2018
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.
Containers for waste, by-products and inedible or dangerous substances, should be specifically identifiable, suitably constructed and, where appropriate, made of impervious material. Containers used to hold dangerous substances should be identified and, where appropriate, be lockable to prevent malicious or accidental contamination of food.
9/20/2018
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.
Where necessary, adequate facilities for the storage of food, ingredients and non-food chemicals (e.g. cleaning materials, lubricants, fuels) should be provided.
Where appropriate, food storage facilities should be designed and constructed to:
- permit adequate maintenance and cleaning; - avoid pest access and harbourage; - enable food to be effectively protected from contamination during storage; and - where necessary, provide an environment which minimizes the deterioration of food (e.g. by temperature and humidity control). The type of storage facilities required will depend on the nature of the food. Where necessary, separate, secure storage facilities for cleaning materials and hazardous substances should be provided.
9/20/2018
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.
9/20/2018
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.
Adequate facilities, suitably designated, should be provided for cleaning food, utensils and equipment. Such facilities should have an adequate supply of hot and cold potable water where appropriate.
9/20/2018
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
9/20/2018
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.
Personnel hygiene facilities should be available to ensure that an appropriate degree of personal hygiene can be maintained and to avoid contaminating food. Where appropriate, facilities should include:
- adequate means of hygienically washing and drying hands, including wash basins and a supply of hot and cold (or suitably temperature controlled) water; - lavatories of appropriate hygienic design; and
- adequate changing facilities for personnel.
Such facilities should be suitably located and designated.
9/20/2018
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
9/20/2018
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
9/20/2018
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.
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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
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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
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OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises

40. SANITATION PLAN FOR: Food Contact Surfaces Floors Equipment & Utensils
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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
See attachment
9/20/2018
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
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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.
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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.
9/20/2018
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
9/20/2018
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
9/20/2018
OAS/SRC Project: Using S&T to Strengthen Rural Food Processing Enterprises