1. Good Hygiene Practices along the coffee chain The Codex General Principles of Food Hygiene – Control of Operation Module 3.3

2. Slide 2 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Objectives  Introduce trainees to Section V of the Codex General Principles of Food Hygiene - Control of operations  Demonstrate relevance of the provisions of general hygiene code on the “Control of operation” to the handling and processing of coffee.  Provide understanding of key aspects of control systems in coffee handling and processing

3. Slide 3 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Content  Scope, outline and objectives of Section V of Codex General Principles of Food Hygiene, “Control of operation”  Principles governing hygiene control systems and their application to the coffee chain  Responsibilities of various stakeholders in the control of operations in coffee processing and handling

4. Slide 4 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Objective of Section V Production of safe and suitable food for human consumption by  Formulating design requirements with respect to raw materials, composition, processing, handling, distribution, and consumer use  Designing, implementing, monitoring and reviewing effective control systems

5. Slide 5 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Control of food hazards  Food hazards should be controlled through the use of appropriate food safety management programmes that  Identify any steps which are critical to safety of food  Implement effective control procedures at those steps  Monitor control procedures  Anticipate emergencies – development of recall procedures  Review control procedures periodically  Systems should be applied throughout the food chain to control food hygiene throughout the product shelf-life

6. Slide 6 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Key aspects of hygiene control  Some food safety issues to be controlled in food processing operations  Microbiological contamination / food poisoning  Chemical contamination  Extraneous material  Correct use of additives  Record-keeping, documentation and labelling requirements

7. Slide 7 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Implement control measures  Specific process steps may be designed to exert control of food hazards. Key process parameters may relate to  Thermal processing  Chilling /freezing  Drying  Washing  Fermentation  Vacuum or modified atmosphere  Other process-specific procedures depending on the production system

8. Slide 8 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Designing / evaluating control measures  Microbiological, chemical and physical specifications  Must be based on sound science  Considerations in establishing microbiological specifications  Growth potential in particular medium  Infective dose  Contamination routes  Spoilage

9. Slide 9 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Common problems in hygiene control  Microbial cross-contamination  Passive transfer by air or water  Transfer / contamination by ‘vectors’  Transfer via surfaces  Transfer via staff  Raw material crossing finished product  Packaging faults

10. Slide 10 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Common problems in hygiene control  Physical and chemical contamination  Contamination during production operations  Chemical residues and extraneous matter in raw materials  Inappropriate use of additives  Glass or metal shards

11. Slide 11 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Building adequate controls into the process  Identification and analysis of potential hazards that could arise is an essential prerequisite for building adequate hygiene controls into the process  All operations involved should be considered:  Raw material receipt  All processing steps  Storage, transport, handling by all intermediate and final users

12. Slide 12 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Temporary storage and transport at each segment Primary transformation Primary processing Secondary processing Exportable coffee Bagging Storage Fresh cherries Dry product Unsorted beans Graded beans ABCD General structure of coffee chain - four main segments with different operations in each segment Hygiene control systems

13. Slide 13 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Segment A: Consists of stabilisation of fresh product by drying. Two basic techniques are used to achieve this goal Hygiene control systems Parchment Wet processing Dry cherries Dry processing Fresh cherries

14. Slide 14 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Wet processing - consists of the removal of pulp and mucilage through successive operations and this shortens time of drying Hygiene control systems  Pulping  Removal of mucilage, mechanically or by fermentation in tanks  Washing, an operation only applied after fermentation to remove pieces of mucilage which could remain

15. Slide 15 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Step 1 - Receiving Hygiene control - receiving  Handling of cherries between harvesting and processing may impact on microbiological condition  Processors should ensure that cherries are received in good condition  Records of deliveries / lists of approved suppliers

16. Slide 16 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Step 2 - Pulping Control of pulping  Establish specifications for acceptability of fresh cherry to be fed into pulper and ensure that specifications are met  Ensure use of water of acceptable quality  Adjust pulper spacings to avoid crushing of beans  Visually check pulped parchments for damage and admixture with skins to verify functioning of pulper Disc pulper Drum pulper

17. Slide 17 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Step 3 – Mucilage removal by fermentation Control of mucilage removal  Time of fermentation defined by local conditions (temperature)  Assure availability of clear water  Ensure adequate removal of skins from parchment  Confirm adequate degradation of mucilage at end of fermentation  Records should include start and end of fermentation and any pertinent comments

18. Slide 18 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Step 3 – Mucilage removal by mechanical action Control of mucilage removal  Establish specifications for acceptability of fresh cherry to be fed into demucilaginator and ensure that specifications are met.  Ensure that water is of acceptable quality  Visual check on condition of outgoing parchment and adjustment of equipment as necessary  Daily removal of residual parchment

19. Slide 19 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Step 4 – Washing (after fermentation) to eliminate residual mucilage adhering to parchment Control of washing  Ensure use of water of acceptable quality  Check adequacy of washing - the parchment should not be gelatinous Mechanical Canal

20. Slide 20 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Step 5 – Drying of parchment Drying of parchment  1250 kg of wet parchment  Contains 600-700 kg of water to be removed  Produces 450-500 kg of dried beans  Produces 110-120 kg of dry parchment husk  Control of the drying operation involves same considerations as drying of cherries

21. Slide 21 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Drying of fresh cherries Hygiene control systems in dry processing  2500-2600 kg of fresh cherries:  Contains 1450-1600 kg of water to be removed  Produces 450 – 500 kg of dry beans  Produces 500 kg of dry husk

22. Slide 22 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Control of drying operations  Parameters to be considered for control of drying  Load of dryer (kg of fresh material/m²) or  Thickness of layer  Findings from the global project (drying on tarpaulin) 15 days 15% Load Layer thickness T1 : 60 kg/m² T2 : 37 kg/m² T1 : 10.5 cm T2 : 3.5 cm

23. Slide 23 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Control of drying operations Recommended loads in sun-drying of coffee  Fresh cherries: 20 - 40 kg/m 2 or 2 - 4 cm thick layer  Parchment: 30 - 50 kg/m 2 or 3 - 4 cm thick layer Drying layer too deepCorrect thickness of drying layer Furrowing to increase surface area

24. Slide 24 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Control of drying operations  Measurable parameters to be monitored for control of drying  Loading on surface (kg of fresh material/m²) or of dryer (kg)  Thickness of layer  Stirring frequency  Temperature, air flow, initial moisture content and residence time (with mechanical drying)

25. Slide 25 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Control of drying operations  Drying yard management  Batches of coffee or parchment in the drying yards should be kept separately  Essential information about any batch should be recorded (actions taken, moisture content, etc.)

26. Slide 26 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Control of drying operations  Drying yard management  Coffee should be covered during the night and when raining  The person responsible for covering any batch of coffee should be clearly indicated

27. Slide 27 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Storage of dry product  Storage of dry cherry  Rigorous testing to assure newly arrived cherry coffee is adequately dried (<12%) and in satisfactory condition (evidence of prior abuse)  The recommended maximum length of storage of dry cherry (before hulling) being confirmed Husk is an important source of contamination But husk is more hygroscopic than bean so may confer re- wetting protection Poor moisture management could lead to increased risk of contamination Practical limitations imposed by hulling capacity

28. Slide 28 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Storage of dry product  Appropriate storage facilities should be provided as outlined in Module 3.2  Permitting adequate cleaning and maintenance  Preventing pest access and harbourage  Providing protection against moisture uptake and new contamination  Inadequately dried coffee (m.c. > 12.0%) should not be put into storage

29. Slide 29 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Management of dry product  Records should be kept of dried product accepted into storage (date, moisture content on receipt, condition, etc.)  Scheduled inspection for insect and rodent infestation made and recorded  Regular inspection for roof / plumbing leaks  Stored products should be subject to effective stock rotation - first in, first out Store bags on pallets but NOT against a wall Avoid poor quality bags stored on the floor

30. Slide 30 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Segment B: Husking consists of the transformation of dry parchment coffee or dry cherries into beans by husking / hulling Hygiene control systems Parchment Dry cherries Beans

31. Slide 31 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Control of husking  Factors to control in husking  Moisture below 13% to avoid excessive heating and crushing of beans  Adjustment of the machine to avoid physical damage to beans  Good separation of husk and beans  When operating in closed place, good ventilation is required  Husk can be highly contaminated with OTA-producing mould and OTA, badly managed husking operations can create contamination risk

32. Slide 32 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Segment C: Cleaning, sorting and grading. Consists of the transformation of dry parchment coffee or dry cherries into beans by husking / hulling Hygiene control systems Unsorted coffee Sorted coffee Defects

33. Slide 33 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Hygiene control in grading and sorting  Sorting and grading are primarily related to quality and marketing of coffee  According to ICO Resolution 407 minimum standards for exportable coffee - < 86 defects in 300g sample of Arabica; < 150 defects in 300g sample of Robusta  ISO 10470 - definitions and characteristics of main defects and foreign matter in green coffee  Quality defects / foreign matter may also be linked to risk of OTA contamination – this is under investigation in the global project OTA content of defects and sound beans sorted from a single batch of bulk coffee

34. Slide 34 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Storage of green coffee  Coffee must be protected from re-wetting during storage  Coffee should be protected from sources of contamination Store bags away from walls Store bags on pallets in ventilated and clean warehouse

35. Slide 35 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Storage of green coffee  Green coffee should be stored separately from dry cherry or parchment  Recommended shelf life under ambient conditions of temperature and relative humidity - under investigation in global project

36. Slide 36 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Incoming material requirements  No raw material or ingredient be accepted if known to contain hazards which would not be reduced to acceptable levels by normal sorting/processing  Raw material should be inspected and sorted before processing and, when necessary, laboratory tests should be made  Routine OTA testing is unreliable and expensive  Prevention of OTA contamination by adherence to good practices throughout the chain  All actors in the coffee chain should require assurance that they receive material from reliable suppliers following recommended practices  Only sound and suitable material should be used

37. Slide 37 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Control of incoming material  Periodic evaluation of incoming ingredients  Written specifications needed and purchasing specifications should meet food laws  Statistically representative sample taken and analysed at scheduled frequency  1OO% lots inspected  A certificate of analysis for each lot  Predetermined sampling plan to verify adherence to specifications  Vendor certification  Specification requirements Strategies for assuring quality of incoming raw material

38. Slide 38 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Packaging  Packaging design and materials should provide adequate protection  Packaging design should allow proper labelling  Packaging materials and gases must be non-toxic  Reusable packaging should be durable and easy to clean Label certifying that this jute bag is suitable for contact with food

39. Slide 39 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Water Water in contact with food: case of wet processing with coffee PulperWashing canal  Water quality specifications have not been established - but clear water is recommended  Avoid water polluted with chemical residues and other toxins

40. Slide 40 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Management and supervision  Management of food establishments must  Establish and document food quality and safety policy for establishment  Facilitate implementation of quality and safety policy through adequate quality /safety management programmes  Improve awareness of all employees of food quality/ safety issues and encourage participation of all in assuring food safety and quality  Provide training to employees in food quality and safety, as appropriate to their function

41. Slide 41 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Management and supervision  Design of appropriate control systems depends on :  Size of business  Nature of activities  Type of food  Constraints in relation to coffee sector  Highly fragmented nature of marketing chain in most producing countries  Predominated by small-holder farms  Limited human, financial and technical resources of most of the economic operators within the chain  Weak or non-existent economic incentives for ensuring quality and safety

42. Slide 42 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Documentation and records  Any food quality and safety system must include documentation, record-keeping and monitoring  Where necessary, records should be kept and retained for a period exceeding the shelf-life of product  Records of incoming raw materials received  Records of processing  Records of distribution  Documentation can enhance  Credibility  Ability to react effectively and efficiently in case of a food safety problem

43. Slide 43 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Documentation and records  A large proportion of the farmers and traders in many coffee-producing countries operate at a micro-scale  Pooling of coffee is widespread in smallholder areas  In many producing countries, regulations governing the condition of coffee traded within the country are outdated or lacking  Instruments for reliable and accurate measurement of moisture in coffee are not widely available for use in the field Factors affecting record keeping in the coffee sector

44. Slide 44 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Ensuring adequate hygiene controls in the coffee sector  To design and implement hygiene control systems covering their entire operation  Industry groups can play an important role in encouraging good practices  Participate in discussions with relevant government agencies on industry concerns, priorities, and provide data as appropriate Role of industry

45. Slide 45 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Ensuring adequate hygiene controls in the coffee sector  Use a risk-based evaluation to ensure best use of available resources for the implementation of good practices within the sector  To establish a sound science-based regulatory framework that ensures food safety without unnecessarily encumbering the industry  Assist industry to meet food safety requirements by providing practical guidelines and training  Commit resources for the implementation of monitoring programmes to allow early detection of problems and other technical support programmes to address key issues  Ensure effective use of resources in addressing problems as they arise Role of government

46. Slide 46 Module 3.3 – The Codex General Principles of Food Hygiene – Control of Operation Next steps…  Reflect on coffee processing operations that you are familiar with - is there adequate control to ensure food safety?  Consider what is your role in ensuring that adequate controls are applied in the processing and handling of coffee?  Next module – ‘Maintenance and sanitation’