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Maintenance_ Sanitation and Personal Hygiene

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					Good Hygiene Practices along the coffee chain




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

   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



               Module 3.4 – The Codex General Principles
                           of Food Hygiene –
Slide 2
                 Maintenance, sanitation and personal
                          Content

   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
               Module 3.4 – The Codex General Principles
                           of Food Hygiene –
Slide 3
                 Maintenance, sanitation and personal
                    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 –
Slide 4
                        Maintenance, sanitation and personal
       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 –
Slide 5
                           Maintenance, sanitation and personal
                 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 –
Slide 6
                        Maintenance, sanitation and personal
          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 –
Slide 7
                 Maintenance, sanitation and personal
                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 –
Slide 8
                          Maintenance, sanitation and personal
          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 –
Slide 9
                         Maintenance, sanitation and personal
                Equipment in coffee processing
             Some processing equipment used in the
                  production of green coffee
          Harvester, bags, baskets                  De-stoner
          Hopper, channels                          De-huskers
          Pulper                                    Extractor fans
          Fermentation vats                         Air buoyancy separators
          Washer                                    Winnowers
          Elevators                                 Gravity tables
          Drying surfaces, tables                   Grader
          Huller / polisher                         Colour sorter
          Conditioning bins                         Generator

                          Module 3.4 – The Codex General Principles
                                      of Food Hygiene –
Slide 10
                            Maintenance, sanitation and personal
            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 –
Slide 11
                    Maintenance, sanitation and personal
             Maintenance of equipment –
                 example of hullers
 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




                    Module 3.4 – The Codex General Principles
                                of Food Hygiene –
Slide 12
                      Maintenance, sanitation and personal
           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 –
Slide 13
                Maintenance, sanitation and personal
            Maintenance and calibration records

           Records of maintenance and calibration of
                   equipment must be kept
                Record of Maintenance of Huller (Code No. -----)
  Date     Description of Action         Comments               Carried out by



                                                     Record of Maintenance of Pulper (Code No. -----)
                                      Date      Description of Action         Comments               Carried out by




                                   Module 3.4 – The Codex General Principles
                                               of Food Hygiene –
Slide 14
                                     Maintenance, sanitation and personal
           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 –
Slide 15
                  Maintenance, sanitation and personal
           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 –
Slide 16
                         Maintenance, sanitation and personal
   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

                       This amount of
                        residue could
                            support
                          significant
                       fungal growth

                    Module 3.4 – The Codex General Principles
                                of Food Hygiene –
Slide 17
                      Maintenance, sanitation and personal
                 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 –
Slide 18
                     Maintenance, sanitation and personal
                 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 –
Slide 19
                     Maintenance, sanitation and personal
            Documenting cleaning programmes
           Programme for weekly cleaning of pulper

   Procedures:
   a) Unscrew supports of disks and blades
   b) Remove disks
   c) Rinse disks, blades and chassis with clean water, wash
      with detergent, rinse with clean water
   a) Reassemble disks and blades
   b) Tighten the bolts firmly

   Supervisor: Mr Peter



 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 –
Slide 20
                                    Maintenance, sanitation and personal
                                                Cleaning programmes

        Cleaning of premises: written cleaning and disinfection
        programmes for preparation, processing, storage areas

Cleaning Record for Fermentation Shelter
   Area/        Method Used         Frequency    Date    Operator Comments
 equipment

 Fermentation Scrub with clean       Weekly     Week 1
tanks         water. Rinse with
              clean water
                                                Week 2

                                                Week 3

                                                Week 4

Ceiling in    Brushing of rafters    Monthly
fermenatation
area




                                                  Module 3.4 – The Codex General Principles
                                                              of Food Hygiene –
   Slide 21
                                                    Maintenance, sanitation and personal
           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 –
Slide 22
                     Maintenance, sanitation and personal
                     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 –
Slide 23
                        Maintenance, sanitation and personal
                      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 –
Slide 24
                         Maintenance, sanitation and personal
                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 –
Slide 25
                   Maintenance, sanitation and personal
              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 –
Slide 26
                        Maintenance, sanitation and personal
               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 –
Slide 27
                     Maintenance, sanitation and personal
                    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 –
Slide 28
                    Maintenance, sanitation and personal
           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 –
Slide 29
                    Maintenance, sanitation and personal
                      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 –
Slide 30
                 Maintenance, sanitation and personal

				
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