PERSONAL HYGIENE

Personal hygiene involves those practices performed by a person to care for their bodily health
and well-being through cleanliness.

Good personal hygiene is essential for any food handler as it minimizes the risk of
contamination. Most people carry harmful bacteria on their bodies and can unwittingly
transport them on food.

Diseases caused by germs and parasites resulting from inadequate domestic and personal
hygiene includes food poisoning, gastro enteritis, diarrhea.

Bacteria that cause food poisoning can be on everyone – even healthy people. You can spread
bacteria from yourself to the food if you touch your nose, mouth, hair or your clothes, and then
food.

Good personal hygiene also makes good business sense. Customers like to see food-handling
staff who take hygiene seriously and practise safe food handling.

Watch how your co-workers handle food and consider it from a customer’s point of view.
Would you want to eat at, or buy food from, the place you work?

Food handlers – personal hygiene tips

To prevent food poisoning using good personal hygiene, follow these tips:

 wash and dry your hands thoroughly before handling food, and wash and dry them
again frequently during work
 dry your hands with a clean towel, disposable paper towel or under an air dryer
 never smoke, chew gum, spit, change a baby’s nappy or eat in a food handling or food
storage area
 never cough or sneeze over food, or where food is being prepared or stored
 wear clean protective clothing, such as an apron
  keep your spare clothes and other personal items (including mobile phones) away from
where food is stored and prepared
 tie back or cover long hair
 keep fingernails short so they are easy to clean, and don’t wear nail polish because it
can chip into the food
 avoid wearing jewellery, or only wear plain-banded rings and sleeper earrings
 completely cover all cuts and wounds with a wound strip or bandage (brightly coloured
waterproof bandages are recommended)
 wear disposable gloves over the top of the wound strip if you have wounds on your
hands
 change disposable gloves regularly
 advise your supervisor if you feel unwell, and don’t handle food.

Food handlers – handwashing

Thoroughly washing your hands reduces the chance of contaminating food with bacteria from
yourself.

Wash your hands with soap and warm water, and don’t forget the backs of your hands, wrists,
between your fingers and under your fingernails.

Thoroughly dry your hands immediately after you wash them. Always dry your hands with a
clean towel, disposable paper towel or under an air dryer. The important thing is to make sure
your hands are completely dry. Never use a tea towel or your clothes to dry your hands.

Wash your hands after:

 going to the toilet

 handling raw food
 blowing your nose
 handling garbage
 touching your ears, nose, mouth or other parts of the body
  smoking
 every break
 handling animals.

EQUIPMENT MAINTENANCE

Equipment maintenance is any process used to keep a business's equipment in reliable working
order. It may include routine upkeep as well as corrective repair work. Equipment may include
mechanical assets, tools, heavy off-road vehicles, and computer systems.

4 types of maintenance strategy, which one to choose?

1) Corrective maintenance.
2) Preventive maintenance.
3) Risk-based maintenance.
4) Condition-based maintenance. Maintenance is carried out following detection of an
anomaly and aimed at restoring normal operating conditions.
 CORRECTIVE MAINTENANCE: Maintenance is carried out following detection of an
anomaly and aimed at restoring normal operating conditions. This approach is based on
the firm belief that the costs sustained for downtime and repair in case of fault are
lower than the investment required for a maintenance program. This strategy may be
cost-effective until catastrophic faults occur.
 PREVENTIVE MAINTENANCE: Maintenance carried out at predetermined intervals or
according to prescribed criteria, aimed at reducing the failure risk or performance
degradation of the equipment.
The maintenance cycles are planned according to the need to take the device out of
service. The incidence of operating faults is reduced.
 RISK BASED MAINTENANCE: Maintenance carried out by integrating analysis,
measurement and periodic test activities to standard preventive maintenance. The
gathered information is viewed in the context of the environmental, operation and
 process condition of the equipment in the system. The aim is to perform the asset
condition and risk assessment and define the appropriate maintenance program.All
equipment displaying abnormal values is refurbished or replaced. In this way it is
possible to extend the useful life and guarantee over time high levels of reliability, safety
and efficiency of the plant.

PEST CONTROL AND MANAGEMAENT

Pest control is a process used in hygiene management that looks to manage the existence and
presence of different types of pests to minimise their impact on the environment they inhabit.
Whilst many pests pose a risk to human health when they are present in places such as homes
and retail or food preparation environments, it is also important to consider their place in wider
food chains and habitats, which is why some pest populations are ‘controlled’ instead of just
eliminated.

3 Types of Pest Control Methods

Pest control services use a variety of approaches to deal with infestations, but these can be
sorted into three main types of pest management, which we will explain in detail below

 Physical control involves removal or installation of physical barriers to exclude pest

species
 Biological control is where predatory or parasitic insects and mites known as
‘beneficials’ or ‘good bugs’ help to control chewing and sucking insects that affect the
quality and productivity of crops by killing them or disrupting their breeding cycle.
 Chemical control involves the use of pesticides in the management of pests. Where
chemical control is required, selective insecticides are chosen which target the pest,
leaving the beneficial population unharmed.

What is IPM?

Integrated Pest Management (IPM) is an effective and environmentally sensitive approach to

pest management that relies on a combination of common-sense practices. IPM programs use
current, comprehensive information on the life cycles of pests and their interaction with the
environment. This information, in combination with available pest control methods, is used to
manage pest damage by the most economical means, and with the least possible hazard to
people, property, and the environment.

STEPS IN IPM

1. Proper identification of responsible pest

2. Monitor pest population and activities
3. Establish act threshold and choose appropriate combination of management
4. Evaluate result or effectiveness of the controls.

STORAGE FACILITY

Storage facilities provide businesses with a convenient place to store inventory, equipment, and
other goods that are not needed on a regular basis. This allows businesses to free up space in
their warehouses or retail locations, and to keep excess goods in a safe and secure location.

Archival and record keeping: Storage facilities are equipped to provide archival and record-
keeping storage solutions for important documents, records, and historical artifacts. It can keep
these items in a controlled environment for preservation in long term.

TYPES

1. Temperature controlled storage facility

2. Non temperature controlled storage facility
3. Portable containers
4. ICT Management

TRACEABILTY

Traceability is the ability to track any food through all stages of production, processing and
distribution (including importation and at retail). Traceability should mean that movements can
be traced one step backwards and one step forward at any point in the supply chain.
Product traceability system allows for complete and up to date histories of all batches of
products from the starting materials to the complete final product. Identification and status of
materials is provided by unique and controlled numbering system.

Traceability in the food industry requires documenting all processes, including receiving raw
materials, food preparation, packaging, and food distribution. The main objective of traceability
is to have a transparent overview of the product's state and safety throughout its production. It
can be used for product quality control and continuous improvement for food processors.

TYPES

1. Forward Traceability
2. Backward Traceability

In case of problems such as a foodborne illness outbreak, traceability records are used to
identify the source of the problems quickly. The records are also used to determine the
potential size of the problem and plan corrective actions accordingly. The traceability system
acts as an integral part of a defense plan for food manufacturing companies and food service
businesses.

Why is traceability important?

1. Traceability is the system that allows business owners to track the flow of food
ingredients and products in the entire supply chain.
2. Establishing a traceability system is a regulatory requirement for countries.
3. An effective traceability system can significantly reduce the effects of a food recall on
your business.
4. Food safety. One of the main benefits of a traceability system is helping food businesses
manage food safety. In case of food safety issues, business owners can immediately
access information about the product in question and identify what caused the problem.
Such information can help authorities promptly release guidelines on how to control the
problem and protect public health
 CHEMICAL HANDLING

There are many ways in which to work with chemicals to reduce the probability of an accident
and to reduce the consequences of such an accident to minimal levels. Risk minimization
depends upon safe practices, appropriate engineering controls, the proper use of Personal
Protective Equipment, the use of the least quantity of chemicals necessary, and when possible,
the substitution of less hazardous chemicals. Essentially, chemical safety is inherently linked to
other safety issues.
TYPES OF CHEMICALS
1. Corrosive Chemical
2. Flammable Chemical
3. Irritants
4. Toxic Chemicals
5. Carcinogenic Chemicals
6. Mutagenic Chemicals
CHEMICAL SAFETY GUIDELINES
1. Assume that any unfamiliar chemical is hazardous.
2. Know all the hazards of the chemicals that you work with.
3. Consider each mixture of chemicals to be at least as hazardous as its most hazardous
component chemical.
4. Never use any substance that is not properly labeled.
5. Follow all chemical safety instructions precisely.
6. Minimize your exposure to any chemical, regardless of its hazard rating.
7. Use personal protective equipment as appropriate.
8. Avoid repeated exposure to any chemical is unprotected.
CHEMICAL HANDLING GUIDELINES
When working with chemicals:
1. Remove and use only the amount of chemicals needed for the immediate job at hand.
2. Properly seal, label, and store chemicals in appropriate containers.
3. Check stored chemicals for deterioration and broken containers.
 4. Do not store chemicals near heat or sunlight or near substances which might initiate a
dangerous reaction if combined.
5. Do not pour hazardous chemicals down sink drains.
6. Clean-up spills and leaks immediately, using only established spill procedures.
7. Be aware of emergency procedures which have implications for hazardous chemical
exposures and spills.
8. Dispose of chemicals using only established disposal procedures.
HOW DOES CHEMICAL GET INTO THE BODY SYSTEM
1. Inhalation through the nose
2. Ingestion, through the mouth
3. Injection e.g using syringe
4. Absorption through the Skin and Eyes.

What is a MSDS sheet?

Employees have a right to know when they work near potentially dangerous chemicals. This
information goes on a Material Safety Data Sheet (MSDS) or Safety Data Sheet (SDS) that
provides information about the chemicals.

What Information Does a MSDS Sheet Include?

The safety data sheet provides employees a summary of the potential dangers associated with
chemicals used in the workplace. There are 16 sections on the SDS which list information like
the manufacturer contact information, hazard classification of the chemical, concentration of
the ingredients in mixtures and other important details about the structure of the chemicals.
Employers must make these sheets available to all employees in an understandable format.

Content of a Safety Data Sheet

In compliance with the new Hazard Communication Standard, SDS are divided into 16 sections
and are required to provide the following information:
1. Identification: Product identifier used on the label; manufacturer or distributor name,
address, phone number, emergency phone number; recommended use; and restrictions
on use.
2. Hazard Identification: This section lists the GHS classification and hazard
statements. Every hazard statement has a corresponding precautionary statement
recommending measures to minimize or prevent adverse effects such as “Do not
breathe dust.” This section may also show the label pictograms and give any other
information related to known hazards of the product. Classifications by other entities
such as OSHA, HMIS, or NFPA may also be given.
3. Composition/Information on Ingredients provides a list of all hazardous ingredients,
their CAS numbers, and their concentrations or concentration ranges in the product. For
each ingredient, the hazard classification is given. Depending on the concentration, the
classification for each individual compound may be different than the classification of
the mixture found under section 2.
4. First-Aid Measures describes potential symptoms and acute or delayed effects resulting
from exposure. It gives information on how to respond to exposure and on appropriate
medical treatment.
5. Fire-Fighting Measures lists suitable extinguishing techniques and equipment as well as
potential hazards arising from a fire, such as toxic fumes.
6. Accidental Release Measures lists emergency procedures for responding to a spill,
required protective equipment, and basic methods of containment and cleanup.
7. Handling and Storage lists brief precautions for safe handling and storage. It should
contain information about incompatibilities with other chemicals, but it is often not
exhaustive. Refer to the DRS chemical storage guide for more detailed information.
8. Exposure Controls/Personal Protection lists OSHA's Permissible Exposure Limits (PELs)
and Threshold Limit Values (TLVs) for each ingredient. This section should also give
information on personal protective equipment (PPE); e.g., appropriate respirators and
gloves, and engineering controls.
9. Physical and Chemical Properties lists the characteristics of the product such as color,
boiling point, pH, and density etc.
10. Stability and Reactivity lists chemical stability, possibility of hazardous reactions,
conditions to avoid, incompatible materials, and hazardous decomposition products.
11. Toxicological Information describes possible routes of exposure; symptoms related to
physical, chemical and toxicological characteristics; acute and chronic effects; and
numerical measures of toxicity such as LD50 values if available.
12. Ecological information includes available information on ecotoxicity, degradability,
bioaccumulation, and other adverse effects on the environment.
13. Disposal considerations is relevant for professional waste disposal services. Refer to the
DRS chemical waste guide for disposal practices.
14. Transport information lists DOT UN number, proper shipping name, and class.
15. Regulatory information includes other applicable local regulations on safety, health, and
environment.
16. Other information includes the date of preparation of the SDS or its last revision.
 TRAINING

Training is teaching, or developing in oneself or others, any skills and knowledge or fitness that
relate to specific useful competencies. Training has specific goals of improving one's capability,
capacity, productivity and performance.

Benefits of Employee Training & Development

 Increased employee performance. ...

 Stronger workforce. ...

 Alignment with organizational goals. ...

 Boosts motivation and engagement. ...

 Expand knowledge sharing. ...

 Fosters innovation in the workplace. ...

 Improves company processes. ...

 Creates a stronger brand.

CLEANING AND SANITATION

Cleaning removes most germs, dirt, and impurities from surfaces. Clean with water, soap, and
scrubbing. Sanitizing reduces germs to levels public health codes or regulations consider safe.
Sanitizing is done with weaker bleach solutions or sanitizing sprays.

Sanitation controls. Sanitation controls include procedures, practices and processes to ensure
that the facility is maintained in a sanitary condition adequate to significantly minimize or
prevent hazards such as environmental pathogens, biological hazards due to employee
handling, and food allergen hazards. Sanitation controls must include, as appropriate to the
facility and the food, procedures, practices and processes for the:
(i) Cleanliness of food-contact surfaces, including food-contact surfaces of utensils and
equipment;

(ii) Prevention of allergen cross-contact and cross-contamination from insanitary objects and
from personnel to food, food packaging material, and other food-contact surfaces and from raw
product to processed product.

There are many different ways to clean and sanitize equipment. These include the use of clean-
in-place (CIP) systems, foaming, clean-out-of-place (COP), spraying, high pressure and manual
systems. Manual is the old-fashioned route that usually involved scrubbing of some sort. But no
matter which kind of cleaning and sanitizing is selected, there are basic issues that must be
considered. These are summarized using the acronym TACT WINS.

T – Time

A – Action

C – Concentration

T – Temperature

W – Water

I – Individual

N – Nature

S – Surface

Cleaning is a necessary first step because one cannot sanitize a dirty surface. An example that is
seen all too often in some plants and by consumers is the use of chlorine as a cleaner. It is not a
cleaner but a sanitizing agent. Let’s look at the eight elements making up TACT WINS.
Time: The time required to properly clean depends on many factors including, but not limited
to, the method of cleaning, the soil and the type of equipment. If too little or too much time is
used, the surface will be dirty. Too much time might seem to be a misstatement, but it is not. A
company that utilizes foam cleaning must rinse the foam from the surface within a set period of
time. If the foam is allowed to remain on the surface for too long, the foam and soil will begin
to redeposit on the surface, dirtying it. Time is one reason that companies manufacturing foods
containing allergens establish production schedules to minimize the number of allergen
cleanings required.

Action: This is the energy required to properly clean a surface. Action brings the cleaning
compounds into contact with the soil and enhances their removal. Examples of action would be
the activity of a foam cleaner, the flow through pipes in a CIP system, the moving water in a
COP tank, or the use of brushes or white pads when doing manual cleaning. Please note the
reference to white pads. When cleaning one should never use green pads. They are too
abrasive and actually damage or score the surface being cleaned.

One type of action that is now discouraged is the use of high-pressure spray devices. These can
aerosolize soil and microorganisms, which may then settle back onto the equipment.

Concentration: To properly clean surfaces, the processor must use the correct cleaning
compound at the proper concentration. There are a wide range of cleaning compounds
available to the industry. What is needed depends upon factors such as the nature of the soil,
water hardness and the surface being cleaned

Temperature: The temperature at which cleaners are used affects their efficacy. The rule of
thumb is that cleaning efficacy doubles (up to a point) for every 10°C increase in temperature.
Each cleaner has an optimum temperature range at which it should be used. When developing
procedures for cleaning, it is imperative that the temperature range at which the product is
used be clearly specified. Temperature is especially important when cleaning fatty products.
Heat will melt fats, allowing them to be removed.
Water: Water is the universal solvent. The first step in cleaning is a rinse with water to remove
gross soil from the surface and away from the equipment. Water is also used to convey the
detergents to the surface and to carry away the soil. The use of surfactants in cleaners
enhances the ability of water to react with the soils. When selecting a cleaning compound, the
hardness of the water is an integral part of the equation.

Individual: Who will do the cleaning? Each person assigned to cleanup must be properly
educated on each and every cleaning procedure that he or she will be conducting. This training
must be based on documented procedures and include the mandatory personal protective
equipment (PPE) needed to properly and safely do the work.

Nature: What products are being manufactured in each plant will determine the kind of soil
that must be removed. There are five basic kinds of soils the food industry must deal with:
fats/grease, proteins, minerals, sugars and complex carbohydrates. The food industry today
must also address food allergens, which will be incorporated into one of the five basic
categories. In addition, part of the equation must also include how the products are processed

Surface: What is the equipment that is being cleaned made of? The most common material is
stainless steel, but one sees plastics in various shapes and forms, rubber, and other metals. All
metals will corrode, some more quickly than others. Stainless steel is favored because it has
high resistance, whereas aluminum corrodes easily. So, these are the elements that must be
addressed to properly clean a surface. Once the surface has been cleaned, it must be sanitized.
Sanitization may be done with chemicals or with heat.

DOCUMENTATION AND RECORD KEEPING

Documentation is any communicable material that is used to describe, explain or instruct

regarding some attributes of an object, system or procedure, such as its parts, assembly,
installation, maintenance and use.

Internal documentation refers to the records that your organization keeps and uses to inform
decisions within your company. You can document pretty much anything from schedules to
 important policies, which means there are tons of different types of documentation out there.
But, they tend to fall into one of three main types of documentation: team documentation,
reference documentation, and project documentation.

Record Keeping: the activity of organizing and storing all the documents, files, invoices,
etc. relating to a company's or organization's activities:

Recording helps you to keep an accurate check on food safety procedures within your business
and enables you to demonstrate that you are controlling hazards in an effective manner.

Characteristics of good documentation

 All relevant information must be recorded

 All paper records must be legible, signed and dated
 Records must be contemporaneous, accurate and kept up to date
 Records must be written in plain English avoiding jargon
 Records must clearly distinguish between statements of fact and opinion
 Paper records if moved to a new location must be monitored and kept securely

AUDIT

An audit as a "systematic, independent and documented process for obtaining audit evidence
[records, statements of fact or other information which are relevant and verifiable] and
evaluating it objectively to determine the extent to which the audit criteria [a set of policies,
procedures or requirements] are fulfilled.

TYPES

 A first-party audit is performed within an organization to measure its strengths and

weaknesses against its own procedures or methods and/or against external standards adopted
by (voluntary) or imposed on (mandatory) the organization. A first-party audit is an internal
audit conducted by auditors who are employed by the organization being audited but who
have no vested interest in the audit results of the area being audited.
  A second-party audit is an external audit performed on a supplier by a customer or by a
contracted organization on behalf of a customer. A contract is in place, and the goods or
services are being, or will be, delivered. Second-party audits are subject to the rules of contract
law, as they are providing contractual direction from the customer to the supplier. Second-
party audits tend to be more formal than first-party audits because audit results could
influence the customer’s purchasing decisions.
 A third-party audit is performed by an audit organization independent of the customer-supplier
relationship and is free of any conflict of interest.

BENEFITS OF AN AUDIT

 Compliance. Obviously this is one of the main reasons to conduct an audit: to meet the
statutory requirements and regulations in your industry. ...

 Business Improvements / System Improvements. ...

 Credibility. ...

 Detect and Prevent Fraud. ...

MANUFACTURING PROCEDURES

Manufacturing process management is a collection of technologies and methods used to define

how products are to be manufactured.

A standard operating procedure is a set of written instructions that describes the step-by-step
process that must be taken to properly perform a routine operations. SOPs aim to achieve
efficiency, quality output, and uniformity of performance, while reducing miscommunication
and failure to comply with industry regulations.

BENEFITS OF HAVIVG WRITTEN SOP

1. Reduce employee training time.Training-related SOPs help standardize

orientation and training. A written set of guidelines helps ensure that all new
hires get the same training, on the same topics and responsibilities, in the same
 amount of time. Not only will this help ensure that new employees settle in
quickly, it will also help save time and money in the long term.
2. Maintain consistency across your brand.You’ve worked hard to establish a very
specific personality, look, feel, and tone for your brand. Protect that hard work
by establishing a set of written branding standards
3. Reduce errors and enhance productivity.
Written SOPs can take the guesswork out of day-to-day operations and help ensure that
all of your employees understand the processes, policies, and procedures associated
with their jobs. And because they provide clear, written examples of what is expected
from employees, SOPs are also helpful when developing employee review or
development plans.
4. Meet legal requirements.Depending on your industry, you may be required to
have written SOPs that protect your employees and/or customers — and ensure
that you won’t be held legally responsible if something goes wrong.
5. Establish a chain of command.Everyone in your company should have a clear
idea of your company’s leadership structure, and this is especially important in
situations where work products go through multiple stages of review and
approval.
6. Transfer work easily.
Most employees take a sick day here and there, but in the case of an extended absence, written
SOPs make it easier to transfer work to another employee.

Work instructions refer to documented guidelines that clarify how to perform assignments.
They provide precise descriptions of task-related steps to reduce potential setbacks, damages,
and inconveniences. Work instructions are also known as work guides, job aids, or user
manuals.
Work instructions are a crucial focal point for both management and workers. They help to
understand what the organisations minimum management expectations are and to provide
instruction and guidance for work tasks for day-to-day operations, non-standard tasks and for
emergency situations.