Good Manufacturing Practices and Hazard Analysis for Critical
Contents
1. USAID IRAQ FROM THE AMERICAN PEOPLE Good Manufacturing Practices and Hazard Analysis for Critical Control Points FOR FOOD PROCESSING PLANTS IN IRAQ Pe dina AND Ee ELE PACKING a eee ama This publication was ae for review by the U S Agency for International Development USAID It was prepared by Kamal Hyder Ph D for the USAID Inma Agribusiness Program implemented by The Louis Berger Group Inc Inma Agribusiness Program USAID Iraq 2008 Contract No 267 C 00 07 00 500 00 An Inma Agribusiness Program Publication Series www inma iraq com 2008 This publication presents an adjustment of the author s original GMP and HACCP for Almond and Dried Fruit Processing Plants in Afghani stan USAID Afghanistan 2006 The original publication was produced un der the USAID RAMP Contract No 306 C 00 03 00502 00 ROP The Inspection for Small Processing Plants Checklist is reproduced with the courtesy of the North Carolina Department of Agriculture and Con sumer Services NCDA amp CS Meat and Poultry Inspection Division The Inma Agribusiness Program and this publication are made possible by the support of the American People through the U S Agency for Interna tional Development USAID The contents of this publication are the sole responsibility of The Louis Berger Group Inc and do not necessarily reflect the views of USAID or the United States Government nma AGRIBUSINESS PROGRAM Good Manufac2. FOR PLANTS All policies regarding the hygiene of employees and visitors should be posted in prominent places They should be strictly enforced Safety of material handling should also be monitored with great care Inma Agribusiness Program 32 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points References Refer to the United States Food and Drug Administration FDA codes Refer to the United States Food and Drug Administration FDA codes in Section 2 of the Code of Federal Regulations Part 10 for further detail 3 For further detail on flow chart and critical control points for HACCP consult the HACCP User s Manual by D A CorlettJr 1988 Aspen Press Gaithersburg MD USA USAID Iraq 33 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points INSPECTION FOR SMALL PROCESSING PLANTS CHECKLIST This checklist was developed for the North Carolina Department of Ag riculture and Consumer Services NCDA amp CS Meat and Poultry Inspec tion Division It has been adapted for Iraq GUIDELINES FOR NEW PROCESSING PLANTS I THE COURTESY REVIEW A Structure e Interior walls and ceiling of waterproof materials e joints tight fitting wall ceiling and wall floor e Adequate ceiling height e Metal doors tight fitting e Floor concrete slanting to floor drains e Covering at the wall floor juncture e Drains in floor four inch w
3. PROCESSING COOKING e All preparatory procedures listed under raw product apply e Cookers are examined for cleanliness and proper function e Cooking time and temperatures are mandated by regulations and must be carefully followed e Cook charts showing temperature and time should be kept e Cooked product should be rapidly cooled in accordance with regu lations and cooling guidelines e A cooling time chart should be kept e Measurements of temperature should be made with a good probe type thermometer e Cooked product should be kept separate from raw product e Shrink test should be done where applicable e Restricted ingredients must be carefully monitored e Accurate inventories should be kept on any restricted ingredients e Identification of lots should be maintained at all stages of processing USAID Iraq 43 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points TRANSPORTATION e Check all product to be shipped to be sure that it is properly pack aged and correctly labeled before it leaves the plant e The transportation vehicle should be clean and cooled prior to loading e The vehicle should be equipped with a thermometer e If an accident occurs call the inspector e Do not distribute product to public unless cleared by the quality inspection service e Transportation boxes must be clean and of the appropriate type Do not use boxes with another establishment s legend
4. property that may cause an unacceptable consumer health risks e Monitoring means a planned sequence of observations or meas urements of critical limits designed to produce an accurate record and intended to ensure that the critical limit maintains product safety Continuous monitoring means an uninterrupted record of data e Preventive measure means an action to exclude destroy eliminate or reduce a hazard and prevent recontamination e Risk means an estimate of the likely occurrence of a hazard e Sensitive ingredient means any ingredient historically associated with a known microbiological hazard that causes or contributes to production of a potentially hazardous food as defined in the Food Code of the FDA e Verification means methods procedures and tests used to deter mine the HACCP system to be in compliance e Flow chart is a diagram that shows how products move through a processing plant Each step or node on the flow chart represents a separate operation that is applied to the product The first opera tion in the flow of product through the plant is reception of the raw product Cleaning sorting grading and packaging are exam ples of other operations that are applied to the product as it flows Inma Agribusiness Program 22 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points through the plant Such operations are represented as nodes on the plant s flow chart One of the first s
5. should be filtered or scrubbed prior to its discharge e Electricity should be supplied through a distribution switch board Proper safety switches and fuse boxes should be installed to avoid overload and electrical fires Wiring inside the plant should be pro tected with waterproof covering that can be wiped during clean up USAID Iraq II Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points e In some cases stand by generators may be needed for refrigerators and freezers to avoid spoilage due to electrical interruptions e Lighting and ventilation systems should be adequate for visibility and safety e All entry points to the building should be secured against insects rodents and other animals e The doors windows walls floors and ceilings should be made of smooth surfaces that can be easily wiped and cleaned e Materials used in construction of floors and walls should be non toxic o Cement walls and floors are acceptable if they are smooth enough without rough corners and crevices Special plastic wall covers such as Kimlite panels may be ideal because they can be easily washed and wiped o Wooden doors and windows may be covered with thin stainless steel sheets but if metal doors and windows are available they are preferable e Toxic materials such as lead paint must not be used Asbestos sheet ceilings should be absolutely avoided Some plants use galvanized iron s
6. and e Hazard Analysis and Critical Control Points HACCP The purpose of this manual is to assist owners and managers of fruit and vegetable processing plants in Iraq obtain a basic understanding of these components of a responsible food quality assurance system and alert them to important issues to consider when installing and operating these systems The manual will discuss basic concepts and suggest the food safety and quality assurance system that should be implemented in food processing plants in Iraq The actual procedures and programs for fresh fruit and USAID Iraq 7 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points vegetable processing plants in Iraq should be developed and installed with the help of food safety experts employed either by the individual plant owners or through some organization of plant owners Inma Agribusiness Program 8 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points Good Manufacturing Practices GMP Good manufacturing practices are the procedures that should be fol lowed during plant construction and operation to assure food whole someness GMP refers to the minimum sanitary and processing condi tions required in a properly built processing plant GMP contains cleanliness and sanitary requirements for personnel build ing and facilities equipment and utensils in addition to food processing requireme
7. ave guards e Safety glasses should be provided e Hazard communication program in inspector file e Lockout Tag out program L Water and Sewer e Water and sewer systems must be approved e Water samples must be submitted regularly e Hot water heater of adequate size and volume M Plant File e Approved labels e Approved blue prints e MSDS sheets e Evacuation plan e Water and sewer letter e Processing reports Inma Agribusiness Program 38 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Operating hours e Activity report e Equipment List e Letters of guarantee e Inedible letter e Pest control letter e Chemicals list e Formulations if any e Plant profile e Application and grant of inspection N Exterior e Graded drive to prevent standing water e Concrete pad at loading door e Weed control around plant e Fly fans and electrocuters where indicated e Control of rust and flaking paint O Employees e Trained in basic hygiene practices e Clean work smocks and aprons e Head covers hard hats or caps e No smoking eating or chewing in processing areas USAID Iraq 39 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Hair and beards should be trimmed e Frequent hand washing and clean nails e All cuts and health problems should be cared for promptly e Safety boots should be provided e No rings watches bracelets w
8. ctices and Hazard Analysis for Critical Control Points e Measures such as sieves traps or metal detectors must be used to protect against the inclusion of metal or other extraneous material in food e Measures such as sterilizing irradiating or pasteurizing must be adequate to destroy or prevent the growth of undesirable micro organisms e Equipment containers and utensils must be constructed handled and maintained to protect against contamination e Fruits and vegetables that are adulterated must be disposed of without contaminating others PACKAGING CODING AND FINISHED FOOD PRODUCTS e A coding system should be utilized that will allow positive lot iden tification in the event it is necessary to identify and segregate lots of fruits and vegetables that may be contaminated e Records should be kept for a period of time that exceeds the self life of the product Inma Agribusiness Program 18 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points PERSONNEL Employee sanitation requires that plant personnel use personal hy giene to insure that food products do not become contaminated Personal hygiene for processing plant personnel includes e Use of protective clothing shoes hair nets beard guards etc approved by management e Washing and sanitizing of hands and body parts that may come in contact with the food during preparation e Food processing personnel should not wear jewelr
9. e toxins heavy metals or pesticide residues It helps monitor strict adher ence to processing and storage parameters Inma Agribusiness Program 20 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points DEFINITION OF TERMS USED IN HACCP Many terms used in discussion of HACCP must be clearly understood to effectively develop and implement a plan The following definitions are provided for clarity e Acceptable level means the amount of a hazard that is unlikely to cause a health risk e Control point means any point where loss of control does not lead to an unacceptable health risk e Critical control point as defined in the Food Code means a point at which loss of control may result in an unacceptable health risk e Critical limit as defined in the Food Code of the FDA means the maximum or minimum value to which a physical biological or chemical parameter must be controlled e Deviation means failure to meet a required critical limit for a criti cal control point e HACCP plan as defined in the Food Code means a written docu ment that delineates the formal procedures for following the HACCP principles developed by The National Advisory Commit tee on Microbiological Criteria for Foods USAID Iraq 2l Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Hazard as defined in the Food Code means a biological chemical or physical
10. ety consultant with technical knowledge to provide guidance at the HACCP meetings The consultant can co ordinate the external testing and laboratory services and discuss test results and corrective measures e Prepare a flow chart of the operation of processing This should be a step by step flow chart e Examine the steps and identify the hazards at each step e Determine curative measures such as cleaning the surfaces in con tact with the product or reducing water and airflow on the pro duce that can contaminate them e Establish tests to measure the elimination of contaminants USAID Iraq 25 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Record all sources of ingredients to establish traceable connec tions to eliminate hazard sources e Display the critical control points and repeat the review of actions taken periodically like daily weekly and monthly e Standardize procedures and update them as frequently as possible with new techniques e Make sure that the management approves and signs records of in spections regularly THE HAZARD ANALYSIS PROCESS The hazard analysis process consists of asking a series of questions at each operational step in the processing of the product as it flows through the plant The analysis examines the effect of a variety of factors upon the safety of the food Sample questions are given below INGREDIENTS e Do the produce con
11. hat it can be cleaned and sanitized e Is there a chance for product contamination with hazardous sub stances e What product safety devices such as time and temperature inte grators are used to enhance consumer safety PACKAGING e Does the method of packaging affect the multiplication of microbial pathogens and or the formation of toxins e Is the packaging material resistant to damage thereby preventing the entrance of microbial contamination e Is the package clearly labeled Keep Refrigerated if this is required for safety e Does the package include instructions for the safe handling and preparation of the food by the consumer Inma Agribusiness Program 28 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Are tamper evident packaging features used e Is each package legibly and accurately coded to indicate production lot e Does each package contain the proper label DETERMINATION OF THE CRITICAL CONTROL POINTS CCP Determination of the Critical Control Points CCP is made by analyzing each operational step in the flow of product through the plant to evalu ate the potential for contamination by biological chemical and physical vectors The table below provides an example of the analysis of the flow of product through a typical food processing plant At each step in the processing plant the potential for biological chemical or physical contami nation is analyzed C
12. heets as roofs This would require a false ceiling of plastic ma terial to cover the iron sheets from the inside Inma Agribusiness Program 12 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points DESIGN OF EQUIPMENT AND UTENSILS Equipment and utensils must be designed for easy cleaning and sanitation Equipment and utensils must be made from non corrosive materials SANITATION FACILITIES AND CONTROL e Toilet hand washing ablution and locker room facilities o Toilets and hand washing facilities must be provided inside the processing centre o Toilet tissue must be provided o Toilets must be kept sanitary and in good repair o Signs must be posted that direct employees to wash their hands with soap or detergent after using the toilet o Toilet rooms must have self closing doors o Toilet rooms must not open directly into areas where proc essed products are exposed unless steps have been taken to prevent airborne contamination example double doors positive airflow etc e Hand washing facilities must provide o Running water at a suitable temperature o Effective hand cleaning and hand sanitizing preparations USAID Iraq 13 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points o Clean towel service or suitable drying devices o Easily cleanable waste receptacle o Water control valves designed and constructed to protect again
13. isms Product flow zones must be protected from all sources of contamination Inma Agribusiness Program 16 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points FOOD PROCESSING It is necessary to process package and store fruits and vegetables under conditions that will minimize the potential for undesirable microbiological growth toxin formation deterioration or contamination This will require careful monitoring via a HACCP program described below of such fac tors as time temperature humidity pressure flow rate etc The object is to assure that mechanical breakdowns time delays temperature fluctua tions or other factors do not allow the fruits and vegetables to decom pose or become contaminated Good manufacturing practices include the following e Fruits and vegetables must be held under conditions that prevent contamination and the growth of microorganisms e Mechanical manufacturing steps such as shelling and packaging etc must be performed in a manner that o provides adequate protection from contaminants that may drip drain or be drawn into the products o adequately cleans and sanitizes all contact surfaces o uses materials for fruit and vegetable containers and packag ing materials that are safe and suitable o uses an HACCP program to check for possible contamination and assure that GMPs are being followed USAID Iraq 17 Inma Agribusiness Program Good Manufacturing Pra
14. ith traps e Adequate square footage for production and equipment e No exposed wood e Ventilation adequate for space and function e Correct traffic flow Inma Agribusiness Program 34 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points B Equipment e Product wash recondition sink e Hand wash sink with foot or knee valve e Equipment wash sink 3 compartments e Hot water supply e Soap and single service towel dispensers e Approved grinders choppers stuffers cookers saws pots lugs knives racks stands tables cutting boards e No exposed wood on tables shelves racks e Hose and hose rack C Lighting e Adequate lighting 50 foot candles at work level e Shatter proof bulbs or light covers with ends e Plastic or stainless fixtures do not rust e Waterproof switches for lights in processing e Must have lighting in coolers freezers dry storage D Coolers e Four inch floor drains e Waterproof walls floor and ceiling e Metal racks 12 inches up off the floor e Tight fitting metal door USAID Iraq 35 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Accurate thermometer e Cooling unit with fan covers and drain pan e Adequate lighting e Separate cooler for chilling cooked product E Welfare e Number of restrooms adequate for number of employees e Equipped with hand wash sink soap and towel dispenser e Hot water supply e Mu
15. nts and controls Cleaning and sanitation is a multi step proce dure that involves first cleaning and then sanitizing in the processing plant Food processing refers to the actual manufacturing operations such as cleaning sorting grading and packaging that are applied to the fresh or processed food products When implemented properly GMP not only re duces new forms of biological chemical and physical contamination but eliminates existing contamination Food processing plants or packing sheds must be constructed with these practices in mind To comply with U S and European standards processing facilities must be constructed with approved materials and maintained USAID Iraq 9 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points under hygienic and sanitary conditions Construction materials should be safe non toxic and approved for use in a processing facility All of the equipment walls floors doors windows and fixtures must meet ap proved standards The plant layout should be such that it can avoid accu mulating dirt and can be easily cleaned and sanitized PLANT AND GROUNDS The design of the plant layout should include the following points e The ground selected should be above the road level and water drainage system e The building should be a few feet above ground level for cleaning water to flow out e Adequate protection should be provided against rain and dust s
16. on HACCP Flow Chart of Food Processing Plant with examples of CCP Inma Agribusiness Program 30 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points Note The sizing and grading operation may not be directly related to health hazards but for quality of fruit size and grade the operation is critical Tests will have to be performed regularly in the plant Some examples of tests are given below e For visual tests magnifiers microscopes and UV lights will be needed e For color control of the fruits color charts or electronic eyes for color comparison may be needed e For microbiological examination equipment will be needed for in cubation and plate count e For physical debris and filth removal cleaning devices cyclones and dust removal equipment will be needed USAID lIraq 3l Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points General Management Principles Management support and involvement are extremely important in achiev ing success The following points for record keeping and plant policies are of paramount importance RECORD KEEPING The procedure of testing and re testing requires record keeping in an ar chive that is chronological permanent and readily accessible It should be maintained by the management in a safe and secured place This will also help product recalls if they are needed MANAGEMENT POLICIES
17. or label Inma Agribusiness Program 44 USAID Iraq An Inma Agribusiness Program Publication Series www inma iraq com Previous publications Lamb Feedlot Management Guide published in English Arabic and Kurdish 2008 Beef Feedlot Management Guide published in English Arabic and Kurdish 2008 To obtain copies of the Inma Program Publication Series please contact info inma iraq com Inma AGRIBUSINESS PROGRAM
18. orn by employees in plant working areas P Transportation e Clean enclosed vehicle e Refrigeration PROCESSING CHECKLIST PRE OF PREPARATION Through cleaning of facilities equipment and containers e Hot water must be available e Cooler must be operating within required limits e Lighting must be adequate e No signs of insects or rodents e No buildup of blood oil tissue or dirt on cutters choppers dicers tables cutting boards or containers e Check equipment for wear of blades loose fittings to reduce chances of metal contamination Inma Agribusiness Program 40 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Trays boxes wrap and other direct contact material checked for cleanliness and e foreign material contamination e Hand sanitizers and or sterilizers available with proper strength and approved chemicals e All chemicals and cleaning materials should be removed from the processing area Coats hats boots and aprons should be checked for cleanliness and wear e All lugs and food containers should be checked for cleanliness and cracks e All floor drains should be functional and free from odor e Check for flaking paint and rust on all metal including fans e Check all raw product for expiration date spoilage species and freshness e Disassembled equipment should be inspected before use PROCESSING UNCOOKED RAW PRODUCT e During processing only authorized employees a
19. re allowed in the processing area e Hands should be thoroughly cleaned with soap and water nails should be clean e Knives should be sanitized or sterilized USAID Iraq 4l Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Clothing such as coat sleeves should not be allowed to contact raw product e Do not put product containers on the floor use stands twelve inches off floor e While cutting examine raw product for foreign material paper plastic wire dirt bone insects and other abnormalities e If foreign material is found processing should be stopped and the entire lot should be examined and identified e If you are unsure about the source or safety of raw product put the product in the retained area of the cooler for examination e Accurate certified scales should be used for net weights e All product should be labeled with an approved label Safe handling labels and nutritional labels when required e Raw product must be cooled refrigerated or frozen immediately after processing e Raw product should be transported in clean containers under re frigeration e All additives should be measured and used in accordance with for mulations and regulations e Inedible material should be denatured and stored in containers with lids marked inedible Inma Agribusiness Program 42 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points
20. ritical Control Points CCP are identified where the potential for contamination is significant USAID Iraq 29 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points Operation Biologi Chemi Physical Critical cal Con cal Con Control Control trol trol Point Point Point Point Receiving Check Check Check Treatment to bacteria pesticide dirt de remove them mold amp insecti bris amp cide filth Fumiga Check Check Treat and re tion if re for resi for insect move physically quired due fragments Culling Check Check Check Remove the Removing for bacte for for dis discolored fruits ria and chemical colored mold residue fruits etc Sizing amp Quality Quality Quality Remove blem No for food Grading check check check ished and off safety grade fruits Line amp QC Final line Final line Final line Eliminate the off Inspection check for check for check for grade items and bacteria any any for clean fruits and mold chemical eign ma residue terial Packing Check Check Eliminate dam packaging packaging aged packaging materials materials materials and for bacte for cartons ria chemicals Storage Check Check Check Make sure the storage storage storage storage area is area area area clean and dry Shipping Check Check Check Clean the ship shipping shipping shipping ping vehicles condition condition conditi
21. st not enter directly into processing e Provide space for lockers hangers and boot racks F Dry Storage e Metal racks stands cabinets for wrap spices labels e Adequate space for volume e Tight fitting construction e Adequate lighting G Office Space e Metal table or desk e File drawer or cabinet lockable e Metal chair e Trash receptacle Inma Agribusiness Program 36 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Dedicated phone line H Entrance Traffic Flow e No direct entrance from outside into processing e Vestibule on outside entrance e Concrete pad at loading area e Employee Only sign on processing door l Separation e Finished goods and raw product should be separated e Inspected and custom product must be separated e Retail and inspected areas must be separated J Chemicals e Approved chemicals cleaners only e Must be stored away from processing area in designated area e Material safety data sheets MSDS for all chemicals e Storage cabinets for flammables K Safety e Lighted exit signs e Exit diagram e Fire extinguishers USAID Iraq 37 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Approved electrical boxes with grounded circuits e Water proof socket covers e Evacuation plan e No spliced wires or undersized extension cords e All fans must have covers and moving parts must h
22. st recontamination of clean sanitized hands o Signs directing employees handling unprotected fruits and vegetables to wash and if appropriate sanitize theirs hands before starting work after each absence from the work station and any other time when the hands have become soiled or contaminated SANITARY OPERTIONS HOUSEKEEPING The plant must develop Standard Operating Procedures SOPs and Stan dard Sanitary Operating Procedures SSOPs relative to all cleaning and sanitizing of the plant facilities and equipment Cleaning operations must be conducted in a manner that will minimize the possibility of contami nating fruits and vegetables and equipment surfaces that contact them Cleaning removes the visible soil and organic matter and most of the harmful bacteria Inma Agribusiness Program 14 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points Plant personnel use brooms brushes high pressure air low and high pres sure water to remove visible soil and organic matter from e Plant floors e Plant walls e Equipment and utensils which must be kept in a sanitary condition through frequent cleaning and when necessary sanitizing If neces sary such equipment must be taken apart for thorough cleaning Cleaning is done on a pre planned regular schedule Most cleaning opera tions are conducted at the end of the work day or at a prescribed time before the shift begins Sanitation req
23. tain any sensitive ingredients that are likely to present microbiological hazards e g Salmonella Staphylococcus aureus chemical hazards e g aflatoxin antibiotic or pesticide Inma Agribusiness Program 26 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points e What is the normal microbial content of the food stored under proper conditions e Does the microbial population change while the food is stored be fore consumption e Does that change in microbial population alter the safety of the food FACILITY DESIGN e Does the layout of the facility provide an adequate separation of raw materials from ready to eat foods e Is positive air pressure maintained in product packaging areas Is this essential for product safety e Is the traffic pattern for people and moving equipment a potentially significant source of contamination EQUIPMENT DESIGN e Will the equipment provide the time and temperature control that is necessary for safe food USAID Iraq 27 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points e Is the equipment properly sized for the volume of produce that will be package e Can the equipment be sufficiently controlled so that the variation in performance will be within the tolerances required to produce a safe food e Is the equipment reliable or is it prone to frequent breakdowns e Is the equipment designed so t
24. teps in establishing HACCP in a plant is to prepare a flow chart with potential hazards identi fied at each step2 Below is an example flow chart in tabular form for a typical fruit and vegetable processing plant Receiving raw materials in the bulk storage bins at the plant raw Receiving raw materials in the bulk storage bins at the plant in the bulk storage bins at the plant Fumigation of raw materials to kill insects and molds prior to processing if required Storage of fumigated raw materials in the processing area Cleaning and removing undesirable fruits and vegetables and drying Sizing sorting and grading Pass through color sorter if necessary Initial quality check to observe any visible defects Quality control tests for moisture density firmness color and flavor Pass through check point to isolate off quality fruits and vegetables Final quality check for physical chemical and sensory tests Bagging and boxing Random batch tests of packaged products for quality Final check of packaged finished goods to avoid any recon Storage of finished packaged products in a cool dry place Shipping of products in bags boxes and large containers with batch control for any recall of product from the market USAID Iraq 23 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points SEVEN PRINCIPLES OF HACCP Seven principles are applied to establish an HACCP program The
25. torms e Areas for incoming raw material and outgoing finished goods should be segregated e Plumbing must be of adequate size and design to o Supply enough water to areas in the plant where it is needed o Properly convey sewage or disposable liquid waste from the plant e Not create a source of contamination or unsanitary condition Inma Agribusiness Program 10 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points o Provide adequate floor drainage where hosing type cleaning is done or where operations discharge water or liquid waste onto the floor floor drains must be designed to trap mate rial that could clog the drainage system floor drains must be designed for easy cleaning to remove trapped material Where practical any solid material that can clog the drains should be removed prior to disposal o Water supply for the plant should be tested to see if it is po table High bacterial count and excessive mineral content should be eliminated by treatment with chlorine and filtra tion or ion exchange system o Used process water should also be treated before disposal to reduce biological and chemical oxygen in the effluent o There should be no backflow from cross connections be tween piping systems that discharge waste water or sewage and those that carry water for fruits and vegetables e Air filters should be used to clean air for in plant use Any emission of air with high polluting materials
26. turing Practices and Hazard Analysis for Critical Control Points FOR FOOD PROCESSING PLANTS IN IRAQ FRESH FRUIT AND VEGETABLE PACKING 2008 Table of Contents Introduction Good Manufacturing Practices Plant and Grounds Design of Equipment and Utensils Sanitation Facilities and Controls Sanitary Operations Processes and Controls Personnel Hazard Analysis for Critical Control Points Definition of Terms used in HACCP Seven Principles of HACCP Critical Steps for the Development of HACCP The Hazard Analysis Process Determination of the Critical Control Points General Management Principles Record Keeping Management Policies for Plant Inspection for Small Processing Plants Checklist Guidelines for New Processing Plants The Courtesy Review Processing Checklist Pre Of Preparation Processing Uncooked Raw Product Processing Cooking Transportation 10 13 13 15 17 19 21 22 25 26 27 30 33 33 33 35 35 35 4l 42 44 45 Good Manufacturing Practices and Hazard Analysis for Critical Control Points Introduction Food processing plant owners have a social responsibility to insure that the food they produce and sell to the general public will not damage con sumers health Responsible plant owners take many steps to make sure that the food they produce is healthy and wholesome for human con sumption The cumulative steps result in a food quality assurance system that includes e Good Manufacturing Practices GMP
27. uires that a sanitizing compound such as chlorine be ap plied to the cleaned surfaces so that the level of bacteria can be reduced to an acceptable level Sanitation is done at different times for various parts of the plant The following is a recommended schedule of sanitation for the various parts of a processing plant e Plant floors every day and during mid shift e Plant walls every day before each shift e Equipment before use for every batch e Other utensils prior to use USAID Iraq 15 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points PEST CONTROL Food plants must have structures to control insects rodents birds cats and other animals Flies bees rats and mice invade the food plants in search of food Cats and other animals enter the plant in search of rats and mice All structures and equipment should be secured against them Doors windows and other openings must be secured Openings that are typically left open for ventilation should be screened Installation of air curtains fans and electrocutors at strategic locations will be extremely helpful Snap traps glue boards and bait stations must be placed around the immediate building exterior and interior walls PROCESSES AND CONTROLS RAW MATERIALS AND CONTAINERS Raw product and finished product must be stored in segregated areas un der conditions that prevent contamination and the growth of undesirable microorgan
28. y are given below with reference to fresh fruit and vegetable processing indus tries Perform analysis of hazard type of physical chemical and biological hazard in fruits and vegetables 2 Determine critical control points locate the areas during handling and processing of fruits and vegetables 3 Establish limits for the critical control points establish the safety limits acceptable at the points 4 Monitor critical control points check and re check the occurrence of hazards at the points 5 Take corrective action establish procedures to eliminate the hazards through treatments 6 Keep records maintain the history of events that includes observation action and results 7 Verify that the system works check and re check that the procedures are updated and functioning Inma Agribusiness Program 24 USAID Iraq Good Manufacturing Practices and Hazard Analysis for Critical Control Points CRITICAL STEPS FOR DEVELOPMENT OF HACCP The following steps are essential for consideration at the time of estab lishing a HACCP program e Assemble a multi disciplinary team that includes managers scien tists process workers engineers and book keepers so that intelli gent input can be provided at periodic HACCP meetings In the case of fruit and vegetable processing people with knowledge of growing handling storage and distribution should be included to provide input of the local conditions e Engage an external saf
29. y while processing food The owner of the processing plant should es tablish strict jewelry rules so that watches rings earrings etc are not worn by processing personnel and may not contami nate the products The plant owner should provide a place for plant personnel to safely store their jewelry prior to entering the processing areas e All personnel should be screened regularly for any illness that can be transmitted to food USAID Iraq 19 Inma Agribusiness Program Good Manufacturing Practices and Hazard Analysis for Critical Control Points Hazard Analysis for Critical Control Points HACCP HAACP is a system for monitoring food processing plants to insure that all established procedures for maintaining food quality are followed It es tablishes a series of scheduled inspections in the plant at critical points of manufacture Physical chemical and biological tests are performed at the critical points When the results are acceptable food processing manufacturing moves forward When the results of tests are unaccept able food processing ceases until the problems are corrected HACCP is not a stand alone system It requires GMP to be in place be fore HACCP can be applied It is now used extensively in the food indus tries all over the world for making sure that processed foods are pre vented from contamination with hazardous elements pathogenic micro organisms physical objects like glass metal or bone and chemicals lik
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