Best in Class Personal Hygiene Practices for Safe Food Realization Through I ple e tatio of I te atio al Re ui e e ts ….

Contents …            

International References Trends in Food borne Illness Personnel Hygiene Access Control Hygiene Station Hand washing requirements Location Selection Layout & Zoning Building Material Receipt & Movement Bore-well Head Protection List of Food Handlers medical test & controls

Date: 2nd Dec 15

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Slide No: 1

International References • CODEX Alimentarius

• • • • • •

FSSAI EHEDG : European Hygienic Engineering Design Group FDA : US Food and Drug Administration NSF: National Science Foundation FSSC 22000: Food Safety System Certification AIB: AIB International

• Canadian Food Inspection Agency • University of Guelph

Date: 2nd Dec 15

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Slide No: 2

Trends in Food borne Illness in USA, 1996–2010

Fig : Changes in incidence of laboratory-confirmed bacterial infections, United States, 2010 compared with 1996–19981 Date: 2nd Dec 15

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Slide No: 3

Integrated Disease Surveillance Project (IDSP) Integrated Disease Surveillance Project (IDSP), launched by Union Minister of Health & Family Welfare, India in November 2004 2000

3000

1964 1675

1585

1584

2636 1667

2500

1500

NO Of Deaths

No. Of Outbreaks

2000

990

1000

1500

799

1108 901

553

1000

810

500 500

50

120

95

77

0 2008

2009

2010

2011

2012

2013

2014

2015(Till 21 Nov'2015)

No. of Outbreaks

553

799

990

1675

1584

1964

1585

1667

Death

50

120

95

77

1108

901

810

2636

0

Source: http://www.idsp.nic.in Geometric increase in number of Food Borne Cases from as well as deaths in India Date: 2nd Dec 15

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Slide No: 4

Personnel Hygiene: USFDA Key Requirements Personnel hygiene is a very vast term which includes following:

Disease control

Storing clothing

Date: 2nd Dec 15

Cleanliness

Wearing outer garments

Wearing hair nets, headbands, caps, beard covers

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personal cleanliness

Jewellery Removal

Hand Washing

Maintaining gloves

Slide No: 5

Hand washing requirements Step 1

Step 2

Step 3

• Wet hands & arms up to the elbows with warm water • Apply small amount of soap

• Wash thoroughly (rub) for at least 20 sec

Step 4

• Brush nails with the nail brush • Rinse brush and keep in container with sanitizer

Step 5

• Rinse well with warm water having temperature at least 43°C (110°F) for at least 10 sec

• Dry with paper towel or dryer Step 6

Step 7

• Put on the approved food grade sanitizer gel and thoroughly (rub)

Date: 2nd Dec 15

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Slide No: 6

Access Control Site security should be reviewed, and the need for CCTV, and/ or security guards should be considered as pert of a food defence programme. In particular, material storage tanks, silos, and line hook ups should be provided with enclosure, security, drainage, space and spill control.

adequate

Protection of products against potential acts of sabotage etc.

Date: 2nd Dec 15

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Slide No: 7

Hygiene Station A Hygiene station consists of: 1. Hand wash station. 2. Foot wash station 3. Access controlled flap gate or tripod turnstile. 4. Hygiene Watch System 5. Disinfectant solution.

Hygiene Station with Access Control Date: 2nd Dec 15

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Slide No: 8

Hygienic Aspects of Locker Area, Toilet & Cubical

Lockers with sloped roof top and step Toilet & Cubical devices to be mounted from the wall to facilitate suitable cleaning .

Date: 2nd Dec 15

over bench in front All Junction with the floor are covered.

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Slide No: 9

Suggested number of lavatories, Urinal stall & Hand wash basins/ number of employees Staff Member

Number of sanitary conveniences MEN

WOMEN

Lavatories

Urinals

Wash basins

Lavatories

Wash basins

10

1

1

1

1

1

20

1

2

2

2

2

40

2

3

2

3

3

60

3

3

2

4

4

80

4

4

3

6

5

100

4

4

3

8

6

120

5

5

4

9

7

140

5

5

4

10

8

180

5

6

5

11

8

Add 1 lavatory, 1 urinals and 1 wash basin for every 70 persons in excess of 280 persons Date: 2nd Dec 15

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Add 1 lavatory, and 1 wash basin for every 35 persons in excess of 280 person Slide No: 10

Hazard Prevention from external to internal environment When ever possible, factories should be located away from or protected against:  Environmentally polluted or remediation areas  Industrial activities which pose a serious threat of contaminating food (e.g. Incinerators, landfills, junkyards etc).  Areas where wastes, either solid or liquid, cannot be removed effectively.

Schematic site plan indicating potential to and from the food manufacturing plant Date: 2nd Dec 15

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Slide No: 11

Hygienic Building Layout A building layout locating production areas, services areas, storage areas (e.g. Chemicals), surrounding areas and main air intake/ outlet locations.

Schematic of Hygienic layout of a building Date: 2nd Dec 15

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Slide No: 12

Zoning Food production areas must be segregated from non-food production areas e.g. Locker rooms, canteens/restaurants, smoking areas, boiler rooms, workshops, living accommodation etc. Food Manufacturers should undertake a hazard analysis to determine how many processing areas or zones are appropriate for the safe manufacture of their product range. Hazard analysis consider:  Hazard present in Raw Material.  Hazard present in the processing environment.  The potential for product microbial spoilage. Etc

Hygienic design criteria for Zones  Food Production areas  Basic Hygiene areas  Medium Hygiene areas  Ingredient preparation area  General processing area  High Hygiene area  Aseptic area Schematic separation of non-microbiological hazard

Date: 2nd Dec 15

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Slide No: 13

Access control during High Hygiene & Low Hygiene Area

High hygiene footwear should be captive to high hygiene.

Date: 2nd Dec 15

Dedicate d maintena nce tools are to be used for High Hygiene & Low Hygiene areas.

Different colour code to be given to the tools.

Foot wares & Aprons shall be changed.

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Foot bath & Foot washers should be used only in low hygiene area.

Flow of waste from High Hygiene Zone to Low

Slide No: 14

Building: Pest proofing measure to prevent entry through foundations Foundation are one of the most important structural members. Foundations shall be designed to guarantee stability and structural safety of the entire building structure and should be concrete based (avoid wood, brick and block foundations).

Pest proofing measure to prevent entry through foundations

Date: 2nd Dec 15

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Slide No: 15

Roof Drainage  

Roofs should be sloped to a minimum of 1-2% to ensure positive drainage. For Flat roofs, water can be transported in channels on the roof over the hygienic areas and then lead into a gravity or vacuum/ siphonic system outside the hygienic areas.

Sloped Roof to ensure positive drainage

Rat Stop for preventing Rodent entry through Roof Drainage Downpipe

Date: 2nd Dec 15

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Slide No: 16

Hygienic Flooring Floors Floors provided the foundation for safe, hygienic food production in factories. The hygienic design and installation of floors to ensure a correct level of ongoing hygiene .

Floors are critical areas, for example they are places where listeria monocytogenes are likely to be found and where the bacteria could persist despite cleaning and disinfection. Slipping correspond to around 20% of work place injuries.

Floor sloped towards the drain

Date: 2nd Dec 15

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Slide No: 17

Hygienic challenges during Flooring Hygienic challenges during Flooring

Bubbles holes in Heavy duty Polyurethane floor

Electronic microscopic pics on an epoxy raisin floor

Lose tile at discharge point due to discharge of Hot & Cleaning Chemicals

Date: 2nd Dec 15

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Slide No: 18

Hygienic design drains Drains: Areas with CIP System Water should be directed into the drainage system by a pipelines. Nevertheless to avoid waste water backflow and to protect line hygiene, air gaps are necessary. The volume and temperature of water must be considered when selecting the product. The drainage products shall includes following features:  Continuous welding of joints  Radiused and rounded corners  Drain ability  No crevices or dead spaces

Drains design

Date: 2nd Dec 15

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Slide No: 19

Building: Hygienic Lighting Placements Lighting: All areas where food is examined processed or stored, and where equipments or utensils are cleaned and in personnel changing areas, must have adequate natural and/or artificial lighting for the activities conducted. Lightening should be suitably sealed to the ceiling or walls in a way that avoid any projection where dust can accumulate or spaced off them to give easy access for inspection and cleaning with the top of the light fittings sloped to 45°C to enable cleaning.

Sloped body light, integrated in the ceiling flush with that ceiling

Date: 2nd Dec 15

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Slide No: 20

Design of Stairs passing over production line & Platform upstairs

 Floors, Stairs, Catwalks, bridges over production lines shall be sealed  Design shall preclude contamination of area below.  They should be constructed with impervious, non corrodible, easy to clean etc.

Date: 2nd Dec 15

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Slide No: 21

Proofing of Ceiling – Pipeline entry points

All ceiling throughput for piping should be well sealed with sealant or a colar

Date: 2nd Dec 15

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Slide No: 22

Clea Co ept Ai Ha dli g U its Traditional Metal Ductwork for Air Distribution

Textile du ts for Air Distri ution  Pest scrolling over the duct is prevented

o Pest scrolling over the duct is likely o Un-Even Air Distribution throughout entire length o Considerably heavy Structural Load on building with simpler suspension system o Higher probability of dirt / dust contamination o Reduced Distribution & Blending of the conditioned air in a given space o U a le “upply ai elo the De Poi t o Higher Maintenance

Date: 2nd Dec 15

 Designed for Even Air Distribution throughout entire length  Reduced Structural Load on building with simpler suspension system  Compactable with disposable HVAC filte s e tified to eet the Food “afe F7/F9 standards.  Dirt / Dust contamination is prevented  Enhanced Distribution & Blending of the conditioned air in a given space  “upply ai elo the De Poi t  Less Maintenance

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Slide No: 23

Clea Co ept Ai Ha dli g U its Traditional Metal Ductwork for Air Distribution

Date: 2nd Dec 15

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Textile du ts for Air Distribution

Slide No: 24

Material Movement: Control Measures to Prevent Pathogens into Plant  This

type of sanitizing equipment is often known as a a ie tu el or sa itizi g tu el .  The tunnel is a belt-driven, conveyor system that sprays a mixture of water and a sanitizing agent to disinfect the containers before they are sent into the food processing plant and opened.

Date: 2nd Dec 15

Mother Dairy- Delhi

Slide No: 25

Material Movement: Transport Dock  Loading dock should be solid structures,  built to match the height of the loading bed of transport vehicle.  Dock doors may be vertical lift doors, garage type up-and-o e

overhead doors

or roller shutter type doors.

Date: 2nd Dec 15

Mother Dairy- Delhi

Slide No: 26

Bore-well Head Protection Well Casing or Lining: All that part of the suction pipe or drop pipe of any well within 3 meters (10feet) of and below the ground surface shall be surrounded by a watertight casing pipe extending above the ground, platform or floor surface, as the case maybe, and covered at the top as herein provided.

Bore-well Head Protected with Solid Concrete

Date: 2nd Dec 15

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Slide No: 27

Initial & Periodic Medical Tests for Food Handlers Pre-Employment Medical Screening-

Annual Medical check up

 General health check-up

 General health check-up

 Urine test (Routine)

 Blood test (HB, CBC, ESR, RBS)

 Vision test

 Urine test (Routine)

 Blood test (HB, CBC, ESR, RBS)

 ECG

 Vision Test  Audiogram Testing

Date: 2nd Dec 15

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Slide No: 28

Innovations in Analytical Techniques Using bio-luminating molecules o Analysis without time-consuming sample preparation o Perform up to 112 different diagnostic tests on a 10 microliter (half a drop) biological sample o Sample is placed into the

a t idge’s port and the

cartridge is docked with the Data Communicator

o Light generating bio-luminating molecules are attached with DNA strands fixed on the base o These DNA strands are complementary with antibodies and DNA of Pathogens (Bio-markers) o When these DNA capture strands binds with respective biomarkers produces light spots o Extremely sensitive light sensor detect the light spots

Date: 2nd Dec 15

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Slide No: 29

Recent Emphasis on Food Security & Bio-Terrorism

Beware of New Employees/ Suppliers/ Security Personnel/ Drivers etc

Date: 2nd Dec 15

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Slide No: 30

Thank You

Date: 2nd Dec 15

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Slide No: 31