ontinue trading. The capability of exporters in developing countries to trade internationally depends critically on their ability to meet stringent food safety standards imposed by trading partners. These standards require more than the basic quality standards of the past. Suppliers must now take into consideration food safety issues such as the safe and appropriate use of agrochemicals, worker health and hygiene, sanitation, water quality, waste disposal as well as social and environmental impact along the entire value chain. These requirements can be met by observing Good Manufacturing Practices (GMPs). GMPs are a set of procedures that ensure food is processed in a manner that meets foontinue trading. The capability of exporters in developing countries to trade internationally depends critically on their ability to meet stringent food safety standards imposed by trading partners. These standards require more than the basic quality standards of the past. Suppliers must now take into consideration food safety issues such as the safe and appropriate use of agrochemicals, worker health and hygiene, sanitation, water quality, waste disposal as well as social and environmental impact along the entire value chain. These requirements can be met by observing Good Manufacturing Practices (GMPs). GMPs are a set of procedures that ensure food is processed in a manner that meets foontinue trading. The capability of exporters in developing countries to trade internationally depends critically on their ability to meet stringent food safety standards imposed by trading partners. These standards require more than the basic quality standards of the past. Suppliers must now take into consideration food safety issues such as the safe and appropriate use of agrochemicals, worker health and hygiene, sanitation, water quality, waste disposal as well as social and environmental impact along the entire value chain. These requirements can be met by observing Good Manufacturing Practices (GMPs). GMPs are a set of procedures that ensure food is processed in a manner that meets fo
Establishment: Design and Facilities
Operations must maintain a plant schematic, which serves as a crucial reference for operators, customers, and government regulators Alongside this, processors are required to develop a process flow diagram that outlines the key features of each processing step.
Depending on the environment and the operations, the facilities should be so located, designed and constructed to ensure that:
• facilities are separated physically (e.g spatially or solid wall) from any other activities and in conformity with national standards (e.g Town and Country Planning Act)
• the design and layout permit appropriate loading, off- loading, maintenance, cleaning, disinfections and minimize airborne contamination
• building is constructed to facilitate adequate ventilation (see Appendix II)
• building is of suitable size, design and construction to permit unobstructed placement of equipment, orderly storage of material, sanitation operation and maintenance
• building surfaces and materials such as floors, walls and ceilings should be constructed of smooth, easily cleanable surfaces and should be suitable, durable and easily maintained
• there is a unidirectional flow of operations to prevent cross-contamination(see Figure 1.1)
Figure 1.1: Unidirectional flow of operations
Packaging Facility
The following shall be implemented to minimize the potential for contamination associated with the surroundings:
To minimize the risk of contamination, it is essential to keep grounds clean and free of garbage and debris Proper grading and drainage should be implemented to prevent water pooling, and vegetation must be managed effectively to deter pest harboring.
To prevent cross-contamination of foods stored or processed at the facility, it is essential to implement preventative measures when there are nearby activities that differ in nature These measures should address potential biological, chemical, or physical hazards.
3 Waste facilities must be well maintained and designed to prevent contamination of the product or packaging material.
Waste containers must be properly covered, secured, clearly identified and emptied in a timely manner.
4 Roads, yards and parking lots must be maintained so they do not pose a risk of contamination to any produce on site.
5 Equipment stored on the grounds must not provide sources of contamination and or pest harbourage.
To minimize odors and prevent pest attraction, it is essential to store, convey, and dispose of garbage and processing waste properly This practice also protects food, food-contact surfaces, water supplies, and ground surfaces from contamination.
An established schedule for garbage disposal must be in place and recorded.
7 Measures must be in place to adequately secure facilities.
Effective internal design and layout of packaging facilities are essential for maintaining good sanitation practices and preventing cross-contamination during processing and handling To minimize contamination risks, specific measures must be implemented within the establishment.
1 Ceilings and overhead fixtures should be constructed and finished to minimize the build-up of dirt and the shedding of particles.
2 Ensure that all lighting fixtures and electrical outlets in pro- cessing facility and warehouse areas are shielded.
3 Provide adequate lighting in all processing and support areas, including hand-washing areas, dressing and locker rooms, restrooms, and all areas where produce are examined, processed or stored.
4 Walls and partitions should have smooth surfaces up to a height appropriate to the operations.
All openings, such as windows and doors, must be designed for easy cleaning and constructed to reduce dirt accumulation Additionally, where needed, they should include removable and cleanable insect-proof screens Doors should feature smooth, non-absorbent surfaces that facilitate straightforward cleaning and disinfection.
6 Facility must be rodent-proof.
7 Floors should be of concrete or other impervious material and constructed to allow adequate drainage and cleaning. Where floor meets wall it should be curved.
8 The use of glass and non-food-grade plastic material is prohibited in the post-harvest facility
9 Provide adequate space and layout to facilitate production and prevent accidental cross- contamination of produce (see Figure 1.1)
10 Ensure that drip or condensation from fixtures, ducts and pipes does not contaminate food, food-contact surfaces, or food-packaging materials.
Working surfaces in food preparation areas must be constructed from smooth, non-absorbent materials that are inert to food, detergents, and disinfectants during standard operations Surfaces that directly contact food should be well-maintained, free from stripping or flaking, and designed for durability and ease of cleaning.
12 Only food-grade paint must be used on machineries, walls and ceilings Corrosion should be prevented.
13 Material used for food-contact surfaces should be food grade, non-absorbent, easy to clean and able to withstand repeated cleaning.
14 All equipment and utensils should be checked regularly to ensure proper functioning; secure any loose parts
15 Avoid oil leaks and overlubrication of machinery to avoid food contamination Use only food-grade oil and lubricants on machinery.
16 A comprehensive machinery and equipment-cleaning and maintenance programme should be in place.
17 Locate and operate fans and other air-blowing equipment in a manner that minimizes the potential for contaminating foods, packaging materials, and contact surfaces.
All areas necessary for food processing, equipment cleaning, utensil sanitation, and employee hygiene must have access to potable water supplied at adequate pressure.
19 Appropriate systems for potable water (hot and cold) storage and use, should be available whenever necessary to ensure the safety and suitability of food.
Pest control
All animals, including mammals, birds, reptiles, and insects, can contaminate processing environments by harboring or acting as vectors for pathogens like Salmonella spp and E coli To mitigate contamination risks from pests such as rodents and insects, each facility must implement a pest control program managed by a certified pest control operator, with proper record-keeping.
The following should be implemented to minimize the potential for contamination within the packing facility and the surrounding grounds:
An effective pest control program requires regular monitoring of both affected and treated areas to evaluate its success It is essential to have a trained staff member oversee the implementation of the program and collaborate with external pest control contractors when necessary Additionally, maintaining detailed logs of pest control treatments, including applicator information and results, is crucial for tracking progress and effectiveness.
2 Pest control programmes should be administered by a certified pest control operator.
3 No animals shall be allowed in any area of a food facility.
To maintain a pest-free environment around the packing facility, it is essential to clear the grounds of all waste, litter, and improperly stored garbage Regularly cutting weeds low will help deter pests like rodents and reptiles Additionally, removing unused and inoperative equipment will eliminate potential hiding spots for these pests.
5 Clean and sanitize daily to remove remnants that attract pests in and around the packing facility
6 Maintain adequate surface drainage to reduce breeding places for pests
Water treatment and disposal systems must be managed to prevent them from becoming sources of contamination or attracting pests Special care is essential, particularly if the facility is located near an unmaintained area.
8 Exclude pests by blocking areas, such as holes in walls, doors, flooring and vents that allow entrance into the facility Screens, wind curtains and traps may be used
Pest control procedures must include detailed logs that specify the locations of outdoor bait stations and glue boards, as bait stations are prohibited inside the plant It is essential to document trap and bait station locations with a schematic map, and these areas should be inspected regularly to monitor for activity, with records maintained accordingly Traps require routine cleaning and maintenance, and any dead pests must be promptly removed and disposed of to avoid contamination or infestation Additionally, ensure that the baits used in the bait stations are food safe.
It is essential to keep detailed records of all pesticides utilized at the facility, including safety data sheets and recommendations Documentation should encompass all pesticide applications, specifying the trade name, active ingredient, concentration, date of application, and the name of the applicator Additionally, all pesticide applicators are required to undergo training and certification.
• All pesticides shall be used in accordance with manu- facturer’s label recommendations and local regulations
• After pesticide application, all food-contact surfaces should be cleaned and properly sanitized
Proper disposal of unused post-harvest pesticides must follow the manufacturer's label instructions and adhere to local regulations Constructing a charcoal pit is recommended for the safe disposal of post-harvest fungicides.
Pesticide containers should be disposed of according to the Pesticide Control Authority (PCA) recommendations
Charcoal: Top layer, absorbing chemical disposed
Mixed Layer: Clay, sand, marl This slows the infiltration rate and aids effective charcoal absorption.
Clay: This is the first layer of the bio-bed Clay pre- vents the Infiltration of chemical into groundwater by creating an imperme- able membrane.
Charcoal: Bottom layer, captures chemical per- colation from the mix layer
A basic disposal system can be created using a 45-gallon plastic drum modified with a bottom outlet, featuring alternating layers of compacted organic materials like dried banana leaves or grass and charcoal It is essential to position the disposal system near the area of chemical usage for optimal efficiency.
The following is strictly prohibited:
• Dumping unused pesticide material into a septic system or drainage ditch
• Burning of empty or partially empty pesticide containers
• Burying of empty unrinsed or partially empty pesticide containers
• Mix pesticide according to manufacturer’s recommendation
• Dispose of unused portion of pesticide according to manufacturer’s guidelines
• Triple-rinse empty pesticide containers Contact the relevant authorities (Pesticide Control Authority) for the disposal of pesticide containers
Figure 1.4: Waste pesticides disposal drum
Sanitary facilities and controls
Water can harbor harmful microorganisms like coliforms, Salmonella spp., Vibrio cholerae, and Shigella spp Even minimal contamination can lead to food-borne illnesses Consequently, it is essential that water used in food processing adheres to national potable water standards.
All water should be tested at least once a year for microbes, pesticide residue and heavy metals
The following practices when assessing water quality and in applying controls to minimize microbial food safety hazards shall be followed.
1 All water used for processing or contact surfaces or used in the facility for employee services must be potable and meet local regulations for drinking water.
2 If self-chlorination of water is done, the concentration of residual chlorine must be monitored daily.
3 There must be no cross-connections between potable and non-potable water supplies A plumbing diagram should be on file to verify this.
To ensure water safety, all hoses, taps, and piping systems must be designed to prevent back-flow or siphonage of standing water, and backflow prevention devices should be installed Additionally, a map detailing the locations of these back-flow devices in the water lines must be readily available, and it is essential that piping systems do not contain any 'dead ends'.
5 For municipal sources, a certificate of analysis must be obtained and must form a part of your records
Operators using non-municipal water sources must ensure compliance with national potable water standards through a testing program conducted by an accredited third-party laboratory.
Regular inspections of water harvesting equipment, including chlorine injectors, filtration systems, and back-flow prevention devices, are essential for maintaining operational efficiency and water quality Additionally, a detailed map indicating the locations of this equipment should be readily accessible.
8 For pre-cleaning/sanitization of produce, water has to be changed frequently in accordance with an established schedule
9 The water supply (hot and cold) must be adequate for peak usage, and for clean-up requirements.
The sewage disposal system must comply with national standards and receive approval from relevant agencies, including the National Environment and Planning Agency (NEPA) and the National Water Commission (NWC).
1 Each processing facility must provide employees with adequate, readily accessible toilet facilities.
2 National health standards (Ministry of Health) require a ratio of one toilet to 25 persons.(Please note: other certi- fication programs may require lower ratios)
3 Signs must be posted showing where restrooms are located Signs must also be posted in restrooms instructing users to wash their hands after using the toilet
Toilet facilities should not have doors that open directly into operational areas unless protective measures, like double doors or positive airflow systems, are implemented to prevent contamination Additionally, these facilities must be equipped with self-closing doors.
Toilet facilities must be maintained in a clean, neat, and well-repaired condition Basins, toilets, urinals, walls, and floors should be cleaned and sanitized at least once daily It is essential to maintain a bathroom cleaning schedule that is visibly displayed.
6 There must be adequate waste disposal Disposal bins must be covered and ‘hands-free’ operated.
7 Toilet facilities must be adequately supplied with toilet paper, soap, hand sanitizer and paper towels or air-dryers
Figure 1.5: Signage for restrooms for drying hands Multiple-use towels must not be used Toilet facilities must be checked daily and restocked as necessary to ensure adequate supplies.
Worker health and hygiene
Food handlers play a crucial role in preventing contamination during food preparation Healthy individuals are more productive and less likely to spread illness, ensuring safer food for everyone The responsibility for food safety lies with those who work directly with food, as they can inadvertently transfer pathogens throughout the entire food chain, from farm to fork Maintaining proper personal hygiene and following correct food handling practices are essential to mitigate these risks.
The objective of the personal hygiene principles is to reduce or elim- inate the risk of contamination by persons who are in contact with food
Effective employee training in food-handling practices is essential for ensuring food safety, focusing on sanitation and worker hygiene All staff, including those indirectly involved like equipment operators, buyers, pest-control operators, and visitors, must adhere to established hygienic standards Additionally, personnel tasked with maintaining facility sanitation should receive proper training.
The following steps should be taken to minimize potential contami- nation associated with employees and visitors to your facility:
1 Employees must be properly attired:
• Must wear suitable protective clothing that includes no shorts, sleeveless shirts or vests Hair must be covered and properly secured.
• Outer garments must be clean to protect against contami- nation of produce or packaging materials
Please wash your hands after going to the toilet
• Garments should have no shedding fibers.
• Footwear must be appropriate and in good repair, no open-toed shoes are allowed
• A plastic apron is recommended when handling water or dirt
• Workers should not wear their coveralls or aprons in areas other than the operation area
• Clothes and personal effects must be kept in appropriate areas exclusively for that purpose (dressing room)
• Food of any kind must not be kept in the dressing room/locker to avoid attracting pests.
• Procedures for the washing of protective clothing should be established and monitored.
2 All employees in the packing facility must have a valid Food Handlers Permit from the Ministry of Health.
All employees are required to wash their hands with soap and potable water before starting work, after using restrooms, when returning from breaks or lunch, and whenever their hands may be soiled While hand sanitizers should be used after washing, they are not a replacement for proper hand washing.
To ensure food safety, hair must be securely tied back and protected with a hair net or cap Food handlers should maintain a well-groomed appearance, avoiding beards, mustaches, or sideburns, and if present, these facial hairs should be completely covered.
5 No food, candy, chewing gum or lozenges should be allowed in the operation areas
6 Personal items such as pens, pencils and cell phones must be stored in lockers or other designated locations outside the operation areas.
All jewellery, except for plain wedding bands covered by gloves, must be removed before entering the packing facility Hairpins and similar items that could contaminate food are prohibited in operational areas Additionally, fingernail polish and false nails are not allowed; nails should be kept short and clean to minimize the risk of pathogenic microorganisms and to prevent damage to produce.
Employees must wear impermeable gloves that are cleaned or sanitized at the start of their shift, after returning to their workstation, or whenever they become soiled Any damaged gloves should be discarded and replaced promptly.
Employees exhibiting symptoms of infectious diseases or having open sores must not handle food or packaging materials Supervisors are responsible for monitoring these health conditions Additionally, any cuts or wounds should be properly covered with waterproof dressings to prevent food contamination.
10 Visitors to packing facility should wear protective clothing and adhere to the same personal hygiene provisions as employees.
A visitors’ log must be kept.
11 The use of glass items of any kind should be avoided in the operation areas.
Before using the restroom, employees must take off their hair covers, gloves, and aprons After using the restroom, it is essential to follow standard handwashing and sanitizing procedures before putting on protective gear again or handling produce.
Smoking is strictly prohibited within the facility, and 'no smoking' signs should be prominently displayed throughout the packing area Additionally, actions such as spitting, chewing, eating, sneezing, or coughing near food are unacceptable due to the heightened risk of contamination A designated area outside the packing facility may be established for these activities.
To prevent cross-contamination with extraneous matter or pathogens, personnel working in cleaning and washing areas must change into appropriate attire before entering other areas of the facility Additionally, forklifts and equipment used in 'dirty' areas should be restricted from moving into processed product areas to avoid contaminating finished products.
Hand washing
Hand washing is the simplest and most effective food safety practice that any facility can adopt It is essential for workers to receive thorough training in proper hand washing techniques, regardless of how straightforward the process may seem.
Thorough hand washing is crucial for employees in the packaging facility, as it must be done before starting work and after using the restroom A proper hand-washing routine, which includes seven simple steps, should be followed before and after the workday, as well as after eating, drinking, or smoking.
1 Wet hands with potable water
2 Apply antibacterial liquid soap from dispenser
3 Scrub hands and fingernails (for 20 seconds)
4 Rinse off soap thoroughly with potable water
5 Dry hands with disposable paper hand towel or with hands-free dryer
6 Discard used towels in trash bin
Figure 1.7: No - smoking sign should be posted at strategic locations
Figure 1.8: Proper hand-washing steps
Every food facility is required to have a well-equipped hand-washing station that includes potable running water, antibacterial soap, hand sanitizer, and sanitary disposable paper towels or hand dryers It is essential to check these stations daily and restock them as needed to maintain sufficient supplies.
• Restroom fixtures, such as water control valves, should be of a type designed to minimize recontamination Hands-free or sensing systems are preferred.
Clear and visible signs should be displayed to instruct employees to wash and sanitize their hands before starting work, after breaks, and whenever their hands may be dirty or contaminated These signs must be strategically placed in restrooms, processing areas, and any locations where food is handled.
• Provide and maintain waste receptacles in ways that protect against food contamination.
Chemicals
Improper chemical use can jeopardize employee safety and food quality To mitigate risks related to chemical handling, it is essential to implement recommended practices and provide thorough employee training.
Employees responsible for handling hazardous materials must receive proper training and sign a training record sheet that includes the date, trainer's name, training duration, and topic It is essential to maintain records of chemicals, their usage, training, and authorization.
1 All chemicals must be properly packaged and labeled.
2 Chemicals must be stored in a secured and enclosed area away from operational areas so as not to contaminate food, food-contact surfaces or food-packaging materials
For safe handling, smaller chemical packages should be clearly labeled with the chemical name, quantity, and usage instructions It is crucial to avoid repackaging chemicals in food containers or drink bottles to prevent contamination.
3 Procedures and controls should be established for the securing, checkout and return of chemicals to avoid unauthorized use.
4 Post-harvest facilities should maintain a chemical inventory and safety data sheets
Effective chemical control procedures must be established, which include a comprehensive list of all chemicals utilized within the facility, guidelines for their usage, handling, storage, and labeling, as well as protocols for the distribution and management of these chemicals Additionally, it is essential to maintain up-to-date Safety Data Sheets and ensure the proper disposal of empty chemical containers and waste chemicals.
6 Cleaning and sanitizing agents shall meet appropriate regulations, and documentation shall be obtained from
7 Only approved chemicals shall be used on food and food contact surfaces and for cleaning and sanitizing
Proper disposal of empty containers and waste must align with local regulations specific to the chemical involved It is crucial to avoid storing empty containers in locations that could risk contaminating food, food packaging, or water sources Additionally, it is essential to follow manufacturers' guidelines for the use of chemicals in or near food-contact areas.
9 Empty chemical containers must never be reused for any purpose.
10 Records must be kept detailing chemical usage, including date of application, location, dosage rate, purpose, etc
Receiving Fresh Produce
Operators must adhere to their Standard Operating Procedures when receiving fresh produce for each specific commodity It is essential to implement supplier verification procedures, which include checking the farmer's receipt, dealer's license, inspecting transportation, and reviewing invoices.
Supplier Verification
The safety of a commodity for export depends not only on what is controlled within the packing house but also depends on the source from which goods are received.
Effective supplier verification and supply chain management are crucial for operators Exporters must source goods from farmers and suppliers (middlemen) who adhere to Good Agricultural Practices.
A Documentation of procedures for receiving produce
B Records of produce received for packing
C Supplier verification activities to ensure that appropriate controls are conducted and documented.
Produce Cleaning and Treatment
Fresh produce should be processed (cleaned, treated, etc.) to prevent contamination from microorganisms and other substances Clean- ing/treatment methods to be employed will vary according to the
Use approved suppliers Determine supplier verification activities
Verify supplierDocument the activities Figure 2.1: Supplier Verification Process
2.3.1 Proper cleaning and sanitizing procedures for fresh produce
Cleaning and sanitizing are essential processes to eliminate biological, chemical, and physical hazards from fresh produce The sanitizing methods differ based on the type of commodity, such as vegetables, ground provisions, fruits, herbs, spices, and condiments A comprehensive cleaning procedure should encompass specific steps tailored to each commodity class.
• Pre-clean by removing soil and debris by dry-cleaning for example brushing
• Wash with potable water to remove surface dirt
• Sanitize with approved food sanitizing agent (usually chemical disinfectant) Follow SSOP Always clean and sanitize containers before and after use.
• All containers must be in good repairs
• Do not use containers intended for fresh produce for any other purpose.
• Use separate containers in each step of the process to prevent cross-contamination Label or colour-code containers
Cooling
Cooling methods are essential for prolonging the shelf life and preserving the quality of fresh fruits and vegetables By effectively removing excess heat, these procedures inhibit the growth of pathogens, ensuring safer produce Typically, cooling is achieved using air, water, or ice as the cooling medium.
When implementing cooling methods, it is crucial to prevent contamination or damage to the produce by the cooling medium Two primary hazards linked to cooling procedures must be carefully managed.
• Biological – water- and ice-cooling methods may present a higher risk of contamination Water and ice must be of potable, microbial-free quality and stored under sanitary conditions.
• Chemical - contamination of produce by refrigerants, cooling and sanitizing agents should be avoide
Packing
To minimize contamination and maintain quality of produce, packing should be done as soon as possible after processing
• Produce should be packed in clean and new containers
• Packaging design and material should provide adequate protection for products to minimize contamination, prevent damage and accommodate proper labelling.
Design and maintain packing surfaces and equipment to minimize produce damage and contamination; no wooden or painted surfaces should be used The design should also facilitate cleaning and sanitizing
Packaging containers may include crates, cartons, bags, palletised containers and bulk bins
Figure 2.2: Yams packed with packing material (coir)
• Packaging material (such as sawdust and paper) should be non-toxic and not pose a threat to the safety and suitability of produce under specified storage
• Printed media MUST NOTbe used as a form of packaging material.
• Areas designated for storage of waste must be at least 4.5 m (15ft.) away from the packing facility and placed so as to minimize the contamination of food.
• Waste containers inside the packing facility must be clearly labelled, conveniently placed and tightly covered when not in use (see figure 3.1).
• Remove all waste products frequently include waste collection procedures in daily cleaning activities;
It is recommended that organic and inorganic waste should be separated for recycling purposes.
Labels
Food labels must clearly indicate the content and quantity of the food inside, excluding any wrappers or packaging materials For minimum labeling standards, refer to the Bureau of Standards Jamaica (BSJ) Essential information required on labels includes specific details about the product.
• The name of the produce
• Name and address of the exporter of the produce
• Lot identification and packer’s code
Labels placed directly on product should be food-grade quality
Figure 2.3: Sample label used on packages for export
Storage
Adequate facilities should be provided for the storage of produce,packing material and chemicals
• Store fresh produce in a clean location using an organized system Storage facilities should have temperature and humidity control devices where necessary.
• Adjust and regulate temperature and humidity according to a commodity's specific requirements.
COMMODITY AMBIENT STORAGE ( C) O COLD STORAGE ( O C)
Mangoes (Julie, East Indian, etc.) 18-25 12-14
Yams (Yellow, Lucea, Negro, etc.) 21-24 15
Table 2.1: Recommended storage temperatures for some fresh produce
• Storage area must be kept clean, dry and free of trash, pests and animals;
• Storage area should be separated from areas with hazardous material, e.g chemicals;
To prevent contamination and facilitate cleaning and inspections, it is essential to store containers and packing materials off the floor Ensure there is a minimum space of 60 cm (2 ft.) between the containers and the wall to allow for proper air circulation and easy access.
• Materials used for packaging, such as sawdust, wood shavings, and paper sleeves should be properly stored and kept in covered containers.
• Storage area should be properly secured to avoid possible contamination and unauthorised access.
Waste products from processing fresh produce, such as trash, cuttings, leaves, and pods, can lead to contamination Decomposing waste may spread microorganisms and produce unpleasant odors, attracting pests that can carry pathogens To ensure safety, it is essential to follow Good Manufacturing Practices (GMPs) for the daily management of waste in packing facilities.
A specific location should be established for the temporary storage of waste, both internally and externally It is essential that all employees receive training to guarantee proper waste handling and adherence to collection procedures.
Figure 3.1: Sample waste disposal bins that should be used in the packing facility
3 WASTE MANAGEMENT, CLEANING AND SANITATION
• Areas designated for storage of waste must be at least 4.5m (15ft.) away from the packing facility and placed so as to minimize the contamination of food.
• This area should be designed to facilitate easy cleaning and removal of the waste to prevent accumulation of residues, pest harbourage and bad odours
• A schedule of frequent waste disposal mustbe established
• Waste container must be clearly labelled and covered at all times.
• Waste containers inside the packing facility must be clearly labelled, conveniently placed and tightly covered when not in use
• Remove all waste products frequently and include waste collection procedures in daily cleaning activities;
• It is recommended that organic and inorganic waste should be separated for recycling purposes
To reduce the risk of produce contamination, all food-contact surfaces must be properly cleaned and sanitized before and after use and records kept
Daily cleaning of the packing facility is essential to prevent food contamination, with a focus on areas that directly contact food Effective cleaning can utilize a combination of physical methods, such as heat, scrubbing, turbulent flow, and vacuum cleaning, as well as chemical methods involving detergents, alkalis, or acids It is important to implement appropriate cleaning procedures to ensure food safety.
• Removing gross debris from surfaces
• Applying a detergent solution to loosen soil and bacterial film and hold them in solution and suspension
• Rinsing with potable water to remove loosened soil and residues of detergents
To effectively reduce microorganisms, it is essential to treat all food-contact surfaces with sanitizing agents However, sanitizing should not replace proper cleaning; all surfaces must first be cleaned to eliminate dirt, dust, food residues, and biofilm, as their presence can diminish the effectiveness of sanitizers.
When selecting a sanitizer for food-contact surfaces, the following considerations should be borne in mind:
• Type of surface being sanitized
• Effectiveness of sanitizing agent against certain pathogens
• Sanitizers must be food safe
Dry cleaning and other suitable methods should be employed to effectively remove and collect residues and debris Disinfection is necessary when required, followed by rinsing, unless the manufacturer's instructions scientifically indicate that rinsing is unnecessary.
Improper handling of cleaning tools can lead to significant biological hazards To prevent the growth of microbes, it is essential to wash and sanitize all cleaning tools after each use and to replace them regularly.
• This area should be designed to facilitate easy cleaning and removal of the waste to prevent accumulation of residues, pest harbourage and bad odours
• A schedule of frequent waste disposal should be established and records kept
Thermal treatment typically utilizes hot water or steam, although dry heat can also be employed It is essential to maintain specific time and temperature conditions during the heat exposure for effective results.
Chemical sanitizers are compounds designed to eliminate or significantly decrease undesirable microorganisms Among these, chlorine-based sanitizers are the most widely utilized in food applications.
3.6 Handling and Use of Sanitizing Agents
• Storage of sanitizers must be separate from fresh produce and packing material;
• Employees should be trained in safe handling and use of sanitizers.
• Carefully follow specific manufacturer’s handling and usage instructions for each product.
• Employees should wear protective gear, such as goggles and gloves, while handling and working with sanitizers.
• Handling and disposal of sanitizers should be in accordance with national standards; refer to the PCA.
Workers involved in food operations must receive appropriate training in food hygiene to ensure safe handling practices Effective employee training in sanitation and hygiene is essential for the success of food safety programs Implementing a documented training program that focuses on general sanitation and hygiene practices can significantly minimize contamination risks It is crucial that all training programs are regularly evaluated and updated to comply with food safety requirements.
All training sessions must be thoroughly documented and filed, with all trainees required to sign the provided register It is essential that personnel working in critical areas, such as the handling of post-harvest chemicals, possess basic numeracy and literacy skills.
Some of the areas of training should include:
Effective transportation of fresh produce is crucial in minimizing microbial contamination and spoilage Raising awareness among personnel involved in the transportation process is essential Proper protection of produce during transit is necessary, with the choice of conveyances or containers tailored to the specific type of food and transport conditions Implementing appropriate measures is vital to safeguard food from potential contamination and damage.
Operators and food handlers responsible for transporting fresh produce should prioritize careful management of product transportation throughout the entire process This involves ensuring proper packaging during the transfer from the field to packing and cooling facilities, as well as during distribution.
5.1 Guidelines for Transport of Fresh Produce
• Use only containers or vehicles designed and designated for transport of produce
• Inspect containers and vehicles for cleanliness before loading, and insist on cleaning if necessary.
• Vehicles and containers should be dry except for refrigerated units
• Enclosed transport units are highly recommended to avoid pest access and contamination.
• Avoid using containers previously used to transport commodities such as meat, eggs, fish manure or live animals If these containers are used they must be properly cleaned and sanitized.
• Vehicles and containers should be cleaned and sanitized after each load.
• Maintain proper temperature during transportation to ensure produce quality and food safety.
• Ensure that produce is loaded carefully in order to minimize damage
• Ensure that transporters maintain integrity of the lot identification and trace-back system in use.
• Make sure that all personnel involved in the transport- ation process practise proper hygiene and are properly attired.
• Records of transportation process/log must be kept.
• Temperature recorders should be placed in all refrigerated fresh-produce vehicles and containers
• Refrigeration and humidity control units should be checked for proper functioning before each trip
• Make sure temperature and humidity are set according to specific commodity requirements
• Minimize time between removal from cooling storage and loading into refrigerated container.
• Allow for adequate air circulation within the transport- ation unit by proper stacking
• Prevent produce contamination by condensation water from refrigeration units;
• Maintain temperature and humidity control during transport and record all data.
• Provide frequent training in temperature control to personnel involved in transportation.
6 TRACE BACK AND PRODUCT RECALL
Trace-back refers to the ability to trace food products back to their original sources, such as growers and exporters While having a trace-back system alone cannot prevent food safety issues or recalls, it is a crucial aspect of good agricultural and manufacturing practices that can help mitigate future problems The insights gained from trace-back investigations are valuable for identifying and eliminating hazardous pathways An effective trace-back system pinpoints the source of contamination to specific regions, packing facilities, or farms, rather than broad inventory categories This capability fosters confidence among regulators, customers, and consumers, demonstrating that the food manufacturing industry effectively manages all stages of production and distribution.
A comprehensive trace-back system must have a process of handling complaints, investigations and product recalls.
A complaint serves as a crucial trigger for activating a trace-back system, encompassing any communication—written, electronic, or oral—that points out deficiencies in a product's identity, quality, or safety An efficient complaint-handling system is vital for quality control, requiring exporters to evaluate every complaint received This evaluation should include thorough investigation and analysis, leading to corrective actions when necessary Ultimately, the process should determine the validity of the complaint, identify its cause, and implement measures to prevent future occurrences, as complaints must never be overlooked.