MODULE 1: Apply Food Safety and Sanitation

LESSON 1: Food Safety and Sanitation

Introduction

Imagine opening the refrigerator and you see a jar of your favorite food. You are
very excited and can’t wait to eat it. But as you opened the lid, the rancid smell
fills your nostrils and you scrunch your face and say, “Yuck!” The food is
expired. But you just bought it last week, you say in vain! 

Imagine opening the refrigerator and you see a jar of your favorite food. You are
very excited and can’t wait to eat it. You open the lid, it looks normal. You eat it
but feel something is off. You spend the next 3 hours at the toilet with an upset
stomach. 

You’d be upset, right? What happened to the food? Most of the time, these
problems arise when food safety and sanitation are neglected.

In this lesson, you will learn the concepts behind food spoilage and the
hazards it poses. This lesson will also cover a food safety management
system designed for eliminating hazards and controlling risks of food spoilage.
Towards the end, you will understand how you can prevent food spoilage by
maintaining personal hygiene and good grooming as a food processing
worker.

TOPIC 1: Food Spoilage

Food spoilage is any change in food which renders it unfit for eating.  It
can be due to contamination or natural decay which are both associated with
the growth of microorganisms. 
Types of Microorganisms
The growth of microorganisms is significantly attributed to the
availability of water. Just like in humans, water supports the growth of
bacteria, yeasts, and molds. You may have observed that most food processing
methods aim to decrease the concentration of free water by adding sugar or
salt or by allowing water to evaporate from the foodstuff. Food spoilage can also
be caused by reactions with oxygen, light, and chemical constituents of the
food. Furthermore, these causes can act together and increase the rate of food
spoilage. When spoiled food is consumed, it can lead to food-borne illnesses.

Common Food-borne Pathogens

Micro-organism Food-Borne Illness Sources
Campylobacter jejuni Diarrhea Raw/undercooked
meat or poultry,
untreated water
Clostridium botulinum Botulism Improperly canned
 food, surfaces of fruits
and vegetables, seafood
Escherichia coli Food poisoning, Raw meat,
Diarrhea, abdominal animal/human fecal
cramps, vomiting matter
Listeria monocytogenes Listeriosis Soil and water, dairy
products,
raw/undercooked meat
or poultry, seafood
Salmonella Salmonellosis Raw/undercooked
eggs, poultry, and meat
Staphylococcus aureus Food poisoning, Cooked foods high in
vomiting, toxic shock protein e.g. cooked
syndrome ham, salads, bakery
products, dairy
products
Shigella Shigellosis Contaminated water
and food, milk and
dairy products, salads
Toxoplasma gondii Toxoplasmosis Meat, primarily pork
Vibrio vulnificus Gastroenteritis, Raw/undercooked food
Primary Septicemia
Norovirus Diarrhea Infected persons or
contaminated food
Common Causes of Outbreaks of Food-borne Illnesses

TOPIC 2: HACCP

Under the Republic Act. 10611, the Department of Health shall ensure the
safety of all food processing and product packaging activities. For this reason,
the Food and Drug Center for Food Regulation and Research enforces HACCP
and other risk-based control measures in food processing. 

Hazard Analyses at Critical Control Points (HACCP) refers to a food safety

management system which identifies, evaluates and controls hazards which
are significant for food safety at critical points during a given stage in the food
supply chain.

Food Safety Hazards is any biological, chemical, or physical agent in food with
the potential to cause adverse effects on health.

Examples:

o Biological: bacteria, viruses, parasites, molds

o Chemical: pesticides, processing chemicals, drug residue, allergens
o Physical: bones, pits, glass, metal, hair

Risk is the result of exposure to a hazard.

How to Develop a HACCP Plan

There are five (5) steps that you must first take in order to develop the HACCP
Plan.

1. Assemble the HACCP Team. Ideally, the HACCP Team is composed of

members from different departments: Top Management, Purchasing, Food
Safety and Quality Assurance, Production, Maintenance, and Sales.

2. Describe the product. What are the raw materials? What are the product
specifications? What should be the conditions for storage?

3. Specify intended use and target consumers. Who can consume the product?
Who should not?

4. Draw a flow diagram to describe the process steps. Begin with the supplier
and take note of every step that the product undergoes up until distribution.

5. Visit the plant for on-site confirmation of flow diagram.

TOPIC 3: Personal Hygiene and Good Grooming

The best way to avoid contamination is to prevent it. Since you will be in direct
contact with food, your role in keeping food contamination-free is essential.
Here’s how you can practice personal hygiene and good grooming:

Proper Handwashing
Proper Handwashing is crucial in preventing contamination.
 Task Sheet Sheet 1.1-1

Title: Developing HACCP PLAN

Performance Objectives:

Given 2 hours of planning time and with appropriate tools and equipment, the
trainees Should be able to develop a HACCP Plan following the standard procedures.

Tools and Supplies/Materials:

Pen, paper

Equipment:
 Multimedia gadgets

Steps/Procedures:

1. Assemble the HACCP Team. Ideally, the HACCP Team is composed of

members from different departments: Top Management, Purchasing, Food
Safety and Quality Assurance, Production, Maintenance, and Sales.

2. Describe the product. What are the raw materials? What are the product
specifications? What should be the conditions for storage?

3. Specify intended use and target consumers. Who can consume the product?
Who should not?

4. Draw a flow diagram to describe the process steps. Begin with the supplier
and take note of every step that the product undergoes up until distribution.

Assessment Method:

 Portfolio
 Questioning

Performance Criteria

CRITERIA YES NO
Did you….
1. Assemble the HACCP Team?
2. Describe the product?
3. Specify intended use and target
consumers?
4. Use appropriate non-verbal-
communication.*
5. Draw a flow diagram to describe
the process steps?
LESSON 2: Food Manufacturing Practices

Introduction

An effective food processing worker possesses knowledge and skills in food

processing techniques. Aside from that, he/she must also be aware of the
supervisory aspects of working in the food processing industry.

In this lesson, you will learn about management practices that aim to (1) meet
quality standards, (2) ensure safety of the workers, (3) maintain cleanliness in
the workplace, and (4) implement proper waste disposal.

TOPIC 1: Good Manufacturing Practices (GMP)

DOH Admin. Order No. 154 s. 2004

TOPIC 2: Occupational Safety and Health

Every 15 seconds, a worker dies from a work-related accident or disease. Every

day, 860,000 workers all over the world suffer non-fatal occupation injuries.
This is according to a report from the International Labour Organization.  

But accidents are highly-preventable. Every worker has a right to safety. Just
like food safety, occupational safety can be ensured by eliminating hazards,
controlling risks, and by being mindful.
Personal Protective Equipment
Proper Handling of Cutting Tools

Fire Safety
The following are the measures you can take to ensure fire safety:

 Inspect wires, plugs, gas range, and other equipment on a regular basis.
  Extinguish the fire! Pull pin. Aim at the base. Squeeze handle. Sweep
from side to side.

 Not all fires are the same. Use the right Class of fire extinguisher for
every type of fire.

o Class A - ordinary combustibles such as wood and paper

o Class B - combustible liquids and gases such as alcohol, LPG,
grease
o Class C - electrical fire
o Class D - combustible metals such as aluminum

5S of Good Housekeeping

5S of Good Housekeeping is another management approach for

productivity and quality that focuses on maintaining orderliness and
cleanliness in the workplace. It is derived from the Japanese words: seiri,
seiton, seiso, seiketsu, and shitsuke.

 Distinguish between what is needed and not needed.

 Secure a place for everything and everything should be in its place.

 Clean, and look for ways to keep it clean and organized.

  Establish guidelines and monitor.

 Commit to a clean and organized workplace. Stick to a cleaning

schedule.

TOPIC 3: Cleaning and Sanitizing Equipment, Tools, and Utensils

 Keeping things clean in the workplace prevents food spoilage and the
spread of food borne diseases. By cleaning and sanitizing equipment,
tools, and utensils, you can ensure the safety of the food being handled
as well as the safety of those working in the area. 

 Cleaning and sanitizing are two separate processes.

Cleaning
Cleaning means to remove unnecessary and unpleasant matter like
garbage, food waste, and grease. Cleaning equipment differs from cleaning
tools and utensils. Equipment is usually bigger and involves electrical wiring.

It is always best to refer to the manufacturer’s instructions when cleaning and

sanitizing equipment. However, there are general rules that must be observed
when cleaning equipment:

1. Make sure that the power is turned off and power cords are unplugged.

2. Gas equipment should be turned off.

3. Proper protective clothing must be worn when cleaning equipment that

deals with chemicals.

4. Ventilation should be provided.

 Detergents remove dirt and grease but they do not kill bacteria and other
microorganisms. This is why cleaning is followed by sanitizing.

Sanitizing
Sanitizing involves the use of a chemical agent to reduce the number of
bacteria to safe levels.
 

Sanitizing generally consists of three steps:

1. Soaking tools and utensils in hot, clean, and potable water (75 °C) for at
least 2 minutes.

2. Immersing in sanitizing solution for at least one minute.

3. Leaving tools and utensils to air dry in a draining rack.

 Preparing a Sanitizing Solution

1 Teaspoon Bleach + 1 Gallon Water

Tips in Cleaning and Sanitizing Tools

1. Pre-cleaning and main cleaning can be combined if there is only light

contamination.

2. If using a hose to wash equipment, use high-volume, low-pressure hose

in order to prevent splashing and spraying pathogens onto surfaces. 

3. Sanitize items that come into direct contact with food or with the hands
of the food handlers.

4. Sanitizers work best at the correct dilution. Be sure to check the label
before applying them.

5. Always label chemical agents.

6. Store chemical agents and cleaning materials away from where food is
being handled.

7. Be sure to clean and dry the cleaning equipment.

TOPIC 4: Proper Waste Disposal

In this topic, you will learn about two common types of waste in food
processing. You will then learn how to manage these wastes. Towards the end,
you will learn about the Food Recovery Hierarchy Model which illustrates
different steps on how to reduce waste. 
Chemical Waste Management
Chemical waste is any solid, liquid, gaseous matter that when improperly
managed or disposed of may pose harmful effects on the environment and to
the surrounding community. Examples:

 Used oil

 Contaminated syringe

 Denatured alcohol

 Industrial cleaners

 Pesticides

 Batteries

 Degreasing solvents

How to Dispose of Chemical Waste:

1. Identify the type of chemical waste.

2. Select appropriate container.

3. Label chemical waste. Include chemical name, quantity, the date the
waste was generated, place of origin (what part of the production line,
room number), assigned personnel. For mixtures, include each chemical
along with their weight or volume.

4. Store in appropriate cabinets and wait for the Pollution Control Officer to
collect.

Republic Act 6969

DENR AO 36 s. 2004
Food Recovery Hierarchy

Activity

Direction: Identify each waste. Choose the answers in the box

provided below.

Recyclables Trashes Food Materials