EPF 3107

MICROBIOLOGY AND SAFE

FOOD PROCESSING
Department of Food Process and Engineering
Dr. Noor Zafira Noor Hasnan
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 Topic 1.5
Legislation and food safety
management system

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Relationship between GMP and HACCP
• HACCP : Hazard Analysis and Critical Control Points 
Designed to control hazards directly related to the food being
processed or the manufacturing process.
• GMP: Good Manufacturing Practice also known as
Prerequisite Programs (PRP)  Designed to control hazards
related to personnel and the food manufacturing
environment, creating conditions that are favourable to the
production of safe food products.
• HACCP system can only be effective if GMP is first
implemented. Hence,

HACCP system = GMP Program + HACCP Plan (s)

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GMP

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 Important for you to understand..
• What is exactly GMP and its requirements
• Importance
• Challenges in implementation

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 What is GMP?
Universal steps or procedures that control the
operational conditions within a food
establishment thereby creating conditions that
are favorable for the production of safe
food/product
Ultimate objective : to make sure the food is safe from hazard that
can bring harm to consumers

Focus: Focus on hygiene surrounding such as people, material, machineries,

method and environmental condition of food production

Reference: GMP Presentation Paper by SIRIM DN BHD (2019) –for education

purpose only and not commercialization 6
Elements of GMP in MS 1514

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What are the problems??? Food hazards??
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1) Design, infrastructure and facilities

Location Layout design

Infrastructure and
Facilities
fittings

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 Objectives of GMP Design
• contamination is minimized;
• design and layout permit appropriate maintenance,
cleaning and disinfections and minimize air-borne
contamination;
• surfaces and materials, in particular those in contact
with food, are non-toxic in intended use and, where
necessary, suitably durable, and easy to maintain and
clean;
• suitable facilities are available for temperature,
humidity and other controls; and there is effective
protection against pest access and harbourage.

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Whats wrong with this floor drain
(gully)??

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 1) Design, infrastructure and facilities
• Location
– Adequate space for the building and future extension

– Away from industrial polluted area, flooding area or area prone

to pest infestation

– Areas where wastes, either solid or liquid, can be removed

effectively e. g. availability Majlis Perbandaran waste collection
service

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1) Design, infrastructure and facilities
When we design layout for food premise, we must consider:
• Buildings, Internal layout
• Movement patterns (people, food material, material
handling equipment, waste etc)
• Openings
• Walls, floors, drains, ceilings and overhead fixtures
• Equipment
• Laboratory
• Storage areas
• Distribution of utilities

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 1) Design, infrastructure and facilities
• Layout
– Operations are separated as necessary to minimize cross-contamination
– Clear physical (e.g. a wall) segregation between "clean" and "unclean" areas
• "Unclean" areas : where raw material is handled and often a cleaning
operation (wash)
• A heat treatment (e.g cooking of shrimp) or any other kill step (e.g
sanitizing washing) or minimizing step (e.g. freezing) is the marking
point, where the process flow goes from "unclean" to "clean" areas.
• A "clean" area : where if any contaminant added to the product , they
will be carried over to the final product since there is no more
subsequent processing step that can reduce or destroy contaminating
microbes
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 GMP-complied layout

Transition
to clean
area
because
of cooking
step 15
 1) Design, infrastructure and facilities
– Layout (continued)

• No "dead ends" in the product flow, where semiprocessed material can

accumulate and remain for a long time at ambient temperature.

• all functions should proceed with no criss-crossing, zig zagging and

backtracking

• Flow of sewage always from clean to dirty area, No any waste flow entering
unpacked product.

• Minimize use of walls as necessary for easy staff and machineries

movement, monitoring and reduce number of walls for cleaning. Ensure to
use correct material of wall which do not accumulate dirt

• ingredients should move from "dirty" to "clean" areas as they become

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incorporated into food products
GMP-complied layout

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1) Design, infrastructure and facilities
– Aisle and working spaces
• Sufficient space for plant operations

• Space is also required for movement of materials and

pedestrians

• Sufficient gap between machines, space between

machine/shelves and adjacent wall for easy cleaning,
maintenance and pest monitoring

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1) Design, infrastructure and facilities
– Structures

• External walls, roofs, doors and windows  water-, insect- and

rodent-proof.

• Internal walls smooth, flat, resistant to wear and corrosion,

impervious, easily cleanable and white or light coloured.

• Floors resistant to spillage of product, water and disinfectants,

durable to impact, resistant to disinfectants and chemicals used, slip
resistant, non-toxic, non-tainting and of good appearance and easy
repairable. Provided with a slope to drains to prevent formation of
puddles.

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1) Design, infrastructure and facilities
– Structures
• All openings (doors, windows, skylights, ventilators) : adequately
screened or otherwise constructed and fitted so as to prevent the
entrance of any pests (flies or rodents).

• Doors surfaces should have smooth, non-absorbent surfaces and be

easy to clean

• working surfaces made of smooth, non absorbent materials, and inert

to the food, to detergents and sanitizers under normal operating
conditions

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 1) Design, infrastructure and facilities
• Facilities
– Water supply
• Potable water: ingredients, washing food-contact surface
and wash raw materials
• Non potable water: fire control or other purpose when does
not contaminate food
– Drainage and waste disposal
• adequate for the purpose intended
• fully or partially open drain should flow from clean to
contaminated/ dirty area.

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 1) Design, infrastructure and facilities
• Facilities

– Personnel hygiene facilities

• Toilet facilities shall be clean, in good condition, provided with self closing door

and not open into areas where food is exposed to airborne contamination, except

where alternate means have been taken to protect against such contamination

(such as double doors or positive air flow systems)

• Hand-wash facilities : Located at points that require employee to wash and/or

sanitize hands, effective hand cleaning and/or sanitizing preparations, suitable

disposable towel or hand drying device, devices or fixtures, such as hands –free

operated taps

• Change room – for operators and visitors to change into personnel hygiene attire

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 1) Design, infrastructure and facilities
• Facilities

– Lighting

• Adequate intensity, lighting fixtures is protected to ensure that

food is not contaminated by breakages

– Air quality and ventilation

• Ventilation systems should be designed and constructed so that

air does not flow from contaminated areas to clean areas, control

odor, temperature, humidity, provide clean air to premise

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 1) Design, infrastructure and facilities
• Facilities

– Temperature control

• monitoring food temperatures for facilities for heating, cooling, cooking,

refrigerating and freezing food, for storing refrigerated or frozen foods.

– Storage

• Facilities for the storage of food, ingredients and non-food chemicals e.g.

cleaning materials, lubricants, packaging materials

• Secure storage facilities for cleaning materials and hazardous substances

• Pest-proof, food are protected from contamination during storage

• Easy to be cleaned and maintained

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Welding not smooth for
surface that is in contact
with food (inside paddle
mixer)
Food may accumulate at
the rough surfaces and
difficult to clean 
microbe growth

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 References
• GMP Presentation Paper by SIRIM STS Sdn Bhd (2018)
• https://www.gov.mb.ca/agriculture/food-safety/at-the-
food-processor/food-safety-program/pubs/fs_16.pdf
• FSMA and Food Safety Systems: Understanding and
Implementing the Rules by Jeffrey T.Barach
• http://www.todaysdietitian.com/newarchives/110413p50.s
html
• https://haccpmentor.com/food-safety-hazards/hazard-
identification-101/
• http://www.nfsmi.org/documentlibraryfiles/PDF/20160318
042445.pdf
• http://www.inspection.gc.ca/food/non-federally-
registered/product-inspection/inspection-
manual/eng/1393949957029/1393950086417?chap=5
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END OF LECTURE 1.5

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