BREAD AND PASTRY PRODUCTION NCII

Chapter I: HEALTH AND SAFETY PRACTICES IN THE WORKPLACE

Definition of Terms
Airborne - carried by air
Antidote - a remedy counteracting a poison
First aid - the provision of initial care for an illness or injury
Injury - damage or harm of the structure or function of the body caused by an outside force, which
may be physical or chemical
PPE - (Personal Protective Equipment) refers to devices worn by workers to protect them against
hazards in the work environment including but not limited to safety helmet, safety spectacles, face
shields etc.
Occupational hazards - refer to various environmental factors or stresses that can cause sickness,
impaired health
Safety - free from danger, risk or injury
Workplace - refers to the office, premises or worksite where a worker is temporarily assigned
Bacteria - a simple, single celled microorganism.
Electroshock - caused by touching exposed electrical wire or a piece of electrical equipment which is
not grounded properly.
Grounded - means that the electrical conductor is connected to the ground, which becomes part of
the electrical circuit
Microorganisms - are living cells so small that they can only be seen in a microscope. They are
commonly found to contaminate food (bacteria, molds, and yeast).
Molds - also a microorganism, that has furry growth often found on spoiled food.
Sanitation - the science and practice of maintaining clean and healthy conditions of food
production so that the food served to customers cannot make him ill.
Toxin - a poisonous substance that makes you sick
Hazards and Risks in the Workplace

HAZARD
Hazard is a term used to describe something that has the potential to cause harm or adverse
effects to individuals, organizations property or equipment. A situation that could be dangerous to
people in the workplace.

Examples include any substance, material, process and practice that has the ability to cause
harm or adverse health effect to a person under certain conditions.

Types of workplace hazards include:

1. On Job Hazards: The safety regulations in the workplace should keep job hazards on top priority.
 The floors have to be checked for tripping hazards.
 All the walkways should be well - lit and in case there are blind spots, all the employees and
workers should be aware of them. This could help avoid untoward collisions and accidents.
 Cords and wires should be secured away from the walkways and the corridors. All electric wiring
should be covered with appropriate material.
 Fire safety regulations and electrical safety regulations should also be made.

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2. Safety hazards: Inadequate and insufficient machine guards, unsafe workplace conditions, unsafe
work practices.

3. Biological hazards: Caused by organisms such as viruses, bacteria, fungi and parasites. (Risk from
skin irritations and allergies to infections)

4. Chemical hazards: Solid, liquid, vapor or gaseous substances, dust, fume or mist especially if you
are working with cleaning products, bleaches, and other chemical agents.
Chemicals should be rightly labeled to avoid any detrimental mistakes. Mixing of the wrong
chemicals can cause a terrible chemical reaction which could be hazardous to all the employees.
There should be measures to taken to ensure that only chemicals that are safe be kept
together and stored together. The supervisor should have full working knowledge of the chemicals
to ensure that no mistakes happen due to ignorance or negligence. The worker should be
guided on the proper chemical storage procedures.

5. Ergonomic hazards: Anatomical, physiological, and psychological demands on the worker, such as
repetitive and forceful movements, vibration, extreme temperatures, and awkward postures arising
from improper work methods and improperly designed workstations, tools, and equipment. It may
include lighting, chairs, lifting, repeated movements, and computer screens.

6. Psychological hazards: Those that are basically causing stress to a worker. This kind of hazard
troubles an individual very much to an extent that his general well - being is affected. Stress can lead
to long term health problems like headaches, anxiety and impatience. Workplace stress may include
heavy workloads, lack of control over pace of work, shift work, noise, working by yourself, fear of
job-loss and conflict with the employer and co-workers.

Work Hazard Example of Hazard Example of Harm Caused

Thing Knife Cut
Substance Benzene Leukemia
Material Asbestos Mesothelioma
Source of Energy Electricity Shock, Electrocution
Condition Wet floor Slips, falls
Process Welding Metal fume fever
Practice Hard rock mining Silicosis

RISK
Risk is the chance or probability that a person will be harmed or experience an adverse
health effect caused by a hazard. It may also apply to situations with property or equipment loss.

Example: The risk of developing cancer from smoking cigarettes could be expressed as "cigarette
smokers are more likely to die of lung cancer than non-smokers.

Factors that influence the degree of risk include:

· How much a person is exposed to a hazardous thing or condition;

· How the person is exposed (e.g., breathing in a vapor, skin contact), and how severe are the
effects under the conditions of exposure.

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Risk assessment is the process where you:

· Identify hazards
· Analyze or evaluate the risk associated with that hazard
· Determine appropriate ways to eliminate or control the hazard.

Hazards Risks Safety measures/ actions

Manual handling of hand tools -
Back injury Teach and remind workers of correct lifting
knives, secateurs, loppers,
Repetitive strain and carrying techniques. Rotate tasks.
crowbars, weed bags, mattocks.
Back injury Teach and remind workers of correct
Lifting heavy objects incorrectly
Repetitive strain Lifting technique. Rotate tasks.

Repetitive movements,
Back / limb injury Teach and remind workers of correct lifting
bending and awkward working
Repetitive strain technique. Rotate tasks.
positions

Warn volunteers and remove trip hazards

before commencing work. Do not leave
Trip hazards Injury tools on path ways. Watch where one
walks, and goes slowly. Mark tools with
fluorescent color.

Keeping a Workplace Clean and Organized

Good housekeeping is one of the sure ways to keep a safe workplace. It is not a result of
cleaning up once a week or even once a day, but of keeping the workplace cleaned-up all the time.
Aside from preventing accidents and injuries, good housekeeping saves space, time and materials.

THE "5S" JAPANESE PRODUCTIVITY PHILOSOPHY

Japanese 5S English Equivalent Meaning

Take out unnecessary items and dispose. Keep
SEIRI Sort only the items you need at work, and discard
or store everything else.
It means that there is a place for everything
SEITON Set in order; Systematize and everything should be in its place. Arrange
necessary items in good order for use.
At the end of each working day, take time to
SEISO Sweep; Shine clean up your office or working space. Keep
the workplace neat and clean.
Maintain high standard of cleaning and
SEIKETSU Standardize; Sanitize
workshop organization at all times.
Do things spontaneously without being told or
ordered. Self-discipline is a condition of
SHITSUKE Sustain; Self-discipline
training people to follow cleaning disciplines
independently.

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PERSONAL PROTECTIVE EQUIPMENT AND CLOTHING (PPE)
PPE can protect you from hazards associated with jobs such as handling chemicals or
working in a noisy environment. In food preparation this is the cooking outfit which gives
protection to the worker against different hazards that may be encountered during cooking.

These are the following:

 Hair covering/ hairnet – prevents hair from falling into food product
 Facial mask – barrier to airborne contamination during sneezing, coughing and talking
 Aprons – reduce risk of contamination and help maintain cleanliness.
 Gloves – reduce risks of contamination.
 Pot holder – protects against burns when taking hot items on top of the stove.

FIRST AID RULES

1. BURNS - Cool the burn with cool water. Do not put grease, or oil on burn, they can make it
worst. Do not try to clean a burn or break blisters. Call a physician.

2. FALLS - Stop severe bleeding. Cover wounds with sterile dressing. Keep the person
comfortable and warm. If you think the bone is broken, do not move the person unless
necessary as in the event of fire, call for a medical assistance.

3. POISONING - Swallowed Poison. If the container is available, use antidote recommended in

the label. If none is given call the emergency station of a hospital, the nearest clinic, or rural
health center. Tell them what kind of poison was taken and they will recommend an
antidote. Do not try to neutralize a poison by giving raw eggs, salt water, mustard,
vinegar or citrus fruit juices as an antidote or to cause vomiting. Never attempt to
induce vomiting by sticking your fingers anywhere in the patient's mouth; this
procedure can be very dangerous.

A SAFETY GUIDELINE FOR YOUR WORKPLACE

Safety Signs and Color at Work
Safety signs and color are useful tools to help protect the health and safety of
employees and workplace visitors.

Safety signs are used to:

 Draw attention to health and safety hazards

 point out hazards that may not be obvious
 provide general information and directions
 remind employees where personal protective equipment must be worn
 show where emergency equipment is located
 indicate where certain actions are prohibited

Sign Categories

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 As shown in the table below, there are three basic sign categories used in the
workplace. Each category is distinguished by its shape.

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 GOOD MANUFACTURING PRACTICES
PERSONAL HYGIENE
Ways to achieve personal hygiene.

1. Regularly wash and cut your hair to keep a neat appearance. If you have facial hair, you can
save money by maintaining it yourself with a set of quality clippers.

2. Visit the dentist at least once a year (twice a year is optimal). Though you are brushing
every day, your dentist will correct any dental problems you have.

3. Bathe every day before work, or every night before you go to sleep. This will help you
cleanse/remove body odor.

4. Wear deodorant or antiperspirant daily if you tend to sweat heavily. Some people can
actually get away with not wearing deodorant, but most people, especially those who
have heavy duty jobs or work in warm climates, benefit greatly from it.

5. Scrub your hands with soap and water before you handle any food especially when you
have just come from the toilet, after touching your hair or other parts of your body,
and after your hands cover your mouth or nose when you cough or sneeze. Be sure to clean
under fingernails where dirt and bacteria tend to accumulate.

6. Trim your nails; especially if you work in the food service. This will help keep your hands
much cleaner and prevent the spread of the germs to the food.

7. Keep hand sanitizer and facial tissues near your work desk. If you do not work on your desk,
put travel sizes of these items in your pocket. Sanitizer and tissues will come in handy
when you're ill and can also prevent the spread of germs resulting from touching items such
as money and computer keyboards.

8. Use a separate towel or cloth for drying dishes, wiping countertops, and wiping
hands.

9. Avoid working with food when you have an open cut, sore, boil, or infected wound in your
hands. Pus and other liquids secreted by the wound contain millions of harmful bacteria that
can cause food poisoning.

10. Keep hands out of food as much as possible. Otherwise, wear disposable gloves.

11. Avoid smoking while preparing or handling food as ashes may drop into the food.

12. Wear suitable clothes at work. Do not wear clothes with long sleeves when working with
food. Wear also comfortable and clean shoes. Be sure aprons are always clean.

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PROPER HAND WASHING
Washing is the single most effective way to prevent the spread of infections. "Germs"
(a general term for microbes like viruses and bacteria) can be spread casually by touching
another person. You can also catch germs when you touch contaminated objects or surfaces and
then you touch your face (mouth, eyes, and nose).

"Good" hand washing techniques include using an adequate amount of soap, rubbing
the hands together to create friction, and rinsing under running water.

HAND SHOULD BE WASHED:

 After using the washroom (includes changing diapers).

 After sneezing, coughing, or using tissue.
 Hands are visibly soiled.
 Before and after eating, handling food, drinking or smoking.
 After touching raw meat, poultry, or fish.
 After handling garbage.
 Handling pets, animals or animal waste.

Right way to wash your hands

 Wet your hands with clean running water (warm or cold) and apply soap.
 Rub your hands together to make lather and scrub them well; be sure to scrub the backs of your
hands, between your fingers, and under your nails.
 Continue rubbing your hands for at least 20 seconds.
 Rinse your hands well under running water.
 Dry your hands using a clean towel or air dry

Other hand issues

 Hand sanitizer should never be substituted to proper hand washing.
 Fingernails should be kept short and without nail polish while handling food.

FOOD HAZARDS
Food hazards are biological, chemical or physical agents with the potential to cause food
spoilage, illness or injury.
Biological hazards include microorganisms like, virus, protozoa and fungi and parasitic
worms. They pose great threat to food safety. Most microorganisms are good and some are bad,
these are called "pathogens" and they produce toxins which cause illnesses.

Microbes are found:

o In air, soil, and water
o In intestines of animals and humans

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 o On skins of fruits and vegetables
o On raw meat, poultry and seafood
o On insects and rodents
o On hand, skin and clothing

Ways to prevent microbial growth

1. Sterilization: destructs microbial spores
2. Pasteurization: destructs most bacteria
3. Refrigeration: slows growth of microorganisms
4. Freezing: will end growth of bacteria
5. Deep freezing: will end growth of molds
6. Vacuum packaging to remove oxygen ; canning

CROSS - CONTAMINATION
Cross-contamination is the transfer of biological or chemical contaminants from foods
(usually raw) to other foods. It is one of the causes of food poisoning.

Practices that would prevent cross-contamination

1. Store raw from ready to eat food.
2. Keep highest hygiene level for ready-to-eat food.
3. Minimize bare hand contact
a. Use utensils
b. Use clean and disposable gloves
c. Wash your hands before touching gloves
d. Change gloves between tasks
- When they are dirty or torn
- When they are contaminated
- Anytime that hand would need washing
4. Don’t prepare food when you are sick
5. Observe proper hand washing
6. Separate different types of raw food.
7. Clean and sanitize/disinfect between container changes of different types of food
8. Use labels and coding in segregating raw materials and utensils

RAW MATERIALS AND PRODUCT HANDLING

Storage of raw materials
1. Apply First In, First Out (FIFO) policy
2. Observe temperature control
3. Separate raw from ready-to-eat food
4. Store dried food off the floor in sealed containers to protect from pest and moisture
5. Label store food with expiration date (sort by date)
6. Never store food together with chemicals

Storage and Transport

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 1. Finished product should be stored and transported under conditions that will protect against
contamination deterioration of the product and damage to the container
2. Periodic inspection of the product during storage should be done
3. Product should be dispatched in the sequence of numbers.

General Storage Guidelines

1. Label food
2. Rotate products to ensure the oldest inventory is used first. (FIFO)
3. Establish a schedule to ensure that stored product is depleted on a regular basis. Example,
flour stored in plastic bins should be used within six to twelve months from the time it was
placed in the bins. After that time period, the bins should be emptied, the flour discarded,
and the bins cleaned and sanitized
4. Discard food that has pass the expiration date
5. If food id removed from its original package: put it in a clean, sanitized container and cover
it. Label the container with the name of the food and the original used-by or expiration date.
6. Never use empty food containers to store chemicals or put food in empty chemical
containers.
7. Check temperatures of stored food and storage areas
8. Do not store food near chemicals or cleaning supplies
9. Keep all storage areas clean and dry

Refrigerated Storage Guidelines

1. Set refrigerators to the proper temperature (41˚F or 5˚C)
2. Monitor temperature regularly
3. Do not overload refrigerators
4. Never place hot food in refrigerator, this can warm the interior and put other food into the
temp. danger zone
5. Keep refrigerator doors closed as much as possible. Frequent opening lets warm air inside
6. Store raw meat, poultry and fish separately from cooked and read-eat-food or below cooked
and read-eat-food
7. Wrap food properly (zip lock). Leaving it uncovered can lead to cross-contamination.

Frozen Storage Guidelines

1. Keep freezers at a temperature that will keep products frozen
2. Check freezers temperature regularly
3. Place deliveries/goods in freezers as soon as they have been inspected
4. Clearly label frozen food that was prepared on site

Dry Storage Guidelines

1. Moisture and heat are the biggest dangers to dry and canned food
A. Keep storerooms
a. Cool (50˚F to 70˚F / 10˚C TO 21˚C)
b. Dry (50% to 60% humidity)
c. Well ventilated
d. Clean

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 B. When storing food in dry storage, keep it away from walls, out of direct sunlight and
at least 6in or 15cm off the floor.

Storing Eggs
1. Keep eggs in refrigerated storage until used
2. Use eggs within 4-5 weeks of packing date

Storing Dairy
1. Follow FIFO
2. Discard products that has passed use-by or expiration dates

General Requirement for Food Contact Surfaces

1. Non-toxic (no leaching of chemicals)
2. Non-absorbent (can be drained and/or dried)
3. Resist corrosion
4. Inactive to cleaning and sanitizing chemicals

Storage of Clothing and Gloves

1. Store in clean and dry place
2. Ensure that clothing and gloves are not exposed to splash, dust or other contaminants
3. Store clean garments separately from soiled garments and gloves

Storing Utensils, tableware and equipment

a. Clean and sanitize drawers and shelves before items are stores
b. Clean and sanitize trays and carts used to carry them
c. Store glasses and cups upside down
d. Store flatware and utensils with handles up
e. Cover equipment food contact surfaces until ready for use

WASTE MANAGEMENT
Waste management is the collection, transport, processing or disposal, managing and
monitoring of waste materials. The term usually relates to materials produced by human activity,
and the process is generally undertaken to reduce their effect on health, the environment or
aesthetics.

Waste management procedures and techniques

1. Waste avoidance is engaging in activity that prevents generation of waste. Waste
segregation is the process of dividing garbage and waste products in an effort to reduce, re –
use and recycle materials.
2. Waste reduction is the minimization of wasteful consumption of goods.
3. Re - use is the process of recovering materials intended for some purpose without
changing their physical and chemical appearance.
4. Recycling is the treatment of waste materials through a process of making them
suitable for beneficial use and for other purposes.

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 5. Composting is the controlled decomposition of organic matter by microorganism mainly
bacteria and fungi into a humus like product.
6. Waste disposal refers to the proper discharge of any solid waste into or any land.

Cleaning and Sanitizing

Cleaning is the process of removing food and other types of soil from a surface. Sanitizing is
the process of reducing the number of microorganisms on a clean surface to safe levels. Surface
must be first cleaned and rinse before sanitized.
Clean all food contact surfaces:
a. Each time you use them
b. When you begin working with another type of food
c. When you are interrupted during a task
d. As often as possible, but at least every four hours if you’re using something constantly

In cleaning floors
a. Sweep
b. Mop on detergent solution
c. Wash
d. Rinse

Storing Cleaning Tools and Chemicals

a. Should be placed in storage area away from food and food preparation areas.
b. Storage area should provide utility sink for cleaning buckets and washing cleaning tools,
floor drain for dumping dirty water and hooks for hanging mops, brooms and brushes to
allow them to air-dry.

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