Food & Beverage Service I (BHM)

Unit 8: Hygiene, Sanitation and Safety

Introduction

Hygiene refers to the science that deals with the promotion and preservation of the health. This
subject has become a very important aspect of the food service industry as it involves food and
beverage products that are served and consumed by the customers thereby benefiting or
adversely affecting health. The consumer is very particular about those things that he/she is
going to consume.

Considerations for hygiene and sanitation

The concern for hygiene and sanitation starts from the time of designing a premise for food
service. There are many inter-related aspects of preparation and service that have to be
considered at the design stage so as to protect the establishment from hazards. The following
table gives the considerations at designing stage for hygiene and sanitation.

Environment Food Handling Personal Hygiene

Site Selection Receiving Clean Clothes
Flooring and Walls Storage Grooming
Equipment Preparation Staff Health
Exhaust Systems Cooking Habits
Lighting Holding
Water Supply Serving
Waste Disposal Clearing & Cleaning
Disposal of waste

1. Site Selection:

Hygiene and sanitation considerations start with site selection stage. The site must not be open to
air pollution or close to sewage dumps. The premises must be away from any sites where there
are hazards of insects and pests. If the premise is part of the existing buildings like office blocks
or malls, then one has to give consideration to the exhaust points, waste disposal processes and
the supply of the drinkable water. The plumbing system has to examine for its quality of pipes
and durability. Similarly, the drainage and waste disposal too has to be examined ensuring that
the municipal garbage disposal method is available.
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2. Floors and Walls:

Floors of the kitchen must not be absorbent, corrosive, slippery but should be fire resistant, free
from joints, not easily damaged and above all easy to clean. Floors should be durable to take
heavy equipment and flow of trolley and personnel. Many kitchen use tiles for its sanitized look
but the problem with the tiles is that it has too many joints where food can deposit and create a
food hazard.

Kitchen walls can be done will the same emulsion finish through ceramic tiles, which are
popularly used. Ceilings too must be high to take the impact of steam, gases and heat. A plaster
paint finish is most suitable.

3. Equipments:

Equipments and work surfaces for food preparation must be very clean at all times. Stainless
steel is now the standard material used for equipment and work tables. They are easily cleaned
and durable. They also give the kitchen a sparkling finish.

4. Exhaust Systems:

The exhaust systems must be efficient in kitchen as well as food service areas to draw out
contamination. Windows are discouraged as they become inlets for dust, insects and flies that are
carriers of bacteria. If the windows are unavoidable then the windows must be fitted with wire
mesh. However, proper ventilation system is essential either using air conditioner or windows.

5. Receiving Area:

The food handling process during operations became an important part of hygiene and sanitation
concerns. It starts with the receiving area when raw materials are received into the property. The
receiving area should be properly tiled and kept clean at all times. For example, it should also
have a sink to wash down vegetables, fruits and fish before they enter the properly.

6. Storage:

Storage facilities are vital to ensure proper hygiene and sanitation conditions. There must be
separate store rooms for different products as per their nature for efficient management of the
store rooms. For examples: perishable stores, dry store, general stores, housekeeping stores,
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engineering stores, stewarding stores, beverage stores etc. The issuing procedure follows “first-in
and first-out” basis method to ensure that foods are not in the stores for long period of time.

7. Cooking:

Kitchen area has to be kept spotlessly clean through frequent cleaning schedules. Food fallen on
the floor cannot be allowed to use. Kitchen must have adequate garbage disposal bins, which
must be emptied at this municipality garbage point frequently. Kitchens and stores must be put
through regular pest control schedule to eliminate rodents, insects and flies.

Contamination can take place from the people who cook and serve the food. Foreign matters like
hair, glass, wood etc. could fall into food at the cooking, holding and service stages.

HACCP

Introduction

Hazard Analysis Critical Control Point (HACCP) system on food safety was developed jointly
by the Pillsbury Company, the United States Natick Laboratories and the National Aeronautics
and Space Administration in 1974. The development of the HACCP concept was to assure one
hundred percent safety to food to be used in space. However, since 1960 quality assurance
principles widely adopted by food industry. HACCP is a now fully recognized as the definitive
certification for safe food operations.

HACCP is a systematic approach to identify, evaluate and control food safety hazards. Food
safety hazards are caused by biological, chemical or physical agents. These agents can cause
injury or illness, if not controlled. The method also has other benefits of maintaining, food
quality and managing food costs. HACCP works on Critical Control Points (CCPs), which if
controlled can eliminate health risks. Each control point has stated Critical Limits, which are
acceptable tolerance parameters within which operations must run. Most food establishments
have nine critical control points as given below.
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CRITICAL CONTROL POINTS

Critical control point (CCP) is the point where failure of standard operation procedure (SOP)
could cause harm to customers and to the business, or even loss of the business itself. It is a
point, step or procedure at which controls can be applied and a food safety hazard can be
prevented, eliminated or reduced to acceptable (critical) levels. The most common CCP is
cooking, where food safety managers designate critical limits.

It is very essential to examine the each control point in order to understand their significance as
potential safety risks in the service chains as follows:

1. Menu Planning
2. Purchasing
3. Receiving
4. Storing
5. Issuing
6. Preparation/Cooking
7. Holding
8. Service
9. Cleaning and Maintenance

1. Menu Planning:

Menu Planning is the first control point in the food service system. There are many
challenges of menu planning. The menu that is offered has a greater impact purchasing,
receiving, storage, equipment, cooking personnel and methods. From the food safety point of
view there must be restriction to the number of raw materials purchased as each would have
its special conditions for storage. The HACCP program also sets the standards for raw
materials which mean the correct quality or grade of food products must be stated and
available at all times. Therefore the items mentioned ‘fresh’ in the menu should not be frozen
or canned. Himalayan trout or Scottish Smoked Salmon must be authentic. Similarly, when
there is mentioned “fat free” or “Low Calorie Diet”, the ingredients should match the claims.
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2. Purchasing:

The menu planned, determines the ingredients that have to be purchased and in what
amounts. The objective of purchasing is to get the right quality at the right price and quantity
at the right time. Therefore, the purchasing function becomes a control point. Purchasing has
to be sure of the suppliers and their methods of procurement ensure the right quality of items
normally defined in a Purchase Specification (the document that defines the standard of the
product). One of the criteria for selection a supplier would be his food safety policies and
standards. This is determined by actually visiting the sites of the supplier and inspecting their
storage and packing methods.

3. Receiving:

The receiving control point follows purchasing. The Receiving function inspects deliveries of
the items purchased in terms of the quality, quantity and price. In this point, the person is
responsible to check each item before taking the ownership of the products on behalf of the
establishment. This step includes the particular check for freshness, expiry dates of canned or
preserved foods. The proper weighing scales must be available to the determine the quantity.
Perishable items are washed at the Receiving facility to reduce the risk of the germs and
bacteria entering the establishments. Similarly, perishable items must come in the
refrigerated vans while each is checked for the way they are packed.

4. Stores:

The storing control point is very critical and serves to protect the food and non-food items
fresh till such time they are ready for consumption. This is the stage that spoilage and
contamination takes place. Therefore, it is essential to ensure the proper storage conditions.
Dry stores are kept at 20˚C - 25˚C and away from the steam and hot water pipes. The items
must be stored on the racks (at least 6" above the floor) and not on the floor to avoid pests.
Perishables are kept in deep freezes at 0˚C - 10˚C temperatures while cold storages are
maintained -5˚C - 5˚C temperature. There must be proper pest control schedule to ensure that
the stores are free from rodents and insects.
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5. Issuing:

The control point of issuing is to ensure that authorized persons withdraw the items from the
store and that spoiled items are not issued. Authorized people will also know the freshness of
items when receiving the items from the store. As mentioned earlier, FIFO (First-in, First-
out) basis method should be employed to ensure that items are kept in the store for a long
time. Storekeepers also give the users feedback on slow moving items so as to reduce the
ordering quantities and avoid the spoilage in storage.

6. Preparation:

The food preparation control point is perhaps the most important safety point for several
reasons. Initially, items are received from the stores are unwrapped and exposed to the room
temperature of the kitchen (a potential source of contamination). Secondly, the temperature
danger zone for all food items is 5˚C - 60˚C. The kitchen cannot guarantee that temperatures
in the kitchen are not within the danger zone. Thirdly, the kitchen brigade (Staffs) could
contaminate the food with their coughs, sneezes and dirty hands. Finally, cold items like
salads and desserts do not have heat treatment like hot foods to kill harmful micro organisms,
they go straight for consumption. It is crucial that they are refrigerated adequately to take
them out of the danger zone before service. The main objectives of heat for cooking are to
destroy the harmful bacteria, to make the food digestible and to change the color, textures
and appearance of the food items.

7. Holding:

Holding is the time period between the completion of food preparation and its service.
Generally, food should be served immediately. However, this may not be possible due to
busy work schedules for banquets and buffets when the food is prepared well in an advance
in view of the quantity involved. Some useful tips that has to be considered are as follows;

 Hot foods must not be allowed to cool. They must be kept in the hot cases or chafing
dish at 60˚C or above.
 Leftovers must be stored in the stainless steel pots.
 Cold items like salads and desserts can be held in the cold refrigerator.
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 When re-heating the food must attain a minimum internal temperature of 74˚C for 15
seconds.
 Holding equipments such as ‘Bain-marie’ must be used to keep the food items warm
and fresh for guests.
 Holding equipment must be cleaned and sanitized immediately after use.

8. Serving:

The food service control point encompasses a number of issues. It starts with the hygiene of
the service staff. Servers can be the carriers of bacteria and diseases.

Some tips for service staff hygiene are as follows:

 Hair must be short. Men and women with long hair must tie it in a bun preferably
with hair netting.
 Hands must be washed frequently.
 Nails must be well-manicured and clean because the guest can see the server’s hand
while serving food to the guest.
 Shoes must be polished and clean.
 Minor cuts must be covered with the band-aid to prevent transfer of blood-borne
pathogens.
 Servers who are ill or have a cough or sneeze should not be allowed to handle food
and serve the guests.
 Avoid smoking and chewing gums in the kitchen and service areas.

Some tips of food hygiene while serving food are as follows:

 Food should be kept out of the temperature danger zone of 5˚C to 60˚C .
 Avoid the contact of food with bare hands. Use gloves, tongs and service spoons to
handle the food.
 Never serve the food that has fallen on the floor.
 Service ware and tableware must be properly polished and sanitized when in use.
 Take a minimum time to serve food after it is cooked,
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 Make sure that all the glasses are held against the light to check for finger prints and
water marks.

9. Cleaning and Maintenance:

Finally the cleaning and maintenance of the kitchen and service equipment needs special
care. Some important tips to be considered are as follows:

 Handle cleaning agents carefully. They must be labeled and the labels should describe
their potency and toxic qualities.
 Cleaning agents must be locked in separate cupboards away from cooking areas.
 Staff must be properly trained in the use of cleaning agents or the job should be given
to qualified contractors.
 Kitchen and service equipments must be sanitized every day, preferably at the end of
the each shift.
 While the kitchen stewarding is responsible for the cleanliness of kitchen and service
ware, it is everybody’s responsibility towards hygiene and sanitation of these areas.
 The water used for washing, rinsing and sanitizing must be changes frequently.
 Equipment and utensils must be scraped and pre-soaked before the washing cycles to
get rid of food particles and grease.

THE HACCP PROCESS

The HACCP process consists of seven principles given below. Each principle is explained
through a series of slides. Each slide is self explanatory. However, there are some terms that
need to be explained to understand the slides better.
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HACCP TERMINOLOOGY

1. Acceptable Level: does not pose risk.

2. Control Point: where there is a risk.
3. Critical Control Point: unacceptable risk
4. Critical Limit: the parameters within which physical, biological and chemical risks must be
controlled.
5. Deviation: failure to control a critical risk.
6. HACCP Plan: formal written procedures for safety.
7. Hazard: unacceptable consumer risk.
8. Monitoring: Planned sequence of observations and measurements to keep accurate record.
9. Preventive measure: means to exclude, destroy, eliminate or reduce a hazard.
10. Risk: a likely occurrence of a hazard.
11. Sensitive Ingredient: any ingredients historically associated with a known microbiological
hazard.
12. Verification: means, methods, procedures and tests to determine if the HACCP system is in
compliance with the HACCP Plan.

7 HACCP PRINCIPLES

1. Conduct a Hazard Analysis

2. Determine the Critical Control Points
3. Establish the critical limits for preventive measures
4. Establish procedures to monitor CCPs
5. Establish corrective actions when limits are exceeded
6. Establish various verification procedures that document HACCP plan.
7. Establish recordkeeping and documentation procedures to verify that HACCP plan is
working.

Principle 1: Conduct a hazard analysis to identify hazards associated with the food and
measures to control those hazards. Hazards could be biological (eg: Germs, bacteria); chemical
(eg: toxins); or physical (eg: metal fragments).
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Principle 2: Identify the critical control points (CCPs). These are points of the process at
which the hazard can be controlled
or eliminated (eg: cooking).

Principle 3: Establish the critical limits for preventive measures. A critical limit is the
criterion that should be met to ensure food safety in a product (eg: minimum cooking
temperature and time to ensure elimination of harmful bacteria).

Principle 4: Establish the procedure to monitor CCP to ensure each CCP stays within its
critical limits. Monitoring involves a series of observations or measurements to determine if the
CCP is under control (eg: determine who and how temperature and time will be monitored
during cooking).

Principle 5: Establish corrective actions when limits are exceededif the CCP is not within
the established limits. By applying corrective actions, the control of hazards is regained (eg:
reprocessing or disposing of food if the minimum cooking time and temperature are not met).

Principle 6: Establish verification procedures that document Haccap plan to confirm that
the HACCP plan is operating effectively and accordingly to written procedures. This verification
may include reviewing HACCP plans, CCP records, microbial sampling (eg: testing time and
temperature recording devices to verify that are calibrated and working properly).

Principle 7: Establish record-keeping and documentation procedures that demonstrate that

HACCP is working properly. This includes monitoring documentation, actions taken to correct a
potential problem, validation documents (eg: scientific information that supports the use of
specific time and temperature for cooking).

CONDUCT HAZARD ANALYSIS

1. Ingredients
2. Intrinsic Factors
3. Procedures used in manufacture
4. Microbial content of the food
5. Facility design
6. Equipment design
7. Packaging
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8. Sanitation
9. Staff hygiene, health and education
10. Conditions of storage
11. Intended consumer

MONITORING CCPs

1. Track operation
2. Identify lack of control or deviation
3. Provide written documentation

CORRECTIVE ACTION

1. Documentation
2. Correction
3. Re-training
4. Information program
5. Close supervision

VERIFICATION

1. Inspection schedules
2. Review of HACCP plan
3. Review of CCPs
4. Review deviations
5. Random sampling
6. Review of records
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RECORDKEEPING

1. HACCP Plan
2. Description of each food product and intended use
3. Flow diagrams indication CCPs
4. Hazards of each CCP
5. Critical limits
6. Monitoring system
7. Corrective actions take
8. Recordkeeping procedures
9. Verification records

SAFETY PROVISIONS DURING PLANNING STAGE

The considerations for safety are factored in at the time of construction and facility planning of
kitchens and food service areas. Planners would have given thought to the following:

 All electrical cables that supply power to the kitchen electrical equipment are certified as
safe using the proper material and standards.
 Cabling must be done through proper metal conduits from the power source to the supply
source. There should not be any loose cabling in the kitchen.
 The kitchen has adequate ventilation and exhaust systems. This is provided by fresh air
ducts, cooking range exhausts and exhaust fans to pull smoke from the kitchen areas.
 All kitchen equipment is form reliable suppliers who have built in safety features and
provide training manuals.
 Traffic movement should be studied and adequate spaces should be provided for staff to
move around. One must understand that they would be carrying hot pots, dishes and
needing free movement.
 Floors must have anti-skidding tiles and hardy enough to take heavy traffic.
 There should ne adequate storage areas for pots and pans so that they do not lie on the
floors to cause tripping and falling.
 The gas banks should be kept outside the building in cages open to the open air.
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 The kitchen should be well equipped with the appropriate fire-fighting equipments
including extinguishers and hoses.
 Appropriate fire exits should be provided for staff and guests to escape in an emergency.
 Kitchen floors must be level from end-to-end. Uneven floors or steps in the kitchen and
definite hazards.
 Switches of electrical equipment must be easily visible and reachable.
 Install fire-detection devices and sprinkler systems for fire.

PRE – OPERATIONS SAFETY PROVISIONS

The first thing before an operation starts is to have written safety policies and procedures. Such
policies should provide:

 Safety training to all the staff

 Supplier training on the correct use of equipment
 First – Aid training
 Fire – safety training especially in the use of extinguishers
 Records and analysis of accidents
 Accountability for safety – the person responsible is usually the chef of the kitchen and
the restaurant manager for the restaurant
 System of inspections internally and by inspectors from the Labor, Health or
Municipality, whoever is responsibility for occupational safety.
 Placing safety posters along the walls of the kitchen
 Certification of fire extinguishers installed and a schedule of replenishment
 Certification of gas pipes and banks by the competent authority
 Ensure that all kitchen equipment purchased conform to the standards code for safety.

The second thing the chef ensures is to provide a first-aid kit in the kitchen normally located in
his cabin itself so that he is aware of nany accidents. A typical first-aid kit will have:

 Crepe Bandages
 Band-aids
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 Cotton Wool
 Antiseptic lotion / ointments
 Iodine
 Tourniquets
 Pain relievers

SAFETY PROVISIONS DURING OPERATIONS

There are precautions taken by kitchen and service staff to prevent burns, cuts, strains and
electrocution and equipment accidents which are explained as follows:

1. Burns:
 Prohibit smoking in the kitchen
 Follow correct procedures to light stoves
 Use pots and pans which have secure handles. Loose handles can break when the pots
are in transportation
 Fill pots and pans to two-third of its capacity. Over-full pots and pan can cause hot
spills during transportation
 Use long-handled ladles to keep hands away from the hot food within pots and pans
 Stir liquid slowly, vigorous movements can lead to splashes across onto the self
 Don’t reach into ovens for fear of burning hands, always use gloves when taking out
items from ovens
 Allow equipment to cool before cleaning commences.

2. Cuts:
 Food must be cut on a table or chopping board and never in the hand
 Knives with loose handles must be discarded
 Do not try to catch a falling knife
 Keep knives away from the table edges. They should be pushed backwards
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 When storing knives with open blades place the handle upwards and the blade
downward
 Do not use knives as screwdrivers or to open tin cans
 Use the right knife for the right purpose
 Minimize the use of glass dishes in cooking. Broken glass must be cleaned
immediately and others warned about it. Use brooms and dust pans when cleaning
broken glass and not the free hands.

3. Strains:
 Kitchen floors must be kept dry at all times and spills must be dried immediately
 Broken kitchen tiles must be replaced immediately to avoid stumbling over broken
patches
 Flat shoes with non-skid soles must be used in the kitchen because it gives ease to the
feet for long hours on the feet but also prevents slippage
 All doors leading to the kitchen must be swinging doors for ease when transporting
goods
 Use stepladders when reaching higher shelves
 Keep heavy items on lower shelves
 Heavy loads are lifted by keeping the back straight, bending the knees to lift the
object and lifting with the legs and not the back.

4. Electrocution:
 Never connect equipment to the main power source unless they have the appropriate
plugging devise. Many cooks do with open wires, which is a hazard.
 Follow the manufacturer’s guidelines when operating electrical equipment.
 Always unplug electrical equipment when cleaning it.
 Never touch electrical sockets with wet hands.
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5. Fire:
 Clean hoods and exhausts periodically.
 Smoking should be prohibited in kitchen. Apart from fire hazards it is also a hygiene
factor.
 The kitchen should display appropriate signage showing “No Smoking”.
 Know how to use fire extinguishers for major fire outbreaks.
 Knowledge of types of fires and which extinguisher to is are also important.
 Use common methods to extinguish simple food fires by spreading salt on the flames
or baking soda.
 All staff must be trained in the use of fire extinguishers.

6. Use of Equipment:
 All staff must be trained in the use of equipment before they actually use it. The best
trainers are the manufacturers or their authorized representatives.
 Always follow safety procedures set by the manufacturers when using equipment.
Place the instructions close to the equipment.
 Ensure a regular preventive maintenance schedule of equipment throughout the year.
The manufacturers are the best to attend to this aspect.
 All equipment must be switched off at close of operations.

SAFETY PROVISIONS AFTER OPERATION (On- going Safety Action)

1. Management must have a written Safety Policy giving priority to it over convenience. It
does not only safeguard the employees but acts as a protection from legal libel action.
The policies must include the following:
 Written manual of safe work practices
 Training of staff and certification
 Conducting safety inspections
 Maintaining records of accidents with full investigation reports
 Emergency procedures
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 Training of identified staff in first-aid procedures

 Equipment preventive maintenance schedules
 Safety meetings and their minutes
 Communication of safe practices
 Recognition and rewards to staff who observe safe practices
 Staff involvement in improving safety practices
 External inspection records.

2. Maintain records of accidents to show to inspectors and to take precautionary measures

for the future.
3. Invite experts from the fire brigade, Ambulance and occupational safety authorities to
give talks, demonstrations and training to staff.
4. Motivate staff with safety awards to encourage others to follow safety rules consistently.
5. Incorporate suggestion schemes for better safety to keep staff ahead of safety concerns.
6. Replenish first-aid kits periodically.
7. Close supervision is the best way to ensure on-going safety.
8. Unsafe practices must be corrected at once.
9. Habitual offenders must be penalized for their actions.