DAY 2

TANWEER level 1
Good Manufacturing Practices

Vetbook organization
 Course Agenda
 Course introduction
 Why food safety is important
to our lives?
 Food born illness
 PRPs – GMPs
 GMP elements
 Examples of PRPs
Pre-requisite programs (PRPs)
 Personal hygiene
 Pest control
 Waste management
 Sanitation
 Maintenance – equipment
 Chemical – microbiological - allergen control
 Customer complaints
 Traceability – recall
 Glass policy
Pre-requisite programs (PRPs)
 Personal hygiene
 Pest control
 Waste management
 Sanitation
 Maintenance – equipment
 Chemical – microbiological - allergen control
 Customer complaints
 Traceability – recall
 Glass policy
 Personal Hygiene
 Health status
 Medical screening
 Frequent medical testing
 Uniforms (clean – intact)
 Leave personal items in lockers
 watches
 Rings
 Jewelry
 Keys
 Personal Hygiene
 Cover hair & exposed skin
 hair net
 beard net
 Gloves
 Face masks
 Avoid using perfumes
 No makeup
 No smoking – chewing gum
Watch the video
 Personal Hygiene
Hand Washing
 When?
 Hand washing procedures:
- Rinse
- Soap
- Rubbing One
- Rinse minute
- Drying
- Sanitizing
Watch the video
How to verify hand washing?
Without washing Water only

Water & soap Water & soap (20

(20 sec) sec) then sanitizer
Pre-requisite programs (PRPs)
 Personal hygiene
 Pest control
 Waste management
 Sanitation
 Maintenance – equipment
 Chemical – microbiological - allergen control
 Customer complaints
 Traceability – recall
 Glass policy
 Pest Control
 Types of pests:
1. birds
2. flies
3. cockroaches – ants
4. rodents
How to prevent pests
Watch the video
Pre-requisite programs (PRPs)
 Personal hygiene
 Pest control
 Waste management
 Sanitation
 Maintenance – equipment
 Chemical – microbiological - allergen control
 Customer complaints
 Traceability – recall
 Glass policy
 Waste management
 Lay out (garbage collection)
 Assigned persons
 Designated waste flow
 Waste sorting
 Consider housekeeping
 Covered (preferred to be hand free) & labeled waste
containers
 Avoid pests accumulation
 Rework designated areas
 Color coding
Pre-requisite programs (PRPs)
 Personal hygiene
 Pest control
 Waste management
 Sanitation
 Maintenance – equipment
 Chemical – microbiological - allergen control
 Customer complaints
 Traceability – recall
 Glass policy
 Importance of cleaning
 Maintains safe hygiene environment
 Remove soils - inhibits microbial growth
 Removes taint/contamination possibilities
 Removes harborage and food for pests
 Reduces risk of foreign body‟ contamination
 Encourages efficiency
 Maintains image to customers and visitors
 Soil
 What is soil?
Matter out of place
 Types of soil:
 Organic food soils (e.g. protein)
“removed by alkaline products, sometimes with chlorine”
 Inorganic food soils (e.g. mineral salts)
“removed by strong acids/sequestering agents”
 Inorganic non-food soils (corrosions – rust)
“removed by acid foam/gel”
 Purpose of sanitation
Remove contamination:
 Physical matter
 Complex matter
Bacterial matter
microbes are everywhere
(air, water, plants, animals, foods)
1. beneficial bacteria (yoghurt, fermented meat)
2. harmful bacteria (food poisoning, food spoilage,
biofilms)
Bacterial food poisoning
 Biofilm
“A community of microbes embedded in an organic
matrix, adhering to the surface”
 Corrosion of surfaces
 Sources for cross contamination into product
 They hide in rough stainless steel and plastic surfaces
(need great design)
 Particularly resistant to routine cleaning methods
Biofilm
Requirements for bacterial growth
Temp. control
pH control

pH range for
Microbe
growth
Moulds 0 – 11
Yeasts 1.5 – 8.5
Bacteria 3.5 – 10.5
How to select detergent for cleaning
The energies of cleaning
 The energies of cleaning = TACT
Mechanical Thermal
energy energy
(Action)

cleaning

Chemical
energy
Time
Watch the video
Frequency
 Cleaning schedule (SOP)

What?
Who?
When?
Where?
How?
How much?
Verification of cleaning
 First we have to validate (qualify) sanitation technique

 Verification after cleaning through:

 Visual inspection
 Microbiological testing
 Bio-trace (ATP detector)
 Records
 Consistent process flow
 H.W 

Create cleaning schedule for virtual area