Food Safety Best Practices

for M/SMEs
(GMP & HACCP)
 Food Safety Basics

• Only safe and wholesome foods may be

marketed
• Government has enforcement responsibility
• Manufacturers, Distributors, Importers and
other are expected to comply
• Regulatory process is transparent and
accessible to the public

2
 Legal Bases
• Republic Act 3720- Food, Drugs and Devices, and
Cosmetics Act as amended

• Republic Act 9711- Food and Drug Act of 2009

• Republic Act 10611- Food Safety Act of 2013

• Administrative Order 153 s. 2004- Revised Guidelines

on Current Good Manufacturing Practice in Manufacturing,
Packing, Repacking or Holding Food
 Good manufacturing Practice (GMP)

Good manufacturing Practice (GMP) is a quality

assurance system aimed at ensuring that products
are consistently manufactured, packed,
repacked, or hold to a quality appropriate to its
intended use. It is thus concerned with both
manufacturing and quality control procedures.
 Food Safety Concerns

• Food safety is primarily concerned with

adulterated or contaminated food which may
result to foodborne disease.
• Contaminants
Biological
Chemical
Physical
 Sources of Contamination

• Man
• Materials
• Machine
• Methods
 Food Safety Concerns
• Foodborne Illness Risk Factors
- Food from unsafe sources
- Inadequate cooking
- Improper holding temperature
- Contaminated equipment
- Poor personal hygiene

7
 Food Safety Concerns

Foodborne Illness Risk Factors

- Food handlers health status
- Water quality
- Presence of pests

8
 Prerequisite Program

Two types of Prerequisite Program

- Those associated with the plant or facility
(Premises, Equipment, Sanitation and Hygiene,
Production and Process Control)
- Those as part of the Quality Management
System (GMP Organization, Quality Audit,
Product Recall, Retention of Samples,
Subcontracting of Manufacture)
RE-TOOLING CCRR SEMINAR.2013 9
 Prerequisite Program
• Where to build it?
• Consider:
location
surrounding

RE-TOOLING CCRR SEMINAR.2013 10

 Guide to Good Practices 1

• Building Standards
• Suppliers Control
• Pest Control Plan
• Personnel Health Policy
• Hand Washing Rules and Cleaning Plan
• Process Control

11
 Guide To Good Practices
• Recipe Control
• Staff Training
• Material Cleaning
• Finished Product Analysis
• Implementation of a System of Traceability
• Hot and Cold Technology

12
 Facility/Building Standards

General Principles
- Onward flow of operation
- No production line criss-cross
- Separation of cool and warm areas
- Separation of clean and dirty areas

13
 Construction Standards
Floors where appropriate, shall be:
- water-proof
- washable
- non-slip materials
- without crevices
- easy to clean and disinfect
- sufficient slope for liquids to drain

RE-TOOLING CCRR SEMINAR.2013 14

 Construction Standards
• Walls where appropriate, shall be:
- water-proof, non-absorbent and washable
materials
- sealed
- light coloured
- smooth and without crevices
at least 2meters high

15
 Construction Standards
• Ceilings shall be:
- smooth
- washable
- light coloured
- at least 2meters from flooring

16
 Construction Standards
• Doors
- self closing
- smooth, non-absorbent surfaces
• Windows
- fitted with insect-proof screens
- internal window sills, if present shall be
sloped to prevent use as shelves

17
 Construction Standards

• Ventilation shall be:

- adequate to prevent build up of heat, dust,
odours and vapours in areas where they
may contaminate food.

18
 Construction Standards

• Lighting shall be:

- bright
- neutral in colour
- provided with shield to protect against
food contamination in case of breakage

19
 Equipment Conformity
• Equipment Food Contact Surfaces shall be:
- made of smooth materials to minimize
accumulation of food particles
- impermeable
- corrosion resistant
- non-toxic materials
- washable
20
 Equipment Conformity
Installation
Equipment shall be suitably installed and
located to eliminate cross contamination
and facilitate the cleaning of equipment and
of adjacent spaces (at least 1meter apart)

21
 Equipment Conformity
• Calibration
Equipment monitoring and measuring device
shall be calibrated regularly
• Maintenance

RE-TOOLING CCRR SEMINAR.2013 22

 Supplier Control
- maximum time from arrival of
raw materials into storage (if chilled or
frozen)
- Intrinsic properties of the raw materials
(inherent toxic chemicals or microbial
pathogens or toxins involved in production,
handling and storage of raw materials)

23
 Supplier Control
• Rejection procedure
- Reason for rejection
- Segregation and identification
- Disposal procedure
- Records

24
 Personnel Health Policy
• Disease Control
- Procedures for disease control including
specific instruction for all personnel to
report their health condition to their
supervisors

25
 Personnel Hygiene
- Proper hand washing
- Maintain adequate personal cleanliness
- Wearing outer garments in a manner that
protects against the contamination of food
- Wearing hairnets where appropriate
- No smoking policy

26
 Personnel Hygiene

- Removing jewelry and objects that may fall

into the foods and equipment
- Maintaining neat short fingernails
- Storing clothing or other personal
belongings in a locker or cabinet

27
 Sanitary Facilities
• Water Supply- shall be of quality necessary for
the product, process or use
• Hand washing facilities shall be conveniently
located in processing areas, with soap and water
• Toilets shall not be opened directly to
production areas and shall have adequate supply
of soap and water
• Eating facilities

28
 Pest Control Plan
• Preventing access
- Holes, drains and other places where pests
are likely to gain access should be kept
sealed.
• Harbourage and Infestation
- Potential food sources of pest should be
stored in covered containers

29
 Pest Control Plan
• Monitoring and Detection
Plant surroundings should be regularly
examined for evidence of infestation
• Eradication
Rodent Control Plan and Insect Control
Plan composed of SOPs defining actions
to be implemented

30
 Premise Hygiene

• Cleaning Plan for plant premises and equipment

Standard Operating Procedures (SOPs)
Work Instructions
Monitoring records (checklists)
Effectiveness of the Cleaning Plan

31
 Premise Hygiene
• Standard Operating Procedures
- When to clean- frequency
- Who will clean- cleaning staff
- What to clean- surfaces and equipment
- Where to clean- CIP and COP
- Why should be cleaned-required results
- How to clean- physical or chemical means
• Records
 Staff Training

 Analyze training needs

 Establish training plan with clearly defined
objectives and indicators
 Carry out the training
 Assess the effects

33
 Staff Training

Remember…..
Inadequate trained personnel poses a
potential threat to the safety of food and its
suitability for consumption

34
 Supplier Control
• Raw Materials, Ingredients and Packaging
Materials
- Purchased from accredited supplier
Suppliers guarantee or certification
- Procedures in receiving, storage and
rejection

35
 Supplier Control
Receiving of raw materials, ingredients and
packaging materials
- Physical condition-free from packaging
damage
- Product identification- labelling conformity
and traceability
- Cleanliness of delivery vehicle
- Temperature of the product, if required
36
 Process Control
• Factors to be considered during processing
Time
Temperature
Humidity
Water activity
pH
Pressure and Flow rate

RE-TOOLING CCRR SEMINAR.2013 37

 Hot And Cold Technologies
• Cold Chain Technology- slows down deterioration of
food
Chilling - 0°C- 05°C
- applied to food to be stored only for short
period of time (2 or 3 days for minced
meat, few weeks for some pasteurized
products like milk); according to food type

38
 Hot And Cold Technologies
• Quick Chilling- rapid cooling technique
relates mainly to products cooked in
advance, and to pasteurized products,
after partial microbial decontamination
by the heating process. Product internal
temperature must go down from 63°C to
10°C in under 2hrs (juice, and sauces in
SUP)
39
 Hot And Cold Technologies

Freezing - -18°C
- inhibits virtually all microbial activity and
retards deterioration of biochemical
origin ( pre-cooked and
ready-to-eat)

40
 Hot and Cold Technologies
• Defrosting- a slower process than freezing and
therefore product undergoing treatment tends
to be in a vulnerable state for longer than in
freezing.
- chill room
- microwave technology
- direct cooking of frozen products
- hot water bath
41
 Hot and Cold Technologies
• Heat Processing Technology- based on the use
of heat (time and temperature combination)
- Cooking
- Pasteurization
- Sterilization in can, bottle, pouch or other
pack by the use of Retort.

42
 Hot and Cold Technologies
• Pasteurization and canning- applicable to
Acidified and Low acid foods
- Each manufactured batch shall be composed
of identical products (same chemical and
physical composition, same size, same
shape, and enclosed in the same packaging)

43
 Finished Product Control

• Protect food from potential sources of

contamination
• Protect food from damage likely to render the
food unsuitable for consumption
• Provide an environment which effectively
controls the growth or survival of pathogenic
microorganisms and the toxins in food.
• Finished product analysis

44
 Requirements Associated With QMS

• GMP Organization
• Quality Audit
• Documentation
• Product Recall
• Retention of Sample
• Subcontracting of Manufacture
 FDA Circular No.2013-010

• Thermally Processed in Hermetically Sealed

Container (glass jars/cans)

Commercial Sterility

46
• Chocolate products/Cocoa powder
Molds- 100 cfu/g
Salmonella 25g- negative
Coliform- 1.8MPN/g
SPC/APC- 1000cfu/g

47
• Baked Goods with Egg
S. aureus- 100cfu/g
Molds and Yeast- 100cfu/g
SPC/APC-1000cfu/g
Coliform- 50cfu/g

48
• Baked Goods Coated or Filled, Dried Shelf-
Stable Biscuits
Coliform- 3cfu/g
Salmonella- negative

RE-TOOLING CCRR SEMINAR.2013 49

• Snack Foods
Molds- 10cfu/g
Yeast- 10cfu/g
Coliform- 10MPN/g
SPC/APC- 1000cfu/g

RE-TOOLING CCRR SEMINAR.2013 50

THANK YOU FOR YOUR
ATTENTION…
www.fda.gov.ph