Safety and sanitation

Question 1

cGMP

Answer 1

Current Good Manufacturing Practices

Question 2

CIP

Answer 2

Cleaned-in-place

Question 3

FSMA

Answer 3

Food Safety Modernization Act (2011)

Question 4

FSP

Answer 4

Food Safety plan

Question 5

HACCP

Answer 5

Hazard analysis, critical control point

Question 6

HARPC

Answer 6

Hazard Analysis and Risk-Based Preventative Controls

Question 7

PCQI

Answer 7

Preventative controls qualified individual

Question 8

Prerequisite program

Answer 8

many components; allows HACCP to
operate (PM, CIP design, SSOP, GMP)

Question 9

SSOP

Answer 9

Sanitation Standard Operating Procedures

Question 10

FSMA

Answer 10

Food Safety Modernization Act

Question 11

GFSI

Answer 11

Global Food Safety Initiative

Question 12

The HARPC Model

Answer 12

Biological, chemical, physical and radiological hazards.
* Natural toxins, pesticides, drug residues, decomposition, parasites,
allergens, and unapproved food and color additives.
* Naturally occurring hazards or unintentionally introduced hazards.
* Intentionally introduced hazards (including acts of terrorism).
* Sanitation procedures at food surface contact points.
* Sanitation of utensils and equipment.
* Staff hygiene training.
* Environmental monitoring program (for pathogen controls).
* Food allergen control program.
* Recall plan.
* Current Good Manufacturing Practices (cGMPs).
* Supplier verification activities.
* Validate, verify.

Question 13

cGMP’s may include

Answer 13

Grounds
* Plant design, construction
* Equipment (see 3A)
* Process and controls
* Cleaning and sanitizing
* Storage systems
* Pest control
* Plant chemical handling
* Personal hygiene
* Packaging
* Traffic patterns, carts

Question 14

3-A SSI

Answer 14

3-A Sanitary Standards, Inc maintains a large
inventory of design criteria for equipment and
processing systems developed using a modern
consensus process based on ANSI (American
National Standards Institute) requirements to
promote acceptance by USDA, FDA and state
regulatory authorities

Question 15

Traffic Patterns

Answer 15

People movement?
– Employees?
– Maintenance?
– Visitors?
* Tools, equipment, supplies, etc?
* Lifts/jacks, carts?
* Packaging?
* Finished product?
* Trash containers?

Question 16

Employees

Answer 16

Hair restraint
* Minimal/no jewelry
* No items in pockets
* Hand habits
* Hand washing
* No eating, drinking, smoking, chewing
* No contagious illness, e.g.:
– Skin
– Respiratory
– Gastrointestinal
– No open wounds
* Documented training, documented understanding

Question 17

Pests

Answer 17

• Insects, birds, rodents
• Traps inside
• Baits outside
• Licensed applicator
• Protective gear
• Recordkeeping is essential!

Question 18

3 E’s

Answer 18

• Entry
• Edibles
• Existence

Question 19

SSOP’s include

Answer 19

Written practices
* Person in charge
* Logs signed by workers
* Records kept
* Pre-operational, operational, post-operational
* Food contact cleaning, maintenance, storage
* Sanitizer application

Question 20

SSOP: Why we clean and sanitize?

Answer 20

Prevent batch to batch contamination
– Spoilage microbes will cause short shelf-life,
more returns, decreased customer satisfaction
– Pathogenic microbes leads to illness or death
– Allergens may cause illness or death
* Prevent growth of microbes
– Short shelf life, toxins, pathogens
* Prevent reduced equipment efficiency
– For example, fouled heat exchangers

Question 21

HACCP Principle 1

Answer 21

– Hazard Analysis – what can go wrong?

Question 22

HACCP Principle 2

Answer 22

– Critical Control Points (CCPs) – what steps must I do to prevent hazards from occurring?

Question 23

HACCP Principle 3

Answer 23

– Critical Limits – what boundaries must these key steps fall within?

Question 24

HACCP Principle 4

Answer 24

– Monitoring – how will I make sure the Critical Limits are met?

Question 25

HACCP Principle 5

Answer 25

– Corrective Actions – what do I do if the Critical Limits are not met?

Question 26

HACCP Principle 6

Answer 26

– Verification – what activities must be done to be sure the system is working?

Question 27

HACCP Principle 7

Answer 27

– Record Keeping – How do I document the system of ensuring food safety?

Question 28

Establishing Critical Limits (CL)

Answer 28

– Limits need to as rigorous as the applicable regulations – Use government guidance, if available – Non-regulatory CL need scientific validation – Choose the best CL parameters (easy, measurable) – Consider operational limits to avoid deviations and corrective actions

Question 29

Establish Monitoring procedures

Answer 29

– Who – What – When – Where – How – Frequency of monitoring is tied to amount of product to deal with after deviation – Start with templates

Question 30

Cleaning and Sanitizing

Answer 30

* The Foundation of SSOP/GMP * Dictates Equipment Design * Often only line of defense

Question 31

Chemicals in Food Processing

Answer 31

* Foodgrade different safe * Labeling in place * MDSs must be – Accurate – Available – Understood * Proper Attire – Eyewear/facemask – Respirator – Gloves – Apron – Footwear

Question 32

“Clean” Defined

Answer 32

Free from protein, carbs, FOG (fat, oil, grease), mineral and water

Question 33

Cleaner Characteristics

Answer 33

Cleaner Characteristics * Cleaners are – 99+% water; water quality? – Designed to lower surface tension – Soil specific – Affected by * Temp * Concentration * Time * Mechanical action * Surface features – Serious health threats if mishandled

Question 34

Alkaline Cleaning Compounds

Answer 34

– Strong, heavy duty, mild – Broad spectrum – May contain chlorine- why? – Can be corrosive – Little effect on mineral deposits

Question 35

Acid Cleaners

Answer 35

– Remove mineral deposits ie milkstone – Corrosive/may cause allergic reactions

Question 36

Detergent Cleaners

Answer 36

– Act like soap – Emulsify FOG – Gentle

Question 37

Enzyme Cleaners

Answer 37

– “Digest” food soils – Less corrosive – Heat sensitive

Question 38

Cleaning Steps

Answer 38

1 Pre-rinse 2 Circulate alkaline cleaner 3 Rinse 4 Acid cleaner 5 Post rinse 6 Cooling 7 Verification

Question 39

Pre-rinse

Answer 39

120°F not hot water to not denaturate proteins, 99% of soils removed

Question 40

Circulate alkaline

Answer 40

concentration of chemicals, temperature, time, turbulence

Question 41

Verification

Answer 41

ATP, visual, blacklight

Question 42

TACT

Answer 42

5 ft/sec, 1.5% NaOH, 180°F, 60 min

Question 43

Cleaning: Surface Features

Answer 43

Pitted Weld quality Pipe fittings, configurations

Question 44

COP

Answer 44

Equipment disassembled * Manual procedure * Equipment not designed for CIP * Side to side/ push pull action * Less expensive * Least repeatable * Safety concern

Question 45

COP Tank - Operation

Answer 45

* Completely dissemble equipment * Place small items in basket/rack * Layout – Avoid inlet/outlet ports – Allow good circulation * Rinse well with warm water, drain open * Completely flood (hot water) all parts/rotate larger ones * Add chemicals after filling – Less splashing – Less equipment damage/staining * Pumps on,15-25 min circulation * Hot water rinse, visual inspection

Question 46

Manual Cleaning

Answer 46

* Completely dismantle equipment * Use manual cleaner * Hottest water you can tolerate * Goggles/shield, gloves * Use mat for delicate parts * Designated cart? - don’t lose parts * Rinse, visual inspection

Question 47

Brushes and Utensils

Answer 47

* Color coded * Nylon/polymer * Good repair * No wood * No steel wool

Question 48

Utensil rack

Answer 48

* Drainage * Air dry * Accountable

Question 49

CIP

Answer 49

* Automated procedure * Equipment must be CIP compliant * Safer to personnel * Most expensive * Most efficient * Most effective

Question 50

Types of spray devices

Answer 50

Fixed spray, rotating spray

Question 51

Fixed spray

Answer 51

Most Common No Moving Parts

Question 52

Rotating spray

Answer 52

Reaction Drive Auxiliary Drive Integrated Turbine

Question 53

“Sanitizing” Definition

Answer 53

Reduction/elimination of primarily bacteria

Question 54

“Sanitizing” Defined

Answer 54

– Does not imply “sterilization” – Required log reductions of target microbes – See Chambers test – Under EPA regulations – Bacterial resistance?

Question 55

Techniques for Killing Microbes

Answer 55

* Heat * Irradiation * Electric currents * High pressure * Other * Chemicals

Question 56

Chemical Sanitizers Properties

Answer 56

* Desirable are: – Broad Spectrum Kill – Good “Cleanability” Properties – Nontoxic/nonirritating – Water Soluble – Odorless – Stable During Storage – Inexpensive – Can use in no-rinse levels * Efficacy Influenced by – Exposure Time – Temperature – Concentration – Water characteristics, pH etc – Soil residual from inadeq. cleaning

Question 57

Chlorine-Based Sanitizers

Answer 57

* Plus – Most Commonly Used – Broad Spectrum Kill – Come in Several Forms – Least Expensive – Can be used at no-rinse levels * Minus – Poor Residual Activity – Corrosive to Equipment – Activity is pH Dependent – More is Not Necessarily Better – Gasses off if heated in open system

Question 58

HOCl is

Answer 58

– 100X more effective than -OCl – Favored at neut. to sl. acidic conditions – More is not necessarily better

Question 59

Acid Sanitizers

Answer 59

e.g. formic, propionic, peroxyacetic acid * Plus – Heat stable <212F – Non-selective – Low toxicity – pH tolerant; acidic conditions favored * Minus – High cost – Can be corrosive – Odor

Question 60

Quaternary Ammonia

Answer 60

* aka “Quats” * Used Often in Foot Baths * Plus – High Residual Activity – Effective Against L. mono. – Less Corrosive * Minus – High Residual Activity – Limited Effectiveness (gm-) – Form Films on Equipment Surfaces

Question 61

Chemical Sanitizers Application

Answer 61

* Done immediately before processing, not necessarily after cleaning * Because each is selective, rotation can be practiced * More is not better – Corrosion – Regulatory issue – Decreased efficacy * Also influenced by – Time – Temperature – Concentration – Mechanical action – Surface features * Not effective in presence of soils