Implementing HACCP based food quality and safety programs at Industries

Dr.A.P.Gnadhi
Principal Scientist (Biochemistry)
Soybean Processing and Utilization Center
Central Institute of Agricultural Engineering, Bhopal (MP), India

For implementing the HACCP at Industries we need to have key sanitation conditions
and practices, some common prerequisite programmes and finally the HACCP plan for
the specific food product.
Key sanitation conditions and practices
- Safety water
- Condition and cleanliness of food contact surfaces.
- Prevention of cross contamination
- Maintenance of hand washing, hand sanitizing and toilet facilities.
- Protection from adulterants
- Labeling, storage and use of toxic chemicals
- Employee health conditions
- Exclusion of pets.

Safety of water: The source of water for processing and other allied activities is to be
different and specified. The water sample is tobe tested periodically for chlorine residual,
pH, alkalinity and color. It should also be tested for metals like aluminum, iron, coliforms
and other physical, chemical and microbial characteristics. The water should be collected
randomly from the source. It should be certified for its purity before using it for
processing.
Conditions and cleanliness of food contact surfaces: Food contact surfaces must be
adequately cleanable (do not have cracks, cavities, crevices, overlapping joints, mineral
scale etc that are not possible to adequately clean and sanitize). Good stainless tables with
poly tops and no wood supports are adequate. One should remember that items that rust
should not be included in a plant with highly corrosive ingredients (salt). Food contact
surfaces are to be cleaned and sanitized. All the sanitizers, cleaners and chemicals
available have to be diluted and transferred to separate containers and adequately labeled.
Workers should wear clean gloves and outer garments. Clothes, gloves, boots and
hairnets must be made available at the plant site. A major job is the washing of clothes.
To ensure there is no contamination of washed laundry and that the correct chemicals are
used there should be a separate laundry attached to the factory or should be cleaned by
the housemaid who is thoroughly trained by the HACCP officer.
Prevention of cross contamination: This involves the prevention of microorganisms
contaminating product in its evolution from a raw product to a final packaged product.
Good basic factory design is necessary. Emphasis should be placed on simple things such
as grounds, wall construction, drains, internal and external flood, sewage and grease trap,
fresh water plumbing antisiphoning devices, waste removal, paint and protective
coverings, bath rooms, laundry and washing chemicals, chemical storage and pest
exclusion.
Maintenance of hand washing, hand sanitizing and toilet facilities: Toilet facilities are
to be provided off the workers’ dressing rooms physically separated from processing
areas. Hand washing/ sanitizing facilities are to be provided in raw and finished
processing areas and in the toilet facility. Hand washing facilities should have knee-
activated valves, liquid sanitizing hand soap and hand sanitizer solution, disposable hand
towels, signs directing the workers to wash their hands and gloves thoroughly. Hands
should be washed and sanitized before starting work, after each absence from the
workstation and anytime they have become soiled or contaminated. Sanitation supervisor
should inspect the hand washing facilities and check the hand sanitizer strength.
Protection from adulterants: Cleaning compounds, sanitizers and lubricants used in
processing and packaging areas are to be approved for use in the food plants. Receiving
Manager should check the invoices at receiving before food grade chemicals are stored.
Food grade and non-food grade chemicals lubricants are to be stored separately outside
processing and packaging areas. Food, food packaging materials and food contact
surfaces are to be protected from adulteration from biological, chemical and physical
contaminants. Safety type light fixtures are to be used in processing and packaging areas.
Sanitation supervisor must inspect the processing and packaging areas. Equipment must
be in good condition with no loose or missing metal parts. Sanitation supervisor must
inspect the processing and packaging equipment. Drip or condensate does not
contaminate food or packaging materials.
Labeling, storage and use of toxic compounds: All toxic compounds in the plant are to
be labeled with the manufacturers’ name, use instructions and the appropriate EPA
approval or have documentation with the necessary information. All manufacturers’
instructions and recommendations are to be followed.
Employee health conditions: Workers must report to their immediate supervisor any
health condition that might result in food contamination. Supervisors report suspected
health problems to the plant manager. The plant manager decides if a potential food
contamination situation exists. Supervisors should check for infected lesions that might
contaminate food.
Exclusion of pests: Plant Manager should inspect the exterior and interior of the building
and treat as necessary with appropriate chemicals. The plant grounds and interior areas
should be kept free of litter, waste and other conditions that might attract pests. Outer
plant doors should be kept closed; processing areas are to be screened with plastic
curtains and electric bug killing devise located outside entrances to processing areas. No
pets and animals are allowed in the plants. Supervisors report any pest problems to the
Plant Manager. The sanitation supervisor inspects for the presence of pests. Rats are a
problem. The plant should be constructed correctly. All walls and doors are to be built to
comply with GMP regulations.
Common pre requisite programmes:
Facilities: Current good manufacturing Practice in manufacturing, packing or holding
human food must be adopted.
Production equipment: The equipment and utensils must be calibrated for precision
control of unit operations during processing.
Standard Operating Procedures: These procedures are to be followed through out the
food chain to maintain the quality and safety of the product.
Storage and handling controls: Storage conditions should be strictly adhered to. The
handling protocols must be followed to minimize the contamination.
Suppliers Control: Incoming materials like ingredients, food additives, packaging,
cartons etc must be as per the prescribed standards.
Product specifications: We should develop written specifications for all ingredients,
products and packaging materials. These are to be sent to the suppliers.
Personal policies: Policies and procedures for employees must be well spelt out. Regular
trainings for GMPs, sanitation procedures, personal safety, and HACCP must be
organized.
Traceability and recalls: There must be provision for the recalls of customers’
complaints handling.
Waste Management: There should be an excellent waste disposal system to maintain the
hygiene.
Product Testing: There should be facilities for getting the product tested for different
physico chemical and microbiological profiles.

HACCP: We should provide the HACCP plan to the employees at all stages of
processing and procurement. The plant should have facility for drafting its own flow
diagram and HACCP plan based on the hazard analysis conducted by the multi
disciplinary team.

If the Plant follows these instructions, a good quality product with safety will be
produced that has domestic as well international demand. Let us strictly follow the total
hygienic practices.