Establishing and maintaining a good "health procedure" is the basis and premise of implementing HACCP plan. If there is no hygienic control over the food production environment, it will still lead to food insecurity. American 21CFR part110 GMP points out: "Foods processed under conditions unsuitable for food production or unsanitary are adulterated foods, and such foods are not suitable for human consumption." No matter from the perspective of human health or the requirements of international food trade, food producers need to establish good sanitary conditions to produce food. Regardless of the scale of the enterprise and the complexity of production, the hygienic standard operating procedures should play such a role. By implementing the health plan, enterprises can control most food safety problems and related health problems most effectively. In fact, a health plan is a preventive measure to control the pollution sources that lead to unsafe or illegal products.
In China, food production enterprises have formulated various hygiene rules and regulations to control the environment of food production, the hygiene of processing and the health of personnel.
In order to ensure that food is processed in a hygienic state and fully meets GMP requirements, the processing factory should formulate and implement written SSOP or similar documents for products or production sites. The most important thing about SSOP is that it has eight aspects of hygiene (including but not limited to these eight aspects), and the processor will implement it according to these eight main aspects of hygiene control to eliminate health-related hazards. There should also be inspection and monitoring in the implementation process. If the implementation is not effective, there is no need to correct and keep records. These hygiene aspects are applicable to all kinds of food retailers, wholesalers, warehouses and production operations. The hygienic quality of production water (ice) is the key factor affecting food hygiene. For any food processing, the safety of water (ice) must be guaranteed first. A complete SSOP plan for food processing enterprises should first consider that the source and treatment of water (ice) contacting with food or the surface of food contacting objects should comply with relevant regulations, and also consider the cross-pollution of non-production water and sewage treatment.
1) Food processors must provide enough drinking water with appropriate temperature (in line with national drinking water standards). For self-prepared wells, it is usually necessary to recognize the surrounding environment and depth of the well. The wellhead must be tilted away from the well to promote proper drainage, and they are also sealed to prohibit sewage from entering. Water storage equipment (water tower, water storage tank, water storage tank, etc.). ) Clean and disinfect regularly. Whether it is urban water supply or self-provided water source, it must be effectively controlled and can only be used after having a certificate of approval.
2) For the public water supply system, the water supply pipe network diagram must be provided, and the outlet number and pipeline distinguishing mark should be clearly marked. Reasonable design of water supply, waste water and sewage pipelines to prevent cross-contamination of drinking water and sewage and cross-contamination caused by siphon reflux. During the inspection, water and sewage should be traced to the cross-contamination area and dead water area of the pipeline.
Key areas prone to cross-contamination in processing operations include:
Faucets need a typical vacuum interrupter or other backflow preventer to avoid negative pressure. If the water pipe is full of water and the water pipe is not protected by backflow preventer, dirty water may be sucked into drinking water.
Cleaning/thawing/rinsing tank: the water level should not enter the air gap at the edge of the water, and the air gap is twice the diameter of the water inlet pipe to prevent back suction.
It is necessary to analyze coliforms and other components that affect water quality regularly. Enterprises should conduct microbial monitoring at least 1 time every month, and monitor the PH value and residual chlorine of water every day. The local authorities report the monitoring of the whole water project twice a year. Every monitoring and sampling of water must include the main outlet, and all outlets should be completed within one year. Sampling method: disinfect and drain for 5 min.
For wastewater discharge, the ground is required to have a certain slope to facilitate drainage, and processing water, table water or water from cleaning and disinfection pools cannot directly flow to the ground. Ditches (open ditches and underground ditches) should be equipped with perforated filter screens (easy to clean and rust-free), so that water flows from clean areas to unclean areas, and the interface with the outside world should be prevented from odor and mosquitoes and flies.
When ice comes into contact with food or food surface, it must be produced and stored in a hygienic way. Therefore, ice-making with water must meet the drinking water standard, the ice-making equipment is hygienic, non-toxic and rust-free, and the containers for storage, transportation and storage are hygienic, non-toxic and rust-free. Food and unsanitary items cannot be stored together in ice. Ice must be protected from pollution caused by people walking on it, and the inside of the ice maker should be checked to ensure that it is clean and free from cross-contamination.
If there is a problem with the treated water, the treatment should be stopped until the problem is solved. Water monitoring, maintenance and other issues should be recorded and preserved. Keeping the food contact surface clean is to prevent food contamination. Generally, the surfaces in contact with food include: direct (processing equipment, tools and desks, hands or gloves of processing personnel, work clothes, etc. ) and indirect (cold storage, toilet door handles, trash cans, etc. that are not cleaned and disinfected. ).
1) The food contact surface should be thoroughly cleaned before and after processing, and disinfected if necessary. Cleaning and disinfection of processing equipment and utensils: firstly, thoroughly clean (remove nutrients that microorganisms depend on to ensure disinfection effect), then rinse and disinfect (first, water at 82℃ such as meat processing plants, disinfectants such as sodium hypochlorite 100~ 150mg/L, physical methods such as ultraviolet rays and ozone, etc.). ). Cleaning and disinfection frequency of processing equipment and utensils: large equipment should be cleaned immediately after each shift, tools and utensils should be cleaned every 2 ~ 4 hours, and processing equipment and utensils (including hands) should be pollution-free.
2) The inspector needs to judge whether the cleanliness is moderate. In order to achieve this, they need to inspect and monitor areas that are difficult to clean and places where aluminum residues may appear, such as drainage holes drilled under the processing table or on the table, which are ideal places for product residues to gather and microorganisms to multiply.
3) The design and installation of equipment should be easy to clean, which is extremely important for health. The design and installation shall be free from rough welds, cracks and depressions similar to the surface to prevent cleaning and disinfection compounds from being avoided. The contact of different surfaces should be smooth transition. Another related problem is that although the equipment is well designed, it has exceeded its service life and has been scratched or dug so that it cannot be completely cleaned, so this equipment should be repaired or replaced.
The equipment must be made of materials suitable for food surface contact. It should be corrosion-resistant, smooth, easy to clean and rust-free. Materials such as porous and hard-to-clean wood should not be used as food contact surfaces. A food contact surface is any surface that food can contact. If food comes into contact with the wall, then the wall is the product contact surface and needs to be designed together to meet the requirements of maintenance and cleaning.
Contact surfaces of other products include those that directly contact food without manual cleaning and disinfection, such as cold storage, toilet door handles, trash cans, raw material packaging and other places that cannot be fully cleaned and disinfected.
4) Gloves and work clothes are also food contact surfaces. Gloves are easier to clean and disinfect than hands. If gloves are used, each food processing factory should provide proper cleaning and disinfection procedures. Don't use gloves, they don't break easily. Work clothes should be cleaned and disinfected centrally, and there should be a special laundry room. Washing equipment and capacity should be adapted to the actual situation. Work clothes in different areas should be separated and cleaned and disinfected every day (work clothes are used to protect products, not processors). When not in use, it must be stored in a pollution-free place.
Several points for attention in cleaning and disinfection of instruments: fixed places or areas; It is recommended to use hot water, and pay attention to steam discharge and condensed water; Use flowing water; Pay attention to the drainage problem; Pay attention to scientific procedures to prevent the residue of cleaning agents and disinfectants.
When problems are found in the inspection, appropriate methods should be taken to correct them in time, such as re-cleaning, disinfection, checking the concentration of disinfectant and training employees. Records include the inspection of food contact surface conditions; Disinfectant concentration; Surface microbial detection results, etc. The purpose of the record is to provide evidence that the factory disinfection plan is sufficient and has been implemented. Correct problems in time when they are found. Cross-contamination refers to the process that raw food, food processors or food processing environment transfer biological or chemical pollutants into food. This aspect involves the personnel requirements for pollution prevention, the isolation of raw materials and cooked food products, and the design of pollution prevention in factories.
1) personnel requirements. Proper hand cleaning and disinfection can prevent pollution. The purpose of hand washing is to remove organic matter and temporary bacteria, so disinfection can effectively reduce and eliminate bacteria. But if this person wears jewelry or draws on his fingers. Wearing tubular, linear ornaments or bandages will not have a good effect on hand cleaning and disinfection. Organic matter hidden between skin and jewelry or thread belt is an ideal part that leads to the rapid growth of microorganisms, and of course it also becomes a source of pollution.
Personal belongings can also cause pollution and need to be stored away from the production area. They can introduce dirt and bacteria from outside the processing plant, and the storage facilities are not necessarily elaborate rooms, or even small cabinets, as long as they are far away from the production area.
You should not eat, drink or smoke in the processing zone, which is the basic food hygiene requirement. In almost all cases, hands are often close to the nose, and about 50% people have Staphylococcus aureus in their nostrils.
Skin pollution is also a relevant point. Unserified elbows, arms or other exposed skin surfaces should not touch food or food contact surfaces.
2) Isolation. One way to prevent cross-contamination is the reasonable location of factories and the reasonable design and layout of workshops. Before general construction, the sketch of the processing plant should be reviewed repeatedly on the principle of reducing problems, and the relevant departments should be contacted in advance. This problem usually occurs when the production line increases output and installs new equipment.
Food raw materials and finished products must be separated during production and storage to prevent cross-contamination. Examples of possible cross-contamination are contact between raw and cooked products, or ready-to-eat foods are also stored in cold storage where raw materials are stored. Raw materials and finished products must be separated, and the separation of raw material refrigeration and cooked food refrigeration is the best way to solve this cross-pollution. Product storage areas should be inspected daily. In addition, pay attention to the direction of people flow, logistics, water flow and airflow. From the high clean area to the low clean area, people are required to walk through the door and things are required to walk through the delivery port.
3) Personnel operation. Personnel operation can also lead to product pollution. When people treat non-food surfaces and then treat food without cleaning and disinfecting their hands, pollution is easy to occur.
The surface of food processing must be kept clean and hygienic. This includes ensuring that the food contact surface is not contaminated by some actions, such as putting containers or raw material packaging bags that have touched the ground on a clean table, or polluting the food processing surface because water and oil on the ground or other processing areas splash on it.
In case of cross pollution, measures should be taken in time to prevent it from happening again; Stop production when necessary until improvement; If necessary, evaluate the safety of products; Record the corrective actions taken. Records generally include: daily health monitoring records, disinfection control records and corrective measures records. The purpose of hand washing disinfection is to prevent cross-contamination. The general cleaning methods and steps are: washing hands with clear water, scrubbing hand sanitizer, washing hand sanitizer with water, immersing hands in disinfectant for disinfection, rinsing with clear water and drying hands.
Hand washing and disinfection stations need to be located in convenient places and have sufficient numbers. If it's inconvenient, you don't have to. It's also a good idea to move the disinfection car. However, they should not be too close to the product, nor should they cause the risk of product pollution. Need to be equipped with hot and cold mixed water, soap and hand dryer, or other suitable hand drying equipment such as hot air. The structure of the washstand needs to prevent re-pollution, and the faucets are knee-operated, electric automatic or pedal-operated. The inspection should include testing a part of the sink to ensure that it can work normally. The frequency of cleaning and disinfection is generally: every time you enter the workshop; Arrive at 1 h every 30 minutes during processing; When hands come into contact with pollutants, wastes, etc.
A common operation is the function of disinfectant on the workbench. This is to disinfect when the processing personnel dirty their hands or equipment, so as to keep the number of microorganisms to a minimum. But even under the best disinfection conditions, it is not completely effective. Because hands and equipment carry organic substances, it may protect bacteria from disinfectants. Under normal circumstances, disinfectants are used up when oxidizing organic matter, and there is no disinfectant to prevent bacteria from growing. In this way, these disinfectants have actually become pollution sources and should not be encouraged to use them.
Toilets should be barrier-free, sanitary and well maintained, and the doors can be closed automatically and cannot be opened to the processing area. This is related to the entry of airborne or floating pathogens and parasites. The inspection should include flushing every toilet in every factory. If the periphery of the toilet is not sealed, people may get feces and dirt on their shoes and bring them into the treatment area.
Facilities requirements of the bathroom: the location should be connected to the workshop, the door should not face the workshop, and the ground should be dry and clean as a whole; The number should be suitable for the processing personnel; Use squat toilets or toilets that are not easy to pollute; Clean toilet paper and paper basket; Hand washing and mosquito and fly prevention facilities; Take off your work clothes and change your shoes before entering the toilet; Generally speaking, to reach the level of a three-star hotel. Food processing enterprises often use some chemicals, such as lubricants, fuels, pesticides, detergents and disinfectants. And in the process of production, there will be some dirt and waste, such as condensed water and floor dirt. Waste should be controlled in production to prevent food and packaging from being polluted. The key sanitary condition is to ensure that food, food packaging materials and food contact surfaces are not polluted by biological, chemical and physical pollutants.
Processors need to know all the ways that may lead to indirect or unpredictable food contamination, which may lead to unsafe consumption, such as contamination caused by lubricants, fuels, pesticides, condensates and residues in toxic cleaners or aerosols. Factory employees must be trained to prevent and identify these indirect ways that may lead to pollution.
The possible causes of external pollution are as follows:
1) pollution of toxic compounds: non-food grade lubricants are considered as a pollutant because they may contain toxic substances; Fuel pollution may lead to product pollution; Only allowed pesticides and rodenticides can be used to control pests in factories, and they should be used according to the label instructions; Improper use of chemicals, cleaning agents and disinfectants may lead to external pollution of food, such as direct spraying or indirect smoke. When food, food contact surfaces and packaging materials come into contact with the above pollutants, they should be removed, covered or thoroughly cleaned; Employees should be alert to toxic fumes from non-food areas or adjacent processing areas.
2) Pollution caused by unsanitary condensate and stagnant water: Contaminated water droplets or condensate may contain pathogenic bacteria, chemical residues and dirt, resulting in contaminated products; Lack of proper ventilation will cause condensed water or water droplets to drip on products, food contact surfaces and packaging materials; The accumulated water on the ground or the water in the pool may splash on the contact surface between products, thus polluting the products. When feet or vehicles pass through stagnant water, they will splash.
Water droplets and condensed water are common, difficult to control and easy to form mildew. The general control measures are: the ceiling is round; Good ventilation; Rational use of water; Clean up in time; Control the temperature stability of the workshop; Cooling in advance; The common control methods of packaging materials such as drying are: ventilation, drying, mildew prevention and rat prevention; Disinfect if necessary; Store the inner package and the outer package separately. When food is stored, articles should not be mixed, and mildew and rats should be prevented. Proper use and storage of chemicals.
Any dopant that may pollute food or food contact surface is recommended to be inspected 1 time every 4 hours at the beginning of production and during working hours, and daily hygiene control shall be recorded. Food processing requires certain toxic substances. These harmful and toxic compounds mainly include: detergents, disinfectants (such as sodium hypochlorite), pesticides (such as 1605), lubricants, laboratory drugs (such as potassium cyanide), food additives (such as sodium nitrate) and so on. Without them, the factory facilities can't operate, but they must be used carefully, according to the product manual, correctly labeled and stored safely, otherwise the food processed by the enterprise will be polluted.
All these items need to be properly marked and far away from the processing zone, and should have the certificate of approval of the competent department for production, sales and use; Main ingredients, toxicity, dosage and precautions; Cabinet with lock; There should be clear identification and expiration date; Strictly use registration records; Its own separate storage area, if possible, cleaning agents and other toxins and corrosive components should be stored in dense storage areas; There should be trained personnel to manage it. Food processors (including inspectors) are people who are in direct contact with food, and their health directly affects the quality of food hygiene. Manage employees who are sick or have trauma or other physical discomfort. They may become microbial contamination sources of food. Health requirements for employees usually include:
Do not suffer from infectious diseases that hinder food hygiene (such as hepatitis and tuberculosis);
No trauma;
Personal items such as cosmetics and jewelry cannot be brought into the production workshop; You must wear overalls, hats, masks, shoes, etc. , and wash your hands in time for disinfection.
They should hold valid health certificates, make physical examination plans and keep physical examination files, including all processing-related personnel and management personnel, and have good personal hygiene habits and hygiene operation habits.
Personnel involved in diseases, wounds or other possible pollution sources should be isolated in time.
Food production enterprises shall formulate health training plans, regularly train processing personnel, and keep records and files. Pests mainly include rodents, birds, insects and other animals that carry some human pathogenic bacteria. The number of food-borne diseases spread by pests is huge, so pest control is very important for food processing plants. Pest elimination and control includes the whole range of the processing plant (mainly the raw material area), and even the surrounding area of the processing plant, with emphasis on toilets, leftovers outlets, garbage bins, canteens, storage rooms, etc. Hygiene of food and food processing areas is very important for pest control.
Removing any breeding ground that produces insects and pests, such as waste, garbage dumps, unused equipment, product waste and uncleared plants, is a factor to reduce the attraction of pests. Safe and effective pest control must start from outside the factory. Windows, doors and other openings of the plant, such as open skylights, sewage holes and cracks around water pump pipes, can all enter the treatment facility area. The main measures taken include: clearing the breeding ground and preventing the wind curtain, screen window and door curtain from entering, proper rat-proof board, turning over water, etc. It also includes pesticides used in the place of origin, fly-killing lamps used at the door of the workshop, mouse glue, mouse traps and so on. But you can't use rodenticide
It is not allowed to keep livestock in food production and storage areas, such as cats used to prevent rats and dogs or pets used for guarding. The risk of food pollution caused by these animals is similar to that caused by animal pests.
Main problems: daily work is neglected, mainly dealing with inspection, untrue records, improper methods and poor results.
After establishing SSOP, enterprises must also establish monitoring procedures and implement inspection, recording and corrective measures. Enterprises should describe how to monitor the healthy operation of SSOP when formulating monitoring procedures. They must specify who, when and how to complete the monitoring. The monitoring results should be checked, and measures must be taken to correct the unqualified results. All the above monitoring actions, inspection results and corrective measures should be recorded, which shows that the enterprise has not only formulated and implemented SSOP, but also is effective.
Daily health monitoring records of food processing enterprises are important quality records and management data of factories, which should be kept in a unified way.
The basic elements of the health monitoring record form are: for the specific health condition or operation to be monitored, the monitoring condition should be recorded at a predetermined monitoring frequency, and the necessary corrective measures should be recorded.
Monitoring procedures should include: what procedures and norms have been implemented and how to implement them; Who is responsible for the implementation of hygiene procedures? Frequency and place of sanitary operation; Establish monitoring records of health plans.
The monitoring and corrective action records in the health plan will show that the operations in the health plan are under control. In addition, records can also help to point out the existing problems and development trends, and can also show the areas that need to be improved in health plans.
It is necessary to comply with SSOP, which can greatly improve the effectiveness of HACCP plan.