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Description : Check out this medical presentation on Food Poisoning, which is titled "Hygienic and Sanitary Practices for Bakery – Basic Level", for a better understanding of food safety and hygiene requirements and high standards of food safety.

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Hygienic and Sanitary Practices for Bakery – Basic Level
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Learning Outcome This manual is for basic manufacturing outlets including small canteens, caterers, bakeries etc. This manual explains General Requirements on Hygienic and Sanitary Practices to be followed by all Food Business Operators engaged in catering/food service establishments, as per Food Safety & Standard Act, 2006. This manual presents bare minimum requirements of Food Safety and hygiene to be followed by Food Business Operators along with Industry best practices. The objective of this manual is to train the Food Safety Supervisors about GHP requirements that should be followed in a catering business. The FSS may interpret these requirement according to the size and type of their establishment. The desired outcome of this manual is better understanding of food safety and hygiene requirements and high standards of food safety. 2
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Modules Introduction to Food Safety Food Safety in Bakery Practices Good Hygiene (GHP)and Good Manufacturing Practices(GMP) in Bakery Regulation and Technical Skills in Bakery 3
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4 Module I - Introduction to Food Safety
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Food Safety Food Safety can be defined as the assurance that food will not cause harm to the consumer when it is prepared or eaten according to its intended use . 5
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Why Food Safety Is Important? 6
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Sources of Food Contamination Food Contamination Food Spoilage Food Poisoning What’s Wrong? 7
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A food contaminant has been defined as any substance not intentionally added to food, which is present in such food as a result of the production, manufacture, processing, preparation, treatment, packing, transport or storage of such food as a result of environmental contamination. Food Contamination 8
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Sources of Contamination From Farm to Table 9
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Food Contamination Types of Food Contamination
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Jewellery, Hair and fingernails Pest droppings, fur, dust and dirt Paper, Cardboard, threads Wood, glasses, bits of equipments Physical Contamination
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Cleaning Agents Pesticides Residues Non-permitted Food Additives Machinery Grease Chemical Contamination
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Bacteria Viruses Yeast & Molds Biological Contamination 13
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Food Allergens in Bakery Gluten Milk Soybean Pea Nuts Tree Nuts Eggs 14
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Contributing Factors to Food Contamination
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Danger Zone Checking internal temperature of cooked food 16
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Food poisoning is an acute illness, which usually occurs within 1 to 36 hours of eating contaminated or poisonous food. Symptoms normally last from 1 to 7 days and include one or more of the following abdominal pain diarrhea vomiting fever collapse Food Poisoning
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Food Poisoning!
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Food Safety Programs are procedural measures that reduce the likelihood of a food safety or a food quality hazard occurring, but one that may not be directly related to activities taking place during production. Different Food Safety Programs: ❖GMP - Good Manufacturing Practices ❖GHP - Good Hygiene Practices ❖HACCP - Hazard Analysis and Critical Control Point Food Safety Programs
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Module II - Food Safety in Bakery
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Bakery businesses are food processors of largely wheat based products cooked in insulated heated space, the bakery ovens. Baking includes the production of such items as bread, cake, pastry, biscuits, crackers, cookies, and pies where flour is the essential and principal ingredient for the base product Introduction
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Establishments should be built away from: ✓Polluted areas and industry activities ✓Areas subjected to floods ✓Areas prone to infestation by pests ✓Areas where waste cannot be removed effectively Bakery Premises - Location
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Premises and Rooms Facilities: appropriate maintenance, cleaning and disinfections Minimizes contamination: Walls, Floors, Partitions, ceilings, windows - well designed and constructed for easy maintenance and cleaning Design and Layout
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Portable water- for manufacturing and hand washing Non portable water can be used for fire control or steam. However lines used be clearly marked Drainage and waste disposal Personal hygiene facilities, lavatories and changing facilities with hot water (> 40⁰C) Natural and mechanical ventilation Proper ventilation and temperature control mechanism. Natural or artificial lighting Waste Bin with foot operated lid Facilities
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Proper procedures should be available for each equipment like Oven, Mixers, Proofer etc. Easy to dismount, Smooth edges and easily accessible for cleaning, free from dust and pest activity Covered or protected to prevent contamination Cleaned and disinfected after every maintenance procedure All interior surface in contact with the product must be emptying Equipments 25
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Keep Bakery Equipments Clean
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Proper placing of Tools/ Equipments
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Bakery Process Flow
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Raw Material •All material should be procured from vendors who have obtained FSSAI license •All material should be clean and uncontaminated, and safe •All material should be examined at point of receiving for ➢Damage or signs of contamination ➢External dirt on packages ➢Labeling, Product name, Manufacturers name and address, date and code, and all information required by packaging Rules. ➢Material should be easily traceable to its source.
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Raw materials, process materials and products are stored separately at ideal conditions of temp, R.H and air velocity Chemicals, bagged raw materials should be stored on sound pallets Storage area must be free from pests and other contaminants Raw material and finished products must be rotated in First In First Out (FIFO) and First Expiry First Out (FEFO) basis. Storage
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Raw Material Storage
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All dry material must be sifted, and liquids must be filtered before use. Vessels should be clean, and of stainless or non rusting material. Formulas and Recipes should be strictly followed and quantity of additives must be within limits. Any bit of dough that falls to the floor should not be re-mixed, as it can pick up bacterial contamination. All hand tools, spatula, spoons and scoops should be clean and be kept on hygienic surfaces like trays, and clean working table tops. Mixing
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Dividing From bulk dough, unit dough piece or batter is separated for processing before baking. High speed machines, Semi-automatic equipment, and hand work may be involved. Dough bits, dusting flour, and oil if allowed to gather for long, will go rancid, allow bacteria to grow, and encourage fungal growth.
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Dividing •Food should be prepared at steady pace and not allowed to stand more than necessary for process. •Temperature control should be maintained as needed by process.
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Baking and Cooling Oven area should be segregated, to avoid cross contamination with fumes and smoke. Controls should be maintained on temperatures, humidity, and timing of baking. Cooling should be done in as clean an environment as possible. Finishing, cutting, and decorating should be done with all precautions.
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Packaging •Packing material can have unwanted smell from paper or inks. These will get picked up by food. •All packs must carry codes to allow quick tracing of material in event of any issue. •Internal records should be accurately kept. 36
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No Packaging Proper Packaging Packaging of End Products
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Requirement of safe and proper transportation of foods Design and construction of vehicle Clean and/or disinfect Separates food from non food item Maintain temperature Prevents contamination Training of carrier personnel Maintenance of records of written procedures, agreements and training (required of carriers) Verification Procedure Inspection of vehicle Programs describing effective cleaning and sanitation Loading/unloading Materials used in vehicles for food transportation Transportation
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Module III – Good Hygiene and Manufacturing Practices
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Personal Hygiene - A healthy human is covered with microorganisms on hair (incl. beards and mustaches) in the nose in the mouth on the skin under the nails
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The human gastro-intestinal tract excretes microorganisms 41
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Infections occur easily when just one food handler does not observe hand hygiene rules. Only minute amount of certain pathogens can cause infections in humans 42
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Take a shower Wash off dead skin and bacteria Put on clean clothes and footwear Clothes and footwear can carry bacteria into the plant Keep fingernails clean, trimmed and without polish Polish or artificial nails can fall off Before you get to work 43
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Personal Hygiene - Do’s and Don'ts
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•before working with food •after using toilet •after handling rubbish/waste •after smoking, coughing, sneezing, using tissue, eating, drinking, smoking •after touching hair or scalp or mouth Sanitizers do not replace hand washing Hands need to be washed regularly and immediately
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Washing hands the right way only require three elements: •running water, •soap, •and something to dry hands with. Steps of proper hand washing 46
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Dirty facilities Clean facilities Use clean facilities 47
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Maintain Correct Food Temperature 48
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Correct Food Storage 49
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Check Expiry dates and Label Foods 50
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Holes, drains and places must be sealed Food sources should be kept away from the walls and above the ground Doors should have self closing facility Use of poisons are strictly prohibited in the raw materials and production area Insecticides and pesticides used should be of low toxicity and should be approved by the regulatory body Plant inspection and surveillance program must be conducted and documented. Pest Prevention and control 51
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Periodic fumigation to be ensured. Method of fumigation should be approved (like use of Aluminium phosphate which is an approved fumigant) Fumigation is recommended to practice minimum Once in a year. Should be carried by an approved third party (expert and experienced) Post fumigation, the area should be inspected and verified for non- presence of any fumigant residue. Pest Control Measures -Fumigation 52
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52 Ultraviolet Mist Net Sticky fly Papers Rodent Traps Pest control in Bakery
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Strip Curtain Air Curtain Pest control measures in Bakery 54
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Premises and refuse areas kept in clean and tidy condition Waste bin should be washed after emptying Waste must not be allowed to accumulate Spillages are cleared away promptly Food should be covered Drains are kept clean and good conditions Sightings of pests or pest damage are reported to management immediately Stock should be checked regularly and damaged stock removed Pest Control Measures -Good House keeping 55
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Procedure and frequency must be documented Cleaning products- recommended for food industry Labelled and kept outside the production area Litter bins should be covered and fitted with plastic insert Silos must be capable of totally emptied and cleaned Adequate preventive and corrective maintenance to facilitate cleaning operations Cleaning and Sanitation 56
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No Eating in processing area NO SNEEZING No Jewellery, Mobile Forbidden behaviour in a food-handling environment 57
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Wear hair nets/ beard nets No beard Net 58 Proper Beard Net
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Forbidden behaviour in a food-handling environment No gloves 59 Wearing Gloves
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60 Stop Cross Contamination Colour coding of chopping board
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Wash hands with soap and clean water before serving food. Keep food covered prior to serving Serving plates and utensils should be cleaned and air dried Do not reuse and reheat food in disposable wares 5. Eat freshly baked food as far as possible Steps to Serving Safe Food Cold foods should be served chilled and stored in fridge (below 5°C) Hot food should be served and kept above 60°C Wash crockery and cutlery after use Do not serve food pr put ice in a glass with bare hands 10. Use a spoons, tongs or gloves while serving food
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Use Stainless steel utensils Use Copper utensils Use food grade glass, ceramics or porcelain Use Safe disposable wares or single service items Safe Serving Materials (Do’s and Don'ts) × Do not use any kind of plastic wares to serve food × Do not use newspaper to serve food × Do not serve anything sour in non-tinned copper and brass utensils, or aluminum utensils
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Power Outages and Food Safety Keep refrigerator and freezer doors closed. The refrigerator will keep food safe for up to 4 hours. If the power is off longer, you can transfer food to a cooler and fill with ice or frozen gel packs. Keep the freezer full. Fill empty spaces with frozen plastic jugs of water, bags of ice, or gel packs. A full freezer will hold the temperature for approximately 48 hours (24 hours if it is half full). During a Power Outage Never taste food to determine its safety. When In Doubt, Throw It Out! Discard food like milk, cream, fillings, cut fruits , cooked vegetables, pies if your refrigerator has been without power for more than 4 hours: Discard any foods like bread or salad greens that may have become contaminated by juices dripping from raw meat, poultry, or fish. In general, if any food has an unusual odor, color, or texture, throw it out. After a Power Outage
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61 × Never cough or sneeze over food × Toilets should not open directly into any room where food is handled. × Do not wear jewelery/ nail polish while preparing/serving food × Cold foods should never be stored on top or near hot food storage × Waste shall not be permitted to build up in food areas × Never prepare the food with open cut/ wound ✓ Keep food covered ✓ Wear gloves while handling and serving the food ✓ Wear a hair restraint when working with food ✓ Clean and sanitize equipment on a regular basis ✓ Hand basins should be located conveniently and used for hand washing only ✓ Prevent cross-contamination Do’s and Don’ts
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Training Controls Before and After Training 65
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Keep Bakery clean 66
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Correct people BUT ALSO praise 67 A personal thankyou from a supervisor for correct behaviour do wonders.
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65 Module IV - Regulation and Technical Skills in Bakery
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Food Laws in India - FSSAI Food Safety and Standards Authority of India (FSSAI) implements a complete law to control food businesses and ensure food safety. It lays down standards on all food categories and guidelines for Good manufacturing practices that need to be followed. FOOD SAFETY AND STANDARDS ACT, 2006 is applicable on all who are handling food, uniformly across the country. FSSAI is the single authority for Scientific development of Standards Ensuring uniform implementation on who handles food, in manufacture, sale or transportation of all food. Encouraging food Business operatives to be responsible for food safety Encouraging food safety management systems Providing stringent penalties for deliberate or negligent acts that would make food unsafe. 69
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Food Safety 70 Food article made in a bakery can become unsafe if strict controls are not followed during processing. FSSAI defines UNSAFE FOOD as an article of food whose nature, substance or quality is such as to make it injurious to health. The article itself, or its package should not be of poisonous or deleterious substance The article should not have any filthy, rotten, or decomposed substance Food should not be prepared under unhygienic processing Food should not have an ingredient which is not permitted Food article should not be coloured, flavoured, coated, or treated as to damage the article or to make it appear better or of greater value than it really is.
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Filing of an Application Processing of Application Grant Registration Certificate if ok or reject or Issue notice for inspection Conduct inspection – suggest improvement if necessary After Inspection and satisfied with improvement grant registration or reject Application Form A Fees Rs 100/- Within 7 days of receipt of application Within a period of 30 days Food Business operator may start business Licensing Filing of a completed Application Acknowledge application & grant unique application no. Scrutiny, notice on any additional information required or incomplete Application if any FBO files additional required information Inspection of premises & issue inspection report, improvement notice Either grant or reject the license Within 60 days of receipt of completed application or within 30 days of inspection 15 days 30 days FBO may start the busines s after 60 days Application form B No inspection Registration
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Factors affecting Quality of Baked Goods Method of preparation pH Specific Gravity of batter Temperature of batter/ dough Scaling and Leveling Baking Water Activity Food safety measures 72
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Process Control Points – Breads & Biscuits Weighing balance should be calibrated correctly Raw material temperature like flour and water temperature Dough / batter temperature, pH Mixing time Proofing time Proofing temperature and Relative Humidity Oven Temperature Baking Time 73
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Process Control Points in Cake Mixing time Mixing Aeration Amount & type of sprayed greasing oil/fat Temperatures of the different zones of the oven, balance between upper and lower heat, Baking Humidity (level of the chimneys) Baking time, etc. Solid ,Liquid/Recipe Balancing Balance of Sugar against flour. Type of Shortening and its balance against eggs. If Milk is used total weight of egg and milk is balanced against sugar. 74
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Conclusion IN PROCESSING OF BAKERY PRODUCTS, FOOD HANDLERS MUST ENSURE THAT ALL PRECAUTIONS FOLLOW REGULATORY CONTROL HAVE BEEN TAKEN TO AS HEALTH OF THE CONSUMERS IS PRIMARY CONCERN FOR ANY FOOD OPERATION ! 75
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