GUIDELINES FOR IMPLEMTING GMP IN FOOD PROCESSING 1. Factory Structure and Fabrication 1.1 Adequate separation including clean and dirty processes 1.1.1 The flow of raw materials, work in progress, finished product, personnel and equipment through the factory should be as linear as possible Auditor's Recommendations Look At: Look For. Factory Layout and Plan Product Flow Diagram Production and process Process Flow Diagram flows in the factory area(s) Product and Process segregated in high and low risk zones describing raw material ersonnel finished product, packaging and waste 1.1.2 Where practical, key process operations should be kept in separate rooms, segregating the early dirty part of the process from the later clean stages Auditor's recommendations Look At. Look For Factory Layout and plan Factory layout with flows indicated clearly with description and no possible Points of possible cross crossing to enable cross-contamination contamination within the flow(s)within the factory 1.1.3 Storage of raw materials and packaging must be segregated to avoid cross contamination and must be separated from the product in production areas Auditors Recommendations Look At Look For Factory Layout and Plan Separated store rooms for dry goods, materials, raw food materials and Observations in plant and finished products 1.1.4 Where segregation is difficult, for example in small, open plan factories, good process flow layout is critically important. The risk of cross contamination may be greatly reduced by the use of physical outs of flo chinery requiring adequa
GUIDELINES FOR IMPLEMTING GMP IN FOOD PROCESSING 1. Factory Structure and Fabrication 1.1 Adequate separation including clean and dirty processes 1.1.1 The flow of raw materials, work in progress, finished product, personnel and equipment through the factory should be as linear as possible. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Production and process flows in the factory area(s) describing raw material, personnel, finished product, packaging and waste. Product Flow Diagram Process Flow Diagram Product and Process segregated in high and low risk zones 1.1.2 Where practical, key process operations should be kept in separate rooms, segregating the early dirty part of the process from the later clean stages. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Points of possible cross contamination within the flow(s) within the factory Factory layout with flows indicated clearly with description and no possible crossing to enable cross-contamination 1.1.3 Storage of raw materials and packaging must be segregated to avoid cross contamination and must be separated from the product in production areas. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Observations in plant and production activity Separated store rooms for dry goods, materials, raw food materials and finished products 1.1.4 Where segregation is difficult, for example in small, open plan factories, good process flow layout is critically important. The risk of cross contamination may be greatly reduced by the use of physical barriers such as partitions (single skin only) or specific layouts of floor machinery requiring adequate space
Auditor's Recommendations Look At: Look For. Factory Layout and Plan Segregation of raw uncooked product from end product within the factory Production and process flow diagrams operations Use of physical boundaries to prevent "free"movement 1.1.5 There must be complete physical separation of the high and low risk areas in terms of raw materials products and personnel. The incorporation of filtered air supplies, positive air pressure and appropriate personnel controls are recommended to maintain the integrity of high-risk areas. This includes facilities to change clothing on entering the department Auditor's Recommendations Look At Look For. Factory Layout and Plan Segregation of High and Low Risk areas is clearly indicated in factory Segregation of High and Low Personnel controls are established at production area entry and exit points, with changing areas segregated from production to maintain control 1.2 Drainage-good repair, dirty and clean separation 1.2.1 The capacity of the drains must be sufficient to cope with the maximum process requirements placed on them Auditor's Recommendations Look At. Look For. Factory Layout and Plan Location of drains in factory related to factory activity to allow suitable Drainage points in factory drainage for process requirement and drain capacity 1.2.2 The floors must be adequately drained with the fall of the floors carefully designed to ensure that all liquids flow towards proper drainage channels. There shall be no standing pools of liquid. These could be minimised by using PVC pipes Auditor's recommendations Look At. ook For: Factory Layout and Plan Camber /slope of floor should be sufficient to safely allow flow to drainage hannes 1.2.3 Drainage channels that are half round in section with both the drains and gullies covered with removable easily cleaned grids are recommended
Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Production and process operations Segregation of raw / uncooked product from end product within the factory flow diagrams Use of physical boundaries to prevent “free” movement 1.1.5 There must be complete physical separation of the high and low risk areas in terms of raw materials, products and personnel. The incorporation of filtered air supplies, positive air pressure and appropriate personnel controls are recommended to maintain the integrity of high-risk areas. This includes facilities to change clothing on entering the department. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Segregation of High and Low risk Segregation of High and Low Risk areas is clearly indicated in factory Personnel controls are established at production area entry and exit points, with changing areas segregated from production to maintain control 1.2 Drainage - good repair, dirty and clean separation 1.2.1 The capacity of the drains must be sufficient to cope with the maximum process requirements placed on them. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Drainage points in factory and drain capacity Location of drains in factory related to factory activity to allow suitable drainage for process requirement 1.2.2 The floors must be adequately drained with the fall of the floors carefully designed to ensure that all liquids flow towards proper drainage channels. There shall be no standing pools of liquid. These could be minimised by using PVC pipes. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Camber / slope of floor should be sufficient to safely allow flow to drainage channels 1.2.3 Drainage channels that are half round in section with both the drains and gullies covered with removable easily cleaned grids are recommended
Auditor's Recommendations Look At: Look For. Drainage Channels Design to meet standard requirements Drain covers/grids suitable Size of apertures in grid suitable to prevent large gross debris from entering for process activity and aid main drain, but does not restrict flow to and through drainage channels Frequency and maintenance of drain covers grids prevents drain blockage Maintenance/cleaning of and formation of standing pools of liquid 1.2.4 In high-risk premises, the flow of the drains shall be from high to low risk to avoid contamination of the clean environment Auditor's Recommendations Look At: Look For. Factory Layout and Plan Slope of drain and separation of drain from high and low risk areas where Drainage channels Flow of drainage through If not possible ensure drain flows from high to low risk to avoid 1.2.5 Positioning of machinery in relation to access to drains shall not compromise regular cleaning Auditor's Recommendations. Look At. Look For Factory Layout and Plan Positioning of equipment does not create blockage of drains nor does it Location of equipment an create an unsafe working environment materials Cleaning Plan and Schedule Use of cleaning schedule to ensure cleaning of drains and their maintenance 1.2.6 Adequate debris traps should be fitted to all drains and any manhole covers properly greased and sealed Auditor's Recommendations Look At Look For Design and positioning of Positioning of debris traps ensure effective retention of heavy / gross debris debris traps Located outside the working environment and properly sealed and maintained to ensure safe access Manhole covers
Auditor’s Recommendations: Look At: Look For: Drainage Channels Drain covers / grids suitable for process activity and aid flow Maintenance / cleaning of grids Design to meet standard requirements Size of apertures in grid suitable to prevent large gross debris from entering main drain, but does not restrict flow to and through drainage channels Frequency and maintenance of drain covers / grids prevents drain blockage and formation of standing pools of liquid 1.2.4 In high-risk premises, the flow of the drains shall be from high to low risk to avoid contamination of the clean environment. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Drainage channels Flow of drainage through factory Slope of drain and separation of drain from high and low risk areas where possible. If not possible ensure drain flows from high to low risk to avoid contamination. 1.2.5 Positioning of machinery in relation to access to drains shall not compromise regular cleaning. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Location of equipment and materials Cleaning Plan and Schedule Positioning of equipment does not create blockage of drains nor does it create an unsafe working environment Use of cleaning schedule to ensure cleaning of drains and their maintenance 1.2.6 Adequate debris traps should be fitted to all drains and any manhole covers properly greased and sealed. Auditor’s Recommendations: Look At: Look For: Design and positioning of debris traps Manhole covers Positioning of debris traps ensure effective retention of heavy / gross debris Located outside the working environment and properly sealed and maintained to ensure safe access
1.2.7 Drainage entry and exit points into the building must be pest proofed. Fumigation of drains is acceptable Auditors Recommendations. Look At: Look For. Factory Layout and Plan Ability for pests to enter Entry and exit points of Suitable pest proofing activities in place to prevent access by pests drainage system 1.2.8 Damaged drains must be repaired as quickly as possible to prevent any blockages or accumulation of debris Auditor's recommendations Look At: Look For: Maintenance and Inspection Up to date records of inspection and maintenance of the drains. This may be covered within appropriate cleaning activities Preventative measures Drain blockages and preventative measure(s) 1.3 Personnel movement, wash hand basin facilities on entry Auditor's Recommendations 1.3.1 All operatives must enter the factory by a specific entrance, to a dedicated changing area where showering, hand washing and toilet facilities are available, and where outer garments are exchanged for work wear Auditor's Recommendations. Look At Look For Factory Layout and Plan Production staff personnel movement within factory meets food safety requirements for entry and exit from production areas Personnel confined to designated work areas 1.3.2 At the entrances to process areas, personnel should be guided to hand wash stations using appropriate means e.g use of guard rails, guard rail supervisor
1.2.7 Drainage entry and exit points into the building must be pest proofed. Fumigation of drains is acceptable. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Entry and exit points of drainage system Ability for pests to enter Suitable pest proofing activities in place to prevent access by pests 1.2.8 Damaged drains must be repaired as quickly as possible to prevent any blockages or accumulation of debris. Auditor’s Recommendations: Look At: Look For: Maintenance and Inspection records Preventative measures Up to date records of inspection and maintenance of the drains. This may be covered within appropriate cleaning activities Drain blockages and preventative measure(s) 1.3 Personnel movement, wash hand basin facilities on entry Auditor’s Recommendations: 1.3.1 All operatives must enter the factory by a specific entrance, to a dedicated changing area where showering, hand washing and toilet facilities are available, and where outer garments are exchanged for work wear. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Production staff / personnel movement within factory meets food safety requirements for entry and exit from production areas Personnel confined to designated work areas 1.3.2 At the entrances to process areas, personnel should be guided to hand wash stations using appropriate means e.g use of guard rails, guard rail supervisor
Auditor's Recommendations Look At: Look For. Factory Layout and Plar Clarity of hand wash signs Position of hand wash Partitioning of basins on Segregated / partitioned hand wash facilities on entry / exit entrance / exit 1.3.3 Hand-washing facilities must be suitably trapped and plumbed directly to drains Auditor's Recommendations Look At Look For Factory Layout and Plan Plumbing of hand-wash facilities directly to drains with suitable traps.This Design of wash basins and should lead directly into the drain and not allow splash, spillage or standing plumbing pools of liquid to form 1.3.4 Movement between different areas of the factory must be minimised, and constantly monitored by management. Recommended that the use of process areas as corridors from one area to another should be controlled Auditor's Recommendations Look At Look For Factory Layout and Plan Description and clear indication of the routes for product, by-product, personnel and raw material transport through the factory 1.3.5 To reduce the risk of cross contamination, boot washing facilities of adequate size and capacity shall be provided at entry points to processing areas and at transfer points between dirty and clean areas Transfer of operatives across these boundaries limited Auditor's Recommendations. Look At Look For Factory Layout and Plan Positioning of suitable wash facilities outside or segregated from the factory production must be provided to restrict and cross-contamination and Washing facilities provided personnel movement at transfer points Siting of equipment 1.4.1 All machinery should be positioned to give easy access to all parts for cleaning. Equipment must be at least 50cm from adjacent walls
Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Position of hand wash basins Partitioning of basins on entrance / exit Clarity of hand wash signs Segregated / partitioned hand wash facilities on entry / exit 1.3.3 Hand-washing facilities must be suitably trapped and plumbed directly to drains. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Design of wash basins and plumbing Plumbing of hand-wash facilities directly to drains with suitable traps. This should lead directly into the drain and not allow splash, spillage or standing pools of liquid to form 1.3.4 Movement between different areas of the factory must be minimised, and constantly monitored by management. Recommended that the use of process areas as corridors from one area to another should be controlled. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Description and clear indication of the routes for product, by-product, personnel and raw material transport through the factory 1.3.5 To reduce the risk of cross contamination, boot washing facilities of adequate size and capacity shall be provided at entry points to processing areas and at transfer points between dirty and clean areas. Transfer of operatives across these boundaries limited. Auditor’s Recommendations: Look At: Look For: Factory Layout and Plan Washing facilities provided at transfer points Positioning of suitable wash facilities outside or segregated from the factory production must be provided to restrict and cross-contamination and personnel movement. 1.4 Siting of equipment 1.4.1 All machinery should be positioned to give easy access to all parts for cleaning. Equipment must be at least 50cm from adjacent walls