SANITATION GUIDEMANUAL Prepared by: The Vinegar Institute 5775-G Peachtree-Dunwoody Road Atlanta, GA 30342-1507 1
INDEX FOREWORD iii FDA S GOOD MANUFACTURING PRACTICE SANITATION GUIDELINES SANITATION EVALUATION SANITATION CHECK LIST PEST CONTROL 2
FOREWORD It is incumbent upon the industry to establish procedures that ensure that each facility and all practices involved in the manufacture of vinegar meet FDA sanitation standards. Chapter 21, Part 110 of the Code of Federal Regulations (CFR) contains the FDA s current food manufacturing practice (sanitation) in manufacturing, processing, packaging or holding human food. The criteria in Part 110 determine whether a food is fit for human consumption and not deemed adulterated. In Part 110, the FDA lists the following factors as sources and routes of contamination in food plants: Poor personal hygiene on the part of employees Prevalence of rats, mice and other vermin Incidence of flies Use of unclean equipment Polluted water or ice supplies Use of unfit raw materials Inadequate service facilities, toilets and washrooms Undesirable structural features of buildings, lights, ventilation Improper waste and sewage disposal FDA s Good Manufacturing Practices (GMPs) have set minimum sanitary standards in all areas that influence the processing and storage of food, including: Personnel Plant and grounds Sanitary operations Sanitary facilities and controls 3
Equipment and utensils Processes and controls Wearhousing and Distribution Defect Action Levels To ensure sanitary manufacturing procedures, manufacturers should set up and enforce stringent sanitation controls. The Sanitation Guide in the VI Basic Reference Manual will assist in developing an effective self-inspection program. The guide includes: 1. FDA Good Manufacturing Practices 2. Sanitation Guidelines 3. Sanitation Evaluation Form 4. Sanitation Check List 5. Rodent and Pest Control System Sample Forms The Guide should be used as a starting point. Each production facility and operation differs, and the information included in this guide should be adapted to your individual needs in order to maintain high sanitation standards. **** 4
FDA GOOD MANUFACTURING PRACTICES https://www.accessdata.fda.gov/scripts/cdrh/cfdocs/cfcfr/cfrsearch.cfm?cfrpart=110&sho wfr=1 5
SANITATION GUIDELINES 6
I. GROUNDS All grounds, including roads and parking lots, should be properly maintained and free from excessive dust. A clear zone of at least 18 inches, free of all vegetation, debris, or other material, is recommended around the perimeter of all buildings. Placement of crushed rock in the clear zone is also advised to further discourage pest activity. Grass, weeds, and other vegetation on other plant grounds should be kept cut. All trash and waste must be kept in containers and covered. All grounds must be kept free of rodents and vermin; where infestation exists, immediate steps must be taken for extermination. Any dock areas and railroad tracks should be kept free of debris. II. BUILDINGS Buildings should be of proper size and construction for an orderly, efficient, manufacturing process. All doors should open outward, and all openings, including doors, windows, roof ventilators, and skylights should be screened and in good repair. Installation of louvers are recommended on all exhaust fans to the plant exterior to reduce pest entry while fans are not in operation. Walls and ceilings are to be clean, smooth, free of holes, and well painted with non-toxic paint. Double walls and false ceilings, which would create a pest harborage, should be avoided. Buildings should have sufficient natural or artificial lighting, with lights clean and equipped with protection covers. To ensure proper drainage, floors should be clean and level. Where flooding-type cleaning, or other excess water is likely, floor drains should be provided. Sewers should be sufficient; drains, pipes and sewage lines clean and unclogged; floor gutters clean and adequate. There should be sufficient hose connections and proper hose storage. Facilities for ventilation and exhaust should be adequate. Rubbish and trash are to be properly contained and removed daily, and all areas kept free from dead or live insects, rodents and birds. There should be separation by partitions or location of those operations which may cause cross-contamination of food products with bacteria, molds, toxic chemicals and other undesirable materials. 7
III. EQUIPMENT AND UTENSILS An efficient sanitation program should be employed, with effective detergents for cleaning, and sanitizers for sanitizing tanks, filters, lines and floors. All detergents and sanitizing agents should be properly marked and segregated. It is recommended that an approved sanitizing procedure be followed, as prescribed in the Milk Ordinance & Code or the Restaurant & Food Establishment Ordinance & Code, U.S. Public Health Service, Washington, D.C. All equipment, utensils, etc., are to be kept clean and in good repair. Where feasible, equipment should be dismantled for cleaning. When purchasing, sanitary provisions and specifications should be taken into consideration. Cleaned and sanitized equipment and utensils should be stored above the floor in a clean, dry location to avoid contamination. The product-contact surfaces of all equipment and utensils should be non-toxic. To reduce the risk of contamination, containers intended for food contact, including finished product packaging, must not be used for storage of materials other than the designated purpose of the container. All containers must be clearly marked. Aisles or working spaces between equipment and between equipment and walls shall be kept clean, clear of debris, and be wide enough to permit employees to perform their duties without contamination of food. IV. VERMIN AND PEST CONTROL A major objective for all housekeeping is to prevent the buildup of materials that can serve as harborage for infestation. This is by far the best tool for effective pest management. An effective control program should be employed to eliminate pests and control breeding. If an exterminator service is used, proper inspection records and findings should be kept. Caution is to be employed in the use of insecticides, to prevent contamination of foods and equipment. All pesticides used in the 8
plant should be USDA approved and have readable labels. certified pest control operators should handle pesticides. Only Particular care should be taken to avoid dirt collecting around wooden tanks. Sample forms are included in this Manual to assist in setting up a vermin control system. V. OPERATIONS AND PROCESSING Raw materials and ingredients are to be inspected on receipt to assure that they are clean, wholesome, and fit for processing into human food. Storage facilities for both raw materials and finished product should be adequate to protect against contamination and minimize deterioration. There shall be a water supply ample for the operations intended. All water and ice used in contact with food products shall be of potable quality, not re-used, and protected from surface contamination. There shall be an adequate supply of running hot water for peak needs, and facilities shall be provided for maintaining water at 170 F. for sanitizing where needed. (Further assistance in this area is available from Standard Methods for the Examination of Water, Sewage and Industrial Wastes, American Public Health Association, 1790 Broadway, New York, New York.) Sewage disposals shall be made into a public sewage system or an adequate private sewerage system. Plumbing shall be of adequate design and size, and properly maintained to carry ample quantities of water throughout the plant, and to convey sewage and waste from the plant to the sewage disposal system. Plumbing cross connections, which might permit back siphonage of sewage into the water supply, shall be avoided. Vacuum breakers or back flow preventers must be installed on water supply lines to prevent contamination of fresh water supply in the event of backflow. An effective system for rotation of vinegar nutrients should be implemented. All ingredients should be stored in covered containers. All storage should be on proper skids or pallets at least six to eight inches off the floor, and 12 to 18 away from the wall. Accurate testing methods should be used to identify and reject sanitation failures or food adulterants. 9
Care shall be taken that packing processes and materials provide adequate protection from adulteration and not transmit contaminants to the product. Containers should be air blown before filling. Effective record-keeping and product coding procedures should be followed, and written records retained for at least two years. Storage and transportation of the finished product shall be controlled to protect against contamination and deterioration. VI. PERSONNEL PRACTICES All employees should wear proper and clean uniforms, and wear adequate head covering, with all hair protected. Clean gloves are to be used in food handling. Employees with colds or other communicable diseases, boils, open sores, bandages, etc. should be transferred to non-product-handling areas. Good toilet habits are to be required, including flushing facilities after using, and hand washing. Hands are to be thoroughly washed and sanitized, if necessary, before starting work, after each absence from the work station, and any other time the hands have become soiled or contaminated. The use of tobacco products, eating, and gum chewing must be prohibited in production areas. Jewelry and fingernail polish are to be avoided. VII. EMPLOYEE FACILITIES Adequate toilet facilities should be available, including hot and cold running water, toilet tissue, soap or detergent, and suitable drying devices. Signs are to be posted requiring employees to wash their hands with soap and water after using toilet facilities. Hand-sanitizing facilities are recommended in food-processing and -handling areas. Faucets should be designed with devices or fixtures such as foot-operated water control valves to protect against recontamination of cleaned hands. 10
Drinking fountains should be convenient and clean, with proper lip guards. All hand-washing, toilet and eating areas should be adequately lighted and ventilated. All locker rooms, lunchrooms and vending machine areas are to be kept clean and free from liter. Trash and garbage containers should be convenient and covered. VIII. HOUSEKEEPING Unused or scrap machinery should be cleaned before storage, or disposed of properly. Maintenance and custodial closets should be kept well supplied and in good condition. Toxic materials are to be kept segregated and well labeled. Cleaning operations are to be conducted in a manner so as to minimize the danger of contamination of food and food-contact surfaces. Paper cups and towels, and other single-use articles, should be kept stored in closed containers and used in a manner that prevents contamination. Sewers, sewer traps, gutters and drains should be properly cleaned. Standing water or wet materials should be effectively and promptly removed. Sufficient waste containers should be conveniently located, and empty containers, such as bags, sacks, etc., should be removed promptly. Care should be taken to avoid spillage; when spillage does occur, it should be promptly removed. All cabinets, shelves, and counters shall be kept clean and neat. A plan for truck cleaning shall be followed. IX. SANITARIAN - SANITATION ORGANIZATION Effective methods should be used in sanitation control. Where feasible, a plant sanitarian should be employed and equipped with inspectional tools and a record-keeping area. There should be an employee sanitation education program, including posters in prominent 11
places throughout the plant. There should be well-organized, up-to-date, written clean-up and sanitation procedures. Definite work schedules and assignments should be set up and followed. Sanitation supervision should be maintained over the receiving, transporting, packaging, preparation, processing, and storage of food. The personnel responsible for maintaining sanitation shall have knowledge and/or experience to fulfill their responsibilities competently. Food handlers and supervisors should receive training in proper food-handling techniques and be aware of the danger of poor personal hygiene and insanitary practices. There should be occasional unannounced sanitation inspections, as well as those regularly scheduled. Continuing, periodic training programs should be set up to review and augment sanitation procedures. Adequate cleaning equipment and supplies should be available. Health and sanitation permits or certificates should be in evidence. 12
SANITATION EVALUATION 13
SANITATION EVALUATION Inspection Date: Date of Report: Inspection Time: Plant Location: Inspected By: Title: Date Last City Regulatory Inspection: Findings: Date Last State Regulatory Inspection: Findings: Date Last Federal Regulatory Inspection: Findings: AREAS INSPECTED Yes No 1. Building Grounds 2. Railroad Track & Sliding 3. Charcoal Room 4. Shipping & Receiving 5. Bottling Floor 6. Finished Goods Storage 7. Vinegar Tank Room 8. Advertising Storage 9. Processing Area 10. Raw Material Storage 11. Processing Area 12. Hallways & Stairwells 14
13. Toilets and Rest Rooms 14. Personnel Hygiene 15. Offices and Closets 16. Safety Inspection Comments: 15
SANITATION INSPECTION CHECKLIST 16
SANITATION INSPECTION CHECKLIST 1. GROUNDS Yes No Grass and shrubbery trimmed Free of weeds Free of excessive dust Trash and waste in covered containers Good drainage Absence of vermin or rodents Docks and sidings maintained All pavements, roadways, fences in good condition Free of unused equipment and litter 2. BUILDINGS Screens on all openings Walls clean and in good repair Floors clean and in good repair Ceilings clean and in good repair Adequate lighting Protective covers on lights Overhead pipes and ducts clean All areas free from waste and rubbish Hoses hung and stored Adequate ventilation Proper drainage Floor gutters clean Refuse receptacles covered Exits free and clear Ceilings and pipes free from condensation, drippage, or leakage Floor-wall junctures flush Sewer lines clear Adequate exhaust fans 17
Louvers on exhaust fans Surfaces free from mold Rooftop equipment and/or storage tanks protected Windows, sills and frames clean and in good repair Doors flush with sills 18
3. EQUIPMENT AND UTENSILS Yes No Equipment properly drained, or self-draining Utensils inspected and cleaned prior to use Utensils properly stored New bottles washed, air blown or vacuum cleaned Used glassware washed and sterilized Bottling equipment clean inside and out Processing equipment clean and in good repair Processing equipment storage areas clean Finished goods storage clean and neat Glass, cap, reshipper, label storage clean and neat Maintenance tools and equipment stored properly Processing equipment free of extraneous material Food packaging materials free of extraneous material Pallets well stored - in good condition Tanks covered and clean Returned goods marked and stored in segregated area All goods stored 18 from wall Raw materials packed in sanitary, approved containers Raw materials covered and stored properly Raw material containers in good condition and clearly labeled Service tables clean and in good condition Scales clean and accurate Sinks with hot, cold water, good drainage Cold storage facilities clean and free of ice Supply lockers neat and clean Pumps clean SS fittings clean and in good condition Strainer and filters in place and functional Alarm on air cleaner active Conveyer covers in place 19
All equipment completely accessibletosightandfeel Proper steam exhaustion All food handling equipment of metal Work tables smooth and free of cracks and crevices Motors free of dripping grease or lubricants Sanitary piping plainly marked, easily dismantled Caps or sanitary covers for tank outlets and hose ends Drip pans clean 20
List below all pieces of equipment which are to be disassembled and cleaned daily. Note on the checklist if the equipment was cleaned. List below all pieces of equipment which are to be disassembled and cleaned weekly. Yes No 4. VERMIN AND PEST CONTROL Eaves and roof area free of roosting birds Rodent- and vermin-attracting food ingredients properly stored Rooms free from cracks and crevices harboring insects Switch boxes and electrical connections not flush 21
with wall for efficient spraying Equipment, food surfaces, and/or product itself adequately protected during spraying Rodent traps in good condition Bait stations in good condition All areas free of evidence of vermin, rodents and birds Fly fans in use of any unprotected doors Precautions taken to prevent unsafe residuals of insecticides Use of proper USDA-approved pesticides All areas free of domestic animals, such as stray cats and dogs Inspections made on a regular basis Up-to-date records kept of inspections 5. OPERATIONS AND PROCESSING Raw ingredients and containers inspected Boxcars inspected Tracks inspected Equipment cleaned before inauguration of processing Equipment cleaned after processing Water supply adequate and sanitary Food ingredients rotated Ingredients stored in covered containers Plumbing and sewerage systems operating efficiently Product coding system followed Finished product tested Perishable products refrigerated or properly stored 6. PERSONNEL PRACTICES Personnel wearing clean aprons, gloves, uniforms Hair covered Free of jewelry 22
Free of nail polish Clean hands and fingernails Hands kept away from nose and mouth Employees refrain from using tobacco in production area Employees refrain from eating in production area Employees respect product and protect it from contamination Absence of rags, portions of lunch, etc. Hands washed after use of toilet Toilet flushed after use Neat lunchroom, locker facilities, toilets Employees refrain from horseplay Employees with colds, sores, etc., kept out of production area Cooperation with plant sanitation and sanitation committee Unauthorized visitors prohibited 7. EMPLOYEE FACILITIES Vending machines and area clean Adequate, clean, drinking fountains located conveniently for all employees Adequate water pressure in drinking fountains Proper lip guards in fountains Toilet facilities in convenient locations Adequate number of stools and urinals Self-closing doors to toilets Vestibule between toilet doors and processing areas Adequate waste containers in toilets and lockers Adequate toilet ventilation Effective toilet flush Toilets clean and private Wash Hands signs posted 23
Lockers, properly ventilated, provided Lockers with sloping tops Lockerseitherflushwithfloororhighenoughto clean underneath Soap and towels in locker room Locker rooms clean All dishes, utensils used in lunchroom kept clean and sanitized Proper refrigeration in lunchroom Sneeze shields over food served on lunch counter 8. HOUSEKEEPING Proper disposal made of scrap or unused machinery and materials Custodial closets well supplied and orderly Toxic materials segregated and clearly labeled Cleaning system conducted to avoid contamination of materials and surfaces Cabinets, shelves, counters clean and neat Single-use articles, such as paper cups and towels, properly stored 24
PEST CONTROL 25
FOG & FLY CONTROL Quantity Used: Week of: Product Used: Area Treated Date Treated Screen Inspection Comments 26
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RESIDUAL INSECT SPRAY CONTROL RECORD Quantity Used: Week of: Product Used: Area Treated Date Treated Screen Inspection Comments 28
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RESTRICTED PESTICIDE PURCHASE RECORD DATE PURCHASED TRADE NAME EPA PRODUCT REGISTRATION NUMBER 30
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