Facility Sanitation and Documentation

Facility Sanitation and Documentation

Documentation There are three types of documents you will need for third party audits of your farm food safety plan: Standard Operating Procedures - A list of more than 2 steps to aid someone in performing a given task. Ideally, having standard operating procedures will minimize errors. Records kept on a regular basis Cleaning logs Employee training logs Seasonal water tests Documents rarely change Farm maps Insurance papers SOP hard copy Record Keeping - electronic

The Big W Written Documentation Standard Operating Procedures for your shed (GHP) and Fields (GAP) addressing: Hygiene program Sanitation program Water monitoring program

If a task has more than 2 steps involved, you should create a Standard Operating Procedure for that task? 1. True 2. False 0% 0% 1 2

Key Areas of Documentation SOP for GAPs (farms) and GHPs (packing shed) Designated food safety individual (someone that can give the full attention) Contact name and phone number visible to all Training workers on hygiene at least yearly Sanitation program - include animal encroachment and manure-based products Water testing on all sources (irrigation, wash, rinse, and ice) and sanitizer levels

The Big W Written Documentation It did not happen or exist if it is not WRITTEN down! Got to have this!

Which three items do third party auditors rely on as proof that you are keeping up with food safety? 1. Employee interviews, security camera tapes, and visual observation 2. SOPs, records and documents 3. Material safety data sheets, pest control reports and insurance papers 4. All of the above 0% 0% 0% 0% 1 2 3 4

Packing Shed Sanitation Major causes of Contamination Workers Water / ice Birds, rodents, insects Equipment and conveyors

WORKERS! No eating, drinking Or smoking! Provide break room for such purposes.

A Clean Packing Shed is a Safe Packing Shed Discard produce that falls on the floor No Animals (domestic or otherwise) Prepare cartons only as needed Remove culls and debris promptly Provide restrooms and hand-washing stations Maintain sanitation records

Sanitation in the Packinghouse Biofilms build up with use Microbes survive and grow on wet surfaces Daily Sanitize: packing line equipment (particularly areas that remain wet, floors, drains) break rooms/bathrooms Monthly or between loads: cold room floors, walls, ceilings, cooling units, doors and curtains

Packing Shed Facility Sanitation Pressure wash and sanitize packing shed facility: Grading and packing lines, dump tanks, immersion tanks, fork lifts etc. Clean and sanitize all floors and dock areas Clean and sanitize Coolers & ripening rooms Walls Floors Drains Refrigeration coils

Developing a Pest Control System Exclude birds from storage areas/loading docks where possible Sanitize and Store pallets and boxes in a clean enclosed room Bird control needed: You can t sanitize filth

Keep Field Trash in the Field Pre-clean and pre-grade produce prior to bringing into shed Dump wash water to clean and remove field heat. Continuously monitor dump water chlorine and ph levels At best bacteria levels are reduced with proper ph levels (6.5 to 7.5 ph) Can not get 100 % kill (only with the use of irradiation) Chlorine is popular because of it s low cost

Packing Sheds and Visitors Only authorized personnel in packing sheds Absolutely no children or pets Authorized visitors also need training Do not allow them to touch produce Shoes etc. are cleaned prior to entering the shed Areas of minimum exposure to produce Groups should be guided by a knowledgeable employee

Ice is Frozen Water Only use ice made from potable water Prohibit ice contact with soil, debris and non essential workers Do not place ice on floors or allow worker to walk in this area Need to have an above floor container from which ice is to be used Clean and sanitize ice makers routinely

Chlorine base sanitizers are most popular because? 1. They are low cost 2. They are 100% effective at killing microorganisms 3. They are effective at proper ph levels 4. Both 1 and 3 0% 0% 0% 0% 1 2 3 4

Biofilms Sticky to slimy accumulations of fungi and bacteria that accumulate on wet surfaces Chlorine doesn t penetrate biofilms, but will prevent their formation Change water daily and maintain constant sanitizer levels in dump tanks and spray washers

Biofilms and Accumulated Organic Matter Contact of plant material (produce) with surfaces: leaves waxes and plant sap accumulations plant residues + moisture + microbes + warm temperatures = biofilms Partially decayed plant material: sticks to surfaces is loaded with microbes

Room & Equipment Cleaning Procedures Empty and sweep cold rooms Pre-rinse equipment or walls Visually inspect surfaces Apply appropriate cleanser Scrub from top, downward Do not allow cleanser to dry on surfaces Rinse from top, downward

Cleaning and Sanitizing Steps Remove heavy debris Pre-rinse remove particulate matter Wash and Scrub remove remaining visible soils with detergents Rinse away detergents Sanitize to reduce microorganisms Final Rinse Dry to eliminate humidity

What are the recommended cleaning and sanitizing steps? Remove heavy debris from floors with brooms or shovels and dry clean processing equipment, if needed. Pre-rinse equipment with adequate amount of quality water. Clean remaining debris from floor. Rinse floor and drains with adequate quality water using a low pressure hose. Use dedicated brushes to scrub floor and drains with an effective cleaner, applying adequate quality water as needed.

Best way to clean and sanitize equipment? Equipment (whether fixed or free standing), fixtures, floors, walls, and other structures in a processing facility can become a source of microbial contamination if not adequately maintained in sanitary condition. To prevent fresh-cut produce from becoming contaminated by equipment or other structures in the facility, employees should be trained on proper cleaning and sanitizing steps within the processing areas.

What are the recommended cleaning and sanitizing steps? Foam and scrub the equipment with an effective cleaner and scrub using dedicated brushes. Thoroughly rinse the equipment, floors, and drains with adequate quality water using a low pressure hose. Remove excess water from floors. Sanitize (according to manufacturer directions) the equipment and floors.

Should you avoid use of high-pressure water? This practice will help prevent aerosols from contacting processing equipment and food-contact surfaces, product, or packaging materials. Therefore, employees should be trained on the proper use of cleaning equipment.

Temperature Management Low temperatures supplement good sanitation practices Avoid delays that postpone cooling Consider: Time from harvest to packinghouse Time from arrival to cooling of produce Speed of cooling & final temperature

Temperature Management Cooling method forced-air, hydrocooling, vacuum cooling, package & top icing Do not use water more than 10 degrees F cooler that the product field temperature Proper hydrocooler management water sanitized continuously incomplete cooling = wet, warm produce = Potential for pathogen buildup

Temperature Management Storage and transport temperatures Optimum temperatures for fruits and vegetables range from 32 F/0 C to 59 F/15 C Most human pathogens grow slowly or not at all below 45 F/7 C Listeria monocytogenes is a special concern in refrigerated environments Maintain records of temperature management

Which set of cleaning and sanitizing steps are in correct order? 1. Remove heavy debris, prerinse, wash & scrub, rinse, sanitize, final rinse, dry 2. Pre-rinse, remove heavy debris, wash & scrub, rinse, sanitize, final rinse, dry 3. Sanitize, pre-rinse, remove heavy debris, wash & scrub, rinse, final rinse, dry 4. None of the above 0% 0% 0% 0% 1 2 3 4

Final Steps of Cleaning Clean and put away supplies Document cleaning practices Periodic QA inspection/swabs Training

For-Sale Items Cornell (National GAPs Program) www.gaps.cornell.edu Information Sources of Help Texas A&M Depart. Of Horticulture http://aggiehorticulture.tamu.edu/extension/tcecommercialhort.html Joint Institute for Food Safety and Applied Nutrition Trainings http://www.jifsan.umd.edu/gaps.html Yourself with DVDs or VHS Tapes Sometimes Extension trainings (Private) Alchemy Training Systems

Audit questions might look like this. Do not need a perfect score.

3 rd Party Auditors USDA GAPs and GHPs Audits USDA Mushroom Production Audit NSF Davis Fresh Scientific Certification Systems (SCS) Safe Quality Food Institute (SQF 1000) Food Safety Net Services Primus LGMA Global GAP Silliker GAP SENASICA Mexico

Goal to Pass 3 rd Party GAP/GHP Audit

Preventative Food Defense Procedures Emergency evacuation plan Food Security training provided to employees Visitors required to check in Minimum level of background checks on employees Positive identification of employees has been established

If I learn only 1 Thing. YOUR unique operation needs to have GAPs and GHP s that are tailored to your commodity and management practices in order to effectively reduce microbial risks and prevent contamination everyday. This is best communicated in an audit if you have a SOP manual for food safety and an individual designated as the Food Safety and Biosecurity person.

After today s training, on a scale of 1 to 4 what is your current knowledge of GAPs food safety? 1. Somewhat 2. Average 3. Above Average 4. Excellent 0% 0% 0% 0% 1 2 3 4