TLE 2nd Quarter - Equipment Preparation & Cleaning Procedures PDF

LO 1 Prepare Equipment and Tools LO 1.1 Preparation of tools for inspection and sorting The purpose of an inspection is to identify whether work equipment can be operated, adjusted and maintained safely -- with any deterioration detected and remedied before it results in a health and safety risk....

LO 1 Prepare Equipment and Tools LO 1.1 Preparation of tools for inspection and sorting The purpose of an inspection is to identify whether work equipment can be operated, adjusted and maintained safely -- with any deterioration detected and remedied before it results in a health and safety risk. Not all work equipment need formal inspection to ensure safety and, in many cases, a quick visual check before use will be sufficient. However, inspection is necessary for any equipment where significant risks to health and safety may arise from incorrect installation, reinstallation, deterioration or any other circumstances. The need for regular inspection and frequency of inspection should be determined through risk assessment. The result of the inspection should be recorded and this record should be kept at least until the next inspection of the equipment. Records do not have to be made manually in writing but, if kept in another form (e.g.in a computer), these should be held securely and made available upon request by any enforcing authority. Work equipment that requires inspection should not be used, unless inspection has taken place. Regular checking and inspection of equipment and machines will facilitate Preventive Maintenance which includes the following: 1\. Machine temperature- checking to avoid overheating. 2\. Hydraulic fluid -- checking to guarantee that equipment/machine which is operated by water or other liquids moving through the pipes under pressure will function. 3\. Wear and surface condition- to make sure no machine parts are deteriorating or defective due to everyday use. 4\. Crack - to see to it that there are no broken parts which will cause the breakdown of the machine or as source of leak 5\. Leak detection --to prevent accidental release of gas, water, oil from the machine. 6\. Vibration -- checking to determine if there is an instance of shaking or moving back and forth rapidly which will affect the performance of equipment or machine. 7\. Corrosion -- checking to minimize wear and tear of parts by washing, drying and lubricating parts. 8\. Electric insulation -- checking to guarantee that there are no live wires exposed during the operation of an equipment which may results in short circuit, electrocution, or even fire. Who Should Carry Out the Inspection of Work Equipment? Equipment can be inspected by someone who has sufficient knowledge and experience to determine: what to look at what to look for what to do in case there is a problem **Guide for Inspection of Tools, Utensils and Equipment** The required level of competence will vary for inspections according to the type of equipment and how or where it is used. The nature of these inspections does not have to be determined by the same competent person who undertakes them. This can often be done in-house by experienced workforce, taking account of: the manufacturer\'s recommendations industry advice their own experience of the equipment, its use, the particular factors of the workplace and the people using the work equipment **Things to remember during inspection** All precautions for inspecting items must be carefully observed prior to sterilization. Check specifically if instruments are: clean and free of any residue, including water in good working order - joints or jaws not stiff complete and all parts present in a multi-part instrument undamaged - not out of alignment meet designed according to specifications regarding tension and grip. When checking multi-part instruments it is necessary to re-assemble them to ensure that they are working correctly. This is also a good way of checking that all the parts are there, but remember they need to be disassembled again prior to sterilization. **LO 1.2 Checking, Cleaning and Sanitizing of Tools and** **Equipment** **A. Cleaning** is the removal of dirt and organic substances, such as fat and protein particles from surfaces of walls, floors, tools and equipment. Through the cleaning procedures, large number of microorganisms (90% and more) present on the mentioned objects will be removed. However, many microorganisms stick very firmly to surfaces, in particular in tiny almost invisible layers of organic materials, called *biofilms*, and will not entirely be removed even by heavy cleaning but persist and continue multiplying. The maintenance of cleanliness in a fish processing plant requires frequent and continuous cleaning as well as at the end of every shift. This will keep wastes from accumulating during the operating day, which not only improves sanitation but reduces the time needed for end of shift cleaning. Waste could be removed by brushing away or wash away with water with aid of appropriate cleaner. **Factors affecting Cleaning** a\. Soil type (organic, inorganic and other source) b\. Soil condition ( Infestation of microorganisms) c\. Water temperature d\. Surface being cleaned e\. Type of cleaning agent f\. Agitation or pressure g\. Length of treatment 64 A clean surface is defined as being free from soil (e.g. food residues), free from bad odors, non-greasy to the touch and having no visible oxidation (e.g. rust). A sanitized clean surface is defined as a surface that is substantially free from pathogenic microorganisms and undesirable number of spoilage microorganisms. Cleaning prior to sanitizing is recommended as it increases the effectiveness of the sanitizing step. Effective cleaning and sanitation programs are required to achieve the correct level of hygiene in food handling or production facilities. If these are not adhered to there is a greater risk of food becoming contaminated by pathogenic or spoilage microorganisms. **B. Sanitation in Fish processing Plant** **Sanitation** in Fish Processing Plants may be defined as the planned maintenance of the work and product environment to prevent or minimize hazards of product contamination and condition that are visually unpleasant to the consumer, and to provide clean, healthy and safe working condition. The use of sanitizing agents leads to effective sanitation of tools, equipment and utensils. Sanitation with the use of physical and chemical sanitizing agents will kill residual microorganisms that remain after cleaning. Cleaning by washing with soap and water is very important as it ensures the removal of dirt or debris by physical and/or mechanical means. Clean water is to be used to finally wash and rinse all utensils, tools and equipment. Sanitizing or disinfecting, on the other hand, rids of or reduces the number of micro-organisms on surfaces where food comes in contact with. It cannot be accomplished until surfaces where food are processed are clean. Moreover, it cannot be effective without a good pest control program. Cleaning alone by washing will not be capable of totally eradicating microbes, germs and viruses, hence the need to use sanitizing agents. Chlorine is one of the cheapest and most easily available sanitizers in the market. It is popularly used in the treatment of water for both household and plant. Likewise, chlorine is also used to sanitize processing equipment. **Importance of Sanitation** 1\. Prevents pest infestation 2\. Kills bacteria already present 3\. Reduces potential for cross contamination 4\. Helps increase shelf- life 5\. Minimizes chance for injury 6\. Helps create a more pleasant work environment **Sanitizer** is a type of antimicrobial that kills or irreversibly inactivates at least 99.9 percent of all bacteria, fungi, and viruses (called microbials, microbiologicals, microorganisms) present on surfaces, tools, utensils and equipment. **Types of Sanitizers**  Quaternary Ammonium Chlorides  Acid-based sanitizers  Chlorine dioxide  Hypochlorites **Categories of Sanitation for Fish Processing Plants**  Housekeeping. Refers to tidiness and proper removal of waste.  Rodent elimination. Knowledge of the characteristics of rodent and permannent control through structural changes in building, removal of possible shelter and food, and supplementary poisoning and trapping is needed.  Insect pest elimination. Recognition of serious infestations and identification including the knowledge on habits and ecology is required. Control may be the safer way of using insecticidal chemicals, building structure is required, equipment and other process change.  Cleaning. Cleaning of Fish Processing Plant and equipment involves careful organization, training work schedule and use of the best available equipment, methods and materials.   Microorganism. The types and significance vary with product and type of operation. The microorganisms found in dried and salted fish differ from canned fishery products.  Construction and maintenance of buildings and equipment. This may simplify sanitation maintenance and reduce cost and contamination hazards.   Employee's facilities. Rest rooms, locker rooms, drinking water, eating facilities and working environment must be well maintained for the comfort and safety of the workers for proper motivation and efficient performance and for excellent production and product quality.  Water. Must be potable and safe for the product and other plant uses.  Waste. Convert fish waste into fish value-added products such as burger, polvoron, spread, embotido, fish ball, meat loaf, luncheon meat, sausage and many others. This will eliminate environmental pollution and promote food security and economic security. 68   Laboratory tests. This is important to the sanitation control program in the Fish Processing Plant; it must be understood and utilized to its best advantage. **LO 1.3 Cleaning and Disinfection Procedure** Cleaning and disinfection are the most frequent operations in modern food processing. Carelessness may cause considerable economic loss, and loss of reputation on the market. The hygienic standards respected in processing plants depend on kinds of production. For example, in the cannery they will be stricter than in plants where fish is only gutted and stored in ice and its shelf life is rather short. Regarding all other technological operations and processes, cleaning and disinfection procedures must follow detailed instructions and responsible personnel be assigned. **Steps/Procedure in Cleaning and Disinfection of Tools, Equipment and** **the Laboratory Area** Various steps should be included in a complete cycle of cleaning and disinfection (Huss, 1994): 1\. Remove food products; clear area from bins, containers, etc. 2\. Dismantle equipment to expose surfaces to be cleaned. Remove small equipment, parts and fittings to be cleaned in a specified area. Cover sensitive installations to protect them against water, etc. 3. Clear the area, machines and equipment of food residues by flushing with water (cold or hot) and by using brushes, brooms, etc. 4\. Apply the cleaning agent and use mechanical energy (e.g., pressure and brushes) as required. 5\. Rinse thoroughly with water to completely remove the cleaning agent after the appropriate contact time (residues may completely inhibit the effect of disinfection). 6\. Control cleaning. 7\. Sterile thru chemical disinfection or heat. 8\. Rinse off the sterilant with water after the appropriate contact time. This final rinse is not needed for sterilants, e.g., Hydrogen Peroxide based formulations which decompose rapidly. 9\. After final rinsing, reassemble equipment and allow it to dry. 10\. Control cleaning and disinfection. 11\. In some cases it will be good practice to re-disinfect (e.g., with hot water or low levels of chlorine) just before production to begin again. As mentioned above, only agents and disinfectants permitted by adequate regulations can be used for cleaning and disinfection operations. During their use, precautionary measures must be observed and this requires proper training of personnel. **LO 1.4 Food Safety Principles and Practices** 1\. Preventing contamination. Prevention of microbial/chemical contamination of foods/fishery products is better than relying on corrective actions once contamination has occurred. 2\. Minimizing contamination. To minimize microbial/chemical food safety hazards in fresh produce, producers and others involved in production should use good agricultural and management practices in those areas over which they have control. 3\. Minimizing contacts from human or animal feces. The major sources of disease-causing microbes are human or animal feces. 4\. Ensuring a safe water supply. Whenever water comes in contact with produce, its source and quality are directly linked to the potential for contamination. 5\. Using manure and municipal sewage safely. Incomplete composted organic fertilizers may contain disease-causing microorganisms from animal or human feces. 6\. Focusing on worker health and hygiene. There is a direct correlation between poor personal hygiene and food-borne disease. 7\. Following the law. Follow all applicable local, state, and national laws and regulations. 8\. Being accountable. Accountability at all levels of the agricultural environment (farm, packing facility, distribution center, and transport operation) is important for a successful food safety program. 70 71 **LO 1.5 Awareness of Codes or Regulations such as Hazard** **Analysis Critical Control Point (HACCP) and Good** **Manufacturing Practice (GMP)** **Hazard analysis** is a preventive food quality management system which identifies, evaluates and controls the hazards significant to food safety specific to a product. **Critical control point** is a point in time or a physical location at which failure of control or preventive measures will expose the consumer to unacceptable health risks. **HACCP** is a national standard for fish and fishery aquatic products. **Major Concepts of Hazard Analysis Critical Control Point (HACCP)**   Preventive system of control for biological hazards  System approach to identify risks in food production and food safety measures.   Universally recognized system as the most effective way to prevent food-born diseases  Scientific-based system to identify specific hazards and measures control to ensure food safety  Capability of accommodating change such as equipment design, processing procedure or technological development  Applicability to establishments that produce, process, treat, pack, trade, transport, serve or are involved in food production   Food safety  Safety programs such as Good Manufacturing Practices (GMP) and Sanitation Standard Operating Procedure (SSOP) **Seven Principles of Hazard Analysis Critical Control Point** **1. Conduct a Hazard Analysis** The application of this principle involves listing the steps in the process and identifying where significant hazards are likely to occur. **2. Identify the Critical Control Points** A Critical Control Point (CCP) is a point, step or procedure in which control can be applied and a food safety hazard can be prevented, eliminated or reduced to acceptable levels. **3. Establish Critical Limits** A Critical Limit (CL) is the maximum and/or minimum value to which a biological, chemical, or physical parameter must be controlled at a CCP (Critical Control Point) to prevent, eliminate, or reduce to an acceptable level, the occurrence of a food safety hazard. The critical limit is usually a measure such as time, temperature, water activity (Aw), pH, weight, or some other measures that are based on scientific literature and/or regulatory standards. **4. Monitor Critical Control Point** Monitoring procedures should describe how the measurement will be taken, when the measurement will be taken, who will be responsible for the measurement, and how frequently the measurement will be taken during production. **5. Establish Corrective Action** Corrective actions are the procedures that are followed when a deviation in a critical limit occurs. This usually includes identification of the problems and the steps taken to ensure that the problem will not occur again. 72 **6. Establish Verification Procedure** Those activities, other than monitoring, that determine the validity of the HACCP plan and ensure that the system is operating according to the plan. **7. Establish Recordkeeping Procedure** A key component of the HACCP plan is recording information that can be used to prove that food was produced safely. The records also need to include information about the HACCP plan. Record should include information, product description, flow diagrams, the hazard analysis, the CCPs, Critical Limits, Monitoring System, Corrective Actions, Recordkeeping Procedures, and Verification Procedures **What are Good Manufacturing Practices?** **Good Manufacturing Practices** (GMPs) are the minimum sanitary and processing requirements necessary to ensure the production of quality food. **Categories of Good Monitoring Practices** 1\. General maintenance of physical facilities 2\. Cleaning and sanitizing of equipment and utensils 3\. Storage and handling of clean equipment and utensils 4\. Pest control 5\. Proper use and storage of cleaning compounds, sanitizers, and Pesticides. 6\. Employee training 7\. Plant design 8\. Quality assurance assessment **Things Needed to Meet Requirementd For Good Manufacturing** **Practices** To meet the general GMP requirements for inspecting and storing raw foods and ingredients, you need to: **Develop** consistent procedures for receiving food or ingredients that describe how they will be evaluated, separated, and cleaned if necessary, and then stored. **Inspect** every delivery to make sure that all items are clean and suitable for use as food. **Separate** any contaminated item and filthy or damaged containers from safe items. **Reject** food or containers that are spoiled, contaminated with filth, or otherwise unsuitable for food, and properly dispose them in a sanitary manner. **Wash** items as necessary if they are acceptable for use, and then repack for storage. **Water** should be potable. **Store** all food and ingredients in containers or in ways that will adequately protect them from contamination from other foods or the plant environment, and allows for routine monitoring for damage, contamination, or intrusion by pests. **Monitor and clean and sanitize** mechanical systems including conveyors to make sure that they do not contaminate food. **Monitor and inspect** every delivery of food, ingredients, or packaging materials.