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Table of Contents
Sanitary operations 7
- General maintenance 7
- Policies and procedures 8
- Facilities and controls 9
Pest control 10
To do this managers must oversee the training of personnel on food protection principles and food handling techniques.
A training program for permanent, temporary, as well as contract employees needs to be created, evaluated each quarter,
and updated if necessary.
3
2. Hygiene and cleanliness. t 5BLFQSFDBVUJPOTUPQSFWFOUDPOUBNJOBUJPOGSPN
foreign substances like perspiration, cosmetics,
:PVTIPVMENBLFTVSFUIBUBMMFNQMPZFFT chemicals, fingernail polish, and medicines
t 8FBSDMFBOHBSNFOUTTVJUBCMFGPSUIFJSBDUJWJUJFT applied to the skin.
Jewelry or other objects must be removed as they
can be a source of microorganisms. Thorough hand washing before commencing work and
after using the restroom is extremely important,
t8FBSDMFBOGPPUXFBSUIBUJTBQQSPQSJBUFGPSUIF as contaminated hands can transmit infectious diseases.
work environment, and available for use in
production areas. :PVNVTUOPUBTTVNFUIBUFNQMPZFFTXJMMLOPXUIF
correct procedure for washing hands.
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(if uniforms are provided). Only impermeable gloves Circulate the following instructions or perhaps post it
should be used and kept clean and sanitary around your facility:
during use.
8FUIBOETXJUIDMFBOXBSNPSIPUXBUFS
t&OTVSFUIBUPVUTJEFDMPUIJOHJTDMFBOBOETBOJUBSZJG 2. Apply soap
they are allowed in production areas. 4DSVCIBOETBOEöOHFSOBJMTGPSTFDPOET
4. Rinse off soap thoroughly with clean water
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5. Dry hands with single-use towels
including facial covering, where products, 6. Discard used towels in trash
food contact surfaces, and packaging 4BOJUJ[FIBOETXJUIBOBQQSPQSJBUFTBOJUJ[FS
materials are exposed. (no touch dispensing systems)
8. Dry hands
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medicine, chewing gum, tobacco products in the Personnel must maintain personal hygiene by washing
storage unit provided. These items need to be hands prior to work, when hands are soiled, after eating,
confined to break rooms, offices, or other and after using restrooms. Any employees who have
designated areas of the facility to prevent contact with food or cigarettes should also wash and dry
product contamination. hands before returning to their workstation.
4
Building & Facilities
All food processing and storage operations must be designed to facilitate maintenance and sanitation operations.
This encompasses:
1. Exterior grounds.
The exterior grounds around your operation need to be
maintained to protect against pests and contamination To prevent other sources of airborne dirt or
from sources such as dust, dirt, or water. contamination that could enter the operation, maintain
To control pests around the building roads, parking lots, and yard areas. Around the exterior
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t Frequently cut weeds and grasses
cover the strip with crushed stone or a similar material.
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Eliminate any source of mud that could be tracked into
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the facility.
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insets and birds It is important to conduct formal audits in a routine
t1SPQFSMZTUPSFJEMFFRVJQNFOUBOEQBSUTUIBUBSFMFGU manner so that corrections can be
outside away from manufacturing buildings. applied quickly if necessary.
t %FTJHOFEUPNJOJNJTFUIFUISFBUPGDPOUBNJOBUJPO t $POTUSVDUFEXJUINBUFSJBMTBOEJOBXBZUIBUBMMPXT
to food, food-contact surfaces, and food packaging walls, ceilings, and floors to be sufficiently cleaned and
materials. For example, by using enclosing systems, kept in good repair.
physical separation (walls or space), logical traffic
flow patterns, appropriate air flow such as positive t 1SPWJEFBEFRVBUFWFOUJMBUJPOUPDPOUSPMGVNFTTVDI
pressure in finished product area, line covers, as from roasters and odors such as in trash
adequate interior and exterior lighting, etc. disposal rooms.
t %FTJHOFEUPDPOUSPMDPOEFOTBUF MFBLTPSESJQQBHF This will ensure that food safety is not compromised.
5
“Doorways play a critical role
in contamination control
of your facilities”
3. Facility Doorways
Doorways play a critical role in contamination control
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to form Airlock entries into your facilities, to prevent
contaminants entering critical hygiene areas.
Doorways should:
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types and vehicles within your operations
t $MPTFRVJDLMZBOEBVUPNBUJDBMMZ BGUFSVTF
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airbourne contaminants or pests
t 8IFSFGPPEDPOUBDUXJUIEPPSTJTQPTTJCMF
construction materials should be certified as
food contact safe
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volume of traffic expected. Design should be such
that will withstand minor impact from traffic.
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&òFDUJWFTBOJUBSZPQFSBUJPOTBSFFTTFOUJBMGPSGPPEQSPDFTTJOHGBDJMJUJFT8FXJMMEJTDVTTXIBUJTJOWPMWFEJOHFOFSBM
maintenance, as well as provide a guide on how you should create a policy.
7
2. Policies and procedures. (for example in buffer/vestibule areas).
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To combat contamination, you must create appropriate
cleaning and hygiene procedures. Product accumulation (on walls, ceilings, conveyor belts,
lids and walls of batch tanks or mixing tanks, and the
8FUDMFBOJOHTIPVMEJODMVEFDPNQMFUFDMFBOJOHBOE bottom of a bucket elevator) should be removed through
TBOJUJ[JOHDZDMFT1BSUJBMXFUDMFBOJOHXJUIPVUTBOJUJ[JOH routine housekeeping – especially for products that are
TIPVMECFBWPJEFECFDBVTFTBOJUJ[JOHJTSFRVJSFEUP hygroscopic or in environments of high humidity leading
inactivate microorganisms after cleaning. UPNPJTUVSFBCTPSQUJPOBOEMPDBMJ[FEDPOEFOTBUJPO
Dry cleaning (using tools such as vacuum cleaners, Remember to keep the air dry, including air entering
brooms and brushes) may be followed by a wet the area and used to dry the product. If compressed air
cleaning as appropriate is used, continuously dry the air, as moisture may be
trapped in the compressed air.
5. Have you established barriers where appropriate and 9. Have you established procedures to monitor and
clearly defined their purpose? If so, are they practical document barrier efficiency?
for persons who enter the area regularly or for a Have you established procedures for maintenance,
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including routine and unscheduled maintenance?
6. Have you considered elements like 11.Have you established a master sanitation schedule to
a. drainage and floor slopes assure timely and effective sanitation of equipment
b. drainage and equipment positions and the processing environment?
c. personnel and material routes 12.Have you trained all personnel about the barriers and
d. rework handling procedures, their purpose, use and maintenance?
e. storage of spare parts
f. maintenance tools and cleaning equipment :PVNVTUSFUSBJOQFSTPOOFMBTPGUFOBTOFDFTTBSZUP
maintain sanitary practices.
8
3. Facilities and controls. t 5SBTIBOEQSPEVDUJPOXBTUFTIPVMECFUSBOTQPSUFE
in a way that does not risk it becoming a source of
All food processing plants must be equipped with contamination or pests.
sanitary facilities. Here are some of the sanitary facilities
that are required: t &RVJQNFOUEFTJHO
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maintenance must contribute to cleanliness and
t "XBUFSTVQQMZPGTBOJUBSZUFNQFSBUVSFBOERVBMJUZ non-contamination of products.
to meet processing, cleaning, and employee
sanitary requirements. t 'PPEDPOUBDUTVSGBDFTBOEVUFOTJMTTIPVMECF
corrosion resistant, non-toxic, cleanable, and capable
t 1MVNCJOHXIJDIDBSSJFTTVóDJFOURVBOUJUJFTPG of withstanding the production environment.
water throughout the operation, and properly
removes sewage and liquid waste from the facility. t 1SPUFDUJPOTIPVMECFQSPWJEFEXIFSFUIFSFJT
:PVNVTUOPUBMMPXDSPTTDPOOFDUJPOTCFUXFFO potential of indirect contamination of food surfaces
discharge waste water or sewage and sanitary water. (eg. A cover over a conveyor moving open containers).
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water systems. t 4FBNTJOGPPEDPOUBDUTVSGBDFTPGFRVJQNFOUNVTU
be continuous and smooth to minimise the potential
t "OFBTJMZBDDFTTJCMFBOEBEFRVBUFBNPVOUPGUPJMFU for food contamination.
facilities maintained in a sanitary condition, with
hand washing reminders prominently displayed. t 'SFF[FSTBOESFGSJHFSBUFESPPNTOFFEOPOHMBTT
calibrated thermometers or temperature recording
t )BOEXBTITUBUJPOTMPDBUFEJOQSPEVDUJPOBSFBTGPS devices. Refrigerated storage rooms should be
convenience. These must be supplied with provided with humidity recorders.
antibacterial soap in a sanitary dispenser, sanitary
hand towels, and a trash receptacle Make sure safeguards are applied to prevent
(for disposal of used towels). contamination from compressed air or other gases. If
they are introduced into foods or onto product contact
surfaces they can be a source of contamination with
water, oil or microorganisms.
9
Pest Control
Pests like rodents, insects, birds and other types of animals must be prevented from entering any area of the food plant.
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prevent these problems from developing.
Prevention programs to prevent pest entry include trapping, elimination of harborage locations, using pesticides, and
monitoring the pest control devices will help you be compliant.
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Here is a pest control checklist for you to use:
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marked and used?
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are weather stripped and maintained on a
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continuing program?
stations of a type and location to
minimise spillage?
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not in use?
t )BWFZPVNBEFTVSFUPVTFCBJUTUBUJPOT
for exterior use, and mechanical traps for
t )BWFZPVJOTUBMMFEBVUPNBUJDDMPTVSFTPO
interior spaces?
exterior doors?
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at least weekly?
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and maintained?
are numbered with the service date listed on
the inside cover, where applicable?
Do you have a map of these devices kept
current and on file?
t )BWFZPVNBEFTVSFUPEPDVNFOUBMM t )BWFZPVNBEFTVSFUIBUFYUFSJPSHSPVOET
insecticide treatments to include date, are well maintained with minimal plants?
operator, compound, concentration of
active ingredients, amount used, where used t "SFFYUFSJPSHSPVOETGSFFPGEFCSJTBOE
(specifically), and how applied (specifically)? stored materials near walls of the facility
and any other objects that could
t %PZPVFOTVSFUIBUXSJUUFOJOTQFDUJPOBOE harbor pests?
service reports are submitted after each
service call and kept on file? t %PZPVTFBMMPBEMFWFMFSTBUEPDLTUP
prevent trash accumulations and rodent
t %PZPVSFHVMBSMZDIFDLGPSSPEFOUCVSSPXT harborage and entry? Do you clean load
in nearby grounds, and activity at floor/wall levers pits regularly?
junctions and doorways?
Make sure your processing plant is nowhere near
t %PZPVSFHVMBSMZDIFDLGPSFWJEFODFPG livestock and poultry operations, as studies show that it
insect activity, especially in long-term will be especially vulnerable to pathogen contamination
supply and stock storage areas? by pests.
11
Pest control procedures checklist
Pests/vermin, such as rodents, flying insects, crawling insects, and others must be kept out of a food
GBDJMJUZ"QSPBDUJWFQFTUDPOUSPMQMBOXJMMIFMQUPBWPJEDPOUBNJOBUJPOPGGPPEBOEQSPEVDUMPTT6TFUIF
following as a starting point to inform your plan:
Check there are no insects, rodents, animals, or birds Check approved pesticides used
Have you reviewed all pesticides used
Check there are no breeding or harborage on the premises?
conditions for insects or rodents (such as clutter, Are pesticides applied according to the use
trash, pooling water or leaky plumbing, damaged/ intended on the label?
open food containers)
Does your monthly self-inspection procedures Number and map all devices/bait stations
include monitoring for and eliminating rodent How are bait stations/devices numbered
breeding and/or harborage conditions? and mapped?
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breeding or harborage conditions are present 6TFBXFFLMZMPH PSEBJMZJGZPVSTJTBQSPEVDF
on your premises? warehouse/farm packing operations, or a
problem is noted)
Check facility is vermin-proof (holes in floors or How will checks be logged?
walls or ceilings, no screens on openable 8IPJTSFTQPOTJCMFGPSDIFDLTPGCBJUTUBUJPOT
windows, or excessive gaps under or around devices both inside and outside of the facility?
openings to the outside)
Do you ensure that when doors are closed, they Have a pest/vermin control service at least monthly.
are closed all the way to the floor? 4FSWJDJOHJOTJEFBOEPVUTJEFOPMFTTUIBOPODFQFS
How will you ensure your facility is vermin-proof? month (do not use bait stations inside)
How often does your PCO service your facility?
Maintain an unobstructed distance from walls to
pallets (paint a stripe) 4UPSFSFDPSET
How will you maintain an unobstructed space 4UPSFBMMQFTUDPOUSPMTFSWJDFSFDFJQUT JODMVEF
between walls and pallets environmental assessment as part of
(or other food/nonfood storage)? service agreement)
Map of all devices/bait stations
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Does your PCO conduct inspections and provide
recommendations as part of your service?
Assign someone in charge of security If applicable, where will you keep the
8IPJTJOSFTQPOTJCMFGPSTFDVSJUZ testing records?
Report unusual activity to manager/security Provide adequate lighting around the outside of
Are employees trained to be aware and report the building
suspicious activity? Is there adequate lighting on the outside
8IBUBSFZPVSQSPDFEVSFTGPSSFQPSUJOHVOVTVBM of your building?
or suspicious activity?
Lock trailers unless loading or unloading, and never
4FDVSFBOEUFTUCBDLøPXQSFWFOUJPOEFWJDFT JG leave filled containers unsupervised
your devices are testable) 8IPJTSFTQPOTJCMFGPSMPBEJOHBOE
If applicable, how often will backflow prevention unloading trailers?
devices be tested? Are they kept locked when not loading?
13
Food storage procedures worksheet
Food must be stored in a way that it is protected from pests and contamination. If certain foods
are not stored properly, microorganisms can grow. Include the below in your written procedures
for safe food storage:
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cleaning items) separate from food
11) Clean and organise food storage areas
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held for sale 12) Maintain proper food storage temperatures
4FQBSBUFSBXBOJNBMGPPETGSPN 13) Maintain an unobstructed, clearly delineated
ready-to-eat foods space between both interior and exterior walls
and stored items
5) Protect foods from contamination
(proper packaging and coverage) 8IPJTSFTQPOTJCMFGPSFOTVSJOHDPNQMJBODF
with food storage procedures?
6) Provide separate and labeled storage are
for salvage items 8IBUQSPDFEVSFTXJMMZPVJNQMFNFOUUPFOTVSF
compliance with each of the items listed above?
7) Implement procedures for
a) handling salvaged, expired, damaged or Records
contaminated foods (include timely disposal o How will you document and where will
of damaged, spoiled or expired products) you store the monthly self-inspection report?
b) documenting disposition of these foods o How will you document and where will you
store the disposition of salvaged, expired,
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damaged or contaminated foods?
14
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Doorways that seal off areas of operation are required to protect your product from things like pests and vermin, as well
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Doorways that respond well to vehicle collisions are necessary to keep operations up and running. If your door is easily
damaged, then it will result in unnecessary production downtime, and potential exposure to contamination from
pests and vermin.
This is why investing in a door that is durable (copes well with harsh weather and forklift accidents), can save you thousands of dollars
in maintenance costs in the long run.
15
1 Mobbs, Emily, “Behind closed doors”, Manufacturers’ Monthly, 2 August 2010, http://www.manmonthly.com.au/news/behind-closed-doors
2 “Good doors boost pro ts”, Warehouse & Logistics News, 15 March 2013, http://www.warehousenews.co.uk/2013/03/doors-curtains-good-doors-boost-pro ts-plan-door-strategies-now-to-meet-
energy-act-requirements/
3 Mobbs, Emily, “Behind closed doors”, Manufacturers’ Monthly, 2 August 2010, http://www.manmonthly.com.au/news/behind-closed-doors
4 Robins, Brian, “Electricity prices set to drop as European links come into play”, Sydney Morning Herald, 24 April 2013, http://www.smh.com.au/business/electricity-prices-set-to-drop-as-european-
Sources links-come-into-play-20130423-2icz4.html
5 Dang, Annie, “High-speed doors dominate the market”, Manufacturers’ Monthly, 24 August, 2011, http://www.manmonthly.com.au/features/high-speed-doors-dominate-the-market
6 Tra, Margaret, “Lack of forklift training leaves worker with amputated leg”, Safe to Work, 12 May 2011, http://www.safetowork.com.au/news/lack-of-forklift-training-leaves-worker-with-amput
1. “Preventing Cross Contamination”,
7 Mobbs, Emily, “Behind closed doors”, Manufacturers’ Monthly, 2 August 2010, http://www.manmonthly.com.au/news/behind-closed-doors
8 “Opening doors to energy savings”, Manufacturers’ Monthly, 21 December 2008, http://www.manmonthly.com.au/news/opening-doors-to-energy-savings
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IUUQXXXGPPETFSWJDFXBSFIPVTFDPNSFTUBVSBOUFRVJQNFOUTVQQMZNBSLFUJOHBSUJDMFT
9 “Opening doors to energy savings”, Manufacturers’ Monthly, 21 December 2008, http://www.manmonthly.com.au/news/opening-doors-to-energy-savings
product-safety-public-health/preventing-cross-contamination-/c28153.aspx
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