the codex general principles of food hygiene – control of operation
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Good Hygiene Practices along the coffee chain
The Codex General Principles of Food Hygiene –
Control of Operation
Module 3.3
Slide 2 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Objectives
Introduce trainees to Section V of the Codex General Principles of Food Hygiene - Control of operations
Demonstrate relevance of the provisions of general hygiene code on the “Control of operation” to the handling and processing of coffee.
Provide understanding of key aspects of control systems in coffee handling and processing
Slide 3 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Content
Scope, outline and objectives of Section V of Codex General Principles of Food Hygiene, “Control of operation”
Principles governing hygiene control systems and their application to the coffee chain
Responsibilities of various stakeholders in the control of operations in coffee processing and handling
Slide 4 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Objective of Section V
Production of safe and suitable food for human consumption by
Formulating design requirements with respect to raw materials, composition, processing, handling, distribution, and consumer use
Designing, implementing, monitoring and reviewing effective control systems
Slide 5 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Control of food hazards
Food hazards should be controlled through the use of appropriate food safety management programmes that
Identify any steps which are critical to safety of food Implement effective control procedures at those steps Monitor control procedures Anticipate emergencies – development of recall
procedures Review control procedures periodically
Systems should be applied throughout the food chain to control food hygiene throughout the product shelf-life
Slide 6 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Key aspects of hygiene control
Some food safety issues to be controlled in food processing operations
Microbiological contamination / food poisoning
Chemical contamination Extraneous material Correct use of additives Record-keeping, documentation and labelling
requirements
Slide 7 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Implement control measures
Specific process steps may be designed to exert control of food hazards. Key process parameters may relate to
Thermal processing Chilling /freezing Drying Washing Fermentation Vacuum or modified atmosphere Other process-specific procedures depending on the
production system
Slide 8 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Designing / evaluating control measures
Microbiological, chemical and physical specifications
Must be based on sound science Considerations in establishing
microbiological specifications Growth potential in particular medium Infective dose Contamination routes Spoilage
Slide 9 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Common problems in hygiene control
Microbial cross-contamination Passive transfer by air or water Transfer / contamination by ‘vectors’ Transfer via surfaces Transfer via staff Raw material crossing finished product Packaging faults
Slide 10 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Common problems in hygiene control
Physical and chemical contamination Contamination during production operations Chemical residues and extraneous matter in
raw materials Inappropriate use of additives Glass or metal shards
Slide 11 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Building adequate controls into the process
Identification and analysis of potential hazards that could arise is an essential prerequisite for building adequate hygiene controls into the process
All operations involved should be considered:
Raw material receipt All processing steps Storage, transport, handling by all intermediate
and final users
Slide 12 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Temporary storage and transport at each segment
Primary transformati
on
Primary processing
Secondary
processing
Exportable coffee
Bagging
StorageFresh
cherries
Dry product
Dry product
Unsorted beans
Unsorted beans
Graded beans
A B C D
General structure of coffee chain - four main segments with different operations in each
segment
Hygiene control systems
Slide 13 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Segment A: Consists of stabilisation of fresh product by drying. Two basic techniques are used to achieve this
goal
Hygiene control systems
Parchment
Wet processing
Dry cherries
Dry processing
Fresh cherries
Slide 14 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Wet processing - consists of the removal of pulp and mucilage through successive operations and this shortens
time of drying
Hygiene control systems
Pulping Removal of mucilage, mechanically or by fermentation in tanks Washing, an operation only applied after fermentation to remove
pieces of mucilage which could remain
Slide 15 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Step 1 - Receiving
Hygiene control - receiving
Handling of cherries between harvesting and processing may impact on microbiological condition
Processors should ensure that cherries are received in good condition
Records of deliveries / lists of approved suppliers
Slide 16 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Step 2 - Pulping
Control of pulping
Establish specifications for acceptability of fresh cherry to be fed into pulper and ensure that specifications are met
Ensure use of water of acceptable quality Adjust pulper spacings to avoid crushing of beans Visually check pulped parchments for damage and admixture with
skins to verify functioning of pulper
Disc pulper Drum pulper
Slide 17 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Step 3 – Mucilage removal by fermentation
Control of mucilage removal
Time of fermentation defined by local conditions (temperature) Assure availability of clear water Ensure adequate removal of skins from parchment Confirm adequate degradation of mucilage at end of fermentation Records should include start and end of fermentation and any
pertinent comments
Slide 18 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Step 3 – Mucilage removal by mechanical action
Control of mucilage removal
Establish specifications for acceptability of fresh cherry to be fed into demucilaginator and ensure that specifications are met.
Ensure that water is of acceptable quality Visual check on condition of outgoing parchment and
adjustment of equipment as necessary Daily removal of residual parchment
Slide 19 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Step 4 – Washing (after fermentation)to eliminate residual mucilage adhering to parchment
Control of washing
Ensure use of water of acceptable quality Check adequacy of washing - the parchment should not be
gelatinous
MechanicalCanal
Slide 20 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Step 5 – Drying of parchment
Drying of parchment
1250 kg of wet parchment Contains 600-700 kg of water to be removed Produces 450-500 kg of dried beans Produces 110-120 kg of dry parchment husk
Control of the drying operation involves same considerations as drying of cherries
Slide 21 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Drying of fresh cherries
Hygiene control systems in dry processing
2500-2600 kg of fresh cherries: Contains 1450-1600 kg of water to be removed Produces 450 – 500 kg of dry beans Produces 500 kg of dry husk
Slide 22 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Control of drying operations
Parameters to be considered for control of drying Load of dryer (kg of fresh material/m²) or Thickness of layer
Findings from the global project (drying on tarpaulin)
0,0
10,0
20,0
30,0
40,0
50,0
60,0
J0 J3 J6 J9 J12
J15
J18
J21
J24
J27
Thick layer (T1) versus thin layer (T2)
T1T2
15 days
15%
Load
Layer thickness
T1 : 60 kg/m²
T2 : 37 kg/m²
T1 : 10.5 cm
T2 : 3.5 cm
Slide 23 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Control of drying operations
Recommended loads in sun-drying of coffee
Fresh cherries: 20 - 40 kg/m2 or 2 - 4 cm thick layer Parchment: 30 - 50 kg/m2 or 3 - 4 cm thick layer
Drying layer too deep Correct thickness of drying layer
Furrowing to increase surface area
Slide 24 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Control of drying operations
Measurable parameters to be monitored for control of drying
Loading on surface (kg of fresh material/m²) or of dryer (kg)
Thickness of layer Stirring frequency Temperature, air flow, initial moisture content and
residence time (with mechanical drying)
Slide 25 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Control of drying operations
Drying yard management Batches of coffee or parchment in the drying yards
should be kept separately Essential information about any batch should be
recorded (actions taken, moisture content, etc.)
Slide 26 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Control of drying operations
Drying yard management Coffee should be covered during the night and when
raining The person responsible for covering any batch of
coffee should be clearly indicated
Slide 27 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Storage of dry product
Storage of dry cherry Rigorous testing to assure newly arrived cherry
coffee is adequately dried (<12%) and in satisfactory condition (evidence of prior abuse)
The recommended maximum length of storage of dry cherry (before hulling) being confirmed
• Husk is an important source of contamination• But husk is more hygroscopic than bean so may confer re-
wetting protection• Poor moisture management could lead to increased risk of
contamination • Practical limitations imposed by hulling capacity
Slide 28 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Storage of dry product
Appropriate storage facilities should be provided as outlined in Module 3.2
Permitting adequate cleaning and maintenance Preventing pest access and harbourage Providing protection against moisture uptake
and new contamination Inadequately dried coffee (m.c. > 12.0%)
should not be put into storage
Slide 29 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Management of dry product
Records should be kept of dried product accepted into storage (date, moisture content on receipt, condition, etc.)
Scheduled inspection for insect and rodent infestation made and recorded
Regular inspection for roof / plumbing leaks
Stored products should be subject to effective stock rotation - first in, first out
Store bags on pallets but NOT against a wall
Avoid poor quality bags stored on the floor
Slide 30 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Segment B: Husking consists of the transformation of dry parchment coffee or dry cherries into beans by husking /
hulling
Hygiene control systems
Parchment
Dry cherries
Beans
Slide 31 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Control of husking
Factors to control in husking Moisture below 13% to avoid
excessive heating and crushing of beans
Adjustment of the machine to avoid physical damage to beans
Good separation of husk and beans
When operating in closed place, good ventilation is required
Husk can be highly contaminated with OTA-producing mould and OTA, badly managed husking operations can create contamination risk
Slide 32 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Segment C: Cleaning, sorting and grading. Consists of the transformation of dry parchment coffee or dry cherries
into beans by husking / hulling
Hygiene control systems
Unsorted coffee
Sorted coffee
Defects
Slide 33 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Hygiene control in grading and sorting
Sorting and grading are primarily related to quality and marketing of coffee
According to ICO Resolution 407 minimum standards for exportable coffee - < 86 defects in 300g sample of Arabica; < 150 defects in 300g sample of Robusta
ISO 10470 - definitions and characteristics of main defects and foreign matter in green coffee
Quality defects / foreign matter may also be linked to risk of OTA contamination – this is under investigation in the global project Sample OTA (ppb)
Bulk coffee 6.3
Sound beans 2.2
Defects 24.5
OTA content of defects and sound beans sorted from a single batch of bulk coffee
Slide 34 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Storage of green coffee
Coffee must be protected from re-wetting during storage
Coffee should be protected from sources of contamination
Store bags away from walls
Store bags on pallets in
ventilated and clean warehouse
Slide 35 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Storage of green coffee
Green coffee should be stored separately from dry cherry or parchment
Recommended shelf life under ambient conditions of temperature and relative humidity - under investigation in global project
Slide 36 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Incoming material requirements
No raw material or ingredient be accepted if known to contain hazards which would not be reduced to acceptable levels by normal sorting/processing
Raw material should be inspected and sorted before processing and, when necessary, laboratory tests should be made
Routine OTA testing is unreliable and expensive Prevention of OTA contamination by adherence to good
practices throughout the chain All actors in the coffee chain should require assurance
that they receive material from reliable suppliers following recommended practices
Only sound and suitable material should be used
Slide 37 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Control of incoming material
Periodic evaluation of incoming ingredients Written specifications needed and purchasing
specifications should meet food laws Statistically representative sample taken and analysed
at scheduled frequency
1OO% lots inspected A certificate of analysis for each lot Predetermined sampling plan to verify adherence to
specifications
Vendor certification Specification requirements
Strategies for assuring quality of incoming raw material
Slide 38 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Packaging
Packaging design and materials should provide adequate protection
Packaging design should allow proper labelling Packaging materials and gases must be non-toxic Reusable packaging should be durable and easy to clean
Label certifying that this jute bag is
suitable for contact with
food
Slide 39 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Water
Water in contact with food: case of wet processing with coffee
Pulper Washing canal
Water quality specifications have not been established - but clear water is recommended
Avoid water polluted with chemical residues and other toxins
Slide 40 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Management and supervision
Management of food establishments must Establish and document food quality and
safety policy for establishment Facilitate implementation of quality and safety
policy through adequate quality /safety management programmes
Improve awareness of all employees of food quality/ safety issues and encourage participation of all in assuring food safety and quality
Provide training to employees in food quality and safety, as appropriate to their function
Slide 41 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Management and supervision
Design of appropriate control systems depends on: Size of business Nature of activities Type of food
Constraints in relation to coffee sector Highly fragmented nature of marketing chain in
most producing countries Predominated by small-holder farms Limited human, financial and technical
resources of most of the economic operators within the chain
Weak or non-existent economic incentives for ensuring quality and safety
Slide 42 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Documentation and records
Any food quality and safety system must include documentation, record-keeping and monitoring
Where necessary, records should be kept and retained for a period exceeding the shelf-life of product
Records of incoming raw materials received Records of processing Records of distribution
Documentation can enhance Credibility Ability to react effectively and efficiently in case of
a food safety problem
Slide 43 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Documentation and records
A large proportion of the farmers and traders in many coffee-producing countries operate at a micro-scale
Pooling of coffee is widespread in smallholder areas In many producing countries, regulations governing
the condition of coffee traded within the country are outdated or lacking
Instruments for reliable and accurate measurement of moisture in coffee are not widely available for use in the field
Factors affecting record keeping in the coffee sector
Slide 44 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Ensuring adequate hygiene controlsin the coffee sector
To design and implement hygiene control systems covering their entire operation
Industry groups can play an important role in encouraging good practices
Participate in discussions with relevant government agencies on industry concerns, priorities, and provide data as appropriate
Role of industry
Slide 45 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Ensuring adequate hygiene controlsin the coffee sector
Use a risk-based evaluation to ensure best use of available resources for the implementation of good practices within the sector
To establish a sound science-based regulatory framework that ensures food safety without unnecessarily encumbering the industry
Assist industry to meet food safety requirements by providing practical guidelines and training
Commit resources for the implementation of monitoring programmes to allow early detection of problems and other technical support programmes to address key issues
Ensure effective use of resources in addressing problems as they arise
Role of government
Slide 46 Module 3.3 – The Codex General
Principles of Food Hygiene –Control of Operation
Next steps…
Reflect on coffee processing operations that you are familiar with - is there adequate control to ensure food safety?
Consider what is your role in ensuring that adequate controls are applied in the processing and handling of coffee?
Next module – ‘Maintenance and sanitation’
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