food safety risk management in bakeries

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Page 1: Food safety risk management in bakeries

Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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Food safety riskmanagement in bakeries

Helen EhavaldFazer Bakeries Estonia

H. Ehavald 2

Introductiono Wide variety of bakery products are produced:

wheat loafs, rye breads, buns, coffee breads,cakes, cookies, pizzas, pies etc.

o Food hygiene is vital throughout the wholefood chain ­ from raw material totransportation of ready products

Page 2: Food safety risk management in bakeries

Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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H. Ehavald 3

Food safety management

o Food legislation (Local andEU legislation)

o Good Manufacturing Practices (GMP), GoodHygiene Practices (GHP)

o HACCP (Hazard Analysis and Critical ControlPoint)

o Quality management system (ISO 9001, ISO22000, BRC, other)

H. Ehavald 4

Product contaminationo The main routes of contamination –

surfaces, air, water, people and pestso Physical contamination ­ pieces of glass, wood, metal,

plastic, film, human hair and fingernails, plasters,jewellery, small personal belongings, pests, paper,cardboard.

o Chemical contamination ­ residues of cleaning anddisinfection chemicals, machinery lubricants, syntheticpreservatives, food additives, pesticides

o Biological contamination –microbiological (bacteria,yeasts, mould, mycotoxins) and pests

Page 3: Food safety risk management in bakeries

Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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H. Ehavald 5

Microbiological contaminationo Spoilage of most bakery products is

caused mainly by moulds, yeasts andseldom by bacteria

o Most bakery products, in general, arenot considered as high­risk foodproducts because baking at relativelyhigh temperatures (around 180­250C) is involved in their preparation

o Many bakery products have reducedwater activity (aw) and pH, whichprevent the growth ofmicroorganisms

o Potentially hazardous foods havea pH >4.5 and an aw>0.84.

H. Ehavald 6

pH Range of Selected BakeryProducts (Cauvain et al., 1999)

o High AcidSourdough bread 4.2–4.6Apple pie 4.2o Low AcidWhite bread 5.7Whole wheat bread 5.6Chocolate nut bread 6.2–

6.6

o Non­AcidCrumpets 6–8Banana nut bread 7.2–7.9

Page 4: Food safety risk management in bakeries

Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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H. Ehavald 7

Range of Water Activity (aw) of SelectedBakery Products (Cauvain et al., 1999)

o Low Moisture ContentCookies 0.2–0.3Crackers 0.2–0.3

o Intermediate MoistureContentCake type doughnuts0.85–0.87Chocolate­coateddoughnuts 0.82–0.83Danish pastries 0.82–0.83Cream­filled cake 0.78–0.81Soft cookies 0.5–0.78

o High Moisture ContentBread 0.96–0.98Pita bread 0.9Yeast­raised doughnuts0.96–0.98Fruit pies 0.95–0.98Carrot cake 0.94–0.96Custard cake 0.92–0.94Cheesecake 0.91–0.95Butter cake 0.9Pizza crust 0.94–0.95Pizza 0.99

H. Ehavald 8

Microbiological contaminationo Flour contains approximately 8000 mould

spores in 1 g.o The most common bread spoilage moulds are

Penicillium spp. and Aspergillus spp.o Both can produce mycotoxins (Ochratoxin A

and Aflatoxin), which are very resistant andcan survive heating process

o Rhizopus (nigricans) stolonifer is the commonblack bread mould

Page 5: Food safety risk management in bakeries

Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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H. Ehavald 9

Microbiological contamination

o Bacillus subtilis and Bacillus licheniformiscan cause ropiness in wheat bread, but ropeis now rare because of adding preservativesand good bakery hygiene practice

o Bacillus cereus may survive baking process,because Bacillus species can formendospores

o A major reservoir of Staphylococcus aureusare humans and some outbreaks have beeninvolved with bakery products (for examplefilled pies)

o Listeria monocytogenes (bakery productscontaining dairy ingredients), Salmonellaspp. (cake mixes made with dry eggs).

H. Ehavald 10

Microbiological contamination

o It is very important to keep the coldchain of frozen bakery products

o Many ingredients, such as fresh andsynthetic cream, cold custard, icings,spices, nuts, and fruit toppings or fillings,are added after baking and may be apotential source of contamination.

o Using preservatives (sorbic acid, calciumpropionate), sourdough, modifiedatmosphere packaging (MAP), vacuumpackaging, microwave and infraredradiation are methods to control themicrobiological spoilage.

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Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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H. Ehavald 11

MAPo Modified atmosphere packaging (MAP) using

CO2­enriched gas atmospheres can extendthe mold­free shelf­life and keeping quality ofa wide variety of bakery products stored atambient temperature.

o Because S. aureus can grow facultatively,MAP will not inhibit its growth or enterotoxinproduction

H. Ehavald 12

Raw materials

o Quality and safety of baking ingredients –flour,yeast, other ingredients

o Cold­chain for fast­spoiling ingredients (transport)o Visual control (broken and dirty package, shelf

life)o Controlling the temperature of

fast­spoiling ingredientso Quality sheets and certificateso Safe handling and storingo FIFO (First in, first out) principle

Page 7: Food safety risk management in bakeries

Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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H. Ehavald 13

Cleaning and sanitation programs

o Documented and monitored programs for building,utilities, plant and all equipment

o Appropriate, effective and regular cleaning methodso Cleaning and sanitation materials –where appropriate,

confirmed suitability for food useo An average shelf life of bread is 3­5 days, but if the

hygiene and sanitation of a bakery is poor, the shelf lifeof bread, especially some wheat bread, can be shorter

H. Ehavald 14

Cleaning and sanitation programs

o Proofing cabinet needs to be cleanedregularly, because proofing conditions(temperature 30­40  C and humidity 60­80%) are appropriate for the growth of bakeryyeast, but also for moulds.

o Conveyor belts, cooling conveyors –regularcleaning is needed!

o It is recommended to disinfect slicing andpacking machines

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Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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H. Ehavald 15

Disinfectiono According to literature Benzalkonium chloride was

efficient against most fungi.o Some fungi (P. roqueforti and P. carneum) showed to be

resistant towards alcohols, but 3% hypochloriteefficiently eliminated them.

o Quaternary ammonium compounds, 70% ethanol, 70%isopropanol and 30% hypochlorite were effective onyeasts.

o It is suggested to use different types of disinfectants atthe same time to prevent resistance problems.

o Problems with mould usually occur more in spring and

summer.

H. Ehavald 16

Personal Hygieneo Documented hygiene rules communicated to all personnelo Regular and effective hand washing (before starting

work, regularly during work, after eating/smoking/usingtoilet)

o Appropriate and clean clothing is critical to the safety ofproducts

o Jewellery and watches shall not be worno All cuts and grazes on skin should be covered with

coloured plaster (blue where possible)o Fingernails –short, clean, unvarnishedo Scalp hair should be fully coveredo Gloves  (blue where possible)o It is permitted to work while being sick!o Rules for mechanics, subcontractors

and visitors

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H. Ehavald 17

Pest Controlo Birds, insects and rodents are

potentially a major contaminationproblem in bakeries

o Appropriate design of productionbuilding, ceilings and walls –to keeppest out and not allow them to livethere

o Written preventive pest control programand regular inspection for all areas ofthe site to minimize pest infestation

o Flour dust spreads easily everywhere ­regular cleaning is very important!

o Silos, ingredient dosing systems,mixers, curling chains, conveyor belts,ovens, cooling conveyors, packagingmachines, walls etc. should be properlycleaned to prevent infestation outbreaks

H. Ehavald 18

Pest controlo Fumigation for silos –a method of pest control that

completely fills an area with gaseous pesticides ­ orfumigants ­ to suffocate or poison the pests within

o Pheromone insect trapo UV lamps –electric trap for flying insectso Insecticides ­ a pesticide used against insects in all

developmental formso Rodenticides ­ pest control chemicals intended to kill

rodents (should be used outside of building)

Page 10: Food safety risk management in bakeries

Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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H. Ehavald 19

Pest control

H. Ehavald 20

Process controlo Foreign body detection ­

sieves, magnets, metaldetectors, x­ray detectors

o Control of preservatives andfood additives ­ the use ofpreservatives and foodadditives should be undercontrol

o Process control –bakingtemperature, cooling time

o Control of cooling and freezingtemperatures

Page 11: Food safety risk management in bakeries

Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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H. Ehavald 21

Process controlo Microbiological samples from

production air, water, product,equipment, crates and hands ofemployees.

o Raw material, pies, pizzas and cakesshould be stored according to theinstructions and kept in fridge ifneeded

o More than 90% of contamination ofbread occurs during cooling, slicingor wrapping operations.

H. Ehavald 22

Process control

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Presentation at the 3Presentation at the 3rdrd SAFOODNET  seminarSAFOODNET  seminarStSt OlavOlav’’ss HotelHotel,, TallinnTallinn, Estonia, Estonia;; MayMay 44­­6, 20096, 2009

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H. Ehavald 23

Equipment and maintenanceo All equipment should be constructed of appropriate

materials and have a suitable design so that they can beeffectively cleaned

o Buildings (floors, walls, ceiling, non­contact surfaces)should be maintained to minimize the risk of productcontamination

o Regular maintenance program  for equipment to preventproduct contamination by foreign bodies arising fromequipment failure

o Paints and lubricants shall be suitable forintended use

o Cleaning of ventilation system (tubes, filters) –inside and outside surfaces

H. Ehavald 24

Trainingo Food hygiene training for bakers, packers, other

operators, warehouse workers, mechanics, supervisors,cleaners, dispatch workers, drivers

o Understanding of HACCP, CCP­s (Critical Control Points),critical limits, GMP, GHP

o Cleaning and sanitation processo Housekeeping ruleso Employees should be trained to understand the risk

associated with cross­contamination from raw foods anddirty surfaces coming into contact with equipment, cleansurfaces and ready product

Page 13: Food safety risk management in bakeries

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H. Ehavald 25

Storage and transporto Procedures to guarantee product safety

during storage, loading andtransportation

o Cleanliness of storage areas and vehicleso Controlling temperatures, cold­chain

(Frozen bakery products)o Use of castors or pallets under crateso Do not leave products outside  ­ BIRDS!o Maintenance for vehicles

H. Ehavald 26

Conclusionso Food safety risk management in bakeries is to

implement practices based upon food storageand handling, cleaning and sanitation, pestcontrol, personal hygiene, maintenanceprogram, safe transportationetc.