the codex general principles of food hygiene – maintenance, sanitation and personal hygiene

Good Hygiene Practices along the coffee chain

The Codex General Principles of Food Hygiene – Maintenance, sanitation and

personal hygiene

Module 3.4

Module 3.4 – The Codex General Principles of Food Hygiene –

Maintenance, sanitation and personal hygiene

Objectives

Introduce trainees to the importance of maintenance, sanitation and personal hygiene programmes in assuring food hygiene

Relate general principles of maintenance, sanitation and personal hygiene programmes to good practices in coffee processing and handling



Content

Scope, outline and objectives of Section VI of Codex General Principles of Food Hygiene, “Establishment: maintenance and sanitation”

Designing and implementing maintenance programmes – application to coffee

Designing and implementing cleaning programmes – application to coffee

Pest control and waste management in coffee processing

General personal hygiene issues



Objective of Section VI

Establish effective systems to Ensure adequate and appropriate maintenance and

cleaning of the establishment and equipment Control pests Manage waste Monitor effectiveness of maintenance and sanitation

procedures

To facilitate the continuing effective control of food hazards, pests and other agents likely to contaminate

food



Outline of Section VI Codex GPFH Establishment: maintenance and

sanitation 6.1 - Maintenance and cleaning

General principles underlying maintenance and cleaning programmes and scope of cleaning procedures

6.2 - Cleaning programmes Outlines the scope of cleaning programmes and practical

guidance for their establishment

6.3 - Pest control systems Outlines main aspects of effective pest control

programmes

6.4 - Waste management 6.5 - Monitoring effectiveness



Maintenance programmes

Establishments and equipment should be kept in an appropriate state of repair to

Facilitate cleaning and sanitation Ensure that equipment functions as intended

(particularly at critical steps) Prevent introducing hazards into food



Maintaining the establishment

Prepare checklist to guide periodic inspection of the establishment

During each inspection notes should be taken of observations

Results of the inspection should be evaluated and recommended actions prioritised according to associated risks

Records should be kept of actions taken to address problems found during inspections



Inspection of the physical plant

Inspection should include Immediate environs of the facility External walls, windows, doors and roof Internal walls Ceiling fixtures Floors



Equipment maintenance programmes

Processors should keep a list of all equipment used in the facility

Programme of preventative maintenance should be documented including procedures and frequencies of maintenance

Based on equipment manufacturers’ instructions

Production experience Operating conditions that could affect

condition of equipment



Equipment in coffee processing

Harvester, bags, baskets Hopper, channels Pulper Fermentation vats Washer Elevators Drying surfaces, tables Huller / polisher Conditioning bins

De-stoner De-huskers Extractor fans Air buoyancy separators Winnowers Gravity tables Grader Colour sorter Generator

Some processing equipment used in the production of green coffee



Maintenance of equipment

Programme of preventative maintenance should be adhered to

Equipment should be maintained to ensure absence of potential physical and chemical hazards (metal shards, flaking paint, lubricants, etc.

Equipment must function properly particularly if involved in a hygiene control step (removal of husk)



Maintenance of equipment –example of hullers

Make routine checks on machine performance: frequency of cherries in output, husk fragments, broken beans, - readjust as indicated

Cherries are sometimes husked at moisture above 15% which causes heating and exceptional wear

Air-borne contamination occurs during hulling



Maintenance of equipment

Equipment for control and monitoring along the coffee chain

Moisture measuring devices

Water activity meters Maintenance and calibration

of equipment should be performed by appropriately trained personnel



Maintenance and calibration records

Records of maintenance and calibration of equipment must be kept



Cleaning programmes - general

Cleaning is required to ensure that food residues and dirt, which may be a source of contamination, are removed from all parts of the establishment including equipment

Appropriate cleaning methods and materials depend on the nature of the business

Cleaning chemicals should be handled and used carefully and stored in accordance with manufacturers’ instructions



Cleaning methods and procedures

Separate or combined methods can be used

Physical methods - heat, scrubbing, turbulent flow, vacuum cleaning

Chemical methods - detergents, alkalis, acids

Cleaning procedures involve: Removing gross debris from surfaces Applying detergent solutions to loosen soil

& bacterial films Rinsing with water to remove residues Dry-cleaning and other similar methods Where necessary disinfection



Cleaning programme – example of hygiene implications in coffee

Dry pulp remaining on the machine could cause contamination by undesirable fungi

Although fermentation presents a hurdle for development of OTA-producers, addition of any undesirable inoculum must be minimized

Unfermented parchment routes such a descascado or split cherry drying would present further risk of fungal development from such a source

This amount of residue

could support significant

fungal growth



Cleaning programmes

Cleaning and disinfection programmes should be documented and monitored

Cleaning programmes should specify Areas, items of equipment and utensils to be

cleaned Responsibility for particular task Method and frequency of cleaning Monitoring arrangements



Cleaning programmes

Establish appropriate cleaning procedures for each piece of equipment

Cleaned out of place (COP) Cleaned in place (CIP)

For equipment, disassembly & re-assembly instructions as required for cleaning and inspection



Documenting cleaning programmes

Cleaning procedures for the equipment

Institute appropriate daily cleaning procedures

Institute more thorough procedures when operation of equipment will be suspended

Programme for weekly cleaning of pulper

Procedures:a) Unscrew supports of disks and bladesb) Remove disksc) Rinse disks, blades and chassis with clean water, wash with detergent, rinse with clean watera) Reassemble disks and bladesb) Tighten the bolts firmly

Supervisor: Mr Peter



Cleaning programmes

Cleaning of premises: written cleaning and disinfection programmes for preparation, processing, storage areas

Cleaning Record for Fermentation Shelter

Area/equipment

Method Used Frequency Date Operator Comments

Fermentationtanks

Scrub with cleanwater. Rinse withclean water

Weekly Week 1

Week 2

Week 3

Week 4

Ceiling infermenatationarea

Brushing of rafters Monthly



Pest control systems - general

Pests pose a major threat to the safety and suitability of food

Pests infestation can occur where there are breeding sites and supply of food

Good hygiene practices should be employed to avoid creating an conducive environment

Good sanitation, inspection of incoming materials and good monitoring can minimise risks of infestation



Pest control systems

Preventing access Buildings should be kept in good repair and condition to

prevent pest access and to eliminate potential breeding sites

Use of wire mesh screens on windows, doors, ventilators Holes and drains kept sealed

Harbourage and infestation Availability of food and water encourages pest harbourage

and infestation: Potential food sources should be stored in pest-proof

containers or Stacked above the ground and away from walls



Pest control systems

Monitoring and detection Establishments and surrounding areas should be regularly

examined for evidence of infestationEradication Pest infestations should be dealt with immediately and

without adversely affecting food safety or suitability Treatments with chemical, physical or biological agents should

be carried out without posing a threat to the safety of food Pesticides used should be acceptable to the food control

regulatory authorities Where applicable, name of the pest control company or any

person contracted for the pest control programme



Waste management

Waste stores and containers must be kept clean

Suitable provision must be taken for the removal, storage and handling of waste

Waste must not be allowed to accumulate in food handling, food storage, and other working areas and adjoining environment



Waste from coffee production

Coffee processors must plan for proper handling of wastes produced from their operations

1 ton dry cherries = 500 kg husk 1 ton of parchment coffee = 200 kg parchment 1 ton fresh cherries = 610 kg pulp 1 ton unsorted beans = 5 - 10 kg of rejects



Monitoring effectiveness

Sanitation systems should be

Monitored for effectiveness Periodically verified through

Audit pre-operational inspections Microbiological inspections

Regularly reviewed Adapted to reflect changed circumstances



Personal hygiene

Ensure that those who come directly or indirectly into contact with food are not likely to contaminate food by

Maintaining an appropriate level of personal cleanliness Behaving and operating in an appropriate manner

Remember that these are general principles to guide all food establishments - some provisions may not be pertinent in the

production of green coffee beans



Personal cleanliness and behaviour

Food handlers should wear suitable protective clothing Personnel should always wash their hands when personal cleanliness may

affect food safety (for example, after handling contaminated material) Personnel should refrain from behaviour that could result in food

contamination (for example, smoking, spitting, chewing/eating) Personnel should not use perfumes and other highly scented substances

that could taint the coffee Personal effects such as jewellery, watches, etc. should not be brought into

food handling areas



Next steps…

Which coffee processing operations that you are familiar with have documented and effective cleaning and maintenance programmes in place?

What can you do to ensure that adequate cleaning and maintenance programmes are implemented by coffee processors?

Next module - Transportation

the codex general principles of food hygiene – maintenance, sanitation and personal hygiene

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