Mohamed ElMouelhy

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Good Manufacturing Practices
GMP

• By
• Mohamed El-Mouelhy

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Results of not having a GMP in Safety

• Loss of business goodwill
• Lack of customer satisfaction
• Increased rejects
• Low employees morale
• Litigation
• Increased insurance premium

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Microorganisms are everywhere.

• Know the source of the raw material (food).
• Determine the probability of soil, water or
  atmospheric contamination.
• Examine handling

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Microbial Growth

• Food, water time
• Optimum temperature, oxygen condition pH

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Log Phase

• This is the time when cells divide into 2

Temperature Generation Time (in hours) 320 C
0.5 210 C 1.0 150 C 2.0 100 C 3.0
50 C 6.0 00 C 20.0 -20 C 60.0
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Control of Diseases

• Food handlers must be free from
• Diseases of the respiratory tract cold, sore
  throat, pneumonia, scarlet fever, tuberculosis,
  trench mouth ..
• Intestinal disorders dysentery, typhoid,
  hepatitis
• 3. Skin disorders Sores, abrasions, lesions,
  boils, scabies, rashes

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Clothing

• a. Hair Restraint

b. Facial Mask
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• c. Apron and Uniform

b. Gloves
c. Footwear
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Plant and Grounds

• 1. Floors and Drains
• 2. Walls and Ceiling
• 3. Ventilation
• 4. Lighting

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Cleaning and Disinfection

• The processing area of the food plant should have
  a regular cleaning schedule to
• Lengthen the shelf-life of the products
• Reduces the risk of product rejection
• Reduces complaints
• Zero food poisoning

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Fundamental Principles of Cleaning

• All food contact equipment shall be properly
  cleaned daily or after each use.
• Equipment shall be cleaned even if not used
• Undersides of equipment shall be kept clean.
• Worn seals, gaskets, o-ring etc to be replaced.

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Proper Steps in Cleaning and Sanitizing a Food
Plant

• A. Removal of visible dirt and other large debris
  (Sweeping and Scraping)
• B. Wetting and removal of surface soil by hosing
• C. Removal of the remaining soil and dirt by
  application of detergent
• D. Rinsing off the detergent
• E. Disinfect to further reduce microbial
  population
• F. Rinsing off the disinfectants
• G. Allow to dry

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Correct Washing of Equipment

• 1. Wash using hot water and detergent
• 2. Sanitize in water at not less than 900C or use
  adequate sanitizing solution such as
• Chemical Concentration
• Chlorine Solution 100 - 250 ppm
• Iodine 12.5 - 25 ppm
• Ammonium 100 - 200 ppm

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Remember

• 3. Remove all materials and supplies from work
  area that would hamper cleaning efficiency.
• 4. Equipment should be cleaned internally and
  externally.
• 5. Keep cleaning implements off the floor
• 6. No glassware is permitted in plant operation
  areas other than those used in plant equipment

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Safety Standing Operating Procedure (SSOP)

• Prevention of contamination between raw and
  processed food.
• Condition and cleanliness of Food Contact
  surfaces.
• Prevention of cross contamination.
• Maintenance of hand washing sanitizing
  facilities.
• Protection from chemical adulteration.
• Toxic compound labeling, storage and handling.
• Control of employees health and conditions.
• Exclusion of pests.

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Safety of Water Supply

• Adequate and sanitary water supply source.
• No cross connection between clean water lines and
  discharge water lines.
• Safety of water for cleaning and conveying food.
• Safety of water for ice making

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Conditions of Food Contact Surfaces (FCS)

• Food contact surfaces cleaned as frequently as
  necessary.
• Portable equipment stored and handled to prevent
  contamination of food contact surfaces.
• Use recommended sanitary materials.

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Adequate Hand Washing, Hand Sanitizing, and
Toilet Facilities

• Toilets to have self closing doors.
• Hand washing facilities conveniently located,
  provided with soaps, brushes, sanitizers, hand
  drying facilities.
• Clear signage on hand washing

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Protection of Food Packaging and FCS from
Adulteration with Contamination.

• Separate operations that can cause contamination.
• Eliminate condensation dripping on FCS and
  packaging.
• Keep premises in good repairs.
• Place safety shields around light fixtures
• Ventilation to be adequate
• Protect against contamination during storage and
  distribution.

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Labeling, Use and Storage of Toxic Compound

• Only materials that are needed within the
  facility should be located therein.
• All toxic materials should be properly labeled
  and stored under lock and key.
• Toxic compounds to be assessed by an authorised
  person.
• First aid box and instructions to be available.

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Exclusion of Pests

• Facilities, fixtures to prevent access of
  insects, arachnids, rodents, bats, birds, cats,
  dogs etc.
• Have regular inspection.
• Maintain cleanliness to deny food to pests.

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Why is GMP necessary?

• Customer protection satisfaction
• Employee protection
• Fulfilling legal requirements
• Good business practice
• Pride in workplace