Ministry of Health Malaysia

Guideliness On Good Hygiene Practices For Small And Medium Scale Food Industries Towards HACCP

Japan International Cooperation Agency (JICA) Division of Food Quality Control Ministry of Health Malaysia

CONTENTS
Committee Representation Foreword 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Introduction Objectives Scope Definitions Buildings And Facilities Personnel Hygiene Facilities And Toilets Equipment Control Of Operations 8.1 8.2 8.3 8.4 8.5 8.6 9.0 Raw Material Requirements Key Aspects Of Process Control System Packaging Water, Ice And Steam Process Control Records Recall Procedures

Establishment: Maintenance And Sanitation 9.1 Maintenance And Cleaning 9.1.1 9.1.2 9.2 9.3 General Cleaning Procedures And Method

Cleaning Programme Pest Controls 9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 General Preventing Access Harborage And Infestation Monitoring And Detection Eradication

9.4

Waste And Effluent Management 9.4.1 9.4.2 Effluent Management Waste Management

9.5 10.0

Monitoring Effectiveness

Establishment: Personal Hygiene 10.1 10.2 10.3 10.4 Health Status Personel Cleanliness Personal Behavior Visitors

11.0

Transportation And Distribution 11.1 11.2 11.3 General Requirements Use And Maintenance

12.0

Production Information 12.1 12.2 12.3 Batch Or Lot Identification Product Information Labelling

13.0

Training 13.1 13.2 13.3 Awareness And Responsibilities Training Programmes Assessment Refresher Training

14.0

References

Committee On The Drafting Of The Guideliness On Good Hygiene Practices For Small And Medium Scale Food Industries Towards HACCP

Mohd. Salim Bin Dulatti Dr. Ikuo Tsukamoto Foo Mong Keng Danny Wee Kong Heng Hazlin Bt Ghazali Sazly Azizuddin Bin Sahaimi Joseph Leong Ah Poh Kamarudin Ismail Zolhani Bin Shaari Thayalan Ramadas Abdul Rahman Bin Ismail Hj Zainal Abidin Bin Tajuddin Ahmad Shafie Bin Ariffin Sazali Harun Mohd Jefri Crossley Azhar Bin Ahmad Aziz Bin Salleh Ahmad Nadzri Sulaiman Amran B. Hassan @ Che Hassan Abdul Ghani Bin Abdul Samah Mahindera Bin Abdul Manaf Doreen Anthony Teoh Tiong Hok Sanimah Bin Abdul Rahman Nor Kamilah Bin Mohamad Alwi Mohd Khaidir Bin Abdul Hamid Fiona Zila Bt Mohd Noor

Chairman, BKMM, Kementerian Kesihatan Malaysia Project Chief Advisor Japanese International Co-Operation Agency Malaysian Agricultural Development Authority (MARDI) Jabatan Kesihatan Dewan Bandaraya Kuala Lumpur (DBKL) Small and Medium Industries Development Corporation (SMIDEC) Jabatan Kesihatan Negeri Perlis Jabatan Kesihatan Negeri Kedah Jabatan Kesihatan Negeri Kedah Jabatan Kesihatan Negeri Kedah Jabatan Kesihatan Negeri Perak Jabatan Kesihatan Negeri Perak Jabatan Kesihatan Negeri Perak Jabatan Kesihatan Negeri Perak Jabatan Kesihatan Negeri Melaka Jabatan Kesihatan Negeri Sembilan Jabatan Kesihatan Negeri Johor Jabatan Kesihatan Negeri Johor Jabatan Kesihatan Negeri Terengganu Jabatan Kesihatan Negeri Kelantan Makmal Kawalan Mutu Makanan Negeri Perlis Makmal Kawalan Mutu Makanan Negeri Pahang Makmal Kawalan Mutu Makanan Negeri Sabah BKMM, Kementerian Kesihatan Malaysia BKMM, Kementerian Kesihatan Malaysia BKMM, Kementerian Kesihatan Malaysia Secretariat, Jabatan Kesihatan Wilayah Persekutuan Secretary, BKMM, Kementerian Kesihatan Malaysia

FOREWORD Small and medium size industries (SMIs) play a vital role in the overall national economic development as they contribute significantly in terms of employment generation and income distribution. The government has been supportive in the growth and development of small and medium size industries (SMIs) by providing a wide range of incentives and support to small and medium scale food industries. This guidebook reflects that Ministry of Health has taken the initiative to compile this manual for the use of small and medium scale food industries in the country with the hope that they will derive maximum benefits from the information provided. As a consequence, the Ministry of Health has taken the initiative to compile this manual for the use of the small and medium scale food industries in the country with the hope that they will derive maximum benefits from the information provided.

Y. Bhg. Datin Hjh. Dr. Harrison Aziz bt. Shahabudin Director, Food Quality Control Division, Department of Public Health Ministry Of Health, Malaysia. March 2002

FOREWORD Implementation of Hazard Analysis Critical Control Point (HACCP) System in the food sectors is recognized internationally as an effective mean in assuring food safety by controlling critical points from raw materials reception to manufacturing and distribution of the finish products. In order to implement HACCP system successfully, food sectors should be operated based on Good Hygienic Practices (GHP), as part of the prerequisite programme. In this prerequisite programme human resource development in particular is critical and important. All food industries and their employees must realize the importance of food safety assurance programme based on the HACCP system. For this purpose, food industry must be committed to nurture staffs and provide them with the knowledge and expertise on HACCP. As part of activities under the collaborative project between Ministry of Health and JICA for Strengthening the Food Safety Programme in Malaysia, JICA was delighted to support the two GHP Workshops held in February and March 2002. On behalf of JICA, I would like to congratulate the workshop participants for their achievement in developing this Guideline as the fruit of these workshops. I hope this Guideline can be fully utilized not only by food handlers, food industry people, but also by the government officers who are responsible in ensuring the nations food safety.

Dr. Ikuo Tsukamoto Chief Advisor, The JICA project for the Strengthening of Food Safety Programme in Malaysia March 2002

GUIDELINES ON GOOD HYGIENE PRACTICES FOR SMALL AND MEDIUM SCALE FOOD INDUSTRIES TOWARDS HACCP

1.

INTRODUCTION: Small and medium scale food industry plays an important role in the economic development of the food sector. However, many are still lacking in hygiene and sanitation requirements. Unsatisfactory hygiene may lead to loss of food quality and safety, which may then result in losses such as product recall cost, liability cost and lost of business. As the current global needs favour HACCP implementation, and with AFTA and WTO agreement, it is imperative that the SMI lays a strong foundation towards this need, so that they can compete in the international market. This guideline is developed to assist the industry to achieve a higher standard of food hygiene and sanitation to meet the basic prerequisite requirements of HACCP. This document will provide a guide for the industry on key hygiene practices from the receiving of raw materials to distribution of the final product. It also highlight the importance of documentation, records and training.

2.

OBJECTIVES a) To guide small and medium scale food industry industries on basic hygiene and sanitation requirements to ensure production of wholesome food. b) To assist small and medium scale food processing industries to fulfill rerequisite requirements for HACCP implementation.

3.

SCOPE This guidelines applies to all small and medium scale food processing industries in Malaysia, which covers from the point raw materials are received, through processing, storage and distribution of final products. The document provides a general guideline and does not include more specific code of practice applicable to a particular sector.

4.

DEFINITIONS For the purpose of this guideline the following expression have the meaning stated: Building: any enclosed permanent structure used for food processing and storage. Cleaning: The removal of soil, food residue, dirt, grease or other objectionable matter. Contamination: The introduction or occurrence of a contaminant in food or food environment. Disinfection: The reduction, by means of chemical agents and/or physical methods, of number of microorganisms in the environment, to a level that does not compromise food safety or suitability. Food Safety: Assurance that food will not cause harm to the consumer when it is prepared and/or eaten according to its intended use. GHP (Good Hygienic Practices): describes the conditions, measures and control for building, facilities, equipment, personnel, process, storage, distribution and environment required for production of wholesome food for human consumption. HACCP (Hazard Analysis Critical Control Point): As in the Malaysian Standard MS 1480: 1999. Hazards: as in the Malaysian Standard MS 1480: 1999. Potable water: water safe for drinking and as specified under Food Act and Regulations 1985 (Regulation 394).

Small and medium scale industry (IKS): Comprises less than 150 full time workers with an annual sale turn-over of not more that RM25 million. 5. BUILDINGS AND FACILITIES a. Building should be designed and constructed according to its intended use and easy to maintain, clean and where appropriate, able to be disinfected. b. Buildings must be located in areas which are free from objectionable odours, smoke, dust or other contaminants and which are not subjected to flooding. c. Buildings used in the manufacture and storage of food are of suitable size, design and construction to permit unobstructed placement of equipments, orderly storage of materials, sanitary operations and proper cleaning and maintenance. d. Ceilings are constructed of smooth, easily cleanable surfaces and are kept clean and in good repair. e. Floors and walls are constructed of smooth, impervious, easy cleanable surfaces and are kept clean and in good repair. f. Floor in wet area should be constructed to allow adequate drainage and of non-slip material. g. Ceilings and overhead fixtures should be constructed to minimize the build up of dirt, condensation, flaking, chipping and easy to maintain. h. Fixtures, ducts and pipes are installed in such a manner that drip or condensate does not contaminate raw materials, utensils, food contact surfaces or finished products. i) food contact surfaces that come into direct contact should be in sound condition, durable and easy to clean, maintain and disinfect. They should be made of smooth, nonabsorbent materials, and inert to the food, to detergents and disinfectants under normal operating conditions. i. Windows should be easy to clean, be constructed to minimize the build up of dirt and where necessary, be fitted with removable and cleanable insect-proof screens, where necessary, disinfect. j. Sufficient working spaces should be provided between equipment and walls to allow ease of operation, cleaning and disinfection. k. Lighting and ventilation should be adequate to allow hygienic operation. l. Store rooms for non-food chemicals (e.g. lubricant, detergent) and food should be separated and should be rodent proof. Appropriate storage facilities should be provided for its intended use. m. The water supply shall be sufficient and derived from a safe source for the operations intended. Potable water shall be provided in all areas where required for the processing of food, for the cleaning of equipment and utensils, food-packaging materials and for employee sanitary facilities. n. If non-potable water is used, it shall be clearly identified and shall not connect with, or allow back flow into, potable water systems. o. Adequate drainage and waste disposal systems and facilities should be provided. They should be designed and constructed in such a manner to avoid cross contamination. 6. PERSONNEL HYGIENE FACILITIES AND TOILETS Personnel hygiene facilities should be made available to ensure that an appropriate degree of personal hygiene can be maintained and to avoid contaminating food. Such facilities should be suitably designated, located and maintained. These facilities should include: a) b) c) adequate means of hand washing and drying facilities, including wash hand basins and constant supply of potable water and sanitizers; adequate number of toilets of appropriate hygienic design; and adequate changing facilities for personnel.

7.

EQUIPMENT a. Equipment and utensils used in food processing should be of appropriate design and those surfaces or parts that come into contact with food be made of non-toxic material that can be easily cleaned and sanitized. b. Equipment should be placed away from walls to provide accessibility for cleaning.

8. 8.1

CONTROL OF OPERATIONS RAW MATERIALS REQUIREMENTS a b Raw materials should be of acceptable quality and where appropriate, specifications for raw materials should be identified and applied. Stock rotation should be practiced (first in first out). Raw material including ingredients and food additives should comply with regulatory requirements.

8.2

KEY ASPECTS OF PROCESS CONTROL SYSTEM Implement effective control procedures at each process step: a) Time and temperature should be controlled effectively to ensure the safety of food. b) All measuring devices which include time and temperature devices or weighing scale should be calibrated based on requirement. c) There should be an effective control of cross contamination for example from raw material to processed food or from personnel to processed food. d) Clean protective clothing including footwear should be made available to personnel entering processing area. e) Steps should be taken to control physical, chemical and biological hazards during processing. Screening devices such as filter, metal detector or sieve should be used where necessary.

8.3

PACKAGING a) Packaging design and materials should provide adequate protection for products to avoid contamination, prevent damage, and accommodate proper labeling. b) Packaging materials and gases where used must be non-toxic and do not pose a threat to the safety and suitability of food under the specified conditions of storage and use. c) Reusable / recycle packages allowed under the Food Regulations 1985 should be cleaned and where necessary disinfect. d) Package for non- food product is not allowed. e) During packaging operation, care must be taken to prevent cross contamination.

8.4

WATER, ICE AND STEAM a) Only potable water or that of drinking water quality as specified in the Food Regulations 1985 should be used for food processing and for making ice (except ice for post-harvest handling for fish). Only steam produced from potable water should be used for food processing and food contact surfaces. b) Ice for consumption, processing and that come into contact with food should be properly handled and stored to protect them from contamination. c) If storage tank is used, steps shall be taken to ensure no form of contamination occurred.

8.5.

PROCESS CONTROL RECORDS Where necessary records of incoming materials, processing, production, storage and distribution should be kept and retained for a period that exceeds the shelf life of the products. e.g. raw material supplier record, stock rotation record, time-temperature record, production batch / lot, final product analysis record and distribution record.

8.6

RECALL PROCEDURES a) Recall procedures should be in place to enable effective recall of products, which fails to meet food safety requirements. b) Appropriate action should be taken on recalled product that does not comply with regulatory requirements. Such action may include destroying, reprocessing or reconditioning or use for animal feed. Food safety requirements should be taken into consideration.

9. ESTABLISHMENT : MAINTENANCE AND SANITATION 9.1 9.1.1 MAINTENANCE AND CLEANING GENERAL Establishments and equipment should be kept in an appropriate state of repair and condition to: a) b) c) Facilitate all sanitation procedures Function as intended, particularly at critical steps to avoid food hazards . Prevent contamination of food e.g. from metal shards, flaking plaster, debris and chemicals.

Cleaning should remove food residues and dirt which may be a source of contamination. The necessary cleaning methods and materials will depend on the nature of the food business. Disinfection may be necessary after cleaning. Cleaning chemicals should be handled and used carefully in accordance with manufacturers instructions and stored, separated from food, in clearly identified containers to avoid a risk of contaminating food. 9.1.2 CLEANING PROCEDURES AND METHOD Cleaning can be carried out by the separate or the combined use of physical methods such as heat, scrubbing, turbulent flow, vacuum cleaning or other methods that avoid the use of water, and chemical methods using detergent, alkalis or acids. Cleaning procedures will involve where appropriate : a) removing gross debris from surfaces; b) applying a detergent solution to loosen soil and bacterial film and hold them in solution or suspension; c) rinsing with water which complies with section 5 (m) & (n), to remove loosened soil and residues of detergent; d) dry cleaning or other appropriate methods for removing and collecting residues and debris; and e) where necessary, disinfection with subsequent rinsing unless the manufacturers instructions indicate on scientific basis that rinsing is not required. f) All equipments which comes into contact with food should be well- maintained, cleaned and sanitized at appropriate intervals. g) Cleaning solvents and lubricants should be properly applied on equipment/machinery so as not to contaminate food

9.2

CLEANING PROGRAMME Cleaning and disinfection programmes should ensure that all parts of the establishment are appropriately clean, and should include the cleaning of cleaning equipment. Cleaning and cleaning programmes should be continually an effectively monitored for their suitability and effectiveness and shall be documented. Where written cleaning programmes are used, they should specify: a) b) c) d) areas, items of equipment and utensils to be cleaned; responsibilities for particular tasks; method and frequency of cleaning; and monitoring arrangements.

Where appropriate, programmes should be drawn up in consultation with the relevant specialist expert advisors.

9.3 9.3.1

PEST CONTROLS GENERAL Pests pose a major threat to the safety and suitability of food. Pest infestations can occur where there are breeding sites and a supply of food. Good hygiene practices should be employed to avoid creating an environment conducive to pests. Good sanitation, inspection of incoming materials and good monitoring can minimize the likelihood of infestation and thereby limit the need for pesticides.

9.3.2 PREVENTING ACCESS Building should be kept in good repair and condition to prevent pest access and to eliminate potential breeding sites. Holes, drains and other places where pests are likely to gain access should be kept sealed. Wire mesh screens, for example on open windows, doors and ventilators, will reduce the problem of pest entry. Animals should be excluded from the grounds of factories and food processing plants. 9.3.3 HARBORAGE AND INFESTATION The availability of food and water encourage pest harborage and infestation. Potential food sources should be stored in pest proof containers and/or stacked above the ground and away from walls. Areas both inside and outside food premises should be kept clean. Where appropriate, refuse should be stored in covered, pest-proof containers. 9.3.4 MONITORING AND DETECTION Establishments and surrounding areas should be regularly examined for evidence of infestation. 9.3.5 ERADICATION Pest infestations should be dealt with immediately and without adversely affecting food safety. Treatment with chemical, physical or biological agents should be carried out without posing a threat to the safety of food. 9.4 9.4.1 WASTE AND EFFLUENT MANAGEMENT EFFLUENT MANAGEMENT Effluent must be discharged in such a manner to exclude contamination from raw materials to finished products and potable water. a) b) c) All plumbing and effluent disposal lines, sewerage systems, must be of sufficient capacity to carry peak loads; All lines must be watertight with adequate traps and vents; Sumps or solid matter traps included in the drainage system must be emptied frequently and at the end of every working day;

9.4.2

WASTE MANAGEMENT Waste must be disposed in such a manner to prevent contamination from raw materials to finished products, potable water and should not give rise to any nuisance to the environment. Suitable provisions must be made for the removal and storage of waste. Waste must not be allowed to accumulate in food handling, food storage, and other working areas and the adjoining environment except so far as is unavoidable for the proper functioning of the business. Waste receptacles and waste accumulating area must be kept appropriately clean and disinfect periodically.

9.5

MONITORING EFFECTIVENESS

The hygiene and sanitation systems should be monitored for effectiveness and periodically verified by microbiological sampling of food contact surfaces, final product testing or other suitable method. 10. ESTABLISHMENT : PERSONAL HYGIENE To ensure that those who come directly into contact with food are not likely to contaminate food by maintaining an appropriate degree of personal cleanliness. They should also behave and operate in an appropriate manner. 10.1 HEALTH STATUS Any person suspected or suffering or carrier of any diseases or illnesses should not be allowed to enter any food processing area. Any person so affected should immediately report illness or symptoms of illness to the management for further medical examination. Condition which should be reported to management so that any need for medical examination and/or possible exclusion from food handling can be considered, includes: jaundice diarrhoea vomiting fever sore throat with fever visibly infected skin lesions (boils, cuts,etc.) discharges from the ear, nose and throat. cough, colds and flu. 10.2 PERSONEL CLEANLINESS Food handlers should maintain a high degree of personal cleanliness and, where appropriate, wear suitable clean protective clothing, head covering, glove and footwear. Cuts and wounds, where food handlers are permitted to continue working, should be covered by suitable waterproof dressings. All food handlers should wash their hands properly using sanitizer and clean water; a) b) c) 10.3 at the start of any food handling activities; immediately after using the toilet; after handling raw food or contaminated material and others

PERSONAL BEHAVIOR Food handlers engaged in food handling activities should refrain from behavior, which could result in contamination of food. Jewelleries, watches, pins or other items should not be worn or brought into food handling areas if they pose a threat to the safety and suitability of food.

10.4

VISITORS Visitors entering food processing or handling areas should, where appropriate, wear protective clothing and adhere to the establishments personal hygiene

11. 11.1

TRANSPORTATION AND DISTRIBUTION GENERAL Food must be adequately protected from contamination and deterioration during transportation and distribution. The type of conveyances or containers used depends on the nature of the food and the conditions under which it has to be transported.

11.2

REQUIREMENTS Producers or distributors should ensure that the transport of the finall product complies with the following conditions: a. all internal finishes of transport vehicles must be clean, in good condition, smooth, can be effectively clean and where necessarily disinfected and sealed to prevent entry of pests and sources or contamination. b. permit effective separation of different foods or foods from non-food items where necessary during transportation and distribution. Provide effective protection from contamination, including dust and fumes. c. can effectively maintain the temperature, humidity, atmosphere and other conditions necessary to protect food from harmful or desirable microbial growth and deterioration likely to render it unsuitable for consumption. d. allow any necessary temperature, humidity and any other condition to be checked. USE AND MAINTENANCE Conveyances and containers for transporting and distributing food should be kept clean, in good repair and condition. Where the same conveyance or container is use for transporting and distributing different foods, or non-foods, effective cleaning and, where necessary, disinfection should take place between loads. Where appropriate, particularly in bulk transport, containers and conveyances should be designated and marked FOR FOOD USE ONLY and not for other purpose.

11.3

12. 12.1

PRODUCTION INFORMATION BATCH OR LOT IDENTIFICATION Batch or lot identification is essential in product recall and also helps effective stock rotation. Each batch or lot of processed food should be identified by specific coding. a) b) c) Records of pertinent processing and production details must be kept concerning each batch or lot. These records must be retained for a period that exceeds the shelf life of the product. Records of the initial distribution of the batch or lot should also be kept (cross-reference to delivery docket, invoice number etc.)

12.2

PRODUCT INFORMATION All food products should be accompanied by or bear adequate information to enable the next person in the food chain to handle, display, store and prepare and use the product safely and correctly.

12.3

LABELLING Lebelled on package or prepackaged foods should have clear instruction to enable the next person in the food chain to handle, display, stored and use the product safely and correctly. Food labeling should comply to Food Regulations 1985.

13. 13.1

TRAINING AWARENESS AND RESPONSIBILITIES All food handlers shall undergo training by food handlers training institutions recognized by Ministry Of Health. All personnel should be aware of their role and responsibility in protecting food from contamination or deterioration. Those who handle strong cleaning chemicals or other potential hazardous chemicals should be instructed in safe handling techniques.

13.2

TRAINING PROGRAMMES ASSESSMENT

Periodic assessment such as observation and evaluation of the effectiveness of training and instruction programmes should be made. Routine supervision and checks should also be conducted to ensure that hygiene practices and procedures are being carried out as planned. 13.3 REFRESHER TRAINING Training programmes should be routinely reviewed and updated where necessary. Systems should be in place to ensure that all food handlers remain aware of all procedures including issues pertaining to food safety. necessary to maintain food safety.

REFERENCES Food Act 1983 and Food Regulations 1985.Malaysia. Guideline for HACCP Certification.MCS1. 2001. Guideliness for Good Manufacturing Practice in Small and Medium Scale Industry.(1997). Malaysian Standard MS 1480:1999. Food Safety According to Hazard Analysis and Critical Control Point (HACCP) System. Department of Standards Malaysia.(1999). Pharmaceutical Legislation.Good Manufacturing Practise.1997.Vol. 4 Recommended International Code of Practise of General Principles of Food Hygiene Texts/Annex to CAC/RCP 1-1969, Rev.3. Codex Alimentarius. (1997).Amd. (1999). U.S. Food Code. 2001.