Food Safety, Sanitation, and Pest Management

Transcription

1 Food Safety, Sanitation, and Pest Management Bhadriraju Subramanyam (Subi), PhD University Distinguished Professor Guest Lecture, GRSC 101 Lecture Objectives Identify reasons for storing grains Describe the risk factors and categories of food and feed hazards Distinguish between safe and wholesome food Explain how a food manufacturer combats hazards Raw and Processed Grains Raw grains Harvested from the field Unclean Stored at various points in the supply chain Processed grains Cleaned Value-added Has fixed shelf life 1

2 Reasons for Storing Grain Harvest occurs only one time per year (usually) Storage occurs multiple times after harvest Grains are utilized throughout the year for various purposes Export markets To obtain the maximum market price For food security purposes To maintain buffer stocks in case of catastrophes Raw Grain Storage Structures Steel bins Concrete silos Poor Storage Structures (Africa) Wetter Regions From: Dr. E. N. Nukenine Dryer Regions Foulde Barn, across ethnic groups Kanouri Moundang Massa Gbaya Improved crib, many ethnic groups Duru Guiziga 2

3 Storage Transport Farm Grain supply chain Consumer Retail store Processing plant Grain Processing Industry Bakeries Flour mills Feed mills Cereals and prepared dry mixes Grain-based chips Pasta Frozen foods (could be grain-based) Pet foods Risks with Raw and Processed Grains Are at risk of being contaminated by foreign material, insects, microorganisms, and vertebrate pests Risk varies from product-to-product, and within a product during its processing, packing, transportation, and storage Risks can exist at various points in the supply chain 3

4 Minimizing Product Risks or Hazards Knowledge of risk factors Physical, chemical, and biological Natural or intentional Categorize hazards Likelihood of occurrence (Low, Medium, High) Severity of injury (Low, Medium, High) Knowledge on how to manage risks Compliance with regulations Institute multi-faceted programs within the company Regulatory Agencies Food and Drug Administration Processed food and food-related products, nonalcoholic beverages, fermented fruit juices, and wine beverages containing <7% alcohol Bureau of Alcohol, Tobacco, and Firearms All alcoholic beverages, and wine beverages containing >7% alcohol USDA-Food Safety Inspection Service (FSIS) Processed egg, meat, and poultry products USDA-Animal and Plant Health Inspection Service (APHIS) Fruits, plants, vegetables, and similar imports USDA-Agricultural Marketing Service (ARS) Grading of grain, fruits, and vegetables Environmental Protection Agency (EPA) Pesticides Occupational Safety and Health Administration (OSHA) Establishes a safe and healthy work environment 4

5 FDA Regulates Foods (processed not raw) Drugs Biological materials Cosmetics Animal products Medical devices Electronic products Import, export, and interstate commerce Definitions What is Food? Articles consumed by humans and animals Includes chewing gum and drinking water 5

6 Low High 11/9/2015 What is Wholesome Food? Nutritionally balanced Food without defects What is Safe Food? Food that does not cause injury or harm when consumed by humans or animals Trust is placed in food manufacturer to produce safe food Consumers are unaware of dangers with food! Food security: Accessibility of wholesome food to everyone on the planet! Food safety: Produce food that does not cause injury ( Food defense: Practices to prevent unintentional contamination of food by physical, chemical, or biological hazards Food protection = Food safety + Food defense 6

7 Hazards in Food Physical- peeling paint, rust, glass, metal, wood or plastic Chemical- grease, lubricants, pesticide residues, allergens, toxins from microorganisms Biological- insects, microorganisms, rodents, birds, and their by-products Sanitation All programs and practices followed by food manufacturers to ensure that the raw and processed materials are free of physical, chemical, and biological hazards Includes building design and preventive controls Maintenance of building exterior Maintenance of building interior Hygiene of personnel Hygienic practices Pests Invertebrate pests: Filth flies Cockroaches Mites Stored-product insects Vertebrate pests: Birds Rats and mice (rodents) 7

8 Pest Management Maintaining levels of pests (insects, birds, rates and mice) at levels where they do not cause damage By using chemical and nonchemical methods Integrated Pest Management (IPM) Nonchemical: closing doors and windows Chemical: Use of pesticides How Does a Food Manufacturer Combat Hazards? Through sanitary programs taking a holistic view of a food plant from the outside in Stop, look, and listen! Seek root cause analysis on eliminating cause and not reacting to symptoms Sanitary Programs Food laws FDA s Federal, Food Drug and Cosmetic Act (1938) FDA s Food Safety Modernization Act (2011) Guidance documents Good Manufacturing Practices (GMPs) Hazard Analysis and Critical Control Points (HACCP) program Inspections Experience 8

9 GMPs Including additives and ingredients at the right level or safe level Keeping exterior and interior of buildings and equipment in a sanitary fashion Making sure that people are following sanitary practices Processing, packaging, and storing food in a sanitary fashion HACCP Systems in place to ensure that food produced does not contain poisonous or dangerous substances It is a 7 step program It has 5 prerequisite programs, GMPs being one of them Examples of Unsanitary Conditions 9

10 Corn Mill Place metal flashing all around as shown to deter rodents; no gaps between metal and concrete. Have sliding doors; make sure there is a mesh to the outside The small arrows show ledges that should be fixed by pouring concrete at 45 degree angle Is this a trash compactor? If so, it should be placed far away from building on a concrete pad Remove wire fence and replace with a compound wall that is 6-8 feet high Remove vegetation, and level the area and also pour concrete between wall and the channel for water Cover the water channel with metal mesh to exclude rodent access to water; inspect and treat with a disinfectant if needed Areas with vegetation should be inspected for rodent burrows Need wall on this side to prevent rodents from coming from the tree line/shrubs 10

11 Build at least a 3 meter high wall to prevent rodents from entering mill from this area Trim vegetation, especially tree branches so rodents and birds do not use them High risk area for microorganisms and rodents Rodent burrow 11

12 Standing water indicative of grading Stranded water can cause contamination problems. What are pallets doing outside? Places such as these need to be repaired to prevent standing water Trucks need a special truck maintenance program 12

13 13

14 Pigeon Fecal contamination Gaps at the beam-wall interface A better design is needed to remove rocks; use of precleaners a must The use of a screen (not good) over grates is unnecessary: this area requires a better design to exclude rocks; or use precleaners prior to dumping Ceiling gaps allow bird entry; remove flat surfaces above to prevent bird landing while grain is being dumped in pit Need better walls that prevent dust adhesion 14

15 Birds can land on the tops of the aluminum ducting Put spike above and seal gaps below the ducts Bird nests a risk of Salmonella for grain being dumped in the pit Need new plastic strips with heavy metal bottom. These Strips do not prevent insects, birds, and rodents from entering this area. 15

16 Close all open doors. This door was open during the visit. This will permit entry of birds/insects. Why is there water spillage? Determine source and fix the problem. Torn screen. Fix problem. Clean up insect debris. Screen size too big and will allow insects. Use 150 micrometer size openings. Very clean area. Seal bases of equipment to floor. Also clean tops of equipment on a regular schedule. 16

17 Seal all gaps with an epoxy sealant. Insects coming from raw grain (auger from bins a likely source). Three different species seen here. Bird fecal material in production area This may result in failing grade Grooves trap dust 17

18 Clean and spray if unable to replace Inspect the area holding wires for dust accumulation and insects Clean up dust on equipment Figure out where the dust is coming from 18

19 A cleaning car should be clean and not dirty; replace brushes Move pallets away from the wall Rodent fecal material Clean augers regularly 19

20 20

21 Do not use tape; find permanent solutions Employees need uniforms and should never wear shorts and tennis shoes. 21

22 They should also wear hair nets and steel toe boots. 22

23 Improve pallet spacing for good inspection Flour product will get contaminated. Move lights. 23

24 Lot of bird activity. Light fixtures are giving opportunity for these birds to build nests again and again Bird fecal material on bulk load out tankers. Unacceptable! Some Good Examples 24

25 Rodent bait stations Baits 25

26 Good to have color coded tools Replace them properly against the wall 26

27 A good pest exclusion practice Sanitary Design Aspects 27

28 Sanitary Design Aspects Inspections Pallets Used equipment Live plants in offices Food prep.; receiving Grain products Spillage on drums Mill for sanitation issues Master Sanitation/Cleaning Schedules Daily versus non-daily; weekly, monthly, quarterly, semi-annual and annual Only way you can answer question: when was the last time this was cleaned? Leave no space blank Keep it simple Floor drains Evaluate and determine economic benefits 28

29 Preventive Maintenance and Work Orders Simple and documented Filters, sifters, strainers, lubricants, magnets and metal detectors People, Equipment and Training Proper people doing the proper job with the proper equipment and documented training Money driven but be careful how you phrase message to employees (motivation) Pest Management 29

30 Crack/crevice spraying Fumigation of Grain Gas monitoring and personal protective equipment are essential Heat treatment: Raising the ambient air temperature to o F (50-60 o C), and maintaining these temperatures for hours Gas heaters Electric heater Steam heater Duct carrying heat from gas heaters Once a Year Fan 30

31 Whole Building Treatments with Fumigants Methyl bromide Sulfuryl fluoride Aerosols (fogging) Kill exposed insects Rodent Baits 31

32 Bait Boxes Baits-Pellets Powders 32

33 Liquid Baits Netting to Exclude Birds Exclusion tactics 33

34 Tactile Deterrents Coils Spikes Ledge Wires Management Systems for Product Safety Organization Employee Training Vendor Specifications Preventive Cleaning QC Programs/Lab IPM programs Access/Sampling Management Self-Inspection Receiving Programs Program Preventive Consumer Complaint/Recall Maintenance/Equipment Program Specifications HACCP Organization Clearly defined charts Clear lines of responsibilities/accountability Trained Staff Open Communication Team Effort 34

35 A Food Manufacturer Should. Monitor ingredient quality Keep an inventory of ingredients/additives Comply with regulatory standards Coordinate delivery of transportation carriers Institute preventive maintenance programs Be computer literate Manage and motivate people Keep abreast of technology and the changing consumer It is not an easy task! Question Why do food safety problems occur (go to recall.gov) despite companies trying their best to comply with food laws and regulations? Thank you 35