Requirements for Small Vegetable Packinghouse

Manual For the Preparation of Fruits and Vegetables

The university of trinidad and tobago.Manual For the Preparation of Fruits and VegetablesFor Use by Namdevco & Other Trinidad and Tobago based entities.

Asha Melissa Morton 566524/7/2014

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How to Use this Manual

The information contained in this Manual is intended to serve three purposes: It is a resource for individuals who work with small scale fruit and vegetable processing entrepreneurs at various areas in Trinidad to use in order to improve and create end products that are not only safe for local use but can be exported to countries that have high standards for fruit and vegetable products.

It is a reference manual to assist these entrepreneurs to continue to improve technical aspects of their businesses.

It is a reference manual that outlines practices and procedures for the production ofsafe, high quality fruit and vegetable-based processed products and for development of Good Manufacturing Practices (GMP) programme that will serve as the foundation before an effective Hazard Analysis and Critical Control Point (HACCP) system can be implemented.

TABLE OF CONTENTS

How to Use the ManualiIntroduction iiThe Site1The Building2 Physical Layout2 Requirements for Production Sites3 Roofs and Ceilings4 Walls, Windows and Doors5 Floors5 Summary6Services8Sanitation and.Health10Personnel Health and Hygiene10Industrial Health Standards12Microbial Hazards12Fruit and Vegetable Preparation14Record Keeping16Food Safety Checklist18References31

Introduction

Fruits and vegetables are foods that are required to be fresh and in pristine conditions whenever placed on sale for consumers. However when processing for the market it should be taken into consideration that these items are usually consumed in their raw state, hence great care must to given so as to inhibit anything that can cause spoilage and illness to the consumer; as this will contribute to foodborne illnesses as well as a loss of business.

It should be borne in mind that this manual was conceived for the local industry, here in Trinidad and Tobago, which, in seeking a better future, should decide to take better advantage of the natural resources that are part of our daily lives, that is, the resources to which we have access to, and which may be easily obtained at a reasonable cost.

Being provided with readily available raw materials at a reasonable cost, will thus be enable many of us to take up the challenge of undertaking activities in processes not always familiar, where general management, however, will have to perfect the obtaining of products that may be safely used by families and by other members of the community.

Different aspects are presented in relation to the implementation of projects for the processing of tropical and subtropical fruits and vegetables, growing in a warm or cold temperate climate. Post-harvest conservation methods aimed at maintaining product quality in processing are explored, along with different facets of the technological processes employed in the processing and conservation of goods. Finally, several aspects related to the ultimate destination of the product are analysed, including self-consumption and marketing.

Special emphasis has been placed on the analysis of the implementation of the facilities for the development of the projects, the infrastructure, equipment, processes, the need for basic services, the quality of the products, and the possibilities existing in terms of processing techniques.

Morton VIII

The Site Fresh fruits and vegetables are both bulky and spoil rapidly; therefore it is better to locate a processing unit in the area where they are grown or in close proximity. This reduces transport costs and also reduces the amount of handling, which means that crops are more likely to be in good condition when they arrive at the processing unit. Once they are in good condition, they can be stored for a few days before they have to be processed. Too much handling bruises them and causes them to spoil quickly. Thereby increasing the cost of production for the processor, as the spoiled food has already been paid for. Processed fruit and vegetable products are likely to be sold in different markets and there is less reason to locate the unit near to customers (in contrast to bakeries for example). An ideal site is close to a fruit and vegetable growing area and near to a main road leading to an urban centre. The location of the processing unit in a rural area means that there may be problems with: Reliable electricity Adequate supply of potable water. Contamination of Supplies Access for workers and staff (public transport, distance down an access road) Quality of the road (dry season only, potholes that may cause damage to glass containers) Absence of other facilities (e.g. schools, medical facilities, shops and entertainment) that make working there less attractive than an urban location Each of these should be assessed before choosing a site. In rural locations there is usually more land available for waste disposal compared to urban sites, but there may be problems caused by insects and birds or stray animals getting into the building. It is therefore important to have a site with cleared and fenced land, preferably having barrier, which helps to trap airborne dust.

The Building All fruit and vegetable processing businesses should have a hygienically designed and easily cleaned building to prevent contamination of products. Buildings in rural areas may cost more to construct because of higher transport costs for building materials, but rents in rural areas are usually lower than urban centres. The investment in construction or the amount of rent paid should be appropriate to the size and expected profitability of the business.

When considering the setting up of a fruit and vegetable processing plant, whether it is a cottage industry or a small industrial scale system, the focus should be on the infrastructure required to properly lodge all of the necessary equipment. Therefore time must thus be devoted so as to coordinate two aspects that are vital to the development of a project of this nature, namely costs and the quality of the infrastructure needed to achieve the established goals.

It must always be borne in mind that since the food to be processed is intended for human consumption, the infrastructure must meet several requirements. The basic general aspects of such requirements will be analysed. The infrastructure comprises different aspects of a project's implementation. Issues like physical layout, basic services or installations and equipment must thus be taken into account.

Physical LayoutThe physical layout of a plan of this nature may be very simple, as it refers to a basic production system, involving small volumes and simple products, from a technological point of view.Nevertheless, in the case of a cottage industry and a small industrial scale system alike, simplicity must never neglect the basic principles governing industrial health and hygiene, which must characterize a food production system.

Requirements for Production SitesWithin the building, food should move between different stages in a process without paths crossing. This reduces the risk of contaminating finished products by incoming, often dirty, crops, as well as reducing the likelihood of accidents or of operators getting in each others way. There should be enough space for separate storage of raw materials, away from ingredients, packaging materials and finished products.

Fig 1.0 Basic Diagram of a Fruit and Vegetable Processing Area.*

*This Diagram was obtained from the FAO Manual on Fruit and Vegetable Production. Roofs and Ceilings Overhanging roofs keep a building cooler, this is especially important when processing involves heat. Fibre-cement tiles provide greater insulation than galvanised iron sheets against heat from the sun. Roof vents allow heat and steam to escape and create a flow of fresh air through the processing room. The vents must be screened with mesh to keep insects and birds out of the room. If heat is a serious problem (e.g. jam boiling), electric fans or extractors can be used if they are affordable. The roof should be properly sealed with a panelled ceiling should be fitted in processing and storage rooms, rather than exposed roof beams, which allow dust to accumulate and fall off in lumps and contaminate products. Beams are also paths for rodents and birds, creating contamination risks from hairs, feathers or excreta. It is important to ensure that there are no holes in the panelling or in the roof and no gaps where the roof joins the walls, which would allow birds, rodents and insects to enter.

Walls, windows and doorsAll internal walls should be plastered or rendered with concrete. The surface finish should have no cracks or ledges, which could harbour dirt or insects. The lower parts of the walls are most likely to get dirty from washing equipment, product splashing etc. They should either be tiled, or painted with waterproof white gloss paint to at least one and a half metres above the floor. Higher parts of walls and the ceiling can be painted with good quality white emulsion paint.Natural daylight is preferable to and cheaper than, electric lighting in processing rooms. The number and size of windows depends on the amount of money that a processor wishes to invest and the security risk in a particular area (windows are more expensive than walls, especially when security bars or grilles are needed). Storerooms do not need to have windows. Open windows let in fresh air, but this also provide easy access for flying insects.All windows should therefore be screened with mosquito mesh. Windowsills should be madeto slope to prevent dust accumulating and to prevent operators leaving cleaning cloths or other items lying there, which can attract insects.Storeroom doors should not have gaps beneath them and should be kept closed to prevent insects and rodents from getting in and destroying stocks of product, ingredients or packaging materials. Processing room doors should be kept closed unless they are fitted with thin metal chains, or strips of plastic or cloth hung from door lintels. These keep out insects and birds, but allow easy access for staff. Alternatively, mesh door screens can be fitted.

FloorsFloors in processing rooms and storerooms should be made of good quality concrete, smooth finished and without holes or cracks. Over time, spillages of acidic fruit products react with concrete and erode it. Paints can protect floors, but vinyl-based floor paints are expensive. Red wax household floor polishes should not be used because they wear away easily and could contaminate products or spoil the appearance of packages. The best way to protect floors is to clean up spillages as soon as they occur and make sure that the floor is thoroughly washed after each days production.Dirt can collect in corners where the floor and the walls join. To prevent this, the floor should be curved up to meet the wall. The floor should also slope to a drainage channel. Proper drainage prevents pools of stagnant water forming, which would allow insects to breed. The drainage channel should be fitted with metal gratings that are easily removed so that the drain can be cleaned. Rodents and crawling insects can also get into the building through the drain and a wire mesh cover should be fitted over the drain opening. This too should be easily removed for cleaning. (Maharaj, 2013)

Several different processes take place on the site where the production activity is performed, from the reception and conservation of raw materials, to the storage of finished products.

One aspect that must be borne in mind relates to construction details, which determine a plant's capacity to meet two objectives: to adjust to the production of foods and to ensure a sufficiently long shelf life. However, when considering home or small-scale industrial processing facilities, the cost of construction is an important factor which must be taken into account.

The building materials must be as light as possible, easy to readapt and install, considering that often the system users develop the plan themselves, by means of self-construction methods.

The buildings materials must be easy to readapt because these home-made systems are rather dynamic, that is, they require frequent changes or must adjust to different processes, so that the space that they occupy may be exploited all year round. On the other hand, these systems must be considered "expandable" to accommodate possible evolutions in time.

In addition to the previously mentioned characteristics, the materials must be easy to wash and disinfect, especially those in the clean areas of the processing rooms. Complex type of construction, resulting in the creation of places that are not easily accessible for cleaning must be avoided, for they may turn into bird nests, and contamination foci for rodents, insects, and of course, micro-organisms. (UNIDO , 2004)

SummaryRequirements pertaining to the materials and construction characteristics of the sites do not vary greatly for home processing or small-scale industrial plants. The basic difference lies in the equipment and the way it is set up in the processing lines. The home-processing system is temporary and versatile, and there are no special areas devoted to a single process. In general, all of the premises serve several purposes, according to the type of process and raw material being used.

The small-scale industrial system, on the other hand, is more complex in its organization, and therefore specific activities are carried out in determined areas. Nevertheless, the general requirements for both systems are similar, the difference being in the way such requirements are met.

Some of the aspects that may be considered important in relation to the architectural and construction elements are listed below:

1. The ceiling and walls of the processing room must be of washable and easily dried materials; they must be neither absorbent nor porous.

2. The lighting should be natural, as far as possible. However, if artificial lights must be used, they should not hinder activities in any way. Artificial lighting must be protected, to prevent fragments of glass from falling into the product as it is being processed, in case of accidents. Additionally they should not trap insects.

3. Ideally, the working environment should always be appropriately ventilated, to facilitate the workers' performance. Poor ventilation in highly enclosed and densely populated premises may generate defects. It is also important to provide for the elimination of heavily contaminating odours, even if they are not necessarily toxic.

On the other hand, excess ventilation, especially in places characterized by great aerial contamination external to the processing site, dust and insects essentially, may prove to be counterproductive. Appropriate ventilation must therefore be based on an efficient system controlling the access of foreign material from the external environment.

1. The floors must be of a solid material, never earth or plant covering. Like the walls and ceiling of the processing room, the floor must be washable, to ensure compliance with the premises' hygienic and health standards. 2. The floor must also be sloped to allow appropriate drainage, avoiding at all costs the formation of pools in the processing area. At the same time, care must be taken to prevent the floor from being slippery.

These are some examples of the features that must characterize a fruit and vegetable processing site to guarantee a quality product suitable for human consumption.

ServicesThree basic services are required for the operation of a processing plant: 1. Electrical power, 2. Potable water supply and 3. The disposal of waste waters. Occasionally, small-scale industrial plants are equipped with a steam production system, which however is more seldom found in home-processing plants.

Even when a home-processing plant can operate without electrical power, it is better for this service to be available, essentially to facilitate the processes by means of small devices that were developed and that improve workers' performance, thus guaranteeing a greater uniformity of products. Electrical power is also absolutely necessary if one is to rely on an appropriate lighting system, so that work shifts may be prolonged, especially when there is a surplus production of raw materials.

In small-scale industrial production systems, electrical energy is indispensable, due to the greater degree of mechanization of the processes involved. All lights must be installed on the ceiling at a safe distance to prevent them from getting wet and getting in the way of workers in the processing room.

As to water supply, the problem is slightly more critical. Sufficient drinking water must be available to ensure the development of a hygienic process, managed by clean people and with appropriately disinfected equipment. Also, many processes require water, as a result of which water of an appropriate quality must be available.

Since water does not come in abundant quantities, its use must therefore be regulated by strict savings principles, especially in small or home-processing installations that normally are not equipped with sophisticated water harnessing devices. Water must be protected from possible sources of contamination and must be supplied on a continuous basis at all times. The consumption of water will depend upon the process in question and the design of the production systems.

The supply of water must be ensured on a permanent basis, as a result of which the plant will need to be equipped with an elevated storage tank to avoid being dependent on the supply of electricity. A reserve must be created, so that water is available even when there is no electrical power. Tank storage will also allow for treatment through the addition of disinfectants.

In general, it is advised that chlorine be added to the water supplying the entire plant, so as to provide for permanent disinfection. To this end, a dose of 2 ppm of residual free chlorine is suggested. It should also be borne in mind that the tank must be covered and not exposed to sunlight, to prevent the chlorine from decomposing. As a term of reference, 100 ml of a sodium hypochlorite solution for every 2000 litres of water may be used, assuming that the hypochlorite solution contains about 50 mgr. of active chlorine per litre of solution. This will prevent the water from having any chlorine-like taste.

Large volumes of liquid wastes are created in fruit and vegetable processing and these should be carefully disposed of to prevent local pollution of streams or lakes. If main drainage is not available, a septic tank should be constructed in a place that cannot contaminate drinking water supplies. Water should not be allowed to simply soak into the ground, because this will create swampy conditions, which attract insects that contaminate products, as well as introducing a health hazard. Toilets should be separated from the processing area by two doors or be located in a separate building. Workers should have hand-washing facilities that are as hygienic as possible with soap and clean towels being provided.

Sanitation and HealthQuality and health standards and regulations must be strictly applied, or the product will be exposed to contamination by bacteria, mould and yeasts, thus jeopardizing the expected development of an agro-industrial enterprise. The importance of food workers understanding and practicing proper hygiene cannot be overemphasized. Workers can unintentionally contaminate fresh produce, water supplies, and other workers, and transmit foodborne illness if they do not understand and follow basic hygienic principles. (Codex Alimentarius, 1998)Therefore measures must be adopted as early as in the production phase, and must continue in the post-harvest, transportation, storage, preparation and processing phases. (UNIDO , 2004)In line with these principles, the following sanitary standards must be fulfilled and applied by workers on the production premises:Personnel Health and HygieneIt is important to ensure that all personnel, including those indirectly involved in fresh produce operations, such as equipment operators, potential buyers and pest control operators, comply with established hygienic practices. Operators should consider the following practices.Establish a training program: All employees, including supervisors, full time, part time and seasonal personnel, should have a good working knowledge of basic sanitation and hygiene principles. The level of understanding needed will vary as determined by the type of operation, the task, and the assigned responsibilities.Each producer should develop a sanitation training program for their employees. Depending on the situation, formal presentations, one-on-one instruction, or demonstrations (example, hand-washing) may be appropriate. Depending on the workers' job requirements, periodic refresher or follow-up training sessions may be needed. If a formalized training program is not practical, such as for part time and seasonal field personnel, the operator or the supervisor should verbally instruct and demonstrate to newly hired workers proper health and hygiene practices, such as proper hand-washing techniques1. Workers must wash their hands and clean their nails carefully before engaging in any process. They must keep their nails short, and if possible, use rubber/food grade latex or plastic gloves.2. Adequate means of hygienically washing and drying hands, including wash basins and a supply of hot and cold (or suitably temperature controlled) water. Hand wash stations should be foot or knee operated.3. Toilets and Showers areas of appropriate hygienic design should be implemented.4. Adequate changing facilities for personnel.5. To enter the working area, workers must wear a clean smock, a hair and beard net to protect the food from possible contamination by hair, and a mask to avoid microbial contamination.6. The working utensils and equipment must be cleaned appropriately to remove any waste or residual organic material.7. The containers (glass jars and bottles) must be washed with hot water before being filled with food.8. The waste generated by the production process must be removed from the production area on a daily basis.9. Clean and dry the outside of the containers with the product before labelling and storing.10. The storage site of the finished product must be clean and free from all possible contamination (it must have been previously fumigated). It must also be cool and dry.11. Once the working cycle has been completed, the production area must be left perfectly clean. It will therefore have to be pre-rinsed with water at a temperature of 40C (to remove about 90% of the dirt), washed with detergent e.g. Numero Uno or other food grade detergents, and finally rinsed with water at a temperature of 38-46C.12. Both the premises and the equipment will have to be disinfected on a weekly basis. Caustic soda will be applied first (2%), and then nitric acid (1.5%) at a temperature of 75C after which they will be rinsed with water.

Industrial health standardsWhereas hygiene is a principle that applies to people, industrial health applies to the equipment, facilities and premises utilized in the production process. It is extremely important to adopt measures to ensure that the facilities meet the industrial health standards which guarantee an efficient implementation of the process.1. The buildings must be adjusted so that they can be easily cleaned. There should be no blind spaces inaccessible to the cleaning and disinfection system.2. The equipment must be designed in such a way that no empty spaces are left to facilitate the accumulation of material that may decompose and cause severe contamination problems.3. All surfaces exposed to food must be properly cleaned and sterilised, with a frequency that will depend upon the type of raw material and process being used. Fruit and vegetable residues are generally easy to clean.4. A disinfection process can never be performed on a dirty surface. In order for the disinfection process to be successful, the surface must have been cleaned beforehand.5. The products used both in the cleaning and disinfection processes must be included in the list of products authorized by local health authorities. Special care must be taken to avoid polluting the environment by using products with an uncertain degradability.6. No disinfection process by itself will ever be able to replace the need for daily compliance with general sanitary requirements. 7. Counter and Table tops should be made of smooth, continuous, impervious material e.g. Stainless steel.Microbial HazardsOutbreaks of foodborne illnesses associated with fresh and minimally processed produce have occurred as a result of produce becoming contaminated with faecal material. Therefore, operators should place a high priority on ensuring the use of agricultural and management practices that minimize the potential for direct or indirect contact between faecal material and fresh fruits and vegetables. In addition, infectious diseases, accompanied by diarrhoea or open lesions, that include boils, sores, or infected wounds, are a source of disease-causing microorganisms.*Inadequate food temperature control is another one of the most common causes of foodborne illness or food spoilage. Such controls include time and temperature of processing and storage. Systems should be in place to ensure that temperature is controlled effectively where it is critical to the safety and suitability of food. (Codex Alimentarius, 1998) The shelf life, water activity, levels of microbiological activity the methods of packaging and processing and the intent of use should be taken into consideration.It is recommended that regular testing should be done, at regular intervals, and recorded for accuracy. Additionally properly calibrated test instruments, and microbiologically testing equipment and record keeping policies are required to ensure that accuracy and accountability are achieved.

*See Table 2 in the appendix.

Fruit and Vegetable PreparationReception1. Wheel bath should be provided on entrance to compound2. Reception area should be free from sunlight but have adequate lighting 3. Unencumbered by debris and packing materials.4. Fruits and vegetables must be weighed and counted by calibrated machinery or the accountability provided if done manually.5. A visual check must be done to evaluate the quality of the produce before sending produce to the packinghouse feeder lines.6. Cleaning is done to remove physical debris from produce. It is suggested by the FAO to use 50-200 ppm of active chlorine per gallon of water used. The use of chlorine etc. is to reduce and remove fungi and other microbes that can cause spoilage.* See Appendix Table 1 and Picture 1.0

Sorting1. Remove products that do not conform to quality standards eg early signs of spoilage, wrinkled appearance, and discolouration, size too small or too big, deformities, bruises.2. The cleaning procedure continues.Sizing1. Should be carried out before grading. This is because it is easier to identify units with defects on a uniform product, either in terms of size or colour.

2. There are two systems - according to weight or dimensions (diameter, length or both). Spherical or almost spherical products like grapefruits, oranges, onions, and others, are probably the easiest to sort by size. Several mechanisms are available from mesh screens to diverging belts Sizing can also be performed manually using rings of known diameter. Sorting by weight is carried out in many crops with weight sensitive trays. These automatically move fruit onto another belt aggregating all units of the same mass. (FAO, 2004)

Grading1. Consists of sorting product in grades or categories of quality. Two main systems exist: static and dynamic. Static systems are common in tender and/or high value crops. The product is placed on an inspection table where sorters remove units which do not meet the requirements for the grade or quality category. The dynamic system is probably much more common. The product moves along a belt in front of the sorters who remove units with defects. Main flow is the highest quality grade. Often second and third grade quality units are removed and placed onto other belts. It is much more efficient in terms of volume sorted per unit of time. However, personnel should be well trained. This is because every unit remains only a few seconds in the worker's area of vision. There are two types of common mistakes: removing good quality units from the main flow and more frequently, not removing produce of doubtful quality. (FAO, 2004)

2. Rejects mainly on aesthetic grounds provide a second or even third quality grade. These can be marketed in less demanding outlets or used as raw material for processing. (FAO, 2004)

ProcessingChemical Treatments 1. Packers should only use chemicals for post-harvest treatments (e.g. waxes, fungicides) in accordance with the General Standard on Food Additives or with the Codex Pesticide Guidelines. These treatments should be carried out in accordance with the manufacturers instructions for the intended purpose. 2. Sprayers for post-harvest treatments should be calibrated regularly to control the accuracy of the rate of application. They should be thoroughly washed in safe areas when used with different chemicals and on different fruits or vegetables to avoid contaminating the produce. (Codex Alimentarius, 2007)Cooling of fresh fruits and vegetables 1. Condensate and defrost water from evaporator type cooling systems (e.g. vacuum cooling, cold rooms) should not drip onto fresh fruits and vegetables. The inside of the cooling systems should be maintained clean. 2. Potable water should be used in cooling systems where water or ice is in direct contact with fresh fruits and vegetables (e.g. hydro cooling, ice cooling). The water quality in these systems should be controlled and maintained. 3. Forced-air cooling is the use of rapid movement of refrigerated air over fresh fruits and vegetables in cold rooms. Air cooling systems should be appropriately designed and maintained to avoid contaminating fresh produce. Cold storage 1. When appropriate, fresh fruits and vegetables should be maintained at low temperatures after cooling to minimize microbial growth. The temperature of the cold storage should be controlled and monitored. 2. Condensate and defrost water from the cooling system in cold storage areas should not drip on to fresh fruits and vegetables. The inside of the cooling systems should be maintained in a clean and sanitary.3. Tropical fruits and vegetables should not be placed in temperatures below 5 C as most products are susceptible to chilling injury.

Record KeepingThe records generated by the GMP system should include all activities and documentation required by the plan, including: monitoring records for all critical control points, deviation and corrective action records, and verification/validation records. Routine critical control point monitoring records should include the following information: 1. Form title 2. Firm name and location 3. Time and date 4. Product identification (including product type, package size, processing line and product code, where applicable) 5. Actual observation or measurement 6. Critical limits 7. Corrective action taken, where applicable 8. Operators signature or initials 9. Reviewers signature or initials 10. Date of review

Deviation and corrective action records should include: identification of the deviant lot/product, amount of affected product in the deviant lot, nature of the deviation, information on the disposition of the lot, and description of the corrective action. Examples of verification and validation records include: in-house on-site inspection, equipment testing and evaluation, accuracy and calibration of monitoring equipment, and Results of verification activities, including methods, date, individuals and/or organizations responsible, results or findings and action taken.

The following is an example of blank standard critical control points check list summary tables. The purpose of the summary table is to aggregate all of the key information regarding implementation of the plan in a single document. The completed summary table should be supported by a variety of other records, including records of the hazard analysis, determination of control points, maintenance of prerequisite programs, methods and procedures, daily operational records, corrective action records, verification and validation records and other supporting documentation.

FOOD SAFETY CHECKLISTDate_______________________________________Observed by_____________________________________________Reviewed byDirections: Use this checklist daily. Determine areas in operations requiring corrective action. Record corrective action taken and keep completed records on file for future reference.

Personal HygieneYes / NoCorrective Action

Employees wear clean and proper uniform including shoes.

Effective hair restraints are properly worn.

Fingernails are short, unpolished, and clean (no artificial nails).

No jewelry such as wedding band and a watch and no bracelets.

Hands are washed properly, frequently, and at appropriate times.

Burns, wounds, sores or scabs, or splints and water-proof bandages on hands are bandaged and completely covered with a foodservice glove while handling food.

Eating, drinking, chewing gum, smoking, or using tobacco are allowed only in designated areas away from preparation, service, storage, and ware washing areas.

Employees use disposable tissues when coughing or sneezing and then immediately wash hands.

Employees appear in good health.

Hand sinks are unobstructed, operational, and clean.

Hand sinks are stocked with soap, disposable towels, and warm water.

A hand washing reminder sign is posted.

Employee restrooms are operational and clean.

FOOD PREPARATION Yes / NoCorrective Action

All food stored or prepared in facility is from approved sources.

Food equipment, utensils and food contact surfaces are properly washed, rinsed, and sanitized before every use.

Frozen food is thawed under refrigeration, cooked to proper temperature from frozen state, or in cold running water.

Thawed food is not refrozen.

Preparation is planned so ingredients are kept out of the temperature danger zone to the extent possible.

Food is tasted using the proper procedure.

Procedures are in place to prevent cross-contamination.

Food is handled with suitable utensils, such as single use gloves or tongs.

Food is prepared in batches to limit the time it is in the temperature danger zone.

Clean reusable towels are used only for sanitizing equipment and surfaces and not for drying hands, utensils, or floor.

Food is cooked to the required safe internal temperature for the appropriate time. The temperature is tested with a calibrated food thermometer.

The internal temperature of food being cooked is monitored and documented.

COLD HOLDING Yes / NoCorrective Action

Refrigerators are kept clean and organized.

Temperature of cold food being held is at or below 41 F.

Food is protected from contamination.

REFRIGERATOR, FREEZER, AND CHILLERYes / NoCorrective Action

Thermometers are available and accurate.

Thermometers are available and accurate.

Food is stored 6 inches off floor or in walk-in cooling equipment.

Refrigerator and freezer units are clean and neat.

Proper chilling procedures are used.

All food is properly wrapped, labeled, and dated.

The FIFO (First In, First Out) method of inventory management is used.

Ambient air temperature of all refrigerators and freezers is monitored and documented at the beginning and end of each shift.

FOOD STORAGE AND DRY STORAGE Yes / NoCorrective Action

Temperatures of dry storage area is between 50 F and 70 F or State public health department requirement

All food and paper supplies are stored 6 to 8 inches off the floor.

All food is labeled with name and received date.

Open bags of food are stored in containers with tight fitting lids and labeled with common name.

The FIFO (First In, First Out) method of inventory management is used.

Food is protected from contamination.

All food surfaces are clean.

Chemicals are clearly labeled and stored away from food and food-related supplies.

There is a regular cleaning schedule for all food surfaces.

Food is stored in original container or a food grade container.

CLEANING AND SANITIZINGYes / NoCorrective Action

Temperatures of dry storage area is between 50 F and 70 F or State public health department requirement

Water is clean and free of grease and food particles.

Water temperatures are correct for wash and rinse.

If heat sanitizing, the utensils are allowed to remain immersed in 171 F water for 30 seconds.

If using a chemical sanitizer, it is mixed correctly and a sanitizer strip is used to test chemical concentration.

Wiping cloths are stored in sanitizing solution while in use.

LARGE EQUIPMENT Yes / NoCorrective Action

Food slicer is clean.

Food slicer is broken down, cleaned, and sanitized before and after every use.

Boxes, containers, and recyclables are removed from site.

Loading dock and area around dumpsters are clean and odor-free.

Exhaust hood, extractor fans and filters are clean.

UTENSILS AND EQUIPMENT Yes / NoCorrective Action

All small equipment and utensils, including cutting boards and knives, are cleaned and sanitized between uses.

Small equipment and utensils are washed, sanitized, and air-dried.

Boxes, containers, and recyclables are removed from site. Work surfaces and utensils are clean.

Work surfaces are cleaned and sanitized between uses.

Thermometers are cleaned and sanitized after each use.

Thermometers are calibrated on a routine basis.

Can opener is clean.

Drawers and racks are clean.

Clean utensils are handled in a manner to prevent contamination of areas that will be in direct contact with food or a persons mouth.

GARBAGE STORAGE AND DISPOSAL Yes / NoCorrective Action

Kitchen garbage cans are clean and kept covered.

Boxes and containers are removed from site.

Loading dock and area around dumpster are clean.

Dumpsters are clean.

PEST CONTROL Yes / NoCorrective Action

Outside doors have screens, are well-sealed, and are equipped with a self-closing device.

No evidence of pests is present.

There is a regular schedule of pest control by a licensed pest control operator.

(National Food Service Management Institute, 2009)

ReferencesCodex Alimentarius. (1998, October 26). Guidance for Industry: Guide to Minimize Microbial Food Safety Hazards for Fresh Fruits and Vegetables. Retrieved from U.S Food and Drug Administration: http://www.fda.gov/Food/GuidanceRegulation/GuidanceDocumentsRegulatoryInformation/ProducePlantProducts/ucm064574.htm#ivCodex Alimentarius. (2007). FAO Corprate Document Repository(Codex Alimentarius) First Edition. Retrieved from Fresh Fruits and Vegetables: http://www.fao.org/docrep/010/a1389e/a1389e00.htmFAO. (2004, March 20). Manual For the Preparation and Sale of Fruits and Vegetables. Retrieved from FAO Corprate Document Repository: http://www.fao.org/docrep/008/y4893e/y4893e00.htmMaharaj, R. (2013, October). Lecture Notes On Quality Assurance and Current Good Manufacturing Practices. Centeno, Trinidad and Tobago.National Food Service Management Institute. (2009). HACCP BASED SOPS. Retrieved from National Food Service Management Institute: http://www.nfsmi.org/documentlibraryfiles/PDF/20130730104656.pdfSingh-Ackbarali, D. (2013). Bacteria that are Food Bourne. Centeno: UTT.Singh-Ackbarali, D. (2013, October). Lecture Notes Food Microbiology. p. 1.UNIDO . (2004). UNIDO Technology Manual: Small-scale Fruit and Vegetable- Production Methods, Equipment and Quality Assurance Practices. Vienna: United Nations Industrial Development Organizaton.

AppendicesTable 1. Common spoilage defects of fruits and vegetables and the Causative AgentsDefect Casual organism

Bacterial soft rot Erwinia carotovora

Gray mold rot Botrytis cinerea

Rhizopus soft rot Rhizopus nigricans

Blue mold rot Penicillium spp

Alternaria rot Alternaria spp

Pink mold rot Trichothecium roseum

Green mold rots Cladosporium, Trichoderma

Watery soft rot, Brown rot Sclerotinia sclerotiorum

Downy mildew Phytophthora, Bremia

Sliminess or souring Saprophytic bacteria

Black rot/ smut/ Black mold Alternaria / Aspergillus niger

Anthracnose Coletotrichum lindemuthianum

(Singh-Ackbarali, Lecture Notes Food Microbiology, 2013)

Table 2: Bacteria responsible for food borne illnessType of disease Causative bacteria Kind and nature of the bacteria Major symptom(s) type

Intoxication Staph poisoning (improper handling by infected persons)

Botulism (incorrectly or minimally processed food)Staphylococcus aureus strains

Clostridium botulinumstrains Gram-positive cocci, present in pairs, short chains or bunched grape like clusters, facultative anaerobes, but grow rapidly under aerobic conditions, mesophiles with a growth temperature range of 7 to 480C and have the ability to grow at low aW (0.86), low pH (4.8), and high salt and sugar concentrations of 15% and in the presence of NO2 (naturally present in the nose, throat, skin, and hair of healthy humans, animals and birds.)

Anaerobic, Gram-positive spore forming rod, sensitive to low pH (