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Food Industry Processes

“STANDARD OPERATING PROCEDURES” Production Department

SUBMITTED BY: MAGAT, SHIRAZ M. BARIBO, REMY LEI SARINO, BEJAY GONZAL, DWAYNE

SOP no.

WASH_SOP_001_1

Effective Date:

January 30, 2023

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TABLE OF CONTENT I.

SOP FOR SANITATION OF EQUIPMENT AND FACILITY i. PRE-OPERATIONAL PROCEDURES ii. OPERATIONAL PROCEDURES iii. SANITARY PROCEDURES FOR PROCESSING

II.

SOP FOR SAFETY FOOD PROCESSING i. FOOD SAFETY PRODECURES ii. SSOP CLEANING AND SANITIZING FOOD CONTACT SURFACE

III.

SOP FOR CLEANING AND DISINFECTIN AREAS IN PRODUCTION DEPARTMENT i.

SOP no.

PROCEDURES a. SLAUGHTER OPERATION b. MANUFACTURING/PROCESSED MEAT OPERATIONS c. COOLERS AND OTHER AREA d. ENTRANCE HALLWAY e. ROOMS FOR PACKAGING f. FRIDGES g. RENDERING AREA

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I. OBJECTIVE/PURPOSE TO PREVENT OR MINIMIZE CONTAMINATION OF FOOD, INGREDIENTS, AND PACKAGING MATERIALS

TO PREVENT FOOD CONTAMINATION BY ENSURING THAT ALL FOOD CONTACT SURFACES ARE CLEANED AND SANITIZED APPROPRIATELY (SINKS, TABLES, EQUIPMENT’S, UTENSILS, THERMOMETERS, CARTS)

II. SCOPE THIS SOP PROVIDES GUIDELINES AND WRITTEN DOCUMENT OF PROCEDURES USED TO MAINTAIN EQUIPMENT AND THE ENVIRONMENT IN A SANITARY CONDITION FOR FOOD PROCESSING. IT IS A STEP-BY-STEP DESCRIPTION OF CLEANING AND SANITIZING PROCEDURES AND SPECIFIES WHAT IS TO BE CLEANED, HOW IT IS TO BE CLEANED, HOW OFTEN IT IS TO BE CLEANED, AND WHAT RECORDS ARE USED TO MONITOR THE PROCEDURES. EVENT OR MINIMIZE CONTAMINATION OF FOOD, INGREDIENTS, AND PACKAGING MATERIALS

III. RESPONSIBILITY QUALITY ASSURANCE MANAGER: DESIGN, IMPLEMENT, AND IMPROVE COMPANY QUALITY STANDARDS. ANALYZE DATA IN ORDER TO FIND AREAS FOR GROWTH. PRODUCTION STAFF/MEMBER: RESPONSIBLE FOR PERFORMING DUTIES IN MANUFACTURING AND INDUSTRIAL PROCESSES, CONDUCTING QUALITY CHECK PROCEDURES FOR THE OUTPUTS, AND INSPECTING THE EFFICIENCY OF ITEMS BEFORE DISTRIBUTION. TEAM CAPTAIN/LEADER: RESPONSIBLE FOR ENSURING THAT MANUFACTURING OF ITEMS IN A PRODUCTION PLANT ARE CARRIED OUT EFFICIENTLY AND WITH STRICT ADHERENCE TO QUALITY STANDARDS.

IV.

DEFINITION

SOP no.

WASH_SOP_001_1

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CONTAMINATION- THE ACTION OR STATE OF MAKING OR BEING MADE IMPURE BY POLLUTING OR POISONING SANITIZING- MAKE CLEAN AND HYGIENIC; DISINFECT DEBRIS- SCATTERED PIECES OF WASTE OR REMAINS

V.

PROCEDURE ALL THE PROCEDURE IN POINTS

VI.

ABBREVIATIONS WASH – WATER, SANITATION, AND HYGIENE. SOP – STANDARD OPERATING PROCEDURE QA – QUALITY ASSURANCE

VII.

REFERENCES SANITATION SOP GUIDE (USDA.GOV)

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I.

SOP FOR SANITATION OF EQUIPMENT AND FACILITY

OBJECTIVE: TO PREVENT DIRECT CONTAMINATION OR ADULTERATION OF PRODUCT. WHO DOES THE PROCEDURE APPLY: TEAM CAPTAIN IS IN CHARGE OF STAFF MEMBERS / PRODUCTION STAFF PERFORMING SANITATION

DAILY

SOPS,

ARE

INSPECTIONS

OF PROFESSIONALS WHO WORK ON A PRODUCTION

DOCUMENTING

THE LINE IN A MANUFACTURING ENVIRONMENT AND

RESULTS, AND TAKING ANY NECESSARY PERFORM A VARIETY OF DUTIES TO ENSURE CORRECTIVE ACTION. THE TEAM

CAPTAIN IS

PRODUCTION

GOALS

ARE

MET

FOR

AN

RESPONSIBLE FOR TRAINING AND ASSIGNING ORGANIZATION. SPECIFIC DUTIES TO OTHER EMPLOYEES AND MONITORING

EMPLOYEES’

THE

SANITATION SOPS' RECORDS,

PERFORMANCE WITHIN THE

SOPS. THE SANITATION STATISTICS, CHECKLISTS,

AND

OTHER

INFORMATION ARE ALL KEPT ON FILE AND MADE AVAILABLE TO INSPECTION PERSONNEL,

WHERE: PRODUCTION AREA PROCEDURE: 1.1PRE-OPERATIONAL SANITATION – EQUIPMENT AND FACILITY CLEANING 1. BEFORE PRODUCTION BEGINS, ALL EQUIPMENT IS DISASSEMBLED,

CLEANED, AND

SANITIZED.

2. PRODUCT DEBRIS IS REMOVED FROM ALL EQUIPMENT. 3. EQUIPMENT IS RINSED WITH WATER TO REMOVE REMAINING DEBRIS. 4. EQUIPMENT IS CLEANED THOROUGHLY USING AN APPROVED CLEANER. 5. EQUIPMENT IS SANITIZED WITH APPROVED SANITIZER AND RINSED WITH POTABLE WATER IF APPROPRIATE. 6. THE EQUIPMENT IS REASSEMBLED TEAM CAPTAINS PERFORMS DAILY ORGANOLEPTIC SANITATION EXAMINATION AFTER PREOPERATIONAL EQUIPMENT CLEANING AND JUST BEFORE SANITIZING AND BEFORE

SOP no.

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THE

RESULTS ARE RECORDED ON THE ESTABLISHMENT’S

PRE-

OPERATIONAL SANITATION FORM.

1.2 OPERATIONAL SANITATION—EQUIPMENT AND FACILITY CLEANING • IT IS PERFORMED UNDER SANITARY CONDITIONS TO PREVENT DIRECT AND CROSS CONTAMINATION OF THE PRODUCT. SANITARY PROCEDURES FOR PROCESSING 1. THE PRODUCTION STAFF/WORKERS CLEAN AND SANITIZE HANDS, GLOVES, KNIVES, OTHER HAND TOOLS, CUTTING BOARDS, TO PREVENT CONTAMINATION OF PRODUCTS. 2. WORKERS SANITIZE THEIR BOOTS IN BOOT BATHS. 3. ALL EQUIPMENT TABLES AND OTHER PRODUCT WORK SURFACES ARE CLEANED AND SANITIZED AS NECESSARY THROUGHOUT THE WORKING DAY. 4. WHEN STAFF EXIT PROCESSING AREAS, OUTERWEAR LIKE APRONS, BOOTS, AND GLOVES ARE PLACED IN DESIGNATED AREAS. OUTERWEAR IS CHANGED WITH MINIMUM OF ONCE PER DAY, AND MORE FREQUENTLY IF NECESSARY TO ENSURE CLEANLINESS AND HYGIENIC CONDITIONS. 5. AT THE END OF THE SHIFT: MAJOR SOLIDS ARE REMOVED FROM FLOORS, EQUIPMENT, AND FOOD CONTACT SURFACES. EQUIPMENT IS DISASSEMBLED AS REQUIRED FOR ADEQUATE CLEANING. ALL SURFACES ARE RINSED WITH COLD WATER. PRODUCT RECONDITIONING: AN EMPLOYEE REMOVES PRODUCT FROM THE FLOOR IN A TIMELY MANNER, TRIM CONTAMINANTS FROM THE PRODUCT SURFACE AREA, WASH THE PRODUCT AT A PRODUCT WASH STATION, AND EXAMINES IT BEFORE RETURNING IT TO PRODUCTION. THIS PROCEDURE IS USED FOR OCCASIONAL INSTANCES OF PRODUCT CONTAMINATION. EMPLOYEE HEALTH: EMPLOYEES ARE INSTRUCTED TO REPORT TO THEIR SUPERVISOR ANY HEALTH CONDITION THAT MIGHT RESULT IN FOOD CONTAMINATION. MONITORING AND RECORDKEEPING: THE TEAM CAPTAIN IS RESPONSIBLE FOR ENSURING THAT EMPLOYEES’ HYGIENE PRACTICES, SANITARY HANDLING PROCEDURES, AND CLEANING PROCEDURES ARE MAINTAINED. THE TEAM CAPTAINS MONITORS THE SANITATION PROCEDURES DURING THE DAY. RESULTS ARE RECORDED ON THE ESTABLISHMENT’S OPERATIONAL SANITATION FORM DAILY. CORRECTIVE ACTION: WHEN THE TEAM CAPTAINS IDENTIFIES SANITATION PROBLEMS, STOP PRODUCTION IF NECESSARY, AND NOTIFY PROCESSING EMPLOYEES TO TAKE APPROPRIATE ACTION TO CORRECT SANITATION PROBLEMS. IF NECESSARY, PROCESSING EMPLOYEES ARE RETRAINED, AND CORRECTIVE ACTIONS ARE RECORDED ON A CORRECTIVE ACTION LOG.

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II.

FOOD SAFETY STANDARD OPERATING PROCEDURE (SOP)

SOP 1.1 PROCESSING RESPONSIBILITY: APPLIES CONTRACTORS.

TO ALL THE EMPLOYEES WORKING IN THE FACILITY, VISITORS, AND

PROCEDURE: 1. THE SLEEVES ARE ROLLED UP TO SHOW THE WRISTS. 2. SOAK HANDS AND WRISTS IN WARM WATER AND APPLY SOAP DIRECTLY FROM THE DISPENSER. 3. RUB HANDS ROUGHLY TOGETHER. SCRUB FOR A MINIMUM OF 20 SECONDS. SCRUB IN AND AROUND THE FINGERS. SCRUB YOUR HANDS AND FINGERS. 4. RINSE HANDS AND WRISTS WITH RUNNING WARM WATER. 5. USING A CLEAN, SINGLE-USE PAPER TOWEL, DRY THE HANDS. 6. USING A PAPER TOWEL, TURN OFF THE WATER TAP. 7. PLACE THE USED PAPER TOWEL IN THE WASTEBASKET. SSOP CLEANING AND SANITIZING FOOD CONTACT SURFACES PURPOSE: TO PREVENT FOOD CONTAMINATION BY ENSURING THAT ALL FOOD CONTACT SURFACES ARE CLEANED AND SANITIZED APPROPRIATELY (SINKS, TABLES, EQUIPMENT’S, UTENSILS, THERMOMETERS, CARTS) RESPONSIBILITY: APPLIES TO ALL WORKERS RESPONSIBLE FOR CLEANING AND SANITIZING FOOD CONTACT SURFACES.

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FREQUENCY: AFTER USING FOOD CONTACT SURFACES AND IF CONTAMINATION OCCURS, STERILIZE IMMEDIATELY. RECORD: CLEANING AND SANITATION RECORD PROCEDURE: 1. BEFORE CLEANING, REMOVE FOOD PRODUCTS AND PACKAGING MATERIALS FROM FOOD-CONTACT SURFACES. 2. SCRAPE FOOD AND EARTH USING A SPOON. 3. THOROUGHLY CLEAN THE FOOD-CONTACT SURFACE WITH HOT WATER IMMEDIATELY FOLLOWING PROCESSING. 4. PREPARE CHEMICAL CLEANING SOLUTION XXX. 5. USING BLUE BRUSHES, APPLY THE CLEANING CHEMICAL TO REMOVE DIRT FROM THE SURFACE. 6. ALLOW THE CHEMICALS TO SETTLE FOR TEN MINUTES ON THE FOOD-CONTACT SURFACE. 7. RINSE WITH SAFE DRINKING WATER. 8. OBSERVE FOR THE PRESENCE OF FOOD RESIDUES ON EQUIPMENT AND FOOD-CONTACT SURFACES. 9. USING THE SANITIZING SOLUTION, SANITIZE THE FOOD-CONTACT SURFACE. CORRECTIVE ACTION: UPON FINDING FOOD REMAINS DURING AN INSPECTION, FOOD CONTACT SURFACES MUST BE RE-CLEANED.

III.

SOP IN CLEANING AND DISINFECTING THE WORKPLACE

PURPOSE: THE GOAL OF CLEANING AND SANITIZING FOOD CONTACT SURFACES IS TO ELIMINATE FOOD (NUTRIENTS) THAT BACTERIA REQUIRE IN ORDER TO DEVELOP, AS WELL AS TO DESTROY ANY BACTERIA THAT ARE THERE. IT IS CRITICAL THAT CLEAN, STERILIZED EQUIPMENT AND SURFACES DRAIN, AND STORE DRY TO PREVENT BACTERIA GROWTH. WHO DOES THE PROCEDURE APPLY: TEAM CAPTAIN IS IN CHARGE OF PERFORMING STAFF MEMBERS / PRODUCTION STAFF ARE DAILY INSPECTIONS OF SANITATION SOPS, PROFESSIONALS WHO WORK ON A DOCUMENTING THE RESULTS, AND TAKING ANY MANUFACTURING PRODUCTION LINE AND NECESSARY CORRECTIVE ACTION. THE TEAM EXECUTE A VARIETY OF ACTIVITIES TO CAPTAIN IS RESPONSIBLE FOR TRAINING AND GUARANTEE AN ORGANIZATION'S PRODUCTION ASSIGNING SPECIFIC DUTIES TO OTHER GOALS ARE REACHED. EMPLOYEES AND MONITORING THE EMPLOYEES’ PERFORMANCE WITHIN THE SANITATION SOPS.

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THE SANITATION SOPS' RECORDS, STATISTICS, CHECKLISTS, AND OTHER INFORMATION ARE ALL KEPT ON FILE AND MADE AVAILABLE TO INSPECTION PERSONNEL.

WHERE: PRODUCTION AREA A. SLAUGHTER OPERATIONS FREQUENCY – AFTER ANY SLAUGHTER OPERATIONS 1. RINSE ALL EQUIPMENT WITH WARM WATER. APPLY CLEANING CHEMICALS TO ANY SURFACES OR LOCATIONS THAT MAY COME INTO CONTACT WITH THE PRODUCT SHOULD BE CLEANED AND STERILIZED.

2. WASH DOWN THE ALLEY, SCALES, AND CONCRETE WITH PENS WHILE THE CHEMICAL SITS TO CLEAN AND STERILIZE THE APPARATUS. 3. HAND SCRUBBING WILL BE PERFORMED ON ANY LOCATIONS OR EQUIPMENT THAT HAVE BECOME SUBSTANTIALLY FILTHY AS A RESULT OF OPERATIONS. 4. BEFORE THE APPLIED CHEMICAL DRIES, RINSE THE FLOORS, WALLS, AND ANY EQUIPMENT WITH WARM WATER. 5. EXAMINE THE CLEANLINESS. IF NECESSARY, RECLEAN. 6. SQUEEGEE STANDING WATER INTO FLOOR DRAINS. 7. ON THE KILL FLOOR, AIR-DRY ALL METAL EQUIPMENT AND TOOLS. TO PREVENT RUST AND CORROSION ON ANY CONTACT SURFACE, APPLY A LITTLE COAT OF EDIBLE OIL TO ALL EQUIPMENT. 8. FOLLOWING THE COMPLETION OF PROCEDURES ON THE KILL FLOOR, THE ENTIRE ROOM AND ALL A QUATERNARY SANITIZER WILL BE USED TO CLEAN THE APPARATUS. THE SANITIZER WILL BE PREPARED ACCORDING TO THE PACKAGE AND APPLIED WITH AN AIR FOGGER.

9. AIR KNIVES MUST BE DISASSEMBLED AND CAREFULLY CLEANED. BEFORE REASSEMBLING, APPLY FOOD GRADE OIL WHERE NECESSARY. SPRAY EDIBLE OIL INTO THE AIR NOZZLE OF THE AIR KNIVES AND RUN FOR AROUND 30 SECONDS. ALLOW EXTRA WATER TO DRAIN BY HANGING UPSIDE DOWN. B. MANUFACTURING/PROCESSED MEATS OPERATIONS FREQUENCY - IMMEDIATELY FOLLOWING ANY FABRICATION/PRODUCTION OF PROCESSED MEATS OPERATIONS. 1. TAKE OUT ALL PRODUCT AND GARBAGE.

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2. WARM WATER SHOULD BE USED TO PRE-RINSE ALL EQUIPMENT, FOOD CONTACT SURFACES, FLOORS, WALLS, TABLES, AND SO ON. 3. USING A PRESCRIBED DETERGENT, CLEAN AND SCRUB EQUIPMENT, AND SURFACES. 4. CLEAN THE EQUIPMENT. 5. INSPECT ALL EQUIPMENT AND TABLES VISUALLY FOR ANY MISSING LOCATIONS. IF THE SURFACE IS NOT VISUALLY CLEAN, REPEAT STEPS 3 AND 4. 6. SANITIZE THE FLOOR AND THE EQUIPMENT. ALLOW THE SANITIZER AT LEAST THE REQUIRED CONTACT TIME. 7. HOT WATER SHOULD BE USED TO RINSE THE SANITIZER. 8. SQUEEGEES CAN BE USED TO TRANSPORT STANDING WATER TO FLOOR DRAINS. 9. AFTER THAT, ALL OF THE EQUIPMENT IS AIR-DRIED. TO PREVENT RUST AND CORROSION, A LIGHT APPLICATION OF EDIBLE WHITE OIL IS APPLIED TO ANY METAL SURFACE REGIONS. C. COOLERS AND OTHER AREAS WHEN NECESSARY, FREQUENCY. (BOTH THE FLOORS AND THE WALLS WILL BE CLEANED SIMULTANEOUSLY.) 1. REMOVE ALL PRODUCT FROM THE COOLER OR ROOM. 2. REMOVE ANY MATERIALS THAT ARE NO LONGER NEEDED. 3. HOT WATER SHOULD BE USED TO CLEAN ALL FLOORS AND WALLS. 4. SCRUB THE FLOORS AND WALLS WITH A CLEANING AGENT. 5. CHECK FOR CLEANLINESS. IF REQUIRED, RE-CLEAN. 6. THOROUGHLY RINSE THE FLOORS AND WALLS. 7. STANDING WATER SHOULD BE SQUEEGEED INTO FLOOR DRAINS. D. ENTRANCE HALLWAY THE FREQUENCY OF PROCESSING IS EVERY DAY. TAKE OUT ANY TRASH AND WASTE. 1. HOT WATER SHOULD BE USED TO RINSE THE FLOOR (180 F) 2. APPLY SOAP AND DEGREASER TO THE FLOOR AND WALLS (AS NEEDED) 3. HOT WATER SHOULD BE USED TO RINSE THE FLOOR (180 F) 4. FLOOR SQUEEGEES E. ROOMS FOR PACKAGING AFTER ANY PACKAGING OPERATIONS, FREQUENCY 1. CHECK THAT ALL MERCHANDISE IS OUT OF THE WAY.

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2. WIPE DOWN THE COUNTERS AND CABINETS WITH A DAMP CLOTH. SANITIZER SHOULD BE SPRAYED ON SURFACES AND CLEAN UP. 3. REMOVE THE VACUUM MACHINE BOARDS AND SCRUB AND SANITIZE THEM. 4. CLEAN THE FLOOR AND THE WALLS. 5. EXAMINE THE AREA FOR ANY LEFTOVER MEAT OR FAT. F. FRIDGES WHEN NECESSARY, FREQUENCY 1. REARRANGE THE RACKS. RACKS OF THE SAME PRODUCT SHOULD BE COMBINED. 2. ALL PACKAGING AND PRODUCTS SHOULD BE LABELED. 3. CHECK THAT ANY BOXES AND BAGS ARE OFF THE FLOOR. 4. SWEEP THE FLOOR TO REMOVE ANY DEBRIS. G. RENDERING AREA WHEN NECESSARY, FREQUENCY 1. HOT WATER SHOULD BE SPRAYED OVER THE FLOORS AND WALLS. 2. USING THE DESIGNATED DETERGENT, SCRUB THE FLOORS AND WALLS. HOT WATER SHOULD BE USED TO CLEAN THE FLOORS AND WALLS. OTHER GENERAL PROCESSES INCLUDE: • SQUEEGEES CAN BE USED TO TRANSPORT STANDING WATER TO FLOOR DRAINS. • SQUEEGEES CAN BE USED TO REMOVE EXCESS WATER FROM TABLETOPS. • AFTER THAT, ALL EQUIPMENT IS DRIED. TO PREVENT RUST AND CORROSION, A LIGHT APPLICATION OF EDIBLE WHITE OIL IS APPLIED TO ANY METAL SURFACE REGIONS.

REVISION NO.: EFFECTIVITY DATE: DOCUMENT PREPARED BY:

SOP no.

WASH_SOP_001_1

Effective Date:

1.0 JANUARY 30, 2023 BARIBO, REMY LEI MAGAT, SHIRAZ SARINO, BEEJAY

January 30, 2023

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DOCUMENT APPROVED BY

SOP no.

WASH_SOP_001_1

Effective Date:

GONZAL, DWAYNE TING, CESAR (PROFESSOR )

January 30, 2023

Version:

V.1