CCP MONITORING

 Once you have established critical control points (CCPs) and critical limits for your HACCP plan, you need to monitor them. Monitoring must provide real-time data. Therefore, microbial sampling and testing is not considered part of the HACCP monitoring plan. They cannot give you immediate feedback and are generally inefficient in identifying defects. In creating your monitoring plan, the primary questions to consider are what will be done, how it will be done, when, or how frequent it will be done, and who will do it.  

What

You will know “what” to monitor based on the type of critical limits that have been set for your CCPs. For example, if a critical limit is pH of no less than 4.6, then pH is what you would be monitoring. Other attributes that you may monitor in a HACCP plan include time, temperature, acidity, flow rate, pressure, or/and presence of intact sieve.  

Introduction to HACCP eBook

How

There are essentially two general ways to monitor critical limits. One is by visual observation and the other is by instrumentation. Operators conducting visual observations should be properly trained to know what they are looking for and when critical limits are exceeded. If instrumentation is used to monitor CCPs, then remember to: 

1. Use the right instrument for the job. For example, don’t use a laser thermometer to measure the cooking temperature of roasted turkey. That instrument will only give you the surface temperature and not the internal temperature which is what you want to see.
2. Calibrate your instrument. This will ensure accuracy, precision, and validity of your data.
3. Train your operators how to properly use the instrument. Have you ever seen anyone taking a thermometer or pH reading with the cap still on the probe? It happens. Another problem that you will likely see is operators using dirty or contaminated probes to take measurement. Monitoring should not be a source of cross contamination. You can avoid this by cleaning and sanitizing probes at set frequencies.

When

In general, monitoring will be done either continuously or discontinuously. In continuous monitoring you are collecting data throughout the entire period of the operation. In discontinuous monitoring, the measurements are collected, or observations made periodically. Continuous monitoring is generally done automatically by instruments. This type of data collection is necessary, particularly when slight deviations from the critical limit can be easily missed by the operator.

Let’s say the critical limit for a canned soup operation is cooking the cans for 10 minutes at a minimum of 240oF. Assume that during the process of one batch, the temperature dropped to 239oF for 3 minutes. This is a deviation that happened quickly and could easily be overlooked resulting in a foodborne disease outbreak. It would therefore make sense to collect a complete profile of the time/temperature schedule. This data is typically collected on an automatic recording chart that the operator can later review and sign. 

Continuous monitoring is not always suitable or practical. Therefore, a discontinuous monitoring approach may be adopted. You should choose discontinuous monitoring when:   

1. The critical limit is to be measured by observation. If the operator were to collect data every minute as in the case of the canned soup above, he wouldn’t have time to do anything else. This would not be practical.
2. The operating condition is way above the critical limit. For example, if your critical limit for oil in your fryer is a temperature of no less than 300oF, and you are frying at 350oF for quality reasons, then discontinuous temperature measurement is acceptable.
3. When continuous measurement is not necessary to assure safety. For example, there is no need to check the temperature of turkey roast at every minute during roasting if the critical limit is set at a minimum final internal temperature. In this case you would only need to measure the final internal temperature of the largest turkey at the end of the process, or randomly take the internal temperature of several turkeys if they are the same size. In the latter case however, you would need to consult with a Statistician to determine the appropriate number of turkey roast to test. 

Who

You should designate the person responsible for monitoring the CCP in your HACCP plan by the individual’s job title. You may add “or designated personnel” just in case you need to pull someone else to accomplish the task at some point. That will give you some flexibility while maintaining the integrity of the HACCP plan. Generally, the person conducting monitoring is the line operator, line supervisor or quality control personnel. If sampling and testing is involved, it is more likely that it will be done by someone in quality control.

CHEMICAL HANDLING AND MANAGEMENT

 Hazardous chemicals and dangerous goods can destroy health, cause severe injury, harm the environment and damage property unless they aren't handled properly. If you’re preparing to implement chemical handling training in your workplace, there are many key topics to cover. You must also consider the format of chemical handling training sessions, so you can provide the best education experience for your staff.

In this post, we offer a 6 step guide to providing effective chemical handling training in the workplace, so you can provide an optimum environment for staff who manage the risks of Hazchem and dangerous goods.

Chemical Handling Training

Training on the safe handling of chemicals is key for any teams who work with, supply, or store hazardous materials.  This protects your people, as well as your organization, community and environment.

As part of your risk management strategy, arming your staff with the proper education about safe chemical training will not only decrease risk and improve efficiency in your operations, but it will assist in maintaining compliance.

To better prepare your team for ensuring chemical safety in the workplace, we have developed some  key points to cover when you're creating dangerous goods and hazardous chemical handling courses for your staff.

Consider the following safety topics when conducting chemical handling training for your hazardous chemicals and dangerous goods.

Educate your Team about Personal Protective Equipment (PPE)

When working with hazardous chemicals or dangerous goods, personal protective equipment (PPE) is a requirement. Equipment must be suitable for the chemical, the task and the staff member, and it must be kept in good condition to ensure safety.

Educate your employees on selecting the correct PPE (personal protective equipment) to use when handling different chemicals. For example, the equipment for corrosive substances will be different to the equipment required when handling toxic chemicals.

Required PPE may include protective clothing, gloves, footwear, facemasks, respirators and goggles. 

This task is made simpler when workplaces use dedicated PPE Cabinets to provide tjhe correct personal protective equipment for that particular worker and task. The location of personal protective equipment in designated, well-identified storage areas, is required safety information for workplaces, as per the Australian Standards. 

Not only should staff be trained in how to select the correct personal protective equipment for that chemical and task, they must also be trained in how to put on, take off and maintain the equipment so there is no risk of chemical exposure. 

PPE should only be selected after all hazards of a specific chemical or task have been identified. 

Safety equipment also needs to be comfortable to prevent incidents from occurring. For example, if touch sensitivity is essential for a task, textured and thin gloves are required to ensure agile movement.

Train Staff in Safe Chemical Handling Practices

Each chemical used within your organization should have a specific procedure for safe handling. Ensure all employees are familiar with these procedures by providing training and refresher courses, as well as competent supervision of work tasks.

Essential aspects of safe handling practices are:

• Reading & re-reading each chemical SDS to minimize the risk of mishandling
• Wearing suitable PPE 
• Disposing of hazardous chemicals appropriately
• Being prepared for emergencies with first aid or emergency decontamination
• Not working with or handling chemicals alone
• Using all precautions to avoid spillage, leakage or dropping chemicals during transportation. Use specialized carriers and carts, such as a transportable gas bottle trolley
  
  

Educate Staff on the Globally Harmonized System of Classifying and Labelling Chemicals (GHS)

GHS labelling for primary and secondary containers is mandatory in most Australian states. The GHS provides a universal standard for the labelling of hazardous goods, and includes information on chemical hazards, as well as storage instructions, placards, and Safety Data Sheets (SDS). 

Chemical labels must adhere to GHS labelling guidelines.

Manufacturers and suppliers should always have the correct GHS labelling on hazardous goods, so it’s important to ensure everyone understands how to read GHS labels, and is familiar with the requirements for labelling. 

Train Staff to Store Dangerous Goods Safely

One of the key ways to reduce risk with chemicals, is understanding where and how to store your Hazchem and dangerous goods. There are many chemical hazards that require a controlled storage environment to mitigate risk, whether it's flammable chemicals, corrosive substances, explosive goods or oxidizing agents.

Some chemicals can pose serious  hazards if they come into contact with, or are stored with, one another. Therefore, dedicated storage for each class or division of dangerous goods is an important part of the risk management process.

Staff must be trained to understand storage requirements, such as flammable cabinets must be seperated from ignition sources, incompatible substances and must only store Class 3 Flammable Liquids. 

Staff should be thoroughly trained on best practice for chemical storage, including what stores or cabinets to house particular goods, the proper housekeeping requirements for that store, how to identify and action any possible hazards (such as combustibles left near a flammable cabinet), how to inspect containers to ensure they are fit-for-purpose and not leaking or cracking, and how to interpret the dangerous goods and hazard signage in the storage area.

Storage information can be found on each chemical’s Safety Data Sheet, but choosing equipment that is made to Australian Standards offers specific controls required for that class or division of chemicals. Always familiarise your team with the correct storage procedures, and keep the SDS close to the store so staff have easy access.

Consider the Transport of Dangerous Goods

Whether you’re transporting hazardous materials within a work site, or between worksites, it’s essential that your team is familiar with the state or territory regulations. 

Each Australian state or territory has different regulations, including no-go transport zones where chemicals can’t be transported, and specific transport documentation requirements. Be sure to contact your local transport regulator to understand your state’s requirements - and relay this information to your team.

Beware of flammable liquids and their flash points.

There are also key elements to be aware of when transporting dangerous goods, including the flash points of flammable liquids, the storage temperatures of goods, and the transportation of goods on work sites. Incorporate these into your training so that your team knows what to keep in mind when moving chemicals in and around the workplace.

Educate Staff on Risk Management Policies and Practices

As part of the Australian Model Work Health and Safety Regulations, businesses have specific duties to manage risks associated with chemicals in the workplace. This means having clear risk management policies and processes in place. 

Your team should be trained on all procedures and policies, including:

• Emergency plans if any unexpected accidents or reactions occur
• Information on where fire safety and first aid equipment is stored
• The correct way to decommission any chemical storage or handling systems
• Spill containment systems for hazardous chemicals
• How to assess risk surrounding dangerous goods

Tips for Your Chemical Handling Training Presentation

There are further considerations when training staff to ensure they are engaged with your course content. Consider the following tips when training your team in chemical handling procedures.

Include a Variety of Training Materials

It’s a common saying that we remember 10% of what we read, 50% of what we see, and 80% of what we experience through practice – so the more practical elements you include in your training, the more effective it will be. 

Incorporate roleplaying into your training to reinforce any policies or procedures, show videos to illustrate the risks associated with different chemicals, or use eLearning materials to test knowledge. The more varied your training, the better!

Training your team includes providing an engaging environment where they are equipped to learn.

Use Real-life Examples

Keep your chemical handling training relevant to your audience and use examples that they can relate to. This means highlighting the hazards of chemicals commonly handled in your workplace, and outlining policies and procedures for situations that your team are most likely to come across on the worksite.

Provide Tools and Ongoing Training

There’s a lot to remember when it comes to the safe handling of chemicals, and sometimes one training just isn’t enough. 

Equip your team with all the resources they need to find information on chemical handling, such as the Safe Work Australia website for hazardous chemicals, or the Hazardous Chemical Information System database where they can quickly find information on which chemicals are hazardous and any safety information that already exists. 

Also schedule in annual or biannual refresher trainings, and have induction trainings in place for any new team members.

Handling Chemicals Safely

As we've highlighted in this post, there are many topics and considerations to cover when developing a chemical handling training course for your organisation. While training will be unique for your site, including your work processes, hazards and volume of chemicals, it's vital that staff are trained (and re-trained) in a way that offers optimum protection for people, property and the environment. Training is part of the risk management process, and can greatly improve safety and compliance in your operations.

If you want to help correctly assess the hazards and risks associated with different dangerous goods, you can access our free chemical risk assessment template. This template will help you accurately identify hazards in your workplace, so you can work towards creating and sustaining a safer work environment. Get your free template pack today.

COLOR CODE IN FOOD INDUSTRY

  Color-coding your commercial kitchen is perhaps the most effective and efficient way to keep things organized, maintain safety standards, and enhance operational efficiency. It is employed by numerous restaurants, hotels, and food processing facilities worldwide for its many benefits. So, if you're wondering why you should color-code your kitchen, you've come to the right place.

What Are The Color Coding Standards In The Food Industry?

To appreciate why color-coding is essential, learning about the predominant color-coding standards in the food industry is pivotal. This system aims to distinctly separate the use of utensils and kitchen gear according to different food types, which are identified by particular colors.

• Blue: Adopted for raw fish, mainly because the blue appears conspicuous against the fish's flesh, a handy tool in preventing pieces of the colored object from ending up in the dish undetected.
• Red: Designated for raw meats like pork, lamb, and beef, it facilitates the separation of raw red meat from other food types, reducing cross-contamination risks.
• Yellow: Assigned for cooked meats; this division aids in warding off bacterial shift from raw to cooked meats, which could lead to foodborne diseases.
• Green: Fruits and vegetables neatly align with green, an intuitive correlative color of the plant kingdom.
• Brown: Utilized for root vegetables such as potatoes, yams, and onions.
• White: Primarily used for dairy, bakery products, and generic food processing tasks.
• Purple: A color reserved for allergen-free production, beneficial in preventing allergenic cross-contamination.
  
  
  

By having a standardized color guide, the kitchen team can avoid confusion and better adhere to quality and safety protocols in food handling.

Why Is Color Coding So Important?

Color coding in a commercial kitchen is crucial for several reasons:

1. Ensures Sanitation and Food Safety

Color coding plays a crucial role in minimizing the risk of cross-contamination between different food types or between raw and cooked items. For instance, designating a green board for raw vegetables and a yellow one for cooked poultry helps prevent any bacteria from the vegetables from contaminating the cooked poultry. By adopting a color-coded system in your kitchen, you can ensure a clean and safe environment, ultimately protecting your customers from foodborne illnesses.

    2.Boosts Operational Efficiency

In a fast-paced kitchen environment, streamlining efficiency is critical for delivering exceptional service. Color coding not only enhances the organization but also substantially reduces time wastage by eliminating unnecessary guesswork. When every item has a designated color, kitchen staff can quickly identify, use, and return them to their proper places, thereby accelerating the operational workflow and promoting productivity.

    3.Meets Hygiene Regulations

A color-coded kitchen goes beyond aesthetics and organization — it demonstrates your professional commitment to maintaining international food safety standards. By also incorporating color coding for HACCP (Hazard Analysis Critical Control Point) inspections, your kitchen visibly displays a thorough understanding and adherence to food hygiene regulations. This system helps your establishment stay compliant with health and safety requirements, ultimately becoming a standout factor during health inspection audits and garnering trust from customers and inspectors alike.

Which Products In My Kitchen Should Be Color Coded?

Ideally, you would want any object that frequently contacts food to be color-coded. Here are some utensils you may consider:

• Chopping Boards: Known to be hotspots in cross-contamination, assigning unique boards for each food group ensures minimal bacterial transfer.
• Knives: Using the same tool to cut different types of food in a sequence without proper cleaning is a common precursor for contamination. Thus, using separate knives for different foods or tasks is recommended.
• Serving Tools: These utensils usually have high contact frequency with various food types; hence, spatulas and tongs, as well as tweezers, should be color-coded to maintain clean usage.
• Storage Containers: Using color-coded holders for food storage assists in quick, efficient identification, further simplifying inventory management.
• Thermometers: Managing cooking temperature is essential in preventing foodborne illnesses. Therefore, having thermometers dedicated to specific food types helps keep the food preparation process sanitary.
• Labels: By using color-coded labels on all containers, utensils, and equipment, kitchen staff can quickly identify which equipment belongs to specific food groups, minimizing cross-contamination risks.
• Cleaning Tools: Even cleaning tools require color-coding to avoid spreading bacteria between differing sectors of the kitchen.

The Convenience And Value Of Color Coding In Cleaning

A color-coded cleaning routine can work wonders in maintaining a sanitary and spotless kitchen. For everyday use, color-coding cleaning tools and products can prevent contamination between surfaces. 

The Food Safety and Inspection Service (FSIS) has recommended that different cleaning equipment be used in different areas to keep surfaces sanitary. 

For example, a kitchen staff equipped with the knowledge that a red mop is for the bathroom floor, a blue brush for the dining area, and a green cloth for kitchen surfaces are less likely to interchange tools, preventing the spread of harmful bacteria from one area to another.