poultry operation, cgmp,5 s,quality stds
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o dffhandler
We Process…Asia’s Best.
o
OPERATIONAL QUALITY STANDARDS
AND
GOOD MANUFACTURING PRACTICES5 S CONCEPT
ENGR. DAN YSMAEL
o dffhandler
We Process…Asia’s Best.
oOBJECTIVE:
TO PROVIDE PROPER GUIDELINES, AWARENESS AND IDENTIFICATION.
ON PROCESS STANDARDS AND GOOD HOUSE KEEPING TO EVERY PRODUCTION FOOD HANDLER TO PROMOTE FOOD SAFETY.
o dffhandler
We Process…Asia’s Best.
oPART 1 OPERATIONAL QUALITY STANDARDS
WHAT ABOUTS.PROPER GUIDELINES.AWARENESS.IDENTIFICATION.
SYSTEM
o dffhandler
We Process…Asia’s Best.
oWHAT ABOUTS...OPERATIONAL QUALITY STANDARDS
“OQS”- IS A SET OF GUIDED TECHNOLOGYTHAT ENCOMPASSES WITH SCIENTIFICPROCEDURES AND IDEAL LIMITS WHICHANSWERS THE POSSIBILITIES IN APROCESS.
TECHNOLOGY PDP POSSIBILITIES
o dffhandler
We Process…Asia’s Best.
oPROPER GUIDELINES...TECHNOLOGY OF POULTRY DRESSING OPERATIONPROCESS FLOWRECEIVING SECTION
1RECEIVING OFLIVE BIRDS
RESPONSIBILITY: RECEIVE BIRDS FOR RESTING PRIOR TO HANGING.
TECHNOLOGY:1. WEIGHING SCALE CALIBRATED AND CHECKED2. 1HR TO 2HRS RESTING OF BIRDS3. DOCUMENTS COMPLETE.4. SEAL INTACT.5. 5 STACKING HIGH, 2 TO 5 INCHES DISTANCES TO
PROVIDE ENOUGH AIR FLOW.6. DO NOT RECEIVE BIRDS WITH DISEASE.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWRECEIVING SECTION
2
HANGING OF LIVE BIRDS
RESPONSIBILITY: HANG LIVE BIRDS UNTO SHACKLES.
TECHNOLOGY:1. DOA/DAA PLACE TO MORTALITY BIN.2. NO EMPTY SHACKLE.3. CAREFUL HANGING OF LIVE BIRDS.4. EMPTY ALL COOPS.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWRECEIVING SECTION
3STUNNINGOFLIVE BIRDS
RESPONSIBILITY: ALL HANGED LIVE BIRDS PASSES THE STUNNING STAGE PRIOR TO BLEEDING.
TECHNOLOGY:1. STUNNER MUST HAVE CONTINOUS WATER SUPPLY.2. VOLTAGE IS MONITORED TO ACHIEVE PROPER BLEEDING.3. ALW 1.4-1.5= 50-55V / 1.6-UP= 60V4. SUSPENSION TIME BEFORE BLEEDING IS 10 SECS.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWRECEIVING SECTION
4NECK SLITTING FOR PROPER BLEEDING
RESPONSIBILITY: SLIT NECK AS PER STD FOR BLEEDING OF LIVE BIRDS.
TECHNOLOGY:1. NECK SLIT IS DONE 3MM BELOW THE EARLOBE.2. DO NOT CUT ALL THROUGH ITS NECK AND ESOPHAGUS.3. MAKE SURE SLIT IS DONE FOR THE PURPOSE OF KILLING LIVE BIRD BY LOSS
OF BLOOD TO AVOID INCOMPLETE BLEEDING AND BIRDS WITH HEMORAGHIC CAUSE.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
5
BLOOD COLLECTION
RESPONSIBILITY: COLLECT BLOOD BY USING CUP.
TECHNOLOGY:1. PRESCRIBE ACCEPTABLE BLOOD COLLECTION IN 1 METER ONLY.2. USE STAINLESS SSQUARE SHAPE CUP.3. BLOOD COLLECTOR SHOULD WEAR YELLOW T SHIRT.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
6
SCALDING OF BIRDS
RESPONSIBILITY: ALL HANGED BIRDS PASSES THE SCALDING STAGE. SCALDER WEAKENS THE FEATHER RETENTION AND FOR EASY DEFEATHERING
TECHNOLOGY:1. SCALDER TEMP SHOULD BE MONITORED EVERY 1 HR.2. STD TEMP IS 57-60 C= HARD SCALD 57BELOW= YELLOW SCALD
61UP= OVER SCALD.3. BOUYANCY SHOULD BE IN ALL AREAS.4. LEVEL SHOULD BE 2-3 INCHES ABOVE HOCK.5. OVERFLOW METHOD.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
7
PLUCKING OF BIRDS
RESPONSIBILITY: ALL HANGED BIRDS PASSES THE DEFEATHERING SECTION, PLUCKER MACHINE IS USED TO REMOVE FEATHERS
TECHNOLOGY:1. MONITORING OF DEFEATHERING EFFICIENCY IS EVERY 1 HR.2. COMPLETE RUBBER FINGERS.3. MUST HAVE WATER AS LUBRICANT.4. ADJUSTED AS THE NEED ARISES.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
8
HEAD PULLING
RESPONSIBILITY: PULLING OF HEAD CONTROLLED BY PULLER CREW WITH THE USE OF HEAD PULLER BAR.
TECHNOLOGY:1. MONITOR HEAD PULLER EFFICIENCY EVERY 1 HR.2. PROPER HEAD PULLING IS WITH ESOPHAGUS AND TRACHEA.3. ALL HEAD SHOULD BE PULLED OFF.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
9
VENT OPENING
RESPONSIBILITY: VENTING OPENING IS DONE WITH A KNIFE BY CUTTING THROUGH ITS BUTT TOWARDS THE KEEL.
TECHNOLOGY:1. KNIFE IS SHARP AND FREE FROM CHIPPED OFFS.2. ALL BIRDS MUST BE VENT OPENED.3. THE CUT SHOULD NOT TOUCH THE KEEL PART AND MUST NOT DAMAGE
THE SKIN AND MEAT.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
10
VISCERAWITHDRAWING
RESPONSIBILITY: VISCERA WITHDRAWING IS DONE WITH THE USE OF VISCERA FORK. ALL INTERNAL ORGANS ARE PULLED OUT FOR PICKING
TECHNOLOGY:1. STAINLESS VISCERA FORK IS USED.2. THE PROCESS SHOWS SCOOPING MOTION.3. ALL INTERNAL ORGANS SHOULD BE VISIBLE UPON PULLING OUT.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
11
LIVER PICKING
RESPONSIBILITY: PICK OUT LIVER WITH CLEAN AND INJURY FREE HANDS
TECHNOLOGY:1. USE CLEAN AND INJURY FREE HANDS.2. THE METHOD SHOULD PRODUCE NO DAMAGE LIVER DURING PICKING.3. HEART SHOULD BE INTACT WITH THE LIVER DURING PICKING.4. NO UNPICK LIVER IN THE LINE.5. LIVER SHOULD BE CHILLED PRIOR TO DISPATCH.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
12
SPLEEN PICKING
RESPONSIBILITY: PICK UP WITH HANDS ALL SPLEEN.
TECHNOLOGY:1. HANDS SHOULD BE CLEAN AND INJURY FREE.2. NO LEFT SPLEEN DOWN THE LINE.3. SPLEEN SHOULD BE CLEANED PRIOR TO DISPATCH.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
13GIZZARD AND INTESTINES PICKING
RESPONSIBILITY: PULL OUT GIZZARD AND INTESTINES WITH HANDS. SEGRAGATE GIZZARD AND INTESTINES.
TECHNOLOGY:1. HANDS SHOULD BE CLEAN AND INJURY FREE.2. NO UNPICK GIZZ-INTESTINES DOWN THE LINE.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
14
BACK NECK SLITTING
RESPONSIBILITY: SLIT WITH THE USE OF A CLEAN AND SHARP KNIFE THE BACK NECK.
TECHNOLOGY:1. HANDS SHOULD BE CLEAN AND INJURY FREE.2. USE CLEAN AND SHARP KNIFE.3. NO UNSLIT CARCASS DOW THE LINE.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
15
CROPS AND PROVEN PICKING
RESPONSIBILITY: PICK OFF CROPS AND PROVEN FROM THE SLIT MADE.
TECHNOLOGY:1. HANDS SHOULD BE CLEAN AND INJURY FREE.2. NO UNPICK CROPS AND PROVEN IN THE LINE.3. INCASE OF FULL CROP, INFORM BAVI.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
16
OPAL REMOVAL
RESPONSIBILITY: CUT OFF OPAL WITH CLEAN AND SHARP KNIFE.
TECHNOLOGY:1. HANDS SHOULD BE CLEAN AND INJURY FREE.2. NO LEFT SPLEEN DOWN THE LINE.3. SPLEEN SHOULD BE CLEANED PRIOR TO DISPATCH.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
17
LUNG REMOVAL
RESPONSIBILITY: REMOVE LUNGS WITH THE USE OF A FORK TOOL.
TECHNOLOGY:1. ALL LUNGS SHOULD BE REMOVE.2. FORK TOOL SHOULD BE CLEAN AND WELL MAINTAINED.3. PLACE ALL LUNGS IN CRATE BIN.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
18
FEATHER FINISHING
RESPONSIBILITY: RUB OFF RETAINED FEATHERS WITH HANDS.
TECHNOLOGY:1. HANDS SHOULD BE CLEAN AND INJURY FREE.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
19
FEET CUTTING
RESPONSIBILITY: CUT OFF FEET WITH THE USE OF A CLEAN AND SHARP KNIFE.
TECHNOLOGY:1. PROPER AMPUTATION- 8 SHAPE2. AVOID OVER OR UNDER AMPUTATION.3. NO UNCUT HOCK DOWN THE LINE.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
20GIBBLETS CLEANING AND CHILLING
RESPONSIBILITY: CLEAN GIZZARD AND LIVER, REMOVE ALL CONDEMN GIBBLETS, CHILLED WITH CHLORINATED WATER WITH NMT 2C.
TECHNOLOGY:1. CHILLING WATER IS NNT 2C2. CL LEVEL IS 50PPM
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWEVISCERATION SECTION
21
BY PRODUCT CLEANING
RESPONSIBILITY: CLEAN INTESTINES, REMOVE FECAL, CLEAN CROPS AND PROVEN, REMOVE FEEDS.
TECHNOLOGY:1. CLEAN INSTESTINES SHOULD BE RINSE WITH CHILLEDCHLORINATED
WATER OF 50PPMAND NMT 2C.2. CHILLING PROCESS IS DONE BY METHOD OF ICE LAYERING AND NO
WATER.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWPACKING AREA
22
PRE WASHING
RESPONSIBILITY: ALL FULLY DRESSED CARCASS PASSES THE PRE WASHING TANK.
TECHNOLOGY:1. TEMPERATURE MONITORING IS EVERY 1HR.2. USE CLEAN WATER.3. CHLORINE LEVEL IS 50PPM4. TEMP IS 11-16 C.5. CHANGE WATER EVERY TRUCK BATCH.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWPACKING AREA
23
CHILLING PROCESS
RESPONSIBILITY: ALL PRE WASHED CARCASS PASSES THE CHILLING TANK.
TECHNOLOGY:1. CHILLING PROCESS IS 40-45MIN.2. CHILLING TEMP IS NMT 2C.3. CL LEVEL IS 50PPM4. ALLOWABLE RESIDUE CL IS 10PPM.5. MONITORING IS EVERY 1 HR.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWPACKING AREA
24SORTING AND CLASSIFYING
RESPONSIBILITY: SORTING AND CLASSIFYING ALL CHILLED CARCASS.
TECHNOLOGY:1. SORT AND CLASSIFY FCA AND FCB FCC.2. FIFO IS OBSERVED.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWPACKING AREA
25
DRIP LINE
RESPONSIBILITY: ALL CARCASS SHOULD BE DRIPPED.
TECHNOLOGY:1. DRIPPING SHOULD BE 2TO3 MINS.2. FIFO METHOD IS FOLLOWED.3. COLD CHAIN CONCEPT IS FOLLOWED.4. FALLEN CARCASS IS DIPPED IN CARCASS DIP FOR DISSINFECTING.5. CARCASS DIP IS 50PPM.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWPACKING AREA
26
PACKING
RESPONSIBILITY: PACK ALL FRESH CHILLED CHICKEN WITH CLEAN, PROPERLY CODED PLASTIC.
TECHNOLOGY:1. PLASTIC SHOULD BE PROPERLY CODED.2. FIFO IS FOLLOWED.3. CREW SHOULD HAVE CLEAN AND INJURY FREE HANDS.4. WEAR GLOVES.5. COLD CHAIN CONCEPT IS FOLLOWED.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWPACKING AREA
27WEIGHING AND RECORDING
RESPONSIBILITY: WEIGHING OF ALL FRESH CHILLED AND PACKED CHICKEN.
TECHNOLOGY:1. WEIGHING SCALE IS CALIBRATED.2. FIFO IS FOLLOWED.3. COLD CHAIN IS FOLLOWED.4. ICE TOPPINGS IS 6 KILOS PER BAG OF 15PCS.5. RECORD ALL WEIGHT FOR THE PRODUCTION REPORT.
o dffhandler
We Process…Asia’s Best.
oTECHNOLOGY OF POULTRY DRESSING OPERATION
PROCESS FLOWPACKING AREA
28STORING AND DISPATCHING
RESPONSIBILITY: STORE ALL CHICKEN IN CRATES INSIDE THE STORAGE, ALL SHOULD BE PROPERLY ICE TOPPED.TECHNOLOGY:1. ALL SHOULD BE STORED WITH FOOT CRATE.2. STORING IS IN ACCORDANCE TO CLASSIFICATION OR PER CUSTOMER.3. FOLLOW THE 16 HOUR RULE FOR DISPATCH.4. IT OF CHICKEN SHOULD BE NMT 4C.
o dffhandler
We Process…Asia’s Best.
oAWARENESS... AWARENESS SHOULD BE DEVELOPED TO EVERY FOOD HANDLER FOR IT SERVES AS THE CORE OF FOOD SAFETY HANDLING.
AWARENESS GUIDES EVERY WORK.
AWARENESS TEACHES US TO WORK PROPERLY.
AWARENESS IS PRESENSE OF MIND WITH WORK DETAIL.
AWARENESS IS A POKAYOKE “ WORKING WITHOUT MISTAKES”
o dffhandler
We Process…Asia’s Best.
oAWARENESS... WHAT ARE THE THINGS WE NEED TO BE AWARE OF AS FOOD HANDLERS...
WORK STANDARDS.QUALITY STANDARDS.HOUSE RULES.
o dffhandler
We Process…Asia’s Best.
oAWARENESS…WORK STANDARDS- THIS ARE THE DETAILED PROGRAM OF WORK INSTRUCTIONS. IT EXPLAINS THE WHOLE MECHANISM OF WORK OR HOW THE WORK MOVES FROM START TO END.
o dffhandler
We Process…Asia’s Best.
oAWARENESS…WORK STANDARDSPOULTRY DRESSING PLANT.
RECEIVING EVISCERATION PACKING
o dffhandler
We Process…Asia’s Best.
oAWARENESS…WORK STANDARDS
RECEIVING/ EVISCERATION / PACKING1. PRE OPERATION-SAFETY, ORIENTATION, TIME.2. DURING- INSTRUCTIONS, EFFICIENCY, TIME.3. POST OPERATION- CLEAN AS YOU GO, SAFETY, TIME.
o dffhandler
We Process…Asia’s Best.
oAWARENESS…QUALITY STANDARDS
RECEIVING / EVISCERATION / PACKINGVOLTAGE SCALDING TEMP PREWASHING TEMPBLEEDING EFF. PLUCKING EFF CHILLING TEMP.CROP MONITORING LINE EFF. CLASSYING EFF.DOA AND DAA SEP. IT IN THE LINE. IT IN THE LINE.CHLORINATION LEVELCHLORINATION LEVEL CHLORINATION LEVEL
WATER ANALYSIS WATER ANALYSISFIFO FIFO FIFOCOLD CHAIN CONCEPT COLD CHAIN CONCEPT. COLD CHAIN CONCEPT
o dffhandler
We Process…Asia’s Best.
oAWARENESS…HOUSE RULES
THESE ARE THE GUIDED POLICY STANDARD SET BY THE MANAGEMENT AS CONTROL AND PROTECTIONFOR EVERY INDUVIDUALS.
Rules1. Late policy 6. Smoking policy2. Absentism policy 7. Gate pass policy3. Insubordination policy 8. Other policies4. Work policy5. CA policy
o dffhandler
We Process…Asia’s Best.
o IDENTIFICATION...
THE WHOLE OPERATION IS A COMPLETE LEARNING PROCESS. INSIDE, EACH OF US LEARN DIFFERENT THINGS. AND WHAT IS IMPORTANT WE IDENTIFY THE IMPORTANCE OF WORK THAT MUST REFLECT THE WORD SAFETY AND HEALTH TO EVERY PRODUCT WE PROCESS... WE MUST BECAUSE.....”WE PROCESS... ASIA’S BEST”...
o dffhandler
We Process…Asia’s Best.
o PART 2GOOD MANUFACTURING PRACTICE-IT IS A SET OF REGULATORY CODES, GUIDELINES, AND PRACTICES TO PROMOTE FOOD SAFETY.
HISTORY1900’s- AN EPIDEMIC WAS SPOTTED IN THE WESTERN SIDE OF THE GLOBE.
THAT EPIDEMIC WAS A RESULT OF FALSE HANDLING OF FOOD PREPARATION.
o dffhandler
We Process…Asia’s Best.
oCAUSES:UNSANITARY PRACTICES.NO QUALITY CONTROLS.CROSS CONTAMINATION.POOR SANITATION.WATER IS NOT COLIFORM FREE.PRODUCT OUTPUT IS NOT FOOD SAFE.RODENTS NOT CONTROLED.
o dffhandler
We Process…Asia’s Best.
oWHERE DOES GMP WILL START?-GMP STARTS FROM ONESELF.
WHEN IT WILL START?-RIGHT NOW.
DO YOU WANT TO KNOW HOW?- WATCH, LISTEN AND UNDERSTAND.
o dffhandler
We Process…Asia’s Best.
oPERSONAL HYGIENE:
BEFORE GOING TO WORKTAKE A GOOD BATH.TAKE A GOOD HEALTHY BREAKFAST.WEAR CLEAN AND NEAT CLOTHES.IF WORKING IN A FOOD PROCESSING PLANT DO NOT PUT PERFUME.DO NOT WEAR JEWERLY THAT CAN BECOME CONTAMINANTS.REMOVE MUSTACHE AND BEARD.HAVE FINGER NAILS TRIMMED.HAVE A GOOD AND PROPER HAIR CUT.
o dffhandler
We Process…Asia’s Best.
oPERSONAL HYGIENE:
PRE OPERATION.WEAR SEPARATE CLOTHING FOR DIRECT WORK.WEAR HAIR NET AND HEAD CAPWEAR NOSE MASK.WEAR APRON.WEAR PROPER BOOTS.WEAR PROPER GLOVES.EXERCISE TO CONDITION THE BODY.WASH HAND 30SEC BEFORE HANDLING RAW AND FINISH PRODUCT.
o dffhandler
We Process…Asia’s Best.
oPERSONAL HYGIENE:
PROPER HAND WASHING.1. MOISTEN HAND AND ARMS.2. LATHER WITH ANTI BACTERIAL
SOAP FOR 30 SEC.3. LATHER FINGERS, PALM, ARM,
ELBOWTHOUROLY.4. RINSE WITH WATER.5. SANITISE HANDS.6. BLOW DRY HANDS.
o dffhandler
We Process…Asia’s Best.
oPERSONAL HYGIENE:
DID YOU KNOW THAT!
AREAS MOST FREQUENTYMISSED
LESS FREQUENTLY MISSED
NOT MISSED
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICES:
DO’S AND DONT’S...PROPER CLOTHING
- IT PROVIDES PROTECTIONTO BOTH THE WORKERS ANDTHE PRODUCT BEING HANDLED.
- WORKING CLOTHES SHOULDNOT BE WORN OUTSIDE.
- ALWAYS WEAR THE COMPLETEDRESSCODE PROPERLY.
o dffhandler
We Process…Asia’s Best.
o
GMP PRACTICE:
DO’S AND DONT’S...HEAD CAP AND MASKS.
- ALWAYS WEAR THEMPROPERLY DURING OPERATION.
- WEAR CLEAN HEADCAP AND MASKS.
o dffhandler
We Process…Asia’s Best.
o
GMP PRACTICE:
DO’S AND DONT’S...GLOVES AND BOOTS.
- ALWAYS WEAR THEMPROPERLY DURING OPERATION.
- WEAR CLEAN GLOVES AND CLEAN BOOTS.
- SANITIZE GLOVES BEFOREHANDLING FOOD.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.SANITIZE HANDS EVERY 30 MINS.
-30MIN IS THE MAXIMUM TIME THAT BACTERIA WILL GROW AFTER BEING EXPOSED TO AIR, WATER, HEAT. AND IT IS IN THIS TIME LIMIT THAT GMP CAN TOTALY CONTROL BACTERIAL GROWTH AT MINIMUM AND SAFE LEVEL.-SANITIZE WITH CHLORINE HAND DIP SOLUTION.
o dffhandler
We Process…Asia’s Best.
o
GMP PRACTICE:
DURING THE OPERATION.SANITIZE AND DISINFECT RAW MEAT THAT ACCIDENTALLY FALLS ON THE FLOOR.USE THE CARCASS DIP PROACTIVELY.CARCASS DIP SHOULD HAVE 50PPM CL LEVEL.
o dffhandler
We Process…Asia’s Best.
o
GMP PRACTICE:
DURING THE OPERATION.SANITIZE TOOLS LIKE KNIFE, CHOPPING BOARD, BASIN, TRAYS.SANITIZE IT WITH 100PPM CL SOLUTION.WASH AND SANITIZE IT BEFORE AND AFTER USE.
o dffhandler
We Process…Asia’s Best.
o
GMP PRACTICE:
DURING THE OPERATION.SEPARATE CONDEMN MEAT FROM GOOD MEAT.HAVE IDENTIFICATION TO AVOID PRODUCT MIX UP.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.WASH AND SANITIZE ALL TABLES, ANDMACHINES.SANITIZE IT WITH 100PPM. CL SOLUTION.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.MAINTAIN THE 50PPM CHILLING CHLORINATION.AT 50PPM BACTERIA FREEZES FROM MULTIPYING.QUALITY BEING ENHANCED.USE THE CHLORINE TEST STRIP FOR MONITORING.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.RELIGOUSLY FOLLOW AND LIVE THE COLD CHAIN CONCEPT DURING PRODUCTION.ITS PREREQUISITE IS THE FIFO AND KEEP IT CLEAN, KEEP IT COLD, KEEPIT MOVING…CARCASS IT SHOULD BE NMT 4 C.ICE IS 6 KILOS PER BAG.RE ICING IS A MUST IF STORAGE IS NOT A CONTROLLED ENVI.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.SNEEZING, AND COUGHIING IS NOT ALLOWED INSIDE THE OPERATION… … BUT THERE IS A WAY TO HAVE IT DONE PROPERLY AS GUIDED BY GMP. .. SNEEZE THRU YOUR SHOULDER… WHILE COVERING THE FACE WITH ARMS.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.LOOSE ITEM MATERIALS LIKE JEWELRIES ARE NOT ALLOWED INSIDE THE OPERATION - CONSIDERED AS CONTAMINANTS.NO HAND LOTION OR COLOGNE.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION. ALWAYS USE FOOT CRATES DURING THE PRODUCTIONA AND TRANSPORT.FOOT CRATES ARE ESSENTAILS AND CONSIDERED AS CRITICAL IN CONTROLLING PRODUCT CONTAMINATION FROM FLOORS AND KEEPS FINISH GOODS CRATES FREE OFF FROM THE FLOOR.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION. ALWAYS OBSERVE CLEANLINESS INSIDE THE PRODUCTION TO AVOID INSECTS ATTRACTION.ENSURE THAT THE WHOLE PRODUCTION AREA HAS NO OPENNING THAT CAN CAUSE INSECT IN FESTATION.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION. STATIONARY WORKERS ARE NOT ALLOWED TO GO FROM DIRTY TO CLEAN AREA OR VISA VERSA.CRATES ARE NOT ALLOWED TO ENTER FROM 1 AREA TO ANOTHER.CONDEMN PRODUCTS ARE NOT ALLOWED TO ENTER THE CLEAN AREA.CROSS CONTAMINATION IS THE TRANSFER OF POSSIBLE BACTERIA FROM 1 MATERIAL TO ANOTHER, OR MIGHT BE BROUGHT BY UNSANITARY WORK MOVEMENTS.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION. NO SMOKING INSIDE THE PRODUCTION.SMOKING AREA SHOULD BE CONTROLLED.AFTER SMOKING, WASH HANDS AND SANITIZE HANDS WITH PROPER SANITIZER.AFTER EATING, GOING TO CR AND SMOKING ALWAYS WASH AND SANITIZE HANDS PROPERLY.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION. PEST CONTROL SYSTEM SHOULD BE IMPLIMENTED TO AVOID INSECT CONTAMINATION.PROPER SANITATION IS THE BEST AND IMMEDIATE COMPAIGN AGAINST SUCH RODENTS.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.TO AVOID CONDENSATES- AVOID PRACTICES THAT WOULD CREATE PASSAGE OF HEAT TRANSFER FROM ANOTHER ROOM OR ENVIRONMENT. LIKE AS SHOWN IN THE PICTURE.IT WOULD ALSO PROVIDE PROTECTION FROM INSECT THAT MIGHT GO INSIDE THE PRODUCTION AREA.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.ALWAYS MONITOR THE INTERNAL TEMP .INCASE OF DEVIATION IMMEDIATE CORRECTIVE ACTIONS SHOULD BE DONE.MAINTAINING THE PROPER TEMP PROVIDES CONTROL IN BACTERIAL GROWTH.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.ALWAYS ORGANIZE THE TOOL ROOM.DON’T LET CLEANING TOOLS JUST BE PLACED ON THE FLOOR.DO NOT LEAVE YOUR TOOLS UNATTENDED.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.TOO MUCH HIGH SPEED WILL BRING MEAT WITH EXCESSICE BLOOD... MAKING THE CHILLING PROCCESS RED.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.AVOID WATER STAGNANTS IN THE PRODUCTION AREA, ENTRANCES, STORAGES, DISPATCH AREA OR EVEN WITHIN THE VICINITY.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
DURING THE OPERATION.PRODUCTION BOOTHS SHOULD NOT WORN OUTSIDE THE PLANT FLAT FORM… DO NOT WEAR BOOTHS IF YOU ARE GOING TO THE CR.FACE MASK, HEAD CAP SHOULD BE ONLY WORN INSIDE THE PRODUCTION.
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
AFTER OPERATIONS. FOLLOW RELIGOUSLY THE CLEAN AS YOU GO POLICY.SANITIZE ALL TOOLS, TABLES, EQUIPMENTS, MACHINES AFTER EVERY DRESSING.WASH AND SANITIZE ALL MACHINES. WASH AND SANITIZE FLOORS.CLOSE ALL UNECESSARY OPENNINGS, DOORS, WINDOWS.DON’T FORGET TO CLEAN THE UNDERNEATH OF EVERY TABLES.
o dffhandler
We Process…Asia’s Best.
oOPERATION IDENTIFICATION
MONITORINGS. DAILY MONITORINGS:
LIVE BIRDS RECEIVING.OPERATIONAL STDS MONITORINGSQUALITY AND WORK OUTPUT MONITORINGS.DAILY SANITATION CHECKLISTSGMP –PERSONAL HYGIENE CHECKLISTSMAINTENANCE CHECKLISTS
o dffhandler
We Process…Asia’s Best.
oGMP PRACTICE:
OTHERS.PLAYING AROUND INSIDE THE PRODUCTION AREAIS PROHIBITED.SHOW COURTESY TO VISITORS. WORK BY HEART AND MIND AND NOT BY POCKET ALONE.RELIGOUSLY THINK OF GMP ALWAYS EVEN AT HOME.THINK GMP AS 3 O’s
o dffhandler
We Process…Asia’s Best.
o
GMP PRACTICE:
REMEMBER THESE.OMNIPRESENT- UNIVERSAL PRACTICE.OMNISCIENT- AN ALL PERFECT SAFETY MEAT SCIENCE.OMNIPOTENT- A POWERFUL PRACTICE.
o dffhandler
We Process…Asia’s Best.
o
THE 5 ‘S’ CONCEPT.
o dffhandler
We Process…Asia’s Best.
oTHE CONCEPT:
BACKGROUND.THE 5 S CONCEPT ORIGINATED FROM JAPAN. IT IS A PRACTICE WHICH IDENTIFIES A STEP BY STEP PROCEDURE IN A WORK PLACE.THE CONCEPT WAS MADE TO ADDRESS WHAT THE JAPANESE EXPERIENCE IN THEIR SEMI CONDUCTOR PLANTS. THEY EXPERIENCE WORK REJECTS, FAULTY DATA, ACCIDENTS WHICH IN THE END ONLY GIVE LOSSES.
o dffhandler
We Process…Asia’s Best.
o
THE CONCEPT:
THE FIRST S
SORT/SORTING- SEGREGATE GOOD FROM BAD AFTER WORK. AS THE FIRST STEP IN THE CONCEPT.
o dffhandler
We Process…Asia’s Best.
o
THE CONCEPT:
THE SECOND S
SWEEP/SWEEPING- REMOVE ALL UNECESSARY THINGS AROUND THE WORKPLACE-STATION. IN SHORT CLEANING.
o dffhandler
We Process…Asia’s Best.
o
THE CONCEPT:
THE THIRD S
SYSTEMATIZE- AFTER CLEANING, PUT SYSTEM IN THE WORK PLACE. ARRANGE THE PLACE WITH A STEP BY STEP FLOW.
o dffhandler
We Process…Asia’s Best.
oTHE CONCEPT:
THE FOURTH S
STANDARDIZE- AFTER PUTTING UP A SYSTEM, OR ORGANIZING THE PLACE,STANDARDIZE IT AS ITS FINAL AND PROPER PLACEMENT WHICH AGREES TO THE STANDARD OPERATING FLOW.
o dffhandler
We Process…Asia’s Best.
o
THE CONCEPT:
THE FIFTH S
SELF DISCIPLINE- PUT DISCIPLNE TO ONSELF, DO IT CONTINOUSLY AND RELIGOUSLY.
o dffhandler
We Process…Asia’s Best.
o
DURING WORK AFTER 5 S
o dffhandler
We Process…Asia’s Best.
o
LETS HAVE A QUIZ
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
SPOT WHAT IS WRONG IN THE PICTURE
o dffhandler
We Process…Asia’s Best.
o
WHAT SHOULD YOU DO?
o dffhandler
We Process…Asia’s Best.
o
WHAT SHOULD YOU DO?
o dffhandler
We Process…Asia’s Best.
o
WHAT SHOULD YOU DO?
o dffhandler
We Process…Asia’s Best.
o
WHAT SHOULD YOU DO?
o dffhandler
We Process…Asia’s Best.
o
YOUR COMMITMENT
o dffhandler
We Process…Asia’s Best.
o
UPHOLD, LIVE AND FOLLOW RELIGOUSLY ALL THE CONCEPT OF:
OPERATIONAL STANDARDS ‘OQS’
GOOD MANUFACTURING PRACTICES
THE 5 S CONCEPT -5 S-
o dffhandler
We Process…Asia’s Best.
o
MARAMING SALAMAT PO!