Bakery Ind Hygiene

8/8/2019 Bakery Ind Hygiene

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Food Safety

(General

FoodHygiene)

Regulations

1995

Food Safety

(Temperature

Control)

Regulations

1995

Industry

Guide to

Good

Hygiene

Practice:

BakingGuide

Chadwick HouseGr oup Lt d.


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Food Safety

(General

FoodHygiene)

Regulations

1995

Food Safety

(Temperature

Control)

Regulations

1995

Industry

Guide toGood

Hygiene

Practice:

Baking

Guide

Chadwick H ouseGroup Ltd.


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PUBLISHED BYCHADWICK HOUSE GROUP LTD.

Chadwick Court

15 Hatfields

London SE1 8DJ

Tel: 0171 827 5882 Main switchboard: 0171 827 9929 Fax: 0171 827 9930

Chadwick House Group Ltd. (CHGL) is a commercial company, wholly owned by the

Chartered Institute of Environmental Health (CIEH). The company's mission is to

provide quality products and services to create awareness and to raise standards in the

health environment and safety of the public. We intend to remain the premier

provider by continual investment in our people, products and services in support ofthe aims of the CIEH. Our main activities are focused on training, communications

and conferences and exhibitions. It also markets a wide selection of books and videos

relating to environmental health. The CIEH is a professional and educational body,

founded in 1883 and dedicated to the promotion of environmental health and to

encouraging the highest possible standards in the training and the work of

environmental health officers. The Chartered Institute has over 9,000 members most of

whom work for local authorities in England, Wales and Northern Ireland. Apart from

providing services and information to members, the Institute also advises government

departments on environmental health and is consulted by them on any proposed

legislation relevant to the work of environmental health officers.The Chartered Institute is a Registered Charity.

Food Safety and H ygiene Working Group for The Baking Guide

App lications for reprod uction should be m ade to Chadw ick Hou se Group Ltd.

First imp ression 1997

ISBN 0 900 103 55 8


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This Ind ustry Gu ide to good h ygiene practice gives advice to

bak ery businesses on how to comply with the Food Safety

(General Food H ygiene) Regulations 1995 and the

correspon din g regulations in N orthern Ireland.

This is an official guide to th e Regulations w hich has b een

develop ed in accordan ce with Article 5 of the EC Directive on

the Hygien e of Foodstu ffs (93/43/EEC).

The Gu ide also contains advice on h ow to comp ly with th e

Food Safety (Temperatu re Con trol) Regulations 1995.

Whilst this Gu ide is not legally bind ing, Food Auth orities

mu st give it due consideration w hen enforcing the

Regulations.

It is hop ed that the information wh ich this Gu ide contains

will help bakers both to meet their legal obligations and to

ensu re food safety.

Part 1 Preface

Chapter 0 Chapter Head ing


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Thanks are du e to the following organisations and th eir representatives wh o

formed the w orking party r esponsible for the d evelopm ent of this Guide:

National Association of Master Bakers

Janet Carr (Chairman of the working party) - Warings Master Bakers Ltd

Chris Dabn er (Secretary to the w orking par ty) - Hygiene & Safety Officer

Biscuit, Cake, Chocolate and Con fectionery Alliance

Nigel Shipman - Lyons Cakes Ltd

Federation of Bakers

Tony Casdagli - DirectorKate Hod getts - Three Cooks Ltd

Scottish Association of M aster Bakers

Ian H ay - Chief Executive

David Clark - Aulds (Foods) Ltd

LACOTS

Mark Du Val

Clare Cunningham

David Lock

Departm ent of Health

William Connon

Peter Martin

The working p arty are gr ateful to all those mem bers of their

Associations/ Organisations wh o read and commented on the drafts du ring

its developmen t. They would also like to thank all those individuals,

organisations includ ing Consumer Grou ps and local authority

environmental health dep artments and liaison grou ps for their commen ts

submitted d uring th e pu blic consultation exercise. These were very useful

and much app reciated.

Finally the work ing party wou ld like to express their thank s to Gillian

Smith of the NAM B for her keyboard skills.

Part 1 Acknowledgements

Chapter 0 Chapter Head ing


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FOR INFORMATION:

If you n eed help to und erstand th e guidan ce in this booklet contact your local environmental

health dep artment.

(Urdu)

(Gujarati)

(Chinese)

(Bengali)

(Punjabi)

(Greek)

(Turkish)


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Contents Page

Part 1 Introduction 1

General Introduction 1

Scope of the Guide 2

Part 2 Hazard Analysis (Regulation 4(3)) 3

The legal requirement to id entify hazard s, measures to control them an d those steps in the

pr ocess which are critical to Food Safety

Part 3 Schedule One of the Regulations -The 'Ru les of Hygiene' 23A detailed gu ide to the requirements

Chapter I General Requirements for Food Premises 24

Chap ter II Specific Requirements for Rooms where Foodstuffs are p repared , t rea ted o r 31

processed

Chapter III Requirements for Moveable and/ or Temporary Premises (such as marquees, 36

market stalls, mobile sales vehicles) premises used primarily as private dwelling

houses, premises used occasionally for catering p urp oses and vend ing machines

(No guid ance has been given as this Chapter is not ap plicable to the baking

industry).

Chapter IV Transport of Food 37

Chapter V Equipment Requirements 40

Chapter VI Handling and Disposal of Food Waste 43

Chapter VII Water Supply 45

Chapter VIII Personal Hygiene Requirements for anyone working in 47

or entering a food bu siness

Chapter IX Requirements for the Hand ling of Foodstuffs 50

Chapter X Training - 54

The requirement for the supervision and instruction and / or training of

food handlers

Part 4 Temperatu re Control 64

A detailed gu ide to th e requirements of the Food Safety (Temperatu re Control) Regulations 1995

for England an d Wales and the separate requirements for Scotland . Including deta ils of the

exemp tions for egg custard s and meat p ies, cornish p asties and sausage rolls and th e scientificassessment for an u pw ard variation in tem peratu re control for cream cakes.

Part 5 Appendices -These do not form part of the Recognised Gu idance. They contain background 78

information an d various forms and record sheets wh ich can be u sed, if approp riate.

Appendix One Daily cleaning checklist 79

Two Example of a p ictorial cleaning schedule 80

Three Cleaning schedule 81

Four Information on wall surfaces 83

Five Information on flooring materials 85

Six Temperature check record 87

Seven Extract from Workplace (Health, Safe ty and Welfare) Regula tions 1992

on sanitary conveniences and washing stations 88

Eight Good hygiene practice table 90

Nine Pre-employment questionnaire 91

Ten Delivery check record 92

Eleven Example of a pest control form 94

Twelve Example of a pest control summary sheet 95

Thirteen Pest control services 96

Fourteen List of organisations providing formal training courses 97

Fifteen Training record 98

Sixteen Personal training record 99

Seventeen Staff training record 100

Part 6 Glossary, References, Useful Addresses 101

Glossary: Definit ions of Various Terms used in th is Guide

References: Details of Other Regulations and Documents mentioned in this Guide

Con tacts: Usefu l Con tact Ad d resses


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The purp ose of this Guide is to provide bakers with gu idance on how to comply w ith

the requirements of the Food Safety (General Food Hygiene) Regulations 1995 and the

Food Safety (Temperature Control) Regulations 1995, and with the corresponding

Regulations in North ern Ireland.

In particular, the Guide will:-

l give clear guidance on wh at is required to comp ly with the requirements of

the Regulations;

l in relation to th e baking indu stry to clarify and explain the terms "where

necessary" and "wh ere app ropriate" where these app ear in the Regulations;

l to provide more specific guidance on practices specific to the baking

indu stry to ensure the safety of the food prod uced;

l to give clear ad vice relating to various aspects of good m anu facturing

practice.

The Guide w as produ ced by a Working Party consisting of mem bers/ representatives

from the N ational Association of Master Bakers, the Scottish Association of MasterBakers, the Federation of Bakers an d the Biscuit, Cake, Chocolate and Confectionery

Alliance, with assistance from representatives from the Depar tment of Health and

LACOTS (see Acknowledgements page for further details).

The Guide has been d eveloped in accordan ce with Article 5 of the Directive 93/ 43/ EEC

on the Hygiene of Foodstuffs and the Departm ent of Healths guid ance booklet - A

Temp late Advice on the Com pilation of UK Indu stry Guides to Good H ygiene Practice.

It has und ergone the required th ree month p eriod of public consultation.

The Guid e has the status im plied by regu lation 8(2)(c) of the Food Safety (General Food

Hygiene) Regulations 1995, regulation 19(2)(c) of the Food Safety (Tempera tu re Con trol)

Regulations 1995 and th e correspond ing Regulations in North ern Ireland. EnforcementOfficers mu st give "du e consideration" to wh at the Gu ide says wh en assessing w hether

bakers are complying w ith the requ irements of these Regulations.

Whilst this Guid e sets out a recomm end ed way by wh ich bak ers can comply with the

Gen eral Food H ygiene and Temperature Control Regulations, there is no legal

requirem ent for bakers to follow the advice. Bakers may be able to find alternative

ways of comp lying with the Regulations. In that event, it is up to the proprietor of

the bu siness to demonstrate to the enforcement au thority that he/she has complied

with the requ irements of the Regulations.

This Guide only deals with the Food Safety (General Food Hygiene) Regulations 1995

and the Food Safety (Temperatur e Control) Regulations 1995 and their N orthern Irelandequ ivalents. There are other Acts (Food Safety Act 1990) and Regulations w hich can or

do govern the pr odu ction and sale of food by bakers. Some may imp inge on general

issues of food h ygiene. For examp le, there are various H ealth and Safety regulations

dealing with th e provision of toilets, wash h and basins, accomm odation for outd oor

clothing, the safety and use of cleaning materials etc; date marking of food is governed

by th e Food Labelling Regulations 1996; the disp osal of waste (Sched ule 1, Chap ter VI)

is regulated by the Env ironm ental Protection Act 1990. In a few instances specific cross

references to other p ieces of legislation have been made for the sake of clarity. In

general it was deemed impractical to include cross references to all the other associated

legislation.

Part 1 INTRODUCTION

1: Introduction 1


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How ever, whilst not dealt with in this Guide, the bakery bu siness mu st be aware of all

the oth er legislation governing its op eration, take accoun t of the various legal

requirements and take action w here necessary to ensu re that th eir business comp lies

with all the legal du ties imposed on it.

Good Practice: The Guide also provides ad vice and information on good p ractice.

These are clearly differentiated from the guidance on compliance and for Schedule 1

Chapters I to IX they app ear in a separate colum n on th e right hand side of the page

head ed "Advice on Good Practice". It is NOT a legal requirem ent to follow th e advice

on good p ractice. It is entirely up to ind ividual businesses whether they w ish to heedand im plement the ad vice given, and it has no legal stand ing with regard to

enforcement of and compliance with the Regulations. The sections on good p ractice are

not comprehen sive.

Documentation an d Records: There is NO explicit requirem ent in the General Food

Hygiene or Temp erature Control Regulations for bakers to docum ent p olicies,

procedu res and systems or to keep records. In a num ber of instances, the keeping of

written records, eg for hygiene training m ay assist in d emonstrating compliance with

the Regu lations. In the event of enforcement action und er these Regulations,

docum ented p rocedu res and r ecords of routine checks may be of use in the

establishmen t of a "due d iligence" defence as described in th e Food Safety Act 1990.

SCOPE

The sectors of the Baking Industry covered by this Guide are :-

l Retail Craft Bakeries

l Wholesale Craft Bakeries

These can vary in size from a small unit behind a shop to a very large bakery

supp lying a large nu mber of either their own bran ch shops or wh olesale outlets,

includ ing catering establishments, with a wid e range of bakery goods including br ead,

rolls, cakes, other flour confectionery and savouries, the majority of which are

un wrap ped . Occasionally, the bakery business may be m ore highly specialised

prod ucing a much more limited range w hich may be packaged.

Instore Bakeries The guidance on compliance given in the Retail Industry

Guide is consistent w ith that given in th is Guide. Therefore,

wh ilst either Gu ide could be u sed, it is recommend ed for

simplicity that the Retail Indu stry Guide is used. In the

circumstances, instore bakeries should be considered ou tside

the formal scope of this Guide for the p urp oses of the

requirements in the legislation that th e Guide be given du e

consideration by enforcement officers.

Bakery Shops Bakery shops should a lso be considered outside the formal scope

of this Guide for the pu rposes of the requirements in thelegislation that th e Guide be given d ue consideration by

enforcement officers.

The Guid e does NO T cover:- Plant Bakeries

Plant bakeries are usually large highly autom ated u nits produ cing a limited range of

bread p rodu cts (mainly sliced an d wrap ped loaves) or biscuits or cakes for w holesale,

the majority of wh ich are packaged and h ave a well know n brand nam e. These bakeries

are often part of a larger bakery group and ar e owned by a national or international

bakery or food group .

2


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Regulation 4(3) requ ires that:-

A proprietor of a food business shall identify any step in the activit ies of the food business which

is critical to ensuring food safety and ensure that adequate safety procedures are identified,

implemented, maintained and reviewed on the basis of the following principles -

(a) analysis of the potential food hazards in a food business operation;

(b) ident ification of the points in those operations where food hazards may occur;

(c) deciding which of the points ident ified are critical to ensuring food safety (critical

points);

(d) ident ification and implementation of effective control and monitoring procedures at

those critical points; and

(e) review of the analysis of food hazards, the critical points and the control and

monitoring procedures periodically, and whenever the food businesss operations

change.

This new legal requirement is the key to th e new General Food H ygiene Regulations

and reflects a fundam ental change in the ap proach to food hygiene compared to

previous regu lations.

Its purp ose is to get the p roprietors of food bu sinesses to :

(a) think about the w ay they hand le, prep are and store food in a structured w ay,(b) to get them to identify and assess the hazard s to the safety of the food at th e various

stages of manu facture,

(c) to devise and im plement w ays of controlling or eliminating th ese hazards w here

necessary so as to ensure the safety of the food p rodu ced.

This section gives practical advice about how to carry out a hazar d analysis, with

examples of what the h azards could be, various op tions for controlling these hazard s

and on how to mon itor these controls, plus an example of a form w hich could be used,

if the prop rietor so wishes to docum ent the hazard analysis.

How ever, the examp les of the types of hazards and possible control and mon itoring

options are just that, examples. They are not by any m eans a complete and exhaustivelist, they may not be ap plicable to the way you make the pr odu ct and there may be

other ways in wh ich you could control the hazard.

Every bakery business is different for a variety of reasons, including:-

(a) the products they produce;

(b) the recipes and methods of production eg is puff pastry made or bought in;

(c) the equipment used ;

(d) the layout and physical condition of the bakery;

(e) the experience, knowledge, und erstanding and capability of the staff and

managers.

Part 2 THE FOOD SAFETY (GENERAL FOOD HYGIENE)REGULATIONS 1995

HAZARD ANALYSIS SYSTEM

(Iden tification of Step s Critical to Food Safety)

2: Hazard Analysis System 3


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Therefore every proprietor of a bak ery must carry out a hazard analysis of their own

bakery op eration following th e five basic principles laid out in Regulation 4(3) and

explained in m ore detail below.

The legal obligation to carry out h azard analysis rests with the p roprietor although it is

expected that h e/ she will use the advice and assistance from staff, app ropriate

ind ividu als or organisations, eg external consu ltants, the local Environm ental Health

Departm ent. In practice only the prop rietor and th e staff truly und erstand how th e

bakery operates, and h ow the p roducts are produced.

The hazard an alysis is relatively straightforward . In simp le terms you have to gothrough how you prod uce your p roducts from the pu rchase/ arrival of the

ingredients through to the dispatch of the finished p rodu ct. At each stage/ step in the

process you n eed to identify if there are any hazards to the safety of the prod uct. If

there are, to assess wh at measures/ controls you already h ave in place, if any. If there

are no controls in p lace already, you need to d ecide wh at controls, or further controls,

may be necessary to eliminate or reduce the hazar d to a safe level. You hav e probably

carried ou t a very similar process already over th e years and h ave pu t in various simple

commonsense, practical measures to control a variety of perceived hazards (eg cleaning

of equipment and the fabric of the bakery, good hou se-keeping, pest control,

refrigeration of perishable prod ucts, segregation of certain r aw and cooked items,

pr otective clothing). Many, if not all of the suggested examples of control and

monitoring p rocedu res will be familiar to you and may already be in p lace. All that isinitially required n ow is that you go back and d o this assessment in a more structured ,

formal and disciplined w ay.

Before d escribing how to carry out an assessment, it is necessary to u nd erstand wh at

some of the terms m ean.

Hazard: is anything that could potentially cause harm to a consumer (injury,

sickness, gen eral ill-health).

Critical Control Points: are the steps or points in the process wh ere the hazard s can

and mu st be controlled to ensu re that the hazard s are eliminated or red uced to a safe

level. NB The term critical points is used in the Regulations.

Food H azards

There are three main typ es of hazards w hich are likely to occur in a bakery and could

result in contamination of the food:-

(a) Microbiological - pathogenic micro-organisms and their toxins, includ ing

bacteria such as Salmonella spp, S taphylococcus aureus.

(b) Physical - foreign bodies such as p aper, string, wood, plastic, metal, stone,

hair, glass, mou se dropp ings.

(c) Chemicals - such as cleaning chemicals, lubricating oils.

More specific examp les are given in the tables at the end of this section.

(a) Analysis of the Potential Food Hazards in a Food Business Operation

Initially you need to think in gen eral terms about the typ e of produ cts you

produce, eg bread, flour confectionery, cream cakes, savouries and which

of the three types of hazards n eed to be considered.

The first step in actually carrying out a hazard analysis is to then w ork

out/ run through the various steps/ stages of how the produ ct is made. To

make th is easier, it is recomm ended that the var ious stages in the p rodu ction

are written dow n. The format which is norm ally used is a flow diagram or

chart (see pages 10, 13 & 16 for examples).

4 Food Safety (General Food Hygiene) Regulations 1995 Guide to compliance by Bakers


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It is not necessary to prod uce a flow chart and a Hazard Analysis for each prod uct, as

this would be impractical for a craft bakery prod ucing many hu nd reds of different

prod ucts. The produ ction p rocesses are very similar, the only difference between one

prod uct and an other may be a change in the principal ingredient eg white flour to

wh olemeal flour or the u se of a different piece of equipm ent eg roll mou lder to french

stick m oulder. Therefore, irrespective of the pr odu cts being prod uced, the hazard s

may be the same.

For simp licity, prod ucts should be group ed together, for a typical craft bakery the

group ings could be:

bread and rolls

flour confectionery

fresh cream filling

egg custard s

meat prod ucts - raw an d cooked

sandw iches (if made centrally in the bakery).

(b) Identification of the Points in the Op eration where Food Hazardsmay O ccur

At each generic stage in the process the various p ossible hazards need to be

ident ified. Your existing contr ol measures, if any, need to be reviewed to ensu re they

are adequ ate. If no controls are in p lace then consideration needs to be given to how

the hazard identified can be controlled. It will then be p ossible to identify w hich are

the critical control point s.

Hazard Analysis is not an end itself, it can be a tool for prod ucing a detailed

set of operating pr ocedu res based on good m anu facturing p ractice wh ich

will ensure the safety of the prod ucts prod uced.

Examp les of the various hazard s to be considered and possible control methods for

the p rodu ction of bread and rolls, the filling of fresh cream cakes and the p rodu ction

of meat p ies are contained at th e back of this section (pages 9 to 19).

(c) Identifying Critical Control Points

To decide whether a step in the process is a critical control point, you have

to ask the question: Is it necessary to control the hazard at th is stage,

or will a subsequent step redu ce or eliminate the hazard ?

Examp le One

Raw ingredients such as m eat may contain food p oisoning bacteria, but if

the raw ingredients are stored and hand led correctly, the baking of the final prod uct

(if done properly) will eliminate or red uce these to a safe level.

Therefore in this instance the d elivery, storage and prep aration pr ior to

baking are not Critical Control Points, as baking will control the hazard .

Therefore in this instan ce, baking is the Critical Control Point.

Nevertheless, at all the previous stages in p rodu ction to m inimise the

growth of any food p oisoning bacteria and in particular any toxins they may

prod uce, the raw ingredients should be kept refrigerated.



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Example Two

Opening of a flour bag could r esult in a p iece of the stitching from the neck of the bag

or a p iece of flour bag becoming d etached and falling on to the top of the flour.

In this instance, the visual inspection of the flour prior to tipping into the m ixing bow l

and the removal of any contamination p resent is the Critical Control Point. There is

no other stage in the process wh ere this contamination could be seen and removed .

(d) Monitoring of Critical Control Points

Critical Control Points mu st be monitored. How ever, the type of monitoring will

dep end on the n ature of the control, and size of the bakery.

To be able to monitor a Critical Control Point, there must be some measure/

standard / target against which the control measure at the Critical Control Point can be

assessed.

The measure (stand ard/ target) may be very simple eg visual assessment, to

check such things as:-

in code or out of code

clean or dirty

damaged or satisfactory

satisfactory or un satisfactory stand ard of dress.

In these instances, it is either right or wrong.

How ever, other measures (standard s/ targets) may require a physical

measurem ent to take place such as monitoring or taking a temp erature eg

temperatu re of r efrigerator.

In some instances, there may be a tolerance or allowance permissible before

corrective action must be taken

eg temperature of fresh cream on delivery

target temp erature 8 C (2 C allowance to allow for hand ling d uring

delivery)

q accept u p to a m aximu m of 10 C.

q reject delivery above 10 C.

Monitoring should be kept as simple as possible, provided it is effective.

For example -

(i) A visual check of a delivery of ingredients to ensure the packaging is

not dam aged or d irty, there is no sign of infestation and the prod ucts

are in code.

(ii) A visual check on the cleanliness of the equipment.

(iii) Monitoring or m easuring the temperature of a chiller.



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Where a m onitoring procedu re shows that the control has not been effective, it

is importan t that Corrective Action is taken to ensure the safety of the food.

For example -

Poor cleaning of food contact Do not use. Take out of use,

equipment - reclean, use alternative clean

equipment. Find out why the

equipm ent was not cleanedproperly.

Contamination of an ingredient by its Do not use. Where possible

packaging - remove the contamination,

reinspect before use. If the

contamination cannot be

removed, d ispose of the

ingredient.

Refrigerator/ chiller too w arm - Check u nit is not on defrost -

recheck; if still too w arm - adjust

or repair. Check condition/

temperatu re of the food. If

satisfactory, mov e food to

another refrigerator/ chiller. If

you ar e not certain th e food is

safe, disp ose of the food.

Staff mu st be aw are that if a control is ineffective:

(i) Corrective action must be taken.

(ii) What the corrective action should be.

(iii) Who should take the corrective action (if it is not themselves) and to

notify them accordingly.

Where appropriate, report to the supervisor/ manager/ proprietor that the

control w as ineffective and corrective action h as been taken. This allows, if

necessary, the control procedure to be reviewed.

(e) Review

Hazard Analysis is not a once and for all process. It must be reviewed

periodically to ensure it is still valid as new hazard s may h ave been

identified. Also, control measures or monitoring p rocedures m ay have been

altered because they w ere ineffective, imp racticable or even u nnecessary.

It must also be reviewed wh en there is a change in the op eration of the

business, wh ich may introdu ce new hazard s or will require new/ different

controls and mon itoring p rocedu res. For example -- new lines are in troduced with new ingredients,

- equipment is replaced, so cleaning procedures may need modifying,

- a new oven is installed, the baking times and temperature may be

different,

- the packaging of an ingredient alters from glued/ easy to open to

string stitched bags,

- new equipment is introduced, like a cream machine to replace savoy

bags so new cleaning p rocedu res will be required.

Establishing a System

As stated in section (e) above, hazard analysis is not a one-off analysis of theproduction processes (an analysis of haza rd s). Rather it is the creation,

establishment of a continuing system of effective controls and monitoring

procedu res which can evolve over time and wh ich w ill require periodic review.



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Records

There is no legal requirement to fill in an d keep records of checks and mon itoring

procedu res carried out. How ever, they can be useful in allowing a m anager or

supervisor to check a procedure is being followed. They are often invaluable in the

event of an enqu iry or investigation by an Environmental Health Officer and in helping

to substantiate a Due Diligence defence.

It is good p ractice to keep records. These may involve the use of special reporting or

recording sh eets eg cleaning checklists, temp eratu re check logs.

In some instances, existing documentation can be utilised, eg the results of a

visual check on a d elivery of ingredients can be recorded on th e delivery note:-

i.e. d elivery ch ecked an d satisfactory

four bags of X dam aged an d rejected.

Records should be kept as simple as possible and the staff involved m ust be instructed

and / or trained to ensure any measurements/ assessments are completed correctly.

Documen tation of Hazard Analysis

Although there is no legal requirement to documen t your H azard Analysis system, a

brief written explanation of the Hazard Analysis carried out w ould be helpful in

(a) show ing the Environmental H ealth Officer that this regulation has been

complied with;

(b) ensuring that all steps/ stages in the p rocess have been covered; and

(c) reviewing the system.

It is good practice to document the Hazard Analysis.

For some comp anies operating more than on e prod uction unit, bakeries or

bake-off operations, the full Hazar d Analysis may n ot be present on site, but h eld at a

central location where the decisions are made eg Head Office.

How ever, various written p rocedu res, instructions, forms an d check sheets arising from

the Hazard Analysis may be present.

Further Information

Further gu idance on ap plying the p rinciples of Hazard Analysis are available in:-

- Assured Safe Catering (ASC) Department of Health

- SAFE (Systematic Assessment of Food Environm ent) British HospitalityAssociation

Both of these booklets, whilst prepared for the catering industry, contain a lot of useful

advice on food p oisoning organisms and the hazard s that may occur.

- A Gu id e to Food H azar ds an d You r Bu sin ess Dep ar tm en t of H ealth

(See References in Par t 6 for further deta ils).



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The three following examples of possible hazard control and m onitoring

procedu res are for:-

(a ) Bread and Rolls

(b) Fresh Cream Filling and the Finished Cake

(c) Meat Pies

The examples are for illustrative purposes only. They do not form part of the

comp liance with th e legal requirem ent.

They are not a comprehensive list of all the possible hazards and all the possible

control and monitoring procedures.

Their p urp ose is to assist bakers in thinking about th e types of hazard s there are,

wh ere in the process these hazard s can occur an d some of the control and

monitoring procedures which can be used.

The controls and m onitoring procedures w hich you as the prop rietor decide to

pu t in p lace to control a particular hazard may be on e, several, all or none of the

controls listed against th at hazard in the accomp anying tables.

If a hazard exists there mu st be an effective mean s of controlling it. The control is

up to you, as the p roprietor of the business, to decide.

GO OD PRACTICE



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EXAMPLE OF A PRODUCTIO N FLOW CHART FOR BREAD AND ROLLS

GO OD PRACTICE

Ingredient Delivery

Storage

Chilled

Dispense

Frozen

Storage Am bient

Mixing

Dividing

Moulding

Proving

Baking

Cooling

Packing/ Wrapping

Source of Ingredients

Ambient

Storage

Decorating w ith Seeds

Dispatch



18/104

Dispense

Possible H azards

Contamination with Pesticides, Herbicides, other chemicals.

Contamination w ith foreign bod ies.

Infestation.

Packaging Damaged/ Dirty.

Contaminated by Other Produ cts carried, eg Chemicals.

Infestation.

Deterioration of Ingred ients, (out of code).

Contamination of outer p ackaging.

Contamination of opened part-used products.

Infestation.

Deterioration of Ingredients stored too long (out of code).

Contamination of Ingredients by packaging.

Foreign bod ies in ingredients.

Possible Control and Monitoring Procedu res

Repu table Supp liers.

Repu table Supp lier

Ingredients screened (sieved, filtered, metal detected) by supplier.

Written confirmation of screening, pest control procedures.(Sup plier Au dits).

Direct Delivery from Sup plier.

Delivery via General Bakery Ingredient Supplier.

Visual check.

Visual Check.

Agreed Code Life on delivery.

Store covered. Store in clean, well main tained ar ea.

Reseal boxes or bags. Turn the tops of bags or polythen e liners over. Transfer to clean lidded containers.

Regular cleaning, pest control measures.

Ensure ingred ients are date-coded . Use on first-in-first-out basis. Rotate stock. Use by recomm end ed date.


19/104

Opening p rocedu re for ingredient packaging. Do not open over mixing bowl.

Visual check.


20/104

Possible Hazards and Controls for Bread and Rolls

Source of Ingredients

Delivery of Ingredients

Storage Ingredients

Dispense

Contamination with Pesticides,

Herbicides, other chem icals.


Infestation.

Packaging Damaged/ Dirty.

Contaminated by Other Products

carried, eg Chem icals.

Infestation.

Deterioration of Ingred ients, (out of

code).

Contamination of outer p ackaging.

Contamination of opened

part-used produ cts.

Infestation.

Deterioration of Ingredients stored

too long (ou t of code).

Contamination by ingredient

packaging, eg pap er, string stitching,

plastic film, yeast wrapper.

Contamination by other ingredients.

Contamination of dispensed

ingredient.

Reputable Suppliers.

Reputable Suppliers

Ingredients screened (sieved, filtered,

metal detected) by supplier.

Written confirmation of screening, pest

control procedures.(Supplier Audits).

Direct Delivery from Supplier.

Delivery via General Bakery Ingredient

Supplier.

Visual check.

Visual Check.

Agreed Code Life on delivery.

Store covered. Store in clean, well

maintained area.

Reseal boxes or bags. Turn the tops of

bags or polythene liners over. Transfer

to clean lidded containers.

Regular cleaning, pest control measures.

Ensure ingredients are date-coded. Use

on first-in-first-out basis. Rotate stock.

Use by recommended date.

Opening procedure for ingredient

packaging. Do not open over mixingbowl. Visual check.

Clean dispensing equipment between

batches of ingredients for different

products. Use separate utensils, scales,

equipment.

Keep covered when not in use. Keep in

lidded containers.

Possible Control and Monitoring ProceduresStages on Flow Ch art Possible Hazards



21/104

Intermediate Storage

Mixing/ Processing

Baking

Cooling

Packing/ Wrapping

Storage

Dispatch

Contamination by/ from d irty

damaged containers.

Contamination from dirty

equipment.

Contamination from damaged

broken utensils or equipm ent.

Metallic contamination at some

stage.

Contamination by foreign bod ies.

Survival of spores which can cause

mould or rope.


equipm ent, cooling r acks.

Contamination by fragments of

packaging.


baskets/ trays.

Contamination by dust/ debris.

Outside of prod uct contaminated ,

packaging damaged or d irty.

Use clean containers, in good condition.

Cleaning in accordance with cleaning

checklist/schedule.

Use of clean equipment and utensils.

Cleaning checklists or schedules.

Regular inspection, maintenance, repair,

replacement of damaged items. Formal

procedures to report damage.

Regular inspection,

maintenance,replacement/

repair of damaged equipment. Procedure

for reporting damage. Procedures for in-

house or contract engineers detailing

precautions to be taken. Thorough

cleaning after maintenance. Inspectionprior to production.

Staff awareness/training in basic hygiene

procedures. Personal hygiene rules.

Good house-keeping. Control of

maintenance engineering contractors.

Good quality flour, stored in a cool

place, turned over quickly. Use of

preservatives. Set baking times and

temperatures.

Regular cleaning. Cleaning checklists orschedules.

Ensure inserts are free of debris.

Remove debris, packaging waste

regularly.

Use of clean baskets or trays.

Store in clean area.

Pre-dispatch check.

Stages on Flow Chart Possib le Hazards Possible Control and Monitoring Procedures



22/104

EXAMPLE OF A PRODUCTIO N FLOW CHART FOR A

FRESH CREAM FILLING AN D TH E FINI SHED CAKE

GO OD PRACTICE

Delivery of Cream

Storage

Whipping

Filling of Savoy Bag

Storage

Piping Storage of Savoy Bag

Packaging/ Wrapping

Dispatch

Storage of Whipp ed Cream



23/104

Possible Hazard s and Controls

For Fresh Cream Filling and Finished Cake

Source of Cream

Delivery of Cream

Storage

Whipping

Contaminated w ith food poisoning

bacteria and/ or high levels of other

bacteria. Contaminated with foreign

bodies

Dirt on ou tside of containers.

Containers dam aged, leaking.

Microbiological growth caused by

the wrong temperatures due to non-

refrigerated vehicle, refrigerator

malfunction, produ ct left outsidebakery.

Growth of bacteria du e to poor

temperatu re control.

Cross-contamination.

Deterioration, growth of bacteria

because stored too long, (out of

code).

Foreign bod y contamination from

container.

Bacterial, physical or chem ical

contamination eg by cleaning

chemical residues du ring whipp ing.

Bacterial growth d uring w hipp ing.

Bacterial contamination from staff.

Foreign bod y contamination from

staff, environment or equipm ent.

Reputable Dairy. Copies of Dairys

Bacteriological Results.

(Audit Dairy).

Direct delivery from Dairy in enclosed

vehicle. Visual check.

Direct delivery from Dairy in

refrigerated vehicle. Agreed delivery

temperature for the cream of less than 8 C. Delivered when bakery open.

Check Temperature of Vehicle,

between pack temperature, temperature

of the cream.

Store refrigerated/cool (below 8 C).

Monitor temperatures of the refrigerator

daily.

Store containers away from raw food.

Store on separate shelves. Store above

raw food. Separate chillers for raw food.

Ensure cream is date-coded. Use on

first-in-first-out basis. Rotate stock.

Observe use by dates.

Opening procedure, ensure any sealing

strips are removed and disposed of.

Use clean and sanitised equipment and

utensils. Rinse equipment after cleaning.


Whip in a cool area of the bakery. Whip

only what is required at that time. Use a

refrigerated whipping machine.

Staff awareness, training in basic

hygiene procedures. Hand washing.

Covering of cuts. Reporting of any

diarrhoeal illness, vomiting or infected

cuts etc. Strict personal hygiene rules.

Strict personal hygiene rules, protective

clothing, good house-keeping. Regular

inspection and maintenance of

equipment and utensils.

Possible Control and Monitoring ProceduresStages on Flow Chart Possib le Hazards

14 Food Safety (General Food Hygiene) Regulations 1995 Guid e to compliance by Bakers


24/104

Storage of Whipped

Cream

Filling Savoy Bag

Piping

Storage of Savoy Bag

Packing/ Wrapping

Storage

Dispatch

Bacterial Cross-Contam ination.


Growth of Bacteria.

Bacterial and / or physical

contamination.

Foreign bod y contamination.

Bacterial contam ination from staff.

Bacterial growth in bulk cream.

Bacterial growth du e to continual

use of same savoy bag.


See Storage of Whipp ed Cream.

Bacterial growth .

Contamination from d irty trays.

Contamination by fragments of

packaging.

Contamination from residues of

previous p roducts on equipment.

See Storage of Whipp ed Cream .

Cross-Contamination.

Bacterial growth .

Segregation. Store covered. Store on

separate shelves, store cream above raw

food including shell eggs. Store in

separate chiller to raw food.

Store covered.

Store refrigerated or in a cool place(below 8 C).

Monitor temperatures of the refrigerator

daily.

Use new disposable savoy bags. Use

clean and sanitised savoy bags.


Ensure savoy bags and equipment are

undamaged.

As previous (Whipping).

Minimise time out of refrigerator.

Return to refrigerator after filling savoy

bag.

For long periods of creaming, change

savoy bags regularly.

Chilled preparation area.

As previous (Whipping).

Minimise time out of refrigeration after

piping.

Use clean trays.

Line with clean food grade paper

(unwrapped goods).

Ensure inserts/trays are free of debris,

remove packaging waste regularly.

Ensure equipment is clean and sanitised

regularly.

Cleaning checklist or schedules.

Segregation of raw and ready-to-eat

products. Dispatch in separate trays,

cover or stack the trays, store ready-to-

eat above raw products. Use separate

racks.

Minimise time out of temperature

control. Pre-cool the cream cakes prior

to dispatch. Dispatch in insulated boxes.

Use a refrigerated vehicle.

Stages on Flow Chart Possib le Hazards Possible Control and Monitoring Procedures



25/104

EXAMPLE OF A PRO DUCTIO N FLOW CH ART FOR M EAT PIES

(NB THIS D OES INCLUDE THE PROD UCTION O F THE PASTRY)

GO OD PRACTICE

Sour ce of Meat

Delivery of Meat

Storage of Meat

Dispensing of Ingred ients for the Filling

Cooking of th e Filling

Filling into th e Pastry Shell

Baking

Cooling

Storage

Dispatch

NB Time related exemptions from

temperatu re control for certain typ es of

meat p ies, pasties and sau sage rolls are

detailed. See on page 65.

Cooling of the Filling

Storage of the Cooled Filling

Jellying

Cooling



26/104

Source of Meat

Delivery of Meat

Storage

Dispense of the

Ingredients for the

Filling.

Cooking o f the Filling

Contaminated with very high

levels of bacteria.

Contaminated with foreign bodies,

eg bone, plastic, metal.

Contamination by general debris

(open trays).

Contamination from dirty trays.

Microbial grow th, high levels of

bacteria possibly causing sliminess

or sourness (due to poor

temp erature control,

non-refrigerated vehicle, chiller unit

malfunction.)

Growth of bacteria due to p oor

temp erature control.

Contaminated with p iece of plasticfrom d elivery tray broken off in

storage.

Contaminated by p iece of plastic

film/ bag from meat wrapping.

Contaminated by p lastic or metal tie

on bag.

Contaminated by p iece of film wh en

cutting/ tearing open knotted bag.

Contamination by pap er string from

dry ingred ient packaging.

Inadequate cooking, bacteria n ot

destroyed.

Possible Hazard s and Controls for Meat Pies

Stages on Flow Ch art Possible Hazards

Reputable Suppl i er . If smal l l ocal butch-

er , vi sit annual l y. Ensur e clean, wel l

managed, fr ee f r om pests.

Del i ver cover ed or wr apped i n pl asti c or

i n

plastic bags.

Deli ver i n clean tr ay.

Agr ee a del i ver y t emper atur e for the

meat, ( pr efer ably 5 C or l ess) . Take

temper atur e of the vehicl e. Pr obe between

packs or pr obe the meat on del i ver y.

Stor e r efr i ger ated ( pr efer ably below 5

C) .

Moni tor temper atur es of t he r efr i ger ator

dai l y. Recor d temper atur es. Pr ocess

i mmediatel y on ar r i val .

Check t r ays undamaged.

Check f i l m i n one pi ece, no fr agments

missing.

Meat del i ver ed i n highly col our ed pl asti c

f i lm .

Do not accept bags wi t h pl ast i c or metal

ties.

Do not accept k notted bags, f ol d fi l m overmeat.

Cut bag cl eanl y bel ow t he knot, account



27/104

Cooling of Filling

Storage of Filling

Filling into Pastry Shell

Baking

Growth of bacteria not killed in

cooking.

Contamination from dirty trays.

Contamination by raw m eat from

trays.

Contamination by foreign bod ies.

Cross contamination of cooked

filling from raw food.

Growth of bacteria.

Contamination by dirt.

Contamination by previous raw

filling.

Contamination by food poisoning

bacteria from sta ff.

Contamination by foreign bodies

from staff (hair, jewellery).

Bacteria not k illed, cooking tim e

inadequate.

Pour f i l l i ng i nto shal l ow metal tr ays.

Al l ow t o cool i n baker y f or two hour s then

r efr i ger ate at 8 C or l ess.

Use cl ean tr ays.

Use di ffer ent tr ays for cooked fi l l i ngs.

Put t r ays on r acks wi th small gap between

each tr ay. Once cool , l i d, cover tr ays.

Stor e cooked fi l l i ng away fr om r aw f ood,

par ti cular l y meat and vegetables. Stor e

cover ed. Stor e on separ ate shelves cooked

above r aw. Stor e i n separ ate ar eas of t he

chi l ler . Use

di ffer ent chi l l er s for cooked and r aw.

Stor e r efr i ger ated at 8 C or l ess.

Monitor

temper atur es of r efr i ger ator dai l y.

Recor d

temper atur es.

Equi pment cl eaned and disi nf ected aft eruse. Visual Check.

Cl eani ng Checkl i sts.

Cl eani ng Schedul es.

Staff tr ai ned how t o cl ean, i mpor tance of

cl eani ng.

Equi pment t hor oughl y cl eaned and di si n-

fected af t er use.

Pr oduct made at dif f er ent t i me ( adequate

ti me for cleaning) .

Pr oduct m ade on dif fer ent day.

Di ff er ent equi pment used for r aw meat

f i l l ing .

Visual check.

Cl eani ng Checkl i st.

Cl eani ng Schedul es.

Staff tr ai ni ng, awar e of hazar ds.

Staff wash hands af ter goi ng to the toi l et .

Awar e of need to r epor t i l l ness, not t o

Stages on Flow Chart Possib le Hazards



28/104

Cooling

Jellying

Cooling

Storage

Dispatch

Growth of bacteria not killed by

cooking.

Contamination by d irt or foreign

bodies on th e trays or cooling w ire.

Contamination of gelatine pow der

by paper/ string from ingredient

packaging.


equipment.

Growth of bacteria in gelatine du e to

inadequate heating.

Contamination of the gelatine by dirt

or bacteria from dirty jellying

equipment.

Contamination of the gelatine by

foreign bod ies from the staff.


Growth of bacteria through slow or

inadequate cooling.

Cross contamination from r aw food.

Growth of bacteria.

Cross Contamination

Contamination from dirty trays

Grow th of Bacteria

Tr ansfer / sli de meat pi es on to col d tr ays

or

cool i ng wir es.

Al l ow to cool in baker y for 2 hour s then

r efr i ger ate at 8

C or l ess.

Use cl ean tr ays or cool i ng wi r es. Vi sual

check.

Opening pr ocedur e f or i ngr edi ent packag-

i ng. Vi sual check of i ngr edi ents.

Use cl ean equipment. Vi sual check.

Ensur e gel ati ne i s vi sual l y boil i ng i mme-

diately befor e use.

NB For Scotl and, t her e i s a speci fi c r egu-

l ati on i n the Food Safety ( Temper atur e

Contr ol ) Regul ati ons 19 95 r egar di ng the

handl i ng of

gel ati ne ( see page 76 ) .

Use cl ean and sani ti sed j ell yi ng equi pment.

Str i ct per sonal hy gi ene r ules, pr otecti ve

clothing.

Staff awar eness, tr ai ni ng i n basi c hygiene

pr ocedur es. Hand washi ng. Cover i ng of

cuts. Repor ti ng of any di ar r hoeal i l l ness,

vomi ti ng or i nfected cuts. Str i ct per sonal

hygiene r ul es.

Refr i ger ate immedi ately after j ell yi ng at

8 C or l ess.

Stor e away f r om r aw food, par ti cul ar l y

meat and vegetables. Stor e cover ed. Stor eon separ ate shelv es above r aw f ood. Stor e

Stages on Flow Chart Possib le Hazards



29/104

GUIDANCE ON GOOD PRACTICE

HAZARD ANALYSIS FORM

A blank suggested Hazard Analysis form is provided, as are a few examples

of how to do a Hazard Analysis.

The following p hrases may h elp wh en deciding w hat to wr ite:-

Hazard:- What can go wrong?

Control:- What can I d o about it, can I eliminate the

hazard or redu ce it to a safe level, what

preventative measures are there?

Monitoring:- How can I check?

Corrective Action :- What if its not r ight?

Ad ditional column s can be add ed to the form if you w ish. These could

includ e the person respon sible or wh at records are to be kept.



30/104


EXAMPLE OF A HAZARD ANALYSIS FORM

Product________________


31/104

Stage

in

Process

Delivery of

ingredients

Ingredients

covered by

statutory

temperature

controls

Dispensing

Mixing

Hazard

Packaging

contaminated or

damaged.

Infested.

Bacterial growth

du e to storage at

the wrong

temperature.

Contamination of

flour by packaging.

Contamination of

mix by flour bag

packaging.

Contamination by

dirty equipment.

Control

(underline

Critical

Control Points)

Reputable Sup plier.

Agreed m ethod of

delivery, clean

pallets, lined w ith

cardboard , palletfilm w rapped ,

delivered on

enclosed lorry.

Agreed delivery

temperature, eg

below 8 C.

Use easy open

bags, follow

procedure on the

bag.

Remove string

stitching cleanly

and dispose of in

waste bin.

Do not open over

the mixing bowl.

Use clean

equipment.

Monitoring

Procedure

Visual check on

arrival, record

findings.

Check temp erature

on arrival and

record.

Visual check of

sur face of the flour

prior to tipp ing.

Visual check. Staff

following

procedure.

Visual check.

Cleaning checklist.

Cleaning

schedules.

Corrective

Action

Reject

unsatisfactory

stock.

If above 8 C seek

ad vice, reject.

Remove pieces of

packaging, string.

Instru ct staff to

follow procedu re.

Instru ct staff to

follow procedu re.

Reclean.

EXAMPLE OF A PARTIALLY COM PLETED HAZARD ANALYSIS FORM



32/104

This section p rovides guidance on the ten Ch apters comp rising

Sched ule O ne of the Food Safety (Gen eral Food H ygiene)

Regulation s 1995, with the exception of Chap ter III wh ich is not

app licable to the bakin g indu stry.

Apar t from Chap ter X, the guidance is laid out in three colum ns:-

Colum n One

This quotes the p rovisions of each Chap ter compr ising Sched ule 1

and lists the legal requirements.

Column Two

This provides gu idance on the legal requiremen t in Column One

and sets out wh at practical measu res can be taken to comp ly with it.

Colum n Two m ust be read in conjun ction w ith Column O ne.

Whilst the guidan ce provides a recomm end ed w ay of complying

with the legal requirement, it may be possible to comp ly with the

Regulations by an alternative means. You d o not have to follow th e

recomm end ations in this Guide.

Column Three

This gives examp les of good practice. It is NOT a legal requ iremen tto follow the ad vice on good practice.

In some instances, the ad vice in the good practice column will

further explain an d/ or illustrate by examples the recommend ation

on compliance given in Column Two.

The ad vice in the good practice column is not comprehensive.

It is up to the prop rietor of the bakery wh ether they wish to heed

and implement the advice given or not. The advice has no legalstand ing with regard to enforcement or comp liance with the

Regulations.

3: The Rules of Hygiene 23

Part 3 THE FOOD SAFETY (GENERAL FOOD HYGIENE)REGULATION S 1995

THE RULES O F HYGIENE


33/104

Schedu le 1

Rules of Hygiene

Chapter IGeneral requirements for food p remises (other than moveable and / or temporary

premises such as marqu ees, market stalls, mobile sales vehicles)

Legal requirement

1. Food premises must

be kept clean

and maint ained in good

repair and condition.

Advice on good practice

It is good practice to 'clean as you go'.

The standard of cleaning should be

checked by a nominated person/

manager/proprietor. Cleaning checklists

and/or cleaning schedules should be used

to ensure that all areas and items of equip-

ment are cleaned regularly and nothing is

overlooked. (See Appendix 1, 2, 3). The

structure and services eg store rooms

extract ventilation should be cleaned peri-

odically. The frequency will depend on

the speed of soiling and potential for

infestation.

In flour stores and lofts, depending on the

build up of flour dust, walls should be

cleaned at least weekly and ceilings,

rafters and roofs at least monthly.

It is good practice that the periodic clean

for more complex plant and extract and

ventilation systems is a deep clean involv-

ing varying amounts of

dismantling of the equipment or

provision of access panels to allow all

areas to be cleaned. This deep clean willin many instances be part of the

routine servicing and maintenance of the

equipment and may only take place once

or twice a year. Often the work will be

done by specialist contractors. In this

instance a clear schedule of works should

be drawn up and agreed.

It is preferable to vacuum up spillages.

There should be a regular inspection of the

premises, preferably documented, to iden-

tify areas requiring repair or

refurbishment.

Repairs should be carried out regularly, eg

monthly.

Gu ide to compliance

Food pr emises must be cleaned

regularly. The p rodu ction of bakery

products will inevitably lead to flour

du st entering the atmosphere and

settling on to sur faces. A film of flour

dust on such surfaces is acceptable

du ring prod uction, even if prod uction

is not currently taking p lace in that

area. Similarly there will also be a

build up of working dirt and d ebris on

the floor and other surfaces. These

mu st be removed once the shift has

finished. In some bakeries, depend ingon wh o does the cleaning and because

of the variation in the shift ending

times, there will be a gap between the

shift end ing and the cleaning

beginning.

The standard of cleaning necessary will

also vary between parts of the prem ises

eg produ ction areas and the warehouse

or store room, p articularly wh ere areas

are only cleaned on a periodic basis eg

weekly, month ly, 3-monthly. Providing

there is no evidence that cleaning isbeing neglected, small amoun ts of du st

and debris are to be expected and are

acceptable. Major ingred ient spillages

mu st be cleaned up as soon as

practicable. How ever, very light

seepage from the end of the bag does

not justify the stripping d own of a

pallet and cleaning of all the stock and

the pallet. In flour stores and flour

lofts, particularly where flour tipping is

taking place, there will be flour dust

presen t on most surfaces. All spillages

mu st be removed d aily.

Food premises must be maintained to a

standard that will facilitate cleaning,

bearing in mind what th at part of the

premises is being used for. Damage

can occur at any time to structural

surfaces. Minor wear and tear such as

small areas of worn or chipped

paintwork or p laster, cracked floor and

wall tiles, must be attended to on a

regular basis. If the damage is in a

place which could result in prod uct

contamination eg on a roof beam above

a prep aration area, any loose materialshould be removed immediately and

the area made good as soon as

possible.

24 Food Safety (General Food Hy giene) Regulations 1995 Guid e to compliance by Bakers


34/104

Legal requirement

2. The lay out , design,

construction and siz e of

food premises shall -

(a) permit adequate

cleaning and/or

disinfection;

(b) be such as to

protect against t he

accumulat ion of dirt,

contact w ith toxic

materials,

the shedding of

particles into food

and the formation of

condensation or

undesirable mould on

surfaces;


The size of the bakery and the

equipm ent layout mu st either allow

access for cleaning around the

equipment or the equipment must be

moveable. Materials used in

construction will dep end in some

instances on the u se to which an areaor room is to be put an d the typ e and

frequency of cleaning which will be

required in that area. For areas wher e

no open food is stored or hand led eg

store room, warehouses, bare brick or

breeze block walls are acceptable, the

floor can be of concrete and the inner

surface of the roof can be precast

concrete, metal decking, wood . In

flour lofts, a wooden floor, and roof

with exposed wood en rafters and

beams is acceptable. (See Appen dix 4,

5).

Ledges and inaccessible areas should

be kept to a minimum .

All building materials must be safe for

use near food. They must not release

toxic vap our s or toxic mater ials

through contact.

The use of mater ials for ceilings/ roofs

which because of the environmental

cond itions are likely to shed par ticles

of paint, plastic, plaster, fibres mu st be

avoided.

Where such problems arise, the loose

material mu st be removed and the

affected area m ade good or covered in

as soon as possible.

Where steam or excessive hu midity

occurs some form of natur al or

mechanical ventilation/ extraction

should be provided. Alternatively, theprovision of add itional heat or better

insulation may prevent condensation.

Where cond ensation is still occurring

due to a particular process and/ or an

inherent problem with the

design/ construction of the building

and add itional ventilation is

impractical the affected areas must be

cleaned and / or redecorated regularly.


Bare brick or breeze block walls should be

painted, preferably with an epoxy resin

based paint.

Concrete floors should be sealed.

Wooden floors should be sealed.

Wall, floor junctions should be coved.

Overhead services such as cable trays,

pipe runs should be kept to minimum and,

if possible, a suspended ceiling installed

beneath. Pipe and cable runs should have

a smooth cleanable finish, U section fit-

ments should be avoided or installed

upside down to prevent dust and dirt col-

lecting. Services, light units should be

mounted flush to ceilings/

roofs or on rods or cables and

preferably not chains. Pipework should

not be boxed in because of the risk ofinfestation.

Any extract or ventilation system should

be cleaned and serviced regularly to

ensure it is operating at optimum

efficiency.



35/104

Legal requirement

(c) permit good food

hygiene practi ces,

including protection

against cross

contamination between

and during operations,

by foodstuffs,

equipment,

materials,

water,

air supply

or personnel

and ext ernal sources of

contaminat ion such as

pests; and


The layout must provide sufficient space

to allow high risk foods to be p repared

safely. Where the same equipm ent and

work surface is used, the preparation

mu st take place at different times and the

work su rfaces and equipmen t cleaned

and disinfected in betw een.

Where the same temperature controlled

storage facility has to be used, raw foods

mu st be stored aw ay from or below

cooked/ ready to eat foods.

Equipment requ irements are detailed in

Chap ter V.

Materials must not present a risk of

contamination and mu st be cleanable.

Water mu st be potable. See Chapter VII.

See provisions 5, 6 and 8 of this Chapter

and Chapter II 1(d).

Facilities for personal hyg iene mu st be

provided.

See prov isions 3 and 9 of this Chap ter.

Premises must be constructed an d

maintained so as to d eny access and

harbourage to p ests.

See Chap ter II(d), Chap ter VI 3 and

Chap ter IX 3.


High risk foods should be prepared in seg-

regated areas or rooms in the

bakery.

Possible entry points for pests should be

proofed. Holes in the external fabric

which could allow pests in should be

sealed eg with concrete or cement and if

necessary mixed with wire wool. Where

pipes, cables, trunking or ducting pass

through internal or external walls, all

holes and gaps should be filled. External

doors should be rodent-proof (eg bristle

strips, rubber compression seals for rollershutters, metal kickplates). Windows in

other parts of the bakery and ventilation

systems may require insect-proofing.

External

openings or doors may require proofing

against insects (eg insect-proof screen

doors, plastic strip curtains, rapid rise

doors). The perimeter of the building

should be kept clean and tidy. Any such

external storage should be kept to a mini-

mum as this will provide a

harbourage for pests. The areas should be

inspected regularly and unnecessary items

removed. The perimeter should be free of

vegetation with a hard stand or gravel bor-

der where possible.



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Legal requirement

(d) prov ide, w here

necessary, suitable

temperature conditions

for the hygienic

processing and s to rage

of products.

3. A n adequate num berof w ash basins must be

available, suitably

located and designated

for cleaning hands .


Provided the p reparation can be carried

out safely, eg by limiting the preparation

time, temperature controlled (chilled)

preparation areas or rooms for high risk

prod ucts are not required. Temp erature

controlled storage facilities mu st be

provided for those ingredients andfinished prod ucts which are required to

be kept refrigerated . These mu st be

capable of keeping the food at the

required temperatu re. Raw ingredients

and cooked, ready to eat products must

be kept segregated by storing in separate

areas of the refrigerator or on separate

shelves with cooked abov e raw. (See

Cha pter IX (2)).

The number of wash hand basinsrequired will dep end on a num ber of

factors, including:-

(a) The nature of the products being

produ ced i.e. high risk, medium or

low risk.

(b) The amount of automat ion, or is

there a lot of hand work.

(c) The frequency of handwashing

needed.

(d ) The number of st aff.

(e) The size and layout of the bakery.

Utensils, equipment or clothes must n ot

be stored or washed in wash hand basins,

which m ust be kept free at all times and

designated for cleaning han ds.

There must be a wash basin situated close

to or within the toilet area. Han d

washing facilities must be p rovided at

strategic places in the production area.


The performance of the refrigeration

equipment should be checked by

monitoring their temperature. It is good

practice to record the checks. (See

Appendix 6).

The equipment should be serviced

regularly.

When preparing high risk ready to eat

foods, it is good practice to either chill the

food eg refrigerated cream machine or

chill the environment eg chilled

preparation room, or carry out the prepara-

tion at a cool time of the day eg early

morning. See provision 5 of this Chapter

for more details and Part 4 on the Food

Safety (Temperature Control) Regulations

1995. Separate

refrigerated facilities should be provided

for raw and cooked/ready to eat

products.

Commercial/industrial refrigerators and

freezers should be used. Separate

storage facilites should be provided for the

storage of ingredients and unbaked

partly-finished products to those for baked

and/or ready to eat finished

products.

Wash hand basins should be provided inareas, rooms where high risk foods are

prepared/produced. Where possible wash

hand basins or troughs should be situated

at the entrance to production areas.

Glazed earthenware basins are

acceptable, but are prone to

discolouration, cracking and wearing of

the glaze over time and to damage.

Stainless steel wash hand basins are pre-

ferred.

Access to the wash hand basins should not

be obstructed.

Wash hand basins should be suitably

marked, eg hand washing only.



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The Workp lace (Health , Safety and

Welfare) Regulat ions 1992 ap ply (See

App end ix 7). For existing bakeries,

Schedule 1 applies and the minimu m

requirement is one lavatory for u p to 25

persons, but separate male and female

lavatories must be provided .

For new p remises or any major

conversions, Regulation 20 app lies. The

minimum requirement where only men

are employed is one lavatory for up to 15

men. Where males and females are

employed, the minimum requ irement is

one toilet for up to 5 persons.

The lavatories must be connected to aneffective drainage system v ia a watertrap.

There must be an intervening space

between the toilet and a room whereopen food is handled. No food or

ingredients should be stored in this

intervening space.

Where there is no demonstrable risk

because food is wrapp ed or p ackaged eg

store room, warehou se, dispatch area, the

amou nt of intervening space n ecessary

will depend u pon w hat is necessary to

permit good hygiene practices in the

par ticular circum stances of the case.

Han d operated tap s and mixer taps are

acceptable. Hot w ater can be piped froma hot water tank or from a w ater heater

situated close to or above the wash hand

basin. The water heater can supp ly both

a wash hand basin and a w ashing up

sink.

A supp ly of soap (liquid or tablet) or

hand cleansing detergent or other

materials for cleaning han ds m ust be

provided.

Hand drying facilities must be availableat all times and may includ e:-

- d isp osable pap er tow els,

- fabr ic rolle r towels in cabinet s,

- p ap er roller tow els in ca bin et s,

- clea n w ash able fa br ic tow els

(changed frequently),

- warm air d ryers.

The sink used for washing food m ust not

be used for hand washing. Where food iswashed , a separate wash han d basin

should be provided


Toilet facilities should be within the main

bakery building. Where external toilets

have to be used the walk-way to them

should be covered.

Where open food is handled, the

intervening space should be ventilated bynatural or mechanical means.

A sign saying "Now Wash Your Hands"

should be displayed on the back of the

cubicle doors and/or in close proximity to

the wash hand basins in the

lavatories.

Non hand operated taps eg knee

operated, photo cell controlled are prefer-able, particularly where high risk foods

are handled. Water should be supplied at

a regulated temperature.

However, where the water is not at a con-

trolled temperature a plug should be pro-

vided.

A liquid bactericidal soap from a

dispenser is recommended, particularly in

areas where high risk foods are

produced.

Where warm air dryers are provided intoilets there should be sufficient so that

staff are not kept waiting. The use of toi-

let paper for drying hands should be pro-

hibited.

Bins for used paper towels should be pro-

vided and emptied regularly. There should

be a system for ensuring clean towels are

always available.

Individual washable fabric towels should

not be used in high risk areas.

Legal requirement

An adequate number offlush lavatories mustbe available andconnected to aneffecti ve drainagesystem.

Lavatories must not

lead directly into roomsin w hich food is

handled.

4. W ash basins for

cleaning hands must beprovided w ith hot and

cold (or appropriately

mixed) running water,

materials for cleaning

hands

and for hygienic drying.

W here necessary, t he

provisions for w ashingfood must be separate

from t he hand-w ashing

facility.



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Legal requirement

5. There must be

suitable and sufficient

means of natural or

mechanical ventilat ion.

Mechanical air flow

from a contam inatedarea to a clean area

must be avoided.

Ventilation systems

must be so

constructed as t o

enable filters and other

parts requiring cleaning

or replacement to be

readily accessible.

6. A ll sanitary

conveniences w ithin

food premises shall be

provided w ith adequate

natural or mechanical

ventilation.

7. Food premises must

have adequate natural

and/or artificial

lighting.


Ventilation either natu ral or mechan ical

mu st be provided to ensure an excessive

build u p of heat and/ or humidity which

could compromise the safety of the food

does not occur. In areas such as toilets,

store rooms and other areas where there

is no large heat sou rce air bricks, louvres,open w indows or small mechanical

extractors are sufficient. For produ ction

areas in small bakeries openable

wind ows can be sufficient and any

mechan ical extraction will normally be

localised to th e heat sou rce. The

Regulations do not requ ire a set num ber

of air changes per hou r.

Inlet ducts for the air supply forprod uction areas mu st be located aw ayfrom extract vents from such areas astoilets, van sheds, wash up areas, rawmeat prep aration areas and waste storageareas, so as to prevent a ir beingmechanically draw n from a contaminatedarea to a clean area.

Filters and any other parts of the systemthat req uire cleaning mu st be accessible.This may requ ire the fitting of accesspanels.

Natural ventilation can be by air bricks,louvres or openable wind ows.Mechanical ventilation can be of integralextract fan or part of a ventilation system.The ventilation provided mu st beadequ ate to prevent as far as possibleaerosols or offensive odours permeatingfood rooms.

Light levels m ust be sufficient to allow

safe food han dling, effective cleaning and

pest control to take place.


External openable windows should be

insect screened. The screens should be

kept clean.

Localised ventilation via extract canopies

or hoods ducted to outside should be

fitted above ovens, doughnut fryers and

other sources of heat and/or steam to

remove the heat and fumes. Where

possible filters should be installed in the

canopy or system to prevent grease and

dust collecting in the ducting. Normally

the extraction should be fan assisted. The

filters should be cleaned regularly. The

fans should be serviced regularly.

Further information is contained in theChartered Institute of Building ServicesEngineers Code (CIBSE).

Filters should be fitted and should be

removable. Fans should be installed on

external walls or roofs where they are

accessible for cleaning or removal to

allow access to the trunking/ducting.

The ventilation system should be

adequately screened against pests.

Uneven lighting, shadows or glare should

be avoided. Lights should be enclosed

where possible, particularly if there is a

risk of breakage or open food is being

handled eg diffusers, plastic sleeves orplastic coated fluorescent tubes. Lights

used in extremes of temperature eg in

freezers or ovens, should be capable of

withstanding the conditions.

Light fittings should be located so as to

minimise the risk of contact and

damage. Light fittings should be flush fit-

ting to assist in cleaning. All walk-in

chillers and freezers irrespective of size

should have lights which operate

independent of the door.

Suggested light levels are contained in the

Chartered Institute of Building ServicesEngineers (CIBSE) codes.



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Legal requirement

8. Drainage facilit ies

must be adequate for

the purpose intended;

they must be designed

and constructed t o

avoid t he risk of

contamination offoodstuffs.

9. Adequate changing

facilities fo r personnelmust be provided where

necessary.


There mu st be su fficient fall to allow a ll

solid and liquid w aste to drain aw ay.

Inspection points must be ad equately

sealed. Where sumps and sump pum ps

are used and there is a risk of

contamination of foodstuffs, the sump

mu st have a sealed, air-tight dou blecover. All waste pipes entering the

system mu st be water trapp ed. Fresh air

inlets or stack ventilation pipes must

terminate outside the building, or have

non-return breather valves fitted.

Staff must be able to chan ge out of their

outd oor clothing away from op en food.Depending on the size of the operation

and the num ber of employees, the

provision of lockers or cupboard s may be

adequ ate. Any add itional protective

clothing eg freezer coat shou ld be stored

away from open food.


Fat traps should be cleaned out regularly

outside of production.

Sump pumps should be serviced

periodically. There should be an

indicator light to show the pump is

working. The sumps should be cleaned

out regularly outside of production hours.

Drains should be laid so that the flow is

from clean to dirty areas. Gulley drains

must have a water trap.

Grids on open floor drains and drainage

gulleys should be cleaned regularly to a

set schedule.

A changing room with facilities for

storing outdoor clothing and other belong-

ings should be provided with hangingfacilities for outdoor clothing to dry. It is

good practice to provide

individual lockers. There should be

separate changing rooms for each sex.

Surfaces should be easy to clean. A recep-

tacle for dirty work wear should be pro-

vided.



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Chap ter II

Specific requirem ents in rooms w here foodstuffs are p repared, treated or p rocessed(exclud ing d inin g areas and those prem ises specified in Chapter III)

This Chap ter only app lies to rooms where food is processed. It does not ap ply to storageareas, dispatch areas or other an cillary areas such as toilets or changing rooms.

Legal requirement

1. In room s where food

is prepared, treated or

processed (excluding

dining areas) -

(a) floor surfaces m ust

be maint ained in a

sound condition and

they must be easy t o

clean and, where

necessary, dis infect.

This w ill require the

use of impervious, non-

absorbent, w ashable

and non-toxic

mat erials, unless the

proprietor of t he food

business can satisfy t he

food authority that

other materials used

are appropriate.

Where appropriate,

floors must allow

adequate surface

drainage;

Adv ice on good pr act i ce

A ny damage shoul d be r epai r ed as

soon as pr act i cabl e, ev en i f i t i s

onl y a

t empor ar y r epai r usi ng a f il l er t o

pr ovi de a cleanabl e sur f ace.

Wat er can be r emoved by mops,

squeegees, w et v acuum cl eaner s,

scr ubber dr i er s. Wher e dr ai ns or

gull ey s ar e pr ov i ded, t he f l oor

shoul d slope towar ds them.


Floors must be kep t in a good state of

repair to enable them to be cleaned.

The floor does not have to be

completely smooth, but it m ust be

cleanab le. Floors in a bakery are

unlikely to need disinfecting, p rovided

they are kep t clean.

The floor must be su fficiently ha rd

and du rable to remain intact and easy

to clean. Suitable mater ials include:

q ceramic tiles;q terrazzo tiles;q concrete suitably sealed or treated

with a waterproof epoxy resin based

floor paint or sealed w ith a

fluorosilicate;q epoxy resins;q metal p late;q natural minerals (slate marble).

Also acceptable, but not as hard

wearing, as resistant to physical/

chemical dam age or th e egress of

water are:

q vinyl tiles;q vinyl sheet;

(See App end ix 5).

The prov ision of floor d rains or

gu lleys is not generally necessary,

where water can be removed by

manu al or mechanical means.

Where considerable quantities of

water are used eg hosing down the

floor or in specialist wash u p areas,

floor dr ains or drainage gu lleys must

be provided.

3: The Rules of Hy giene 31


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Legal requirement

b) w all surfaces must

be maintained in a

sound condition and

they must be easy t o

clean and, where

necessary, dis infect.

This w ill require theuse of impervious, non-

absorbent, w ashable

and non-toxic

mat erials and require a

smoot h surface up to a

height appropriate for

the operations, unless

the proprietor of the

food business can

satisfy t he food

authority that ot her

mat erials used are

appropriate;

(c) ceilings and

overhead fixt ures m ust

be designed,

constructed and

finished to prevent t he

accumulat ion of dirt

and reducecondensation, t he

grow th of undesirable

moulds and the

shedding of particles;

(d) windows and other

openings must be

constructed to prevent

the accumulat ion ofdirt.


Walls mu st be kept in a good state of

repair. Wall surfaces do not have to be

of one material or typ e, eg tiles with

painted plaster above or coated

brickwork w ith washable pan els

above, are acceptable. Any loose,

flaky, powd ery material caused bydam age or general deterioration of the

wall surface or coating which could

become a contamination risk to

prod uct, should be removed

immediately and the wall refurbished

as soon as p ractical. Suitable finishes

include:

q ceramic tiles;q washable painted p laster or

rendering;q epoxy resin and similar coatings;q fibre glass;

q plastic cladding;q plastic coated fibre board or

chipboard;q refrigeration panelling;q metal sheeting.

In high risk areas wh ere food could

come into contact with the wall, the

sur face mu st be disinfected

period ically. (See Appendix 4).

Ceilings and overhead fixtures must

be so constructed and finished as to

prevent the accumu lation of dirt and

shou ld be cleanab le. Suitable

materials include:

q metal d ecking;q painted p laster or plasterboard;q plastic panelling;q suspend ed ceilings where the p anels

have a w ashable surface and

normally can be removed for

cleaning;q sealed (varnished) or painted wood .

Ceiling design and / or ventilation oradd itional heat can help to prevent

condensation. Where mould growth

does occur the area m ust be cleaned

and disinfected regularly and / or

redecorated.

The window openings, skylights and

doors shou ld have as few ledges,

ridges, decorative fixtures as possible.

Advi ce on good pr act ice

Wher e ther e is a li

Bakery Ind Hygiene

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