Food Safety Management for Manufacturing Level 4

Day 1 
Session 1 - Course Introduction  
Session 2 – Understand how food business operators can ensure compliance with food safety legislation

• Explain food business operator and staff responsibilities with regard to food safety legislation 
  
• Analyze the requirements of food safety legislation and procedures for compliance and enforcement  

• Explain the requirements for temperature control within a specified food business 
  
• Discuss the implementation, management, and application of good hygiene practices, including cleaning, disinfection, waste disposal, and pest control 
• Explain procedures for the control of contamination and cross-contamination

• Outline processes for designing and implementing food safety management procedures, including allocating resources, roles, and responsibilities 
  
• Analyze the risks to food safety from microbial, physical, chemical, and allergenic hazards in a specified food business 
• Communicate food safety management information to staff, visitors, and suppliers

Day 2
Session 5 – Understand the controls required for food safety

• Review controls for microbial, physical, chemical, and allergenic hazards in a specified food business
  
• Discuss methods for monitoring and recording food safety hazards
• Determine the corrective actions required if food safety hazards are not controlled

• Explain methods for verifying the effectiveness of food safety management procedures Describe how to implement adjustments to food safety management procedures and the circumstances which may require adjustments to be made
  
• State the need for, and benefits of, staff training and the maintenance of training records Outline strategies for developing and maintaining a food safety culture within an organization

Day 3 
Session 7 – Food Safety and Contamination

• Explain procedures for the control of contamination and cross-contamination 
  
• Define key terms relating to food safety such as food safety/hygiene, food poisoning, contamination, hazard, risk, control, monitoring, corrective action, verification and validation, food safety management system, pathogen, and safe food
• Identify the benefits of good food hygiene and the cost of poor food hygiene
• Explain the importance of food safety procedures
• Outline different food types 
• Outline high-risk food 
• Outline low-risk food 
• Outline ready to eat and raw foods 
• Define the four main food safety hazards: microbiological, physical, chemical, and allergenic
• Examples of physical hazards
• Examples of chemical hazards
• Symptoms and side effects of allergenic reactions and examples of allergen
• Principle routes of contamination and cross-contamination 
• Hazards of food safety hazards are not controlled

• The main characteristics of micro-organisms including
  
• Structure, size, and shape of bacteria and distinguish between the main types of bacteria.
• describe how bacteria multiply, and identify factors influencing bacterial growth
• state the temperature range of the danger zone, optimum temperatures for bacterial growth, temperatures when most pathogens will stop multiplying, and temperatures where they will die 
• identify timescales involved in bacterial multiplication and explain the significance of the bacterial growth curve 
• Identify effective methods for microbes such as heat, usage of chemicals, and methods of preservation. 
• explain the terms ‘bacterial spore’, identify the role spores play in the survival of bacteria, describe the conditions under which spores are formed and the consequences these may have on food safety
• describe how some bacteria produce toxins and distinguish between exotoxins and endotoxins
• identify the signs of spoilage and identify what may cause spoilage o signs of spoilage include bacterial activity, enzyme activity, molds, physical damage 
• describe controls that can be utilised to control microbial and enzyme activity to reduce the rate of spoilage in food

• explain the main differences between food poisoning and food borne disease
  
• distinguish the differences between toxic and infectious causes of food borne illness 
• explain the symptoms, sources, incubation periods, and controls for the principal pathogens that cause food poisoning 
• identify groups of people most at risk from food poisoning 
• explain the symptoms, sources, incubation periods, and controls for the principal pathogens that cause food borne diseases 
• explain the symptoms, sources, incubation periods, and controls for food related viruses and protozoa
• know that chemicals, metals, poisonous plants and fish can cause serious problems in the food industry and provide examples of each
• identify the role of the manager, supervisor and food handlers in food poisoning outbreak investigation
• develop, implement and review procedures relating to food poisoning outbreak control 
• describe the role of the consultant in communicable disease

• explain hazards associated with infections, skin complaints, and injury and describe how these can be controlled 
  
• describe the responsibilities of all staff regarding personal hygiene 
• describe how non-food handling personnel (for example maintenance, contractors, visitors, delivery personnel) can contaminate food and be able to develop, implement and monitor procedures to control from these personnel 
• outline unhygienic practices to be avoided in food handling areas, describe how they may cause contamination and suggest suitable controls 
• describe the importance of hand wash and explain suitable procedures for effective hand wash. Outline important times when hands should be washed
• Handling practices 
• Protective clothing 
• Fitness to Work, including relevance of the term ‘carrier’ 
• Role of those working in a manufacturing environment in securing high standards of personal hygiene
• Open wounds and first aid dressings
• Hand washing facilities that should be provided in a manufacturing environment, and how these facilities can be managed and monitored on a day to day basis 
• Common barriers to effective hand washing, how to overcome these to ensure food handlers wash hands effectively at appropriate times and how this can be monitored 
• The importance of implementing and enforcing systems regarding the reporting of illness and infections promptly, and actions to be taken if a food handler poses a threat to the safety of the food, including the terms ‘healthy’ and ‘convalescent’ carrier

• state the need for, and benefits of, staff training and the maintenance of training records identify the benefits of training, and explain why planned training is essential within a food business
  
• explain how training can assist in the development of a positive food safety culture
• outline the legal requirements relating to the training of food handlers
• explain the factors requiring consideration (including content) when developing and implementing a food safety training program
• identify the benefits of assessing training needs for all levels of staff (including contractors and temporary staff) when developing a food safety training program
• state the importance of considering staff role, experience and skill and explain how barriers to learning such as language or literacy may be overcome 
• describe a variety of methods that can be used to effectively communicate information and responsibilities regarding food safety, including procedural and legislative changes describe sources of information and guidance which may be used when developing a food safety training program
• know the importance of implementing food safety training and outline methods by which this can be achieved
• explain the reasons for providing feedback to staff regarding food safety matters 
• outline the importance of developing supervisors to enable effective reporting from management to supervisor regarding food safety and outline the importance of refresher training

• Definitions of:
  
• Cleaning 
• Bactericide 
• Detergent
• Disinfectant 
• Disinfection 
• Sanitizer 
• Sanitization 
• Biodegradable 
• Contact time  
• The reasons for cleaning 
• How cleaning processes can be effectively supervised, including the use of cleaning schedules 
• The steps involved in cleaning and disinfecting or in sanitizing 
• The importance of using the correct equipment, utensils, and chemicals when cleaning 
• Safety precautions that should be considered when storing chemicals and cleaning, and when disinfecting work areas or equipment 
• The hazards associated with poor cleaning 
• The difference between ‘clean as you go’ and ‘scheduled cleaning’ 
• Typical areas in a manufacturing operation that will require cleaning, disinfecting, and/or sanitizing 
• The hazards associated with incorrect waste management 
• How to clear and dispose of waste safely

• Meaning of terms contamination, cross-contamination, raw food to be cooked, high-risk food, low-risk food, and ready-to-eat raw food 
  
• Types of microbiological contaminants (bacteria, virus, mould) 
• Common sources, routes and vehicles of microbiological contamination in a food manufacturing environment 
• Recognition of main characteristics of food poisoning bacteria, factors influencing microbiological multiplication and survival (including spores and toxins) and consequences these may have for food safety and basic controls 
• Examples of basic controls to prevent microbiological contamination, including keeping raw and ready to eat separate, separate areas/sections for food production, use of correct equipment to prevent contamination (including colour coding), reporting damaged equipment, including work surfaces 
• Examples of common physical hazards within food preparation areas and basic controls 
• Examples of common chemical hazards within food preparation areas and basic controls 
• Identification of common allergenic foods and risks associated with allergenic hazards. 
• Awareness of ways to prevent allergenic contamination during food production and allergen controls within food manufacturing

• identify hazards that may be present at each stage of food production and service including purchase, delivery, storage, preparation, cooking, hot holding, cold holding, and packing 
  
• outline the processes and potential hazards associated with interrupted manufacturing processes such as cook-chill, cook-freeze, and sous vide 
• explain the importance of reviewing potential hazards and controls in the event of a change, for example, the introduction of a new process, equipment, or product change
• identify suitable methods of selecting, and monitoring suitable suppliers 
• outline requirements for safe transport, delivery, and receipt of stock 
• outline how to monitor supplier food deliveries and describe suitable management actions in the event of poor supplier performance regarding food safety 
• describe and explain the principles of temperature control during storage for different food types and be able to develop, implement and monitor controls for ambient, chilled, and frozen storage of food 
• describe the principles of stock rotation and outline how to design, implement and monitor the effectiveness of the system 
• state the requirements of statutory date marking of food and explain the terms ‘use by’ and ‘best before’ and outline rules regarding labeling of both packaged and open foods 
• describe the types of food packaging available which is designed to reduce the risk of contamination 
• outline the role of management regarding the production and sale of safe food, including the need to identify staffing requirements and provision of other adequate resources 
• identify the role of management regarding the provision of suitable resources, equipment, and procedures for the transportation of food
• outline extra controls which may be required when providing food to vulnerable groups
• develop, implement, monitor, and explain suitable procedures for thawing, chilling, freezing, preparation, cooking, cooling, packing, labeling, and distribution of food
• outline the legal and recommended temperatures and conditions for storage, preparation, cooking, cooling, packing, labeling, and distribution of foods

Day 5
Session 14 – Food Safety Management and HACCP

• outline processes for designing and implementing food safety management procedures, including allocating resources, roles, and responsibilities 
  
• review controls for microbial, physical, chemical, and allergenic hazards in a specified food business
• identify the origin and purpose of HACCP based food safety systems 
• explain how the development and effective implementation of food safety management systems will benefit both consumers and food businesses 
• describe how food safety management systems may be developed, implemented, and maintained within a food business 
• identify and give examples of, expert guidance and support that a food business may need to develop and implement food safety management systems
• explain the basic terminology of HACCP 
• explain what is meant by a pre-requisite program, and explain the importance of prerequisites in a food business 
• identify the importance of a team approach when developing a HACCP study and discuss the attributes and roles required for team members  
• outline training that HACCP team members require 
• List and describe the seven principles of HACCP 
• explain the importance of determining the scope of the HACCP study, describing the product, and identifying the intended use and users 
• explain the importance of conducting a hazard analysis and describe how it may be carried out 
• describe the purpose of control measures and provide examples of controls that can be applied during the production and service of food 
• describe the significance of determining critical steps in the process and identify how they may be identified using the decision tree 
• outline the criteria that should be used to establish validated critical limits, tolerances, and target levels at each critical control point

• explain the importance of developing and implementing suitable monitoring procedures and identify how these can be developed and give examples of a variety of monitoring methods that may during the production and service of food 
  
• explain the importance of establishing suitable accurate recording systems and describe monitoring records that may be produced for the production and service of food 
• explain the manager’s role with regard to establishing roles, responsibilities, and reporting routes for the monitoring and supervision of control measures
• identify types of failures that may occur at critical control points and give examples of suitable corrective actions which may be applied during the production and service of food 
• explain the manager’s role with regard to establishing roles, responsibilities, and reporting routes for corrective action plans 
• explain why corrective action plans should be established in advance of failures and how this can help to prevent food safety problems
• describe documentation that should be developed as part of a HACCP study
• outline the legal requirements for food safety management systems

• communicate food safety management information to staff, visitors and suppliers 
  
• discuss managers’ role in ensuring food safety
• outline the manager's role in developing, implementing, monitoring, reviewing, evaluating and reviewing food safety procedures 
• describe ways to determine the success of food safety management procedures and outline how to audit, review and improve food safety management procedures
• state why all staff within a food business have responsibilities for food safety and outline the importance of clear reporting routes 
• explain the role and responsibilities of food handlers with regard to food safety, including following procedures and monitoring of controls  
• explain the role and responsibility of supervisors with regard to food safety 
• describe how effective supervision procedures can assist in ensuring food safety and outline methods of developing, implementing, monitoring evaluating and reviewing those procedures
• explain general content and importance of a food safety policy with reference to both routine and non-routine procedures 
• explain the importance of including policies and procedures regarding investigation of food poisoning allegations and customer complaints
• identify other relevant sources of further information advice and guidelines relating to food safety and identify when this may be required
• explain the importance of developing a positive food safety culture within a food business
• identify means of achieving and improving a positive food safety culture, for example effective development and communication of food safety procedures, provision of training and other resources, encouraging feedback, having clear reporting routes

• explain food business operator and staff responsibilities with regard to food safety legislation
  
• explain the role of authorized officers and enforcement authorities
• know-how legislation is applied 
• understand the role of enforcement authorities and authorized officers
• describe the purpose of codes and practice and industry guides and identify
• outline actions that may be taken by enforcement officers 
• know the implications of non-compliance with food safety legislation and the penalties which can be applied 
• explain the defense of due diligence in the food industry 
• explain the role of the manager with regard to the development, maintenance, and monitoring of food safety and explain how this will contribute to a due diligence defense