Food Safety in Manufacturing Level 3

Day 1 
Session 1 - Course Introduction  
Session 2 – Understand the requirements for ensuring compliance with food safety legislation and management procedures

• Recognize the importance of implementing food safety management procedures 
  
• Recognize the responsibilities of those working in a manufacturing environment in respect of food safety legislation and procedures for compliance 
• Identify the process for applying a food safety management system into a food business 
• Identify methods for, and the importance of, verifying food safety controls and procedures 
• Recognize the responsibilities of those working in a manufacturing environment when identifying and selecting suitable controls and monitoring, to prevent food safety hazards from purchase to service 

• Identify the process of implementing and maintaining high standards of personal hygiene within a manufacturing operation
  
• Recognize the requirements for induction and ongoing training of staff to ensure competency
• Identify the process of implementing procedures for cleaning, disinfection, and waste disposal
• Identify the actions that need to be taken with regard to pest control
• Recognize the responsibilities of those working in a manufacturing environment when identifying hazards posed by, and procedures to control microbiological, chemical, physical, and allergenic contamination
• Recognize the importance of, and methods for temperature control within a food manufacturing process

• How good personal hygiene in a food manufacturing environment can reduce microbial, chemical, physical, and allergenic contamination

Day 2
Session 5 – Recognize the importance of implementing food safety management procedures

• Food hygiene/safety 
  
• Food poisoning 
• Food safety hazard 
• Food safety management system
• Contamination 
• Cross-contamination 
• Causative agent 
• Food vehicle 
• Incubation/onset time 
• Pathogen 
• Common symptoms

• Recognize the responsibilities of those working in a manufacturing environment in respect of food safety legislation and procedures for compliance:
  
• Awareness of requirements for HACCP based procedures 
  
• Temperature control 
• Contamination 
• Handling practices 
• Personal hygiene 
• Cleaning and disinfection
• The role of those working in a manufacturing environment in internal and external food safety inspections/audits 
• The role of those working in a manufacturing environment in dealing with food complaints, food poisoning allegations, and investigations
• The role of those working in a manufacturing environment during a food safety inspection Importance of accompanying enforcement officers 
• The importance of accurate written records 
• The potential consequences of non-compliance or the prosecution of a manufacturing business and awareness of the penalties that can be applied to both food handlers and food business operators for non-compliance with food safety legislation 
• Due diligence defense

Day 3 
Session 7 – Identify the process for applying a food safety management system into a food business
Food safety management systems 

• The importance of identifying hazards, control measures, monitoring actions, corrective actions, verification and validation, and documentation at steps in the manufacturing process which are critical to food safety
• Responsibilities and daily activities of food handlers and supervisors to implement and monitor food safety practices and procedures, including opening and closing checks o Role of those working in a manufacturing environment in ensuring appropriate corrective actions for deviations from control points in food production, including supervisory actions to take when performance does not achieve standards and targets 
• The importance of providing feedback to those responsible for the food safety procedures and the types of issues you need to address 
• The importance of up-to-date, accurate documentation and records, and examples of the type of records that may be used in a manufacturing business

• Implementing and monitoring controls to minimize hazards from delivery and unloading o The importance of clear labeling of food 
  
• Ensuring and monitoring food storage conditions are suitable and specify the temperatures required for different food 
• Why stock rotation procedures are important Distinguish between ‘Use By’ and ‘Best Before’ date codes and explain why food past its code must be disposed of 
• Role of those working in a manufacturing environment in implementing and controls at the stages of thawing, preparation, cooking, cooling, reheating, holding, and serving food

• Identify the process of implementing and maintaining high standards of personal hygiene within a manufacturing operation
  
• Handling practices 
  
• Protective clothing 
• Fitness to Work, including the 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 handwashing, 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

• The objectives and benefits of food safety training to ensure competency 
  
• The importance of training records 
• How to communicate standards and procedures to staff 
• How to assess the competency of staff

• What to report, when to report, who to report to with regards to:
  
• Hazards, infestations/signs of pests, and spoilage in a food manufacturing environment

• 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, mold) 
• 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, include keeping raw and ready to eat separate, separate areas/sections for food production, use of correct equipment to prevent contamination (including color 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

• Common food pests 
  
• The main signs of pest infestations 
• Why food pests are a hazard to food safety 
• The role of those working in a manufacturing environment in preventing the access and harbourage of pests and in implementing suitable control measures
• The role of those working in a manufacturing environment in pest management

• Microbiological hazards posed by
  
• Raw food
• High-risk foods
• Low-risk foods
• Raw ready-to-eat raw foods
• Sources of contamination hazards
• The different types of microbes of interest to the food industry, including pathogens, low
• dose pathogens, spoilage, and beneficial
• The principal causes of microbiological multiplication and survival
• How good design can help avoid cross-contamination through workflow and layout

• Factors that influence the multiplication of food poisoning bacteria 
  
• The terms ‘bacterial spore’ and toxin 
• The conditions under which spores and toxins are formed and the consequences these may have for food safety 
• The temperatures which support the most rapid multiplication of food poisoning bacteria
• Suitable temperatures and/or timescales for thawing, cooking, cooling, and reheating alongside hot and cold holding of food. 
• Methods of minimizing and preventing bacterial multiplication including the need for good ventilation 
• The methods used to destroy food poisoning bacteria in food
• Correct use, and simple methods of, validating the accuracy of thermometers