Training Manual For Meat Handlers

TRAINING MANUAL FOR MEAT HANDLERS
Bhutan Agriculture and Food Regulatory Authority

(BAFRA)
Ministry of Agriculture and Forests
FHTM/04/April 2014
FHTM/04/April 2014
1. INTRODUCTION
2. SCOPE
3. FOOD SAFETY
4. HAZARDS AND CONTROLS
5. GMP IN DESIGN AND FACILITIES FOR FOOD PROCESSING PLANT
5.1 General requirements
5.2 Environment
5.3 Location of establishment
5.4 Layout of premises and workplace------------------------------------------------------- 9
5.5 Utilities - air, water, energy ----------------------------------------------------------- 11
5.6 Waste disposal------------------------------------------------------------------------------- 12
5.7 Equipment suitability, maintenance, cleaning and sanitation
5.8 Control of operations - management of purchased materials
5.9 Prevention of cross contamination
5.10 Cleaning and sanitation
5.11 Pest control
5.12 Personal hygiene and employees facilities
5.13 Re-use or rework
6. STANDARD SANITATION OPERATING PROCEDURES
6.1 Water
6.2 Ice
6.3 Waste disposal
6.5 Glass / metal policy
6.6 Protection from adulterants
6.7 Rodent/ pest control
6.8 Cleaning and disinfection
6.9 Maintenance
6.10 Staff Cafeteria
7. SPECIFIC SANITARY AND HYGIENE REQUIREMENTS FOR RETAIL
SHOPS FOR MEAT AND MEAT PRODUCTS
7.1 Location
7.2 Size of meat shop
7.3 Premises
FHTM/04/April 2014
7.4 Ventilation
7.5 Equipment and other accessories
7.6 Transportation
7.7 Pest control
7.8 Personal hygiene
7.9 Sanitary practices
7.10 Other requirements
7.11 Operators’ Check System (Annexure II)
8. SANITARY AND HYGIENE REQUIREMENTS FOR ABATTOIRS
8.2 Location of premises
8.3 Premise requirements
8.5 Equipment & machinery
8.6 Personnel hygiene
8.7 Animal welfare
Annexure I
Annexure II - Operators’ Check System Log
REFERENCES:
FHTM/04/April 2014
1. INTRODUCTION
Food shall be clean and safe. This is not only the requirement of Bhutan alone,
but a current global demand today. Over the past two decades, consumers have
been exposed to a series of food safety scares including major outbreaks of Food
Borne Diseases (FBDs), food security issues, tainted food and feed supplies and
widespread prevalence of Bioterrorism. Under these uncertainties, there is a
growing need to address these issues in a scientific and transparent manner in
the national regulations of the country and make the Food Business Operators
(FBOs) aware of the mandate to ensure food safety in their areas of activities.
The urgent goal of food safety can be achieved only through the following:
• Strong regulations
• Inspection and monitoring activities
• Laboratory testing
• Education, training and competence
Bhutan has already established the food safety regulation in 2007 and is trying
to implement the same in the most practical possible manner. The country has a
national food testing lab under the regulatory authority which has already been
accredited under ISO17035:2005, catering to the routine testing needs of the
country. However, it is true that testing cannot eliminate the problem. It is the
commitment of all the stake holders in the food chain to see that such food safety
issues are not introduced into the food chain at any stage of the food handling,
storage or distribution. This preventive approach only can ensure clean and safe
food for the consumers and transform the country to a destination for safe food.
To achieve this goal, Bhutan has to develop the knowledge and the skill of all
involved in the food safety sector, not limited to the regulators, but all from farm
to table. Simple need based training to cater to the different sectors in food
handling is the need of the hour so that each one can be made aware of the
importance of the activity he is performing and the responsible person shall be
accountable for the food safety concerns in the products released by him.
Responsibility and accountability have to be shouldered by the FBOs under the

new regulation and the mandate of the regulators is to check and verify and
guide or take actions in case of violations or non compliances.
For this, training is the priority. This Manual deliberates scientifically the need
for Good Hygiene Practices (GHPs) and Good Manufacturing Practices (GMPs)
and the practical way in which many of these can be implanted in the meat
handling so that the FBOs can demonstrate their compliance to the food safety
officials during their visit to the facility. In other words, today under the global
food safety regulation the responsibility to ensure food safety has been shifted to
the FBOs. They have to design GMPs, practice, check, verify and keep records as
evidence to prove compliance. THIS IS WHAT IS DESCRIBED IN THIS
MANUAL. BAFRA food safety officials will be over viewing the system in place
in the food handling facility and will provide guidance for continual
improvement.
FHTM/04/April 2014
2. SCOPE
The manual specifies requirements for establishing, implementing and

monitoring the Good Hygiene Practices (GHPs), Good Manufacturing Practices
(GMPs) and the need for documenting the same for compliance with the national
food safety regulations and the specific regulations for meat and meat products.
Food business is diverse and food production and service differs in requirements.
However, safety requirements can never be compromised and accordingly this
manual has been developed to train and communicate to the food handlers
whether they are micro, small, medium or large, the basic hygiene and other
control measures to be applied in their facility to prevent a hazard introduced
into the products manufactured, packed and/or sold by them.
Any exclusions or alternative measures adopted should not affect the capability
of the organization to comply with these requirements. The exclusions or
alternative methods developed and applied need to be justified to ensure that
food safety and other legal compliances are not diluted.
Examples of such exclusions can be in;
• Construction, layout of buildings and associated utilities eg. street vendors

• Layout of premises, including work place and employees facilities
• Supply of air , water, energy and other utilities
• Supporting services including waste and sewage disposal
• Suitability of equipments and the accessibility for cleaning, maintenance
and preventive maintenance.
A small or medium establishment or a meat shop may have to alter many of the
points but it shall not affect the safety of the products they serve to the
consumers.
FHTM/04/April 2014
3. FOOD SAFETY
Safe Food
What is safe food? Is it a clean food which is safe?

A clean, tasty and well packed food need not be safe.
So what is safe food?
Codex defines safe food as “Food that will not cause any harm to the consumer
when it is prepared and/or eaten according to its intended use”. In other words,
food which is free of contaminants and will not cause harm, injury or illness.
What is contamination?
Contamination is the presence or introduction of a contaminant in the food or

food environment (EC Regulation No. 852/2004).
Contaminant
Contaminant is any biological or chemical agent, foreign matter or other

substances not intentionally added to food which may compromise food safety or
suitability.
Cross contamination
Cross contamination is transfer of contaminant particularly bacteria from

contaminated foods generally raw to ready-to-eat foods by direct contact, drip or
indirect contact using a vehicle such as hand, clothes, knife, thermometers, etc.
How to prevent cross contamination?
Through Hygiene or Good Hygiene Practices (GHPs)
What is Hygiene?
All measures and conditions necessary to control hazards to ensure food safety
and fitness for consumption of a food taking into account of its intended use (EC
Regulation No. 852/2004). This involves preventing objectionable foreign matter
getting into the food.
Application of food hygiene includes but not limited to;
• Rejecting contaminated food from suspected sources

• Protecting food from contamination such as pathogens, poisons, toxic
chemicals, allergens, and foreign bodies.
FHTM/04/April 2014
Food Poisoning
Acute illness usually with diarrhea and /or vomiting caused by the consumption
of contaminated or poisonous foods (multiplication of microorganisms and toxin
production occurs within the food).
Food Borne Disease (FBD)
An illness caused by consumption of food contaminated by pathogens,

characterized by having a low infectious dose and no requirement for the
multiplication of the pathogens within the food to cause illness. All hygiene
practices are based on the risk factors associated with foods.
Risk
Risk is the probability of occurring the problem. Based on the nature of the foods
identify how best it support the growth, multiplication and survival of pathogen
and leads to FBD.
How are foods categorized based on the risk?
High Risk Foods (HRFs)
HRFs are identified as vehicle for food poisoning and FBDs outbreak. RTE foods
support rapid growth of food poisoning bacteria. Intended use of RTE is without
further heating to destroy bacteria. Usually high protein and high moisture
content favours the growth. Highly perishable food requires refrigerated storage
eg. raw meat, fish, poultry etc. Cooked meat and poultry, dairy products, cooked
fish, shell fish, cook-chill meals, baby foods, etc. must be kept separate from raw
foods. Raw foods are often contaminated with large no of bacteria including
pathogens and it shall be kept separate from RTE foods even if frozen.
Low Risk foods
Normally kept in ambient temp as they cannot promote multiplication of

bacteria (dry products). This category of foods is rarely implicated for food
poisoning. Foods with high sugar content, acid or acidified foods, fried or dried
foods with low Aw (less than 0.85), baked foods, canned foods, powdered foods,
etc. are examples but once the powder is reconstituted, the same becomes High
Risk Foods.
Ready to Eat Raw Foods
These are always risky and should be protected from contamination, subjected to
washing and disinfection prior to consumption. Raw vegetables, salads, cooked
meat mixed with raw vegetables are few examples. There is always a risk from
low dose pathogens such as Salmonella, E.coli 0157 and so on. Good handling
FHTM/04/April 2014
practices, good storage practices and overall hygiene is the most important to
prevent contamination and multiplication and to avoid food poisoning.
What are the risk factors associated with foods and FBDs?
Understanding these risks is necessary to control them as we know it is the risk

that is to be prevented, eliminated or reduced to acceptable level through the
hygiene and prerequisite programs and hazard control.
The probable risk factors are;
• Cross contamination
• Raw materials from unsafe sources
• Inadequate heat treatment without proper validation
• Improper holding temperature and lack of good storage practices
• Contaminated equipment
• Poor personal hygiene
• Health status of the food handlers
• Poor water quality
• Lack of pest management
• Lack of training
• Lack of TCS system (Time, Temperature, Humidity Control System to
contain pathogens)
• The issue of Mycotoxins
Codex General Principles of Food Hygiene and Application of HACCP in food

handling establishments, if applied adequately, the concept of safe food can be
easily achieved. This document describes the minimum requirements to produce
safe and clean foods. The areas where the GMPs and GHPs are to be designed,
applied, complied with and maintained are described separately in this manual.
FHTM/04/April 2014
4. HAZARDS AND CONTROLS
Hazards
The objective of this section is to make the trainees aware of the types, sources
and routes of contaminating hazards including microbiological, chemical,
physical and allergens and understand their role in food safety. Hazard is an
agent in foods which causes disease / illness or injury to the consumers, eg.
pathogens in foods (present in raw materials or introduced at some time from
delivery to service).
Hazards are categorized into;
a) Microbiological
• Food poisoning bacteria or pathogens or their toxins in foods
• Spoilage bacteria
• Yeast and mold
• Viruses
b) Physical hazards or foreign bodies in the final product causing cuts,

choking, broken teeth and so on.
• building materials
• glass pieces
• loose metals
• plastic pieces
• stones
c) Chemical hazards
• Acute or chronic carcinogens
• Industrial chemicals (PCBs)
• Pesticide residues
• Drug residues
• Toxic metals (lead, arsenic, cadmium, mercury, etc)
• Cleaning chemicals
d) Allergic hazards
What is allergen?
Allergen causes the body’s immune system to react, often within minutes. In
serious cases, a person may face life threatening anaphylactic shock.
• Peanut, nuts (walnut, brazil nut, almonds)

• Milk (lactose)
• Eggs
• Shell fish
• Soya
• Cereals
• Sesame seeds
FHTM/04/April 2014
• Mustard
• Celery
All these hazards need to be prevented, eliminated or reduced to acceptable level

as specified in the regulations.
a) Control of bacterial hazards

• Remove sources
• Purchase from reputable suppliers
• Check delivery vehicles
• Inspect food on arrival
• Immediate storage
• Integrated pest management
• High standards of personal hygiene
• Visitors’ policy
• Control of cross contamination
• Prevention of multiplication of pathogens
• Destroying pathogens through processing
• Segregate fit and unfit materials
Remember 5 Cs - Clean, Cook, Cover, Chill, Cross-contamination.
Control of Physical hazards
Control of –
• Raw material
• Packaging materials
• Control of structure, equipments and machineries through maintenance
• Personal hygiene
• Pest control
• General control measures during processing by the use of sieves, filters,
magnets, color sorters, x ray machines, metal detectors, magnifying glass
Control of chemical and allergens
Control measures include;

• Reputable suppliers with declaration of all ingredients used (labeling)
• Segregation of materials with contamination
• Segregation of serving utensils with allergens in catering
• Prevention of cross contamination or carry over
• Labeling of the products
• Cleaning schedule and program
• Training of the personnel in handling of allergens
• Supervision
• Designated storage for allergen containing product controlled use
• Communication
In all food processing activities, micro, small or large, a documented system shall
be developed to identify hazards in all areas and evaluate them based on risk
FHTM/04/April 2014
and severity to determine which hazards are significant in a specific food product
so that the same can be prevented or eliminated to produce a safe product.
Hazards are specific to the products, process, the facility and the location. Both
Government and the industry shall work as a team to have a successful food
safety program in the country which requires commitment from all stake holders
in the food chain.
FHTM/04/April 2014
5. GMP IN DESIGN AND FACILITIES FOR FOOD PROCESSING PLANT
5.1 General Requirements
Building shall be designed, constructed and maintained in a manner appropriate

to the nature of the processing operations to be carried out, the food safety
hazards associated with such operations and the potential sources of
contamination from the plant environment. Building can be of durable
construction which presents no hazard to the foods produced. This is applicable
even to the mobile or street vending operations. For example, self draining,
roofing without stagnant water and leakage.
5.2 Environment
Consideration shall be given to potential sources of contamination from the local

environment. The effectiveness of measures taken to protect the product against
potential contaminants shall be reviewed regularly.
5.3 Location of establishment
Site boundaries shall be clearly identified and access to site to be under control
(exceptions shall be justified). The site shall be well maintained, fruit trees shall
not touch the buildings, roads shall be well maintained and the yards too.
Drainage facilities to be in good order and no stagnant water in the compound
near the facility.
5.4 Layout of premises and workplace
5.4.1 General requirements
Internal layout shall be designed, constructed and maintained to facilitate GHPs

and GMPs. The traffic inside the plant, of the materials, products and people and
the layout of the equipment shall be designed to protect against product
contamination sources.
5.4.2 Internal design, layout and traffic pattern
The building shall provide adequate space with a uni-directional flow of the
materials, products and personnel and physical separation of the raw from the
processing areas. Eg of separation include barriers, physical separation or
sufficient distance to minimize the risk of cross contamination. Openings or
chute doors for transfer of materials shall be designed to minimize entry of
foreign matter or pests.
FHTM/04/April 2014
5.4.3 Internal structures and fittings
Process area walls and floors shall be washable or cleanable as appropriate for
the process or product hazard. Materials of construction shall be resistant to the
cleaning system applied. Floor wall junctions shall be rounded off to facilitate
cleaning and prevent pest infestation. Proper slope for the floor must be provided
to facilitate drainage and to prevent stagnant water. All drains shall be sealed or
screened to protect the entry of rodents and vermins.
Sealing and overhead structures shall be designed to protect from condensation

drippings and dust accumulation. All external openings, exhaust vents shall be
screened. Exit doors and all external doors shall be self closing and tight fitting
and to be ensured that they are in closed condition. Otherwise, screen or net
doors can be provided as addition to prevent pest entry.
5.4.4 Location of equipments
Equipment shall be designed and located so as to facilitate good hygiene

practices and monitoring. Equipment shall be located to permit access for
operation, cleaning and maintenance.
5.4.5 Laboratory facility
Inline or online sampling and testing facilities shall be controlled to prevent

product contamination. It is strongly recommended that chemical and micro labs
shall be separated from the processing area.
5.4.6 Temporary or mobile premises and vending machines
Temporary or mobile facilities shall be designed, constructed and located to

prevent pest harborage, and potential contamination of the products. Additional
hazards and controls can be assessed in the case of temporary facilities
depending on the product and services rendered.
5.4.7 Storage of food, packaging materials, ingredients and non food

items
Facilities used to store ingredients, packaging and products shall provide

protection from dust, condensation, drains, waste, pests and other sources of
contamination. Storage area shall be dry and well ventilated. Monitoring of
temperature and humidity shall be applied where specified. Storage area shall
be specially designated to allow segregation of raw materials, work in progress
and finished goods. All materials shall be stored off the floor on palettes away
from the wall and from ceilings to facilitate cleaning, inspection and pest control
activity. Exceptions or additions for bulk storage ware houses shall be as defined
in the national regulation.
FHTM/04/April 2014
5.5 Utilities - Air , Water , Energy
Provision and distribution routes of utilities shall be controlled and monitored to

prevent cross contamination of the product or environment.
5.5.2 Water supply
Potable water shall be available in adequate quantity and the potability shall be
ensured through a well designed water quality management program. Water
used for processing shall be well protected. Facilities for storage, distribution and
where needed temperature control of the water shall be designed to meet the
national standard. Water used as an ingredient shall meet the drinking water
standard for the country. Water potability shall be ensured through sampling
and testing for chemical as well as microbiological parameters for compliance at
regular intervals - once in a year for all parameters and once in 6 months for
microbiological compliance. Water for cleaning of food contact surfaces where
there is potential for indirect product contamination shall also be potable. In case
water is chlorinated the residual chlorine level shall be as given in the regulation
and the same shall be monitored and recorded for compliance.
If non-potable water is used, the same shall be identified and care shall be taken
to prevent the possibility of refluxing the same into the potable water system. A
program shall be designed for cleaning of the water tank and disinfection
including the pipeline.
5.5.3 Boiler chemicals and other water purifying chemicals
Boiler chemicals if used shall be approved by the BAFRA in case of water for
drinking.
5.5.4 Air quality and ventilation
In case air come in contact with the foods at any stage, the same shall be checked
for quality particularly for microbiological parameters and recorded. If
temperature and humidity are critical for the product safety and shelf life,
control system shall be put in place. Ventilation shall be provided to remove
excess steam, odor, or dust and to facilitate drying after cleaning. Protocols for
air quality monitoring shall be in practice to minimize contamination, if
identified as a need. Air flow shall not be from dirty to the clean area. And air
supply ports shall be examined for physical integrity.
5.5.5 Compressed air and other gases
Compressed air, if used in the manufacturing or packing, the quality shall be

ensured. It should be free from dust, oil and water. Where oil is used in
compressors, measures to be identified and monitored to prevent contamination
with organic residues or grease. Air filtration shall be close to the point of use.
FHTM/04/April 2014
5.5.6 Lighting
Lighting should allow the operators to perform their job hygienically. The
intensity of light should be appropriate to the nature of the work done. However,
in the processing and inspection areas it is recommended to have 500 lux. Light
fittings shall be protected to ensure materials, products or equipments are not
contaminated in case of breakages.
5.6 Waste disposal
5.6.1 General Requirements
Waste materials shall be identified, collected, removed and disposed of in a

manner which prevents contamination of product or production areas.
5.6.2 Containers for waste and inedible or hazardous substances
Containers for waste and inedible materials shall be;

• Clearly identified for the intended purpose
• Located in a designated area
• Constructed of impervious material which can be easily cleaned and
disinfected
• Closed when not in immediate use
• Stored locked where waste may pose problem to the product.
5.6.3 Waste collection, management and removal
Provision shall be made for collection, segregation of wastes, and storage and
removal. Accumulation of waste shall not be allowed in food handling areas.
Removal of waste shall be in sufficient frequencies to avoid cross contamination.
This frequency shall be minimum once in a day. Labeled materials, products,
printed packages and labels shall be disfigured or destroyed so that misuse of the
same can be avoided. Records for destruction as well as the responsibilities for
ensuring timely disposal shall be kept for verification.
5.6.4 Drains and drainages

Drains shall be designed, constructed and located so that the risk of
contamination of material or products is avoided. Drains shall have capacity to
remove the flow loads. Drains shall not pass over process lines. Drainage
direction shall not be from contaminated area to the clean area.
5.7 Equipment suitability, maintenance, cleaning and sanitation
5.7.1 General
Food contact equipment and surfaces shall be designed and constructed to

facilitate cleaning, disinfection and maintenance. Contact surfaces shall not
affect or be affected by the intended product or cleaning system. Food contact
FHTM/04/April 2014
equipment shall be constructed of durable materials, able to resist repeated
cleaning.
5.7.2 Hygienic design
Equipment shall be able to meet the established principles of hygienic design

including;
• Smooth accessible cleanable surfaces, self draining in wet process areas

• Use of materials compatible with intended products and cleaning or
flushing agents
• Framework not penetrated by holes or nuts and bolts
• Pipings and duct work shall be cleanable, drainable and with no dead ends
• Equipment shall be designed to minimize contact between the operators
hands and the products
5.7.3 Product contact surfaces
Product contact surfaces shall be constructed from materials designed for food.
They shall be impermeable and rust or corrosion free.
5.7.4 Temperature control and monitoring equipment
Temperature control equipment used for thermal processing shall be able to

meet the temperature gradient and holding conditions given in the relevant
product specifications. Equipment shall provide for the monitoring and control of
temperature.
5.7.5 Cleaning plant, utensils and equipment
Wet and dry cleaning program shall be documented to ensure that all plant,
utensils and equipment are cleaned at defined frequencies. Program shall specify
what is to be cleaned including the drains, the responsibility, the method of
cleaning (COP or CIP), the use of dedicated cleaning tools, removal and
disassembly requirements and method for verifying the effectiveness of cleaning.
5.7.6 Preventive and Break down maintenance
A preventive maintenance as well as a breakdown maintenance program shall be

designed and shall include the devices used to monitor and or control food safety
hazards eg. screens, filters, magnets, metal detectors, X-rays etc. Corrective or
breakdown maintenance shall be done in such a way that production nearby
areas or equipment used are not at risk of contamination. Maintenance request
which have an impact on food safety shall be given priority. Temporary fixes
shall not contaminate the products. A request for permanent repairs or replacing
the temporary one shall be included in the maintenance program requirements.
Lubricants and heat transfer fluids shall be food grade where there is a risk of
direct contact to maintenance activities in the processing areas or indirect
FHTM/04/April 2014
contact with the products. The procedure for releasing the maintained
equipment back to production shall include clean up, sanitizing, where specified
in the process sanitation procedures and pre use inspections. Local area PRP
requirements shall be applied to maintenance areas and maintenance activities
in processing area. Maintenance personnel shall be trained in the product
hazards associated with their activities.
5.8 Control of operations - management of purchased materials
Purchasing of materials which has an impact on food safety shall be controlled to

ensure that suppliers have the capability to meet the specified requirements.
The conformance of incoming materials to specified purchase requirements shall
be verified.
5.8.2 Selection and management of supplies and suppliers
There shall be a defined process for the selection, approval and monitoring of
suppliers. The process used shall be justified by hazard assessment, including
the potential risk to final product and shall include;
• Assessment of the suppliers ability to meet quality and food safety

requirements and specifications
• Description of how suppliers are assessed i.e supplier auditing or third
party certifications, CoA availability, etc.
• Monitoring of the suppliers performance to assure continued approval
status (monitoring includes conformity with material or product
specifications, fulfilment of CoA requirements, satisfactory audit outcome,
etc.)
5.8.3 Incoming material requirements or purchase specification
Incoming material requirements (raw ingredients, packaging)
Delivery vehicle shall be checked prior to and during unloading of materials to

verify that the quality and safety of the material has been maintained during
transit (eg. integrity of seals, freedom from infestation, existence of temperature
record). Material should be checked or inspected, tested or covered by CoA to
verify conformity with the specified requirements prior to acceptance or use. The
method of verification shall be documented. The frequency of inspection based on
the non-compliances noted, hazards involved in the material and the risk
assessment of the specific suppliers. Materials which do not conform with the
relevant specifications shall be handled under a documented procedure which
ensures they are prevented from unintended use. Access point to bulk material
receiving line shall be identified, capped, and locked. Discharge to the system
shall take place only after approval and verification of the material to be
received.
FHTM/04/April 2014
Program shall be in place to detect and control contamination. Measures to

prevent physical, allergen and microbiological contamination shall be included.
5.9.2 Microbiological cross contamination
Areas where potential for microbiological cross contamination exists (airborne or

from traffic patterns) shall be identified and a segregation (zoning) plan
implemented. A hazard assessment shall be carried out to determine potential
contamination sources, susceptibility of the products and control measures
suitable for these areas shall be practiced;
• Separation of raw from finished or ready to eat (RTE) products.

• Structural segregation - physical barriers, walls or separate building.
• Access control with requirements to change into the relevant attire codes
for that place.
• Traffic patterns or equipment segregation---people, materials, equipment,
tools including the use of dedicated tools.
• Establishing controlled environment.
5.9.3 Allergen Management
Allergens present in the product, either by formulation of the product or by

potential manufacturing cross contact shall be declared. Many allergens are
already declared under the regulations. Declaration shall be on the label for
packed products in consumer pack or the accompanying documents for products
intended for further processing.
Products shall be protected from intended allergen cross contact by cleaning and
line change over practices and or product sequencing. Cross contamination can
arise during manufacturing either from;
• Traces of products from the previous production line which cannot be

adequately cleaned from the product line due to technical limitations or
• When contact is likely to occur in the normal manufacturing process with
products or ingredients that are produced on separate lines or in the same
or adjacent processing areas.
Rework of products containing allergens shall be used only in products

containing the same allergen or through a process which demonstrate that the
allergen can be completely removed. Employees handling food should receive
specific training in allergen awareness and control measures to be taken during
the manufacturing and handling process
FHTM/04/April 2014
5.9.4 Physical contamination
When brittle materials are used, periodic inspection requirements and defined
procedures in case of breakages shall be developed and personnel are to be
trained well to practice. Where possible, brittle materials such as glass and
plastics shall be avoided. Glass breakage records shall be in place. Based on
hazard assessment procedures, measures shall be put in place to prevent, control
or detect potential contamination.
Control measures include:

• Adequate covering of the products
• Use of screens, filters, magnets or sieves
• Use of detection/ rejection devices such as metal detectors or x – rays
Sources of potential physical contamination include wooden pallets, tools, rubber

seals, caps, cello tapes, packaging materials, personal utilities, and equipment.
5.10 Cleaning and sanitation
Cleaning and sanitizing program shall be established to ensure that food

processing or handling facility and equipment are maintained in a hygienic
condition. The program shall be monitored for its continuing suitability and
effectiveness.
5.10.2 Cleaning and sanitizing agents and tools
Facilities and equipment shall be maintained in a condition which facilitates wet

or dry cleaning and sanitation easily. A well maintained facility and equipment
only could be cleaned and sanitized effectively. Cleaning and sanitizing agents
shall be clearly identified with proper labeling. They shall be stored away from
food areas and used only according to the label instructions. The use of the same
shall be under supervision and control by the responsible personnel. Tools and
equipment shall be of hygienic design and maintained in a condition which does
not present a potential source of extraneous matter contamination
5.10.3 Cleaning and Sanitizing Programs
Cleaning and sanitizing programs shall be established and validated by the

organization to ensure that all parts of establishment and equipment are cleaned
and /or sanitized as per a defined schedule including the cleaning of equipment.
A minimum cleaning and sanitizing program shall specify;
• Areas, items of equipment and utensils to be cleaned and/or sanitized

• Responsibility for the task specified
• Cleaning and sanitizing method and frequency
• Monitoring and verification arrangements
FHTM/04/April 2014
• Post clean inspections
• Pre start up inspections
• Training details and requirements
5.10.4 CIP system
CIP system shall be separated from the active product lines. Parameters for CIP
cleaning shall be defined and monitored (including type, concentration, contact
time and temperature of any chemical used).
5.10.5 Monitoring sanitation effectiveness
Cleaning and sanitation shall be monitored at frequencies specified by the

organization in their SSOPs to ensure their continuing suitability and
effectiveness.
Monitoring program includes;
• Visual observation, lab analysis of swabs drawn aseptically from the

cleaned surface immediately for microbial pathogen or even contamination
at a higher level, use of rapid test kits and so on.
• In case failures are noticed, immediate corrective action or preventive
action shall be taken. The corrective action includes, change of detergents
and sanitizer, method of cleaning, increase the frequency, training,
demonstration and so on.
The results of implementation and corrective action and its verification for
effectiveness shall be documented and be available for BAFRA officials for their
verification on demand. Employees training details also shall be documented and
recorded.
5.11 Pest Control
Hygiene, cleaning, incoming material inspection and monitoring procedures shall

be implemented to avoid creating an environment conducive to pest activity. It
should be understood by everyone in food handling that it is not pest control, it is
pest management. How effectively each facility is managing the pests without
getting entry into their facility and infesting or contaminating the food.
5.11.2 Pest control program
Establishment shall have a responsible person to manage all the pest control
activities, including dealing with the out sourced expert pest control contractors.
Pest management program shall be documented and shall identify target pests
and address plans, methods, schedules, control procedures and where necessary
FHTM/04/April 2014
training requirements. The program shall include a list of chemicals which are
approved for use in the country by the National Plant Protection Centre to be
used in the specified areas of the establishment.
5.11.3 Preventing Access
In pest control, remember three principles;

1. Prevent access to pest inside, don’t be hospitable to pests.
2. Deny food for them or keep clean
3. Deny shelter to prevent harboring
Buildings shall be maintained in good repair. Holes, drains, gaps and other
potential pest access points shall be sealed. External openings, doors,
ventilations, etc shall be designed in such a way to minimize the entry of pests.
Doors can be self closing and tight fitting. All openings can be screened. Insect
electrocutes can be fitted at the entry doors as a part of prevention. Positioning
of the insect killers are to be decided so that the entry is prevented. Do not fix
the insect killers over the processing table.
5.11.4 Harboring and infestation
Storage activities shall be designed to minimize the availability of food to the

pests.
Materials already infested shall be handled in such a way that they should not
contaminate other materials, products or establishment. Inspection for incoming
materials shall be strong and pest affected material shall not be taken in. All
holes or broken or damaged areas in the processing facility can harborage pest if
not repaired. If storage outside is in ware houses, the area shall be protected
from the entry of birds to prevent contamination with bird droppings, feathers,
etc. Waste collection and timely disposal if done can reduce the pest access, and
harborage to a great extent.
5.11.5 Monitoring and detection
Pest monitoring program shall include the placing of detectors, traps, glues in
key locations to identify pest activity. A map of detectors can be kept. The
detector shall be kept and monitored in such a way that no potential
contamination to the products can happen. Detectors and traps shall be of
robust, tamper resistant and shall be appropriate for the target pest. The person
responsible for pest control shall monitor the bait and keep record of the same.
In case pests are detected inside the processing facility, immediate corrective
and/or preventive action shall be taken and effectiveness of the same verified
and recorded.
5.11.6 Eradication
Eradication measures shall be put in place immediately after evidence of pest

infestation is reported. Pesticide use and application shall be restricted to
trained personnel and shall be controlled to avoid product safety hazards.
FHTM/04/April 2014
Records of use of pesticides shall be maintained to show the type, quantity,
concentration used, where, when, and how applied and the target pests.
5.12 Personal hygiene and employees facilities
Requirements for personal hygiene and behaviors proportional to the hazard

posed to the process area or products shall be established and documented. All
personnel, visitors and contractors shall be required to comply with the
documented protocols.
5.12.2 Personal hygiene facilities and toilets
Personal hygiene facilities shall be available to ensure that the degree of

personal hygiene required by the organization can be maintained. The facilities
shall be located close to the points where hygiene requirements apply and shall
be clearly designated.
Establishment shall;
• Provide adequate numbers, locations and means of hygienically washing,

drying and where required sanitizing hands (include wash basins, supply
of hot and cold water, soap and/or sanitizer).
• Have sinks designated for hand washing which can be non hand operable
to have the hygiene conditions and prevent cross contamination.
• Food or equipment washing sinks shall not be used for the purpose.
• Provide adequate no of toilets of sanitary design, each with hand washing
and sanitizing facility.
• These facilities shall not open directly to the process areas.
• Have adequate changing facilities for the personnel equipped with lockers
for valuables and hangers for uniforms provided and hangers for aprons
and separate hangers for street clothes, and racks for foot wears.
• Have changing facilities well equipped to ensure that the risk of cross
contamination from personnel are minimized in the facility while handling
foods.
5.12.3 Staff Canteens and designated eating areas
Staff canteens and designated areas for food storage and consumption shall be
situated in an area to minimize the potential for cross contamination with food
waste and pests. Staff canteen shall be managed to ensure hygienic storage,
preparation of food and storage and serving of the prepared foods, storage and
storage conditions, cooking and holding temperatures, time limitations for
holding of the prepared foods all shall be specified. Employees own food shall be
stored and consumed in designated area only. No food shall be stored in the
change room or in the processing areas.
FHTM/04/April 2014
5.12.4 Work wares and protective clothings
Personnel who work in or enter into the facility where exposed food or food
materials are handled shall wear work clothings that is fit for the purpose, clean
and in good repair. Clothings mandated for food or hygiene purpose shall not be
used for other purposes. Work ware shall not have buttons, outside pockets, zips
or pressed studs or well crow is advisable. Work wear shall be laundered based
on the required frequency based on the intended use of the dress. Work wear
shall provide adequate protection to ensure that hair, perspiration, etc shall not
contaminate the product.
Hair, beards, moustaches shall be covered by restraints. Where gloves are used
as product contact surface, they shall be cleaned and sanitized at regular
intervals and procedures and practices shall be in place and monitored.
Otherwise, use of gloves will provide a false sense of security. If disposable gloves
are used, the same shall also be changed frequently to avoid contamination. Use
of latex gloves shall be avoided.
Shoes used shall be fully enclosed and shall be made from non absorbent
materials.
Personal protective equipment shall be designed to prevent product
contamination and shall be well maintained.
5.12.5 Health status
Subject to the legal restrictions, all employees prior to appointment in a food

handling operation shall undergo a medical examination and health card shall be
retained to ensure that he or she is free from any contagious diseases and fit to
work in a food industry. This examination shall be repeated every six months
and when required by the BAFRA officials.
5.12.6 Illness and injuries
Exclusion Policy
The facility has to document its policy on exclusion in case of personnel with
illness or injuries. The employees shall be required to report the following
conditions to the management for possible exclusions from food handling areas -
jaundice, diarrhoea, vomiting, fever, sore throat, visible infections on skin,
lesions, boils, cuts or sores, discharges from eye, ear or nose.
People known or suspected to be infected or carrying a disease transmissible

through food shall be prevented from food handling. Personnel with cut or
wounds shall cover and protect them with designated coverings or dressings. Any
lost dressing shall be reported to the supervisor. Dressings shall be brightly
colored for easy detection or metal detectable in a metal detector.
FHTM/04/April 2014
5.12.7 Personal cleanliness
Personnel working in food production area shall wash hands before start and
sanitize if required;
• Before starting any food handling activity
• Immediately after using toilets
• Blowing nose (sneezing)
• Scratching head or body parts
• Whenever feel the hands are contaminated
• Immediately after handling any contaminated or spoiled material or waste
or cleaning materials
Personnel shall refrain from sneezing over the product or materials. They shall
cover nose and wash hands and sanitize after sneezing. No spitting in and
around the processing area and premises. Smoking shall be prohibited in food
handling area. Finger nails can be kept clean and trimmed.
5.12.8 Personal behavior
A documented policy shall be to describe the behaviours of the personnel in the

processing, packing and storage areas. The policy shall cover minimum;
• Permission to smoking, eating, chewing in the designated areas only

• Control measures to minimize hazards presented by permitted jewellery
due to reasons related to religion, culture or other ethnic issues.
• Permissibility to carry and use medicines in the designated areas only
• Prohibition of use of nail polish, false nails, eyelashes, etc
• No permission to carry writing implements behind the ears
• Maintenance of lockers to ensure they are free from rubbish and soiled
linen and other items
• Storage of maintenance tools in personal boxes. The same shall be in the
tool box designated or in the designated areas.
• Sign boards shall be displayed in prominent places in simple language for
easy understanding of the Dos and Don’ts.
5.13 Re-use or rework
5.13.1 General requirement
A system shall be established and procedures need to be developed with specific

responsibilities assigned to designated personnel to take decisions on reuse or
rework.
5.13.2 Dealing with non conformances
In case of non conformances due to quality issues, if it can be rectified without

compromising food safety, the same can be done and verified by a competent or
supervisory person. However, till the non conformity is corrected the product
FHTM/04/April 2014
shall be identified clearly as defective and segregated without being serviced to
the customer. All relevant records of corrective actions shall be maintained for
verification by the authorized personnel.
5.13.3 Dealing with Food safety issues
In case of suspicion of any contaminant being introduced into the products which
may have the potential to cause harm to the consumer, the same shall be
withdrawn from the line and isolated with clear identification. If on further
investigation, it is found satisfactory by a competent person, the same can be
released. Otherwise, the same shall be rejected and disposed as stated in the
regulation. Any reprocessing of unsafe food shall be carried out only with the
knowledge of the BAFRA officials and following the legal requirements. Action
shall be initiated to ensure that such incidences are not repeated. All the
relevant records shall be maintained for verification in future. Big
manufacturers shall develop a system for traceability and recall through proper
labeling and control and shall practice the same.
5.14 Recommended Records for GMPs and GHPs
• Responsibility or organization chart for establishments with authority and

responsibility.
• Competence, training and awareness
• Water quality records
• Raw material specification and purchase, receipt and control
• Perishable goods storage temperature log
• Cleaning schedule and daily cleaning and monitoring record
• Personal hygiene monitoring record
• Pest control record
• Lab test reports and samples of foods
• Sampling and inspection and release record
• Cooking or other temperature control record
• Calibration record
• Maintenance both preventive and breakdown
• Hot holding temperature or time record
• Cold holding time and temperature record
• Production log in case of manufacturers
• Waste disposal log
• Inventory control and storage control of toxic chemicals
• Document --- Sanitation Standard Operating Procedures (SSOPs) stating
who, what, when and how for application, verification and record keeping
for compliance with GMPs for the specific situation.
FHTM/04/April 2014
6. STANDARD SANITATION OPERATING PROCEDURES
“Sanitation is a way of life”. This statement by the National Sanitation

Foundation tells the story of the contents of this section in just a few words.
This describes how we meet certain key sanitation conditions and practices
and also describes how the operations will be monitored to ensure Good
Hygiene Practices and Good Manufacturing Practices. The monitoring
frequency has been described depending on the requirement and the level of
risk.
The sanitation/hygiene policy has to be formulated in accordance with the GMP

regulations in the country. The eight key areas of sanitation controls designated
as in Codex is taken into account while preparing the SSOP’s. Each organization
has to tailor this procedure to suit to its needs.
6.1 Water
Water is the single largest ingredient or substance used in the preparation of

foods, washing, cleaning and for many other purposes, and hence the safety of
water used is a priority in the food business whether small or big the caterers as
well as street vendors shall take care of the water quality they use in to ensure
safety and suitability.
Water used for washing shall be protected from external contamination. The
source of water supply must be identified and potability ensured. If suspected
not safe, chlorination to a level of less than 1ppm (residual Chlorine) can be a
method to have safe water. Chlorine tablets and rapid test methods to verify the
level of residual chlorine are all available. If water is collected in jars or pots the
same shall be covered and used hygienically. If water taps are provided, ensure
the cleanliness and see no taps are leaking. If hoses are connected the same shall
not be on floor to avoid back flow. Hoses shall be on hose resters. The
underground tank and overhead tanks if installed are to be covered properly to
avoid contamination due to wind, dust, insects, etc. These tanks are cleaned and
sanitized once in six months.
Procedure
Initial stage of tank cleaning begins with thorough cleaning of manhole of tank
by pressure jet spraying to remove dirt and algae that are impossible to remove
by conventional method. Drain out dirty sludge and clean manually by brushing
with bleach and rinse of all bleach. Check water and ensure chlorine free. Rinse
several times.
FHTM/04/April 2014
Monitoring
What How Frequency Who Verification Record
Condition of Visual Weekly Weekly Daily/weekly

water tank observation sanitation form
Person
respon
Chlorine test Using Daily Weekly Chlorine
sible
in water chlori-test verification of concentration
paper records record
Water tank Visual Once in -do- Water
cleaning observation three Tank
months cleaning record
Bacteriologic Lab analysis Once in a Microbiological
al standards month analysis report
Quality
Water pot Lab analysis Once in a Control Potability
ability year ler certificate
6.2 Ice
In case ice is used, the same shall be from safe source and shall be handled
hygienically. The ice manufacturing unit shall have approval from the BAFRA
and shall operate with GHPs.
6.3 Waste disposal
Separate garbage bags can be used for collection of solid waste, cans and
glass bottles. The solid waste collected is disposed to the garbage disposal
area and ensure that the waste shall not contaminate the food or food
contact surface. Waste shall not be thrown on the floor or open places
elsewhere.
Monitoring
What How Frequenc Who Verificatio Record

y n
Waste collection
and disposal
Visual Once in a DP Waste
Cleaning of observation day Disposal
containers and Log
waste room
FHTM/04/April 2014
Every day before the start and end of the work, the area in and around the
operating unit shall be ensured clean. No rubbish or offal is allowed to be piled
up in the premises, which can harbor pests.
All measures are being taken in the facility to avoid cross contamination of the
product through restricting traffic and avoiding even the slightest backtracking.
The structure and layout of the processing facility is such that the movement of
the people, product and utensils are from dirty area to the clean area as the
process moves forward and not vice versa. The product movement and personal
movement are unidirectional. No personnel are allowed to move in and out of the
processing hall without adequate protective gear. The construction of the facility
is such that it provides adequate space to prevent overcrowding of personnel and
equipment and maintains hygiene and sanitation. The facility is protected well
against the entry of pests, insects and vermin. The material used for
construction permits easy and adequate cleaning. The area in which the raw
material is received is separated from the process area.
There is clear separation between the preprocessing area and the finished
products area. All chances of cross contamination are prevented. The walls and
floors are easily washable and light coloured. The floor is smooth to keep the
area clean and sanitized. All the processing areas are well lighted and lights are
of protective type to avoid contamination. The entire process facility is
maintained as new as possible.
Monitoring
What How Frequenc Who Verification Record

y
The above Visual Daily Responsible Weekly Daily
practices observatio person verification sanitation
n form
6.5 Glass / metal policy
All possible precautions must be taken to see that the products are not
contaminated with glass and metal pieces. No glass vessels are taken inside the
production area. Incase of an accidental breakage, the broken glass pieces are
removed using brooms exclusively used for this purpose. If mops are used they
shall not be used in other areas. The food handlers are not allowed to take
ornaments or other personal belongings (like hair pins, watches, equipment
parts, etc.) to the processing area.
6.6 Protection from adulterants
All foods, food contact surfaces and serving dishes are protected from
adulteration with lubricants, fuels, pesticides, cleaning compounds, sanitizing
agents and other physical and chemical hazards. Only necessary chemicals are
FHTM/04/April 2014
stored in the premises. Chemicals are stored in a separate area away from the
preparation area, such that they can’t contaminate food, food contact surfaces,
serving dishes, etc. All chemicals are labeled properly. Insecticides and
rodenticides are not used inside the area. Detergents and chlorine disinfectant
solutions are thoroughly washed out after cleaning. The soaps and other
cleaning chemicals shall be used by only authorized personnel.
Monitoring

y n
Proper labeling Visual
and storing of observatio
chemicals n
Daily Responsi Weekly Daily
Presence of Visual - ble verification sanitation
cleaning observatio personne form
compounds on n & chlori- l
food contact test paper
surfaces
6.7 Rodent/ pest control
Integrated pest management is practiced especially in relation to cockroaches,

mice and insects by denial of access incorporated in design, maintenance and
proofing of building. Pest control is primarily managed by outside agency on
contract basis and relevant records are monitored and documented by the
concerned supervisor and verified by designated personnel. Doors and windows
are kept closed and if left open, they shall be air screened with fine mesh.
Doorways are protected with automatic door closers. Flycatchers are installed at
various locations to control flies and other insects. Access holes are sealed by
metal sheets or mesh. Drainage channels are suitably covered to prevent entry of
rodents to the processing hall. Food spillage and debris are cleared promptly,
waste are not allowed to accumulate. Food is stored off floors and away from
walls. Food is stored in pest proof containers and lids are always replaced.
Regular inspections are made and appropriate actions taken for any sightings of
pests or pest damage or droppings. Deliveries - food serving is checked and
corrective action is taken to ensure that it is pest free.
Control
Pests are controlled by chemical methods by an authorized private agency.

Different chemicals are used in interiors and exterior areas. It is ensured that
the chemicals used inside are an approved one. Spraying is not done when work
is going on in the area. All foods are covered well or sealed.
FHTM/04/April 2014
Baiting
Rat traps are kept at different area for pest and check every day. Areas where
traps are kept are indicated in the rodent map. Related records are documented
and maintained by the designated personnel. If any rodent has been identified in
any area, preventive action is taken immediately.
Monitoring

y n
Presence Visual Twice Supervisor Pest
of flies observation daily Weekly by Control
Form
Rodent Visual Every day Rodent
Trap observation trapping
chart
6.8 Cleaning and disinfection
The cleaning is well planned, organized and implemented in all areas of food
premises. Cleaning schedules are monitored and documented and kept filed. All
chemicals and disinfectants are stored separately from food. Cleaning equipment
are kept clean, dried; brushes and mops are hung off the floor in well-designated
cleaning equipment area. Food contact surfaces, equipment, food containers,
cutting boards, preparation surfaces, slicing machines, utensils, etc are cleaned
and disinfected in chlorinated water (100 PPM) after every usage for a suitable
contact time to destroy bacteria. At least within 2 hours of time, all the food
contact surfaces shall be disinfected if in use. If other sanitizers are available,
the same can also be used.
Monitoring
What How Frequenc Who Verification Record

y
Cleaning and Visual Daily DP Weekly Cleaning
sanitation observation verification Schedule
of records by record
Sanitizing Using Daily Hygiene Weekly Daily

solution chlori-test Officer verification Chlorine
concentratio paper of records by Check
n list
Cleanliness Swab Once in Quality
of food analysis three Controller
contact months
surfaces
FHTM/04/April 2014
Procedures for cleaning
The cleaning consists of various stages
a. Pre cleans – removing waste by wiping with a wiper and pre rinsing.
b. The dishes are loaded into a plastic crate and then on to the dishwasher.
c. The dishes are washed in a three-cycle process with automatic dosage
cleaning liquids with properties of destroying micro organisms. The
automatic dosage pump is checked and monitored by the supervisor for
every batch.
Work Area
The work area including tables, racks, storage area and surrounding floors are
cleaned before actual assembly work begins. Periodic cleaning of these areas is
made necessary and, cleaning is done at least once during each operating shift.
The concerned area is rinsed with water and detergent, scrubbed with brush and
washed and disinfected with chlorine water (100 PPM) and mopped dry. In the
final rinse, it is ensured that all the particulate matter and detergent are
removed effectively. In case of heavy soiling, the utensils are soaked for some
time, scrubbed, rinsed and washed.
Thermometer disinfection
The calibrated thermometers are disinfected with chlorinated water ( 50

PPM) before and after every use.
Personnel Hygiene
Personnel hygiene is the key area where adequate concentration is given to

ensure safety of the product. Food handlers are trained to observe high
standards of personal hygiene. Repeated training classes are conducted to give
awareness about the potential hazards and how GOOD HYGIENE
PRACTICES can control them. The food handlers adopt all good practices and
procedures in order to minimize microbial and physical contamination.
Daily check of the personnel hygiene of every employee shall be done. Checks
whether the nails and hairs are trimmed properly, jewellery are avoided, any
cuts or wounds are present, if present kept covered or not, and for any signs of
skin diseases etc. They are also interviewed for the presence of symptoms of
intestinal infection. The food handlers are strictly instructed to report to their
supervisor, if suffering from any of communicable disease or symptoms. It is
ensured that no food handler known or suspected to be suffering from or to be a
carrier of disease likely to be transmitted through food is allowed to work.
FHTM/04/April 2014
Monitoring
Employees Visual
health, proper observation
cutting of nails,
presence of Weekly Personal
ornaments and daily verification of Hygiene Log
cuts and wounds records
Cleanliness of Visual
head cap, observation
uniforms and
aprons
Hand wash
All area is provided with turn off taps, sufficient liquid soap, soft bristled
nailbrush, disposable paper towels and hand dips of chlorinated water (20
PPM) solutions. Food handlers are instructed to wash their hands regularly
throughout working hours especially after visiting toilets and entering the
food processing halls. The DP also monitors the effectiveness of hand wash.
Monitoring
Adequate supply Visual

of detergents, observation
nail brush, DP
towels etc. Weekly Daily
Daily verification of sanitation
records form
Chlorine level in Using chlori- do
hand dip test paper
Change rooms for processing facility
Separate change rooms are provided for all executives, gents and ladies staff.
Each employee is provided with 3 sets of uniforms. Every day they are issued
with clean uniforms coming from the outside laundry by the linen keeper.
Appropriate clean protective clothing is issued to necessary food handlers.
FHTM/04/April 2014
Protective clothing is removed when visiting the toilets. Uniforms are not
worn outside premises.
Footwear & Caps
All the staff inside the unit will wear clean and hygienic footwear. The ladies
wear suitable head covering enclosing the hair inside the head caps. All the
issues of shoes, caps and uniforms are documented and recorded. Separate
uniform checklists are maintained. All these are documented by Linen
Keeper, verified by DP.
6.9 Maintenance
Goal
All the facilities including building, equipment, machinery, utensils, etc are
maintained in good condition on a regular basis. Even in case of street vendors,
proper maintenance of the utilities shall be done.
Procedure
A regular maintenance program is established for different sections. Building is

maintained periodically to prevent leaks that may contaminate the product. All
cracks, holes on the floor, walls, and ceiling shall be repaired as soon as detected.
All product contact surfaces are kept in good repair. Equipment or parts thereof
which are not in proper condition will be removed or repaired or replaced in a
timely manner.
Monitoring
Condition of Visual Weekly once Weekly

building and observation verification Maintena
equipment DP of records nce record
Maintenance Visual At the time of
work observation maintenance
6.10 Staff Cafeteria
Separate cafeteria is provided with non-vegetarian and vegetarian food for all
staff on duty. A Bain Marie in the cafeteria facilitates the food to remain hot.
Instrument Calibration
All the equipments and instruments used in the measuring or testing are
calibrated for accuracy. Thermometers used for checking product
FHTM/04/April 2014
temperature are calibrated once in a year with thermometer traceable to
national standards.
Training
A training program is implemented to ensure competency of all food
handlers to produce safe food. All food handlers receive appropriate
supervision, instructions, commensurate with their work activities, thus
ensuring that they are aware of the hygiene hazards associated with their
job to ensure safety of food produced.
FHTM/04/April 2014
7. SPECIFIC SANITARY AND HYGIENE REQUIREMENTS FOR
RETAIL SHOPS FOR MEAT AND MEAT PRODUCTS
Bhutan does not have a well organized slaughterhouse or meat processing plant.
However, a few such units are under consideration. Meat and meat products are
one of the major foods consumed by the public and hence the hygiene and safety
of the meat sold in Bhutan is a thrust area under the Food Act of Bhutan (2005)
and the Livestock Act of Bhutan (2001). Major quantity of meat is being
imported in the country. The slaughtered carcasses are imported into the
country from India and the officials of BAFRA ensure that they are transported
under hygienic conditions to Bhutan. There is a good system of verification and
clearance of the meat for quality and freshness at the entry point.
Meat and meat products are the most high risk foods, easily perishable and are
subject to contamination due to various handling process throughout the food
chain from Farm to Fork. BAFRA is having veterinarians and paravets
throughout the country who have been trying to guide and assist the retailers to
comply with the specific requirements in GMPS and GHPs on a continuous basis
to guarantee safety and suitability of the meat sold in Bhutan.
The Basic GMP and GHP Requirements for a Meat Shop.
7.1 Location
7.1.1 The meat shop shall be located as a unit of meat market preferably, away
from vegetables, and other food market and shall be free from undesirable
odor, smoke, dust and other contaminants.
7.1.2 Where meat market is not available, individual shops can be set up
considering the above factors which have an impact on the hygiene
conditions of the meat shop and safety of the meat sold.
7.2 Size of meat shop
7.2.1 The size of the meat shops shall be determined by the concerned BAFRA
officials based on the space available, types and quantity of meat handled
on a daily basis.
7.2.2 The height of the shops (from floor to ceiling) shall not be less than 3
meters and if air conditioned, the height should not be less than 2.5
meters.
7.3 Premises
7.3.1 The building shall be structurally sound. The walls up to the height of 5
feet from the floor level shall be made of impervious materials (glazed
tiles, hygienic panels, SS sheets etc) for easy washing and cleaning
purposes.
FHTM/04/April 2014
7.3.2 The floors should be made of impervious material, non slippery with a
slope for easy cleaning and removal of filth, waste and dirty water. The
wall to floor joints shall be coved or rounded off for easy cleaning and pest
prevention.
7.3.3 All the fittings in the meat shop shall be non-corroding and non-rusting.
7.3.4 All processing tables, racks, shelves, boards have washable surfaces for
easy cleaning.
7.3.5 A sign board indicating the type of meat shall be displayed prominently.
Nothing else but meat should be sold at the premises.
7.3.6 Ideally, fish shall be sold from a separate shop to prevent cross
contamination due to intact guts, gills, scales. In case, fish need to be sold
from a meat shop, the same shall be done in a separate counter along with
designated utilities such as knives, cutting boards, freezers, weighing
machine, etc
7.3.7 Meat to be displayed for sale must be segregated by type of meat and
displayed in a refrigerated display cabinet.
7.3.8 The shop must have connection to the drainage for proper discharge of
waste water. The same shall not be exposed to open areas outside and the
opening shall be screened to prevent pest entry.
7.3.9 All openings such as windows, exhausts etc shall be protected with insect
proofing nets which can be removable and washable. In case the door is
with screens they shall also be washable.
7.3.10 There shall be connection for continuous potable water supply, if not
arrangements shall be made for collection of water from a potable water
supply and storage.
7.3.11 Door of the meat shop shall be self closing and shall always be closed.
7.3.12 In case glass doors are provided, they shall be protected using sun film to
avoid glass pieces falling into the product in case of a breakage. Open
bulbs hanging over the products are also to be protected to prevent
physical hazard of foreign object.
7.4 Ventilation
7.4.1 The meat shop should have proper ventilation. At least one electric fan
and one exhaust fan shall be provided to facilitate cross ventilation.
7.4.2 The rails and hanging hooks provided for hanging carcasses shall be made
of and easily cleanable. The hooks shall be sufficiently apart (preferably
30 cms) and the distance between the rails shall be 60 to 70 cms
FHTM/04/April 2014
depending on the type of carcasses to be hanged to keep the carcass
hygienically.
7.5 Equipment and other accessories
7.4.1 The meat shop shall have suitable arrangements for fly proofing in the
form of air curtains, flytraps or screens. The positioning of the fly traps
shall be placed inside of the entry point.
7.4.2 The shop should have cabinet type refrigerator of size for maintaining the
temperature at 4 to 8 degree Celsius or freezing cabinet if the meat needs
to be stored for more than 48 hours. The condition and cleanliness of the
chillers and freezers shall be checked by the owner or supervisor daily
before start and at the end of business.
7.4.3 The weighing scale shall be of stainless steel or any material easily
cleanable.
7.4.4 The knives and other cutting or handling tools shall be non-corrosive and
have designated area or cupboards to keep it hygienically.
7.4.5 There should be provision for hot water at a temperature above 82°Celsius
(geysers) in each meat shop to sanitize the premises and equipment used
in the shop.
7.4.6 Wash basins made of stainless steel or ceramic shall be in each meat shop
and shall be provided with soap and disinfectant for hand washing and
sanitizing. Single use towel is preferable for hand drying. In case,
community towels are used the same shall be replaced every 2 hours and
cleaned and disinfected. Electric dryer is another option.
7.4.7 Chopping boards shall be of food grade synthetic materials which do not
contaminate the meat as it is easily cleanable. If wood is used, they shall
be hard wood trunks and shall not be damaged with crevices. The surfaces
shall be shaved and kept easily cleanable and shall not contaminate the
products.
7.4.8 At the end of the day or at each break, the chopping equipment shall be
cleaned and disinfected with preferably 100 ppm chlorinated water.
7.4.9 Waste bins shall be with pedal operated cover for collection and disposal of
waste
7.6 Transportation
7.6.1 Transportation of carcasses (beef, pork, chevon, mutton) shall be done

under hygienic conditions on suitably constructed racks preferably in
closed refrigerated vans. The racks must be washed daily.
FHTM/04/April 2014
7.6.2 The cleanliness of the vehicle shall be ensured prior to loading as well as
after delivery and cleaning. Carcasses shall never be carried out in a
vehicle used for human transport or in an open vehicle.
7.6.3 Chicken and fish must be transported under refrigerated conditions or in

ice prepared using portable water. For other types of meat, if the
transportation time of the meat takes more than 8 hours, the meat shall
be cooled by placing crushed ice bags all around and in between the
carcasses so that the material will be in chilled condition. Care shall be
taken to ensure that ice will never be in direct contact with the meat.
7.6.4 If the transportation of meat takes more than 48 hours, the same shall be
in frozen condition.
7.6.5 Unloading of the carcasses to the shop shall be done hygienically. A

stainless steel trolley can be used to shift them to the shop instead of
carrying on the back of the workers.
7.7 Pest control
7.7.1 The meat shop shall have a continuous program for control of insects,
rodents, animals and vermins within the premises. The surrounding area
also shall be kept clean so as to prevent pest infestation.
7.7.2 Any chemical used shall be with the approval of the BAFRA. Only those
chemicals approved for use in the country by the National Plant
Protection Centre shall be used. The records of use shall be maintained
along with instructions and inventory of chemicals.
7.7.3 The pest control measures adopted shall be kept as record by the owner of
the shop for verification by the BAFRA officials.
7.7.4 No organochlorine or phosphorous pest control chemicals are allowed to be

used in the meat shop and shall not be stored anywhere in the premises.
7.7.5 Strict control for the collection of wastes and regular timely disposal and
scheduled cleaning of the entire shop with adequate supervision can
prevent the attack of pests.
7.7.6 Proper maintenance of the shop and insect proofing also shall be under
regular supervision by the owner and inspection by the BAFRA officials.
No live animal or birds are allowed inside the facility.
7.8 Personal hygiene
7.8.1 Every person engaged in meat handling should have undergone a medical
check-up and the certificate of fitness to work in a meat handling facility
shall be maintained in the shop to be inspected by the BAFRA officials on
FHTM/04/April 2014
demand. The medical check-up shall be repeated once in every 6 months
and as and when deemed necessary by the BAFRA officials. The medical
examination shall be as required under the Food Act of Bhutan (2005) and
its rules.
7.8.2 No worker suspected to be suffering from fever, diarrhoea, vomiting,

typhoid, infected cuts, boils or any contagious disease shall be permitted to
handle the meat.
7.8.3 All the meat handlers in meat shop shall keep their hair and nails short
and trimmed and keep them clean always. Wash hands with warm soapy
water before start of the work and at every break.
7.8.4 Eating, chewing tobacco or betel leaves, spitting, nose blowing, scratching
over the body, smoking, etc. are not allowed in a meat handling shops.
Sign boards prohibiting all the above shall be placed prominently in the
shop.
7.8.5 All employees shall cover their hair with a clean head gear, and have
mouth covers and aprons worn. They shall refrain from using any loose
jewelries while working as it is difficult to clean and sanitize them.
7.8.6 All meat handlers shall be trained in basic hygiene, GHPs and the need
for complying with the regulations.
7.8.7 Records of regular checking of the employees’ practices and facilities shall
be available in the meat shop for verification by the BAFRA officials.
7.8.8 Toilets in meat shops must be hygienically maintained at all times and
any maintenance work required must be carried out promptly.
7.9.1 All chopping blocks and food contact surfaces shall be cleaned and
sanitized either by hot water above 82 degree Celsius or with Chlorine
(100 ppm) at the end of the day or at break.
7.9.2 The floor should be washed with kitchen grade detergent and disinfected
with chorine or hot water at the end of the day or at break.
7.9.3 There should be high standards of cleanliness in the working area in the
shop with no signs of meat waste on the floor.
7.9.4 All the cooling and storage equipment shall be cleaned at regular intervals
and well maintained. There shall be a schedule for cleaning and shall be
done under supervision. The functioning of the refrigerator and freezers to
be ensured as a part of temperature control.
FHTM/04/April 2014
7.9.5 Records of compliance of the cleaning procedures shall be maintained.
7.9.6 At a scheduled interval, the BAFRA officials shall draw samples of swabs
from the cleaned food contact surfaces from each shop and test in the lab
to verify the effectiveness of cleaning and in case coliforms and/or E. coli
are detected, corrective actions must be initiated in the shop. Corrective
action may include, but not limited to increasing the frequency of
inspection, more training in cleaning operations, strengthening
supervision, change in the detergent and disinfectant and methods of
cleaning.
7.9.7 Slaughtering of any bird or animal in the meat shop is strictly prohibited.
7.9.8 The carcasses shall not be covered with any kind of clothes.
7.9.9 Wholesome meat from authorized suppliers and abattoirs only be sold in
the shop. Records thereof shall also be maintained.
7.9.10 Premises shall not be used for residential purpose or it shall not be
attached to residential facility. No personal belongings such as clothings,
beddings, shoes and such other items shall be kept in the premises of the
shop. All waste shall be disposed and the waste bins shall be cleaned and
sanitized daily.
7.9.11 Hides, skins, hoofs, heads and unclean guts shall not be allowed to be
stored in the shops. Guts if required to be sold, must be cleaned and sold
as tripe.
7.9.12 The cutting utilities shall be cleaned every break and at the end of
business and disinfected.
7.9.13 Preparation and consumption of food inside the area shall be strictly
prohibited.
7.9.14 Meat shops are not allowed to sell uninspected or illegally supplied meat.
They shall not accept and sell meat without certification/stamping by the
BAFRA officials. Provision for confiscation of unauthorized meat supply
shall be there for the BAFRA officials.
7.9.15 The manager/proprietor of the meat shop shall keep current inventory of
meat received and sold along with details of the supplier of the material as
a part of identity.
7.9.16 In case of frozen meat, it is recommended to check the temperature or at

least the hard frozen nature of the products.
FHTM/04/April 2014
7.10 Other requirements
7.10.1 Prepared or processed meat shall be packaged in food grade packaging

materials and kept separately from raw carcasses and cut meat.
7.10.2 Handling of the meat by customers shall be discouraged. A board can be

displayed with this request.
7.10.3 Regular services of the BAFRA officials from the Government shall be
available for control and verification of the GMPs and maintenance of
records of actions taken.
7.10.4 In case the services of the BAFRA officials are not adequate, contractual
arrangements shall be made with qualified professionals under the
supervision and monitoring of the BAFRA officials. At no cost, the meat
shops as well as meat processing units shall be left without proper
inspections and controls taking into the high risk nature of the food.
7.10.5 All meat shop owners shall have valid trade licenses issued by the
concerned authority and are liable to comply with the above requirements.
All the meat handlers shall undergo basic hygiene training and possess a
valid meat handlers’ license.
7.10.6 Meat shop owner must issue cash receipt to the customer for every
transaction conducted.
7.11 Operators’ Check System (Annexure II)
7.11.1 A check list incorporating the minimum requirements to be checked by the

meat shop owners or the supervisor, shall be in use to ensure self
discipline by the meat shop operators. Every day before start of the
business and at the end, the designated responsible person shall check
and record in the format (Annexure II) his findings or observations and in
case any area not complying with the specified requirements corrective
action shall be applied. This operators’ check system can continuously
improve the meat processing as well as sales shop conditions in Bhutan.
7.11.2 The BAFRA officials can verify this report and will be a useful tool to
review and schedule their inspection and monitoring activities based on
the level of compliance by the meat shop operators.
7.11.3 Non-compliance of serious nature or any malicious activity in the meat

shop must be reported to BAFRA officials.
FHTM/04/April 2014
8. SANITARY AND HYGIENE REQUIREMENTS FOR ABATTOIRS
Meat processing plant which slaughters large animals and small animals
including sheep and goat or poultry birds within the premises of the factory for
production of meat/ meat products for supply / sale/ distribution to the public
shall comply with the following requirements.
8.1.1 No Objection Certificate to be obtained from Local Authority before grant

of license.
8.2 Location of premises
8.2.1 Such abattoirs should be located away from vegetable, fish or other food
markets and shall be free from undesirable odour, smoke, dust or other
contaminants. The premises shall be located at elevated level in a sanitary
place.
8.3 Premise requirements
8.3.1 The abattoirs shall have a animal holding yard/lairage, slaughter hall,
side halls for hide collection, paunch collection, offal collection, and
separation, holding room for suspected/condemned carcass, by-product
harvesting, refrigeration room/cold room etc.
8.3.2 Every such abattoirs shall make separate provision in the slaughter hall
for the slaughter of different species which are proposed to be slaughtered
(like large animal viz. cattle and buffalo, and small animals like sheep,
goat and pigs) and for different methods of slaughter (like Halal, Jewish
and Jhatka). After every type of operation the abattoirs shall be cleaned,
washed wiped/dried and sanitized thoroughly.
8.3.3 The abattoirs shall have separation between clean and dirty sections and
shall be so organized that from the introduction of a live animal into the
abattoirs up to the emergence of meat and offal classed as fit for human
consumption there shall be a continuous forward movement without any
possibility of reversal, intersection or overlapping between the live animal
meat, and between meat and bye products or waste.
8.3.4 The animal holding yard/ lairage shall have facilities for watering and
examining animals. Animals suspected of contagious or infectious diseases
shall be segregated and kept in separate isolation pens which shall also be
provided with arrangements for watering and feeding. After confirmation
for any notifiable disease outbreaks or case of notifiable disease detected,
the concerned authority shall notify the disease as per the existing
procedures. The resting yard must have overhead protective shelter.
FHTM/04/April 2014
8.3.5 The lairage shall be adequate in size for the number of animals to be
laired.
8.3.6 Separate space shall be provided for stunning (wherever applicable), for
collection of blood and for dressing of the carcasses. The slaughtering of an
animal shall not be done in the sight of other animals. The dressing of the
carcass shall not be done on the floor. Suitable hoists will be provided to
hang the carcass before it is eviscerated.
8.3.7 All the floors in lairage, slaughter halls, work rooms, hanging rooms shall
be of impervious and non slippery material.
8.3.8 The internal walls will be paved with impervious glazed tiles up to 1
meter height in case of poultry and small ruminant animals and 5 meter
height in case of large ruminant animals. The walls and floors should be
epoxycoated so as to avoid accumulation/absorption of dust, blood/meat
particles, microbial/fungal growth.
8.3.9 Ceiling or roofs shall be so constructed and finished so as to minimise

condensation, mould development, flaking and accumulation of dirt.
8.3.10 Suitable and sufficient accommodation shall be provided for segregation,

storage and disposal of condemned meat.
8.3.11 The abattoir shall be so constructed and maintained as to permit hygienic

production.
8.3.12 Windows, doors and other openings must be screened and shall be fly
proof. All doors shall be self closing .
8.3.13 All operations in connection with the preparation or packing of meat /

meat food products shall be carried out under hygienic conditions. No
portion of the abattoirs premises shall ever be used for living or sleeping
purposes unless it is separated from the factory by a wall.
8.3.14 There shall be efficient drainage and plumbing systems and all drains and
gutters shall be properly and permanently installed. There shall be
provision for the disposal of refuse.
8.3.15 The drainage system for blood shall either be underground with facility for
easy cleaning or a portable receptacle with lid. All drainages will have
traps and screens so as to prevent entry of scavengers like rats, mice,
vermin etc.
8.3.16 The rooms and compartments where edible products are handled shall be
separate and distinct from the rooms and compartments for inedible
products.
8.3.17 Suitable and separate space shall be provided for the storage of hides and
skins. This room shall have a separate exit.
FHTM/04/April 2014
8.3.18 A constant and sufficient supply of clean potable cold water with pressure
hose pipes and supply of hot water should be made available in the
slaughter hall during working hours.
8.3.19 Suitable and sufficient facilities shall be provided for persons working in
the abattoirs for changing their clothes and cleaning their footwear, and
cleaning their hands before entering rooms used for the preparation and
storage of meat.
8.3.20 Provision for toilets and change rooms will be made. Sufficient number of
urinals, washbasins and bathrooms for each gender shall be provided.
8.3.21 Suitable and sufficient facilities shall be provided in convenient places

within the abattoirs for the sterilisation of knives and sharpeners and
other equipment used in the abattoirs. The knives and sharpener shall be
of stainless steel only.
8.3.22 Whenever cooking is done on open fire, chimneys shall be provided for
removal of smoke and soot.
8.3.23 Whenever the dressed meat is not used up for the preparation of meat food
products and some portion has to be stored without further immediate
processing, such storage shall be in a room maintained at 0° C to 5°C.
8.3.24 All abattoir refuse and waste materials will be suitably processed to
prepare animal by-products or dumped in pits that are suitably covered so
as to prevent access to scavengers. For large abattoirs, a suitable provision
of effluent treatment plant will be made.
8.3.25 In case of small abattoirs, waste material may be composted which can be
used for manure purpose and in case of large abattoirs, waste material
should be rendered (cooked) in a rendering plant to produce meat, bone
meal and inedible fats.
8.3.26 Suitable and sufficient facilities shall be provided for the isolation of meat
requiring further examination by the authorised veterinary officer in a
suitable laboratory (within the premises of the abattoirs).
8.3.27 Consistent with the size of the factory, volume and variety of meat
products manufactured, a laboratory shall be provided, equipped and
staffed with qualified and trained personnel.
8.3.28 Adequate natural or artificial lighting should be provided throughout the

abattoir/ meat processing unit. Where appropriate, the lighting should not
alter colours and the intensity should not be less than 540 Lux (50 foot
candles) at all inspection points, 220 Lux (20 foot candles) in work rooms
and 110 Lux (10 foot candles) in other areas. Light bulbs and fixtures
suspended over meat in any stage of production should be of safety type
FHTM/04/April 2014
and protected to prevent contamination of meat in case of breakage. As far
as possible meat inspection shall be carried out in day light. Every
abattoir shall be provided with well distributed artificial light.
8.4.1 Every part of the internal surface above the floor or pavement of such
abattoirs shall be washed thoroughly with hot water and disinfected.
Every part of the floor or pavement of the abattoirs and every part of the
internal surface of every wall on which any blood or liquid refuse or filth
may have been spilt or splashed or with which any offensive or noxious
matter have been brought into contact during the process of slaughtering,
dressing and cutting, shall be thoroughly cleaned, washed with water,
wiped/dried and disinfected within three hours after the completion of
slaughter.
8.4.2 Rooms and compartments in which animals are slaughtered or any

product is processed or prepared shall be kept sufficiently free from steam,
vapours and moisture and obnoxious odours so as to ensure clean and
hygienic operations. This will also apply to overhead structures in those
rooms and compartments.
8.4.3 All parts of the abattoirs shall always be kept clean, adequately lighted
and ventilated and shall be regularly cleaned, and disinfected. The
floorings shall be impervious and washed daily. Lime washing, colour
washing or painting as the case may be, shall be done at least once in
every twelve months.
8.4.4 All yards, outhouses, stores and all approaches to the abattoirs shall
always be kept clean and in a sanitary condition.
8.4.5 Suitable and sufficient receptacles furnished with closely fitted covers
shall be provided for collection and removal of all garbage, filth and refuse
from the abattoirs at a convenient time to a place away from the factory
for disposal.
8.4.6 All blood, manure, garbage, filth or other refuse from any animal
slaughtered and the hide, fat, viscera and offal there from, shall be
removed from the abattoirs within 8 hours after the completion of the
slaughtering and in such a manner and by such means as will not cause
nuisance at the premises or elsewhere. Every such vessel or receptacle
shall be thoroughly cleaned and disinfected immediately after use and
shall be kept thoroughly clean when not in actual use.
8.4.7 The inner side of the skin shall not be rubbed or caused to be rubbed upon
the ground within any portion of the slaughter hall. Hides and skins shall
not be dragged within the slaughter hall. No gut-scraping, tripe cleaning,
manufacture or preparation of meat food products, household washing of
clothes or work of any nature other than is involved in the slaughter and
FHTM/04/April 2014
dressing of the carcass shall be permitted in any slaughter hall except in
the adjuncts to the slaughter hall intended for these products and
purposes.
8.4.8 The premises shall be cleaned thoroughly with disinfectants, one day in
advance of production of meat food products and the equipment shall be
sterilized/sanitized before use. The rooms and compartments in which any
meat food product is prepared or handled shall be free from dust and from
odours emanating from dressing rooms, toilet rooms, catch basins, hide
cellars, casing rooms and livestock pens.
8.4.9 Every practicable precaution shall be taken to exclude flies, rats, mice and
vermin from the establishments / abattoirs. The use of poisons for any
purpose in rooms or compartments where any unpacked product is stored
or handled is forbidden. The use of approved bait poisons in hide cellars,
compartments where inedible products are stored, outhouses or similar
buildings containing canned products is, however, not forbidden.
8.4.10 It shall be ensured that dogs, cats or birds do not have access to the
slaughter hall. Open areas in the factory shall have covered wire rope
netting to prevent carrion birds from access to the slaughter hall or the
factory.
8.4.11 Water used in the abattoirs shall be potable. The water shall be examined
chemically and bacteriologically in a recognized laboratory. The water
quality shall comply with the standards prescribed.
8.5 Equipment & machinery
8.5.1 The equipment and fittings in slaughter hall except for chopping blocks,
cutting boards and brooms, shall be of such material and of such
construction as to enable them to be kept clean. The implements shall be
of metal or other cleanable and durable material resistant to corrosion.
8.5.2 No vessel, container or other equipment, the use of which is likely to cause
metallic contamination injurious to health shall be employed in the
preparation, packing or storage of meat food products. (Copper or brass
vessels shall always be heavily lined. No iron or galvanised iron shall
come in contact with meat food products).
8.6 Personnel hygiene
8.6.1 No person suffering from infectious or contagious diseases shall be allowed

to work in the factory. Arrangements shall be made to get the factory staff
medically examined at such intervals as the licensing authority deems fit,
to ensure that they are free from infectious, contagious and other diseases.
A record of these examinations signed by a registered medical practitioner
shall be maintained for inspection.
FHTM/04/April 2014
8.6.2 The staff shall be vaccinated against the enteric group of diseases and a
certificate thereof shall be kept for inspection.
8.6.3 In case of an epidemic, all workers should be vaccinated.

8.6.4 The workers working in processing and preparation shall be provided with
proper aprons and head wears which shall be clean. The management
shall ensure that all workers are neat, clean and tidy.
8.7 Animal welfare
Animal welfare is a major concern in meat production. It is essential that

animals be reared, handled, transported, and slaughtered using humane
practices. A healthy and peaceful animal is an essential requirement for hygienic
slaughter, and quality and safety of the meat product. Careful handling of
animals during loading / unloading, transportation and at slaughtering helps in
improving the quality of meat and reduction in losses in the value of the
carcass/meat. Hence, all the animal welfare standards as prescribed in the
Livestock Act of Bhutan (2001) and its rules must be fulfilled in addition to the
following.
8.7.1 Precautions for animal welfare:
a. General
1. The floor of the slaughter area should not cause slipping or falling of
animals.
2. Vocalization is an indicator of animal discomfort and need to be watched
for.
3. Use of electric pods for moving animal should be discouraged. Movement of
animals can be managed by grouping, use of plastic wrapped sticks etc.
4. Pen stocking density should be monitored. All animals should have room to
lie down simultaneously. The condition of animals arriving for slaughter
should be closely monitored so that injured, diseased animals are not
slaughtered.
5. High pitch sounds such as whistling and yelling should be avoided to spare
distress to animals.
b. The following factors have been identified as critical to animal

welfare:
1. Supervision and training of employees.

2. Designing of animal transport cart and unloading bay.
3. Proper construction of holding/resting pen, stunning box, maintenance of
stunning equipment, restraining systems, gates and other animal handling
equipment.
4. Avoiding distractions that make animals refuse to move.
5. Monitoring the condition of animals arriving at the plant.
6. Proper design of equipment in the abattoirs.
FHTM/04/April 2014
Keeping this in view, the following need to be observed to ensure humane

treatment of animals brought for slaughter:—
1. Pre-slaughter handling of animal should be carefully done to reduce stress.

Resting of the animals is essential. Only animals which are disease free
and in a condition to walk should be brought for slaughter.
2. Distractions that impede animal movements such as, reflections, air
blowing towards animals and movement or high pitch noise, need to be
avoided. Herding of animals should not be done through electric prods but
with the help of plastic bags or sticks.
3. A high standard of training is required for employees to ensure that the
basic hygiene and safety practices are followed while handling animals.
4. Equipment which is used for slaughter such as captive bolt stunner, gates,
hooks etc should be kept in good working condition and cleanliness of floors
etc. needs to be ensured. There should be daily check to ensure the smooth
working of equipment and cleanliness of floors.
5. The condition of the animals arriving at the plant should be monitored.
Animals which are injured or not in a condition to walk should not be
slaughtered.
6. Inspecting personnel should pay particular attention to these points to
ensure reasonable standards of animal welfare.
7. A schedule shall be kept for inspection of the condition and cleanliness of
the facility and the same shall be followed, recorded and verified by the
authority.
8. In case of serious violations actions shall be initiated
FHTM/04/April 2014
Annexure I
Definitions
Establishment
Any building or area in which food is handled and the surroundings under the
control of the same management.
Food Safety
Assurance that food will not cause harm to the consumer when it is prepared
and/or eaten according to its intended use.
Standard
Standard is a document approved by a recognized body that provides, for
common and repeated use, rules, guidelines or characteristics for products &
related processes and production methods, with which compliance is not
mandatory. It may also deal with terminologies, symbols, packaging, marking or
labeling requirements as they apply to a product, process or production method
(WTO-TBT- Annex 1).
Regulation
Technical regulation is a document which lays down product characteristics or
their related process and production methods, including the administrative
provisions with which Compliance is Mandatory. It may also include or deal
exclusively with terminologies, symbols, packaging, marking or labeling
requirements as they apply to a product, process or production methods (WTO-
TBT-Annex 1).
Food
Any substance, whether processed, partially processed or unprocessed, which is
intended for human consumption and includes primary food to the extent
defined, genetically modified or engineered food or food containing such
ingredients, packaged drinking water, beverages, chewing gum, and any
substance, including water used into the food during its manufacture,
preparation or treatment but does not include any animal feed, live animals
unless they are prepared or processed for placing on the market for human
consumption.
Food Business Operator (FBO)

A person by whom the business is carried on or owned and is responsible for
ensuring the compliance of the Act, rules and regulations applicable to the
business.
Sampling and Analysis

Taking food or any other substance (including from the environment) relevant to
the production, processing and distribution of food in order to verify through
analysis compliance with food law /regulations.
FHTM/04/April 2014
Sample
A set composed of one or several units or a portion of matter selected by different
means in a population or in an important quantity of matter, which is intended
to provide information on a given characteristic of the studied population or
matter and to provide a basis for a decision concerning the population or matter
in question or concerning the process which has produced it.
Food Safety Management System (FSMS)

The adoption of Good manufacturing Practices, Good Hygiene Practices, Hazard
Analysis and Critical Control Points and such other practices as may be
specified in the regulation for the food business
Contaminant
Any biological or chemical agent, foreign matter, or other substances not
intentionally added to food products that may compromise food safety or
suitability
Contamination
The introduction or occurrence of a contaminant in food or food environment.
Control measure
Any action and activity that can be used to prevent or eliminate a food safety
hazard or reduce it to an acceptable level.
Corrective action
Any action taken when the results of monitoring indicate a loss of control (Codex
Definition).
Food Handler
Any person who directly handles packaged or unpackaged food, food equipment
and utensils, or food contact surfaces and is therefore expected to comply with
food hygiene requirements.
Food Hygiene
All conditions and measures necessary to ensure the safety and suitability of
food at all stages of the food chain.
Foreign Matter or Extraneous Matter

The presence in the sample unit of any matter, which had not been derived from
food that does not pose threat to human health and is readily recognised without
magnification or is present at a level determined by any method including
magnification that indicates non compliance with good manufacturing and
sanitation practices.
FHTM/04/April 2014
Good Manufacturing Practices (GMP)
Food handlers Compliance with the Structural and Operational requirements of
Act and Regulations to ensure that food is not contaminated due to insanitary
conditions.
Inspection
Evaluating for conformity by measuring, observing, testing or gauging the
relevant characteristics to assess compliance with specified standards.
Monitoring
The act of conducting a planned sequence of observations or measurements of
control parameters to assess whether a Critical Control Parameter is under
control.
Potable water
Water that is fit for human consumption as prescribed by WHO.
Pre requisite program (GMPs & GHPs)

Basic conditions and activities necessary to maintain a hygienic environment
throughout the food chain, suitable for the production, handling and provision of
safe end products to the consumers.
Processing
An operation affecting the wholeness or any other chemical or physical
characteristics (heating, salting, dehydration, canning, bottling, pulverising,
blending or extraction).
Sanitize
Adequate treatment of surfaces by a process that is effective in destroying
vegetative cells of micro-organisms to a safe level.
Standard Sanitation Operation Procedure (SSOP)

Procedure to ensure sanitary conditions usually related to the entire processing
facility or an area, not limited to a specific processing step of CCP to prevent
adulteration due to unsanitary conditions.
Verification
The application of methods, procedures, tests and other evaluations, in addition
to monitoring to determine compliance with the documented procedures.
Process Hygiene Criteria

Criteria indicating the acceptable functioning of the process. Such a criteria is
not applicable to the products placed on the market or finished goods. It sets an
indicative contamination value above which corrective actions are required in
order to maintain hygiene of the process in compliance with food law.
Food Safety Criteria

FHTM/04/April 2014
Criteria defining the acceptability of product or a batch of food stuff, applicable
to products placed on the market (Finished Goods).
Cleaning
Removal of soil, dirt, grease, oil , food residue or other objectionable matter.
Zoning
Demarcation of an area within an establishment where specific operating,
hygiene or other practices may be applied to minimize the potential for
microbiological cross contamination.
FHTM/04/April 2014
Annexure II - Operators’ Check System Log
Month: Date & time:
Hygiene & Sanitary Daily Weekl Monthl Designated Verified by Corrective CA verified by MO
condition of y y Personnel Action (CA) with remarks &
item/area/activity Signature
Surroundings *
Premises *
Floor/walls/ceilings *
w/o crevices
Corrosion on the fittings & *
unprotected fittings
Dents, damages, *
crevices on the food contact
surfaces & with food residues
Sign boards *
Stagnant water *
Leaking taps/water tanks * *
Refrigerator and freezers *
Freshness of carcasses *
Uncompatible items displayed *
eg. hides, other meat products,
separate from meat
Cross contamination *
Cleaning and disinfection of *
chopping boards
FHTM/04/April 2014
Knives *
Work surfaces *
Hot water provision and its *
use
Storage of chemicals *
H.W facility cleanliness *
Towels changed *
Cleanliness of workers *
Health status *
Cuts /wounds covered *
Hair protected/ *
Jewelery worn
Pest prevention *
Screens intact
Pest control monitoring and *
recording
Waste collection, disposal, *
cleaning of bin
Left over of the day- storage *
and use
Quality check of frozen and *
fresh meat
Toilet sanitatation *
FHTM/04/April 2014
REFERENCES:
1. Codex Alimentarius, Food Hygiene – Basic Text, Fourth Edition-2009
2. Guidelines for the design of control measures for street-vended foods (Africa)
CAC/Gl 22r – 19

Training Manual For Meat Handlers

Uploaded by

Copyright:

Available Formats

Training Manual For Meat Handlers

Uploaded by

Copyright:

Available Formats

TRAINING MANUAL FOR MEAT HANDLERS

Bhutan Agriculture and Food Regulatory Authority

Responsibility and accountability have to be shouldered by the FBOs under the

The manual specifies requirements for establishing, implementing and

Examples of such exclusions can be in;

• Construction, layout of buildings and associated utilities eg. street vendors

What is safe food? Is it a clean food which is safe?

So what is safe food?

Contamination is the presence or introduction of a contaminant in the food or

Contaminant is any biological or chemical agent, foreign matter or other

Cross contamination is transfer of contaminant particularly bacteria from

How to prevent cross contamination?

Through Hygiene or Good Hygiene Practices (GHPs)

Application of food hygiene includes but not limited to;

• Rejecting contaminated food from suspected sources

Food Borne Disease (FBD)

An illness caused by consumption of food contaminated by pathogens,

How are foods categorized based on the risk?

High Risk Foods (HRFs)

Low Risk foods

Normally kept in ambient temp as they cannot promote multiplication of

Ready to Eat Raw Foods

Understanding these risks is necessary to control them as we know it is the risk

The probable risk factors are;

Codex General Principles of Food Hygiene and Application of HACCP in food

Hazards are categorized into;

b) Physical hazards or foreign bodies in the final product causing cuts,

• Peanut, nuts (walnut, brazil nut, almonds)

All these hazards need to be prevented, eliminated or reduced to acceptable level

a) Control of bacterial hazards

Remember 5 Cs - Clean, Cook, Cover, Chill, Cross-contamination.

Control of Physical hazards

Control of chemical and allergens

Control measures include;

5.1 General Requirements

Building shall be designed, constructed and maintained in a manner appropriate

Consideration shall be given to potential sources of contamination from the local

5.3 Location of establishment

5.4 Layout of premises and workplace

5.4.1 General requirements

Internal layout shall be designed, constructed and maintained to facilitate GHPs

5.4.2 Internal design, layout and traffic pattern

Sealing and overhead structures shall be designed to protect from condensation

5.4.4 Location of equipments

Equipment shall be designed and located so as to facilitate good hygiene

5.4.5 Laboratory facility

Inline or online sampling and testing facilities shall be controlled to prevent

5.4.6 Temporary or mobile premises and vending machines

Temporary or mobile facilities shall be designed, constructed and located to

5.4.7 Storage of food, packaging materials, ingredients and non food

Facilities used to store ingredients, packaging and products shall provide

5.5.1 General requirements

Provision and distribution routes of utilities shall be controlled and monitored to

5.5.2 Water supply

5.5.3 Boiler chemicals and other water purifying chemicals

5.5.4 Air quality and ventilation

5.5.5 Compressed air and other gases

Compressed air, if used in the manufacturing or packing, the quality shall be

5.6 Waste disposal

5.6.1 General Requirements

Waste materials shall be identified, collected, removed and disposed of in a

5.6.2 Containers for waste and inedible or hazardous substances

Containers for waste and inedible materials shall be;

5.6.3 Waste collection, management and removal

5.6.4 Drains and drainages

5.7 Equipment suitability, maintenance, cleaning and sanitation

Food contact equipment and surfaces shall be designed and constructed to

5.7.2 Hygienic design

Equipment shall be able to meet the established principles of hygienic design

• Smooth accessible cleanable surfaces, self draining in wet process areas

5.7.3 Product contact surfaces

5.7.4 Temperature control and monitoring equipment