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Good Hygiene Practices along the coffee chain

Module 3.2

The Codex General Principles of


Food Hygiene Establishment:
design and facilities

Objectives
To make trainees aware of the importance of
good hygienic design and construction of food
establishments
To relate the general code to the handling and
processing of coffee
To create awareness of the roles of different
stakeholders in ensuring good practices

Slide 2

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Content
Scope and objectives of Section IV of the Codex
General Principles of Food Hygiene
Discussion of food hygiene principles relevant to
Establishment: design and facilities and their
application to coffee handling and processing
Discussion of the roles of producers and
government in ensuring good practices

Slide 3

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Establishment: design and facilities


Objective of Section IV

Depending on the nature of the operations, and the risks


associated with them, food establishments should be designed
and constructed and equipped to ensure that
Contamination is minimised
Appropriate maintenance cleaning and disinfection is
permitted

Codex definition of establishment:


...Any building or area in which food is handled and the
surroundings under the control of the same management.

Slide 4

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Establishment: design and facilities


Section IV of Codex GPFH covers:

Location of establishments
Premises and rooms design, layout and internal structures
Design of equipment and its placement in the establishment
Supporting facilities and services

Food hygiene considerations are important at the very first


stages of planning a food establishment
Slide 5

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Location of establishments
Establishments should not be located near

Slide 6

Polluted areas that pose a serious threat of contaminating food


Areas prone to pest infestation
Areas prone to flooding, high humidity, etc.
Areas from which waste cannot be easily removed

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design and layout of establishments


Internal design and layout of establishment should
Permit good hygiene practices
Minimise possibility of cross contamination

There should be separate


channels for

Raw
materials

Waste

Raw material (fresh cherries)


Intermediate product
(parchment, dry cherries)
Waste (pulp, husk)
Final product (green beans)

Work rooms

Offices
End-products
Warehouse

Generalised lay-out for processsing


facility showing product flow

Slide 7

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Layout of facility
To optimize proper functioning of each
element of procedure
Pulpers should be located near a clean
water source
Fermentation vats should be located
near to pulpers
Waste outlet should be directed away
from production and processing areas
Drying yards and other processing
areas should be away from
contamination vectors
Slide 8

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design and construction of drying areas


Coffee drying yards should have
Adequate capacity
Smooth drying surfaces
Adequate provisions for drainage
Full exposure to sunlight

Slide 9

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design and construction of


fermentation vats
Fermentation vats should
Be located in the pulping house
Be adequate in number and
capacity
Have smooth surfaces
Have a maximum depth of 1m
Slope gently towards the outlet

Slide 10

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Internal structures and fittings


Internal structures should be
Made of durable materials
Easy to clean and maintain

Open beams and rafters


accumulate dust

Slide 11

Tiled and smooth surfaces


suitable for cleaning

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Internal structures and fittings


General considerations
Walls and partitions should be easily cleaned
Floors should be constructed to allow adequate cleaning and
drainage
Ceilings and overhead fixtures should be constructed to
minimise build up of dirt and condensate
Working surfaces in direct contact with food should be durable
and easy to clean

Slide 12

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Facilities - air quality and ventilation


Adequate ventilation is required to
Minimise build-up of dust and husk particles from
handling operations
Control temperature and prevent condensation
Dissipate odours that might taint the coffee

Slide 13

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Facilities - lighting
Adequate natural or artificial lighting should be
provided to enable operations to be carried out
satisfactorily

Slide 14

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Facilities - storage
Adequate storage facilities should be provided
for coffee to permit
Adequate maintenance and cleaning
Avoid pest access and harbourage

Slide 15

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Facilities - storage
Adequate storage facilities should be provided
for coffee to
Enable food to be protected from contamination
during storage

Thulha - Brazil

Slide 16

Storage in a wet room


with mouldy walls

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Facilities
Containers for storage of dangerous materials
(fuel, chemicals for cleaning, disinfestation, etc.)
should be clearly marked and safely stored
Water supply - water of acceptable quality
standard should be available for processing
Systems carrying unsuitable water should be
separate
Electricity supply operators should ensure
alternative sources of electricity in case of cuts
to the central power supply
Slide 17

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Facilities
Drainage and waste disposal
Cleaning facilities - should
allow for adequate cleaning
of equipment and facilities
Personal hygiene facilities adequate toilet,
handwashing and changing
facilities should be provided
for staff

Slide 18

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

One of a series of pools for


treatment of waste water, at
one wet processing facility

Design of equipment
Equipment should be
designed and constructed
to ensure that they can be
adequately cleaned and
maintained

Slide 19

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Sharp corners and crevices


may create areas where food
material can lodge, making
equipment hard to clean

Design of equipment
Where necessary, equipment should be movable or
capable of being disassembled to allow for
maintenance, cleaning, monitoring, etc.

Pulpers used in wet processing

Slide 20

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design of equipment
Equipment should be designed such that their operation is
compatible with conditions necessary to ensure food safety
and suitability. Main types of equipment in coffee processing
include

Dryers
Pulpers
Hullers
Sorting equipment
Moisture monitoring equipment
Several variations of basic coffee processing technology exist and
different equipment may be used

Slide 21

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design features of simple


sun-drying equipment
Coffee is spread on a support (wire tray, woven mat,
etc.) raised off the ground. Air can circulate freely above
and below the support
Trays might be movable or fixed
When raining, trays are moved under a shelter or
covered with plastic or any other material

Slide 22

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design of simple solar dryers


Parabolic solar dryers - the shape
of the transparent roof is more or
less cylindrical so as to
concentrate heat in the drying
zone and protect from rain.

Heat cumulates between the


coffee and the plastic and the air
starts to circulate. This dryer is
mounted on a pivot so it can be
turned towards the sun.
Slide 23

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design of simple solar dryers


Various solar dryer designs can give faster
drying times by
Improving airflow and increasing temperature
of drying air

Participatory approaches are necessary if


potential advantages of solar
technology are to be matched with
farmers needs
Capacity, capital cost, running costs, space
requirement, ease of management, etc.

For additional information see Section 5


of Introduction to coffee drying [.pdf]
Slide 24

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design of equipment mechanical dryers


Mechanical batch dryers are used in coffee
drying - primarily for parchment
Horizontal dryers
Vertical dryers
Fixed-bed type dryers

Slide 25

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design features of pulpers


Traditional designs are drum and disc
pulpers

Main performance criteria include


Capacity; separation efficiency; physical damage to
product; durability; ease of maintenance and
cleaning
Slide 26

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design features of pulpers


Important innovations are
Low water-use pulpers
Pulping systems that
accept mixtures of green
and ripe cherry and
separate the greens
without crushing

Slide 27

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Design of hullers
Considerations in the selection of a huller
include:

Slide 28

Capacity
Energy requirement
Efficiency of husk removal
Extent of physical damage to beans
Separation of loose husk
Durability
Ease of maintenance
Module 3.2 The Codex
General Principles of Food
Hygiene Establishment:

Equipment for control and monitoring


Methods for the determination of water in coffee
can be categorised as follows
Direct

Removal of water and determination of weight loss

Indirect

Some variable that is dependant on moisture is measured

Empirical subjective
This includes methods such as biting, shaking and cutting
NB - These empirical methods of moisture determination in coffee
have been shown to be unreliable

Slide 29

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Equipment for control and monitoring


Factors to be considered include

Cost
Transportability
Robustness
Stability
Repeatability
Sensitivity
Accuracy
Rapidity

The choice of method / equipment depends on

How the equipment is to be used


Who is to use it

Slide 30

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Equipment for monitoring


moisture in the field
Restricting water
availability is the main
method for control of
mould growth and
development throughout
the coffee chain
The global coffee project
has investigated methods
of moisture determination
so as to identify methods
suitable for use in the field

Slide 31

One type of low-cost


moisture meter
investigated under the
global coffee project

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

EDABO
distillation method
of moisture
determination
developed in Brazil

Location of equipment
Equipment should be
located:
To permit adequate
maintenance and cleaning
In accordance with
requirements for proper
functioning
To facilitate good hygiene
practices, including
monitoring

Slide 32

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Assessment of establishment
A plant assessment can help processors determine if
facility design is appropriate
A checklist containing all vital areas and items to be
considered should be prepared
During the inspection notes should be made in relation
to all points contained in checklist
Evaluation of the design and construction of the
establishment and facilities should be based on
thorough knowledge of operations and potential hazards
Corrective action taken according to evaluation

Slide 33

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Assessment of establishment
Government
Establish national standards,
codes of practice, etc.
Support industry efforts to
meet required regulations
(information dissemination,
new equipment design etc.)
Provide oversight to ensure
industry compliance

Slide 34

Local coffee industry


Collaborate with government in
developing sound and practicable
guidelines and standards
Entrepreneurs must ensure that
the design of their establishment
is consistent with principles of
food hygiene
Entrepreneurs must establish
adequate hygiene and GMP
programmes to ensure that
equipment functions properly and
that they do not lead to hazards
in the coffee

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

Summary
Inappropriate site selection for coffee processing facilities
can lead to quality and safety problems in the product
Plant layout should minimize the opportunity for cross
contamination
Facility design and construction can affect the quality and
safety of coffee
Equipment must be designed and located so as to facilitate
its correct functioning, sanitation and maintenance
Government and industry must work together to improve
hygiene conditions of coffee processing establishments

Slide 35

Module 3.2 The Codex


General Principles of Food
Hygiene Establishment:

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