warehousing techniques
TRANSCRIPT
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Principles of Food Warehousing
By
Dr Deryck D. Pattron, Ph.D.Public Health Scientist & Consultant
Trinidad, West Indies
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Definition of food warehouse
Any food storage facility, storing large or nor solarge amounts of food for either short or longperiods, for distribution in normal food channels
Important link in the food chain from theprocessor to consumer
Vary in nomenclature, size, function andphysical conditions
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What is the importance of safefood warehousing?
To prevent economic losses
To promote health and well being
To facilitate trade To facilitate economic prosperity
To prevent spread of diseases
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What is the importance of safefood warehousing? (cont’d)
To provide a readily available source of food
To provide revenue and job opportunities
To prevent burden on health care facilities To ensure a steady supply of goods on the
market
To ensure consumers have access to foods in
and out of season both locally andinternationally
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What types of food warehousesexist?
Dry storage warehouse
Chilled storage warehouse
Frozen storage warehouse Dry and chilled storage warehouse
Dry and frozen storage warehouse
Chilled and frozen storage warehouse Dry, chilled and frozen storage warehouse
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Warehouse grounds
Areas surrounding warehouse should be: Free from weeds, grass and bush
Free from trash, rodent tracks and burrows
Free from standing water and clogged drains Walkways and driveways paved and kept in a
good state of repair
Well drained Ideally located away from potential
environmental hazards
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Warehouse building (external)
Walls and roof should be painted andmaintained in a good state of repair
Doors and windows should be screened proofed
Wall and ceilings should be free from cracks andholes
Pipes entering the building should be sealedproperly to prevent entry of pests
Roofs should be maintained in a good state ofrepair and not leak
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Warehouse building (internal)
Floors, walls and ceilings should be smooth,clean and maintained in a good state of repair toprevent cross contamination
Windows and doors should seal tightly toprevent entry of pests
No dead spaces around equipment or otherstructures that would provide harborage forpests and prevent efficient cleaning
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Warehouse equipment
Chillers Freezers
Forklifts
Shelves Storage bins
Temperature and humidity gauges
Pallets
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Warehouse equipmentcharacteristics
Rust resistant
Odour resistant
Non-porous Easily cleaned and sanitized
Suitably colored
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Warehouse equipmentcharacteristics (cont’d)
Food grade or compatible
Non toxic
Located in an area that facilitates easy cleaningand maintenance
Free from grease and other chemical or physicalcontaminants
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Warehouse storage conditions
Food items should be stored on pallets
46 cm off ground and 46 cm off wall
Non crowded
Clean and sanitary
Food items stored and rotated on a first-in-first-outbasis
Maintained at proper temperature and humidity
Free from physical, chemical and microbiologicalhazards
W h d h dli
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Warehouse storage and handling
of hazardous materials
Poisonous chemicals such as pesticides,cleaning solvents, lubricants and othercompounds should be safely and securelystored
Accessed by authorized, trained employees
Properly labelled
Follow manufacturers instructions as to the
quantity for safe use Use protective ware when handling hazardous
materials
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Warehouse storage temperature
All frozen food products should be at –18º C or below
During transport the temperature should not behigher than – 12 ºC
Temperatures for chilled storage should be keptbetween 1º C and 4 º C
Dry storage areas should be between 10 º C and21 º C
Thermometers should be present in all frozenstorage, chilled storage and dry storage areaswith on site temperature logs
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Warehouse storage temperatureand relative humidity
Products Temperatures Relative Humidity
Frozen meats: -23 º to -17 º C ------------Canned products 4.4 º to 16 º C 50 to 60 %
Grains 4.4 º to 16 º C 50 to 60 %
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Warehouse air circulation
Important factor in the proper storage of food
Food products should be stacked on pallets
46 cm wall clearance and 5 cm ceiling clearance
Sufficient working aisle space
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Warehouse ventilation
To prevent excessive heat, steam condensationand/or dust from accumulating within a confinedarea
Should never be from dirty to clean area Openings should be screen proofed
Should be natural or artificial
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Warehouse lighting
Essential for:
General cleaning
Reading and identifying labels, colours
Recognising the condition of the food stored
Preventing injuries
Preventing cross contamination of food products
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Warehouse lighting specifications(cont’d)
At least 540 lux at all inspection points
At least 220 lux in work areas
At least 110 lux in other areas
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Warehouse sanitary operations
To avoid contamination of food products To ensure detergents, sanitizers, hazardous
materials and other supplies used in safe andeffective manner
Cleaning compounds and hazardous materialskept in original containers, stored separate fromfood products
Garbage properly stored and protected frominsects, rodents and other pests and/or disposedin an adequate manner
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Warehouse sanitation operations(cont’d)
A permanent cleaning and disinfecting scheduleshould be developed and enforced
All cleaning workers should be well trained in
cleaning and disinfecting procedures
All floors are not cleaned in the same manner:-some floors are wet cleaned using a strong
cleanser, rinsed and allowed to dry, other floorsare cleaned by sweeping and brushing
W h h i l f
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Warehouse chemicals for
disinfection Chlorine and chlorine-based products
100-250 mg of available chlorine per litre Two minutes exposure time Rinse after exposure
Iodophors 25-50 mg per litre of available iodine Two minutes exposure time Rinse after exposure
Quaternary ammonium compounds 200-300 mg per litre Two minutes exposure time Rinse thoroughly after exposure
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How to handle garbage in foodwarehouse?
Quickly remove and store in covered bins
Excellent breeding ground for pests
Broken down pallets and cardboard boxesshould be disposed of in an appropriate manner
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Transportation practices to andfrom food warehouse
Transport at the proper temperature
Maintain a temperature log for each trip
Protect food from thermal, physical, chemicaland microbiological injury
Protect from unsanitary conditions
Protect from poor handling and packing
Transport food in covered reliable well cleanedand maintained vehicles
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Requirements for incoming raw
materials in food warehouse
Temperature of food product Absence of pesticide residues
Microbiological quality
Chemical quality Absence of physical contaminants
Clean and sanitary surroundings
Grade or type Conform with regulatory agency’s requirements
Absence of insects, rodents or bird activity
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Rotation of stored food inwarehouse
Food products should be rotated based on theexpiry date and perishability
Old products should be kept in front of the new
products All incoming products should be dated
Food containers should not be dusty, faded or
discoloured
Repackaging operations in food
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Repackaging operations in food
warehouse Should be done under strict hygienic and
sanitary conditions
All equipment should be clean free from debrisand properly sanitized
Packaging should be food grade andunadulterated
Audit for quality by ensuring all packagingseams are intact, no foreign contaminants, filled
to stated weight or volume Audit for safety by performing random or
systematic sampling of repackaged products forchemical, physical and microbiological
consistency
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Quarantine in food warehouse
Products spoiled by physical, chemical andmicrobiological damage, insects, rodents orother causes should be stored in a designatedquarantine area
Quarantined items should be disposed of quicklyto avoid pest harborage and infestation of storedfood
Incoming materials that are damaged and not inaccordance with suppliers specifications shouldbe rejected
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Pest control in food warehouse
Perform regular pest inspections in and aroundwarehouse
Be vigilant and on the look out for burrows, urinetracks, fecal pellets, rub marks, snawing marks,
hairs, dead rodents, etc.
Pesticides are poisons and should beadministered by a competent person
Pesticides should be placed at marked positionsthroughout the warehouse and checkedregularly
Recall types for potentially
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Recall types for potentiallyhazardous food distributed from
food warehouseThree types of FDA recall:
Type I= Most serious, high risk, potential injuryor death
Type II = Minimum risk, temporary healthproblems
Type III = Least severe, unlikely to cause health
problems, violate FDA manufacturing or labelingregulations
Recall procedures for potential
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Recall procedures for potentialhazardous food distributed by food
warehouse Maintain a current list of all purchasers:• Person name doing business on behalf of
company• Name of company• Mailing address• Phone number
• Email address
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Recall procedures for potentiallyhazardous food distributed by food
warehouse(cont’d)
Each product sold/distributed should have a
batch number indicating time, date, batch, shiftwith respect to its manufacture
Each product withdrawn from the market shouldbe able to be traced back to its source andpossible areas of concern identified andcorrected for future products
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Employees code of practice in foodwarehouse
Good hygienic practices
Good sanitary practices
Suitable safety ware such as clothing, face
mask, respirators, weight lifting belts, steel tipbooths
Properly trained staff
T il t f iliti il bl t
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Toilet facilities available to
employees in food warehouse
Toilets should not open directly into food storageareas
Sewage line should not pass over stored food
The number of toilets should be appropriate tothe number of staff, both male and female
Warning signs should be posted on entering
toilet areas advising users to wash handsthoroughly after use
T il t f iliti il bl t
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Toilet facilities available to
employees in food warehouse
(cont’d) Toilets should be equipped with toilet paper,
soap, sanitizer and potable water
Toilets should be maintained clean and sanitaryat all times
Toilets should be properly ventilated and may be
fitted with extractor fans
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Hand washing facilities available toemployees in food warehouse
Suitably located and present in the sufficientnumbers to ensure safe and hygienic operations
Prevent cross contamination of stored food
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Changing room facility available to
employees in food warehouse
Should be equipped with lockers
Prevents employees using street clothes
Provides a place to change clothes and to put onprotective gear
Should be maintained in a good state of repair
Separate for males and females
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Conclusions
Food warehouses are an important link in thefood chain from “farm to fork”
Food warehouses provide a readily available
reserve supply of food allowing consumers toenjoy a wide variety of foods out of season aswell as in season
Food warehouse like other food facilities mustbe built in a non hazardous environment andmaintained in a good state of repair to preventadulteration of stored food
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Conclusions (cont’d)
Employees who work in food warehousesshould observe proper hygienic guidelines andsanitation standard operating procedures
Proper employee facilities should be in placesuch as toilet facilities, hand washing stations,changing rooms, lunch rooms to preventadulteration of stored food
Proper protocols should be implemented fortransportation, receiving, storage, and recall offood
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References
Food and Agricultural Organization of the Unitednations. 1984. Manuals of Quality Control 5.Food Inspection.
Longree, K. 1985. Quality Food Sanitation. New
York: John Wiley & Sons.
Pattron, D. 2004. Quality Assurance & FoodService. New York: Scientific Publishers.
Pattron, D. 2004. Food Safety. New York:Scientific Publishers.
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D D P Ph D
The End
Thank You
Dr Deryck D. Pattron, Ph.D
Public Health & Safety Consultant
Trinidad, West Indies
Email: [email protected]