In-Plant Training Report
Suviska Tea Factory
Neluwa
Galle
.
Thilina Amarasiri
AS68235/2010/2011
AS2011704
Department of Food Science and Technology
Faculty of Applied Sciences
University of Sri Jayewardenepura
Gangodawila
Nugegoda
Industrial training report submitted for the partial fulfillment of the requirements of the B.Sc. special degree in Food Science and Technology
Declaration
Industrial training report submitted for the partial fulfillment of the requirements of the B.Sc. special degree in Food Science and Technology.
(Course unit FST 496 5.0)
By Thilina Amarasiri AS68235/2010/2011
AS2011704
Department of Food Science and Technology
Faculty of Applied Sciences
University of Sri Jayewardenepura
Gangodawila
Nugegoda
I hereby
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References
ISO 22000:2005 Food Safety Management System Requirements
SLS143: 1999 General principles of food hygiene Food Act No. 26 of 1980 Food hygiene regulations Sri Lanka Tea Board regulations
2.2 Terms and Definitions
2.2.1 Food safety
The concept that food will not cause harm to consumers when it is prepared and/or eaten according to its intended use.
2.2.2 Food chain
Sequence of the stages and operations involved in the production, processing, distribution, storage and handling of a food and its ingredients.
2.2.3 Food safety hazard
Biological, chemical or physical agent in food, or condition of food, with the potential to cause an adverse health effect.
2.2.4 Food safety policy
Overall intentions and direction of an organization related to food safety as formally expressed by top management.
2.2.5 End product
Product that will undergo no further processing or transformation by the organization.
2.2.6 Flow diagram
Schematic and systematic presentation of the sequence and interactions of steps.
2.2.7 Control measure
Food safety action or activity that can be used to prevent or eliminate a food safety hazard or reduce it to an acceptable level.
2.2.8 Pre-requisite program
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2.8.2.3 These Good Manufacturing Practices (GMPs) are those used as pre-requisites for developing of ISO 22000:2005 based Food Safety Management System. The effective implementation of f GMPs identified shall ensure the reliability and credibility of the HACCP addressed in the Food Safety Management System.
2.8.2.3.1 Construction and layout of buildings and associated utilities
The processing facility shall be located in an environment without any pollution and industrial activity which could contribute to and serious threat of contaminating the product.
The factory shall be located at a high elevation without any possibility of flooding. The infestation of pests from the factory environment is remote with the well maintained surrounding.
2.8.2.3.2. Lay-out of premises &workspace & employee facilities
2.8.2.3.2.1 Design & layout
The internal layout of the factory shall permit good hygiene practice, including protection against cross-contamination between and during operations.
Adequate number of toilets shall be provided with flush systems. Toilets shall be hygienically designed and provided with wash basins and soap for effective
The HHP program is implemented to ensure adequate sanitation and housekeeping while providing hygiene facilities that are regularly cleaned and maintained so that they do not affect the safety of food and workers. Regular housekeeping and maintenance always help to determine potential issues or problems and take preventive action before problems develop into more critical stage. Implementation
After, sections seven and eight specify food and drug adulteration and misbranding. Section nine arranges safety from trial for food and drugs that have been impure or mislabeled and do not meet foreign countries requirements. Section 10 decides where a case of adulteration or misbranding will be put on trial if the alleged product has been shipped to other countries or across state lines. Section 11 assembles random inspections of drugs and food being brought into or shipped out of the United States. Lastly, section 12 clarifies the liabilities, as 13 states the effective date.
Large farms, processing facilities, and factories are used by the industry with a variety of levels of security. There are often sanitation processes, good manufacturing processes, and hazard identification and control systems in place at processing facilities and factories. Even with these systems and processes in place, the overall facility or a single batch remain vulnerable. The highest risk comes from the employees either intentionally or unintentionally contaminating a batch of food. Testing is supposed to ensure the food is within specific allowances for contaminates, but the laboratory confirmation takes time that perishable items may not have to wait.
Winnable Battle- Safe Food Objectives: Approximately 1 of 6 people in America get sick from eating contaminated food. Some people recover and few others may suffer from complication such as kidney failure, miscarriage or brain and nerve damage (10 Colorado winnable battles). In Colorado, there is at least 41% of foodborne outbreaks report and investigation each year. This is an enormous number that underscores the need for vigilance and highlights the importance of the food safety programs to identify foodborne illnesses (10 Colorado winnable battles).
Food is the sustaining life force that drives the human race forwards from day to day. As daily consumers of food products, it is automatically expected that the producers of such important products aim to produce goods that will help the consumer and attribute to their health. Unfortunately, this is not always the case. At the turn of the twentieth century, food sanitation in factories was at an all time low. Adding to this issue were the harsh conditions in which the workers were forced to work in.
Food is the fuel for humans, supplying energy and nutrients to get them throughout the day. But how has the way of getting food changed as a result of industrialization? Consider the tomato; it is ripe, farm fresh, and transformable to any desired recipe. However, today’s tomatoes are grown in places that consumers would probably not be able to locate on a map, ripened with assistance of ethylene gas, and picked while they are green. The process of obtaining food has undoubtedly changed.
The code addresses controls for risk factors to protect consumer health. There were five key interventions established to achieve this goal of addressing risk factors. These interventions are: demonstration of knowledge, employee health controls, controlling hands as a vehicle of contamination, time and temperature parameters for pathogen control, and consumer advisory. The goal of the Food Code is to regulate food processing. This goal is achieved in many ways, but a few are: setting a proper holding temperature for food, identifying incompetent cooking (raw food), restricting contaminated cooking equipment, finding safe sources for food, and setting standards for the personal hygiene of people around and handling food.
The term "health hazard" encompasses the following: • Toxicity – is the ability of a substance to cause a harmful effect. Everything is toxic at some point. Even too much WATER can KILL! • Toxicity vs. Dose o Toxicity – level of poison o Dose – amount exposed to o Less the toxicity, greater dose one can tolerate without ill effects o Greater the toxicity, less dose one can tolerate without becoming sick • Acute vs.
INTRODUCTION: Bloodborne pathogens are microorganisms that present in human blood and they can cause diseases. These pathogens include: – Viruses such as hepatitis B (HBV), hepatitis C (HCV) and human immunodeficiency virus (HIV), also, parasites such as malaria and certain fungi. Sharp-tools, needle-sticks and other apparatus-related injuries may expose stuff to bloodborne pathogens. To eliminate the risk of occupational exposure to bloodborne pathogens, implement an exposure control plan for workers on their worksite with enough details on protection measure.
Processed includes chemically processed, refined ingredients, and artificial substances. They have many artificial ingredients with many to zero real food. Using preservatives manufactures can stop spoiling, colorants to make desirable, with flavor and text rants. The production and consumption of processed foods and the artificial ingredients has lead to numerous health related problems in today’s society, including low nutritional intake, over consumption, obesity and illness. II.
Process and tools Target Corporation uses tolls and process for product safety and quality assurance. The company assesses a program for risk –based product safety and quality at every stage in the product life cycle, from development through the life of brand product. Target global team implement a program across 36 countries and 2228 factories producing target product, during the process will require independent third-party testing to validate safety and quality before the guests purchase product. the vendor in the company are expected to employ best practices, including clearly defined and well-documented manufacturing and quality processes including staff training , and record keeping. What does the TC required to do the job?
In a study by Vollard A.M., Ali S., van Asten H.A., Ismid I.S., Widjaja S., Visser L.G., Surjadi C.h., and van Dissel J.T. on “Risk Factors for Transmission of Food-borne Illness in Restaurants and Street vendors in Jakarta, Indonesia”, the risk factors of contracting food borne diseases were affected by poor hand washing hygiene of the food handlers (street vendors), further relating to the fact that the food handlers may come in direct contact with the food by using their bare hands when handling the food, and also their low educational level which hinders them from the basic knowledge of proper personal hygiene which led to faecal contamination of drinking water, dish water and ice cube. A study by M.P. Azanza, C. Gatchalian, and M. Ortega,
o Cleanliness of rooms and walls: Keep the surroundings clean o Personal cleanliness: Keep patient clean and dry. o Variety: Have variety in the patient’s room to avoid depression.
Using chitosan as a food preservative allows for reuse of this waste, making its use environmentally beneficial; while also reasonably cheap and cost-effective in production and usage. - Its biodegradability also allows chitosan biofilms to be beneficial to the environment. - The chitosan film has antibacterial and antifungal properties, meaning that it ultimately prolongs shelf-lives of the foods which it coats. - As chitosan film is a polysaccharide which physically coats the food product, it offers the advantage of being edible,
• In China, government regulation and policies regarding food products are very strict due to various food safety scandals in recent years. All biscuit manufacturers have to reach the state standard requirements for quality, packaging etc. (IBISWorld, 2010). In order to meet the tightened regulatory requirements on food quality and environment protection, this would require huge investment in stringent quality and hygiene control measures for new entrants (Euromonitor, 2014). • Existing competitors that have achieved economies of scale in production has an advantage over new entrants in terms of the burdening of overall expenditures