Tag Archives: captive footwear

Nick Warrick

Standards and Trends for Protective Apparel in the Food Industry

By Nick Warrick
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Nick Warrick

Employees who work in the food manufacturing and processing industries need proper personal protective equipment (PPE). As with other industries, PPE is used to protect employees against injuries, but for the food industry, it is also designed and used to reduce the risk of food contamination.

When selecting PPE for your workers, you need to consider specific contamination and safety risks, such as risk of abrasions, punctures, cuts, flash fires, and cryogenic hazards, based on the employee’s specific roles and duties.

The proximity to food requires prioritization of high standards of hygiene for all employees, as well as protection against individual risks based on setting. For instance, those working in commercial kitchens with high temperatures need loose and light apparel. On the other hand, those working in cold rooms need heavier outfits.

Factors to Consider When Selecting PPE in the Food Industry

Following are key factors to consider as you investigate apparel to keep your company’s employees safe and comfortable.

Effectiveness and Cost. Consider the quality standards you need to meet and the tear resistance of the material. Choosing one-time use or disposable apparel might seem expensive, but laundering of reusable gear can make the material more prone to wear and tear, thus lowering its effectiveness. Going for the lowest quality items to minimize costs can end up being more expensive. Therefore, you need to set your quality standards first to ensure the effectiveness of the PPEs.

Fit and Comfort. One of the factors that employers tend to overlook when shopping for their employees’ PPE is fit and comfort. Food industry workers operate several machines and stand for many hours. Inappropriate sizing makes the employee uncomfortable, resulting in less productivity. In addition, baggy or oversized gear may get caught in machinery or pose a fire risk if used near ovens or other high-heat areas.

Types of PPE for Food Safety

Several types of PPE are required in the food industry. Including gloves to prevent contamination, work shoes, facemasks, and aprons.

While face masks might not fully prevent inhalation of particles, they do prevent large respiratory drops from worker’s mouths and noses from coming into contact with food, thus preventing food contamination. Workers exposed to dangerous inhalants may require respirators to prevent illness.

The food industry involves a lot of movement. It also involves working with sharp objects such as knives. Good quality work shoes are required to protect your employee’s feet against cuts and other injuries. In addition, in a RTE environment, captive footwear programs reduce the risk of cross contamination. Employees also need anti-slip shoes to protect you against slips and falls.

The first step in determining your PPE needs is to conduct a hazards assessment of your work environment, and then match the needed PPE for each environment.

Latest Fashion Trends for Protective Apparel in the Food Industry

Fashion trends change in the clothing industry, and PPEs are no exception. Some of the recent trends in the food industry protective apparel include:

Lightweight apparel. At one time, it was believed that protective apparel should be heavy. But as textiles evolve and employee comfort and need for agility became greater concerns, apparel manufacturers and designers have learned how to combine thinner and lighter materials that provide the same protection as their older, heavier counterparts.

Need for higher level protection. The COVID-19 pandemic created a greater awareness of the importance of proper PPE, which led companies to seek PPE that that offers higher than the standard protection to protect their employees and food products.

Online presence. The growth of the Internet and e-commerce means many PPE users are increasingly relying on digital/e-commerce sites to evaluate and purchase PPE.

The food industry depends on multiple types of PPE to protect its workers as well as the products they make. When investigating PPE for employees, companies need to consider not only employee safety and comfort, but also food safety and protection. This can make it more challenging to make the right decision. Nevertheless, there are federal regulations as well as industry-set standards to help you find the best quality apparel for maximum user protection as well as hygiene and comfort.

Stacy Vernon

Lessons Learned from Listeria Recalls

By Food Safety Tech Staff
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Stacy Vernon

Listeria monocytogenes continues to be a key factor in food recalls. While it is not the most common pathogen behind foodborne illness, it does have a high mortality rate. Listeria is hearty. It thrives in cold, moist environments, can grow under refrigeration temperatures and is salt tolerant. The risk of listeria contamination can be reduced through stringent sanitation, and environmental monitoring and testing. But far too often, it takes an outbreak or recall for companies to truly understand the efforts needed to find and destroy it in their facilities.

At Food Safety Tech’s Hazards Conference in Columbus, Ohio, in April, Stacy Vernon, Food Safety Operations and Program Manager at CIFT, an Ohio Manufacturing Partner, shared lessons learned from food companies that have experienced Listeria in their facilities and resulting product recalls.

Lesson Learned: Regulatory Requirements

The regulatory requirements related control of listeria monocytogenes can be found at USDA 9 CFR Part 430.4 and FDA 21 CFR Part 117. Both agencies offer guidance documents that serve as valuable resources that food companies can use to build their food safety programs:

USDA FSIS: FSIS-GD-2014-0001 “Controlling Listeria monocytogenes in Post-lethality Exposed Ready-to-Eat Meat and Poultry Products”

FDA: FDA-2008-D-0096 “Control of Listeria monocytogenes in Ready-to-Eat Foods”

“The question is, are your people reading these? Are they aware they exist?” asked Vernon. “In speaking with companies who have gone through recalls, many were not even aware these guidance documents existed or were not utilizing them.”

Lesson Learned: Sanitation Program Shortcomings

“Sanitation is the No. 1 program that you need to have on point,” said Vernon. “Unfortunately, labor shortages and turnover have made this a big challenge in recent years.”

Issues that companies uncovered following recalls include:

  • A lack of understanding of the difference between cleaning and sanitizing
  • Sanitation teams not given enough time to properly sanitize equipment
  • Lack of easy access to the tools needed to sanitize properly
  • Lack of training on or understanding of the seven steps of sanitation
  • Lack of training on what biofilms are and how to detect them

“Sanitation teams tend to be small, and they need to be everywhere,” said Vernon. “Are you looking at their foot traffic? Your sanitation team should get, at least, general training on food safety and pathogens. Make sure this department is not overlooked because they do pose one of the highest risks of cross contamination.”

Lesson Learned: Poor Sanitary Design

Companies cited similar shortcomings in sanitary design. Vernon recommended that companies implement the following practices, if they are not currently following them:

  • Involve your food safety professionals in the purchase of new equipment
  • If purchasing used equipment, make sure that it has been maintained
  • Google “Sanitary Design Checklist.” These free downloads are available from the American Meat Institute, U.S. Dairy and other organizations and are great resources
  • Look for facility and equipment design flaws, such as cracks or separations in the floor, exposed threads, hallow pipes not sealed, bad welds, and water/product accumulation points

“Drain maintenance is also key. One company uses a snake to swab their drains, so they know if they have listeria before it works its way back up into the facility,” said Vernon.

Lesson Learned: Poor Environmental Monitoring Programs

The goals of an environmental monitoring program (EMP) is to aggressively seek and destroy pathogens. “You need to know where listeria is entering the facility, where it harbors and how it moves in your facility so you can effectively eradicate it,” said Vernon. “There is still a mentality that people are scared to find it, so they swab the safest areas. We need to change that mindset to ‘I want to find it and I want to eliminate it.’”

EMPs need to be tailored to your specific facility. Some of the issues companies found with their EMPs following recalls included a lack of internal knowledge to build a comprehensive and custom program and failure to swab properly. “Ask yourself, who is responsible for setting up our EMP and can they do it alone, or do we need outside expertise?” said Vernon.

When swabbing, you need to apply pressure and seek out hard to reach areas. When determining which zones to swab, consider the following:

  • Your risk assessment and hazard analysis
  • Previous environmental monitoring data collected
  • Visual appearance of surface
  • Products produced and intended users
  • Potential for growth after packaging

“Focus on areas where RTE products are exposed. Companies often do not want to swab Zone 1, but one company that went through a recall has implemented swabbing in Zone 1 while they are sampling their products,” said Vernon. “Their reasoning is, the products are already on hold and if they have to throw one shift of product away, it costs much less than a recall or outbreak.”

Lesson Learned: Lack of Employee Knowledge

Several of the companies Vernon spoke with found that they had inadequate food safety and pathogen training and knowledge at all levels; and that they did not have a good sense of employee traffic flow and habits. “When is the last time you stepped back to evaluate traffic flow in your facility?” asked Vernon. “Companies that took the time to evaluate traffic flow and employee practices were often surprised that they did not understand their employees’ movement within the facility or work habits.”

Key areas to investigate include:

  • How do employees and product move through your facility?
  • What is your footwear policy?
  • Are employees following appropriate GMPs for handwashing, PPE, product handling, etc.?
  • Are sanitation employees cleaning properly?

“Changing employee practices doesn’t take a lot of capital,” said Vernon. “It is one of the cheapest ways to mitigate risk.”

Lesson Learned: Not Reassessing Programs

EMP and sanitation programs should be reassessed when findings occur or changes happen in the facility, including anytime you bring in new equipment. “Start with a document review and then reassessment of your environmental monitoring program,” said Vernon.

 

 

 

 

 

 

Food factory workers

Key Components of Environmental Control

By Food Safety Tech Staff
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Food factory workers

Ready to eat foods (RTE) pose a significant risk of foodborne illness, if proper safety precautions are not followed. Key to keeping contaminants out of your RTEs and keeping regulatory action at bay is developing a strong environmental control program (ECP).

We spoke with Benjamin Miller, vice president of regulatory and scientific affairs at the Acheson Group, about the core components of an ECP and the biggest risk areas for producers of RTE foods.

There are three key components of an ECP:

  • Hygienic design of a facility and equipment
  • People management within a facility or operation
  • Sanitation

“From a facility standpoint, you want a facility that is constructed well,” says Miller. “The floor, walls and ceilings are in good condition. You have adequate water drainage, if you’re going to be using a wet clean as part of your sanitation program and, from the equipment standpoint, you want equipment that is designed to be cleaned and is easy to clean. That is one of the areas where we see some of the biggest issues in terms of risk from environmental contaminants and pathogens.”

There are multiple challenges to keeping equipment clean and santized, notes Miller. And it starts with a lack of standardization. There is little regulation on equipment design for food processing, although there have been efforts among industry, with groups such as the 3-A Consortium in the dairy industry and the European Hygienic Engineering and Design Group (EHEDG). “But a lot of equipment is custom fabricated in the food manufacturing space, and equipment is expensive and has a long serviceable life span,” says Miller. “So, while we do understand the good principles of hygienic design, those are not always baked into equipment design, either because of the cost or the complexity of the design of the equipment itself.”

Equipment Considerations

When investigating new equipment or reviewing your existing equipment, you want to look at the materials used as well as placement of the equipment. “We think about stainless steel as being easy to clean and sanitize, but even with stainless steel there are different finishes that can make it more difficult to clean, so you need to think about the the different finishes that come on the equipment, the seams where the weld points are and how smooth those weld points are,” says Miller.

Flat surfaces can collect dirt, debris and water. “Rotating existing infrastructure or equipment components can make a significant difference in cleanability, drying and run off,” says Miller.

The placement of the equipment in the facility can also affect cleanability. “A good analogy is, if you look under the hood of your car some engines are in there so tight that you have to take everything apart to get in there to fix or replace a specific part,” says Miller. “Other cars, you can practically climb inside and get to every piece of equipment easily.”

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If equipment that needs to be cleaned and maintained on a regular basis is up against a wall, it will be very difficult to get back there to work on the equipment or do a thorough cleaning.

“You need to think about hygienic design, equipment design and placement, materials selection and cleanability. These are all really important. The other thing is flow—facility flow and people movement within a facility,” says Miller.

Facility Traffic Flow

Some pathogens will occur more frequently in areas where raw food is handled. People can also bring contaminants into a facility on their clothes or shoes. Limiting foot and equipment traffic within the facility—and restricting high care (or high risk) areas where RTEs are assembled and packaged—reduces the risk of food contamination.

“Ideally, you want a very clear delineation between where the food is raw up to the point where the kill step is applied and then where the RTE environment is,” says Miller. “You want a linear process and design flow from where you receive your raw materials, where you do your raw material prep and assembly, through to the area where you do your cook or kill step. The people and food should flow through the environment in a way that the risk of contamination from raw product is minimal.”

Developing a captive footwear program where employees in high care areas are provided with dedicated footwear and limiting traffic within those areas is required. “Often when we see people struggling with their environmental control programs, it’s because they don’t have adequate separation of people movement and equipment movement within the facility. Either everyone’s going everywhere or they have a defined program, it is just not enforced,” says Miller.

He relates the challenge to an age-old design adage: “There is a saying that, if you’re designing a campus, wait to put down the sidewalks until you see where people naturally walk,” says Miller. “Because they will choose the most efficient route to get from building A to building B. That’s often what happens in the food manufacturing or processing facility. If you don’t have active enforcement in high care areas, people will naturally take the most efficient route to go from point A to point B, and that creates risk.”

The best approach to reduce that risk is to engineer out the hazards, so people don’t have the option not to comply. “You can close off spaces that are natural cut throughs so that people cannot take the shortcut,” says Miller.

Visual programs, where employees in the high care areas wear white smocks and those in the low care areas wear red, for instance, can help with oversight and compliance. “But you also need to positively reinforce behavior, which gets to the hot topic of food safety culture,” says Miller. “Is it acceptable to cut through, or is somebody going to stop that person and report what is happening because your team understands the risk? And are you addressing that behavior in a nonpunitive way, and instead explaining why this is important? Companies should be rewarding people who call out safety hazards as well. The primary challenge for facilities that are not designed well in terms of either equipment design or traffic flow is that it takes time and effort to enforce and build that culture.”

Drainage and Sanitation

Drains can a source of contamination if not properly designed, used and maintained. Trench drains are harder to clean and maintain than circular drains. “People sometimes use their drains as a garbage disposal, which provides food for bacteria,” says Miller. “Limit the amount of food going down the drain and, ideally, you want to use a circular drain with stainless steel sieve in high care areas.”

In the past, it was not uncommon for facilities to perform high-pressure cleaning of drains, which can then aerolize the bacteria in the drain. “Use low pressure mechanical or steam cleaning of drains,” says Miller. “Again, this comes back to design. You want to start with well-designed drains and follow good sanitation practices.”

Sanitation and cleaning products used in food processing and manufacturing faciities are regulated and safe to use in the food environment, provided all instructions are followed. “Read chemical labels to make sure you are using the correct concentrations and the correct cleaning/rinse cycle,” says Miller. “The label determines how the cleaning agent should be used and whether it can come in contact with food.”

Companies can help maintain a strong ECP by giving their food safety and quality assurance teams a seat at the table, particularly when developing their capital improvement plans. “If you know a particular piece of equipment is really hard to clean and has been a source of contamination over the last couple of years, how can you repair or redesign that equipment so that it is easier to clean or replace it with something that’s going to be easier to clean?” says Miller. “A key piece of managing food safety is understanding where your highest risk points are, and then making sure those areas are part of your capital improvement plan.”