FOOD SAFETY MANAGEMNET SYSTEM (FSMS)

GUIDANCE DOCUMENT

BAKERY &
BREADS BAKERY
PRODUCTS
CAKES

Version 01: November 2016

Prepared by
CII-HUL Initiative on Food Safety
Sciences (CHIFSS)

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 ACKNOWLEDGEMENT
Food Safety is best achieved when all the stakeholders join hands and contribute in
tandem for this noble cause. ―Food Safety Management System (FSMS) for Bakery and
Bakery Products‖ is one such initiative, which we believe will go long way in ensuring the
bakery products, produced in India are manufactured with scientifically validated
processes that ensures safety for the consumers.

This document is prepared by CHIFSS (CII-HUL Initiative for Food Safety Sciences).
While a large number of people contributed for this document, we would like to extend
special thanks to Dr. K. N. Shashikanth (CII-FACE Senior Consultant), who provided his
insights, experience and greatly contributed to this document.

We thank and acknowledge all the contributions of the below listed companies, for their
comments and/ or recommendations on earlier draft versions of this document; that
greatly improved and added value to this work.

1. ITC Ltd.
2. Mondelez India Foods Pvt. Ltd.
3. Bakemate (Pahal Foods Exim Ltd.)
4. TRPD Group
5. Cremica Food Industries Ltd.
6. Britannia Industries Ltd.
7. Bisk Farm

We would also like to acknowledge all the illustrations shared by the below companies;
which can act as an easy and quick visual impact to our readers on the subject.

1. ITC Ltd.
2. Mondelez

We are also thankful to CEO-FSSAI, Shri Pawan Kumar Agarwal for his constant inspiration
and encouragement, especially to contribute to food safety matters.

CHIFSS TEAM

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 PREFACE
This Food Safety Management System (FSMS) for Bakery and Bakery Products is prepared
with an intent to provide general guidance to manufacturers to ensure that critical food
safety related aspects are addressed during the manufacturing process. This document
mainly contains pragmatic approaches which a business can adopt during manufacturing of
bakery products. However, manufacturers may adopt higher stringent levels, depending on
the needs.

It is advised that anyone involved in manufacturing of Bakery products is trained

appropriately to implement the measures and to demonstrate the behaviors mentioned in
the document.

It is to be noted that this guidance document does not intend to replace any legal provisions
required by law as applicable from time to time. Further, wherever the provision of this
document conflicts with Schedule IV of (regulation 2.1.2) of Food Safety Standards
(Licensing and Registration of Food Business Operators) Regulations 2011 or any other
regulations, for that matter, the provision given in the regulations shall prevail.

CHIFSS TEAM

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 CONTENT
ABBREVIATIONS

DEFINITIONS

SCOPE

MANUFACTURING/ PROCESSING PARAMETERS

1. Manufacturing and Processing Parameters
1.1 Manufacturing Flow diagram-
a) Biscuits
b) Breads
c) Cakes
1.2 Procurement, storage and handling of bakery ingredients
1.3 Raw material storage – refrigerated and non-refrigerated
1.4 Manufacturing area
A. Technical measures for reducing flour dust
B. Working practices for reducing flour dust
C. Premixing
D. Mixing
E. Air handling unit
F. Baking
G. Cooling
1.5 Packaging and storage of finished product
1.6 Slicing/packing of bread and confectionary products
1.7 Despatch and loading
1.8 Retail and display

2. Loading / Unloading, Transportation, Retail Precautions related to Food Safety and Quality
2.1 Control of storage conditions
2.2 Control of transportation conditions

PRE-REQUISITE PROGRAMS
1. Location and Surroundings
2. Layout and Design of Food Establishment Premises
3. Equipment & Containers
4. Facilities

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 Water Supply, Cleaning Utensils and Equipment, Washing of Raw Materials, Ice and Steam,
Drainage and Waste Disposal, Personnel Facilities and Toilets, Air Quality and Ventilation,
Lighting
5. Food Operations and Controls
Procurement of Raw Materials, Precautions on Food Ingredients, Storage of Raw Materials and
Food, Food Processing (Time and Temp Control, Preparation), Food Packaging, Food
Distribution/ Service
6. Management and Supervision
7. Food Testing Facilities
8. Audit, Documentation and Records
9. Validation Procedures
10. Sanitation and Maintenance of Establishment Premises
Cleaning and Maintenance, Pest Control Systems, Allergen Protocols Applicable
11. Personal Hygiene
Health Status, Personal Cleanliness, Personal Behavior, Visitors
12. Product Information and Consumer Awareness
13. Training
14. Non-Conformance Management, Rework
15. Customer Complaints Handling
16. Traceability & Recall Management
17. Food Defense, Biovigilance And Bioterrorism

HAZARDS ASSOCIATED WITH BAKERY PRODUCTS

MANUFACTURING & HACCP IMPLEMENTATION FOR IMPORTANT
CONTROL MEASURES
HAZARDS IN MANUFACTURING PROCESS:
 Microbiological Hazards
 Chemical Hazards
 Physical Hazards
 Allergen Hazards

REFERENCES / SUGGESTED READINGS

ANNEXURES
Annexure 1: Specific Regulatory requirements for Biscuits; Breads
Annexure 2: Cake specific- Sterilization of critical areas, Ways of reducing microbial spoilage
Annexure 3: Packaging and Labelling Requirements
Annexure 4: FSMS Related Document & Record Templates (Listed in below table)

LIST OF TABLES
Table 1: Technical measures for reducing flour dust
Table 2: Light requirements in Baking area/Pastry shop

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 LIST OF FIGURES/ ILLUSTRATIONS
Figure 1: General Biscuit Manufacturing Flow chart
Figure 2: General Bread Manufacturing Flow chart
Figure 3: General Cake Manufacturing Flow chart
Figure 4: Hygienic Layout of Equipments & Packing materials
Figure 5: External boundary wall to prevent un-authorized entry and entry of pets/ animals, etc.
Figure 6: Restriction of access to water/ oil storage tanks installed outside the plant - to avoid
bio terrorism
Figure 7: Water seepage / leakage in the walls / ceilings
Figure 8: Provision of wall guards to avoid frequent damages and subsequent foreign matter
contamination
Figure 9: No paint peel off
Figure 10: Etching on containers for identification to ensure recipe
Figure 11: Damaged containers (source of foreign matter contaminations) should not be used
inside process
Figure 12: Usage of appropriate food grade gaskets
Figure 13: RO plant for water treatment to meet Potable water requirements
Figure 14: Provision of foot operated closed waste bins
Figure 15: Adequate lighting inside the process sections
Figure 16: Tube lights should have covers
Figure 17: Electrical panels/ boards should be covered
Figure 18: Raw material should be stored on pallets
Figure 19: Stand for keeping batch cards for identification and traceability of raw materials
Figure 20: Temperature zones for different bacterial activity
Figure 21: Floor should be in kept clean and tidy
Figure 22: Cloths used for cleaning purposes should not have loose threads
Figure 23: Insecticutors should be “ON”
Figure 24: Opaque PVC strip at entrance to avoid flies/ insect attraction inside the plant
Figure 25: No gaps around apertures/ doors inside the plant
Figure 26: No infestation/ flies/ insect inside the plant
Figure 27: Arrangement of periodic medical check-ups and vaccinations in line with Schedule IV
(FSSR 2011) for employees and food handlers
Figure 28: Proper apron to be used before entering into process hall. Hairs should not be long
and covered properly
Figure 29: No religious threads (especially exposed)- source of foreign matter contamination
Figure 30: Usage of lint roller to remove loose hairs before entering into process
Figure 31: Touch free (hands free) taps at wash basins to avoid cross contamination
Figure 32: Automatic IPA hand sanitizer at entrance
Figure 33: Auto Shoe cover dispenser
Figure 34: Automatic hand-washing & foot cleaning system
Figure 35: Provision of hand dryer for drying hands at entrance
Figure 36: Usage of sanitizer (IPA) before going inside process
Figure 37: Storage of personal hygiene clothing
Figure 38: No usage of Gutkha/ tobacco inside the plant
Figure 39: Classroom training
Figure 40: Visual displays in processing areas

LIST OF RECORD TEMPLATES

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 Processing Record Title
Area
QUALITY 1 Food Safety & Quality Policy-Updated
2 Food Safety & Quality Objectives-Updated
3 Management Review Meeting
4 Internal Audit Plan
5 Internal Audit Schedule
6 Internal Audit Observation & Non-Compliance report
7 FSMS Team members- Updated
8 Product Information & Intended Use
9 Process Flow Diagram and Control steps
10 Hazard Analysis
11 HACCP Plan
12 HACCP Verification record
13 HACCP Validation record
14 Control of System Documents
15 Valid FSSAI License
16 Recall & Withdrawal record
17 Product Identification & Traceability
18 Mock Recall record
19 Trend Analysis
20 MSDS of all chemicals & processing aids
21 Correction & Corrective Action report
MARKETING 22 Customer/Consumer complaints records
23 Determination of Customer Satisfaction
HUMAN 24 Training Need Identification
RESOURCE 25 Training Calendar
26 Training Conducted record
27 Training Effectiveness record
28 Visitor record
29 Pre-employment medical record
30 Regular medical record
31 Monitoring of personnel hygiene
PRODUCTION 32 Non-conforming product record
33 Glass & Brittle Plastic Breakage record (Tubeights, windows, etc.)
34 Knife/ other utensil control record
35 Control of handling of unsafe food
36 CCP Monitoring record
37 Operation Log sheets
38 Breakdown record
LABORATORY 39 Analytical record
40 External Lab record
41 Internal Calibration record-In house laboratory
HOUSEKEEPIN 42 Housekeeping record

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 G 43 Cleaning & Sanitation record
44 Pest Management Plan
45 Pest Management Map
46 Monitoring record of pest & fly catchers
47 Valid Contract from 3rd party
48 Waste Disposal record
PURCHASE & 49 Approved Supplier list
STORE 50 Supplier self-assessment & approval form
51 Supplier Evaluation
52 Purchase Order
53 Incoming Material Inspection record
54 Incoming Vehicle inspection record
MAINTENANCE 55 External Calibration record
56 Internal Calibration record- Processing
57 Preventive Maintenance Schedule
58 Preventive Maintenance record
59 Pre-inspection record- Processing
60 Fire extinguisher record
WAREHOUSE/ 61 Product Release record
DISPATCH 62 Outgoing Vehicle Inspection record

Records/ Documents should be available with the manufacturing facility.

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ABBREVIATIONS
CCP
Critical Control Point

FSMS
Food Safety Management System

HACCP
Hazard Analysis Critical Control Point

QA
Quality Assurance

ACP
Allergen Control Point

ISO
International Organization for Standardization

GMP
Good Manufacturing Practice

GHP
Good Hygiene Practice

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DEFINITIONS
In order to provide guidance to the readers/ users, below key terms have been defined to interpret as
desired by the document.

Act: The Food Safety and Standards Act, 2006

Regulation: The Food Safety and Standards Regulations, 2011

Adulterant: Any material which is or could be employed for making the food unsafe or sub-standard
or mis-branded or containing extraneous matter.

Baked goods: Baked goods refers to process of cooking using dry heat, especially in oven. These
are usually prepared from flour or meal derived from some form of grain.

Best before: the date which signifies the end of the period under any stated storage conditions
during which the product shall remain fully marketable and shall retain any specific qualities for which
tacit or express claims have been made. Beyond that date, the food may still be perfectly safe to
consume, however, its quality may have diminished. However, the food shall not be sold if at any
stage the product becomes unsafe.

Biscuit: It is a small baked unleavened cake, typically crisp, flat, and sweet. It is often confused with
‗Cookie‘ which is more flat, small and sweetened and often added with nuts, etc.

Bread: It is a staple food prepared from a dough of flour and water, usually by baking.

Cake: Cake is a form of sweet dessert that is typically baked. Typical cake ingredients
are flour, sugar, eggs, butter or oil, a liquid, and leavening agents, such as baking soda and/or baking
powder.

Cleaning: The removal of soil, food residues, dirt, grease or other objectionable matter.

Critical Control Point (CCP): A step at which control can be applied (and is essential) to prevent or
eliminate a food safety hazard or reduce it to an acceptable level.

Consumer: persons and families purchasing and receiving food in order to meet their personal
needs.

Contamination: Unintended ingress of microbial pathogens, chemicals, foreign bodies, spoilage

agents, objectionable taints and unwanted matter, into the product and/ or process.

Date of Manufacture: the date on which the food becomes the product as described.

Date of Packaging: the date on which the food is placed in the immediate container in which it will
be ultimately sold.

Food: any substance, whether processed, partially processed or unprocessed, which is intended for
human consumption and includes primary food, genetically modified or engineered food or food
containing such ingredients, infant food, packaged drinking water, alcoholic drink, 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, plants, prior to harvesting, drugs and medicinal products,
cosmetics, narcotic or psychotropic substances, provided that the Central Government may declare,

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by notification in the Official Gazette, any other article as food for the purposes of this Act having
regards to its use, nature, substance or quality.

Food additive: any substance not normally consumed as a food by itself or used as a typical
ingredient of the food, whether or not it has nutritive value, the intentional addition of which to food
for a technological (including organoleptic) purpose in the manufacture, processing, preparation,
treatment, packing, packaging, transport or holding of such food results, or may be reasonably
expected to result (directly or indirectly), in it or its by-products becoming a component of or
otherwise affecting the characteristics of such food but does not include ―contaminants‖ or
substances added to food for maintaining or improving nutritional qualities.

Food business: any undertaking, whether for profit or not and whether public or private, carrying
out any of the activities related to any stage of manufacture, processing, packaging, storage,
transportation, distribution of food, import an includes food services, catering services, sale of food or
food ingredients.

Food business operator: a person by whom the business is carried on or owned and is responsible
for ensuring the compliance of this Act, rules and regulations made there-under.

Food safety: assurance that food is acceptable for human consumption according to its intended
use.

Food Safety Management System: the adoption Good Manufacturing Practices, Good Hygienic
Practices, Hazard Analysis and Critical Control Point and such other practices as may be specified by
regulation, for the food business.

Hazard: a biological, chemical or physical agent in, or condition of, food with the potential to cause
an adverse health effect to people or to the environment.

Hazard Analysis Critical Control Point (HACCP): A system that identifies evaluates and controls
hazards, which significant for food safety.

Ingredient: any substance, including a food additive used in the manufacture or preparation of food
and present in the final product, possibly in a modified form.

Label: any tag, brand, mark, pictorial or other descriptive matter, written, printed, stencilled,
marked, embossed, graphic, perforated, stamped or impressed on or attached to container, cover, lid
or crown of any food package and includes a product insert.

Lot number‖ or ―code number‖ or ―batch number‖ the number either in numerical or alphabets
or in combination thereof, representing the lot number or code number or batch number, being
preceded by the words ―Lot No‖ or ―Lot‖ or ―code number‖ or ―Code‖ or Batch No‖ or ―Batch‖ or any
other distinguishing prefix by which the food can be traced in manufacture and identified in
distribution.

Manufacture: a process or adoption or any treatment for conversion of ingredients into an article of
food, which includes any sub-process, incidental or ancillary to the manufacture of an article of food.

Manufacturer- FSSA: a person engaged in the business of manufacturing any article of food for
sale and includes any person who obtains such article from another person and packs and labels it for
sale or only labels it for such purposes.

Must: ―To be implemented immediately, compulsory, mandatory‖

Package: a pre-packed box, bottle, casket, tin, barrel, case, pouch, receptacle, sack, bag, wrapper
or such other things in which an article of food is packed.

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Risk: in relation to any article of food, means the probability of an adverse effect on the health of
consumers of such food and the severity of that effect, consequential to a food hazard.

Sanitation: Also called Disinfection, is the reduction, by means of chemical agents and/ or physical
methods, of the number of microorganisms to a level that does not compromise food safety or
quality.

Should: ―Strongly advised for current operations and may become mandatory in the future‖

Unsafe: an article of food which is injurious to health:

a) By the article, itself, or its package thereof, or
b) Consists wholly or in part, any filthy, putrid, rotten, decomposed or diseased animal substance or
vegetable substance; or
c) Is processed unhygienically or the article of food has harmful substance in it or is infected or
infested with worms, weevils or insects; or
d) Has been substituted by inferior or cheaper substance whether wholly or in part; or
e) uses a substance directly or as an ingredient or as additive which is not allowed under the law; or
f) By virtue of its being prepared, packed or kept under unsanitary conditions; or
g) By virtue of its being misbranded or sub-standard or food containing extraneous matter; or
h) By virtue of containing pesticides and other contaminants in excess of quantities specified by
regulations.

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SCOPE
This FSMS Guidance Document covers the manufacturer, storage and distribution of Bakery and
bakery products. It deals primarily on Food safety science including related hazards and risks; and
guidance on processing, storage, distribution to reduce the same.

INTRODUCTION OF BAKERY PRODUCTS

Baking is the oldest cooking methods and the process is some thousand years old. There are various
products that can be made through baking. The most common been: breads, biscuits, cakes, muffins,
buns, pizza base, pies, tarts, crackers, brownies, cupcakes, and the list goes on.

In this document, we will mainly discuss on BREADS, BISCUITS and CAKES.

The major ingredients in all the three baked products remains same with addition of other ingredients
and method of preparation.

Common Baked Ingredients and Their Functions:

Is the major ingredient in making bread. It provides the structural framework

Flour of the bread because it contains gluten, which gives the bread strength to keep
its shape when baking
Is the leavener used in bread making. Yeast acts with the sugar in water to
Yeast form carbon dioxide which will make the bread rise. Two kinds of yeast are
compressed or fresh yeast and dry yeast
Is added as food for the yeast and also for flavor. It also helps in browning the
Sugar
crust.
Does not only improve or enhance the flavor of the bread it also controls the
Salt
growth of the yeast to prevent over rising of the dough.
Such as water, milk, and juice, is needed to hydrate and bind the flour, to
Liquid develop the gluten, and to dissolve the yeast

Is added to make bread tender, rich in flavor, and golden brown in color. It acts
Egg as an aeration medium.

In the form of oil, butter, margarine, or shortening, is added to enrich

Fats and oils the dough and to keep it soft. It gives the bread a moist crumb with a soft
crust.
Other like dried fruits and nuts, cheese, and flavorings to make the product more
ingredients flavorful.

Some Bakery products that contribute to Healthier Life style and thus they have varying addition of
food ingredients:
a) Whole wheat bakery products

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 b) Multigrain bakery products
c) High fiber bakery products
d) Sugar free bakery products (Saccharine or Aspartame or Acesulfame Potassium or Sucralose)
e) Organic bakery products

MANUFACTURING/ PROCESSING
PARAMETERS FOR BAKERY PRODUCTS
1. Manufacturing/ Processing Parameters

1.1 Manufacturing Flow Diagram

a. Biscuit Manufacturing Flow diagram:

Procurement and Quality

inspection of Raw Materials

Storage of Raw Materials

Weighing and Premixing of Raw

materials

Mixing Ingredients as per

Standardised Recipe

Biscuit Piece Formation

Baking and
Garnishing/Oiling/Sandwiching

Aeration or Cooling

Packaging & Labelling

Quality Evaluation

Storage of Finished Products

Loading and Dispatch of Finished

Products (Biscuits)

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 b. Bread Manufacturing Flow Diagram:

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 Receiving and Quality Inspection of Raw
Materials

Storage of Raw Materials

Weighing and Pre-Preparation of Raw

Materials as per Standardised Recipe

Premixing/Mixing

Scaling, Dividing and Rounding

Inerprooving

Moulding

Final Prooving

Baking

Aeration or Cooling

Slicing and Packaging

Quality Evaluation

Storage of Finished Products

Loading and Dispatch of Finished

products (Bread)

c. Cake Manufacturing Flow Diagram:

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 Receiving and Quality Inspection of
Raw Materials

Storing of Raw Materials

Weighing and Pre-preparation of

Ingredients as per Standardised Recipe

Batter making

Batter Scaling Deposition and Leveling

into Moulds

Baking

Cool at Ambient Temperature and

Forced Cooling of Cake

Slicing and Packing

Quality Evaluation

Storage

Loading and Dispatch of Finished

Products (Cake)

Figure 1: General Manufacturing Flow chart

1.2 PROCUREMENT, STORAGE AND HANDLING OF RAW OIL SEED

a) Eggs

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 i) Ensure that egg shells are not cracked upon receipt. Discard cracked eggs.
ii) Store eggs in the chiller until they are needed. If you need to store eggs at room
temperature, use the current batch of eggs and replenish the stocks daily.
iii) Wash hands, utensils and surfaces thoroughly with sanitizing solution and water after
handling eggs and before any contact with other food to prevent cross-contamination.
iv) If you are breaking eggs for future use (also known as ‗pooling‘), pool the number of eggs
you require just before use.
v) Prepare raw eggs away from other food, especially cooked/ready-to-eat food to avoid cross-
contamination.
vi) Wash or clean all eggs before use to avoid any food cross-contamination.

b) Dry ingredients like wheat flour, sugar and cocoa powder

i) Conduct a visual inspection during procurement to ensure the raw materials received are free
from foreign material such as stone, glass, hair, jute thread, etc. This can be done by
appropriate test sieves.
ii) Raw material should be stored in a room that has the required humidity and temperature and
the store room should be away from non-food materials to prevent cross-contamination.

c) Ready-to-eat products containing lightly-cooked or uncooked eggs (e.g.

mayonnaise, cream, icing, mousse, butter)
i) Prepare only what is required in small batches. Estimate the demand to avoid over-
production and prolonged storage.
ii) Use liquid egg or egg powder instead of shell eggs where possible.
iii) Observe good personal hygiene practices when preparing/handling the ready to- eat
products.
iv) Store the finished products in covered containers in the chiller at 4°C and below. Ensure they
are stored on separate shelves above raw food (including shell eggs).
v) Take out what is necessary from the chiller in small batches. Minimise the time products that
are left out of the chiller. Store the products in the chiller as soon as possible after use.

1.3 RAW MATERIAL STORAGE – REFRIGERATED AND NON-REFRIGERATED

a) All raw materials should be –
i) Stored off the floor and off the walls to ensure easy and adequate cleaning.
ii) Free from insect and rodent infestation or adulteration
iii) Free of contamination from other sources, e.g. birds, moisture, mould etc.
b) Refrigerated items like chocolate, eggs should be stored at proper temperatures.
c) If bulk floor handling and storage is in use then,
i) Hose couplings, inside and outside plant, should be adequately protected from rodents, clean
and in good repair
ii) Dust collectors or ventilation bags at top of the bulk tank should be clean and insect free
iii) If system contains inspection ports, they should be cleanable/covered and free from
contamination
iv) Tailings from sifting operations should be free from contamination.
d) Periodic fumigation to be ensured.
i) Method of fumigation should be approved (like use of Aluminium phosphite which is an
approved fumigant).
ii) Fumigation is recommended to practice minimum Once in a year.
iii) Should be carried by an approved third party which is expert and experienced.
iv) Post fumigation, the area should be inspected and verified for non- presence of any
fumigant residue.
e) All containers for storing raw materials are to be kept covered.
f) FIFO (First In First Out) system should be applied to release the raw material from the store
g) Expired material should be discarded and not enter into the manufacturing process.
h) Food colours and additives should be used within the safe limits prescribed in FSS Act 2006.

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1.4 MANUFACTURING
a) All pieces of food contact equipments viz. Dough mixers, conveyors, rounders, dough dividers,
racks, proofing equipments, oven, rollers, slicers, sifters etc. should be clean and in good repair.
b) All the equipments and their surroundings should be free from dirt, dust and evidence of rodent
or insect activity
c) All equipments should have smooth edge and devoid of spot welding and any paint flakes.
d) Inspection cleaning ports on flour conveyor systems should be accessible and easy to open.
e) Conveyor systems should be free from pest activity
f) Proofing equipment should be free from evidence of insects or rodents
g) Temperature and humidity of proofing equipment, ovens and cooling area should be maintained
h) Baking pans or storage bins should be clean
i) Equipments should be cleaned before use
j) Utensils like spoons, beaters, pans, bowls, trays, spatulas etc. should be clean and free from
adulterants
k) Utensils and equipment washing facilities should be clean and adequate and should be kept in a
designated place.
l) Cleaning agents and compounds should be labelled properly and kept separate from food items
to prevent cross-contamination
m) Weighing practices should be accurate to ensure the declared quantity of contents would be
achieved.
n) All high temperature equipment should be equipped with high-temp cut-off devices which cut off
the fuel or power source if the upper safe limit is exceeded.
o) Working area as well as the outside premises should be free from spilled powders or liquids,
trash etc. which may attract or harbour pests, rodents or micro-organisms.
p) Protective Equipment:
 For silo cleaning and for other heavily dust-laden activities, a fine dust Mask should be
used
 Heat protection gloves should be used in the case of work with ovens.

A. Working practices for reducing flour dust

i) Applying the separating flour on the work surface by sprinkling, rubbing in or with a sieve,
instead of by throwing flour (fine dust technique)
ii) Gently sweeping of the excess separating flour on the work surface into a suitable container,
instead of casting it onto the flour
iii) Using closed containers for storing flour
iv) When using goods in sacks, adding a second pressure-relieving cut (on the underside of the
sack) when emptying.

B. Technical measures for reducing flour dust

Mixing  Closed system in flour delivery and in dough production.

space:  Regular cleaning of the dust filter in the case of the cyclone and
exclusive use of original filters
 Sufficiently long cloth or fabric hose for the flour delivery, and
maintenance of it.
Work  Dust protection lid on the kneading machines instead of grilles (if the
equipment: diameter of the kneader is larger than 510 mm)
 The use of automatic flour sprinklers for the individual machines; set
them correctly and carry out regular maintenance.
 The exhaust air from the motors of the bakery machines must not be
led over the flour containers.
 Access guards in roll or bread plants, through closed components or
corresponding grilles (closed coverings or cladding are preferable to
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 grilles, on account of the better protection they offer against dust).
Technical  The technical ventilation measures are restricted to dust extraction
ventilation and vapour traps.
plan for  Depending on the quantity (volume flow) of the extracted air,
reducing mechanical provision of incoming air is necessary.
hazardous  Minimum requirements made of the ventilation plant:
substances i. Vapour traps over bakery ovens and fat-frying devices
ii. Spot flour dust extraction in the case of bread tin dusting and in
the case of individual processing machines that produce large
amounts of dust.
iii. Mechanical supply of incoming air
iv. Mechanical extraction of general waste air (if necessary)
v. free flowing ventilation openings capable of being regulated
vi. free flowing ventilation openings not capable of being regulated,
due to production circumstances (gates at despatch
vii. Sugar grinding system should be equipped with proper dust
collection system to avoid any fire hazard.

Table 1: Technical measures for reducing flour dust

C. Premixing
i) Flour should be sieved through minimum 32 mesh and the sieve should be cleaned regularly
ii) If weevils are found, such consignments should be rejected.
iii) There should be a periodic cleaning mechanism to prevent cross-contamination and dust
generation and to ensure safe collection of unwanted materials like dust, dirt, foreign objects if
any.
iv) (Good Practices; such as vacuum cleaning, collection of debris through hypochlorite can be used)
v) Sugar to be passed through magnetic grill before use and periodic cleaning of magnetic grill to be
ensured.
vi) Sugar bags to be free from any external contamination like dust, dirt, rice bran, etc.
vii) Egg trays to should be free from dirt or pests
viii) Broken egg- shells to be stored in plastic bags and disposed off at regular intervals.
ix) Fruit cuts to be washed with ozonized water before use.
x) Potassium sorbate to be dissolved thoroughly in water before use. Only freshly prepared sorbate
solution to be used.

D. Mixing
i) Mixing room should be clean & dry without any spillage
ii) All mixing utensils should be free from grease and old batter. This is ensured by using washing
before use.
iii) Mixing bowls, beaters and scrappers to be washed with hot water at least once in 24 hours
iv) Egg whisk to be added in mixing through strainer only. The strainer to be cleaned with hot water
at least once in each shift followed by swabbing with hypochlorite solution. The strainer is to be
dipped in 500ppm Sodium Hypochlorite solution, when not in use.
v) Mixing room floor to be cleaned with hot water followed by mopping with hypochlorite solution

E. Air Handling Unit

i) Air handling unit should be maintained inside the pre-slab and oven room. Positive pressure is
maintained in the order Pre-slab room > oven room.
ii) Air is blown inside the oven and Pre-slab room through sets of micro filters – first through 20
micron, then through 10 micron and finally through 5 micron filter for the oven room.
iii) Additionally the air is passed through Hepa filter for pre-slab room.
iv) 20 and 10 micron filters are cleaned by water and 5 micron filter is cleaned by forced air at least
once in a fortnight or as required.
v) Hepa filter is changed when the same is choked or non-functional.

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F. Baking
i) Baking room should be clean & dry. This room is to be mopped with 500ppm Sodium Hypochlorite
solution, at least once in each shift
ii) Ozonizer at the baking room to be maintained at 5gm per hour level
iii) Cake cooling trolleys are to be mopped with 500ppm hypochlorite solution daily.

G. Cooling
a) Room temperature cooling of cakes at ambient room

i) This room should be clean & dry and mopping of floor to be done with 500ppm hypochlorite
solution at least once in each shift
ii) After baking, bar cakes are to be transferred immediately to the ambient room
iii) Positive pressure at ambient room is to be maintained
iv) Ozonizer at this room is to be maintained at 2gms per hour level
v) UV lights to be always put on during cooling of cakes. Personnel entry is to be restricted in this
room
vi) Workmen unloading cakes should use a disinfectant solution to disinfectant their hands.

b) Forced cooling at slab cooling room

i) This room should be clean & dry and weekly sanitization to be done with 500ppm hypochlorite
solution
ii) UV lights should always be put on during cooling of cakes. Personnel entry is to be restricted in
this room
iii) Temperature of this room to be maintained at 8-10 deg Centigrade. The same is to be noted &
recorded.

1.5 PACKAGING AND STORAGE OF FINISHED PRODUCT

a) Only food grade packaging material (printed/unprinted) should be used for wrapping and
packaging of food items. The food grade certificate/ declaration should be checked in the COA
during receiving of the materials.
b) Packaging material should also be kept and stored under hygienic conditions in a room intended
for the purpose.
c) All the products should be labelled according to the Food Labelling Act.
d) Immediately after packaging and proper labelling, the products should be placed in the rooms
provided for storage under required temperature and humidity conditions.
e) Temperature and relative humidity of the storage area should be maintained to optimum required
level.
f) FIFO system should be applied for dispatch of all products.
g) Temperature of cake slabs at the time of packing out from the Slab cooling room should be within
the range of 14 – 190C
h) Packing room temperature is to be maintained at 22-24 deg Centigrade
i) Packers handling naked cakes to use sterilized gloves. Disinfectant solutions to be used by all
packers as and when required
j) Slicer blades & conveyor belts to be sterilized with isopropyl alcohol at least 3 times in each shift
or as & when required
k) Contact parts of packing machines to be cleaned with 500 ppm hypochlorite solution
l) Exposure of UV light on PVC trays, cakes & wrappers to be done during packing
m) Metal Detectors to be checked with probes before every start of the packing machine
n) Uniform sorbate spray to be done on the top surface of the naked bar cakes before packing.
o) Air of sorbate spray line is filtered through the Ultra filter unit, which is checked by the Supplier
and changed, if required.

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