THE UNIVERSITY OF TRINIDAD AND TOBAGO.

Manual For the

Preparation of Fruits
and Vegetables
For Use by Namdevco & Other Trinidad
and Tobago based entities.
Asha Melissa Morton 56652

[Type the abstract of the document here. The abstract is typically a short
summary of the contents of the document. Type the abstract of the document
here. The abstract is typically a short summary of the contents of the document.]

Morton 0

How to Use this Manual

The information contained in this Manual is intended to serve three purposes:

It is a resource for individuals who work with small scale fruit and vegetable
processing entrepreneurs at various areas in Trinidad to use in order to improve and
create end products that are not only safe for local use but can be exported to
countries that have high standards for fruit and vegetable products.

It is a reference manual to assist these entrepreneurs to continue to improve technical

aspects of their businesses.

It is a reference manual that outlines practices and procedures for the production of
safe, high quality fruit and vegetable-based processed products and for development
of Good Manufacturing Practices (GMP) programme that will serve as the
foundation before an effective Hazard Analysis and Critical Control Point (HACCP)
system can be implemented.

Morton 1

TABLE OF CONTENTS
How to Use the Manual
Introduction
The Site

i
ii
1

The Building
Physical Layout
Requirements for Production Sites
Roofs and Ceilings
Walls, Windows and Doors
Floors
Summary
Services
Sanitation and.Health
Personnel Health and Hygiene
Industrial Health Standards
Microbial Hazards
Fruit and Vegetable Preparation
Record Keeping
Food Safety Checklist
References

2
2
3
4
5
5
6
8
10
10
12
12
14
16
18
31

Morton 2

Introduction
Fruits and vegetables are foods that are required to be fresh and in pristine conditions whenever
placed on sale for consumers. However when processing for the market it should be taken into
consideration that these items are usually consumed in their raw state, hence great care must to
given so as to inhibit anything that can cause spoilage and illness to the consumer; as this will
contribute to foodborne illnesses as well as a loss of business.
It should be borne in mind that this manual was conceived for the local industry, here in Trinidad
and Tobago, which, in seeking a better future, should decide to take better advantage of the
natural resources that are part of our daily lives, that is, the resources to which we have access to,
and which may be easily obtained at a reasonable cost.
Being provided with readily available raw materials at a reasonable cost, will thus be enable
many of us to take up the challenge of undertaking activities in processes not always familiar,
where general management, however, will have to perfect the obtaining of products that may be
safely used by families and by other members of the community.
Different aspects are presented in relation to the implementation of projects for the processing of
tropical and subtropical fruits and vegetables, growing in a warm or cold temperate climate.
Post-harvest conservation methods aimed at maintaining product quality in processing are
explored, along with different facets of the technological processes employed in the processing
and conservation of goods. Finally, several aspects related to the ultimate destination of the
product are analysed, including self-consumption and marketing.
Special emphasis has been placed on the analysis of the implementation of the facilities for the
development of the projects, the infrastructure, equipment, processes, the need for basic services,
the quality of the products, and the possibilities existing in terms of processing techniques.

Morton 3

The Site
Fresh fruits and vegetables are both bulky and spoil rapidly; therefore it is better to locate a
processing unit in the area where they are grown or in close proximity. This reduces transport
costs and also reduces the amount of handling, which means that crops are more likely to be in
good condition when they arrive at the processing unit. Once they are in good condition, they can
be stored for a few days before they have to be processed. Too much handling bruises them and
causes them to spoil quickly. Thereby increasing the cost of production for the processor, as the
spoiled food has already been paid for.
Processed fruit and vegetable products are likely to be sold in different markets and there is less
reason to locate the unit near to customers (in contrast to bakeries for example). An ideal site is
close to a fruit and vegetable growing area and near to a main road leading to an urban centre.
The location of the processing unit in a rural area means that there may be problems with:

Reliable electricity
Adequate supply of potable water.
Contamination of Supplies
Access for workers and staff (public transport, distance down an access road)
Quality of the road (dry season only, potholes that may cause damage to glass containers)
Absence of other facilities (e.g. schools, medical facilities, shops and entertainment) that
make working there less attractive than an urban location

Each of these should be assessed before choosing a site. In rural locations there is usually more
land available for waste disposal compared to urban sites, but there may be problems caused by
insects and birds or stray animals getting into the building. It is therefore important to have a site
with cleared and fenced land, preferably having barrier, which helps to trap airborne dust.

The Building
Morton 1

All fruit and vegetable processing businesses should have a hygienically designed and easily
cleaned building to prevent contamination of products. Buildings in rural areas may cost more to
construct because of higher transport costs for building materials, but rents in rural areas are
usually lower than urban centres. The investment in construction or the amount of rent paid
should be appropriate to the size and expected profitability of the business.
When considering the setting up of a fruit and vegetable processing plant, whether it is a cottage
industry or a small industrial scale system, the focus should be on the infrastructure required to
properly lodge all of the necessary equipment. Therefore time must thus be devoted so as to
coordinate two aspects that are vital to the development of a project of this nature, namely costs
and the quality of the infrastructure needed to achieve the established goals.
It must always be borne in mind that since the food to be processed is intended for human
consumption, the infrastructure must meet several requirements. The basic general aspects of
such requirements will be analysed. The infrastructure comprises different aspects of a project's
implementation. Issues like physical layout, basic services or installations and equipment must
thus be taken into account.
Physical Layout
The physical layout of a plan of this nature may be very simple, as it refers to a basic production
system, involving small volumes and simple products, from a technological point of view.
Nevertheless, in the case of a cottage industry and a small industrial scale system alike,
simplicity must never neglect the basic principles governing industrial health and hygiene, which
must characterize a food production system.

Requirements for Production Sites

Morton 2

Within the building, food should move between different stages in a process without paths
crossing. This reduces the risk of contaminating finished products by incoming, often dirty,
crops, as well as reducing the likelihood of accidents or of operators getting in each others way.
There should be enough space for separate storage of raw materials, away from ingredients,
packaging materials and finished products.

Fig 1.0 Basic Diagram of a Fruit and Vegetable Processing Area.*

*This Diagram was obtained from the FAO Manual on Fruit and Vegetable Production.
Roofs and Ceilings
Morton 3

Overhanging roofs keep a building cooler, this is especially important when processing involves
heat. Fibre-cement tiles provide greater insulation than galvanised iron sheets against heat from
the sun. Roof vents allow heat and steam to escape and create a flow of fresh air through the
processing room. The vents must be screened with mesh to keep insects and birds out of the
room. If heat is a serious problem (e.g. jam boiling), electric fans or extractors can be used if
they are affordable.
The roof should be properly sealed with a panelled ceiling should be fitted in processing and
storage rooms, rather than exposed roof beams, which allow dust to accumulate and fall off in
lumps and contaminate products.
Beams are also paths for rodents and birds, creating contamination risks from hairs, feathers or
excreta. It is important to ensure that there are no holes in the panelling or in the roof and no
gaps where the roof joins the walls, which would allow birds, rodents and insects to enter.
Walls, windows and doors
All internal walls should be plastered or rendered with concrete. The surface finish should have
no cracks or ledges, which could harbour dirt or insects. The lower parts of the walls are most
likely to get dirty from washing equipment, product splashing etc. They should either be tiled, or
painted with waterproof white gloss paint to at least one and a half metres above the floor.
Higher parts of walls and the ceiling can be painted with good quality white emulsion paint.
Natural daylight is preferable to and cheaper than, electric lighting in processing rooms. The
number and size of windows depends on the amount of money that a processor wishes to invest
and the security risk in a particular area (windows are more expensive than walls, especially
when security bars or grilles are needed). Storerooms do not need to have windows. Open
windows let in fresh air, but this also provide easy access for flying insects.
All windows should therefore be screened with mosquito mesh. Windowsills should be made
to slope to prevent dust accumulating and to prevent operators leaving cleaning cloths or other
items lying there, which can attract insects.
Storeroom doors should not have gaps beneath them and should be kept closed to prevent insects
and rodents from getting in and destroying stocks of product, ingredients or packaging materials.
Morton 4

Processing room doors should be kept closed unless they are fitted with thin metal chains, or
strips of plastic or cloth hung from door lintels. These keep out insects and birds, but allow easy
access for staff. Alternatively, mesh door screens can be fitted.
Floors
Floors in processing rooms and storerooms should be made of good quality concrete, smooth
finished and without holes or cracks. Over time, spillages of acidic fruit products react with
concrete and erode it. Paints can protect floors, but vinyl-based floor paints are expensive. Red
wax household floor polishes should not be used because they wear away easily and could
contaminate products or spoil the appearance of packages. The best way to protect floors is to
clean up spillages as soon as they occur and make sure that the floor is thoroughly washed after
each days production.
Dirt can collect in corners where the floor and the walls join. To prevent this, the floor should be
curved up to meet the wall. The floor should also slope to a drainage channel. Proper drainage
prevents pools of stagnant water forming, which would allow insects to breed. The drainage
channel should be fitted with metal gratings that are easily removed so that the drain can be
cleaned. Rodents and crawling insects can also get into the building through the drain and a wire
mesh cover should be fitted over the drain opening. This too should be easily removed for
cleaning. (Maharaj, 2013)
Several different processes take place on the site where the production activity is performed,
from the reception and conservation of raw materials, to the storage of finished products.
One aspect that must be borne in mind relates to construction details, which determine a plant's
capacity to meet two objectives: to adjust to the production of foods and to ensure a sufficiently
long shelf life. However, when considering home or small-scale industrial processing facilities,
the cost of construction is an important factor which must be taken into account.
The building materials must be as light as possible, easy to readapt and install, considering that
often the system users develop the plan themselves, by means of self-construction methods.

Morton 5

The buildings materials must be easy to readapt because these home-made systems are rather
dynamic, that is, they require frequent changes or must adjust to different processes, so that the
space that they occupy may be exploited all year round. On the other hand, these systems must
be considered "expandable" to accommodate possible evolutions in time.
In addition to the previously mentioned characteristics, the materials must be easy to wash and
disinfect, especially those in the clean areas of the processing rooms. Complex type of
construction, resulting in the creation of places that are not easily accessible for cleaning must be
avoided, for they may turn into bird nests, and contamination foci for rodents, insects, and of
course, micro-organisms. (UNIDO , 2004)
Summary
Requirements pertaining to the materials and construction characteristics of the sites do not vary
greatly for home processing or small-scale industrial plants. The basic difference lies in the
equipment and the way it is set up in the processing lines. The home-processing system is
temporary and versatile, and there are no special areas devoted to a single process. In general, all
of the premises serve several purposes, according to the type of process and raw material being
used.
The small-scale industrial system, on the other hand, is more complex in its organization, and
therefore specific activities are carried out in determined areas. Nevertheless, the general
requirements for both systems are similar, the difference being in the way such requirements are
met.
Some of the aspects that may be considered important in relation to the architectural and
construction elements are listed below:
1. The ceiling and walls of the processing room must be of washable and easily dried
materials; they must be neither absorbent nor porous.

Morton 6

2. The lighting should be natural, as far as possible. However, if artificial lights must be
used, they should not hinder activities in any way. Artificial lighting must be
protected, to prevent fragments of glass from falling into the product as it is being
processed, in case of accidents. Additionally they should not trap insects.
3.

Ideally, the working environment should always be appropriately ventilated, to

facilitate the workers' performance. Poor ventilation in highly enclosed and densely
populated premises may generate defects. It is also important to provide for the
elimination of heavily contaminating odours, even if they are not necessarily toxic.

On the other hand, excess ventilation, especially in places characterized by great aerial
contamination external to the processing site, dust and insects essentially, may prove to be
counterproductive. Appropriate ventilation must therefore be based on an efficient system
controlling the access of foreign material from the external environment.
1. The floors must be of a solid material, never earth or plant covering. Like the walls and
ceiling of the processing room, the floor must be washable, to ensure compliance with the
premises' hygienic and health standards.
2. The floor must also be sloped to allow appropriate drainage, avoiding at all costs the
formation of pools in the processing area. At the same time, care must be taken to prevent
the floor from being slippery.
These are some examples of the features that must characterize a fruit and vegetable processing
site to guarantee a quality product suitable for human consumption.

Services
Three basic services are required for the operation of a processing plant:
1. Electrical power,
2. Potable water supply and
Morton 7

3. The disposal of waste waters.

Occasionally, small-scale industrial plants are equipped with a steam production system, which
however is more seldom found in home-processing plants.
Even when a home-processing plant can operate without electrical power, it is better for this
service to be available, essentially to facilitate the processes by means of small devices that were
developed and that improve workers' performance, thus guaranteeing a greater uniformity of
products. Electrical power is also absolutely necessary if one is to rely on an appropriate lighting
system, so that work shifts may be prolonged, especially when there is a surplus production of
raw materials.
In small-scale industrial production systems, electrical energy is indispensable, due to the greater
degree of mechanization of the processes involved. All lights must be installed on the ceiling at a
safe distance to prevent them from getting wet and getting in the way of workers in the
processing room.
As to water supply, the problem is slightly more critical. Sufficient drinking water must be
available to ensure the development of a hygienic process, managed by clean people and with
appropriately disinfected equipment. Also, many processes require water, as a result of which
water of an appropriate quality must be available.
Since water does not come in abundant quantities, its use must therefore be regulated by strict
savings principles, especially in small or home-processing installations that normally are not
equipped with sophisticated water harnessing devices. Water must be protected from possible
sources of contamination and must be supplied on a continuous basis at all times. The
consumption of water will depend upon the process in question and the design of the production
systems.
The supply of water must be ensured on a permanent basis, as a result of which the plant will
need to be equipped with an elevated storage tank to avoid being dependent on the supply of

Morton 8

electricity. A reserve must be created, so that water is available even when there is no electrical
power. Tank storage will also allow for treatment through the addition of disinfectants.
In general, it is advised that chlorine be added to the water supplying the entire plant, so as to
provide for permanent disinfection. To this end, a dose of 2 ppm of residual free chlorine is
suggested. It should also be borne in mind that the tank must be covered and not exposed to
sunlight, to prevent the chlorine from decomposing. As a term of reference, 100 ml of a sodium
hypochlorite solution for every 2000 litres of water may be used, assuming that the hypochlorite
solution contains about 50 mgr. of active chlorine per litre of solution. This will prevent the
water from having any chlorine-like taste.
Large volumes of liquid wastes are created in fruit and vegetable processing and these should be
carefully disposed of to prevent local pollution of streams or lakes. If main drainage is not
available, a septic tank should be constructed in a place that cannot contaminate drinking water
supplies. Water should not be allowed to simply soak into the ground, because this will create
swampy conditions, which attract insects that contaminate products, as well as introducing a
health hazard.
Toilets should be separated from the processing area by two doors or be located in a separate
building. Workers should have hand-washing facilities that are as hygienic as possible with soap
and clean towels being provided.

Sanitation and Health

Morton 9

Quality and health standards and regulations must be strictly applied, or the product will be
exposed to contamination by bacteria, mould and yeasts, thus jeopardizing the expected
development of an agro-industrial enterprise. The importance of food workers understanding and
practicing proper hygiene cannot be overemphasized. Workers can unintentionally contaminate
fresh produce, water supplies, and other workers, and transmit foodborne illness if they do not
understand and follow basic hygienic principles. (Codex Alimentarius, 1998)
Therefore measures must be adopted as early as in the production phase, and must continue in
the post-harvest, transportation, storage, preparation and processing phases. (UNIDO , 2004)
In line with these principles, the following sanitary standards must be fulfilled and applied by
workers on the production premises:
Personnel Health and Hygiene
It is important to ensure that all personnel, including those indirectly involved in fresh produce
operations, such as equipment operators, potential buyers and pest control operators, comply
with established hygienic practices. Operators should consider the following practices.
Establish a training program: All employees, including supervisors, full time, part time and
seasonal personnel, should have a good working knowledge of basic sanitation and hygiene
principles. The level of understanding needed will vary as determined by the type of operation,
the task, and the assigned responsibilities.
Each producer should develop a sanitation training program for their employees. Depending on
the situation, formal presentations, one-on-one instruction, or demonstrations (example, handwashing) may be appropriate. Depending on the workers' job requirements, periodic refresher or
follow-up training sessions may be needed.
If a formalized training program is not practical, such as for part time and seasonal field
personnel, the operator or the supervisor should verbally instruct and demonstrate to newly hired
workers proper health and hygiene practices, such as proper hand-washing techniques

Morton 10

1.

Workers must wash their hands and clean their nails carefully before engaging in any
process. They must keep their nails short, and if possible, use rubber/food grade latex or

2.

plastic gloves.
Adequate means of hygienically washing and drying hands, including wash basins and a
supply of hot and cold (or suitably temperature controlled) water. Hand wash stations

3.
4.
5.

should be foot or knee operated.

Toilets and Showers areas of appropriate hygienic design should be implemented.
Adequate changing facilities for personnel.
To enter the working area, workers must wear a clean smock, a hair and beard net to
protect the food from possible contamination by hair, and a mask to avoid microbial

6.

contamination.
The working utensils and equipment must be cleaned appropriately to remove any waste

7.

or residual organic material.

The containers (glass jars and bottles) must be washed with hot water before being filled

8.

with food.
The waste generated by the production process must be removed from the production

area on a daily basis.

9. Clean and dry the outside of the containers with the product before labelling and storing.
10. The storage site of the finished product must be clean and free from all possible
contamination (it must have been previously fumigated). It must also be cool and dry.
11. Once the working cycle has been completed, the production area must be left perfectly
clean. It will therefore have to be pre-rinsed with water at a temperature of 40C (to
remove about 90% of the dirt), washed with detergent e.g. Numero Uno or other food
grade detergents, and finally rinsed with water at a temperature of 38-46C.
12. Both the premises and the equipment will have to be disinfected on a weekly basis.
Caustic soda will be applied first (2%), and then nitric acid (1.5%) at a temperature of
75C after which they will be rinsed with water.

Industrial health standards

Morton 11

Whereas hygiene is a principle that applies to people, industrial health applies to the equipment,
facilities and premises utilized in the production process. It is extremely important to adopt
measures to ensure that the facilities meet the industrial health standards which guarantee an
efficient implementation of the process.
1.

The buildings must be adjusted so that they can be easily cleaned. There should be no
blind spaces inaccessible to the cleaning and disinfection system.

2.

The equipment must be designed in such a way that no empty spaces are left to facilitate
the accumulation of material that may decompose and cause severe contamination
problems.

3.

All surfaces exposed to food must be properly cleaned and sterilised, with a frequency
that will depend upon the type of raw material and process being used. Fruit and
vegetable residues are generally easy to clean.

4.

A disinfection process can never be performed on a dirty surface. In order for the
disinfection process to be successful, the surface must have been cleaned beforehand.

5.

The products used both in the cleaning and disinfection processes must be included in
the list of products authorized by local health authorities. Special care must be taken to
avoid polluting the environment by using products with an uncertain degradability.

6.

No disinfection process by itself will ever be able to replace the need for daily
compliance with general sanitary requirements.

7.

Counter and Table tops should be made of smooth, continuous, impervious material e.g.
Stainless steel.

Microbial Hazards
Outbreaks of foodborne illnesses associated with fresh and minimally processed produce have
occurred as a result of produce becoming contaminated with faecal material. Therefore, operators
should place a high priority on ensuring the use of agricultural and management practices that
Morton 12

minimize the potential for direct or indirect contact between faecal material and fresh fruits and
vegetables. In addition, infectious diseases, accompanied by diarrhoea or open lesions, that
include boils, sores, or infected wounds, are a source of disease-causing microorganisms.*
Inadequate food temperature control is another one of the most common causes of foodborne
illness or food spoilage. Such controls include time and temperature of processing and storage.
Systems should be in place to ensure that temperature is controlled effectively where it is critical
to the safety and suitability of food. (Codex Alimentarius, 1998) The shelf life, water activity,
levels of microbiological activity the methods of packaging and processing and the intent of use
should be taken into consideration.
It is recommended that regular testing should be done, at regular intervals, and recorded for
accuracy. Additionally properly calibrated test instruments, and microbiologically testing
equipment and record keeping policies are required to ensure that accuracy and accountability
are achieved.

*See Table 2 in the appendix.

Morton 13

Fruit and Vegetable Preparation

Reception
1.
2.
3.
4.

Wheel bath should be provided on entrance to compound

Reception area should be free from sunlight but have adequate lighting
Unencumbered by debris and packing materials.
Fruits and vegetables must be weighed and counted by calibrated machinery or the
accountability provided if done manually.
5. A visual check must be done to evaluate the quality of the produce before sending
produce to the packinghouse feeder lines.
6. Cleaning is done to remove physical debris from produce. It is suggested by the FAO
to use 50-200 ppm of active chlorine per gallon of water used. The use of chlorine
etc. is to reduce and remove fungi and other microbes that can cause spoilage.* See
Appendix Table 1 and Picture 1.0

Sorting
1. Remove products that do not conform to quality standards eg early signs of spoilage,
wrinkled appearance, and discolouration, size too small or too big, deformities,
bruises.
2. The cleaning procedure continues.
Sizing
1. Should be carried out before grading. This is because it is easier to identify units with
defects on a uniform product, either in terms of size or colour.
2. There are two systems - according to weight or dimensions (diameter, length or
both). Spherical or almost spherical products like grapefruits, oranges, onions, and
others, are probably the easiest to sort by size. Several mechanisms are available
from mesh screens to diverging belts Sizing can also be performed manually using
rings of known diameter. Sorting by weight is carried out in many crops with weight
sensitive trays. These automatically move fruit onto another belt aggregating all units
of the same mass. (FAO, 2004)

Grading

Morton 14

1. Consists of sorting product in grades or categories of quality. Two main systems

exist: static and dynamic. Static systems are common in tender and/or high value
crops. The product is placed on an inspection table where sorters remove units
which do not meet the requirements for the grade or quality category. The dynamic
system is probably much more common. The product moves along a belt in front of
the sorters who remove units with defects. Main flow is the highest quality grade.
Often second and third grade quality units are removed and placed onto other belts.
It is much more efficient in terms of volume sorted per unit of time. However,
personnel should be well trained. This is because every unit remains only a few
seconds in the worker's area of vision. There are two types of common mistakes:
removing good quality units from the main flow and more frequently, not removing
produce of doubtful quality. (FAO, 2004)
2. Rejects mainly on aesthetic grounds provide a second or even third quality grade.
These can be marketed in less demanding outlets or used as raw material for
processing. (FAO, 2004)
Processing
Chemical Treatments
1. Packers should only use chemicals for post-harvest treatments (e.g. waxes,
fungicides) in accordance with the General Standard on Food Additives or with the
Codex Pesticide Guidelines. These treatments should be carried out in accordance
with the manufacturers instructions for the intended purpose.
2. Sprayers for post-harvest treatments should be calibrated regularly to control the
accuracy of the rate of application. They should be thoroughly washed in safe areas
when used with different chemicals and on different fruits or vegetables to avoid
contaminating the produce. (Codex Alimentarius, 2007)
Cooling of fresh fruits and vegetables
1. Condensate and defrost water from evaporator type cooling systems (e.g. vacuum
cooling, cold rooms) should not drip onto fresh fruits and vegetables. The inside of
the cooling systems should be maintained clean.
2. Potable water should be used in cooling systems where water or ice is in direct
contact with fresh fruits and vegetables (e.g. hydro cooling, ice cooling). The water
quality in these systems should be controlled and maintained.
3. Forced-air cooling is the use of rapid movement of refrigerated air over fresh fruits
and vegetables in cold rooms. Air cooling systems should be appropriately designed
and maintained to avoid contaminating fresh produce.
Cold storage
Morton 15

1. When appropriate, fresh fruits and vegetables should be maintained at low

temperatures after cooling to minimize microbial growth. The temperature of the
cold storage should be controlled and monitored.
2. Condensate and defrost water from the cooling system in cold storage areas
should not drip on to fresh fruits and vegetables. The inside of the cooling
systems should be maintained in a clean and sanitary.
3. Tropical fruits and vegetables should not be placed in temperatures below 5 C as
most products are susceptible to chilling injury.

Morton 16

Record Keeping
The records generated by the GMP system should include all activities and documentation
required by the plan, including:

monitoring records for all critical control points,

deviation and corrective action records, and
verification/validation records.

Routine critical control point monitoring records should include the following information:
1.
2.
3.
4.

Form title
Firm name and location
Time and date
Product identification (including product type, package size, processing line and product
code, where applicable)
5. Actual observation or measurement
6. Critical limits
7. Corrective action taken, where applicable
8. Operators signature or initials
9. Reviewers signature or initials
10. Date of review
Deviation and corrective action records should include:

identification of the deviant lot/product,

amount of affected product in the deviant lot,
nature of the deviation,
information on the disposition of the lot, and
description of the corrective action.

Examples of verification and validation records include:

in-house on-site inspection,

equipment testing and evaluation,
accuracy and calibration of monitoring equipment, and
Results of verification activities, including methods, date, individuals and/or
organizations responsible, results or findings and action taken.

Morton 17

The following is an example of blank standard critical control points check list summary tables.
The purpose of the summary table is to aggregate all of the key information regarding
implementation of the plan in a single document. The completed summary table should be
supported by a variety of other records, including records of the hazard analysis, determination
of control points, maintenance of prerequisite programs, methods and procedures, daily
operational records, corrective action records, verification and validation records and other
supporting documentation.

Morton 18

FOOD SAFETY CHECKLIST

Date_______________________________________
Observed by_____________________________________________
Reviewed by
Directions: Use this checklist daily. Determine areas in operations requiring corrective action.
Record corrective action taken and keep completed records on file for future reference.

Morton 19

Personal Hygiene
Employees wear clean and

Yes / No

Corrective Action

proper uniform including

shoes.
Effective hair restraints are
properly worn.
Fingernails are short,
unpolished, and clean (no
artificial nails).
No jewelry such as wedding
band and a watch

and no

bracelets.
Hands are washed properly,
frequently, and at appropriate
times.
Burns, wounds, sores or scabs,
or splints and water-proof
bandages on hands are
bandaged and completely
covered with a foodservice
glove while handling food.
Eating, drinking, chewing
gum, smoking, or using
tobacco are allowed only in
designated areas away from
preparation, service, storage,
and ware washing areas.
Employees use disposable
tissues when coughing or
sneezing and then
immediately wash hands.
Employees appear in good
health.
Hand sinks are unobstructed,
Morton 20

operational, and clean.

Hand sinks are stocked with
soap, disposable towels, and
warm water.
A hand washing reminder sign
is posted.
Employee restrooms are
operational and clean.

FOOD PREPARATION
All food stored or prepared in

Yes / No

Corrective Action

facility is from approved

sources.
Food equipment, utensils and
food contact surfaces are

Morton 21

properly washed, rinsed, and

sanitized before every use.
Frozen food is thawed under
refrigeration, cooked to proper
temperature from frozen state,
or in cold running water.
Thawed food is not refrozen.
Preparation is planned so
ingredients are kept out of the
temperature danger zone to
the extent possible.
Food is tasted using the proper
procedure.
Procedures are in place to
prevent cross-contamination.
Food is handled with suitable
utensils, such as single use
gloves or tongs.
Food is prepared in batches to
limit the time it is in the
temperature danger zone.
Clean reusable towels are used
only for sanitizing equipment
and surfaces and not for
drying hands, utensils, or
floor.
Food is cooked to the required
safe internal temperature for
the appropriate time. The
temperature is tested with a
calibrated food thermometer.
The internal temperature of
food being cooked is
monitored and documented.
Morton 22

COLD HOLDING
Refrigerators are kept clean

Yes / No

Corrective Action

and organized.
Temperature of cold food
being held is at or below 41
F.
Food is protected from
contamination.

Morton 23

REFRIGERATOR,

Yes / No

Corrective Action

FREEZER, AND CHILLER

Thermometers are available
and accurate.
Thermometers are available
and accurate.
Food is stored 6 inches off
floor or in walk-in cooling
equipment.
Refrigerator and freezer units
are clean and neat.
Proper chilling procedures are
used.
All food is properly wrapped,
labeled, and dated.
The FIFO (First In, First Out)

Morton 24

method of inventory
management is used.
Ambient air temperature of all
refrigerators and freezers is
monitored and documented at
the beginning and end of each
shift.

FOOD STORAGE AND

Yes / No

Corrective Action

DRY STORAGE
Temperatures of dry storage
area is between 50 F and 70
F or State public health
department requirement
All food and paper supplies
are stored 6 to 8 inches off the
floor.
All food is labeled with name
and received date.
Open bags of food are stored
in containers with tight fitting
lids and labeled with common
name.
The FIFO (First In, First Out)
Morton 25

method of inventory
management is used.
Food is protected from
contamination.
All food surfaces are clean.
Chemicals are clearly labeled
and stored away from food
and food-related supplies.
There is a regular cleaning
schedule for all food surfaces.
Food is stored in original
container or a food grade
container.

CLEANING AND

Yes / No

Corrective Action

SANITIZING
Temperatures of dry storage
area is between 50 F and 70
F or State public health
department requirement
Water is clean and free of
grease and food particles.
Water temperatures are correct
for wash and rinse.
If heat sanitizing, the utensils
are allowed to remain
immersed in 171 F water for
30 seconds.
If using a chemical sanitizer, it
is mixed correctly and a
sanitizer strip is used to test
chemical concentration.
Wiping cloths are stored in
sanitizing solution while in
Morton 26

use.

LARGE EQUIPMENT
Food slicer is clean.
Food slicer is broken down,

Yes / No

Corrective Action

cleaned, and sanitized before

and after every use.
Boxes, containers, and
recyclables are removed from
site.
Loading dock and area around
dumpsters are clean and odorfree.
Exhaust hood, extractor fans
and filters are clean.

Morton 27

UTENSILS AND

Yes / No

Corrective Action

EQUIPMENT
All small equipment and
utensils, including cutting
boards and knives, are cleaned
and sanitized between uses.
Small equipment and utensils
are washed, sanitized, and airdried.
Boxes, containers, and
recyclables are removed from
site. Work surfaces and
utensils are clean.
Work surfaces are cleaned and
sanitized between uses.
Thermometers are cleaned and
sanitized after each use.
Thermometers are calibrated
on a routine basis.
Can opener is clean.
Drawers and racks are clean.
Clean utensils are handled in a
manner to prevent
contamination of areas that
will be in direct contact with
food or a persons mouth.

Morton 28

GARBAGE STORAGE

Yes / No

Corrective Action

Yes / No

Corrective Action

AND DISPOSAL
Kitchen garbage cans are
clean and kept covered.
Boxes and containers are
removed from site.
Loading dock and area around
dumpster are clean.
Dumpsters are clean.

PEST CONTROL
Outside doors have screens,
are well-sealed, and are
equipped with a self-closing
device.
No evidence of pests is
present.
There is a regular schedule of
pest control by a licensed pest

control operator.
(National Food Service Management Institute, 2009)

References
Codex Alimentarius. (1998, October 26). Guidance for Industry: Guide to Minimize Microbial
Food Safety Hazards for Fresh Fruits and Vegetables. Retrieved from U.S Food and
Drug Administration:
Morton 29

http://www.fda.gov/Food/GuidanceRegulation/GuidanceDocumentsRegulatoryInformatio
n/ProducePlantProducts/ucm064574.htm#iv
Codex Alimentarius. (2007). FAO Corprate Document Repository(Codex Alimentarius) First
Edition. Retrieved from Fresh Fruits and Vegetables:
http://www.fao.org/docrep/010/a1389e/a1389e00.htm
FAO. (2004, March 20). Manual For the Preparation and Sale of Fruits and Vegetables.
Retrieved from FAO Corprate Document Repository:
http://www.fao.org/docrep/008/y4893e/y4893e00.htm
Maharaj, R. (2013, October). Lecture Notes On Quality Assurance and Current Good
Manufacturing Practices. Centeno, Trinidad and Tobago.
National Food Service Management Institute. (2009). HACCP BASED SOPS. Retrieved from
National Food Service Management Institute:
http://www.nfsmi.org/documentlibraryfiles/PDF/20130730104656.pdf
Singh-Ackbarali, D. (2013). Bacteria that are Food Bourne. Centeno: UTT.
Singh-Ackbarali, D. (2013, October). Lecture Notes Food Microbiology. p. 1.
UNIDO . (2004). UNIDO Technology Manual: Small-scale Fruit and Vegetable- Production
Methods, Equipment and Quality Assurance Practices. Vienna: United Nations Industrial
Development Organizaton.

Morton 30

Appendices
Table 1. Common spoilage defects of fruits and vegetables and the Causative Agents
Defect

Casual organism

Bacterial soft rot

Erwinia carotovora

Gray mold rot

Botrytis cinerea

Rhizopus soft rot

Rhizopus nigricans

Blue mold rot

Penicillium spp

Alternaria rot

Alternaria spp

Pink mold rot

Trichothecium roseum

Green mold rots

Cladosporium, Trichoderma

Watery soft rot, Brown rot

Sclerotinia sclerotiorum

Downy mildew

Phytophthora, Bremia

Sliminess or souring

Saprophytic bacteria

Black rot/ smut/ Black mold

Alternaria / Aspergillus niger

Anthracnose

Coletotrichum lindemuthianum

(Singh-Ackbarali, Lecture Notes Food Microbiology, 2013)

Morton 1

Table 2: Bacteria responsible for food borne illness

Type of disease

Causative
bacteria

Kind and nature of the

bacteria

Major symptom(s) type

Intoxication

Staphylococcus
aureus strains

Gram-positive cocci, present in

pairs, short chains or bunched
grape like clusters, facultative
anaerobes, but grow rapidly
under aerobic conditions,
mesophiles with a growth
temperature range of 7 to 480C
and have the ability to grow at
low aW (0.86), low pH (4.8), and
high salt and sugar
concentrations of 15% and in the
presence of NO2 (naturally

GIT (enterotoxin)

Staph poisoning
(improper handling
by infected persons)

salivation, nausea and vomiting,

abdominal cramps & diarrhea.
Secondary symptoms are
sweating, chills, headache and
dehydration.

selective differential media like

Baird-Parker agar
Morton 2

present in the nose, throat, skin,

and hair of healthy humans,
animals and birds.)

Botulism

Clostridium
botulinumstrains

(incorrectly or
minimally processed
food)

Anaerobic, Gram-positive spore

forming rod, sensitive to low pH
(<4.6), lower Aw (0.93), and
moderately high salt (5.5%). The
spores are heat-resistant (killed
at 1150C) and can survive in
foods that are incorrectly or
minimally processed. Spores do
not germinate in the presence of
nitrate (250 ppm). (distributed in
soil, sewage, mud, sediments of
marshes, lakes and coastal
waters, plants- fruits (figs and
peaches) and vegetables (green
beans, corn, spinach, pepper) and
intestinal contents of animals and
fishes)

Produces an Exotoxin (can be

destroyed by heat). Non-gastric
- blurred or double vision,
difficulty in swallowing,
breathing and speaking, dryness
of the mouth, and paralysis of
different involuntary muscles
that spreads to the lung and
heart (neurotoxin)

Rod shaped, motile, non-spore

forming, Gram-negative,
facultative anaerobic, motile
bacteria. mesophiles with a
growth temperature range of 5 to
460C and optimum growth
temperature of 35 to 370C. They
are sensitive to low aW (<0.94)
and low pH (4.5 or below). Food
Associated are - raw meats,

GIT - salivation, nausea and

vomiting, abdominal cramps &
diarrhea. Secondary symptoms
are sweating, chills, headache
and dehydration.

Infection
Salmonellosis

Over 2000
Salmonella
spp. (except S.
typhi and
S. paratyphi)

As few as 15-20 cells can cause

illness in some cases.

Morton 3

poultry, eggs, milk and dairy

products, fish, shrimp, frog legs,
yeast, coconut, sauces and salad
dressing, cake mixes, creamfilled desserts and toppings,
dried gelatin, peanut butter,
cocoa, and chocolate.
Bacteria are also present in soil,
water and sewage contaminated
with fecal matter from where
they can contaminate foods
directly or indirectly

Campylobacter
enteritis

Campylobacter
jejuni & Cam.
coli strains

Gram-negative, slender, curved,

motile, microaerophillic (has a
requirement for reduced levels of
oxygen) rod. Sensitive to
environmental stresses (e.g.,
21% oxygen, drying, heating,
disinfectants, acidic conditions).
Contaminates raw chicken, raw
milk, carries by cattle and flies
on farm, can be present in nonchlorinated water.

GIT - diarrhea, which may be

watery or sticky and can contain
blood (usually occult) and fecal
leukocytes (white cells). Other
symptoms often present are
fever, abdominal pain, nausea,
headache and muscular pain.

, properly cooking chicken,

pasteurizing milk, and
chlorinating drinking water will
kill the bacteria. It is considered
as one of the most frequent cause
of food infection next to
salmonella.

Morton 4

Gram-negative, motile, nonsporulating, rod shaped

facultative anaerobic bacterium.

Non-hemorrhagic E.
coli strains
E. coli strains like
E. coli 026: H11

Contamination of water with

human sewage may lead to
contamination of foods. Infected
food handlers may also
contaminate foods. These
organisms are infrequently
isolated from dairy products such
as semi-soft cheeses.
Raw beef and chicken, although
any food exposed to fecal
contamination is strongly
suspect.

Enterohemorrhagic
E. coli colitis
E. coli 0157:H7
Shiga-like toxin
producing

Undercooked or raw hamburger

(ground beef) has been
implicated in many of the
documented outbreaks, however
E. coli O157:H7 outbreaks have
implicated unpasteurized fruit
juices, dry-cured salami, lettuce,
game meat, and cheese curds.

Gram+, motile, non-sporulating,

rod shaped facultative anaerobic,
psychrotrophic bacterium.

GIT travelers diarrhea,

dehydration, blood in stool,
abdominal cramps, low-grade
fever, nausea and malaise
(discomfort or uneasiness)
Infantile diarrhea - diarrhea in
infants is prolonged, leading to
dehydration, electrolyte
imbalance and death (50%
mortality rates have been
reported in third world
countries).
severe cramping (abdominal
pain) and diarrhea which is
initially watery but becomes
grossly bloody. Occasionally
vomiting occurs. Fever is either
low-grade or absent.

The sensitive group includes

pregnant women, unborn
fetuses, infants, elderly people
and immuno-compromised
people.
Septicemia, meningitis,
encephalitis, and intrauterine or
cervical infections in pregnant
women, which may result in
spontaneous abortion (2nd/3rd
trimester) or stillbirth. These are
usually preceded by influenzaMorton 5

Listeriosis
Listeria
monocytogenes

Quite hardy and resists the

deleterious effects of freezing,
drying, and heat remarkably well
for a bacterium that does not
form spores. associated with
such foods as raw milk,
supposedly pasteurized fluid
milk, cheeses (particularly softripened varieties), ice cream, raw
vegetables, fermented raw-meat
sausages, raw and cooked
poultry, raw meats (all types),
and raw and smoked fish. Its
ability to grow at temperatures as
low as 3C permits
multiplication in refrigerated
foods.

like symptoms including

persistent fever. Gastrointestinal
symptoms such as nausea,
vomiting, and diarrhea may
precede more serious forms of
listeriosis or may be the only
symptoms expressed.
As few as 10 cells can lead to
illness.
Abdominal pain, cramps,
diarrhea, fever, vomiting,
accompanied by blood, pus, or
mucus in the stools. Infections
are associated with mucosal
ulceration, rectal bleeding,
drastic dehydration; fatality may
be as high as 10-15% with some
strains.

Gram-negative, non-motile, nonspore forming rods. grow

between 7 and 460C, with an
optimum at 370C. They can
survive for days under
refrigeration, freezing, and 5%
NaCl and pH4.5, but are
sensitive to pasteurization.

Shigellosis
Four shigella
spps. e.g.

Frequently found in water

polluted with human feces. The
foods implicated in outbreaks
include salads, raw vegetables,
milk and dairy products, and
Morton 6

Sh. dysenteriae

poultry. Contamination of these

foods is usually through the
fecal-oral route. Fecal
contaminated water and
unsanitary handling by food
handlers are the most common
causes of contamination.

Bacillus cereus

Anaerobic, Gram+, spore

forming rod

Toxicoinfection
Bacillus cereus
gastroenteritis

(illness are
caused by two
distinct
metabolites)

GIT - onset of watery diarrhea,

abdominal cramps, and pain
after 6-15 hours of consumption
foods including meats, milk,
of contaminated food. Nausea
vegetables, and fish have been
may accompany diarrhea, but
associated with the diarrheal type vomiting (emesis) rarely occurs.
food poisoning. The vomitingThe emetic type of food
type outbreaks have generally
poisoning is characterized by
been associated with rice
nausea and vomiting within 0.5
products; however, other starchy to 6 h after consumption of
foods such as potato, pasta and
contaminated foods.
cheese products have also been
Occasionally, abdominal cramps
implicated.
and/or diarrhea may also occur.

A total dose of greater than one

million organisms may cause
disease. Diarrhea, abdominal
cramps, nausea, vomiting,
headache, fever, and chills may
be associated with infections
caused by this organism. The
Morton 7

Cholera

Vibrio
parahemolyticus

Gastroenteritis by
opportunististic
pathogens

Gram-negative, non-sporulating
motile curved rods with an
optimum temperature of 30 to
370C, but can grow over a
temperature range of 5 and 420C.
The cells can grow quickly in a
salt concentration of 3 to 5%
NaCl but are sensitive to 10%
salt. Produces heat stable toxin.
raw, improperly cooked, or
cooked, recontaminated fish and
shellfish. Improper refrigeration
of seafood contaminated with
this organism will allow its
proliferation, which increases the
possibility of infection.

Vibrio vulnificus

illness is usually mild or

moderate, although some cases
may require hospitalization.

causes wound infections,

gastroenteritis, or a syndrome
known as "primary septicemia".
Compromised persons can get
infected with as little as <100
cells. Individuals with chronic
disease who are infected can
also experience distinctive
bulbous skin lesions.

lactose-fermenting, halophilic,
gram-negative, opportunistic
pathogen, is found in estuarine
environments and associated
with various marine species such
as plankton, shellfish (oysters,
clams, and crabs), and finfish.
Consumption of these products
raw or recontaminated may
result in illness.

(Singh-Ackbarali, 2013)

Morton 8

Picture 1.0. Washing of Pears for Processing

Morton 9