HACCP ポイントメモ

how to use an adhesive roller

shoulder

from chest to stomach

legs (front)

legs (back)

Mr. Mitsuo Kato,
an instructor authorized by International HACCP Alliance

Basic general ideas of HACCP

Points for the construction of prerequisite programs (PP)

Going into ISO22000 Era

Examples for HACCP and PP

Important points for HACCP

Technical tarms for HACCP

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Let’s begin with uniforms

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Mr. Mitsuo Kato
an instructor authorized by International HACCP Alliance and President in Foods Design Co. Ltd.

Important points for packing materials

Important points for edible meat

Important points for HACCP

１	To decide entrance procedures
２	Before entering changing rooms
３	Procedures for using an adhesive roller, after using it, checking it
４	How to clean and keep boots
５	Cleaning uniforms and the introduction of lease
６	A survey as to how much hair fall out and where it is
７	From towels to counter clothes
８	Emergent measures for norovirus in winter
９	So that dirty things from an air shower room should not come into a work room
１０	A cap with a stopper for hairs
１１	Measures for rest hours
１２	Preventing falling hairs
１３	Basic education for new employees
１４	Contamination by hairs
１５	“Knowledge” is important for hygienic education
１６	Cleaning uniforms
１７	Boots or shoes
１８	How to move between zones
１９	Measures for norovirus in fall

１	To decide entrance procedures	Here are details.
	No people wash their hands before going to a rest room.	You should have the roller from your head.
	People wash their hands after finishing what they need in the rest
	room. Then which should we do earlier, using an adhesive roller or
	washing our hands? The answer is to use the adhesive roller.
	If we use the adhesive roller after washing our hands, our hands
	will have some dusts again.

	The general procedures for entrance and exit of a manufacturing
	room: a cap → a working jacket → a roller → washing hands →
	drying → washing hands in alcohol → an air shower → entrance
	But the procedures can be sometimes changed. They depend on
	factories. It is possible to finish washing hands, drying, and washing
	hands in alcohol after the air shower.
	It is good to wash hands just after employees go into the
	manufacturing room.
	The procedures are different in different factories. Some employees put on their nets before putting
	on their caps. In order to prevent falling hairs some employees use the roller before putting on their
	working jackets. If you don’t dry your hands perfectly, washing hands in alcohol doesn’t work well.
	You should consider what is the best for your factory.
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２	Before entering changing rooms
	You have a lot of dusts and so on when commuting by trains and cars.
	If you go into a work room in the clothes you had in the rains and the cars, it means that you are
	bringing the dusts into the work room.
	If a changing room is dirty, there are possibilities that your working jacket will be dirty.
	You have to remove every dirt before entering the changing room.
	In a factory there are simple air showers in the hallway and employees take the air showers before
	entering their changing room.
	In a factory there are brushes which are used by
	employees to remove their dirt before entering their
	changing room.
	People have 60 fallen hairs in a day. The brushes
	sometimes have some fallen hairs.
	After brushing the employees enter their changing room.
	But there are still some dirt and hairs there.






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３

Procedures for using an adhesive roller, after using it, checking it

Here are details.

An adhesive roller is effective to remove hairs.

It is important to recognize the advantages of the adhesive roller.

It takes 15 minutes to use it.

The adhesive roller should go to: a cap → shoulder →

arms ( inside ) → arms (outsides) → sides → neck →

chest → waist → back →　pants (front) → pants (back)

After using the roller, employee should check how much dust

and hair it has. Usually it has a lot.

People are surprised at a lot of dust and hair after checking it.

Then they recognize the importance of the roller.

It may be good to use a new roller every time.

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４	How to clean and keep boots
	Workers should clean their boots just after they exit from their working area.
	After washing them, they should dry them as quickly as possible.
	They should understand how to keep their boots
	after drying.
	Boot lockers should not have doors to prevent moisture
	and the increase of bacteria.
	Some companies use bars to keep boots because it is
	easier to check boot soles. If the boot soles have some
	dusts and hairs, employees have possibilities to bring them
	into their working area.
	When the employees go into their working area, they
	should have clean boots.










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５	Cleaning uniforms and the introduction of lease	Here are details.
	Cleaning uniforms is not inexpensive. In a factory there are about 100 employees and the factory
	has to spend approximately Y2,480,000 for cleaning their uniforms in a year. Women often clean
	their uniforms but men don’t. If they wash their uniforms in their houses, they probably wash them
	with other things. It means there are possibilities to contaminate their uniforms. Although the
	factory distributes two uniforms to each employee every other year, it has some problems.
	Then rental uniforms are considered.

	The rental uniforms per person employed are 3 jackets and 3 pants, and they will be cleaned once
	a week.
	They are controlled based on hygienic standards with highly efficient specification by Sun-S Co. Ltd.
	A rule is that everyone has to ask a laundry worker to clean his/her uniform once a week.
	It contributes to control hygiene and expenses.
	Usually employees have two uniforms with them and one is cleaning.
	It is possible to have week-to-week lease.
	It is easy to find rental uniforms.
	Free fix
	There are some advantages and total expenses will be Y900,000.
	The factory decided to try the rental uniforms.

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６

A survey as to how much hair fall out and where it is

Because a food factory had hair problems, a manager in the food factory decided to examine how

much hair is in the factory.

He used adhesive rollers to check a chamber for cooking sushi, cooking tables, a cooking room,

packing tables, a hand- wash station (1) , a hand- wash station (2 ), picking tables in the factory.

《The number of hair》

month	March	April	May	June	July
chamber for cooking sushi	１	１１	１	９	７
Cooking tables	４５	３５	２５	４８	６０
cooking room	１６	１３	１１	１８	２１
Packing tables	３３	２９	２１	４８	４３
Hand-wash station 1	２１３	２３４	２７６	２７５	２６９
Hand-wash station 2	７	１９	１１	２６	２８
Picking tables	２７		４２
Total	３４２	３４１	３８７	４２４	４２８

As a result there were a lot of hairs on the floors in the hand-wash station 1.

In the factory employees had air showers and rollers before washing their hands.

It was effective.

This time the employees washed their hands before taking the air showers and had their boots.

It was effective, too.

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７

From towels to counter clothes

Old towels have some loose threads which have possibilities to contaminate food.

In a meat factory people used towels to clean some juice from meat but they had hygienic

problems. Then they began to use counter clothes.


a towel		a counter cloth

The counter clothes are good to clean some juice because they don’t have any loose threads,

keeping moisture.

There are two types of the counter clothes. They are repeatable clothes after washing and

disposable ones. In a rice factory people used clothes without edge-stitched seams when they

cooked rice by gas. Now they use clothes with the edge-stitched seams.

Please check whether there are some things that may contaminate food in your factory.

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８	Emergent measures for norovirus in winter
	In December and January foodborne illness by　norovirus is common.
	People should recognize how dangerous norovirus is.
	Washing hands is the best way to prevent it. If you don’t wash your hands after going to a rest room,
	you will have a lot of norovirus.
	When you get only 50 or 60 norovirus, you will have foodborne illness. Norovirus are very strong.
	The norovirus you have on your hands is going to spread through your uniform, your apron,
	doorknobs, adhesive rollers.
	A woman working on a school lunch made the cause of mass food poisoning because of the virus
	between her finger and her ring.
	You need to wash your hands thoroughly.
	You should make a habit of washing your hands for 30 seconds by focusing on your fingers and
	following a manual.


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９	So that dirty things from an air shower room should not come into a work room
	Just after using an air shower, you should not open the door of a manufacturing room.
	Because your hair and dust are still floating in the shower room, they may go into the
	manufacturing room.
	After using the air shower, you should wait for 2 seconds and open the door of the manufacturing room.
	If　the door is automatic, you should arrange the automatic door so that it will open 2 seconds later.

	Employees need to understand the importance of this rule.
	When you check whether you brought your hair and dust into the manufacturing room, you should
	use an adhesive roller. You can check around the shower room by using the adhesive roller.
	You can check anywhere in your factory by the adhesive roller.
	When you use only the air shower, it is not effective enough.
	You need to use both the air shower and the adhesive roller.
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１０	A cap with a stopper for hairs	Here are details.
	People have dusts on their heads. If they wash their heads every morning, it is good.
	But it is not always that every employee does so.
	If the dusts with staphylococcus aureus contaminate food, they may be the cause of foodborne illness.
	When staphylococcus aureus is in some warm water whose temperature is about 10 C, it
	discharges poison.
	A milk manufacturer in Osaka, Japan has had serious
	foodborne illness because of the same type of poison.
	You should use a cap which prevents falling hairs and dusts.
	We also recommend hoods.
	In a factory people have changed from caps to hoods.
	It was effective. Sun-S Co. Ltd. can provide cool hoods
	for summer.










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１１	Measures for rest hours
１．	When going into a lounge in your uniform on your long lunch break,
	you may get a lot of dusts in the lounge.
	You should take off your uniform and cap before going there. You should keep them on a hanger
	that was preparedbefore the lounge.
２．	When you have a short break, you don’t need to take off your uniform and cap. Some factories
	have a rule that you should not take off your cap during the short break.
３．	Smoking In a factory a red bucket is kept in a refrigerator. People are smoking around the red
	bucket. In a factory there is a smoking room. People using the room have to take responsibility for
	cleaning the room. If the room is dirty, smoking is going to be prohibited.
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１２	Preventing falling hairs	Here are details.
	Employees have half sleeves in summer and in places whose
	temperatures are high. In this case there are possibilities to
	fall their fallen armpit hairs from their half sleeves. It is safe
	to use a uniform that has inner nets under its armpits.
	It is important to pay attention to undergarments.
	If they prevent dusts, they are fine. But if they are wool
	sweaters, they may have some hairballs, which may contaminate
	food.
	A client complained that she found a red string in beef.
	It was a piece of wool from a worker having a wool undergar
	ment in a meat factory whose temperature was 5 C.
	Although low temperature is necessary for products, it is cold
	for workers. They should be allowed to have sweaters.
	In this case it is helpful to use a jacket that has an inner net at
	the waist of the jacket. The inner net prevents falling strings,
	hairs, and so on.




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１３	Basic education for new employees
	New employees are sometimes the cause of a problem.
	A lot of clients began to complain about products in a factory.
	At first time people didn’t know the cause of the problem in spite of their investigations.
	Later they got the cause of the problem. It was new foreign employees that related to the problem.
	Because the basic education for the new employees was not enough, they didn’t understand how to
	use their uniforms, caps, and adhesive rollers and so forth.
	Employees should have enough education before beginning to work.
	There are a lot of different habits between countries.
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１４	Contamination by hairs	Here are details.
	Fallen hairs are a serious problem in a food factory where there are a lot of employees.
	A person has 60 fallen hairs in a day.
	When we only contact with people, fallen hairs are falling. An adhesive roller is helpful.
	In a factory there is a room whose entrance is small. Employees often touch their heads on the
	ceiling of the entrance when going into the room.
	Because of clients’ complaints about hairs in food one day people in the factory checked which
	places had a lot of hairs. They found a lot of hairs around the entrance. A lot of head hairs were
	fallen when the employees touched their heads on the ceiling of the entrance.
	After they had a bigger entrance, they could solve the hair problem.
	In a factory workers had to pass a small passage when going to an office.
	Because sometimes they passed each other or contacted with other people, there were a lot of
	hairs there. The location of the office was changed so that the workers didn’t have to pass
	the passage when going there. Then they didn’t receive complaints about hair from their clients.
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１５	“Knowledge” is important for hygienic education
	Everyone needs to understand how important hygienic education is.
	In a food factory a man asked an employee why the employee needed to keep food 75C after cooking.
	The employee said, “I don’t know. But someone told me to do so.” After the man told him that 75C
	was hot enough to kill bacteria, he understood why he had to do so.
	Workers need to recognize why their uniforms have no pockets and why they need to put on inner
	nets before putting on their caps. It is better for them to understand procedures and rules. When
	they wash their hands, they have 4 steps, such as before washing hands, having some hot water
	before using some soap, washing hands for 10 seconds by using some soap for, washing hands for
	30 seconds by using some soap.
	Hot water very much removes dirt, which makes people surprised.
	Washing hands for 30 seconds by using some soap is more effective than doing hands for 10 seconds
	by using them. People understand that washing hands for a longer time is better.
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１６	Cleaning uniforms
	If employees wash their uniforms in their houses, they probably wash them with other things.
	It means there are possibilities to contaminate their uniforms.
	If their uniforms are contaminated, their uniforms may contaminate food in their factory.
	When they dry their uniforms outside, their uniforms may have some dusts, insects, and leaves.
	If their uniforms having no buttons and no loose
	threads are washed in the factory, they won’t
	contaminate food there.
	In a factory there is a big container for dirty
	uniforms in a locker room. Workers leave their
	dirty uniforms in the big container after work.
	Then their uniforms will be washed and dried in
	their laundry room.
	When you use rental uniforms, you should check
	whether the rental uniforms are not
	contaminated.

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１７	Boots or shoes
	In a meat processing plant employees have a problem with sweaty feet in their boots.
	Why do the employees need to have their boots in the plant? Because they use a lot of water
	there. Recently many plants try a way which workers don’t have to use a lot of water.
	We can prevent the outbreak of bacteria and mold if we don’t use a lot of water.
	The workers should work on dry floors and after work the dry floors should be washed by water.
	It is important to remove humidity.
	If they work on the dry floors, it is easier for them to work in shoes. Shoes are also cheaper
	than boots.
	When walking, people usually have their shoes and they don’t have their boots.
	In a food factory employees work in their shoes during the manufacture of food. When they clean
	the factory, they have their boot. Then they don’ need to have their boots for a long time and
	they have no problem with sweaty feet. You should consider which is better, shoes or boots?
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１８	How to move between zones	Here are details.
	Is it ok that workers with food in a pre-cleaned zone go into a cleaned zone?
	Is it also ok that tools in the pre-cleaned zone are brought into the cleaned zone?
	It is impossible for the workers to change their uniforms and wash their hands before going to the
	cleaned zone.
	It is fine that the workers in the pre-cleaned zone stay in the cleaned zone for a while to convey
	some food. It is also fine that employees in the cleaned zone go to the pre-cleaned zone to get
	some food.
	For example, casters are rolling on the floors which are contaminated zones. If some food drop
	down on the floors, we can’t sell it any more.
	It is very significant to understand that floors are always contaminated zones. In some factories
	people change their uniforms based on zones.
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１９	Measures for norovirus in fall
	Foodborn illness usually occurred only in summer before. But recently foodborn illness by norovirus
	occurs in fall.
	Because people didn’t know about norovirus before, it was not common. It was called SRSV.
	Recently there are a lot of norovirus patients between December and February. The main cause
	of spreading norovirus is workers with norovirus don’t wash their hands thoroughly.
	The norovirus goes to a doorknob, a fridgeknob and so forth. Sometimes the workers with norovirus
	touch food directly.
	Without washing hands thoroughly after going to a rest room, people with norovirus may be the cause
	of foodborn illness by norovirus.
	Washing hands thoroughly is the most important and every employee needs to recognize it.
	Please start perfect education related to how to wash hands and so on.
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