Good Manufacturing Practices (GMP) Basics

Good Manufacturing Practices (GMP) in food plants are a comprehensive system of guidelines designed to protect food from potential contamination, which are outlined by the USDA and FDA.

Core Principles of GMP:

·         Personal Hygiene – team members must follow strict handwashing, use of protective clothing such as smocks, hairnets/beardnets, gloves, prohibitive use of jewelry, and prevention of eating/drinking or other personal actions that could contaminate food.

·         Facility Design/Infrastructure – effective ventilation, lighting, adequate drainage (no pooling of water) and design to prevent contamination of food or food contact equipment (no flaking paint/rust or loose caulking).  Light fixtures and other glass must be properly covered or protected in case of breakage (shatterproof is best design).

·         Chemical control – chemicals used to perform cleaning or for maintenance of equipment (such as lubricants) should be approved for the intended use and stored in locked/secured areas used only by trained/authorized individuals.

·         Pest Control – an effective program covers the elimination and prevention of bugs/insects and rodents.  Devices should be mapped.  There are effective 3^rd party companies that can provide services and effective documentation to prove compliance in this area.

·         Equipment Design and Maintenance – machinery should be easily cleaned, corrosion-resistant (such as Stainless Steel), designed of non-toxic materials, and regularly maintained (see BLOG-POST regarding Preventative Maintenance: https://www.faithfulfoodsolutions.com/post/preventative-maintenance-and-its-importance-to-food-safety-quality ).

·         Raw Material Control – maintenance of temperature, packaging integrity, and security of ingredients upon receipt and while being stored.  Use of food-grade packaging is another important element.  Incoming trailers must be inspected for damage, infestation, off odors, contamination, and proper temperatures.  Suppliers can provide documentation for storage temperatures of ingredients and certification that packaging meets food-grade standards.

·         Water Potability – water used must be potable/safe.  Municipalities can provide documentation, but if from a well it should be tested to ensure it is safe.  Back flow prevention devices must be installed on all water and steam lines and certified annually.

·         Employee Illness – team members should be required to report illness to appropriate facility management or medical staff before working; open wounds or abrasions should be adequately covered with metal detectable bandages.

·         Handwashing Stations – signs should be present identifying handwash stations and each equipped with 100-degree Fahrenheit water, soap and drying options located to assure sanitation standards are adequate to prevent contamination and ensure employee hygiene.

·         Sewage/Restrooms - Sewage must be disposed of into an adequate sewage system or disposed of through other adequate means.  Restrooms must have handwashing stations, maintained/cleaned, and adequate to handle the number of team members in the facility.

·         Waste Receptacles – these should be sufficient in location and number to assure adequate containment of facility rubbish/trash with timely removal.

·         Storage of Finished Product and Outbound Trailers – finished product must be stored in conditions that protect the integrity of the finished product containers at required temperatures based on product type, and upon shipping be inspected for damage, infestation, off odors, contamination, and proper temperatures.

·         Facility and Grounds - the grounds surrounding the facility must be maintained in a manner which will prevent rodent and insect harborage, reasonably free of litter and debris, and properly surfaced and designed to prevent offensive odors and for adequate drainage (minimal standing water).  An adequate number of exterior waste containers should exist which are well maintained and in good condition. The frequency or removal of the waste shall be timely.

As with all key facility food safety/quality programs, adequate maintenance of documentation showing compliance is critical.  Team member training during Orientation/On-Boarding and annually thereafter is also crucial.

By adhering to GMPs, food plants create reliable processes that protect consumers, ensure regulatory compliance and maintain high quality food products through all stages of processing.