Module 4 · Physical, Chemical and Allergenic Hazards

Module 4 · Physical, Chemical and Allergenic Hazards0% complete · 13 slides left

Level 2 Food Hygiene and Safety for Manufacturing
Module 4

This course contains audio. Use headphones in public places.

Introduction

Not every hazard is microbiological. Food can also be made unsafe by foreign objects, by harmful chemicals, and by allergens.

This module explains physical, chemical and allergenic hazards, how they are controlled in a manufacturing environment, and the law on the 14 named allergens.

In This Module

These hazards are controlled by many of the checks you carry out on the line every day. This module covers:

Physical hazards, and how they are controlled.
Chemical hazards, and how they are controlled.
Allergenic hazards, and the 14 named allergens.
Allergic reactions and anaphylaxis.
Allergen information and labelling.
Controlling allergens in production.

Physical Hazards

A physical hazard is a foreign object that gets into food. It can injure a consumer, causing choking, cuts or broken teeth, and it can also carry bacteria.

Examples include broken glass, metal fragments, hard plastic, wood, stones, hair, fingernails, jewellery, plasters, packaging materials, pest droppings, and pieces of equipment such as nuts, bolts and blades.

Controlling Physical Hazards

Keep food and ingredients covered, and store them correctly.
Wear the correct protective clothing, with hair fully covered.
Do not wear jewellery, and use blue, metal-detectable plasters.
Follow the glass and hard plastics policy, and report any breakage immediately.
Check equipment for damage and missing parts, before and after use.
Make sure metal detectors and other checks are working, and never bypass them.
Remove outer packaging before taking ingredients into production areas.

Chemical Hazards

A chemical hazard is a harmful chemical in food. Common sources in manufacturing are cleaning chemicals and sanitisers, machine lubricants and oils, pest control products, and residues from packaging or raw materials.

Some chemical hazards occur naturally, such as toxins in certain mushrooms, fish or mouldy grain.

Chemicals can taint food, or make people seriously ill, so they must be carefully controlled.

Controlling Chemical Hazards

Store chemicals in a separate, secure area away from food, clearly labelled.
Never decant chemicals into unmarked containers, or into food containers.
Use only approved, food-grade lubricants on food equipment.
Follow the manufacturer’s instructions for dilution and contact times.
Rinse surfaces after cleaning where the instructions require it.
Cover or remove food and packaging before cleaning nearby.
Only allow trained people to use chemicals.

Allergenic Hazards

An allergen is a food or ingredient that can cause an allergic reaction. For a person with a food allergy, even a tiny trace can be dangerous, or even life-threatening.

In a manufacturing site, allergens can easily spread between products through shared equipment, dust, spillages, rework and packaging mix-ups.

Allergen control is a legal requirement in every food business.

The 14 Named Allergens

Food law names 14 allergens that must be declared:

Celery, cereals containing gluten, crustaceans, eggs, fish, lupin and milk.
Molluscs, mustard, tree nuts, peanuts, sesame seeds, soya, and sulphur dioxide and sulphites.

Any product containing one of these, even as a minor ingredient, must declare it. Other foods can also cause allergies, but these 14 cause most serious reactions.

Allergic Reactions and Anaphylaxis

An allergic reaction can range from a rash, itching or swelling, to anaphylaxis. Anaphylaxis is a severe, potentially fatal reaction that can affect breathing and blood pressure, and can develop within minutes.

Anaphylaxis is a medical emergency. The person needs adrenaline, usually from an auto-injector, and an ambulance straight away.

This is why every allergen check on a production line matters.

Allergen Information and Labelling

Accurate allergen information is a legal requirement. Under Regulation (EU) No 1169/2011 on food information to consumers, prepacked food must list all ingredients, with any of the 14 allergens emphasised, for example in bold.

For food that is not prepacked, allergen information must still be available and accurate, as explained in guidance from the Food Safety Authority of Ireland.

Always make sure the right label goes on the right product.

Controlling Allergens in Production

Know which allergens are used on your line, and in every product you make.
Store allergenic ingredients separately, in sealed and labelled containers.
Follow the production schedule, which usually runs allergen-free products first.
Clean thoroughly between products, and complete the allergen clean-down checks.
Use dedicated, colour-coded equipment where required.
Never guess. Check the specification if you are unsure.
Check that every label and pack matches the product inside.

Summary

In this module, you have learned that:

Physical hazards, such as glass and metal, and chemical hazards, such as cleaning products, must be kept out of food.

There are 14 named allergens, and even a trace can cause anaphylaxis, a severe, life-threatening reaction.

Allergen information must be accurate, and allergens kept apart through storage, scheduling, cleaning and label checks.

In the next module, we will look at food storage.

Knowledge Check

How many named allergens must legally be declared in food?

Select one answer, then press Check.

10.

14.

20.

Correct. There are 14 named allergens that must be declared.

Not quite. Think of the full list: from celery and cereals containing gluten to sulphites. Try again.

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