This document discusses food safety challenges in bakeries. It notes that sanitation can be difficult due to equipment design issues that make parts inaccessible for cleaning, a lack of employee training, and other maintenance and procedural problems. Foreign materials and allergens are common issues in bakery recalls. The document emphasizes that even with 99% safety, many contaminated products could still reach consumers due to the large volumes produced. Overall sanitation in bakeries requires attention to facility, equipment, and process design as well as employee training and cleaning validation.

1. commercialfoodsanitation.com
Food safety and sanitation
challenges in bakeries
Sanitation Standards | Hygienic Design | Sanitation Expertise | Sanitation Business Optimization

2. commercialfoodsanitation.com
Bakeries
• Food Safety in Bakery
Industry
• Sanitation challenges
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3. commercialfoodsanitation.com
What about other
industries?
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4. commercialfoodsanitation.com
The Car Industry
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5. commercialfoodsanitation.com
Volkswagen T1 1970s
• No airbags
• No air-conditioning
• Manual wind-down
windows
• No power-steering
• No cruise control
• No parking assist
• No ABS
• No child-locks
• AM radio
• …
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6. commercialfoodsanitation.com
Mazda CX9 2017 • Airbags SRS Front (Driver & passenger); Side
(front); Curtain (Front & rear)
• Anti-lock Braking System (ABS) Standard
• Blind Spot Monitoring (BSM) Standard18
• Child restraint anchor points ISOFIX x2, top
tether x5
• Childproof rear door locks Standard
• Driver Attention Alert (DAA) Standard18
• Dynamic Stability Control (DSC) Standard
• Electronic Brake-force Distribution (EBD)
Standard
• Emergency Brake Assist (EBA) & Emergency
Stop Signal (ESS) - Standard
• Parking sensors Rear17
• Rear Cross Traffic Alert (RCTA) Standard18
• Remote central locking Standard, 2 transmitters
• Reverse camera Standard
• Roll Stability Control (RSC) Standard
• Seat-belt warning Driver & all passengers
• Seat-belts (front) 3-point lap-sash with
pretensioners, load limiters and height
adjustable shoulder anchorages
• Seat-belts (second row) 3x 3-point lap-sash
with pretensioners and load limiters
• Seat-belts (third row) 2x 3-point lap-sash
• Traction Control System (TCS) Standard
• Trailer Stability Assist (TSA) Standard
• Whiplash-minimising front seats Standard
• Satellite Navigation
• etc
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7. commercialfoodsanitation.com
What is the difference?
The focus in the car
industry has been on
customer safety,
efficiency and
convenience.
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8. commercialfoodsanitation.com
How does this tie to Food
Safety in Bakeries?
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Food Safety
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10. commercialfoodsanitation.com
The world today & tomorrow
• Expectations going up
• More intense media
research & attention
• Ever increasing social
attention
• Technology
• Regulatory
• Liability
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11. commercialfoodsanitation.com
Salmonella
• Dry environment
• Salmonella does not grow in
dry products and does survive
for a long time
• Extremely low contamination
levels can cause illness in dry
& high fatty foods!
• Cross contamination
– Food handling
– GMP/GHP
• 2015 - Europe - chocolate
• 2016 - USA – chocolate
• 2016 - Australia - cakes
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12. commercialfoodsanitation.com
Listeria
• Wet environment
• Listeria can grow in low
temperatures (refrigerators)
• Listeria can survive freezing
temperatures
• Cross contamination
– Food handling
– GMP/GHP
• 2015 – Europe – Frozen Corn
• 2017 – South Africa – Cold
Meat
• 2018 – Australia – Rock melon
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13. commercialfoodsanitation.com
FoodAllergens
Recallspast10 years
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• 35% allergen related
– 31% Dairy
– 20% Peanut
– 11% Baked goods
• Better protection of
consumers
• Brand protection
• Allergen Management
– Ingredient control
– GMPs, HACCP, SSOPs
– Validation of above
Source; FSANZ

14. commercialfoodsanitation.com
Foreign Materials
Recallspast10 years
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• 17% of recalls are FM related
• Main materials; Metal, Plastic
and Glass
• Ex. Mars 2016 recall due to
plastic – covering 55 countries
• Better protection of consumers
• Brand protection
• Foreign Material Control;
– HACCP
– Hygienic Design
– Preventative Maintenance
– Sanitation

15. commercialfoodsanitation.com
Sanitation challenges
In Bakeries
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16. commercialfoodsanitation.com
Hygienic Facility Design
• Presence of drains
• Flooring
−Type
−Maintenance
• Equipment
placement
• Newly integrated
lines
• Utilities
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17. commercialfoodsanitation.com
Hygienic Equipment Design
• Accessibility for
cleaning
– Inaccessible parts:
rollers, sprockets,
inside conveyors
• Not designed for
cleaning
– Not easily dismantled
equipment for cleaning
and inspection
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18. commercialfoodsanitation.com
Cleaning techniques
• Employees not
knowing the
equipment
– Employee Retention
– Employee Training
• CIP system
knowledge
• Sequencing and
cleaning techniques
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19. commercialfoodsanitation.com
Sanitation Tools
• The right tools
• Clean tools
• Maintain and monitor
• Sanitary storage
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20. commercialfoodsanitation.com
Maintenance
• Belt not replaced in a
timely manner
• Equipment
modifications creating
harbourage
• Tool sanitation
• GMPs
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21. commercialfoodsanitation.com
Other challenges
• Time
• Cleaning Procedures
• Cost effectiveness
– Down-time
– Chemicals
– Tools
• Seasonality
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22. commercialfoodsanitation.com
What if…..you’re not 100% perfect
You produce 200mln portions per
year – what is the risk
• 99 % Safe 2,000,000
• 99.9% Safe 200,000
• 99.99% 20,000
• 99.999% 2,000
• 99.9999% 200
• 99.99999% 20
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23. commercialfoodsanitation.com
Thank you!
Happy to answer questions
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