warehousing techniques

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Principles of Food Warehousing

By

Dr Deryck D. Pattron, Ph.D.Public Health Scientist & Consultant

Trinidad, West Indies



Dr D. Pattron, Ph.D 2

Definition of food warehouse

Any food storage facility, storing large or nor solarge amounts of food for either short or longperiods, for distribution in normal food channels

Important link in the food chain from theprocessor to consumer

Vary in nomenclature, size, function andphysical conditions




What is the importance of safefood warehousing?

To prevent economic losses

To promote health and well being

To facilitate trade To facilitate economic prosperity

To prevent spread of diseases




What is the importance of safefood warehousing? (cont’d)

To provide a readily available source of food

To provide revenue and job opportunities

To prevent burden on health care facilities To ensure a steady supply of goods on the

market

To ensure consumers have access to foods in

and out of season both locally andinternationally




What types of food warehousesexist?

Dry storage warehouse

Chilled storage warehouse

Frozen storage warehouse Dry and chilled storage warehouse

Dry and frozen storage warehouse

Chilled and frozen storage warehouse Dry, chilled and frozen storage warehouse




Warehouse grounds

Areas surrounding warehouse should be: Free from weeds, grass and bush

Free from trash, rodent tracks and burrows

Free from standing water and clogged drains Walkways and driveways paved and kept in a

good state of repair

Well drained Ideally located away from potential

environmental hazards




Warehouse building (external)

Walls and roof should be painted andmaintained in a good state of repair

Doors and windows should be screened proofed

Wall and ceilings should be free from cracks andholes

Pipes entering the building should be sealedproperly to prevent entry of pests

Roofs should be maintained in a good state ofrepair and not leak




Warehouse building (internal)

Floors, walls and ceilings should be smooth,clean and maintained in a good state of repair toprevent cross contamination

Windows and doors should seal tightly toprevent entry of pests

No dead spaces around equipment or otherstructures that would provide harborage forpests and prevent efficient cleaning




Warehouse equipment

Chillers Freezers

Forklifts

Shelves Storage bins

Temperature and humidity gauges

Pallets




Warehouse equipmentcharacteristics

Rust resistant

Odour resistant

Non-porous Easily cleaned and sanitized

Suitably colored




Warehouse equipmentcharacteristics (cont’d)

Food grade or compatible

Non toxic

Located in an area that facilitates easy cleaningand maintenance

Free from grease and other chemical or physicalcontaminants




Warehouse storage conditions

Food items should be stored on pallets

46 cm off ground and 46 cm off wall

Non crowded

Clean and sanitary

Food items stored and rotated on a first-in-first-outbasis

Maintained at proper temperature and humidity

Free from physical, chemical and microbiologicalhazards

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Warehouse storage and handling

of hazardous materials

Poisonous chemicals such as pesticides,cleaning solvents, lubricants and othercompounds should be safely and securelystored

Accessed by authorized, trained employees

Properly labelled

Follow manufacturers instructions as to the

quantity for safe use Use protective ware when handling hazardous

materials




Warehouse storage temperature

All frozen food products should be at –18º C or below

During transport the temperature should not behigher than – 12 ºC

Temperatures for chilled storage should be keptbetween 1º C and 4 º C

Dry storage areas should be between 10 º C and21 º C

Thermometers should be present in all frozenstorage, chilled storage and dry storage areaswith on site temperature logs




Warehouse storage temperatureand relative humidity

Products Temperatures Relative Humidity

Frozen meats: -23 º to -17 º C ------------Canned products 4.4 º to 16 º C 50 to 60 %

Grains 4.4 º to 16 º C 50 to 60 %




Warehouse air circulation

Important factor in the proper storage of food

Food products should be stacked on pallets

46 cm wall clearance and 5 cm ceiling clearance

Sufficient working aisle space




Warehouse ventilation

To prevent excessive heat, steam condensationand/or dust from accumulating within a confinedarea

Should never be from dirty to clean area Openings should be screen proofed

Should be natural or artificial




Warehouse lighting

Essential for:

General cleaning

Reading and identifying labels, colours

Recognising the condition of the food stored

Preventing injuries

Preventing cross contamination of food products




Warehouse lighting specifications(cont’d)

At least 540 lux at all inspection points

At least 220 lux in work areas

At least 110 lux in other areas




Warehouse sanitary operations

To avoid contamination of food products To ensure detergents, sanitizers, hazardous

materials and other supplies used in safe andeffective manner

Cleaning compounds and hazardous materialskept in original containers, stored separate fromfood products

Garbage properly stored and protected frominsects, rodents and other pests and/or disposedin an adequate manner




Warehouse sanitation operations(cont’d)

A permanent cleaning and disinfecting scheduleshould be developed and enforced

All cleaning workers should be well trained in

cleaning and disinfecting procedures

All floors are not cleaned in the same manner:-some floors are wet cleaned using a strong

cleanser, rinsed and allowed to dry, other floorsare cleaned by sweeping and brushing

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Warehouse chemicals for

disinfection Chlorine and chlorine-based products

100-250 mg of available chlorine per litre Two minutes exposure time Rinse after exposure

Iodophors 25-50 mg per litre of available iodine Two minutes exposure time Rinse after exposure

Quaternary ammonium compounds 200-300 mg per litre Two minutes exposure time Rinse thoroughly after exposure




How to handle garbage in foodwarehouse?

Quickly remove and store in covered bins

Excellent breeding ground for pests

Broken down pallets and cardboard boxesshould be disposed of in an appropriate manner




Transportation practices to andfrom food warehouse

Transport at the proper temperature

Maintain a temperature log for each trip

Protect food from thermal, physical, chemicaland microbiological injury

Protect from unsanitary conditions

Protect from poor handling and packing

Transport food in covered reliable well cleanedand maintained vehicles




Requirements for incoming raw

materials in food warehouse

Temperature of food product Absence of pesticide residues

Microbiological quality

Chemical quality Absence of physical contaminants

Clean and sanitary surroundings

Grade or type Conform with regulatory agency’s requirements

Absence of insects, rodents or bird activity




Rotation of stored food inwarehouse

Food products should be rotated based on theexpiry date and perishability

Old products should be kept in front of the new

products All incoming products should be dated

Food containers should not be dusty, faded or

discoloured

Repackaging operations in food




Repackaging operations in food

warehouse Should be done under strict hygienic and

sanitary conditions

All equipment should be clean free from debrisand properly sanitized

Packaging should be food grade andunadulterated

Audit for quality by ensuring all packagingseams are intact, no foreign contaminants, filled

to stated weight or volume Audit for safety by performing random or

systematic sampling of repackaged products forchemical, physical and microbiological

consistency




Quarantine in food warehouse

Products spoiled by physical, chemical andmicrobiological damage, insects, rodents orother causes should be stored in a designatedquarantine area

Quarantined items should be disposed of quicklyto avoid pest harborage and infestation of storedfood

Incoming materials that are damaged and not inaccordance with suppliers specifications shouldbe rejected




Pest control in food warehouse

Perform regular pest inspections in and aroundwarehouse

Be vigilant and on the look out for burrows, urinetracks, fecal pellets, rub marks, snawing marks,

hairs, dead rodents, etc.

Pesticides are poisons and should beadministered by a competent person

Pesticides should be placed at marked positionsthroughout the warehouse and checkedregularly

Recall types for potentially




Recall types for potentiallyhazardous food distributed from

food warehouseThree types of FDA recall:

Type I= Most serious, high risk, potential injuryor death

Type II = Minimum risk, temporary healthproblems

Type III = Least severe, unlikely to cause health

problems, violate FDA manufacturing or labelingregulations

Recall procedures for potential




Recall procedures for potentialhazardous food distributed by food

warehouse Maintain a current list of all purchasers:• Person name doing business on behalf of

company• Name of company• Mailing address• Phone number

• Email address




Recall procedures for potentiallyhazardous food distributed by food

warehouse(cont’d)

Each product sold/distributed should have a

batch number indicating time, date, batch, shiftwith respect to its manufacture

Each product withdrawn from the market shouldbe able to be traced back to its source andpossible areas of concern identified andcorrected for future products




Employees code of practice in foodwarehouse

Good hygienic practices

Good sanitary practices

Suitable safety ware such as clothing, face

mask, respirators, weight lifting belts, steel tipbooths

Properly trained staff

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Toilet facilities available to

employees in food warehouse

Toilets should not open directly into food storageareas

Sewage line should not pass over stored food

The number of toilets should be appropriate tothe number of staff, both male and female

Warning signs should be posted on entering

toilet areas advising users to wash handsthoroughly after use

T il t f iliti il bl t




Toilet facilities available to


(cont’d) Toilets should be equipped with toilet paper,

soap, sanitizer and potable water

Toilets should be maintained clean and sanitaryat all times

Toilets should be properly ventilated and may be

fitted with extractor fans




Hand washing facilities available toemployees in food warehouse

Suitably located and present in the sufficientnumbers to ensure safe and hygienic operations

Prevent cross contamination of stored food




Changing room facility available to


Should be equipped with lockers

Prevents employees using street clothes

Provides a place to change clothes and to put onprotective gear

Should be maintained in a good state of repair

Separate for males and females




Conclusions

Food warehouses are an important link in thefood chain from “farm to fork”

Food warehouses provide a readily available

reserve supply of food allowing consumers toenjoy a wide variety of foods out of season aswell as in season

Food warehouse like other food facilities mustbe built in a non hazardous environment andmaintained in a good state of repair to preventadulteration of stored food




Conclusions (cont’d)

Employees who work in food warehousesshould observe proper hygienic guidelines andsanitation standard operating procedures

Proper employee facilities should be in placesuch as toilet facilities, hand washing stations,changing rooms, lunch rooms to preventadulteration of stored food

Proper protocols should be implemented fortransportation, receiving, storage, and recall offood




References

Food and Agricultural Organization of the Unitednations. 1984. Manuals of Quality Control 5.Food Inspection.

Longree, K. 1985. Quality Food Sanitation. New

York: John Wiley & Sons.

Pattron, D. 2004. Quality Assurance & FoodService. New York: Scientific Publishers.

Pattron, D. 2004. Food Safety. New York:Scientific Publishers.



D D P Ph D

The End

Thank You

Dr Deryck D. Pattron, Ph.D

Public Health & Safety Consultant

Trinidad, West Indies

Email: [email protected]

mailto:[email protected]

mailto:[email protected]

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