Inka Burger: Food Prep & Hygiene Standards
Inka Burger: Food Prep & Hygiene Standards
LA SERENA
COQUIMBO REGION
BACKGROUND
COQUIMBO.
July 2019
July 2019
DESCRIPTION:
Establishment dedicated to the preparation of food within this facility; which corresponds to
buy and take away, or consume the food inside, in designated bars in the sales area.
Fines:
The main emissions into the atmosphere correspond to emissions from combustion eventually.
smoke generation, resulting from the food preparation operation. For the control of this
situation, the premises has exhaust fans equipped with filters with absorption systems designed for
according to the size of the premises and air flows to be managed. The generation of smoke in many cases
linked to a problem of odor generation.
Normally, there are odor problems that can become excessive and even annoying.
effect of food manufacturing operations. The issue of odors is typically associated with
frying operation of materials, especially if the oil begins to exceed its useful life limit,
generating smoke at a lower temperature that also carries volatile compounds responsible
of the odor. Regarding heat sources (stoves and fryers), an appropriate system will be in place.
extraction of vapors and gases.
Frying Process
The proper control in the use of frying oils in this type of establishment. These do not
They must be heated above 180 °C, as higher temperatures break them down.
producing physical and chemical changes that alter its nutritional and sensory quality (smell, color and
flavor), and also in the generation of smoke and odors.
The Health Services have made demands to comply with the regulations on this topic.
(Supreme Decree No. 144 of 1961 from the Ministry of Health), a very important factor for staying free
of smells.
One of the main pollution problems in the sector is the runoff of fats and
oils in the wash effluents. However, in the event that there is a drag of these
Waste, the establishment has grease traps installed.
Without regular maintenance, a large amount of grease will accumulate, which will generate emanation of
odors, gradual loss of efficiency of the trap, and finally, system collapse (ducts
covered), not to mention the derivation of the problem to the municipal drains. For
solving this problem will require stopping operations, having personnel available to restore the
flow in ducts, repair corroded pipes due to the action of hydrogen sulfide (generated by the
decomposition of deposited fats) and frequent pole cleaning, hire a truck for removal
physical of fat, etc.
Technologies for the Control of Odors and Fumes
Technologies for Control Through Extractors and Filters: The emissions of odors and fumes,
generated from frying French fries, it is possible to significantly reduce through the
application of prevention measures, but they also require control measures to comply with
the existing regulations. The treatment must be sized specifically according to the source of
emission, the dimensions of the premises and the type of infrastructure, among other parameters.
GENERAL DESCRIPTION OF THE MANUFACTURING PROCESSES
The processes developed within this sector are basically food preparation.
including selection operations for the required raw materials, initial preparation,
preparation of the final product, delivery to the user for consumption.
Auxiliary operations of the process include the cleaning of utensils, equipment, and the premises.
In the case of large chains, most operate with a purchasing center that supplies to
all the venues according to their requirements.
The general concept of food preservation is to prevent or avoid the development of microorganisms.
(bacteria, yeasts, and molds) so that the food does not deteriorate during storage. At the same time,
The chemical and biochemical changes that cause deterioration must be controlled. In this way, it is achieved
obtain a food without alterations in its typical organoleptic characteristics (color, flavor, and aroma), and
it can be consumed safely for a certain period (not less than a year).
WASHING
Washing is an operation that generally constitutes the starting point of any process.
food production.
The operation consists of removing the dirt that the material brings with it before it enters the line.
process, thus avoiding complications arising from the contamination that the raw material may contain.
This wash should be done with clean water, as pure as possible, and if necessary, made potable by means of the
addition of sodium hypochlorite, at a rate of 10 ml of a 10% solution for every 100 liters of water.
SELECTION
Once the raw material is clean, the selection process begins, that is, separating the material that
it will really be used in the process.
Sometimes, to appreciate the uniformity or quality of a material, it is necessary to cut it in two to
check its interior. Uniformity is a relevant quality factor, as the greatest importance is given to
that the material is homogeneous and uniform. The selection fulfills the function of producing such homogeneity.
Bald
Peeling is an operation that allows for a better presentation of the product, while also benefiting
the sensory quality by removing material of firmer and rougher texture for consumption. In addition, the skin many
sometimes it presents a color that is affected by the thermal processes normally used in the methods of
conservation.
Sliced
A common operation usually included in various preservation processes is slicing. This is a
operation that allows achieving various objectives, such as uniformity in the penetration of heat in the
thermal processes.
The cutting must be done with two special precautions. Firstly, one must have
tools or chopping equipment that produce clean cuts. In addition, the chopping must be carried out with
in such a way as to achieve a satisfactory performance. One should always look for ways to obtain a
cut that delivered the largest possible amount of usable material.
THE PRINCIPLES OF FOOD PRESERVATION
Food preservation can be defined as the set of treatments that extends the shelf life of
those, maintaining, to the greatest extent possible, their quality attributes, including color, texture, flavor and
especially nutritional value.
This definition involves a wide range of conservation timescales, from short periods, given by
domestic cooking and cold storage methods, for very prolonged periods, provided by processes
industries strictly controlled such as canning, frozen foods, and dehydrated products.
Cooling
Refrigerated storage with modified atmosphere
Figure 1: GENERAL LOCAL PREPARATION DIAGRAM 'BURGUER ARO'
Cooking/Frying/Baking
Water + detergents and
sanitizers
Solid waste
Food leftovers:
Organic waste
The food preparation area is separated from the designated areas, sanitary services and
garbage accumulation.
The access routes and circulation areas that are within the premises of the establishment or in its vicinity,
It presents a hard surface, paved in such a way that controls the presence of environmental dust.
WORK AREAS
The operations will be carried out under proper hygienic conditions and where the flow is guaranteed.
production process from the arrival of the raw material at the premises to the obtaining of the product
finished. Ensuring also, appropriate temperature conditions for the production process and
for the product.
The walls (1.8 meters) are waterproof, non-absorbent, washable, non-toxic, and light-colored.
The ceilings are designed in such a way as to prevent the accumulation of dirt and reduce it to
minimum water vapor condensation and mold formation, and they are easy to clean.
The establishment has an effective wastewater evacuation system including the systems of
sewerage, which must be kept in good working condition.
It has hygienic services without direct communication with the handling areas. The services
Hygienic facilities are well-lit and ventilated, and equipped with cleaning supplies for hand hygiene.
Regarding the heat sources (stoves, ovens, kettles, fryers), there will be an adequate system of
extraction of vapors and gases.
In the preparation areas, there are sinks equipped with soap and hygienic means for drying hands.
hands, such as: single-use towels.
WASTE DISPOSAL SYSTEM
OBJECTIVE:
Define the management, removal, and disposal of waste generated by the kitchen, warehouse, etc.
establishing appropriate safety and hygiene measures, to ensure that these do not
they constitute a source of contamination and thus, prevent cross-contamination with other elements
METHODOLOGY:
General waste management: Any material considered as trash or waste that needs to be disposed of.
(papers, cardboard, plastics, waste from the production process, etc.) must be placed in bins with
lids and identified with a number to ensure proper control of the containers.
Garbage removal: Production workers are responsible for removing at least once.
Daily accumulate the trash in the dumpsters and transfer it to the garbage collection container for removal.
from the plant by the municipal truck at least three times a week.
Order, maintenance, cleaning, and sanitization of trash cans and containers: The workers have the
responsibility to keep the trash bins tidy, covered, and in good condition
Structure, clean and sanitized to avoid the attraction of pests and cross-contamination.
Trash bins and containers must be washed and sanitized once a week.
Order and cleanliness of the storage area: The workers are responsible for maintaining the correct
disposal of garbage in the collection area, reaffirming that the garbage is being removed properly
by the municipal truck.
MONITORING
Responsible: Designated worker.
Frequency: Twice a week
Monitoring Methodology: Ensure that the dumpsters and containers are in good condition
structural and hygiene conditions. Additionally, confirm that the garbage has been removed to the area of
collection.
It must be confirmed that the garbage is being properly removed by the municipal truck.
Immediate corrective actions;
If the garbage has not been properly removed, request the corresponding pickup.
Request the cleaning of the corresponding container to the cleaning staff.
The main environmental issues associated with the fast food sector, restaurants, have
relationship with solid and liquid waste and emissions of unpleasant odors.
The waste generated in the establishment that prepares and sells food can be classified into the
following types:
Solid Waste:
Organic waste from food preparation
Organic waste from uneaten food
Remnants of disposable containers
Organic waste from cleaning gutters, grates, or grease traps
Liquid waste:
Frying oil residues
Washing water
Noises
There is also noise generation due to the operation of air extraction equipment.
bells and refrigeration equipment.
In the processes of the restaurant food sector, there are two major sources of waste generation.
liquids:
One of the main wastes of the sector is used oils, which for this purpose
they will be classified as liquid waste although in fact, their method of transportation and disposal is through
the use of containers.
The repeated use of oils in various frying is a common practice; however, it degrades them.
gradually, producing potentially toxic compounds (since substances are generated
potentially carcinogenic.
The discarded frying oils are temporarily stored for 2 to 4 weeks in drums.
up to 200 liters that are removed by third parties. The removal of the oils is usually done by third parties.
These drums are removed by companies that usually rent the bins or drums, and then
Once filled, they are removed and dispatched to the treatment companies.
Disposable containers, mainly made of cardboard and plastic: (cups, packaging leftovers and
plates, papers, sachets, small boxes, etc.
Empty containers of raw materials, such as polyethylene bags, leftover cardboard, and boxes
cardboard, papers, and drums.
Uneaten food scraps and leftover food (it is estimated that of the total waste
30% of this sector corresponds to this type of waste.
Organic waste from food preparation (considered of little relevance, no more than 1% of
total raw materials that enter.
Organic waste from cleaning gutters and grates
Buy juices and concentrated drinks and milk in bulk containers. Prefer dispensers.
instead of individual containers, as long as this does not affect the quality of the product.
Prioritize buying pre-cut vegetables and meats
Carefully review the raw materials upon receipt (for example, date of
expiration, color characteristics, odor, etc.). Request suppliers to certify the
quality of their products and carry out the return if the requirements are not met
established
Optimize the storage, handling, and use of raw materials.
Perform periodic cleaning of the raw material cooling systems in order to
check the conditions of the stored materials.
Keep the vegetables refrigerated to avoid dehydration and deterioration.
RAW MATERIALS
The raw materials used in fast food establishments correspond to a wide range of
food products such as bread, meats, eggs, vegetables, concentrates for preparation of
juices and carbonated drinks, and dressings like mayonnaise and ketchup. Most of the ingredients
Cousins arrive ready for their preparation. Table 1 includes details of the method of reception.
of the main raw materials.
Other important materials are the packaging elements of finished products, among which
that are counted: wrapping paper for products, cardboard boxes, plastic cups; in addition to
materials for immediate use by the client (plastic services, napkins, cups, and plates)
plastic or cardboard disposables.
SUBJECTS FORM OF
PRIMAS RECEPTION
Lettuce It arrives packaged in bags. Origin is national and imported. They are kept in
cold chain (refrigerated) until preparation
Meats (beef, pork The meat (steaks and roasts) arrives cut, and cooking is done on-site.
and others) and water or grilled. The same for hamburgers. Imported origin and
hamburgers national. It is kept in cold chain (refrigerated) until its preparation
Tomatoes They are washed and chopped in each location, national origin. They are kept in a cold chain.
(refrigerated) until preparation
French Fries They arrive at the establishment packaged in bags or boxes (cut and pre-fried). The frying is
performed in the store. Imported and national origins. They are kept in the cold chain.
(refrigerated) until its preparation
Avocado It is prepared on-site, of national origin.
Onion Rings Arrives cut and ready to fry
Mayonnaise and ketchup It arrives packaged either in bulk containers or in delivery sachets.
to the public.
Pan It arrives packaged at the stores. Its approximate duration is 4 days.
Flour It arrives packed in 50 and 80 Kg bags. Of national origin.
Drinks, juices, and milk The drinks and juices arrive in the form of concentrates in high packaging.
capacity. Drinks are also received in 350 cc cans. Milk arrives in
boxes.
Oil and/or butter It comes in plastic containers of 5, 12, and 20 liters, and another option is the butter that
for frying It arrives in solid form, to then be melted in the pools.
dry, removing as much as possible
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SANITARY QUALITY CONTROL SYSTEM
DETAIL
Type of pollution Pathogenic Microorganisms Contributed by Dirty Surfaces - Residues
Crusade of Detergents
Classification Safety
Preventive measure of Cleaning and Sanitization of Surfaces
Control (1) Cleaning and sanitization procedures are carried out in all areas.
from the plant and the correct rinsing of washed surfaces is indicated
sanitized
Records and documents of Visual Inspection Record of Cleaning in the Baking Plant.
backup (1)
CONTAMINATION DUE TO POOR STORAGE OF MATERIALS
RAW MATERIALS, SUPPLIES OR FINISHED PRODUCTS.
DETAIL
Type of Contamination due to Poor Storage of Materials
y
Crusade Inputs or Finished Products
Classification Safety
Preventive measure of Control of receipt of raw materials and supplies
Control (1) Visual inspections of the integrity of the containers are carried out.
they request at reception the certificates or documents that guarantee the
quality and safety of the raw materials and requested supplies.
The conditions that must be maintained for the correct delivery are provided.
storage of raw materials and supplies
Records and documents Registration of the receipt of raw materials, supplies, and cleaning products
backup (1) Quality certificates of raw materials and supplies
DETAIL
Type of pollution Contamination of allergenic products with non-allergenic products
Crusade allergens
Classification Safety
Preventive measure of - Allergen Management
Control (1) Procedures are indicated for:
- Identify the allergenic raw materials used.
- Avoid cross-contamination during operations.
from reception to the obtaining of the final product.
- Identify the allergens in the finished product, whether it is
because it usually contains it or through its inclusion via
components of the raw materials used for its production.
- Avoid errors in consumers about the nature and
product characteristics, identity, quality, composition, and shape of
manufacturing or obtaining, among others.
DETAIL
Type of pollution Direct contamination from the mixture of processed products
Crusade and unprocessed products
Classification Safety
Preventive measure of Product Development
Control (1) Instructions are provided for the proper use of raw materials.
and the correct manufacturing of products avoiding the mixing of products
processed and unprocessed throughout the entire chain of activities of the
productive processes.
MONITORING
Responsible: Designated operator described in each preventive measures procedure.
Frequency: Described in each preventive measures procedure.
Monitoring Methodology: Carry out the monitoring activities described for each
procedure for preventive measures described to control Cross-Contamination.
Corrective actions: Carry out the corrective actions described for each procedure.
necessary preventive measures to control Cross-Contamination.
VERIFICATION
Responsible: Production Manager or Designated Worker
Monthly
OBJECTIVE
Define the requirements and methodology to be followed by the store workers during the reception of
raw materials and manufacturing ingredients, supplies and cleaning products, so that everything the
product entered into the store meets the quality requirements, ensuring the acquisition of a product
final that meets the required quality and safety standards.
METHODOLOGY
Acquisition of Products: The Production area generates the need for raw materials, inputs and
Cleaning products. For this purpose, an inventory is carried out that generates the needs that must be addressed.
supply.
The commercial area makes quotes with suppliers authorized by email or
phone, once the quotes are obtained, a purchase order is issued where the product is established,
volumes and delivery schedule. The reception of the products is coordinated with the program of
production and existing stock in order to optimize space in the warehouse.
RECEPTION OF PRODUCTS
The designated worker to receive the products is the first entity to control the personnel that
enter the store.
Food products must comply with the legislation according to the Sanitary Regulation of the
Food, Articles 106 to 121.
All food products that are stored, transported, or expanded in packaging must carry a
label or tag that contains the following information according to the regulations required by the Sanitary Regulations
of food according to TITLE II OF FOOD Paragraph I
Food name
Resolution
Supplier
Net weight
Nutritional information
Traceability, which may be mentioned as follows;
Ingredients, the label must include the list of all the ingredients and additives that make up the
product, with their specific names, in decreasing order of proportions.
A visual inspection of the condition of the product containers to be received (containers, bags, sacks,) is carried out.
boxes, buckets) and the following quality parameters are monitored:
Free of foreign materials,
Packaging that prevents the exposure of the container or packaging to the environment (without breaks)
Proper labeling (quantity, content, date of production, batch or box number, supplier)
Control of food products according to defined requirements
c) Quality certificates
You must request technical data sheets from suppliers for their products to verify that the product
Received meets the quality requirements stipulated in the purchase.
You must request quality certificates that demonstrate that the production batch being
received was subjected to quality control by the supplier.
Storage
The materials are stored in such a way that those for daily use can be removed first and
permanent. The lower consumption materials are located in more remote places.
The shelves are clearly identified to allow for quick and efficient stock handling.
time to facilitate controls.
Cleaning materials should be stored in a place that prevents cross-contamination.
where they are not in contact with other materials, and in a locked closed space.
Monitoring
Responsible: Designated Worker
Frequency: Every time raw materials and manufacturing ingredients, supplies, and products are received
cleaning.
Monitoring Methodology: A visual inspection of the condition of the product containers is carried out.
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mentioned (barrels, bags, boxes, buckets) and the following quality parameters are monitored:
Exempt from foreign subjects,
Packaging that prevents the exposure of the container or packaging to the environment (without breaks)
Proper labeling (quantity, content, date of production, batch or box number, supplier)
Control of food products according to the requirements defined in this Procedure.
Hygienic conditions of transportation
This information is recorded in the Raw Materials, Supplies, and Products Reception Register.
cleaning.
Corrective actions:
a) Partial Receipt of the Product.
The product is partially received and the non-compliant quantity is returned as long as it does not affect the
safety and quality of the products to be made.
b) Total Product Return
The entire non-conforming product is returned to the supplier.
Verification
Responsible: Designated Worker
Monthly
Methodology: Analyze the set of records generated in the monthly period; at the level of form,
content and compliance.
OBJECTIVE
Control and ensure the production of products, in such a way as to guarantee safety and quality.
of the obtained foods.
This Procedure applies to the activities carried out in the Baking Plant that are
necessary for the manufacturing of products, considering from the reception of the raw material,
manufacturing ingredients and supplies, up to the production process.
METHODOLOGY
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The production of products, which also show the necessary production controls.
to obtain safe and high-quality food.
Physically receiving corresponds exactly to what was requested. These must be inspected for
agreement to:
Labeling
Integrity of containers and packaging
Amount received
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