Glorious Crab Company
Seaside, Maryland

SANITATION STANDARD OPERATING PROCEDURES (SSOP) GUIDELINES

1. Goal: Water that comes in direct contact with food or food -contact surfaces or is used in the manufacturing of ice is derived from a safe and sanitary source.
   
   Procedure: Glorious Crab Company uses potable water throughout processing including ice. Municipal water is injected with liquid chlorine at the plant using a commercial system designed for this purpose. Microbiological safety is assured by contract laboratory analysis (standard methods); copies of which are kept on file. Purchased ice is certified safe by the supplier. The plant�s chlorinator is inspected daily and maintained as required. Results are recorded on the daily sanitation audit form.
   
   
2. Goal: There are no cross-connections between the potable water system and any non-potable system.
   
   Procedure: The quality-control supervisor performs a monthly inspection to determine that no cross connections exist between potable-water and non-potable or waste water systems. The results of the inspection are recorded on the monthly sanitation audit form.
   
   Procedure: The quality-control supervisor performs a monthly inspection to determine that no cross connections exist between potable-water and non-potable or waste water systems. The results of the inspection are recorded on the monthly sanitation audit form.
   
   
3. Goal: All food-contact surfaces of plant equipment and utensils are designed of such material and workmanship to be easily cleaned and maintained in a sanitary condition. Such surfaces will be constructed of nontoxic materials and designed to withstand the environment where it is used and the action of cleaning compounds and sanitizing agents.
   
   Procedure: Presently, all plant equipment and utensils meet current recommended U.S. federal and state standards. Prior to replacing any major piece of equipment, the president, quality control supervisor and maintenance personnel meet to evaluate the equipment. The evaluation determines whether replacing the equipment will impact adjacent processing steps. Specifications for all equipment are reviewed to ensure it is able to withstand the intended use and be easily cleaned. The same evaluation is conducted on material used in the modification of the physical plant. If necessary, the manufacturers of cleaning and sanitizing compounds or chemical application equipment are contacted to consider their impact on plant equipment and utensils. The results of these evaluations are kept on file. The quality control supervisor evaluates the condition of plant equipment and utensils monthly. The results of these evaluations are recorded on the monthly sanitation audit form.
   
   
4. Goal: All utensils and surfaces of equipment that contact food during processing are cleaned and sanitized with effective cleaning and sanitizing preparations on an appropriate schedule.
   
   Procedure: Cleaning and sanitation are performed at the following frequencies. Details for cleaning each plant area are provided in the cleaning and sanitation standard operating procedures following this section.
   
   Food contact surfaces:
   
   1. Cleaned and sanitized at the end of the day's operations;
   2. Picking knives and plastic crabmeat containers -- cleaned and sanitized at least every four hours during processing using alkaline or chlorinated detergent (soak tank and hand scrubbing with Scotch-Brite green pads), followed by a rinse and dip in 100ppm chlorine sanitizer;
   3. Picking and packing tables and other fixed, food contact equipment -- swept free of debris and sanitized at least every four hours during processing;
   4. Shovels used to distribute cooked crabs in cooking area � soaked in 100-200ppm chlorine or equivalent (200ppm quat or 25ppm iodine) when not in use during day;
   5. Large cart and plastic crates used with cooked crabs -- wetted with 100-200ppm chlorine or equivalent (200ppm quat or 25ppm iodine) between uses;
   6. Sanitized before the day's operations begin.
   
   All processing areas, regardless of the intended purpose, are cleaned during:
   
   1. Each break and lunch break, but at least every four hours, following the start of production. This consists of sweeping the area and removing any buildup of debris or other materials. The equipment is inspected by the quality-control supervisor prior to the start-up of processing and the results recorded on the daily sanitation audit form. Note: Processing will not resume until plant conditions are determined to be satisfactory.
   2. In addition, picking and packing areas are cleaned of debris and sanitized at least every 6 hours after production starts. Sanitation involves wetting surfaces with 200 parts per million (ppm) quaternary ammonium sanitizer or its equivalent (e.g. 100-200ppm chlorine) then excess liquid removed with a sanitized squeegee or single-use paper towel. The equipment is inspected before start-up by the quality control supervisor. The concentration of the sanitizer is checked by the quality-control supervisor before it is used. The results are recorded on the daily sanitation audit form. Note: Processing will not resume until plant conditions are determined to be satisfactory.
   3. At the end of the production day, a cleaning crew designated by management cleans and sanitizes all equipment, utensils and the facility for the next production day. A food-grade chlorinated or alkaline detergent will be used for cleaning, followed by a water rinse and a final spray with 200ppm quat or its equivalent (100-200ppm chlorine or 25ppm iodine). A top to bottom cleaning sequence is followed. Extra care is taken when cleaning the floor to avoid recontaminating plant surfaces. Water is not sprayed directly into drains, although they are detergent cleaned and sanitized. High pressure spray is not used on the floor. The concentration of the sanitizer is checked by the quality-control supervisor before it is used. The results are recorded on the daily sanitation audit form. Before the production day begins, the quality control supervisor or designee conducts a pre-operational sanitary inspection. The observations are recorded on the daily sanitation audit form. Note: Processing will not resume until the plant conditions are determined to be satisfactory.
   
   
5. Goal: Gloves and outer garments that contact food or food-contact surfaces are made of an impermeable material and are kept clean and sanitary.
   
   Procedure: The company issues employees smocks, head protection, plastic or rubber aprons and work gloves (where appropriate). The crab and shrimp processing room supervisors ensure that employees are issued this gear. Employees are not allowed to use personal gear in place of these items unless authorized by the supervisor. Employees are required to maintain this gear in a sanitary and functional condition and, if necessary, must request replacement of gear from the supervisor. Gloves used to handle cooked crab contact surfaces are color-coded red. These gloves are never used on other surfaces. The supervisor checks this equipment at the beginning of each day's operation. Observations are recorded on the daily sanitation audit form.
   
   
6. Goal: Employees' hands, gloves and outer garments, utensils, equipment or other food-contact surfaces that come into contact with waste, the floor, or other unsanitary objects do not touch food products without first being adequately cleaned and sanitized.
   
   Procedure:
   
   1. Employees will be trained on how and when to properly wash and sanitize hands. Training will be documented and kept on file.
   2. The crab processing supervisors maintain hand-washing stations and hand dips (cans of sanitizer) used in the picking and packing areas. Hand dip stations are maintained at 20-25ppm iodine or 50-100ppm chlorine.
   3. The picking room supervisor will maintain separate utensil wash stations and sanitizer dips for knives, shovels, buckets and other utensils used in the process.
   4. Should the processing area become contaminated by any form of waste or floor splash, the supervisor or designated person will immediately stop production. The section affected will be cleaned, sanitized and inspected before production starts again. Results will be recorded on the sanitation audit form.
   5. Supervisors, maintenance workers, quality-control and production personnel who handle waste, touch the floor or other insanitary objects, must clean and sanitize their hands and gloves before handling products or food contact surfaces. These practices will be observed every four hours by the quality-control supervisor and the results will be recorded on the daily sanitation audit form.
   6. Utensils and other food-contact surfaces that contact the floor, waste or other insanitary objects must be washed and sanitized before being used in processing of product. These practices are observed every four hours by the quality-control supervisor and the results will be recorded on the daily sanitation audit form.
   
   
7. Goal: Where applicable, employee's hands, gloves and outer garments, utensils and food-contact surfaces or equipment that come in contact with raw products will not contact cooked products or ice used on cooked products without first being adequately cleaned and sanitized.
   
   Procedure: Employees working in the crab cooking area are supervised to ensure that they clean and sanitize their hands or gloves, and outer garments before crossing between raw seafood and cooked crab functions. Gloves and equipment is designated for either raw or cooked crab functions and identified by color-coding. The designated color-coding is respected. These practices are observed every four hours by the quality-control supervisor and recorded on the daily sanitation audit form. Supervisor's, maintenance workers and others who are required to move between raw and cooked crab areas must first clean and sanitize their hands, gloves and outer garments.
   
   
8. Goal: Handwashing and hand-sanitizing facilities are located in all processing areas where sanitary practices require employees to wash and sanitize their hands. These must be equipped with hand-cleaning and effective sanitizing preparations and disposable towels.
   
   Procedure:
   
   1. Handwashing stations and hand sanitizer dips are located at or near entrances to all processing areas. These must be used upon entry to the process floor prior to handling product or food contact surfaces. Hand sanitizer dips are also located at the ends of each row of picking tables. In addition, employees must step in footbaths containing sanitizer (approximately 400ppm quat, or equivalent), which are located at each entrance to the picking and packing areas.
   2. The handwashing stations and hand dips must be used each time an employee contaminates hands or gloves and upon return to the cooked crab/crabmeat processing or packing areas.
   3. Handwashing stations are equipped with warm water, hand soap, and sanitizer hand dip.
   4. The handwashing stations will be checked by the quality-control supervisor for adequate supplies before operation begins and every four hours during operation. The concentration of the hand-dips will be checked before operation and every four hours during operation by the quality-control supervisor. They are to be maintained at 20-25ppm iodine or 50-100ppm chlorine. The result of these checks are recorded on the daily sanitation audit form.
   
   
9. Goal: Food, food-contact surfaces and food packaging shall be protected from the adulteration with lubricants, fuel, pesticides, cleaning compounds, sanitizing agents, metal fragments or other chemical or physical contaminants.
   
   Procedure:
   
   1. All cleaning compounds and sanitizing agents are clearly identified and stored away from the processing area and any other lubricants and chemicals. The quality control supervisor obtains and reviews material-safety data sheets for all compounds and agents stored at the plant.
   2. All food-grade products are stored separately from nonfood-grade lubricants and are properly labeled.
   3. Pest management is a contract service and pesticides are not stored in the plant. Material-safety data sheets are reviewed and available for pesticides or traps used for pest control.
   4. The maintenance supervisor stores and properly labels all nonfood lubricants in the maintenance area. No fuels are stored in the facility. All gas fuels (i.e., oxygen and acetylene) are stored in portable tanks outside the plant and are brought inside only when production has stopped. If it becomes necessary to use such fuels during production, maintenance personnel raise barriers to ensure that the process is not contaminated. When finished, the area is thoroughly cleaned, sanitized and inspected before production starts again.
   5. Boiler treatment compounds, if used, are approved for food processing applications.
   6. The quality-control supervisor inspects the processing area daily during operation for possible contamination sources and to make sure toxic compounds are labeled and stored properly. The results are documented on the daily sanitation audit form.
   
   
10. Goal: Any toxic compound allowed in the plant shall be identified, held, used and stored in a manner that protects against contamination of food, food-contact surfaces or packaging materials.
    
    Procedure: The quality-control supervisor inspects the processing area daily during operations for possible contamination sources and to make sure toxic compounds are labeled and stored properly. The results are documented on the daily sanitation audit form.
    
    
11. Goal: Food, food-contact surfaces and food-packing materials will be protected from contaminants that may be sprayed, dripped, drained or drawn into food.
    
    Procedure:
    
    1. Glorious Crab Company management is responsible for ensuring adequate ventilation and airflow to prevent or inhibit formation of condensates in the processing and storage areas. Condensates can lead to contamination of product, product-contact surfaces or packaging materials.
    2. Supervisors ensure that no floor splash occurs in the processing areas during cleaning or sanitizing during production hours. They make sure that the area is cleaned, sanitized and inspected before restarting production. To prevent recontamination of previously cleaned surfaces, the cleaning protocol requires a top to bottom sequence of cleaning and sanitation. The final rinsing and sanitation of floors is conducted at low to moderate water pressure. Water or solutions are not sprayed directly into floor drains. (Drains are cleaned and sanitized daily, however.) The crab-processing area and cooked crab cooler is inspected for possible sources of contamination, including condensates, by the quality-control supervisor each day during operation and the results recorded on the daily sanitation audit form.
    
    
12. Goal: Ready-to-eat fishery products, including raw molluscan shellfish, will be physically separated from raw fishery products during refrigerated storage.
    
    Procedure:
    
    1. Pasteurized crabmeat is sealed and not subject to contamination. Under existing conditions at Glorious Crab Company, cooked crabs and crab parts are not stored in coolers containing other products. If this becomes necessary, they will be physically separated from any raw product by a minimal distance of three feet. NO exceptions are allowed. In addition, all ready-to-eat product (raw or cooked, packaged or unpackaged) will be clearly identified by lot number, species and intended final-product form.
    2. The cooler will be inspected daily for product separation during operations by the quality-control supervisor. Observations will be recorded on the daily sanitation audit form.
    
    
13. Goal: Anyone that has or may have, by medical examination or supervisor observation, an illness, infected wound, an open lesion such as a boil or sore, or any other problem that might contaminate food, food-contact surfaces or packaging materials shall be excluded from operation until the condition is healed or corrected.
    
    Procedure:
    
    1. As a part of a new employee orientations, staff are briefed on the need to notify immediate supervisors of any illness or injury that may lead to contamination of any part of the process. Employees must notify immediate supervisors if they have been exposed to a confirmed disease outbreak of Salmonella (such as typhoid), Hepatitis A or Shigella, especially when employees are free of symptoms. In addition, employees will be informed that, if at all possible, they will be assigned duties that will not compromise the process. The results of the training are documented and kept on file.
    2. It is the responsibility of all supervisory personnel to observe the apparent well-being of their personnel. Employees are reviewed for signs of medical problems daily before operations begin by the crab and shrimp processing supervisors. At any indication of injury or illness that may compromise the process due to contamination, the supervisor removes that person from the area and reports to the plant manager. If that employee cannot be assigned other duties, he or she will be sent home until the situation is alleviated or a medical authority states that he or she may return to work. Observations will be recorded on the daily sanitation audit form.
    
    
14. Goal: Adequate, readily accessible toilet facilities that provide for proper sewage disposal shall be available and maintained in a sanitary condition and in good repair.
    
    Procedure:
    
    1. Separate toilet facilities are provided for male and females employees in the changing room building near the processing and packing areas. Each restroom is well-ventilated. The number of toilets provided is based on the number of employees, with consideration given to gender. Glorious Crab Company has approximately 15 male and 100 female employees. There are two toilets for males and five toilets for females. Extra toilets will be installed if an increase in employees occur.
    2. During production hours, the quality-control supervisor checks that toilet facilities are sanitary and well stocked. Following production, the designated cleaning crew is responsible for cleaning and sanitizing toilet facilities and for restocking them.
    3. Maintenance personnel keep toilet facilities operable and in good repair.
    4. The condition of sanitary facilities is inspected daily by the quality-control supervisor. The results are recorded on the daily sanitation audit form.
    
    
15. Goal: Pests are excluded from all areas of a food plant.
    
    Procedure: Rodents, insects, birds or other pests in the plant must be controlled. Glorious Crab Company contracts with a local pest control company to implement both routine and problem-specific pest control measures. The use and schedule of control strategies vary according to need. However, maintenance programs for fly and cockroach control are ongoing. Glorious Crab Company employees clean up processing wastes through the day to minimize attraction of pests. Material data sheets for all the pesticides used by the company are on file. Facilities maintenance checks include insect and rodent exclusion at doors, window screens, etc. In addition, the quality-control supervisor inspects the facility for the presence of pests daily before operation. Observations are recorded the daily sanitation audit form.
    
    
16. Goal: The plant is designed to minimize the risk of contamination of the food, food-contact surfaces and food-packaging material.
    
    Procedure:
    
    1. The quality-control supervisor and maintenance personnel schedule a monthly review of the plant layout and structure to ensure that contamination of any aspect of the process does not occur from internal or external sources. Observations are recorded on the monthly sanitation audit form.
    2. Any modification to the physical facility which might impact food safety is first reviewed with state health officials and an individual familiar with U.S. FDA regulations.