Development of Training Module on GMP and GHP for Associates in Large Scale Biscuit and Cake Manufacturing Unit: A Scientific Approach

The challenge of preparing quality safe food begins with well trained and knowledgeable work force. As per WHO (paper on food safety, 4/10/2024) an estimated 600 million - almost 1 in 10 people in the world - fall ill after eating contaminated food and 420000 die every year. US$ 110 billion is lost each year in productivity and medical expenses resulting from unsafe food in low- and middle-income countries.While most food born diseases are sporadic and often not reported, outbreaks of food borne disease may take one massive proportions. Food contaminations problems may assume significant proportion in large scale food processing Industry when food is manufactured in bulk quantity. This is also important for the reputation of the brand and its overall business performance. A preventive approach to food safety includes GMP and GHP which ensure that the manufacturers examines every stage of the process, identify the essential ways to control the food safety hazards and makes sure that the process parameters/control measures remain consistent and effective and the final food product is safe and suitable for human consumption. Each firm including biscuit and cake manufacturing unit must develop procedures to ensure that an effective food safety program has been implemented and that adequate supervision and monitoring and training systems are in place to ensure quality of food.
 
What is GMP/GHP training
 
Food safety training is a professional training program for employees and supervisors to create awareness about GMP, GHP as well as food safety and hygiene standards.

Who should be trained
 
Different types of training are needed for individuals with different roles and responsibilities. Managers, supervisors, quality control staff and others with overall responsibilities for developing and implementing effective procedures to meet GMP requirements should understand or be aware of all of the GMP requirements and appropriate strategies to meet them. These individuals are likely to need more comprehensive training than production or other working personnel assigned to tasks. In this training, participants are trained on food safety rules, regulations and policies. The idea is to maintain safety standards through quality control measures.
 
Benefit of training
 
There are several reasons why it is important to train staff in GMP, GHP practices:
1.     The workers are the ones actually handling food. It is important that they do so in a safe manner.
2.     Reduce the risk of food poisoning. 
3.     Training helps with quality control. GMP,GHP is a huge part of quality control when staffs are properly trained. 
4.     Training helps regulate food production waste.
5.     Behavior will change.
6.     Employees can gain a better appreciation for their jobs.
7.     Build up reputation and brand value of the Company. (Gaungoo et al., 2013).
 
Effectiveness of training
       
In a study by Murlidhar Meghwal, Uday Heddur Shetti and Ravikumar Biradar as published in  Chapter 1002 P22 Revised by Goyal 14 Jan 2016 in ‘Good manufacturing practices for food processing industries: purposes, principles and practical applications’ it was observed that the quality of food processing trainings was found very effective by most of the trainees as 88.8% graded it in very good category. Participants felt that their level of confidence and work efficiency had enhanced during the training.                        

Some authors including Bryan et al., (1992); Osimani et al., (2011), have reported positive association of training protocols with good hygiene practices of trainees, others including Egan et al., (2007); Lilian Soares et al., (2012), have reported otherwise. Krishnasree et al., 2018, also reported that even though majority of food handlers were aware of the safe food handling practice it was not followed appropriately during food preparation. Some of the factors blamed for lack of success in hygiene training were methods used, demographics of trainees and their preparedness to learn, lack of supervision after training, absence of refresher programmes (Gilling et al., 2001). Adolf and Azis (2012); Feglo and Sakyi (2012), equally highlighted the importance of hygiene training in the food industry.
       
Effective food safety training involves two stages. Firstly, it provides knowledge in a way that develops a positive attitude. The second stage involves the implementation of the knowledge properly when required. Practice, motivation and effective supervision, especially coaching, should result in the objective being achieved, i.e. the competency of the food handler and implementation of good practice at all times (Sprenger, 2009).

Methodology of the study hereby clarifies the area selected for the study, time period of study and total number of samples under study.
 
Selection of area of study and place
 
The survey was conducted among the personnel working in the biscuit factories in Bhubaneswar, Odisha by using a questionnaire for general associates and specialized personnel (Quality/production) to find out extent of knowledge of GMP, GHP. This will inturn help to assess training need in terms of duration and frequency of training as per prevalent practice in the factory. Name of the Institute is West Bengal University of Animal andFisheries Science being study center for IGNOU.
 
Time period of study/year of experiment
 
One light duty hour over a period of four weeks of January 2024 was selected.
 
Population and sample size
 
As all spectrums of workers of large scale biscuit and cake manufacturing factory was chosen for study the sample size is of 70 associates divided into two groups, 58 general associates and 12 specialized associates.
 
Limitation of Research
 
Ø The present study focuses only to workers employed in Biscuit and Cake manufacturing Industry of  Bhubaneswar, (Odisha) locality conducted in early 2024.
Ø The present study focuses only on self-help skills which can be done by workers themselves without any further change in factory set-up or mechanization.
Ø Sample size is limited to 70 in total only, which is only representative.

Outcome of the survey
 
Lack of knowledge of Good Manufacturing Practice (GMP) as well as Good Hygiene Practice (GHP) among associates is quite clear from the survey data (Fig 1-3). Data reveals that only 57% shave regularly (Fig 1). 16% does not know how to wear head cap properly, 98% do not know colour coding of products (Fig 1). However, strict restriction is present against wearing ornaments, which is rigorously followed (100% as in Fig 1). Again 95% do not follow proper hand washing technique and even 92% do not wash hand before entering into manufacturing area (Fig 2). However 61% of the associates use washed and clean cloth regularly( Fig 2). Almost 62% rated that they have some knowledge about GMP,GHP and 80% feels that floor in the manufacturing area should be cleaned everyday and rest 20% feels that it may be cleaned in alternate days (Fig 3). 23% of the associated use cleaned apron daily (Fig 3). Fig 4 shows that 98% of associates working in the biscuit and cake manufacturing factory showed interest in further training in GMP, GHP and 93% feel that future training will improve their performance. 87% of associates prefer short duration training and 83% prefer training with demonstration and picture aid. (Fig 4) Generally most of the training in the factory is of the duration of 10-20 minutes as well as 20-30 minutes (Fig 5).










 
Findings of the survey are presented graphically hereunder
 
Training need assessment
 
Need analysis begins with problem identification. It is believed that a main step in any training programme is to determine whether training is needed and if so, to specify what that training should provide (Hosure et al., 2009). From the survey data it is clear that 93% of associates feel that future training will improve their performance (Fig 4). As evident from the outcome of the survey that only 61% of the factory workers use washed and cleaned cloths daily (Fig 2) and only 23% use clean apron after washing it daily (Fig 3). 92% personnel do not wash their hand every time before entering into the manufacturing area (Fig 2). 16% does not know how to wear head cap property (Fig 1). Thus there is a serious lack of understanding of personal hygiene among workers. In the own admission of the workers about 62% workers has some knowledge about GMP, GHP (Fig 3). Thus personal Hygiene would be of primary part of training. Deficiencies in knowledge is observed in survey about colour coding for easy identification of product (98% are not aware about it , Fig 1) and proper hand washing (Fig 2), so these are included in training. To make the training outcome better, training for short duration (as per practice of factory shown in Fig 5 and preference of 87% of associates for short training shown in Fig 4) with demonstration and picture aid may be incorporated (83% prefer for it as in Fig 4). Further, workers should also understand basic of operations, ingredients and underlying principles (Kaur et al., 2019) in biscuit and cake manufacturing as without this knowledge they would not understand principles underlying GMP, GHP and feel confident in their working sphere. They should also know ideal working conditions governing GMP /GHP and what are GMP, GHP requirements in a factory. The training should also guide them the way forward and for new idea.
 
Training module In GMP, GHP For biscuit and cake manufacturing unit
 
Based on detailed study and after assessing Structure of the organisation and label of understanding of GMP, GHP in workers of the factory following 7 (seven) training modules for workers on GMP and GHP in bakery industry were developed. Maximum total duration of training of 1 hr 15 min and minimum total duration of 15 minutes training were worked out. But per day maximum duration was kept at 30 minutes based on survey outcome. Details are presented below-


 
Brief description of training module
 
Module 1
 
Baking - Introduction - Types of products manufactured. Ingredients for bread, cake, biscuit-classification - role of ingredients in food manufacturing- finished products-packaging-storing-health and hygiene-personal hygiene-floor hygiene-hygiene at storage place-pests and its control. Machineries involved in bakery.- Cleaning methods - CIP- Clean-out-of-Place - Manual cleaning -  Cleaning agents -Sanitizers, HACCP plan- 5 Preliminary steps-7 Principles of HACCP.
 
Module 2
 
General introduction to baking, Baking - classification - role of ingredients -Baking chemistry and technology -Quality assessment - Dough rheology- rheological properties-mixograph/ farinigraph/extensograph / viscoamylograph. Quality control, standards and Specifications.
 
Module 3
 
General Manufacturing Practice, Raw material-vendor selection- Sign of contamination-storage of raw material-What is First in First Out (FIFO)and Last In First Out (LIFO) GMP Scope-Environment and location Building and factory facilities, Fan light running Status, Facility and sanitary activity, Pest Control System, Employee’s Hygiene, Process Control. Surveillance Management. Personal Hygiene-Dress code- Physical appearance code. Using soaps and sanitizer.
 
Module 4
 
General Manufacturing Practice; What is food safety, Why important- FIVE P’s OF GMP-  place, primary materials, people, process and product are five important factors. Food contamination-sources of contamination, Pest Prevention and control-Pest control measures-Good Hygiene Practice. What is Good Hygiene Practice(GHP), Employee’s hygiene requisite:- Maintaining their body hygiene.- Wearing working outfit and its equipment.- Covering any wounds- Always washing hands using soap.
 
Module 5
 
Some special hand washing rules as part of GHP for food workers with practical demonstration.
 
Module 06
 
Demonstration of colour coding of material, disposal of waste, ‘Do’s’ and Don’ts in manufacturing area relating to GMP, GHP  for food workers with the help of picture.
 
Module 07
 
Understanding and following of Checklists as part of GMP, GHP procedure for workers as quality and Production personnel.

As consumers can’t always tell whether food products are safe just by looking at them, manufacturers have a tremendous responsibility to provide safe, quality foods to the public. Training to workers and subsequently following GMPs and GHPs rules help to promote quality, ensuring safe products for mass distribution and subsequent consumption. This increases the likelihood of products being free of dangerous substances or contaminants that could cause harm to consumers which in turn make the food safe. This in turn benefits the company in the long run.

The present study was supported by friends and colleagues of Anmol Industries, BBSR plant.
 
Disclaimers
 
The views and conclusions expressed in this article are solely those of the authors and do not necessarily represent the views of their affiliated institutions. The authors are responsible for the accuracy and completeness of the information provided, but do not accept any liability for any direct or indirect losses resulting from the use of this content.
 
Informed consent
 
No animal procedures for experiments. However, animal procedures, if any, were approved by the Committee of Experimental Animal care and handling techniques were approved by the University of Animal Care Committee.

 The author declares that there are no conflicts of interest regarding the publication of this article. No funding or sponsorship influenced the design of the study, data collection, analysis, decision to publish, or preparation of the manuscript.