Cleanliness and hygiene are the bedrock of the food processing industry. They ensure food products are safe for consumption and free from contaminants. Adhering to these practices safeguard public health, maintain consumer trust and protect a brand’s reputation. Independent Consultant in Food and Quality & FSSC India Representative Smita Murthy stresses the urgent need for change in the Indian food industry with Special Correspondent Keerthana Sundar.
Hand washing is non-negotiable in food processing. Technology can assist, but it can never replace the basics of hygiene. A single lapse can put public health and a company’s reputation at risk.
— Smita Murthy
What are the common hygiene mistakes that are made by those in this industry?
The first one is not putting focus on personal hygiene. Many companies do not train employees in proper hand washing. This is a critical step in food handling. Inadequate or skipped hand washing is a major issue. Cross contamination is another significant problem. This often stems from poor facility layout and zoning. Storage practices are a third common mistake. Failure to follow the principle of FIFO (first-in-first-out) is quite frequent. Temperature-controlled storage is sometimes not monitored. A fourth error is poor equipment hygiene. This includes dirty or damaged tools and surfaces. Scheduled cleaning is often missed. The final mistake is using broken equipment instead of replacing it. These harbour bacteria and can become a hazard.
Are these mistakes, or do they occur due to oversight or lack of knowledge?
It is entirely due to lack of understanding and awareness. The ‘chalta hai’ (it is alright) attitude is a major cultural hurdle. The belief that nothing bad will happen is common. This mindset must change if the industry wants to meet global food safety standards.
But every outlet can’t be the same, is it not?
That’s true. But food safety and good hygiene are non-negotiables… the size, type does not matter. I am happy that the mindset is changing. Growing awareness is now supported by the internet and social media. People document hygiene failures on their mobile cameras and share them. This creates public accountability. New age companies are being held responsible to higher standards.
What measures do outlets take towards maintaining hygiene?
Beyond the basics there are some emerging requirements. For example, real-time tracking of hazards. Predictive analysis can anticipate when equipment needs cleaning. Hygienic design of equipment is now a major focus with groups like the European Hygienic Engineering Design Group providing guidelines. Microbiological risk mapping is also being used.
How do they help?
They help in identifying specific risks to a product. There are new technologies for detecting biofilms. These new methods can analyse water activity. This is important for assessing microbial growth control. Sustainable hygiene practices are also emerging. They use ecofriendly cleaning agents and also less water. Wearable technology is now used for monitoring hand washing. It ensures compliance before entering food processing areas.
Is the industry receptive to new technology?
Cost is the main barrier for Indian companies. New technologies are often expensive. However, with India aiming to be a global food processing powerhouse and the kitchen of the world, adopting modern technology is essential. As with all technology, costs will decrease with time. The basics must still be followed regardless of technology. Proper training on hand washing is non-negotiable. Hygienic design must become mandatory. It must be easy to clean the equipment.
How does the industry bring about a change in current practices?
Well-structured onboarding programs are the key. There should be dedicated time allocated to hygiene practices. Hands-on demonstrations and visual aids are very effective. Gamification of hygiene training can also be used. This makes the process engaging. Employees can be given points and rewarded for compliance. Digital technology makes this possible. Standard operating procedures and checklists are also necessary. A feedback loop with monitoring and consequences is essential.
What are the hurdles that need to be crossed?
The single biggest challenge is poor hygienic design of equipment with companies often choosing the cheapest. They do not think about whether it can be cleaned easily. This leads to inaccessible areas where dirt accumulates. A lot of old factories have poorly designed layouts. Machines are placed too close to the floor. It becomes impossible to clean their underside. Designing equipment for easy access and cleaning is crucial.
Is automation the answer for hygiene?
Automation brings opportunities. But it can also create complexities. Automated machinery has complex electronic parts. These require specialised cleaning. They cannot just be sprayed with water. An entrepreneur must ensure that cleaning processes for new machines are validated. Employees must be trained in these new methods. Automated CIP (Cleaning-in-Place) systems are a great help. However, they must be monitored. A false sense of security can arise from automation. Sensors must be calibrated properly. The basics of microbiology testing remain essential. You must still test the product to confirm cleanliness. The most important need is for skilled employees. They must be able to handle complex automated systems.
Can you cite some examples to show good and bad practices?
I once audited a small seafood processing company. The facility was run perfectly. The hygiene from the floor to the equipment was flawless. There was no foul smell. Waste was removed frequently. Everything was well designed. The conveyor system had no dead spaces. This showed a strong commitment to quality. In contrast, I have also seen an Indian fried snacks and spice mix company with appalling conditions. The room had poor ventilation and lighting. Personal protective equipment was not used. There was no concept of hand washing. The working conditions were difficult for employees.
Have you noticed any new trends?
New technologies are being adopted to extend the shelf life of products. Modified atmosphere packaging is a new trend. Plastics are still a key material. Bioplastics and new recycling methods are emerging.
In Short
1. Design for hygiene
2. Integrate smart monitoring
3. Validate and audit regularly
4. Upskill the workforce
5. Look at your hygiene data and identify broad trends