Food Safety Guide for Bakeries

Food hazards in farm shops

For most people, food hazards are something that we are naturally aware of in our day-to-day lives. However, the level of awareness of food hazards needed is different when you are working in a bakery. The FSA describes a food hazard as “something that could make food unsafe or unfit to eat”. The hazards can either be biological, chemical, physical or allergenic.

Biological

Biological food hazards are microorganisms or other living organisms. Some microorganisms can cause disease or illness in humans if they are consumed through contaminated food. The most common biological hazards in food include bacteria, viruses, parasites and fungi.

• Bacteria – Certain bacteria, such as salmonella, campylobacter and Escherichia coli (E. coli), can cause food poisoning when they are present in contaminated food.
• Viruses – Viruses such as norovirus and hepatitis A can be spread through contaminated food and cause gastrointestinal illness.
• Parasites – Parasites such as cryptosporidium and Toxoplasma gondii can be found in contaminated food and cause illness in humans.
• Fungi – Some types of fungi can produce toxins that contaminate food and cause illness such as Aspergillus flavus which produces the toxin aflatoxin.

 

Chemical

Chemical food hazards refer to harmful substances that can contaminate food and cause illness or disease when consumed. Chemical food hazard substances can occur naturally in the environment or be added to food either purposefully or accidentally.

Some chemical food hazards include:

• Pesticides – Pesticides are chemicals used in farming to control pests and diseases in crops. If used improperly or in excess, they can contaminate food and cause health problems. In a bakery, this may apply to grains that are used in the baking process before they’re refined into flour.
• Heavy metals – Heavy metals such as lead, cadmium and mercury can contaminate food through soil and water pollution, or from the use of contaminated packaging or equipment.
• Food additives – Certain food additives, such as artificial sweeteners, colours, preservatives and flavourings, can cause adverse reactions in some people, particularly if they are used in excess of what is considered safe.
• Contaminants from packaging – Chemicals from packaging materials such as plasticisers and bisphenol A (BPA) can migrate into foods and cause health problems.
• Acrylamide – Acrylamide is a chemical that forms naturally in some foods such as potatoes and bread during high-temperature cooking methods like frying, roasting or baking and has been linked to cancer. Whilst this may not be a huge risk in a bakery, it is still important for bakers to be aware of it.

 

Physical

Physical food hazards refer to foreign objects or materials that may contaminate food during the production process either accidentally or intentionally. These hazards can cause harm to customers such as choking, cuts and causing damage to teeth.

Physical hazards include:

• Glass or metal fragments – These can make their way into food during the production process such as if a glass jar or metal equipment is broken.
• Stones or dirt – These hazards can occur if food is not properly washed before preparing it or not properly sorted. Vegetables and salads are common places where these hazards occur. Whilst these ingredients are not often used in most bakes, some bakeries do make products containing vegetables and salad crops and, as such, it’s an important physical hazard to be aware of.
• Bone fragments – Meat and fish products are prone to this physical hazard if they are not properly removed during processing. Again, it is rare that bakeries will handle meat and fish that is not already processed for things like sausage rolls, but it is important to be aware of which products may contain unexpected bone fragments.
• Plastic or rubber materials – These hazards can be introduced during food packaging or equipment used during processing or handling.
• Jewellery, hair or nails – If employees do not follow good food safety practices including good self-hygiene, hairnets, properly fitting clothing and removing jewellery before preparing food, these items can find themselves in the food being prepared.

To prevent contamination of physical hazards, bakeries should always use reputable suppliers for their ingredients such as flour. They should ensure that the suppliers screen their products including sieving, filtering or detecting any metal fragments that have found their way into the raw ingredients. When the supplies arrive, bakery staff should check the packaging and ensure that it is in good condition and is not dirty or damaged. Once the packaging is opened, the bakers should check for any infestations such as flour weevils. Bakery owners should also inspect machinery and utensils regularly for wear and tear. Regular maintenance should be carried out and any damaged items should be replaced.

Allergenic

Allergenic hazards in food are those which can cause an allergic reaction in people with food allergies. Allergens are typically proteins that are found in certain foods and when someone with an allergy consumes them, their immune system reacts by releasing histamines and other chemicals that can cause mild to severe symptoms, including anaphylaxis which can ultimately lead to death. Bakeries are often a huge risk for those with serious allergies due to the ingredients used and the increased risks of cross-contamination, particularly with gluten and egg-containing products.

Some of the most common allergenic hazards in food include:

• Peanuts and tree nuts.
• Milk and dairy products.
• Eggs
• Shellfish
• Wheat and gluten
• Soy

As mentioned, food safety laws mean that certain allergens must be emphasised and clearly labelled on the packaging and that food establishments like bakeries must also have allergy information available for customers on the items that they make and sell. There must also be proper allergen management controls in place. Many bakeries also provide allergen-free options such as making gluten-free, wheat-free or egg-free products for their customers.

Food allergens in bakeries

A bakery is a place where many allergens are found. For people with allergies, encountering something that they’re allergic to in a baked good can be fatal. For most people, allergies are unpleasant or produce only mild symptoms, but severe allergies cause anaphylaxis. For this reason, many bakeries do not profess to make any allergen-free products as the risk of cross-contact is so great in this environment.

A food allergy is where the body reacts to a food due to an antibody named Immunoglobulin E (IgE). This antibody can cause a variety of symptoms, usually beginning within two hours of eating the food but often almost immediately. Essentially, the body is treating the allergen as a pathogen – an “invader” – and an immune response happens. This is the allergic reaction. Some people experience hives, itching and swelling of the tongue and/or lips. Others may experience stomach cramps, and an itchy nose or eyes. The most intense reaction is anaphylaxis, where swelling blocks the airway and the blood pressure drops. It is a ‘shock’ reaction to the allergen.

There are 14 allergens that must be listed on packaging and menus by law due to the severity of the reaction that they can cause in some people.

These are:

• Celery
• Cereals containing gluten such as wheat, rye, barley and oats.
• Crustaceans, such as prawns, crabs and lobsters.
• Eggs
• Fish
• Lupin
• Molluscs such as clams, mussels and oysters.
• Mustard
• Nuts such as almonds, hazelnuts, walnuts, cashews, pecans, macadamia nuts, pistachio and Brazil nuts.
• Peanuts
• Sesame seeds
• Soybeans
• Sulphur dioxide and sulphites (at concentrations of more than 10mg/kg or 10mg/litre).

 

In a bakery, the most common allergens found are wheat, milk and eggs. Milk and eggs often produce severe reactions in those who are allergic, including anaphylaxis. However, unlike milk and eggs, there have been no known recorded deaths from anaphylaxis due to wheat consumption.

Whilst some people have a wheat allergy, most have an intolerance or suffer from coeliac disease. Coeliac disease is where the body has an auto-immune response to the gluten found in grains like wheat, barley, rye and oats. Whilst this is extremely unpleasant and involves the immune system, it’s not an allergy per se and does not pose the risk of anaphylaxis.

In a bakery, allergen information should be available on packaging or labels if the baked goods were prepared on-site and pre-packaged for sale (PPDS) as per Natasha’s Law. Allergen information should also be readily available in documents and folders and on menus or posters within the bakery by law.

When preparing baked goods on-site or when handling them to distribute to customers, bakeries should take precautions to ensure products with allergens are handled properly to avoid cross-contact.

This includes:

• Ensuring that allergenic hazards are included in HACCP systems and controls are put in place.
• Providing training on allergens for staff, including what to do in emergencies if a customer has an allergic reaction.
• Looking for allergenic ingredients on purchased products before using or supplying them (i.e. Worcestershire sauce contains anchovies which is a type of fish).
• Preparing products containing allergens in a separate area from non-allergenic products, for example using different coloured chopping boards.
• Storing allergen-containing products separately from non-allergen-containing products.
• Cleaning surfaces and utensils thoroughly between uses where separate equipment is not possible.
• Checking pre-packaged ingredients thoroughly for allergens especially considering many pre-bought items can change ingredients or formulation without warning even if you have used the product before.
• Labelling containers with any allergens stored within them.
• Recording information regarding allergens accurately, including on-shelf labels or ingredient labels and recipes.

Unlike pathogens such as bacteria, allergens are not affected by heating or cooling. As a result, bakeries should be extra careful when handling any allergens and proceed with caution if a customer reports an allergy. Many bakeries state that they handle all 14 allergens on the premises and cannot guarantee that their products are free from certain allergens, to be on the safe side.

Safely storing food in a bakery 

Food should be stored correctly in a bakery to maintain the quality of the baked goods as well as prevent any foodborne illnesses.

There must be stringent systems in place when it comes to storage, including:

• Storing food at the right temperature. The refrigerator should be kept at or below 5°C and frozen food at or below -18°C. Some bakeries keep items warm so they are ready to eat. To keep hot food hot, it should be at or above 63°C.
• The temperature of the fridge and freezer should be checked regularly to ensure that they are working correctly.
• Storage containers should be food-safe and should be labelled with the name of the food and the date it was stored as well as labelling any allergens within it to ensure proper and safe storage.
• Food should be stored in clean, dry and well-ventilated areas to prevent the growth of bacteria and mould.
• Advice for specific food storage should be followed. For example, potatoes, tomatoes and bananas should not be stored in the fridge.
• Rotate food regularly to ensure that older food is used up first. Have a system with first-in-first-out (FIFO) stock rotation.
• Dispose of any spoiled or out-of-date food promptly.

 

Hot holding

Some bakeries may keep food such as pies and pasties in heated units on display. This provides an opportunity for bacteria to grow if the temperature is not correct. As mentioned in the list above, hot food should be kept at 63°C or above to prevent this from occurring. If it is kept below this temperature for over two hours, it cannot be safely consumed.

By following these safe storage rules, bakeries can meet the necessary food safety legislation to prevent their customers from coming to any harm.

Safely serving food in a bakery 

In a bakery, baked goods are often on display on counters and are chosen by the customer before being packaged for sale. Items mustn’t be contaminated during handling and packaging. Utensils should be used to handle food, if possible, rather than hands. If using tongs, they should be cleaned regularly, preferably between uses if they are handling different items that may contain allergens. If utensils are not used, the staff should wear disposable gloves. The staff handling the food should be trained in the importance of good personal hygiene.

Waste management in a bakery

Bakeries often produce substantial waste including food waste and packaging waste. Handling the waste effectively in a bakery is essential as, if it is poorly managed, it can result in problems with pests. Waste also increases the presence of bacteria and viruses. Food that is not disposed of correctly can also rot, which will increase the risks of pests as well as cause an unpleasant aroma for customers or nearby businesses. Waste in a bakery should be separated into appropriate containers.

Waste management in a bakery should include the following principles:

• Removing waste regularly from food areas to avoid accumulation.
• A good number of bins that are accessible inside the bakery and also outside.
• Bins allocated to different waste types including food and recycling.
• Bins operated by foot pedals to avoid touching them by hand.
• Lidded bins that are secure to avoid pests having access to the contents.
• Cleaning bins regularly and using suitable bin liners.
• Regular emptying of bins.
• Locking outdoor bins when not in use.

Pest control in a bakery

Pests and bakeries do not mix. You only have to read about The Lefterist Bakery’s cockroach and mice infestation above to start itching and twitching. Thankfully, since the prosecution, the bakery has changed hands.

Pests are not just limited to mice and cockroaches.

They include:

• Rodents – including rats and mice.
• Insects such as cockroaches, flies and ants.
• Stored product pests such as flour weevils, merchant grain beetles, and Indian meal moths.
• Birds – pigeons, house sparrows or other birds nesting on the premises can be problematic. Seagulls can also be troublesome outside of a bakery.

Preventing infestations of pests in a bakery is essential to the good running of the business as well as complying with the law.

Bakeries should prevent and control pests by:

• Keeping the bakery clean and tidy. This includes cleaning the floors, walls and counters. Food spills should be cleaned promptly.
• Disposing of waste correctly, particularly food waste as this is what attracts pests the most. Bins should be tightly sealed.
• Storing food correctly in tightly sealed containers. Containers should not be on the floor to prevent pests from entering them. When a food delivery arrives, the contents should be inspected carefully to make sure no pests are being introduced to the bakery.
• Sealing any pest entry points such as cracks and gaps around windows, pipes, doors and floor. This will help to prevent pests from entering the bakery.
• Using products if pests are suspected to catch and/or eliminate them.
• Hiring professionals in to clear any pest infestations so that the job is done properly.
• Training the staff who work in the bakery to promote the importance of good practices within the bakery and how to prevent pests.

By following such tips, the bakery and its customers can be sure to be as safe as possible.