Australian Bakels Induction Material

Australian Bakels (Pty) Ltd Silverwater Employee

About Us

“Bakery Ingredients since 1904”

• Founded in Amsterdam – now in many parts of the world
• Australian Bakels is the largest company within the Bakels Group
• Silverwater manufacturing site was founded in 1952
• Currently Silverwater has over 200 employees

Australian Bakels’ core business and technical expertise is in specialized bakery and food ingredients, which we supply to domestic and export markets.

For more information see www.bakels.com.au

Our product range includes

• Bread fats
• Bread improvers
• Cake emulsifiers
• Chocolate products
• Release agents
• Fillings
• Toppings
• Icings
• Bread and dry cake mixes
• Frozen unbaked cookies
• Muffins and cakes

Why Induction?

We care about the safety of our customers, employees, visitors and contractors.

As a food manufacturing company, Australian Bakels must ensure our products are food-safe at all times.

We want you to know our company policies and abide by them at all times whilst on site.

Purpose

The information that follows will inform you of your responsibilities whilst on site:

• to act safely
• to ensure the safety of our products.

Failure to comply with Australian Bakels’ company policies could result in your removal from the site.

Responsibilities

You are responsible for:

Complying with Bakels’ policies and standards to protect your own and others’ health and safety.
Notifying any situation you believe could pose a risk of personal injury, property damage, or a workplace hazard.
Reporting immediately any personal injury or property damage.
•Participating in and contributing to the effectiveness of Bakels’ health and safety activities.

Safety Basics

Fire extinguishers and hydrants are in key locations
Evacuation Diagrams show exits & fire equipment
Speed limit of 15 km/h applies
Fire doors and fire-fighting equipment must be kept clear and unobstructed at all times
• No practical jokes or running on site
• No drugs or alcohol
• No smoking (Designated smoking areas shown on site map)

Emergency Evacuation

An emergency may be signaled by an alarm or announcement.

In the event of an emergency:

• if possible, Warn others in the immediate area
• if safe, Assist in controlling the emergency
Evacuate

Follow the area Fire Warden who will be wearing a red or yellow hard hat.

Emergency Exits – Site Map

(Click Image to Enlarge)

Bakels Map Small

Standards of Conduct

Australian Bakels will not tolerate harassment, discrimination or bullying.

Sexual harassment can include:

• Comments about a person’s appearance or sexual life
• Suggestive behaviour
• Offensive telephone calls
• Unnecessary physical intimacy, e.g. brushing up against a person
• Sexual jokes, photographs, reading matter or objects
• Sexual propositions or continued requests for dates
• Physical contact e.g. touching or fondling
• Indecent assault or rape (both criminal offences)

 Australian Bakels abides by the Anti-Discrimination Act 1977, the Federal Human Rights & Equal Opportunities Commission Act 1986, the Federal Racial Discrimination Act 1975, the Sexual Discrimination Act 1984, the Federal Disability Discrimination Act 1992 and the Federal Age Discrimination Act 2004.

BAC

The misuse of alcohol and drugs can seriously impair the ability to work safely and productively.  Australian Bakels acknowledges its responsibility to take all reasonable action to safeguard the health and safety of all its employees and will expect strict adherence to this policy.

It is a requirement for all full time and part time employees, contractors and agency staff working at any Australian Bakels site, to present for work with a Blood Alcohol Concentration (BAC) limit of less than 0.02g/100mL.

Site Security

Security cameras have been installed around:

• production areas
• entries & exits
• car parks & yard area

Areas of surveillance have been clearly identified.

Removing stock/equipment without correct invoicing/written authority is illegal.

Breaches will result in removal from the site & possible legal action.

Product Tampering

ALL workers are responsible for ensuring that our food products are safe for our consumers.

Any intentional act by an employee or contractor that could render an ingredient, product or package unsafe for consumers will result in termination and removal from site. 

The company will pursue all legal remedies, including criminal prosecution.

Employees who observe any such deliberate act must immediately report this activity to their Supervisor.

Unknown Persons

Employees are encouraged to challenge unidentified or unknown persons on site or notify a Supervisor or Manager.

Visitors/Contractors should be wearing a visible visitors tag.

Visitors should be accompanied by a staff member.

When on Site

For your own safety you must wear a High-Vis vest at all times while  walking through the site.

You can contact Reception by dialing 9 from any extension (7.30 am – 5.00 pm).

Taking photos or videos (including by cameras or phones) is not permitted on site without prior consent from a Senior Manager.

Section 2

Workplace Health & Safety

PPE

Steel capped safety footwear is mandatory outside painted walkways and MUST be worn at all times when in

• production
• dispatch
• warehouse

Eye protection must be worn when using

• compressed air
• chemicals
• maintenance equipment (e.g. grinders, welders, etc.)

Personal Protective Equipment (PPE) appropriate to the individual’s requirements must be worn.

CGMP requires additional hygiene standards in production areas.

Moving around Site

Pedestrians must:

• wear enclosed footwear & use the painted safety pedestrian walkways at all times
• if not on painted walkways wear steel capped safety footwear

Drivers must:

• stay below 15 km/h
• obey stop signs & traffic flow indicators
• carry the relevant license (e.g. forklifts, cherry pickers) at all times (according to WorkCover NSW)

Injuries

First Aid can only be administered by a qualified First Aider

• Ask Factory Supervisors or Managers in your area
• Any cuts must be covered with blue metal detectable dressings supplied from First Aid Kit

All incidents and injuries must be reported & recorded!

If you are injured at work you must:

1. Report it to an Australian Bakels Manager/Supervisor
2. Record it in the Australian Bakels First Aid book in
− Frozens; or
− WH&S & Rehabilitation Manager’s office (main admin building)

Hazards

 Out of Service tags & Danger tags

MUST be used
• DANGER tag may only be removed by the person who issued it.

Confined spaces

• are marked
• Only trained & approved persons may enter

Hazardous & Dangerous Substances

• must be approved in advance. See
• WH&S and Rehab Manager
• QA
MSDS is required

Cutting & Welding

Hot Work Permit must be obtained before starting work with
• naked flames
• hot metal grinding

Excavations & Floor Openings

• must be barricaded & signposted

Working at heights

Before working at heights (an unprotected drop of more than 2 meters):

1. Conduct a risk assessment
2. Obtain a Work at Height Permit
3. Prepare a safety harness/fall arrest or safety cage system

Scissor lifts must NOT be used at height around moving forklifts.

When using scissor lifts at height:

Barricade off the area of work and
Prevent forklifts from coming within 5 metres

Section 3

Food Safety

Our Food Safety Program

The goal of the food safety program is to protect consumer health.

Bakels’ Food Safety Program is based on the principles of Hazard Analysis Critical Control Point (HACCP). It ensures our product is safe.

Bakels is certified for BRC Global Food Safety Standards.

Our Food Safety Program

We take a continuous improvement approach to food safety to ensure we never compromise product safety. This extends to our:

• key suppliers
• staff
• processes. 

All aspects of our processes directly effecting Quality & Food Safety are documented.

• this includes critical limits, which form a part of our Food Safety Monitoring.

Responsibilities

We train staff and provide resources to ensure our program is understood and maintained to the highest possible level.

All positions within our company have clearly defined responsibilities with regard to food safety.

Review & Improvement Processes

We capture non-conformances, improvement requests and customer complaints affecting product safety. We encourage this at all levels of our company

Our process of internal audits including site inspections and process auditing ensures our systems are reviewed.

We also conduct regular food safety meetings.

HACCP

HACCP is an internationally-recognised standard that is used to prevent problems that could make food unsafe to consume.

HACCP

HACCP works by identifying & controlling potential biological, chemical and physical hazards on a line.

GMP

GMP   =  Good Manufacturing Practice

GMP guidelines are used in Australia and worldwide to ensure product safety.

GMP principles include the following:

• manufacturing processes should be clearly defined & controlled
• procedures are in clear language
• operators are fully trained in procedures
• traceable records are made of each step in a process

 

GMP  = code of Good Manufacturing Practice

Accessing Production Areas

Entrance/exit to production areas is controlled.

You may NOT enter warehouse & and production area unless wearing suitable clean protective clothing.

You MUST clean your hands using the hand washing stations before or immediately upon entering a production area.

NEVER take glass, crockery or drink/water bottles into the production and storage areas.

These items cannot be detected if they fall into mixes or food items and can cause a major health risk to our customers.

Forbidden Items

The following items are not allowed in production and food storage areas (Powders, Pre-Weight Room, Frozens, Fats & Liquids):

•  Retractable or Stanley knives
•  Wood (except wooden pallets controlled through GMP)
•  Glass*
•  Pins, staples & paper clips
•  Pen & pencils  (only metal detectable pens are permitted in factories)
•  Personal items (if essential medicine, notify Supervisor)

* Eyeglasses are permitted. Loss/breakage must be reported to Supervisor immediately.

Personal Items

No personal items (including medicines) are permitted in the production and warehouse areas.

Keep personal medication in lockers in the amenity rooms

− If it is critical to your health, notify your Supervisor.

All clothing and footwear not being worn must be stored in personnel lockers/change rooms or designated areas away from the production and warehouse areas.

Do not bring personal valuables on site.

Personal Hygiene

Poor hygiene habits that spread illness are not tolerated. e.g.:

• picking nose
• biting nails
• licking fingers
• dipping fingers in food
• sneezing without covering your mouth


Spitting is not permitted and may lead to your removal from site

• NO strong perfume or aftershave in manufacturing areas
• NO false fingernails, false eye lashes, make up or nail polish
• NO eating or drinking in production or warehouse areas including offices within these areas

Hygiene: Handwashing

Keep yourself clean at all times

Hands MUST be washed BEFORE entering production areas

Hands must also be washed after:

• using the toilet
• leaving the staff lunch room
• handling waste
• any cleaning procedure
• smoking

……and as frequently as necessary during the day.

Handwashing Technique

1. Wash hands thoroughly in hot water with a bactericidal soap.
2. Dry hands thoroughly with disposable paper towels/warm air dryer.
3. Sanitise with a hand sanitizer

Fingernails must be kept short, clean and unvarnished.

Hygiene: Jewellery

Jewellery is not permitted in the factories & warehouse. This includes:

• watches, wedding bands, rings
• studs in exposed parts of the body
e.g. ears, nose, tongue & eyebrows

Medical identification jewellery is acceptable but must be secured

• so that no risk of contamination to product is possible.
• Advise your Bakels Supervisor of the medical condition

Hygiene: Cuts & Sores

If you have an open lesion you must notify your Supervisor – you may be excluded from areas where there is direct contact with food.

Sores, cuts and grazes must be covered after treatment, with a blue coloured, metal detectable, waterproof dressing.

Change dressings frequently and report any lost plasters in production areas.

Metal detectable plasters are available from First Aiders or your supervisor/host.

Hygiene: Illnesses

Persons are not permitted to enter manufacturing areas if they are showing symptoms of any illness and are considered to be a risk to product safety

• Illness may include infections or discharge from the ear, nose or eyes
• Notifiable symptoms include diarrhoea, vomiting & high temperature.

Return to Work after Illness

Personnel who have suffered from diarrhoea and/or vomiting must not return to work until they have been:

symptom free for 48 hours, and
• passed fit by a medical practitioner.
• If returning to work in low care areas segregation    conditions must apply to limit exposure to food handling.
• On returning to work practice good hygiene, particularly hard washing.

Hygiene: Uniforms

Manufacturing employees are provided with freshly laundered, well maintained uniforms and safety footwear.

• Uniforms are laundered in house. Place soiled uniforms in cages separated from clean clothing.
• Uniforms must be changed daily and when soiled (at the minimum).

Notify your supervisor if your uniform has been soiled or contaminated. You must replace your uniform before returning to work.

Hygiene: Protective Clothing

Hairnets and/or beard nets (as appropriate) must be worn at all times in manufacturing areas.

− Wear a hairnet above any religious hair coverings
− Ensure all hair and ears are covered

Protective footwear MUST be worn at all times in production, dispatch & warehouse areas.

Smoking whilst wearing protective clothing is not permitted (contamination risk).

Contractors and maintenance staff will be provided with disposable overalls when entering frozens or RTR Icing areas.

Hygiene: Frozens Liquids & Fats

Blue disposable gloves are issued in the Frozens, Liquids & Fat Factories. 

Change gloves when:

• there are signs of wear and tear
• glove  is used to pick product from floor
• glove has touched non-food contact area
• exiting manufacturing area.

If glove is damaged during use, inform Supervisor if there is a missing part of  the glove that could have fallen into the product.

Protective disposable aprons are used in mixing areas of Frozens Factory.

• Aprons must be removed when leaving the production floor.
New aprons are issued on re-entering.

Cleaning

Cleaning equipment is HACCP colour coded:

Red   – Drains

Blue   – Floors

Green   – Food contact surfaces

Yellow   – Chemical used for food contact

Any spilled or dropped product must be discarded.

Littering and other poor housekeeping practices are not allowed.

All refuse must be placed in properly identified containers.

Product packaging must NOT be used to collect rubbish.

Allergens

Allergen is a material that, when consumed, brings about a negative health effect for certain sensitive population.

The main food allergens in Australia are:

• Milk & milk products
• Egg
• Cereals containing gluten
• Soy
• Tree nuts e.g. walnuts, almonds, hazelnuts etc.
• Sesame seeds
• Crustaceans (seafood)
• Fish
• Peanuts

Allergens are used on site and are controlled through our Allergen Management System. Allergens greyed out are not used on site as ingredients or finished product.

Avoid Contamination

• Be aware of food allergens.
• Certain materials require the use of dedicated utensils/ equipment e.g. dedicated scoops for raw ingredients.
Follow HACCP colour coding for cleaning equipment & brushware.
• Ensure uniform is not contaminated.
• Wash hands thoroughly before entering manufacturing areas.
• Refer to signage in the lunch rooms.
• NEVER sit or step on the packed product or lined pallet.

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