Know: Personal Protective Equipment (PPE)

Sector-Specific Information

The Food Industry Hub knowledge centre delivers a wide range of sector-specific information for food industry professionals.

The below is one topic from our knowledge centre. You can return to all topics by clicking here.

Personal Protective Equipment (PPE)

Definition

Personal Protective Equipment (PPE) refers to any clothing, equipment, or device designed to protect workers from health and safety risks in the workplace. PPE also includes any article of personal equipment or clothing intended to protect food from contamination by personnel. In the context of food manufacturing, PPE plays a critical role in preventing contamination, ensuring food safety, and safeguarding the health of employees.

The use of appropriate PPE helps to minimise the risk of contamination by creating barriers between workers and food products. It also protects workers from physical hazards such as cuts, burns, or exposure to hazardous substances. Given the high standards required in food manufacturing, the use of PPE is fundamental to ensuring that food products are safe for consumption.

Types of PPE in Food Manufacturing

1. Protective Clothing (Workwear)
• Uniforms and Aprons: Workers in food manufacturing environments are required to wear overalls or aprons to prevent contaminants from personal clothing from coming into contact with food products. Contamination can be diret, environmental transfer, or foreign bodies directly from clothing such as buttons. Protective garments are designed to be easily cleaned and maintained. In some cases, aprons are also designed to protect workers from potential chemical or heat exposure.
• Disposable Protective Clothing: In certain high-risk areas, disposable PPE such as gowns, gloves, and boot covers are used. Disposable workwear is particularly important in cleanroom or high-care environments, where contamination risks are higher.
• Lab Coats and Smocks: These are often worn by personnel in laboratories or during product testing to protect against spills and contamination.
2. Head and Hair Protection
• Hair Nets and Caps: Hair nets or caps are worn by all workers in food production areas to prevent hair from falling into food products, where it could lead to contamination. Beard snoods are also required for workers with facial hair.
3. Hand and Arm Protection
• Gloves: Gloves are an important piece of PPE in food manufacturing. They act as a barrier to protect both food products and workers’ hands from contamination. In food production, disposable gloves made of latex, nitrile, or vinyl are commonly used, depending on the tasks performed. Gloves must be changed regularly, especially when switching between raw and ready-to-eat food processing or after handling contaminated materials.
• Arm Covers: In some food manufacturing areas, arm covers are used to protect the food from contamination, especially when handling large volumes of raw materials or working in high-risk zones.
4. Footwear
• Non-slip Shoes or Boots: Non-slip footwear is essential in food manufacturing to prevent accidents caused by spills or slippery floors. Additionally, protective footwear helps to prevent the contamination of food by ensuring that workers do not carry dirt or chemicals into food processing areas. Footwear worn in production areas must not be worn outside for this reason.
• Boots and Gaiters: In areas where workers may be exposed to wet or hazardous environments, rubber boots or gaiters are often worn to protect against liquid splashes, chemicals, or biological contaminants.
5. Face and Eye Protection
• Face Shields: In environments where there is a risk of splashing from chemicals, hot liquids, or other hazardous substances, face shields offer additional protection to workers’ faces and eyes.
• Safety Glasses or Goggles: Protective eyewear is essential when workers are exposed to substances that could irritate the eyes, such as cleaning agents or during high-pressure washing.
6. Respiratory Protection
• Dust Masks or Respirators: In some food manufacturing environments, workers may be exposed to airborne particles, dust, or chemicals that can be harmful if inhaled. Respirators or face masks are used in these environments to protect workers from inhaling hazardous substances.
• Powered Air Purifying Respirators (PAPR): In highly sensitive areas, especially when dealing with volatile chemicals, more advanced respiratory protection such as a PAPR system may be required.

PPE Usage Guidelines and Best Practices

1. Training and Education
   All food manufacturing employees must receive training on the correct use and maintenance of PPE. This includes:
• How to put on, wear, and remove PPE correctly.
• When to use PPE (e.g., during certain tasks, in specific zones).
• How to inspect PPE for wear or damage.
• The importance of changing PPE regularly and keeping it clean.
2. Proper Selection of PPE
   PPE must be chosen based on the specific hazards present in the workplace. For example, gloves used for food processing must be food-safe and free from harmful chemicals. Similarly, clothing must be designed to prevent the transfer of contaminants between workers and food products.
3. Regular Maintenance and Replacement
   PPE must be regularly inspected for signs of damage or wear. Worn-out or damaged PPE should be replaced immediately to ensure it continues to offer adequate protection. PPE should also be cleaned adequately to prevent cross-contamination.
4. Hygiene and PPE Control
   To prevent contamination, workers should follow strict hygiene practices when putting on and removing PPE. This includes:
• Washing hands before and after handling PPE.
• Ensuring gloves and protective clothing do not come into contact with surfaces that may lead to contamination.
• Putting on and removing articles of PPE in the correct sequential order (e.g. putting on hairnet first and overalls second, to ensure the overalls are protected from hair contamination).
5. Designated PPE Zones
   In high-care food manufacturing areas, designated zones for donning and doffing PPE are required. These zones should be separated from food production areas to avoid contamination. This system is often part of a broader hygiene control system, where staff are required to pass through clean rooms before entering production areas.
6. PPE Compliance Monitoring
   Companies should implement regular audits and monitoring to ensure PPE is being worn correctly and consistently by all employees. Supervisors should be tasked with ensuring that PPE compliance is adhered to during shifts, especially when workers move between different areas of production.

Regulatory Requirements and Standards

1. HACCP (Hazard Analysis and Critical Control Points)
   As part of the HACCP food safety management system, companies are required to implement appropriate PPE policies to control contamination risks. These policies are an essential part of prerequisite programmes that form part of the HACCP systems in food production.
2. GMPs (Good Manufacturing Practices)
   GMPs require food manufacturers to establish PPE protocols to protect both workers and the product. Specific guidelines around PPE use in food production are detailed in GMPs to prevent cross-contamination and ensure that food is produced in a safe environment.
3. Regulations
   Regulation (EC) No. 852/2004 in the EU, outline hygiene requirements for food businesses, including the use of PPE to protect both the food and workers. Employers are legally required to provide the appropriate PPE to ensure food safety and employee health.

Conclusion

Personal Protective Equipment (PPE) is an essential element of food safety and hygiene in manufacturing. It provides a crucial barrier to prevent contamination, safeguard workers’ health, and ensure compliance with regulatory standards. By providing the correct PPE, ensuring its proper use, and maintaining a rigorous hygiene and monitoring program, food manufacturers can protect both their products and workforce from potential risks. Proper training and regular audits will help embed PPE use into the food safety culture of the organisation, contributing to better food quality, safety, and regulatory compliance.

About The Food Industry Hub Knowledge Centre

The Food Industry Hub knowledge centre delivers informative content on a variety of topics pertinent to the food manufacturing industry.