19 replies to this topic

[QAKat]

Hello everyone.

 

Can you guys share what methods you have in place for prevention of hair in your facility and products.

We have recently encountered a big problem with hair (kind of everywhere) and I'm working on getting to the root cause but maybe some suggestions might help so I can take to Senior Management. 

I suggested lint rollers so everyone can remove any hair/thread they may have in their clothing before starting their shift and also using them on their smocks after breaks/lunches. We are a small company so any suggestion that involves money gets ignored or they think training is the solution to everything. Luckily we have great employees who are on the lookout for such hazards that senior management can no longer ignore the issue as employees have been finding a lot of hair. 

 

Thank you! 

[Tony-C]

Hi QAKat,

 

There is normally a simple solution to this sort of problem. Have you checked that personnel are following the correct robing and disrobing procedures, for example putting on a hairnet before the protective clothing?

 

Discussion on the subject can be found in this topic: https://www.ifsqn.co...-contamination/

 

Kind regards,

 

Tony

[Utama]

Hello everyone.

 

Can you guys share what methods you have in place for prevention of hair in your facility and products.

We have recently encountered a big problem with hair (kind of everywhere) and I'm working on getting to the root cause but maybe some suggestions might help so I can take to Senior Management. 

I suggested lint rollers so everyone can remove any hair/thread they may have in their clothing before starting their shift and also using them on their smocks after breaks/lunches. We are a small company so any suggestion that involves money gets ignored or they think training is the solution to everything. Luckily we have great employees who are on the lookout for such hazards that senior management can no longer ignore the issue as employees have been finding a lot of hair. 

 

Thank you! 

 

Hi QAKat,

 

There is normally a simple solution to this sort of problem. Have you checked that personnel are following the correct robing and disrobing procedures, for example putting on a hairnet before the protective clothing?

 

Discussion on the subject can be found in this topic: https://www.ifsqn.co...-contamination/

 

Kind regards,

 

Tony

 

Yupp...

 

In your company besides of use hygiene uniforms, also have a procedure before entering the hygiene area.. such as using an adhesive roller to the uniforms before entering, or checking the sanitation on the uniform by using a mirror, so the employee can check their own hygiene uniform through the mirror.

 

Thanks

[SHQuality]

Normally, people put on a hairnet and then get into a fresh work clothes at the start of the day.

Do people bring in pet hair from home? Do they shed their own hair before they put on a hairnet?

 

I'd start by doing spot checks on employees while they're working, to see if they're hair free while at work and take it from there.

[cookinmaple]

Seems a little unusual to be finding lots of hair in the facility, when hairnets are in use. I have seen Air curtains used at main entrances to remove loose particles such as hair before entering the building. Here I ask staff to keep hairnets on during breaks, unless they leave the building then it must be removed. I also ensure hairnets are changed in specific locations like the locker room and washroom, and always have staff don hairnets before other protective clothing. We also ask staff with long hair to tie it back before coming to work.

 

Some other questions to help find the root cause.

Are the hairnets appropriate size? I have seen some people with long hair need larger hairnets or they double up.

Are you sure nobody is removing the hairnet and adjusting their hair on the production floor?

How frequently are the hairnets changed?

Is the staff coming to work in clean clothing? 

 

Maybe training is the answer here, to ensure staff are following Personnel GMPs. Hope you can find a solution.

[Charles.C]

Hi QAKat,

 

So (bated breath) are hairnets in use ?

 

Where was the "Problem" ?

 

Definitely human ? I have experienced major feline ingress in overtime working.

[Brothbro]

You mention you use smocks, which is great start. If you can confirm that you're using hairnets, you would have the basic anti-hair measures in place. Small companies often do their own smock laundry; how do smocks look when coming out of the wash? Is there still hair on them? Some basic washing machines don't do a good job of removing excessive hair. Do you see hair even on your freshly cleaned smocks? The type of hair you're finding will also help determine a root cause. Is it coming in from people's street clothes, or are they shedding it throughout the day? Human? Animal (pet)? 

[QAKat]

Hi QAKat,

 

There is normally a simple solution to this sort of problem. Have you checked that personnel are following the correct robing and disrobing procedures, for example putting on a hairnet before the protective clothing?

 

Discussion on the subject can be found in this topic: https://www.ifsqn.co...-contamination/

 

Kind regards,

 

Tony

Hello Tony. Yes they are trained and I can't see them when the sift starts but I do keep my eye on them when they come back from their breaks. 

Hairnet is put on first, then hand washing/sanitizing then the smock.

 

Thank you for the link to the other discussion post.

[QAKat]

Yupp...

 

In your company besides of use hygiene uniforms, also have a procedure before entering the hygiene area.. such as using an adhesive roller to the uniforms before entering, or checking the sanitation on the uniform by using a mirror, so the employee can check their own hygiene uniform through the mirror.

 

Thanks

Hello RafifUtamaPutra.

 

Today we started using the lint rollers as a preventive measure. We will see how it works and go from there.

 

Thank you!

[QAKat]

Normally, people put on a hairnet and then get into a fresh work clothes at the start of the day.

Do people bring in pet hair from home? Do they shed their own hair before they put on a hairnet?

 

I'd start by doing spot checks on employees while they're working, to see if they're hair free while at work and take it from there.

Hi SHQuality!

 

The spot checking is a very good idea. I am the only QA/QC and though a small company (30 employees) there is still so much that has to be done on a day to day basis especially being SQF, so sometimes I get side tracked with other things. I will begin doing this as often as I can because it has become a big issue. I don't need any customer complaints or worse. 

 

Thanks!! 

[QAKat]

Seems a little unusual to be finding lots of hair in the facility, when hairnets are in use. I have seen Air curtains used at main entrances to remove loose particles such as hair before entering the building. Here I ask staff to keep hairnets on during breaks, unless they leave the building then it must be removed. I also ensure hairnets are changed in specific locations like the locker room and washroom, and always have staff don hairnets before other protective clothing. We also ask staff with long hair to tie it back before coming to work.

 

Some other questions to help find the root cause.

Are the hairnets appropriate size? I have seen some people with long hair need larger hairnets or they double up.

Are you sure nobody is removing the hairnet and adjusting their hair on the production floor?

How frequently are the hairnets changed?

Is the staff coming to work in clean clothing? 

 

Maybe training is the answer here, to ensure staff are following Personnel GMPs. Hope you can find a solution.

We actually had an issue with really small hairnets about a month back. The plant manager got size 21 instead of 24 and everyone was having issues with keeping their hair in the hairnet. We encourage employees that they can use double hairnets if needed, some employees do this already. Hairnets are to be changed when they rip, if taken outside or to the restroom, besides that when they go to break/lunch they hang the hairnet with their smock and as I'm typing I can see some problems with this      . The employees know they have to come in clean clothing and as far as I've seen they do.

 

Thank you!

[QAKat]

Hi QAKat,

 

So (bated breath) are hairnets in use ?

 

Where was the "Problem" ?

 

Definitely human ? I have experienced major feline ingress in overtime working.

Hi Charles.C

 

Yes hairnets are being used. 

 

The problem (hair) is on the product, on the floors, on the smocks (even before the employees put them on). Today I found one stuck on the unused smock I was going to wear, so part of the problem might be coming from smock supplier. We have problems with the towels they provide for us too with things like metal, hair, gaskets, burnt like material.  

 

Not 100% sure but 98% look like human hair either head hair or facial/body hair.

 

Thanks! 

[QAKat]

You mention you use smocks, which is great start. If you can confirm that you're using hairnets, you would have the basic anti-hair measures in place. Small companies often do their own smock laundry; how do smocks look when coming out of the wash? Is there still hair on them? Some basic washing machines don't do a good job of removing excessive hair. Do you see hair even on your freshly cleaned smocks? The type of hair you're finding will also help determine a root cause. Is it coming in from people's street clothes, or are they shedding it throughout the day? Human? Animal (pet)? 

Hi Brothbro!

 

Hairnets are being used. We don't unfortunately. We have a smock/towel supplier and they SUCK!!! so many problems with them but being a small company owners are not willing to changer because of the contracts/lawyer stuff. I found a hair today on the smock I was going to wear!!! I should go see their facility and verify their HACCP program 

The type of hair looks like human hair mostly. We started using lint rollers today so employees can use them on their street clothes before starting their work shift and on their smocks after breaks.

 

Thank you! & everyone else for your feedback! 

[Sayed M Naim Khalid]

Here are 3 recommendations: 

1. Employee hygiene: Employees should be trained to keep their hair tied back, wear hairnets or other hair restraints, and wash their hands regularly.
2. Physical barriers: Installing physical barriers, such as partitions, screens, or hoods, can help to prevent hair from getting into food.
3. Cleaning and sanitizing: Regular cleaning and sanitizing of the food production line, including conveyor belts and packaging equipment, can help to reduce the risk of hair contamination.

[SHQuality]

I suspect that if you have a problem with the smock supplier, talking to them (or maybe auditing them would be my first step.

[FurryCrow]

Have you tried op's using hairnets first then mob caps?

[Brothbro]

Hi Brothbro!

 

Hairnets are being used. We don't unfortunately. We have a smock/towel supplier and they SUCK!!! so many problems with them but being a small company owners are not willing to changer because of the contracts/lawyer stuff. I found a hair today on the smock I was going to wear!!! I should go see their facility and verify their HACCP program 

The type of hair looks like human hair mostly. We started using lint rollers today so employees can use them on their street clothes before starting their work shift and on their smocks after breaks.

 

Thank you! & everyone else for your feedback! 

 

Sorry to hear your smock/towel supplier isn't up to par QAKat, they sound like at least one of the root causes to your hair issue. If there are any other suppliers in your area, it would be worth looking into their services! Perhaps a different company could live up to the minimum standard of supplying clean smocks/towels.

 

Outside of that, a chronic issue like this may warrant a deep-cleaning day. See if production can be paused for a day while employees work to remove all the hair in the facility. Start fresh, and this will help you best determine where the hair is coming from. Of course, all employees involved in cleaning should be wearing their best hair-free clothes as well.

Edited by Brothbro, 02 February 2023 - 04:53 PM.

[Gelato Quality Lead]

Hi,

 

Apart from talking to your laundry supplier about their not providing fully cleaned smocks, I would recommend not letting team members reuse hairnets. 

 

We have had the issue of hairs getting stuck to the hairnet and then when the smock and hairnet are hung up together for breaks, the hair gets transferred to the smock. We have also see that hairnets are accidentally being put on inside out, so any hair that was previously caught, is now on the outside of the hairnet, ready to fall into the production area.

 

Our hair situation improved after a training related to the aforementioned, as well as putting up acrylic mirrors in the change room and providing lint rollers.

[Sayed M Naim Khalid]

Here are some strategies for prevention: 

1. - hair net, baseball caps, (normal)
2. - All hairs covered like head scurf (intermediate)
3. - Hire people with no hair or bald people (extreme)
4. - Ask everyone to shave head and beard like the army (extreme)

 

In the process/production area: 

• I will also do random check for hair as a physical hazard in the end product, product tables and equipment. If you find more hair in these areas, you may need to strengthen your prevention, if not, then you can go with a basic strategies of hair net or baseball caps. 

[Gelato Quality Lead]

 

Here are some strategies for prevention: 

1. - hair net, baseball caps, (normal)
2. - All hairs covered like head scurf (intermediate)
3. - Hire people with no hair or bald people (extreme)
4. - Ask everyone to shave head and beard like the army (extreme)

Eliminate the contamination once and for all