Preparing sugar pastry is a fundamental skill in food and beverage operations, especially within Kenya’s vibrant hospitality and catering sectors. Mastery of sugar pastry preparation not only enhances product quality but also ensures customer satisfaction and compliance with food safety standards. This chapter focuses on the hygiene practices essential to producing safe, high-quality sugar pastries that meet both local and international standards. Emphasizing hygiene is critical due to the susceptibility of pastries to contamination and spoilage in Kenyan commercial kitchens and bakeries.

2.1 Hygiene practices

Hygiene in sugar pastry preparation protects the customer, the product and the business. Sugar pastry is rich in butter, eggs and sugar, and it is often filled with custards, fruit, frangipane or lemon curd, which are ideal foods for bacteria if they are handled carelessly. Good hygiene covers three areas: the food handler (personal hygiene), the kitchen and its equipment (environmental hygiene) and the food itself (food hygiene, controlled through HACCP). Kenyan food premises must also meet the Public Health Act and the Food, Drugs and Chemical Substances Act, and are inspected by county public health officers. Example: the pastry section of a beach hotel in Kilifi checks every cook's uniform, hands and work station at the start of each shift before any tart cases are rolled.

2.1.1 Personal hygiene

Personal hygiene is the cleanliness, health and conduct of the people who prepare sugar pastry. Hands touch the dough during rubbing in, kneading and lining of flan rings, so anything on the hands or clothing can end up in the product. Staff turnover in many kitchens is high, so every new member of staff must be trained before handling food. Example: a family bakery in Karatina gives each new baker a one-page hygiene card and checks it with them on their first day.

Hygiene and appearance standards

• Hand washing: Hands are washed with soap and warm running water for at least 20 seconds before starting work, after handling raw eggs, after using the toilet, after handling waste and after touching the face or hair. Hands are dried with paper towels, not aprons.
• Clean uniform: A clean chef's jacket, apron, trousers and closed non-slip shoes are worn and changed daily. Uniforms are not worn outside the kitchen, so dust and germs from outside do not reach the pastry area.
• Hair control: Hair is tied back and covered completely with a hair net or chef's cap. Beards are covered with a beard net.
• Nails and jewellery: Nails are short and clean with no polish or artificial nails. Rings, bracelets and watches are removed, since they trap dough and dirt and can fall into the mixture.
• Health and wounds: Staff with diarrhoea, vomiting, fever, a sore throat or skin infections report to the supervisor and stay away from food. Cuts are covered with a blue waterproof dressing that can be seen if it falls into the dough.

Behavioural hygiene practices

• Avoiding touching the face or hair: Touching the face, nose or hair while working transfers bacteria such as Staphylococcus aureus to the hands and then to the pastry.
• No smoking, eating or chewing: Smoking, eating, chewing gum and spitting are not allowed in the preparation area. Breaks are taken in a separate staff area.
• Coughing and sneezing: Staff turn away from food, cover the mouth with a tissue and wash their hands at once.
• Tasting correctly: Fillings and creams are tasted with a clean spoon that is then sent for washing, never with fingers or the mixing spoon.
• Use of disposable gloves: Gloves are worn when handling finished, ready-to-eat items such as glazed fruit flans, and are changed between tasks. Gloves do not replace hand washing.

2.1.2 Environmental hygiene

Environmental hygiene is keeping the premises, work surfaces, equipment and surroundings clean and free from pests, so that the pastry is not contaminated by its surroundings. Sugar pastry work leaves flour dust, butter smears, egg spills and sugar on surfaces, all of which attract insects and rodents if not removed. Example: a mission hospital kitchen in Kapsabet runs a written daily, weekly and monthly cleaning schedule for its bakery corner, signed by the supervisor.

Pest control

• Proofing the building: Gaps around doors, pipes and drains are sealed and windows have insect screens so that rodents, cockroaches and flies cannot get in.
• Storage of dry goods: Flour, sugar and ground almonds are kept in lidded containers raised off the floor, since open sacks attract weevils and rats.
• Monitoring: Staff look for droppings, gnawed packaging and live insects every day, and a licensed pest control contractor inspects and treats the premises at set intervals.
• Electric fly killers: These are mounted away from work tables so that dead insects do not fall onto food.

Ventilation and temperature control

• Adequate ventilation: Extractor hoods and fans remove heat, steam and flour dust. Good airflow stops condensation dripping from ceilings onto work tables.
• Room temperature: A cool pastry area keeps butter firm and slows bacterial growth. Perishable fillings and creams are kept in the refrigerator until needed.
• Lighting: Bright lighting lets staff see dirt, spills and foreign objects during work and cleaning.

2.1.2.1 Cleaning procedures for work surfaces and equipment

Cleaning procedures are the set steps followed to remove dough, fat, egg and sugar residues from tables, mixers, rolling pins, flan rings, baking sheets and utensils, and then to kill the bacteria left behind. Surfaces are cleaned as you go, between tasks and at the end of every shift. Example: a resort pastry kitchen in Ukunda scrapes and wipes its marble rolling table after every batch of sweet paste and sanitises it before the next.

1. Prepare: Switch off and unplug electrical equipment such as mixers before cleaning, and dismantle removable parts such as the beater, bowl and guard.
2. Pre-clean: Scrape off dough, flour and burnt sugar with a plastic scraper or dry brush, and empty crumbs into the waste bin.
3. Wash: Wash with hot water (about 50 degrees Celsius) and detergent to dissolve fat and egg residues, using a cloth, sponge or brush.
4. Rinse: Rinse with clean hot water to remove detergent and loosened soil.
5. Sanitise: Apply a food-safe sanitiser at the strength on the label, or use very hot water of about 82 degrees Celsius, and leave it for the contact time stated.
6. Dry: Air dry on racks or wipe with a clean disposable cloth. Metal flan rings and baking sheets are dried completely to prevent rust.
7. Store and record: Reassemble equipment, store it covered and off the floor, and sign the cleaning schedule.

2.1.2.2 Cleaning materials for work surfaces and equipment

Cleaning materials are the chemicals and tools used to carry out the cleaning procedure. The right material depends on the surface and the soil: fat and egg need a detergent, burnt sugar needs soaking, and bacteria need a sanitiser. Example: a training restaurant at a technical college in Eldama Ravine labels each chemical with its use and dilution and keeps them in a locked cupboard away from the pastry stores.

• Detergents: Remove grease, fat and food soil. A liquid detergent is used for hand washing of bowls and utensils and a machine detergent in the dishwasher.
• Sanitisers: Reduce bacteria to a safe level on clean surfaces. Chlorine based and quaternary ammonium sanitisers are common, mixed exactly to the label.
• Sanitiser-detergents (two in one): Clean and sanitise in one product for quick cleaning as you go, though heavily soiled items still need washing first.
• Descalers: Remove limescale from kettles, dishwashers and steam ovens where hard water is used.
• Cleaning tools: Plastic scrapers, nylon brushes, colour-coded cloths and sponges, mops, buckets and squeegees. Steel wool is not used on stainless steel because it scratches it and leaves fragments.
• Personal protective equipment: Rubber gloves, aprons and goggles protect staff when mixing and using chemicals.

2.1.2.3 Waste disposal

Waste disposal is the safe collection, separation, storage and removal of waste from the pastry kitchen. Poorly managed waste attracts flies and rats, produces smells and contaminates food. Waste is put in covered, foot-operated bins, which are emptied at least at the end of each shift and washed regularly.

Types of waste

• Food waste: Dough trimmings that cannot be reused, failed or burnt products, egg shells, fruit peels and cores from apple and pear preparation.
• Packaging waste: Flour and sugar sacks, cardboard boxes, butter wrappers, egg trays and plastic wrap.
• Liquid waste: Waste water from washing, and used cooking fat or oil, which must never be poured down the drain.
• Hazardous waste: Empty chemical containers and used pest control materials.
• Sharp and broken waste: Broken glass, chipped crockery and damaged metal flan rings.

Methods of waste disposal

• Segregation at source: Waste is separated into colour-coded bins for food, recyclables and general waste at the point where it is produced.
• Composting: Fruit peels, egg shells and other vegetable waste are composted for gardens or farms.
• Recycling and reuse: Cardboard, plastic and glass are sold or given to licensed recyclers, and clean egg trays may be returned to suppliers.
• Animal feed: Some food waste is collected by licensed pig farmers where county rules allow it.
• Collection by licensed handlers: General and hazardous waste is collected by the county or a licensed waste company. Used fat is stored in sealed drums for collection.
• Grease traps: Drains are fitted with grease traps that are emptied regularly so fat does not block sewers.

2.1.3 Food hygiene

Food hygiene is the handling, storage and preparation of ingredients and finished pastry so that they stay safe to eat. Sugar pastry products include high risk items such as custards, cream, lemon curd and meringue made with eggs, so temperature control and separation from raw foods are vital. Example: a day school kitchen in Othaya that bakes jam tarts for its pupils keeps eggs in the refrigerator and uses them within their date.

Safe handling of ingredients

• Approved suppliers: Flour, sugar, butter, eggs and fruit are bought from reliable suppliers who meet Kenyan food safety standards.
• Receiving checks: Deliveries are checked for damage, date marks, temperature of chilled items and signs of pests. Cracked or dirty eggs are rejected.
• Correct storage: Flour and sugar are kept in clean, dry, labelled, lidded containers. Butter, eggs and dairy are refrigerated at 1 to 5 degrees Celsius.
• Clean utensils: Ingredients are scooped with clean scoops, never with hands or cups that are then left in the bin.

Control of foodborne pathogens

• Temperature control: Perishable fillings are kept at 5 degrees Celsius or below. Custards and curds are cooked thoroughly and cooled quickly before chilling.
• Separating raw and ready-to-eat food: Raw eggs and their shells are kept away from baked cases and finished tarts to prevent Salmonella reaching them.
• Potable water: Only safe drinking water is used in dough and for washing fruit.
• Washing fruit: Apples, pears, bananas and lemons are washed in clean water before peeling or zesting.

Hygiene in final product handling

• Cooling: Baked pastries are cooled on clean wire racks in a clean area, then covered.
• Minimal contact: Finished products are handled with tongs, palette knives or gloved hands.
• Shelf life awareness: Products are dated and sold or served within their shelf life. Out of date items are discarded, not reworked.

2.1.3.1 HACCP

HACCP is the food safety management system that a pastry kitchen uses to prevent hazards rather than discover them after a customer falls ill. It is required for many hotel, airline and institutional kitchens and supports KEBS food safety certification. Example: a dairy cooperative's bakery in Ol Kalou keeps HACCP records for every batch of custard filled tarts it supplies to local shops.

Definition

HACCP stands for Hazard Analysis and Critical Control Points. It is a systematic, preventive approach to food safety that identifies the biological, chemical and physical hazards in each step of production, finds the points where they can be controlled, and sets limits, monitoring, corrective actions and records for each point. In sugar pastry, biological hazards include Salmonella from eggs and bacteria growing in fillings; chemical hazards include cleaning chemicals and allergens such as nuts, gluten and eggs; physical hazards include eggshell, glass, metal and hair.

Identification of critical control points

A critical control point (CCP) is a step at which control can be applied and is essential to prevent, remove or reduce a hazard to a safe level. CCPs are found by drawing a flow diagram of the process and asking, at each step, whether a hazard exists and whether this step is the last chance to control it.

1. Describe the product and process: Write down the product (for example lemon tart), its ingredients and how it is stored and served.
2. Draw the flow diagram: List every step in order: purchase, receiving, storage, weighing, mixing, chilling, rolling, baking blind, filling, baking, cooling, storage and service.
3. List hazards at each step: Note what could go wrong, such as eggs contaminated with Salmonella, a filling left warm, or glass from a broken jar.
4. Apply the decision questions: Ask whether a control exists, whether the step removes or reduces the hazard, whether contamination could rise to an unsafe level, and whether a later step will remove it.
5. Confirm the CCPs: Steps where the answers show the hazard is controlled only there become CCPs.
6. Set limits and monitoring: Give each CCP a measurable limit and a check, then record it.

Typical CCPs in sugar pastry production:

• Receiving: Chilled butter, cream and eggs arrive at 5 degrees Celsius or below, in date and undamaged.
• Cold storage: Refrigerators held at 1 to 5 degrees Celsius, checked and recorded twice a day.
• Cooking of fillings: Custards, curds and frangipane cooked or baked to a core temperature of at least 75 degrees Celsius.
• Cooling: Cooked fillings cooled from 63 to below 5 degrees Celsius within 90 minutes.
• Cold holding and display: Filled tarts and lemon meringue pie kept at 5 degrees Celsius or below until service.

Chapter Summary

This chapter covered essential hygiene practices necessary for preparing sugar pastry, emphasizing both personal hygiene and maintaining a clean working environment. It detailed the proper cleaning procedures and materials required for work surfaces and equipment, along with effective waste disposal methods to prevent contamination. Food hygiene was addressed with a focus on identifying and managing critical control points through HACCP to ensure product safety. The sugar pastry making process was explained step-by-step, highlighting the techniques needed to achieve quality results. Different types of flan cases were described, illustrating their role in forming sugar pastry products. Various sugar pastry products were then explored, showcasing their characteristics and uses. Finally, the chapter concluded with guidance on appropriate packaging and storage practices to preserve freshness and maintain hygiene standards.