Title Page
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Document No.
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Audit Title
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Client / Site
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Conducted on
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Prepared by
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Location
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Personnel
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FeedSafe audit v9
0. Corrective Actions from the Audit
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Add Corrective Actions
1 Feed Hazard Risk Assessment
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1.1 Has a site food safety risk assessment been done
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1.2 Does the risk assessment use HACCP principles
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Feed safety elements
- regularly reviewed
- Uses HACCP principles
- identifies risks
- provides for the management of the risks
- has all elements, team, scope, product description, sensitive customers, process flow chart, hazard analysis, critical points, monitoring systems, corrective action for deviation, verification process,
- has verification of risk management
- flow charted
2 Premises and buildings
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2.1 Site plan available
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Site plan elements
- major buildings identified
- storage areas identified
- processing areas identified
- chemical storage identified
- hazardous goods identified
- pest control bait stations identified
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2.2 Does the site have suitable drainage
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2.3 Are roadways maintained in good condition
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2.4 Are grounds machinery and buildings cleaned regularly
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2.5 Any non-RAM products made on site if so are there seperate receival hoppers
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RAM & non-RAM elements
- separated receival hoppers
- written procedures for joint receival hoppers
- flushing procedures in place
- flushing procedures verified
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2.6 Is there a written cleaning procedure in place
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Cleaning procedure elements
- regular cleaning records
- aeeas assigned to staff
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2.7 Is site security sufficient to stop accidental or deliberate contamination
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Security elements
- unauthorised access to site
- access to chemicals controlled
- receival pits screen/covered secure and locked
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2.8 Are ther written procedures controlling both visitors and contractors entering the site
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2.9 Is there a written procedure to make all visitors aware of their potential impact on product safety, quality and the environment
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2.10 Is there a written and documented pest control program
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Pest control program elements
- regular bait station checking
- management review and adjustment of actions to pest activity levels
- covers rodents
- covers birds
- covers insects
- covers weeds
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2.11 Is waste and contaminated material regularly removed from site
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2.12 Is wate and contaminated material controlled
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Waste control elements
- waste containers clearly marked
- waste and process materials cannot be accidently mixed
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2.13 Can raw materials or finished goods be unloaded / loaded in the rain without significant water damage (mold growth?)
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2.14 Is ventillation adequate
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Ventillation elements
- steam air moisture (mold) accumulation controlled
- dust accumulation controlled
- airborne contaminats controlled
3 Personnel
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3.1 Are personnel suitable to the task
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3..2 Are employees provided with written duties
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Personnel elements
- qualified or experienced
- have written duties
- have a job descrition
- have work procedure and/or work instructions
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3.3 Are employees trained in GMP as it relates to their duties
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Documented in employee records
- qualified or experienced
- have written duties
- have a job descrition
- have work procedure and/or work instructions
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3.4 Is there a training program in place
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3.5 Are maintenance staff trained to identify equipment faults which impact upon product quality and safety
4 Plant and Equipment
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4.1 Is the design and construction appropriate to meet the requirements
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Pant and equipment elements
- Silo or bin clearly and uniquely identified
- drivers record bin/silo deliverd
- when customer changes bin delivery this is recorded
- Spillages are reported back to base and steps taken to rectify
- truck compartments inspected for completion of unloading
- system in place to coordinate delivery vehicles in a biosecurity breach or disease outbreak
- Customer quarantine and biosecurity measures known and adhered to by drivers and mill staff
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4.2 Is the equipment designed and maintained to prevent contamination during the manufacturing process
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Equipment design elements
- sound condition
- minimal leaks
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4.3 is ther appropriate dust extraction on equipment
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4.4 Is equipment designed and installed to allow for routine cleaning, mainteance and inspection.
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4.5 Is a preventative mainteance program in use
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Preventative Maitenance elements
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4.6 Are monitoring and/or controlling devices monitored for accuracy and recalibrated when required
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Monitoring devices elements
- includes weight scales
- includes trade certified measurement
- includes high temp probes
- includes low temp probes
- includes flow meters
- includes gas meters
- includes lifting chains
- includes calibration accuracy
- includes calibration frequency
- includes records of external calibration
- includes records of internal calibration
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4.7 Do appropriately trained personnel carry out the maintenance and calibration of equipment
5 Raw Materials sourcing and pricing
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5.1 Is there as documented purchasing program for the purchasing of raw materials and packaging
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Purchasing program elements
- Uses raw material purchasing standards
- reflects treatment and/or withholding periods
- Suppliers aware of the standards
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5.2 Is every load of incoming material cross referenced to purchasing documentation
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5.3 Does the site maintain a register of compliant raw material suppliers
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Register elements
- suppliers list linked to QA program
- provision of vendor declarations
- DIFOT monitored
- agreement to specification monitored
6 Raw Material receivals
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6.1 Is every load of incoming raw materials cross referenced to purchasing documentation
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6.2 Is a record of origin, date of receipt, quantities of each raw material kept on file
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6.3 Does the site have a written raw material quality control program
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Raw Material QC program elements
- sampled
- tested
- confirmed against specifications
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6.3.1 Are suitably trained or experienced staff assigned to raw material receivals
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6.3.1 RM receivals elements
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6.3.2 Are the recieval tests appropriate
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6.3.2 Receival test elements
- grains
- soft meals
- processed goods
- pacaking materials
- Micro ingredients
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6.3.3 Are retentions samples taken and kept for at least three months
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6.3.3. Retention sample elements
- HACCP linked
- supplier history linked
- greater than 3 months
- externally tested (composite)
- externally tested ( individually)
- retention samples ID includes date
- retention samples ID includes material ID
- retention samples ID includes weighbridge number
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6.3.4 All packaged raw materials are adequately labelled
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6.3.4 labelling elements
- feeding ban ( RAM statement)
- non- RAM statemnt
- Identitiy clear
- supplier ID clear
- shelf life stated
- packaging appropriate to contents
- medicatins clearly identified
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6.3.5 are labelling and packaging materials assessed for quality before use
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6.4 Are raw materials found to be outside specification clearly identified and appropriately dealt with by authorised personnel
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6.3.5.1. Are labels stored securely with use adequately controlled
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6.3.5.2. Are bags stored securely with use adequately controlled
7 Raw Material Storage
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7.1 Are storage areas designed and maintained to prevent damage to, contamination, unintended mixing, or spoilage of ingredients or packaging materials
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7.2 Are storage bins, silos, tanks, and storage areas clearly identifed
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7.2 Storage ID elements
- Clearly Identifed
- unique ID
- written documentation of contents of each sorage vessel within the facility
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7.3 Is there an inspection and maintenance programme for storage silos, bins, tanks, which prevents raw material quality being compromised
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7.3 Storage vessel elements
- Documented
- vessels emptied and inspected
- regular inspection pattern
- spot shecks at stock take
- inspection pattern includes daily checks
- inspection pattern includes monthly checks
- inspection pattern quarterly
- inspection pattern 6 monthly
- inspection pattern annually
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7.4 Are all packaged raw materials stored adequately allowing separation of different raw materials
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7.4 raw material storage elements
- multi level racking in place
- first in first out stock rotation
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7.5 Are storage areas clean and tidy and have steps been taken to minimise vermin and bird presence
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7.5 Storage areas elements
- clean
- tidy
- gaps between pallets and walls for vermin deterrent
- bird deterrents in place
- RAM in a designated area
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7.6 are feed additive ( and medications) clearly identified and stored in accordance with labels ( or regulations)
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7.6 feed additive and medication storage elements
- temperature matched
- humidity matched
- secure area
- cross contamination controls in place
- dispensing area handling tailored to materials
- S4 and medications kept in locked secure area
8 Products / agents on site not used in feed storage, handling or use
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8.1 Are hazardous materials such as pest control baits, boiler chemicals, fuel, cleaning agents stored securely away from ingredient handling areas to prevent mistaken use
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8.1 Non Manufacturing chemical materials elements
- Stored close to intended use
- stored securely
- labelled and or clearly dentifed
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8.2 Are Pest control chemicals controlled
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8.2 pest control elements
- use controlled
- secure storage are
- record of cleaning agents used on site
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8.3 Are cleaning agents controlled
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8.3 cleaning agents control elements
- use controlled
- secure storage are
- record of cleaning agents used on site
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8.4 Is there any form of inventory controll system for non-manufacturing chemicals
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8.5 Are all non-ingredient materials managed to ensure they are not mistakenly incorporated into product
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8.5 non-ingredient chemical elements
9 Formulation and manufacturing instructions
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9.1 Is there a written formulation master file
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9.1 Master file elements
- record of dates of use
- version controlled
- maintained by an authorised person
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9.2 Do the formulas meet the needs for audit trails
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9.2 Formula elements
- name of product
- unique identity code
- animal type to be fed
- precise quantity of each raw material
- location raw material drawn from
- identifies RAM products from non-RAM products
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9.3 Formulation changes done by and authorised person and these are documetned
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9.4 is there a written procedure to prevent cross contamination of feeds with incompatible feed ingredients that is verified through inspection, sampling and testing
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9.5 Are precautions taken to prevent cross contamination of finshed mixes/products
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9.5 cross contamination elements
- flushing in place
- sequencing used
- cleaning at key changeover points
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9.6 Is there a procedure for the labelling, storage, and handling of reworkes and returns
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9.6 rework elements
- status labelling applied
- identity labelling applied ( e.g NCR number)
- bag reworks sealed
- seperated storage
- when classifed waste this is clearly identified
- RAM and Non-RAM separated
- target for reprocessing into like product ( food safety wise)
- reformulated by authorised person
- rework and return policy, procedure or task instruction documented
10 Production
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10.1 Are there written work instructions for the critical manufacturing process jobs
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10.1 Work instruction elements
- connects to CCP in HACCP
- instruction or records when process departs from defined procedure
- Work instructions and manufacturing procedures regularly reviewed
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10.2 Are veterinary chemical products in use registered by the APVMA and dispensed according to veterinary prescription
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10.3 Are veterinary prescriptions kept on file
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10.3 Vet script elements
- no more then 6 months cover
- veterinary license stated
- dosage stated
- start date stated
- archived for one year once lapsed
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10.4 are batching records kept to show product made to formulation
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10.5 Are there specified material weighing tolerances and are these monitored
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10.6 Are there records to confirm the mixer has been tersted for mixing efficiency in the past 12 months
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10.7 Are production records kept for at least 12 months
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10.8 Are out loading and packaging systems including Silos, bins and tanks designed and operated to maintain separation of finished product
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10.8 Bins and Silos elements
- Identified with unique ID or numbering
- clear identification of what is stored in tanks, silos or bins
- silos and bins cleaned and maintained to keep quality integrity
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10.9 Are clearly labelled finished product samples taken and retained for at least three months
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10.10 Is te person doing the production supervisor and/or manager's role appropriately trained
11 Labelling of Bagged Product
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11.1 Are bagged finished goods correctly packaged and labelled at the time of manufacture
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11.1 Bagged goods elements
- bag used identified
- bags properly sealed
- where appliable, label is secured without damage to regulatory controlled statements
- labels clear in print quality
- Date of manufacture stated
- shelf life stated
- batch coded
- if applicable RAM and non-RAM statement evident
- bags check weighed
- label if used identified
- if needed flushing procedure in place
- in process routine QC/QA tests done
- if used label numbers are reconciled
- bags numbers are reconciled
- bagging are free of foriegn bags or other jobs
- Directions for use evident on bag or label
- if present medications and dosage identified
- if present regulated key trace elements and amounts identified
12 Labelling of Bulk Product
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12.1 Does the bulk delivery docket/invoice documents meet regulatory requirements
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12.1 Bulk goods elements
- bag used identified
- bags properly sealed
- where appliable, label is secured without damage to regulatory controlled statements
- labels clear in print quality
- Date of manufacture stated
- shelf life stated
- batch coded
- if applicable RAM and non-RAM statement evident
- bags check weighed
- label if used identified
- if needed flushing procedure in place
- in process routine QC/QA tests done
- if used label numbers are reconciled
- bags numbers are reconciled
- bagging are free of foriegn bags or other jobs
- Directions for use evident on bag or label
- if present medications and dosage identified
- if present regulated key trace elements and amounts identified
13 Loading, transport and delivery
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13.1 are there loading and delivery procedure for loading bulk and bagged products which ensures loading the delivery vehicles with the correct product without risk of damage, unintended mixing, or contamination
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13.2 Is there a formal system of allocating finished product orders to outloading bins and delivery vehicles
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13.2 delivery vehicle loading elements
- Outloading bins clearly identified
- transport vehicles and compartments clearly identified
- inspected for residue if carried different products previously
- cleaned aand/or flushed and this is recorded if swapping from RAM to non-RAM or other incompatible products in bins or tanks
- external carrier previous load carried ( and if needed cleaaning) confirmed
- Pallets are checked prior to use to ensure they are in good condition and checking recorded
- Broken, damaged, part filled finished products dealt with to ensure not delivered nor can cross or be cross contaminated
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13.3 Are delivery vehicles kept in a clean well maintained roadworthy condition, designed so feeds are kept dry and protected from contamination
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13.3 Delivery bvehicle elements
- Loads covered during delivery
- drivers documents identify products, bin allocation, precise delivery address, site delivery bin to be placed
- If feed contaminated due to an incident/accident, there is a system for reporting, determining follow up actions for delivery, return or disposal
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13.4 Feed delivery, clients reminded of responsibility to provide safe and unobstructed facilities
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13.4 Feed delivery elements
- Silo or bin clearly and uniquely identified
- drivers record bin/silo deliverd
- when customer changes bin delivery this is recorded
- Spillages are reported back to base and steps taken to rectify
- truck compartments inspected for completion of unloading
- system in place to coordinate delivery vehicles in a biosecurity breach or disease outbreak
- Customer quarantine and biosecurity measures known and adhered to by drivers and mill staff
14 Inspection Sampling and Testing
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14.1 Are key staff aware of requirement to allow unhindered access to state authorities for sampling and auditing to TSE ruminant feed ban
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14.2 Is sampling of finished product conducted so that samples are sealed, separated and retained for easy retrieval and in appropriate conditions
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14.3 Is sample testing adequate
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14.3 Sample testing elements
- on site with appropriately trained and equipped staff
- off site from reputable (e.g.NATA) laboratory and certified practitioner
- inspection results assessed against documented tolerances or standards
- outside of specification tolerances has method and responsibilities in place for investigations and corrective actions
15 Records
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15.1 Are records kept to allow finished product trace back of r12 months or more
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15.1 Record elements
- includes raw materials source and storage
- includes production batching
- includes product quality test results
- includes delivery details
- includes verified flushing and sequencing
16 Customer Complaint Investigation
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16.1 Is there a customer complaint procedure for registering and investigating problems
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16.2 Is there a record of timely resolution of complaints with appropriate corrective and preventative actions
17 Product recall system
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17.1 Is there a recall committee with clearly defined memebers and documented responsibilites
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17.2 Is there a written product recall procedure and is this linked to tte customer complaint procedure
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17.3 Does the recall procedure call for; prompt retrieval from the market place, notification of relevant government authorities, minimisation of disruption ot end users.
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17.4 does the recall procedure apply in other cisrumstances like out of specification products
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17.5 Does the recall procedure specify methods to identify, locate, and return/isolate/control recalled product
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17.6 Does the recall procedure include emergency out of hours contact person/people
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17.7 Is the recall system periodically reviewed/tested for effectiveness
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17.8 Is each recall incident documented and reviewed to ensure procedure was adequate with a review of manufacturing practices to ensure they prevent reoccurrance
Other Observations or Comments
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Observation / Comment
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