Process Controls: CFMSR V2 25.2 – 25.4 Process Deviation; Trend Analysis

  • A control must be in place to identify and segregate production and maintenance equipment between High areas and Base / Medium areas. Eg, different colour codes for pasteurised / unpasteurised, allergen/non‐allergen, organic/non‐organic, waste etc. Applicable only to sites with High areas.

  • If the process deviates from specification / procedure corrective actions must be taken and documented.
    If the deviation could cause a legal, quality, or food safety issue, then the State Regulatory Authority and Private Label QA Contact (Coles Product Technologist / WW Category Brand Manager) must be notified.
    A trend analysis system is used for monitoring process deviation, to enable a reduction in non conformances and business / product improvement.
    Best Practice is to conduct Trend Analysis for monthly review and report to Management Review.

Control of Non Conforming Product: BRC V8 3.8.1; Approved Arrangement 5.6.10; CFMSR V2 25.5 Hold and release; CFMSR V2 8.12 (non conforming raw materials); CFMSR V2 25.6 Notifying Brand Owner; WSEP V2 6.6 Investigation of Cause CFMSR V2 25.5.3 Product Control; WW COP Own Brand Requirements 4.1 Product Release; WSEP V2 6.13 Stock Rotation; WW V2 COP Own Brand Section 5 Woolworths Quality Team Notification

  • A documented ‘Hold and Release’ procedure must be in place to manage non‐conforming raw materials, packaging or products. As a minimum, this must include procedures to include:
    • The requirement for staff to identify and report a potentially non-conforming raw material, packaging or product
    • The nature of the incident and the time / date material or product was placed hold / quarantined
    • Clear identification of non-conforming ingredients, packaging, rework, WIP, finished products etc involved (e.g. direct labelling or the use of IT systems)
    • Affected product isolated, segregated, labelled and rejected in secure storage to prevent accidental release (e.g. physical or computer-based isolation). A defined Hold area must be identified both in raw material/packaging storage and finished product areas.
    • Referral to the brand owner where required
    • Defined responsibilities for decision-making on the use or disposal of products appropriate to the issue (e.g. destruction, rework, or acceptance by concession)
    • Records of the decision on the use or disposal of the product
    • Records of destruction where a product is destroyed for food safety reasons.
    Investigation of root cause must be conducted and corrective action to address issue/s found.
    Raw materials, finished goods and packaging shall be assessed by QA prior to removing their hold status.
    Records of non-conforming product must be maintained and include:
    ● Reason for non-conformance
    ● Investigation to the source of the issue
    ● Corrective actions
    ● Final disposition (re-work, donation to charity, destroyed etc)

    Review the following national procedures and ensure the site complies;
    QA-009-01 QA Product Release Criteria -Micro Specs
    QA-010 Pathogen & Allergen Detection Limits & Notification Requirements
    QA-011 QA Core Sampling/Testing Plan
    MO-018-01 Incoming Goods Procedure

  • WW V2 COP Own Brand Section 5 Woolworths Quality Team Notification - Non conformance to any criteria defined in the Woolworths product specification must be communicated formally to Woolworths QA Team in writing, with a proposed action plan. Issues related to products supplied to Woolworths which may lead to a product withdrawal/recall must be reported within 60 minutes of the decision to withdraw/recall. Also issues/events identified regarding product safety, quality or regulatory compliance that have the potential to impact Woolworths’ products or other suppliers of Woolworths own brand products, e.g. allergen contamination of raw materials.
    At least once per annum, the Supplier’s mock recall procedure must be undertaken on a product supplied to Woolworths. Records of the Woolworths Branded Product mock recall must be maintained.

  • Relevant Private Label Brand contacts (Coles PT, WW CBM), and regulatory authorities must be notified immediately of any illegal and / or unsafe products which have been despatched. (WW COP Own Brand Requirements 4.1 Product Release)
    This is a corporate function in Parmalat. The site notifies the National Quality Manager first, who is the contact point between the business and Major Customers (Coles / Woolworths/Aldi).

  • A stock rotation policy must be documented and implemented for raw materials, work in progress and finished product.
    Raw materials are to be used within the allocated shelf life.

  • CFMSR V2 35.14 Action / Investigation - Action and investigation must be evident where results fail to meet specified limits and reported to Coles CBM / PT within the agreed time frames.

    Ongoing trend analysis must be in place for all testing results.

    A Certificate of Product and Public Liability Insurance must be available and reflect $A10 million insurance coverage. This is displayed on the Parmalat Australia website - Info Centre\Policies & Accreditation\Certificates & Accreditations\ Insurance Certificates.

  • CFMSR V2 35.15
    Trend Analysis BRC V8 5.6.1.2 - Ongoing trend analysis must be in place for all testing results.

Batch Specific Retention samples WW COP Own Brand Requirements 3.4 Retention Samples; CFMSR V2 25.8, 35.11 Shelf Life Retention

  • Batch Specific Retention samples of each formulation or flavour variant, shall be retained for the duration of shelf life and assessed before discarding.
    WW require 3 samples per run (start, middle and end of run) for retention samples and samples are to be held for an extra day after the coded shelf life.
    For Coles - Samples are from each type / size / volume / weight of retail and bulk packaging in which the product is sold. Eg;
    • Skim 600ml, Skim 1L, Skim 2L (three packaging variants, even though the content is the same product).
    The procedures must document the frequency of testing conducted, and analysis to be done (e.g. organoleptic, microbiological, etc.).
    Retention samples shall be held at + 4°C +/- 1°C for chilled products

    A risk assessment shall be conducted to assess the potential contamination hazard from the storage and disposal of sample product.
    A risk assessment must be undertaken based on product safety, risk and volume of product supplied to determine the number of product samples to be retained per production run. This must be documented in the product specification. This must be reviewed at least annually or when a change in safety, risk or significant volume occurs.
    Product assessment is to be carried out during and at the end of the shelf life and documented records of all checks must be maintained.
    • Woolworths may request retention samples to be submitted to assist with an investigation of potential food safety or quality issues.

Shelf Life Validation and Verification: BRC V8 5.6.1.3; CFMSR V2 25.9; WW COP Own Brand Requirements 1.3; WW COP Own Brand Requirements 3.2.4, 3.2.5

  • Verification of Shelf Life Samples;
    Check the shelf life schedule is up to date and correct tests, days tested and storage temperature are being done. – Quality Assurance National \ Laboratories \ National \ Shelf Life \ 2019.
    REVIEW:
    QA-013 Shelf Life Protocol – Microbiological, Chemical and Sensory
    QA-013-01 Shelf Life Validation and Approval Process.
    Address any queries to Irena Gorsky.
    The sample retention period and storage conditions must be agreed with the Private Label QA contacts(Coles PT / WW CBM / Aldi).
    Shelf Life validation of finished products shall occur on all new products and whenever the formulation, unit size, or packaging material is altered, or a significant change to the process has occurred. When conducting shelf life validation, include challenge testing of product - elevated temperatures and transport.
    Product assessment is to be carried out during and at the end of the shelf life and documented records of all checks must be maintained.
    Woolworths may request retention samples to be submitted to assist with an investigation of potential food safety or quality issues.
    If no alterations have been made, shelf life validation and product labelling verification (NIP testing) shall be conducted at least annually by a 3rd party independent laboratory, NATA accredited.
    Check the NIP Schedule for your site (Quality Assurance National\ Laboratories\ Your Site \ NIP folder).
    Review QA-016 Nutritional Testing for NIP procedure
    Any queries are to be addressed to Jeff Lyndon.

Product Control: CFMSR V2 25.11 – 25.15

  • Transfer of raw materials and packaging must use double bagging method with effective outer packaging removal procedures in place. The process must be validated, verified, and monitored.
    Materials with special handling requirements e.g. organic & allergens must be segregated during storage and processing. Allergens are to be stored below non allergens.
    Where re‐work is permitted, it must be traceable. A break in the re‐work usage must occur at a defined frequency. Re-work must be clearly labelled with process by dates, time, and product details.
    A re‐work shelf life must be established.
    The use of re‐work in Coles products requires approval from Coles PT and must be detailed in the Coles specification.

  • SPECIFICATIONS CFMSR V2 29.1 – 29.6 Coles Agreed Specifications; WSEP V2 5.1 – 5.3 Internal Specifications; SQF Ed 8 2.3.5
    All Private Label specifications shall be current, accurate, (accessible in WW PLMS or Coles Fusion) and available on day of audit.
    Supporting validation data for product specification information must be maintained. For example; Nutrition Information Panel (NIP) test results, shelf life test results, raw material specifications, packing material specifications, etc.
    Validations and testing must meet the agreed specifications.

    Best Practice is to print out all Private label specs from PLMS (Woolworths), Coles Fusion or Aldi for products produced on site and review at least every 12 months – including required final product tests. For Coles and Woolworths products, check Parmalat controlled specs against Coles Fusion specs and Woolworths PLMS.
    WW specs must meet Woolworths Brand Guideline criteria and be Active within a month post launch.
    All spec enquiries to Adriana Hincapie during an external audit
    Check Parmalat Internal specification meets External specification requirements.

Private Label - Rejected Product, Obsolete Packaging and Donations: CFMSR V2 29.7, 29.9, 29.10 Sale/Gift of Private Branded Products; Excess/Obsolete Packaging/Labels CFMSR V2 29.11 Donation of Coles Product

  • Any rejected private labelled product must be securely disposed of through an authorised route or the packaging removed with records of destruction retained.
    Private Label branded products shall not be sold or given to staff.
    Review MO-042 Managing Private Label Requirements.
    Obsolete Private Label packaging or labels shall be securely disposed with records maintained.
    The Private Label Category Manger (Coles PT, WW CBM) shall be contacted to determine the method of disposal.
    Donations to charity of Coles Brand products may be made where there is no food safety issue (e.g. underweight product). Written authorisation must be obtained from the relevant CBM / PT prior to the donation.
    A log must be maintained which clearly records the date of the donation, product details, batch numbers, Use‐By / Best Before dates, quantities, reason for donation, and maintain a copy of the written approval.
    Coles approved food collection charities are SecondBite and Foodbank. Donations to SecondBite or Foodbank approved by Coles and entered into the log do not need to have Coles branding removed or defaced. Donations to charities outside of SecondBite and Foodbank must have their Coles Brand packaging removed or the labelling defaced.

Product Claims: CFMSR V2 30.4 Product Claims; WW V2 COP Own Brand 1.2 Product Claims; CFMSR V2 30.7 Identity Preserved; CFMSR V2 30.6 Country of Origin Claims

  • The supplier shall develop controls that ensure all product claims are accurate, legal and can be verified.
    The status of the batch of raw material shall be verified where claims are made on finished packaging that describe:
    • A specific provenance origin
    • Assured status (e.g. organic)
    • Identity preserved
    • Named specific trademarked ingredients
    Where claims made relate to certification schemes (e.g. organic), proof of certifications shall be available.
    The process flow for the production of products where claims are made must be documented and potential areas for contamination or loss of identity identified.
    Appropriate controls must be established to ensure the integrity of the product claims.
    For any on pack Country of Origin claim, there must be an annual reconciliation of country of origin data to validate this claim. (Product of Australia).

Environmental Monitoring: CFMSR V2 35.1

  • Procedures shall be established to determine zones, frequencies, target organisms, and acceptable levels, for environmental monitoring.
    Target organisms shall include pathogens as well as spoilage organisms.
    Hygiene standards must be verified by equipment swabbing or exposure plates according to a risk assessment.
    ATP test kits are used to release key items of equipment post cleaning prior to use.
    Swabs and plates must be tested a maximum of 24 hours after sampling.
    Results of environmental monitoring activities shall be reviewed by a competent person and action levels shall be defined. Results are recorded, trended and mapped, with action evident for adverse trends.
    Corrective actions for results outside of acceptable levels shall be recorded. Where an adverse result is for a food contact surface, the corrective action must include actions related to products produced and in the marketplace.
    Procedures shall be in place for retesting of processes after corrective actions have taken place.
    Where monitoring has identified a presumptive pathogen (e.g. Listeria Species) on a food contact surface, supplier must immediately notify their Coles PT.
    The supplier must immediately update Coles with any further retesting results.
    Where a pathogen has been detected then root cause analysis shall be undertaken and the HACCP Plan reviewed to determine whether the hazard analysis and control measures are still appropriate.
    Review following procedures and ensure site compliance;
    QE-01 Factory Sampling Program and External Testing
    QA-004-01 National Pathogen Sampling program
    QA-006 Acupoint ® Advanced ATP Hygiene Monitoring System
    QA-006-01 Acupoint ® Advanced System – Data Management
    QA -009-01 QA Product Release Criteria – Microbiological Specifications
    QA-010 Pathogen and Allergen Detection Limits and Notifications
    QA-011 Quality Assurance Core Sampling/Testing Plan

Raw material Testing CFMSR V2 35.2: WW V2 COP Own Brand 3.3

  • Specs must be available for all raw material inputs and reviewed annually. The supplier shall conduct testing or analysis identified by the raw material and finished product risk assessment and the corresponding specifications will determine the testing and analysis required. Records of testing shall be maintained.
    Review QA 023 Raw Material Quality Control Management
    Raw material specs are found in W: under Supplier of raw material or Spec Management System\Raw Materials.

Finished Product Testing: CFMSR V2 35.4 Product Inspection: WW V2 COP Own Brand 3.3 Finished Product Verification and Testing; WW V2 COP Own Brand 3.2 Claim Integrity and Verification; CFMSR V2 35.5 Product Verification

  • Product microbiological testing must be completed to ensure compliance with Private label product specifications.
    A sampling plan must be in place and followed, to ensure requirements are met.
    Testing requirements are by product spec as well as QA-011 Quality Assurance Core Sampling/Testing Plan.
    A minimum ‘annual’ testing regime is required for all product attributes listed in the approved product specification in PLMS.
    WW V2 COP Own Brand 3.2 Claim Integrity and Verification - All claims must be validated and records of product assessments shall be maintained.
    Shelf Life, NIP and claim validation and verification is to be by each pack size. Product testing for label verification must be completed to ensure compliance with Private Label product specifications at minimum annually or as per the criteria and frequency stated in the approved specification.
    CFMSR V2 35.5 Product Verification - The following assessments / checks of final product to be done. At a minimum, these assessments / checks must be undertaken at the start and end of each product per variant or pack size run:
    • The packaging, labelling, and date‐coding
    • Weight, volume, or count
    • Matching top and bottom labels, or tub and lid sets etc.
    Review Parmalat National Procedure MO-038 Product Quality Checks at Fillers for Finished Product.

  • The following Woolworths specific requirements must be referenced in the Supplier’s documented Product Recall and Withdrawal Procedure:
    Woolworths Contacts (Business Manager, Quality Manager & National Operations Support) to initiate & approve Recall / Withdrawal Action; A/H Contact (Central Monitoring Station CMS) 1800 638 434 .
    Login and Password details to WOWlink website (www.wowlink.com.au).
    Online System (Australian WOWLINK USERS only): reference PWRM User Guide.
    Manual System (Optional): PWRM Manual Notification Form (use if online system is not available).
    NOTE: This is for your info only. Recall/Withdrawal procedure is a corporate function. All Woolworths contacts are kept in Quality Assurance National\Product Recall and Withdrawal\ Major Customer Contacts.

  • WW V2 COP Own Brand Section 4 Product Release - Sampling and Testing must comply to QA-011 QA Core Sampling and Testing Plan as well as the Private Label Specifications.

    Product should be released on the agreed criteria with the Major Customer (Specs).

Product Packaging: BRC V8 5.5.2, 5.5.3; WW COP Control & Verification of Packaging 3.1, 3.2; CFMSR V2 25.3 Production Equipment; CFMSR V2 25.19 Product Changeover

  • WW COP Control & Verification of Packaging 3.1, 3.2; CFMSR V2 25.3 Production Equipment - Each batch of packaging (primary/secondary) must be assessed for compliance to spec.
    On arrival to site, record each batch number on Incoming Goods Log MO-018-A and check packaging against Product Identification sheet.
    Packaging that comes into direct contact with food must comply with either FDA CFR Title 21 or EU Directive Commission Regulation EU2011/10. Evidence in the form of a Food Contact Certificate can be found in W: drive - supplier information to A certificate of conformance, or a certificate from the applicable regulatory authority must be maintained.
    Raw material and Primary Packaging must be stored in a secure and protected area with adequate signage indicating storage of similar packs.
    This applies to part packs of used packaging material.
    There must be only one set of packaging and labels present on each production line and this must be verified as correct before packing commences.
    A sample of each packaging label and code must be retained (including any change-over labels)
    Ensure coding for fresh milk is as per MO-009 Product Coding Standard.
    Crates for Work In Progress (WIP), or finished product, must not be placed directly on the floor.
    Packaging must not be used to store anything but the intended product.
    Check compliance to MO-038 Product Quality Checks at Fillers.

  • BRC V8 5.5.2, 5.5.3 Product Packaging - Product liners and bags purchased by the company for use in direct contact with ingredients, or work in process, shall be appropriately coloured (e.g. contrasting colour to the product) and resistant to tearing to prevent accidental contamination.
    The company shall have a procedure to manage obsolete packaging (including labels). This shall include:
    • mechanisms to prevent accidental use of obsolete packaging
    • control and disposal of obsolete packaging and obsolete printed materials (e.g. rendering trademarked
    Records of the packaging assessments / checks shall be maintained. These assessments are verification checks and are conducted by QA in addition to normal line checks.

  • BRC V8 5.5 Product Packaging; WSEP V2 5.4
    All packaging must have current specs available. Packaging for WW branded products must have WW written approval for use.
    There must be a Certificate of Conformance for all packaging used for product contact.

  • Crates or Trays used for Work In Progress (WIP), or finished product, must not be placed directly on the floor.
    Packaging must not be used to store anything but the intended product.

Packaging and Labelling Supplied to Line: CFMSR V2 36.1–36.3; BRC 6.2.1, 6.2.2 Packaging and Labelling Supplied to Line / Line Changeover; WSEP V2 COP Verification of Packaging, Labelling, & Coding 2.1.1, 3.2.3; SQF Ed 8 2.6.1.3; CFMSR V2 35.16 Packaging Integrity

  • Packaging and labels supplied to the production line must be controlled, checked, and recorded to ensure each is correct and for the right product.
    CFMSR V2 25.19 Product Changeover - There must be only one set of packaging and labels present on each production line and this must be verified as correct before packing commences.
    A sample of each packaging label and code must be retained (including any change-over labels)
    Ensure coding for fresh milk is as per MO-009 Product Coding Standard.

    Packed product shall be checked at start, during, end of run or change of packaging material, for correct labels, codes and packaging integrity.
    At start up and changeovers, documented line checks must be done –line must be clear of any product, packaging and labels not required for the next production run (including promotional packaging).
    Partially used packaging from production lines must be effectively protected and labelled/identified prior to being returned to storage.
    A method shall be defined and documented for the integrity of inspection and testing of finished product packaging seal and tamper seal (if used).
    Packaging integrity checks shall be undertaken on a frequency based on a risk assessment, and shall include samples at the beginning, middle and end of run at minimum.
    Packaging seal checks shall be undertaken by trained personnel and recorded.

Labelling and Code Line Checks: CFMSR V2 36.4 Control of Coding; CFMSR V2 36.6 – 36-14 Product Labelling and Code Line Checks ; WSEP V2 COP 2.1.1 Verification of Packaging, Labelling, & Coding; CFMSR V2 36.14 Reworking of Labelled, Coded Products; CFMSR V2 36.15 Control of Bar Codes

  • The correct document controlled coding schedule must be available on line with the date information.
    Coding schedules and promotional information must be cross‐checked by an authorised person prior to issue. The authorised person has been trained and assessed as competent.
    Labels used for special promotions must be highlighted on the coding schedule with start and end date of labelling clearly stated.
    A labelling and coding procedure must be in place including actions to be taken in the event of an error. Review MO-009 Coding Requirements.
    UHT, cultured products and Desserts coded as per specs.

    Check WW and Coles specs for format of code (eg DDMMYY)on products.
    All personnel conducting labelling and coding checks must be trained and assessed as competent against the procedure and refresher training must be provided/recorded annually.
    Records with actual copies of the label must be authorised and retained.
    Product labelling and coding checks must be completed and documented at start up (‘first off the line’), end of run, at minimum hourly intervals, in between and after line disruption (e.g. reel changes, fire‐alarm, breakdown, breaks).
    Parmalat has 15 minute packaging checks – Review MO-038 Product Quality Checks at Fillers to ensure site complies.

  • Coding checks must be completed for all runs including ‘top up’ runs, and records including physical labels / sleeves retained.
    A sample of the actual code printed on the packing from each check must be retained.
    Real time should be printed on product labels.
    Production date and time must always be the actual date and time of production. Parmalat changes the Julian code after midnight for traceability – the use-by date does not change as the product is part of the same batch in case of a recall/withdrawal.
    All off line printing must be controlled/checked. The material must be stored in a restricted access area until issued to production line.
    An ‘Issued to Line’ log must be kept. Unused coded packaging e.g. labels, cartons, must be accounted for, disposed of, and recorded.
    Procedures must be in place to control unlabelled or offline labelled product.

  • Re‐labelling of products due to printing faults or incorrect labelling must be done in a controlled manner.
    Records must be retained, including details of reasons for re‐labelling.
    Over‐labelling is not permitted.
    Barcodes on all packaging must be checked against Coles issued information before the packaging is used.

Obsolete Private Label Packaging and Labels: CFMSR V2 36.19 Obsolete Coles Brand Packaging and Label; WSEP COP V2 WW Own Brand Food Product 2.3.4

  • Obsolete Coles Brand packaging or labels shall be securely disposed and records must be maintained. The supplier shall contact Coles PT to determine the method of disposal.
    Suppliers of Woolworths branded products must have documented and implemented procedures to demonstrate:
    • Excess and/or obsolete packaging is securely disposed.
    • Product must not be supplied in superseded packaging.
    • Control of surplus packaging and packed product.
    • That excess finished product is not given to staff or sold through factory shops etc.
    Review MO-042 Managing Private label Requirements.

Weight, Volume and Count: CFMSR 37.1 – 37.4 Finished Product/ Weight/Vol/Count; BRC V8 6.3; WSEP V2 COP Weight, Volume and Count Section 2.1.1, 3.1.2; CFMSR V2 37.6 Training; BRC V8 7.1.5.

  • Sites must have a clear documented procedure for the management of weight, volume, and count for each product manufactured, which conforms to legal requirements for sale in Australia as well as the requirements in product specification.
    Review compliance to MO-015 Weight Checks for Fillers.
    Coles Requirement: All finished products shall be equal to or above the minimum net stated label weight / volume at the time of production, and allowance shall be made for any weight loss during shelf life to ensure the stated net weight is maintained.
    WW Branded Product requirement: 12 sample protocol with every unit above the declared weight/volume stated on the label.
    Procedures must detail the actions to be taken if the results fail to meet specification.
    The following combination of equipment and process inspection and testing methods is an acceptable alternative to 100% check weighing for the beverage category:
    Regular on-line weight (using Specific Gravity to calculate volume from weight) or decanted volume checks based on risk assessed frequency (consideration of the line speeds and number of filler heads/jaws) and results documented in production Quality records.
    Products for sale in Australia must comply with the requirements set out by the National Measurement Institute (www.measurement.gov.au).
    NOTE 1: Coles does not allow suppliers to adopt the Average Quantity System (AQS) for Coles Brand Products without written approval from a Coles PT.
    NOTE 2: The word ‘Net’ is no longer required on packaging with measurement marking.
    Net weight shall be rounded down.
    All personnel involved in the management of product weight, volume, and count must be trained and assessed as competent in the correct use of the documented procedures.

  • Tare Weights: CFMSR V2 37.17 Tare Weights; WSEP V2 COP Weight, Volume and Count Section 3.2 .3 , 3.2.6; CFMSR V2 37.5, 37.9 Equipment Settings /Security
    Records must show the individual finished pack results for each batch, including tare weight information

    Procedures must be in place to calculate and verify packaging tares used at a suitable frequency to ensure the actual product net weight / volume is measured accurately.

    All scales and equipment used for finished product weight control must have documented checks using identifiable calibrated weights at a minimum of twice per production day as part of the verification process.
    The supplier shall develop procedures to describe the processes used to tare scales and check weighers, consistent with the requirements of the Australian Government National Measurement.
    Current supporting and validation data for tare weight procedures shall be maintained.
    Packaging Tares must be verified at a frequency of no less than one unit every 15 minutes or one unit every 30 products and ensure the start, middle, end and at product changeover for every pack size
    Scales should be tared as part of 15 minute weight check procedure. Refer MO-015 Weight Checks for Fillers.

Manual Weight / Volume / Count Control: CFMSR V2 37.9 Manual Weight / Volume /Count Control; CFMSR V2 37.10 – 37.12 Volume Filling; WSEP V2 COP 3.6 Weight, Volume and Count; CFMSR V2 37.16 Scales and Check Weighers; CFMSR V2 37.16.12, 37.16.3 Scales and Check Weigher verification

  • Where manual weight / volume / count / systems are used, weight, volume, count, random weight information, and tare verification checks are completed at a frequency of no less than one unit every 15 minutes or one unit every 30 products and ensure the start, middle, end and at product changeover and for every pack size. Records of weight, count, and volume checks shall be maintained.
    Where products are filled by volume all filler heads must be checked for their fill accuracy at least once per day.
    Where weight checks are performed - to verify volume contents, there must be validation records for each product to convert volume to weight using a specific gravity calculation.
    All scales and equipment used for finished product weight control must have documented checks using identifiable calibrated weights at a minimum of twice per production day as part of the verification process. Accuracy to be verified prior to the commencement of each day’s packing of finished product.
    Test weights must represent the weight range of the products being assessed. Records of the daily verification checks shall be maintained.
    Scales and check weighers shall be individually numbered and cross referenced with the calibration register. The location of the number shall visible without the need to move the scale or check weigher.
    Scales and Check weighers shall be verified at the commencement of each shift using certified test weights.
    Records of scale and check weigher verification shall be documented, including any adjustment made, and the records shall be signed off by a supervisor each day.
    Where scales or check weighers have failed their verification, and action to correct them has failed, they shall be tagged out of service and removed from the area.

Automated Weight / Volume / Count: CFMSR V2 37.7, 37.14. Automated Weight / Volume / Count; CFMSR V2 37.8 Inline Check Weighers; CFMSR V2 37.5 Equipment Settings / Security

  • Where automatic controls are used, weight, volume, count, and random weight verification checks are completed at start‐up, middle, end of run, product changeovers, and for every product pack size.
    Tare weight checks shall be conducted at the start and end of each run.
    Weight check records must be signed off by a supervisor at the conclusion of each shift.
    Where In‐line check‐weigh systems are used, rejected products must be rejected into a locked bin or other controlled method.
    Bins for weight rejection must be separate to other rejection boxes (e.g. metal detectors).
    Where inline check weighers are used that do not record information, manual verification checks must be carried out and recorded.
    Automated content control equipment must have adequate security devices and only operated by authorised, trained personnel assessed as competent . Changes to settings must be recorded.

Laboratory Testing: BRC V8 5.6.2.4; WW V2 COP Own Brand Section 4 Product Release; WW V2 COP Own Brand Section 5 Woolworths Quality Team Notification; CFMSR V2 35.1 Trend Analysis; BRC V8 5.6.1.2

  • Procedures shall be in place to ensure reliability of laboratory results. These shall include:
    In‐house test methods shall be validated against NATA accredited laboratory methods, and a proficiency testing scheme introduced.
    The laboratory must operate to requirements and principles of ISO/IEC 17025.
    Staff must be trained and competent to carry out analysis required.

    Review all Veritest Proficiency Testing results and ensure any out of spec results have corrective action recorded with retest results verifying effectiveness.

  • Sampling and Testing must comply to QA-011 QA Core Sampling and Testing Plan as well as the Private Label Specifications.
    Product should be released on the agreed criteria with the Major Customer (Specs).
    Non conformance to any criteria defined in the Woolworths product specification must be communicated formally to Woolworths QA Team in writing, with a proposed action plan.
    Issues related to products supplied to Woolworths which may lead to a product withdrawal/recall must be reported within 60 minutes of the decision to withdraw/recall. Also issues/events identified regarding product safety, quality or regulatory compliance that have the potential to impact Woolworths’ products or other suppliers of Woolworths own brand products, e.g. allergen contamination of raw materials.
    Ongoing trend analysis must be in place for all testing results.

  • Action / Investigation: CFMSR V2 35.14
    At least once per annum, the Supplier’s mock recall procedure must be undertaken on a product supplied to Woolworths. Records of the Woolworths Branded Product mock recall must be maintained.
    Action and investigation must be evident where results fail to meet specified limits and reported to Coles CBM / PT within the agreed time frames.
    A Certificate of Product and Public Liability Insurance must be available and reflect $A10 million insurance coverage. This is displayed on the Parmalat Australia website - Info Centre\Policies & Accreditation\Certificates & Accreditations\ Insurance Certificates.

  • CFMSR V2 35.7, 35.8, 35.9 Internal Laboratories, Laboratory Protective Clothing
    Coat, hair covering, gloves, and shoes worn in on‐site microbiology laboratories shall be distinguishable from normal site protective clothing (ideally a different colour) and must not be worn in any other site areas, including offices. This includes chemical laboratories where toxic chemicals are used.
    Laboratory garments including coats, hair covering, gloves, and shoes shall be changed / removed when leaving the laboratory.

External Laboratories: CFMSR V2 35.6; WW V2 COP Own Brand 3.3.3; BRC V8 5.6.2 Laboratory Testing; CFMSR V2 35.13 Reporting

  • Pathogen testing must be contracted to an external laboratory, NATA accredited for the product category and testing undertaken.
    If Listeria spp. is detected in product, notification to label owner shall occur as soon as advice has been received that the result is confirmed. Immediate testing of a reference product from the failed sample must be carried out to enumerate and confirm the species of Listeria. The results must be communicated immediately to brand owner (eg Woolworths / Coles/Aldi), by the National Quality Manager. Out of specification and presumptive pathogen results (e.g. Listeria Species) must be reported to the Coles PT within 24 hours.

Waste, Rework and Work in Progress: WESP V2 Section 6.4

  • Waste (including work-in-progress, material out-of-spec and non-conforming product) must be clearly identified and segregated for storage and/or disposal.
    ● Controls for handling of waste must include:
    − Process waste
    − Waste as a result of non-conforming products
    − Used packaging materials and consumables
    Control procedures must be documented and implemented for any food product which is dropped on the floor or non-food grade or un-sanitised surface.
    Review MO-017 Dropped Product Procedure.
    Suitable identifiable waste containers must be used in production areas.
    These containers must be:
    − Cleanable
    − Leak and spill-proof
    − Not used for raw material, rework, WIP or finished product
    − Emptied and cleaned by designated staff on a regular basis or as required to prevent a build up.

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