Title Page
-
Date:
CHECK SOP AND DOCUMENTS POSTED
-
ARE ALL DOCUMENTS OR SOP POSTED ON BULETIN BOARD UPDATED?
-
ARE ALL DOCUMENTS OR SOP POSTED INSIDE THE PLANT UPDATED?
-
ARE ALL DOCUMENTS OR SOP POSTED INSIDE THE DUMP SHACK UPDATED?
-
ARE ALL DOCUMENTS OR SOP POSTED INSIDE THE SHIPPING BULDING UPDATED?
GLASS AND PLASTIC INSPECTION SHIPPING BUILDING
-
All plastic for damages around the shipping building. Ex: Wall clock, overhead grading light
- Good
- Fair
- Poor
- N/A
-
All fluorescent lights and other glass for damages
GLASS AND PLASTIC INSPECTION PROCESSING PLANT
-
Inspect all plastic and glass around the plant for damages
-
Inspect all fluorescent lights and other glass for damages
PERSONNEL HYGIENE AND EMPLOYEE FACILITIES
-
Employees shall not be allowed to work in areas of the facility where they may contaminate product from an illness, open lesion, boils, sores, infected wounds, or any other abnormal source of microbial contamination. Department supervisors are responsible for evaluating employees with possible illnesses that potentially could affect product integrity
-
Employees shall enter the processing areas through the personnel access doors only. All doors must be kept closed and not be opened for extended periods of time
-
Packaging materials, product, and ingredients shall be kept in appropriate containers and stored as required.
- G - All requirements are met (3 points each)
- NI - Needs improvement - Needs more attention in regular housekeeping schedule (2 points each)
- U - Unsatisfactory - immediate corrective action required ( 1 point each)
-
Waste bins must be identified for its purpose and removed as needed.
-
Hand washing signs are posted in washrooms and at entrances to food processing areas.
-
Eating food, drinking beverages, and chewing gum shall be restricted to non-production, designated areas. Eating or tasting product on the processing floor is prohibited. Open containers of food or beverages should not be carried through any food processing area. If passage through a processing area is unavoidable all containers must be covered to prevent spillage and shall not be made of glass. Employee lunches and/or personal items are to be stored away from production or ingredient storage areas. The use of tobacco products in any form shall be restricted to designated areas only.
-
Staff with exposed cuts are not permitted to handle products unless suitable protective coverings are applied, and these coverings monitored regularly by responsible personnel to ensure they remain effective. Band aids must be of a distinctive color (e.g. blue) and metal detectible. Dressings on hands and fingers are required to be covered with a suitable glove. First Aid kits are located throughout the facility.
-
After use, all hoses must be properly stored and hung on racks
-
This policy establishes the requirement of the company uniform policy or dress code for all employees in the facility. Deviations from this uniform standard can only be made with the prior approval of management. All employees are required to wear clean outer garments to work. If provided uniforms, the work shirts shall be constructed without front shirt pockets and with snaps in lieu of buttons. The uniform shall bear the individual’s first name above the area where the right pocket would normally be
-
Shorts, tank tops, and sleeveless shirts are not acceptable. Contractor employees will not be held to the requirement of wearing a uniform but will be required to wear clean outer garments and shall not be allowed to carry articles in shirt pockets. Employees’ garments shall not be stored in production areas but placed in personal storage areas or lockers.
-
Hair nets are required to be worn by all personnel working in oil load out food processing areas. Hair nets shall be worn in such a manner so as to encapsulate all the hair on a person’s head. Shaved heads do not require hairnets. Bump caps and eye protection are required to be worn throughout the entire facility. If employees in food processing areas have beards, they must be completely covered. Beards are defined as facial hair in excess of one day’s growth or 1/8th inch. Mustaches must be neatly trimmed and should not extend beyond the corners of the mouth. Mustaches extending beyond the corners of the mouth shall be covered by a beard net.
-
If gloves are used in food handling they must be maintained in a clean and sanitary condition. When not in use, store in a designated area. Disposable gloves shall be changed after each break, upon re-entry into the processing areas and when damaged.
-
Insecure jewelry such as necklaces, watches, earrings or body piercing items are prohibited at load out. Medic Alert necklaces and religious affiliated necklaces are acceptable provided they are on a continuous chain and kept inside a shirt or blouse. All other type necklaces are considered unsecured and are prohibited. Wedding bands without stones and bands with channeled stones are allowed.
-
All visitors are required to wear clean clothing and footwear. If visitors enter the processing area, they must remove jewelry and other loose objects that may fall or get caught in equipment. Visitors shall sign in the Visitor Log and shall be accompanied at all times by a company employee or have permission from Department Manager to enter any processing or storage area. Visitors shall not be permitted to handle any product or equipment while in the processing areas. Visitors shall also be required to comply with all hand washing and personal practice requirements
CONSTRUCTION AND LAYOUT OF BUILDINGS
-
Exterior grounds should be free of debris and refuse, adequately drained and maintained to minimize environmental hazard. Site boundaries will be clearly identified and access to the site is controlled to prevent access.
-
Roads, yards, loading/unloading areas, parking lots must be properly maintained and drained to prevent accumulations of standing water, dust, spilled product, etc.
-
Sites will be graded to allow for proper drainage from roofs, surface areas, etc.
-
Sites will be kept free of garbage, weeds, tall grass etc. within the immediate vicinity of any production facility. Weeds are to be spray treated with Round-up herbicide.
-
All exterior sites must be kept free of potential rodent harbourage areas.
-
Walls, roofs, and foundations need to be in good repair to prevent entry of water or pests.
-
Any equipment stored outside must be off the ground and away from walls to prevent harbourage and facilitate cleaning. Storage out of doors must be kept to a minimum.
-
Product spillage as a result of unloading/loading operations must be cleaned up daily.
-
Appropriately positioned and designed waste containers must be available for collecting waste and emptied on a regular basis. Waste containers must be marked as “waste containers”. Removal frequencies are to be managed to avoid accumulations. Labelled materials, products or printed packaging are to be destroyed to ensure that trademarks cannot be reused. Removal and destruction are to be carried out by approved disposal contractors.
Buildings – Exterior
-
Buildings must be maintained to provide the necessary barriers for effective protection against birds, rodents, and insects.
-
Doors are to be closed after use to minimize contamination by pests. Clearance at the bottom of exterior doors must not exceed 1/4 inch
-
Exterior concrete surfaces must be kept in good repair.
-
Holes in exterior walls for piping runs etc. must be properly sealed to prevent insect rodent and bird entry.
-
Exterior doors must be lockable, self-closing and kept in good repair.
WASTE DISPOSAL
-
Containers for waste shall be: <br>a) Utensils and containers used to collect, hold, and dispose of waste are identified; <br>b) located in a designated area; <br>c) designed to be effectively emptied; <br>d) leak proof. <br>Waste management and removal provision shall be made for the segregation, storage, and removal of waste. In the plant it is removed daily and a contractor will remove the waste on a predetermined timeframe contractually agreed.
-
Accumulation of waste shall not be allowed in processing areas. Removal frequencies (from processing areas) shall be managed to avoid accumulations. Waste accumulation shall occur only in designated storage areas and not pose a risk of product contamination.
-
Waste shall be managed in a manner that prevents it from becoming a source of food to pests. NOTE: Waste materials produced in the manufacture of animal food can attract animals, including insects, rodents, and wild birds. It is important to prevent animal access to such materials.
-
Labelled products (bulk or packaged) and product labels designated as waste shall be disposed of in a manner that prevents unauthorized use (disfigure or destroy) to ensure that trademarks cannot be reused. Records of destruction by an approved disposal contractor shall be maintained.
EQUIPMENT SUITABILITY, CLEANING AND MAINTENANCE
-
Presently, all plant equipment meets current recommended food processing industry standards. The equipment is to meet the following principles of hygienic design:<br>a) smooth accessible, cleanable surfaces, use of materials compatible with intended products and cleaning agents<br>b) the materials are to be impermeable and rust or corrosion free.<br>c) framework not penetrated by holes or nuts and bolts <br>d) piping and ductwork are to be cleanable, drainable and with no dead ends <br>
-
Equipment used in the production facility where practicable is to be designed to minimize contact between the operator’s hand and the product.
-
In the event that the plant has equipment used for thermal processes, it must meet the temperature gradient and holding conditions that are PLC controlled to relevant product specifications. Equipment, where required, is to be provided for the monitoring and control of temperature.
-
Prior to replacing any major piece of equipment, the food safety team, production, and maintenance department will meet to evaluate the equipment utilizing the management of change form. Production equipment is to be installed with enough access and space for cleaning. All repairs in the facility are documented in FIIX CMMS Maintenance program
-
Critical equipment has been identified that must be operable to ensure manufacturing capability. A master schedule is prepared in the Preventative Maintenance Program FIIX. Equipment has been selected based on its importance and a frequency has been established and programmed. Frequencies are weekly, monthly, quarterly, semi-annually, and annually.
-
Maintenance procedures are in place to perform for each preventative maintenance task and the records completed to demonstrate their completion. Maintenance procedures may be the equipment manufacturers manual or equivalent. The oil used to lubricate equipment that come into contact with the food are food grade.
-
Maintenance staff and contractors observe the following practices when undertaking maintenance and repairs in any food processing, handling, or storage areas:
-
Temporary materials such as tape, wire, string, cardboard, paperboard, absorbent pads, and plastic are not to be used for permanent repairs. If these are used for emergency repairs, it is to be dated and replaced with a proper permanent repair as soon as possible.
-
When painting is to be performed where the paint is in a food handling or contact zone, maintenance shall use on a non-toxic paint shall be suitable for use and in good condition.
-
When maintenance is performed on or near a food contact surface, the area must be inspected, cleaned, and sanitized by trained personnel before being released back into production.
-
Work Orders are to be created on FIIX for all repairs and preventative maintenance activities in the facility and are logged
-
Food grade lubricants should be considered where the chemical hazard may have an adverse effect on the food product
CLEANING AND SANITIZING
-
The facility has a documented cleaning and sanitation program for premises, productions and storage areas to be cleaned to ensure all parts of the establishment are cleaned and/or sanitized to a defined schedule.
-
Product contact services and utensils are to be cleaned on a regular basis and as often as necessary to eliminate product residues, microbial contamination and to maintain a good appearance.
-
Upon completion of the tasks assigned, the sanitation records will be submitted to the supervisor for review, verification and signed off by the supervisor.
-
In the event of maintenance being conducted on equipment, the equipment will be inspected, sanitized and released back into production with a record documenting the equipment release
Pest Control
-
Contractors must be certified pesticide applicators with a current copy of the certification kept on file. A contract is required documenting the specific services to be rendered including materials to be used, methods, precautions and SDS documentation. Records of pesticide use are maintained to show the type, quantity and concentrations used, where, when and how applied and the target pest.
-
Bait boxes should be placed strategically to prevent rodent entrance into the plant. Consider contracting rodent control to a contractor to ensure consistency of control. The contractor should provide a map of the plant to identify the location of detectors and traps. Outside bait stations should be tamper resistant and be properly positioned and anchored. An inspection report prepared by the contractor and/or facility will provide the status and effectiveness of the program to be reviewed monthly and signed off by the company representative. A monthly activity tracking report will be maintained and reviewed by management.
-
Material data sheets for all pesticides used by the contractor will be maintained on file.
Housekeeping
-
2.1.1 A Monthly Housekeeping Audit will be conducted to ensure compliance and the appropriate actions are taken. In most cases daily cleaning must follow at the completion of a shift prior to the next rotation as per Section 11.0 Cleaning and Sanitizing and as per the sanitation schedule and reports.
-
2.1.2 Storage areas must be kept in a neat and orderly fashion. Spills when they occur must be cleaned up promptly.
-
2.1.3 Spider webs and dust on walls, beams, pipes and ceilings must be swept on a regular basis.
-
2.1.4 The yard must be kept free of debris and trash.
-
2.1.5 Grass must be cut on a regular basis with weeds sprayed to keep vegetation under control. Keep the weeds and grass cut short around all buildings to prevent the attraction of rodents.
-
2.1.6 Unused machinery and parts are to be stored off the ground to discourage rodents.
-
2.1.7 Windows must be kept in good repair, i.e. no broken windows, no holes/tears with screens in place to prevent rodent, insect or bird entry.
-
2.1.8 Waste material and sweepings must be identified and disposed of appropriately to prevent inadvertent addition to food products. All waste containers should be cleaned regularly and in a manner that does not contaminate product and appropriately marked as waste.
-
2.1.9 Spilled ingredients should be cleaned up in a timely manner to mitigate rodent activity
-
2.1.10 Doors that do not fit properly should be fixed to prevent entrance of rodents and birds
-
2.1.11 Holes in the floors and/or walls should be filled with steel wool and covered to prevent rodent activity.
Maintenance Cleaning
-
Non-sealed electrical panels and boxes are to be cleaned every four weeks.
-
Maintenance mess and debris created during repair or alterations is promptly removed. Nuts, bolts, washers, tape, welding rods or other small items must be accounted for.
-
Grease smears and excess lubricants are to be properly removed from equipment
-
Only clean tools are to be used on product zones. Maintenance personnel are to observe hygienic practices when working in product zones.
CALIBRATION
-
For all inspections, measurements or tests performed, to establish or verify product requirements, such measurements must be identified with their required accuracy and the equipment used to make the measurements. All inspection, measuring and test equipment must have an associated equipment number.
-
Measuring equipment have a schedule for equipment calibration according to regulatory requirement
-
Inspection, measuring and test equipment, which fails in operation or is damaged, must be immediately labelled and removed to prevent inadvertent usage.
-
A calibration record is required for each measuring device. The information available should be: a) Details of the equipment type;<br>b) Unique identified location and/or number;<br>c) Frequency of checks;<br>d) Check method;<br>e) Action taken when results are unsatisfactory.<br>
-
Calibrations are to be against certified measurement standards, which have a known relationship to a nationally registered standard. In cases where no standard exists, the basis for calibration is documented in internal procedures
-
If any piece of equipment is found out of calibration, previous results from such equipment must be assessed where available and documented to see if any corrective actions are needed.
-
Inspection, measuring, and test equipment is to be used in a suitable work environment to ensure proper equipment operation, and handled, and stored to ensure the accuracy and fitness of use is maintained.
-
Inspection, measuring and test equipment must be safeguarded from adjustments, which would invalidate the calibration setting
-
Calibration records for inspection, measuring and test equipment are to be maintained through the calibration records and/or internal record system
Warehousing and Storage
-
Where applicable incoming ingredients, products and materials are verified when they are received to ensure that they: • are properly labelled and identified,<br>• are in good condition, not damaged or soiled,<br>• meet purchasing specifications,<br>• are accompanied with a certificate of analysis or letter of guarantee, as applicable<br>
-
Effective control of temperature, humidity, or other environmental conditions (i.e., dry, and ambient) is provided where specified by product or storage to maintain the condition of the raw and finished product. Instruments are used that control, indicate and record temperature and humidity levels where necessary.
-
Where possible, storage spaces should permit segregation of raw materials, work in progress and finished products.
-
Raw material, packaging and finished product are stored on pallets or shelves off the ground to protect them against contamination from pests, including insects, rodents, and other vermin.
-
Incoming product is stored and removed from storage in a manner that prevents contamination and cross contamination with finished product. Receiving dates are visible on the bottom unit of the pallet or individual container or package.
-
Ingredients, supplies, and other materials are rotated on a first-in, first out (FIFO) basis to ensure stock rotation. Specified stock rotation systems (FIFO) for finished product are to be observed to ensure maintenance of product condition.
-
A separate area or other means of segregating materials identified as non-conforming within the process shall be provided.
-
Where product is returned and/or considered unacceptable, it shall be stored separately, processed to prevent contamination and a corrective action initiated.
-
Non-food chemicals, i.e., detergents, lubricants, are to be properly labeled and stored and used as per procedure to prevent possible contamination. All food contact processing aids are segregated from non-food materials.
-
Chemicals are stored in areas where they are kept dry, well ventilated and separate from processing areas
-
Gasoline or diesel-powered forklift trucks are not to be used in food ingredient or product storage areas.
-
security inspections of storage facilities including vehicle storage, and all doors are locked
Vehicles, Conveyances and Containers
-
Vehicles, conveyances, and containers are maintained in a state of repair, cleanliness, and condition consistent with the requirements given in relevant specifications to ensure adequate protection against damage or contamination of the product.
-
Where the same vehicles, conveyances and containers are used for food and non-food products, cleaning shall be carried out between loads. Prior to loading, a trailer and/or container must be inspected. The following are areas to be addressed: • Outside area for damage, structural defects that may allow entry of water, infestation, or contamination. This includes door seals intact and tight-fitting walls and ceilings in good repair and free of holes.<br>• Interior good condition, clean, dry, and free of any foreign material buildup, debris, moisture, infestation.<br>• Detection of odor (i.e., chemical, animal, etc.)<br>
-
Vehicles must be fit for purpose and presented clean upon arrival. Vehicles that are not clean or free of contaminants will not be loaded or unloaded. protection against damage or contamination of the product.
-
Vehicles required for effective control of temperature, humidity, or other environmental conditions (i.e., dry, and ambient) is provided where specified by product to maintain the condition of the raw and finished product received and/or shipped. Instruments are used that control, indicate and record temperature and humidity levels where necessary.
-
Distribution records are to be maintained to identify distribution and finished products shall be handled and transported to prevent actual or potential adulteration.
AUDIT SUMMARY:
-
Were all issues from previous Housekeeping Audit addressed?
Verification
-
Verified By:
-
Signed By:
