Sterilizing plant check sheet - VPN 43

Information

Audit Title
Client / Site
Conducted on
Prepared by
Location
Date of application
Approval number (Registration certificate number)
Physical address
Postal address
Postal code
Town
Province
Telephone number
Fax number
Name of the manager / owner
Manager/ Owner telephone number
Manager/ Owner fax number
E-mail address of manager / owner
Name of the hygiene manager
Hygiene manager cellphone number
E-mail address of hygiene manager
Name of authorised veterinarian responsible for veterinary inspections and export certification
Names of Authorized Provincial Officer(s) Responsible for Inspecting The Establishment on a Regular Basis
Countries exporting to
Category of establishment
Number of full time equivalent employees
Number of hazard studies

Working hours

Hours per shift
Shifts per day
Days per week

General

Layout Map

Is there a personnel flow diagram?
Is the product flow diagram adequate?
Is the schematic plan of the facility adequate?
Is a site plan and detailed plans of the establishment attached?
a) the location of the facility in relation to public roads, farms or buildings/structures adjacent to the site
b) The scale used (1.200 or otherwise approved by provincial executive officer)
c) The true north.
d) Situation and direction of the boundaries of the site
e) Situation of access roads to and inside the site
f) Structural specifications of fences and gates including the height
g) Detail, position and construction of the sewerage systems
h) Detail of storm water drainage
I) Position of access control system,
j) Position of receiving end.
k) Flow of product through the facility including processing, equipment and packaging areas.
I) Position of storage of controlled substances
m) Position of dispatch of final product.
n) Position of waste containers
o) Position of workers canteen
p) Position of the ablution facilities,
q) Position of bait stations for pest control
Is this a sterilization plant?
Is copy of the Act36 registration attached?
Is the sterilizing plant registered under the Occupational Health and Safety Act, 1993 (Act No. 85 of 1993)?
Does the plant process fish or fish products?
Is the plant in possession of a permit to operate a fish processing establishment, issued in terms of section 13 of the living Resources act, 1998(act 18 of 1998)?
Permit number:
Valid from:
Valid to:
Issue date:
Fish which may be processed?
Is this a New application?
Indicate the expiry date of the previous ZA certificate.
Is the certificate displayed?
Other listings or certifications:
Expiry date of certification:
Name of listing:
Certification body:
Review of Legal Requirements
Is there a documented hygiene management system?
Title of the system:
Date the system was last reviewed:
Is a list of Final Product(s) attached with a confirmation of current registration with act 36?
What countries are exported to / does the company want to export to?
Does it process more than 1 category?
Is this a permanent approval?
Are there other facilities under the establishments control?
Add a facility?
Facility name:
Facility registration number:
Is the facility approved by DAFF?
For all storage facilities on-site (same physical address as production facility) then the storage has the same number as the production plant
In instances where the storage is located at a different geographical location – then a separate inspection and a different ZA number is needed.
Are records need to be kept for at least 2 years?
Is there a list of meat suppliers attached?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Export certification has been suspended until the non-conformance has been corrected
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Raw materials

Are raw materials from animal origin used?
Is a list of the ZA approved sterilizing plants that supply the pet food ingredients attached if the establishment does not sterilize its own ingredients?
What species is the raw material derived from?
What organs are used?
Are any of the raw materials imported?
List the countries:

Controlled substances

Are there any controlled substances on site?
Are there steroid growth promoters on site?
Are there Beta-agonists on site?
Are there antibiotics on site?
Is there a veterinary prescription for antibiotics at the facility?
Is there a register for all controlled substances entering and leaving the controlled lockable area?
Please supply details of what, how much and how controlled substances are stored.

GMOs

Are GMO’s used in manufacture of feed?
If GMO’s are present describe them as described by the facility representative:
Is the feed tested for GMO’s?
How is equipment cleaned between batches to prevent contamination of products? After the use of animal products and after the use of control substances?

Declarations

Declaration by establishment:

I, the undersigned owner/manager or authorized representative of the establishment mentioned above, hereby agree to comply with all the requirements set by the Department of Agriculture, Forestry and Fisheries for the approval of this establishment and I agree to co-operate with the veterinary officials in this regard.

I understand that the approval of the establishment can be withdrawn at any time if any shortcomings are detected.

I am aware that the establishment must be re-approved on an annual basis and that the onus for the application for re-approval rests with the owner of the establishment.
Owner, Manager or Authorized representative
Witness

Declaration by auditor

I, the undersigned the official veterinarian responsible for providing an inspection and certification service at the establishment mentioned in the preceding pages hereby agree to abide by the conditions set by the Department of Agriculture, Forestry and Fisheries and importing countries (where applicable) for the approval for this establishment.
A comprehensive inspection report is attached to this application and, in case of a new registration, all supporting documents are provided.
This application is for approval of this establishment for:
To the following countries:
Veterinarian

Hygiene management programmes (HMPs) and procedures

Training

Training:

Is there file with detailed job descriptions for each work station?
Is there documented training program for workers at each work station on the floor?
Is there a register for the training of workers on the floor.
Is there a program for the regular checking of all stations?
Is there a register for the daily checks for compliance with job descriptions.
A schematic representation of all the work stations on the floor?

Cleaning team training:

Is there a documented procedure for the training of the cleaning team?

Personal hygiene training

Is there a documented procedure for personal hygiene training?
How does the establishment monitor if the training was effective?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Personnel practices:

Is there a documented procedure for personnel practices?
Are there separate personnel for handling raw and finished products?
Are personnel movement procedures established?
Do personnel wash their hands and disinfect their boots before leaving?
Do personnel change from their soiled protective clothing and footwear and thoroughly clean themselves with soap and water before leaving the premises?

Protective clothing:

Do all personnel have to where protective clothing?
Is the protective clothing clean and neat?
Is the protective clothing washed in house?
Is the clothing washed at an approved laundry?
Is protective clothing provided to all personnel working and visitors entering the production areas?
Is there a documented procedure for visitors & maintenance personnel
Are the clothes color coded to visually distinguish personnel working in the raw/contaminated area?
Is provision made for change-over areas before entering processing and clean areas?
Staff should not wear protective clothing outside processing areas. Is this enforced?
Is there signage to inform all persons entering the feed handling areas to adhere to the protective clothing policy?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Hand washing:

Prior to work shift?
After toilet, touching face?
Handling money etc?
After smoking?
Every time he or she has blown his or her nose or after his or her hands have been in contact with perspiration or with his or her hair, nose or mouth?
After contamination?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Cleaning and sanitation:

Is the proper use of foot baths and wheel baths described?
Are there appropriate arrangements for the cleaning and disinfection of containers and vehicles to avoid risk of contamination?
Are there adequate facilities for cleaning and disinfecting the containers in which animal by-products are received and the means of transport, other than ships, in which they are transported?
Are cleaning procedures shall be established and documented for all parts of the establishments or plants?
Are the floors, walls and equipment cleaned daily after cessation of operation according to the hygiene management plan?
What verification to ensure effective cleaning?
How is Equipment cleaned?
Is there sufficient production capacity for hot water and steam for the processing of animal by-products?
Is there a master cleaning schedule
Are there clear cleaning instructions for all areas?
Are there clear cleaning instructions for all equipment?
Is continuous cleaning included?
Is the method of continuous cleaning described?
Is there a program for the regular checking on continuous cleaning?
Is there a list of cleaning chemicals used?
Is there material safety data sheets available for all cleaning chemicals used?
Are all the cleaning chemicals approved for use in a food factory?
How is cleaning monitored?
How has the company verified that cleaning is effective?
Is there a sampling program for laboratory analysis?
Is there a schedule for checking of surfaces?
Are all surfaces sampled over a reasonable period of time?
Is there a trend analysis of results?
Are there results of pre-production cleanliness checking?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Soap/ toilet paper/ disposable Towels:

Is there a written procedure to ensure that there is always soap toilet paper and disposable towels available?
How is this monitored?

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Pest control:

Is there a documented pest control program?
Is there a pest control map indicating all the bait stations and any other equipment applicable to pest control?
Are there records of pest monitoring?
Please list the pest which are monitored:
Are all the chemical registered with Act 36?
Are there logs for the chemicals used?
Are there MSDS's available for all the chemicals?
Are the pest controllers registered with act 36?
Pest control registration details:
Pest controller regstration number:
Expiry date of pest controller
Is there training for pest control and pest sightings?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Construction and maintenance:

What is done to ensure that installations and equipment are in good condition?
Is there a documented procedure for construction and maintenance?
Is the content of the procedure adequate?
Is provision made for all pieces of equipment?
Are all building areas which need maintenance covered by the procedure?
Are the manufacturers guidelines taken into account in the maintenance program?
Are there people specifically trained for the maintenance of critical equipment?
Are records of maintenance maintained for at least one year?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Waste disposal:

Is there a documented procedure for waste disposal?
Is waste management contracted to an external company?
Is low risk waste dumped at an approved dumping site?
Is high risk waste only dumped at high risk dumping ground?
Are there records of waste disposal?
Describe the waste removal program for low- and high-risk waste:

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Contact wrapping and packing materials:

Has the establishment ensured compliance with import regulations of the countries where product is going to be sent?
Is there a procedure for contact wrapping and packing materials?
Does the procedure cover receiving of materials?
Are test conducted to verify supplier claims?
Are tests conducted to ensure adequite storage of contact wrapping and packing materials?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Enter the regulatory reference if applicable:
Signature of company representative

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Water quality

Is only potable water used if included as an ingredient in the product?
Is there a waste water disposal system which meets hygiene requirements?
What is the water source?
Minimum Chlorine dioxide value after chlorination?
Is the frequency of chlorination testing adequate?
Chlorine dioxide added at the plant?
Minimum Chlorine dioxide value after chlorination?
is the contact time adequate?
Are there water holding tanks / intermediate storage?
Time of intermediate storage?
Are the tanks on the master cleaning program?
How frequent are the tanks cleaned?

Non-conformnce

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Dress code and code of conduct:

Is jewelry allowed?
Are fingernails & hands kept clean?
Is spitting, smoking prohibited on the premises?
Is finger licking face touching etc.. prohibited?
Is coughing, sneezing on the prohibited on the production floor?
Is sitting/ leaning on food surfaces prohibited?
Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Medical fitness of staff:

Does each staff member get examinde for fitness to handle food at least once a year by a medical professional?

Daily medical checks:

Are there daily medical checks for staff members?
Does the dailyscreening look for personnel with a suppurating abscess or a sores or a cuts or abrasions,
If an such abscess, sore, cut or abrasion is found are there facilities and trained staff member to ensure that the potential source of contamination is covered with a moistureproof dressing which is firmly secured?
Do daily checks screen for people suspected of suffering from or being a carrier of a disease or condition in its contagious stage that can be transmitted by food?
If a person is suspected to carry a disease transmitted by food is such person responsible to immediately reports the disease or condition to the person in charge?
Is a certificate by a medical practitioner stating that such person is fit to handle food is submitted before a suspected carrier of disease is allowed to commence work which could contaminate food?
Does the establishment ensure that all staff members are medically fit? Please describe.

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Process control

Hazard analysis and control:

Are there dedicated lines for specific products?
Please list the lines:
Has the establishment identified any hazards that must be prevented, eliminated or reduced to acceptable levels?
Have critical control points been identified at the step or steps at which control is essential to eliminate or reduce the identified hazards to acceptable levels?
Did the establishment establishing critical limits at critical control points which separate acceptability from unacceptability for the prevention, elimination or reduction of identified hazards?
Material that did not receive the specified heat treatment,(such as material discharged at start up or leakage from cookers) must be recirculated through the heat treatment or collected and reprocessed or disposed of.
Did the establishment establish and implement effective monitoring procedures at critical control points?
Has the the establishment taken corrective action when monitoring indicates that a critical control point is not under control
Are there procedures to verify that the measures outlined are complete and working effectively? Verification procedures shall be carried out regularly
Are there documents and records commensurate with the nature and size of the businesses to demonstrate the effective application of the measures set out in points?
Is there a description of the process by a process flow diagram?
Is the system reviewed with process changes?
Is the system reviewed with product changes?
Is the system reviewed with periodic review?
Describe the processing of the animal products.

Critical limmits

Are the following CCP’s correctly identified and monitored?
raw material particle size?
Give the limit:
temperature achieved in the heat treatment process?
Give the limit:
pressure, if applied to the raw material?
Give the limit:
duration of the heat treatment process or feed rate to a continuous system?
Give the limit:
pH adjustment achieved if chemical treatment (method 6)
Give the limit:

EU Methods

EU method 7

Sampling of the final product on a daily basis over a period of 30 production days
AIVC3 G c i-ii
AXC1 and C2B3.b
where:
n = number of samples to be tested;
m = threshold value for the number of bacteria; the result is considered satisfactory if the number of bacteria in all samples does not exceed m;
M = maximum value for the number of bacteria; the result is considered unsatisfactory if the number of bacteria in one or more samples is M or more; and
c = number of samples the bacterial count of which may be between m and M, the samples still being considered acceptable if the bacterial count of the other samples is m or less.
i. Samples of material taken directly after the treatment:
Clostridium perfringens absent in 1 g of the products
Samples of material taken during or upon withdrawal from storage:
Enterobacteriaceae: n=5, c=2; m=10; M=300 in 1 g
Salmonella: absence in 25g: n=5, c=0, m=0, M=0

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Production

Are animals processed a.s.a.p.
Please define what is a.s.a.p. as given by the company
Is product handled in such a way to avoid risks re-contamination?
Records of quantities produced each day?
Are records of species of origin, including an indication of whether the aquatic animals were caught in the wild or produced in aquaculture kept?
How is the material disposed of?

Invoices

Does the invoice contain date on which the material was taken from the premises?
The description of the material?
The quantity of the material?
The name and address of the carrier?
The name and address of the receiver and if applicable, its approval number?

Movement permits:

Is there a file for all movement permits, import permits and release documents pertaining to ingredients?

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Trace-ability and recall:

Back trace-ability:

Is there identification and recording of all ingredients?
Is there identification and recording of all packing materials?
Is there identification of all wrapping materials?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Forward trace-ability:

Is there identification of all dispatched products?
Is there a documented recall procedure?
Does the recall procedure contain notification of the state authorities?
Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Traceability requirements set by Regulation (EC) No 178/2002 A (3)

a) is there an accurate description of the food?
b) is the volume or quantity of the food indicated?
c) has the name and address of the food business operator from which the food has been dispatched recorded?
d) has the name and address of the consignor (owner) if different from the food business operator from which the food has been dispatched recorded?
e) has the name and address of the food business operator to whom the food is dispatched been recorded?
f) the name and address of the consignee (owner), if different from the food business operator to whom the food is dispatched;
g) a reference identifying the lot, batch or consignment, as appropriate
(h) the date of dispatch

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Final product testing:

Is there a documented procedure for final product testing?
Does the laboratory used take part in the DAFF laboratory program?
Are all the tests required by the importing countries tested for?
Please list the tests required:

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Corrective action procedure and reports

Is there a documented corrective action procedure?
Is there a register of all corrective actions?
Are there actions taken to correct the problem and prevent re-occurrence?
Is there a register of all customer complaints?
Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

South African Method for sterilisation

South African Method

Select the method:
- Method 1
- Method 2
- Method 3
- Method 4
- Method 5
- Method 6

Method 1 (compulsory for ruminant animal by-products)

(1) where the particle size of the animal by-product to be processed is more than 50 mm, then the size must be reduced using appropriate equipment so that the particle size after reduction is less than 50 mm and conforms to the requirements.
(2) animal by-products must be heated to a core temperature of more than 133 °C for at least 20 minutes without interruption at a pressure (absolute) of at least 3 bars by saturated steam meaning that all air is evacuated and replaced by steam in the sterilization chamber; the heat treatment may be applied as the sole process or as a pre- or post-process sterilization phase.
(3) The process may be carried out in batches or in a continuous system.

Method 2

(1) where the particle size of the animal by-product to be processed is more than 150 mm, then the size must be reduced using appropriate equipment so that the particle size after reduction is less than 150 mm and conforms to the requirements.
(2) animal by-products must be heated to a core temperature of more than 100 °C for at least 125 minutes, a core temperature greater than 110 °C for at least 120 minutes and a core temperature greater than 120 °C for at least 50 minutes without interruption.
(3) the process may be carried out in a batch system.
(4) animal by-products must be cooked in such a manner that the time-temperature requirements are achieved at the same time.

Method 3

(1) where the particle size of the animal by-product to be processed is more than 30 mm, then the size must be reduced using appropriate equipment so that the particle size after reduction is less than 30mm and conforms to the requirements.
(2) animal by-products must be heated to a core temperature of more than 100 °C for at least 95 minutes, a core temperature greater than 110 °C for at least 55 minutes and a core temperature greater than 120 °C for at least 13 minutes without interruption.
(3) the process may be carried out in batches or in a continuous system.
(4) animal by-products must be cooked in such a manner that the time-temperature requirements are achieved at the same time.

Method 4

(1) where the particle size of the animal by-product to be processed is more than 30 mm, then the size must be reduced using appropriate equipment so that the particle size after reduction is less than 30mm and conforms to the requirements.
(2) animal by-products must be placed in a vessel with added fat and heated to a core temperature of more than 100 °C for at least 16 minutes, a core temperature greater than 110 °C for at least 13 minutes, a core temperature greater than 120 °C for at least 8 minutes and a core temperature greater than 130 °C for at least 3 minutes without interruption.
(3) the process may be carried out in batches or in a continuous system.
(4) animal by-products must be cooked in such a manner that the time-temperature requirements are achieved at the same time.

Method 5

(1) where the particle size of the animal by-product to be processed is more than 20 mm, then the size must be reduced using appropriate equipment so that the particle size after reduction is less than 20 mm and conforms to the requirements.
(2) animal by-products must be heated until they coagulate and then pressured so that fat and water are removed from the proteinaceous material. The proteinaceous material must be heated to a core temperature of more than 80 °C for at least 120 minutes and a core temperature greater than 100 °C for at least 60 minutes.
(3) the process may be carried out in batches or in a continuous system.
(4) animal by-products must be cooked in such a manner that the time-temperature requirements are achieved at the same time.

Method 6

1. where the material to be processed consists of whole fish, fish by-products or fish off-cuts, it must be heated in a continuous cooking process to coagulate the protein for at least 20 minutes with an exit temperature of not less than 85 degrees Celsius;
2. the size must be reduced to 10 mm or less after cooking and pressing or decanting;
3. further heat treatment of the material shall, in a direct drying process, consist of retention in a continuous dryer for a period of not less than 20 minutes and, in an indirect drying process, consist of retention for a period of not less than 30 minutes, the exit temperature in both cases must at all times be a minimum of 80 degrees Celsius. Where the material is dried in two stages, the exit temperature from the pre-dryer shall at all times be a minimum of 80 degrees Celsius.

Calibration, instrumentation and temperature control

Temperature control

Is there a procedure for temperature monitoring?
Is the procedure adequate?
Is there an adequate safety system to prevent insufficient heating?
Are all installations equipped with: measuring equipment to monitor temperature against time and, if applicable for the processing method used, pressure at critical points?
Is there a continuously recording devices?
Are the results accessible for the purpose of checks and official controls?
Thermometer calibration
Identification of theremometer
Is the thermometer calibrated?
Date of calibration:
Is there a map for temperature control?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Hot temperature control

Is there a cooking step in the process?
Are there records to show the temperature time combination?
Are there sterilizers?
Is the temperature checked?
Are the sterilizers set at above 82 deg C?
Is there an over flow?
How is the accumulation of fat in the sterilizer prevented?

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Import requirements

Country's import requirement
Name of country?
Does the company have the requirements?
Requirement
Can the company provide evidence of conformance?
Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Notes:

Documents examined:
Records examined:
Personnel interviewed:
Comments:

Facility inspection

External

PREMISES

Does the premises have adequate access control?
Image of access control:
Is the premises fenced?
Is the plant on the same premises as another food production Unit?
Are they physically separated?
Is there a conveyor system which cannot be by-passed?
Are there separate entrances, receptions, equipment and measures to prevent risk spread by personnel?
Are the building, loading areas and equipment must be designed so as not to create health hazards, also with regards to prevention of foreign material In the product?
Is there clean and unclean areas and are they separated?
Are there separate entrances for raw materials and finished products?
Are there any animals or dogs or cats or birds kept on the premises of the sterilizing plant?
Are the roads and walk ways covered to prevent dust?
Is there any water pooling that could lead to contamination?
Is the receiving areas covered?
Is the dispatch area covered?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Raw material receiving area

Constructed to facilitate cleaning and disinfection?
Is there separate colour-coded cleaning equipment?
Are one of the following provided at all exits from the unclean area?
Hand-washing facilities and disinfectant foot baths?
Boot-washing facilities for cleaning and disinfection of hands and boots?

Cleaning of Equipment

Is there equipment for cleaning and disinfecting the containers in which animal by-products are received and the means of transport, other than ships, in which they are transported?
Is the cleaning equipment adequate?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Stores

Add a store
Choose the type of store

Chemical store

General store

Name of store?
Is the store pest proof?
Is the store clean and neat?
Is the first in first expired principals followed?
Are all the stored materials identified?
Are there any expired ingredients?
Is there separate colour-coded cleaning equipment?
Are there any prohibited or dangerous substances?

Major and critical non-conformances

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Final product store

General store

Name of store?
Is the store pest proof?
Is the store clean and neat?
Is the first in first expired principals followed?
Are all the stored materials identified?
Are there any expired ingredients?
Is there separate colour-coded cleaning equipment?
Are there any prohibited or dangerous substances?

Major and critical non-conformances

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Packing store

General store

Name of store?
Is the store pest proof?
Is the store clean and neat?
Is the first in first expired principals followed?
Are all the stored materials identified?
Are there any expired ingredients?
Is there separate colour-coded cleaning equipment?
Are there any prohibited or dangerous substances?

Packing store specific

Is the packaging stored off the floor?

Major and critical non-conformances

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Production areas

Production area

Production area

Area name:
Separate areas for different product risks?
Area clean and neat?
Is equipment in good working order and maintained well?
Is there separate colour-coded cleaning equipment?
Lights covered?
Drains covered?
Roofs/ ceilings maintained?
Floors maintained?
Walls maintained?
Dust controlled?
Area suitable to prevent contamination?
Sufficient light?
Sufficient ventilation?
Is this a un-clean area?

Un-clean area

Is the entry to the sewer provided with a grating to prevent the ingress of solid matter?
Is the entry to the sewer provided with a fat-trap?
Is the drainage system so designed that it will prevent the emission of offensive odours?
Are all apertures at floor level in the wall provided with raised sills to prevent the escape of effluent from the floor to any place other than the drainage system provided?
Is ventilation provided? It may not take place from the unclean to the clean area
Are all the internal angles between the walls, floors, steps and other aspects rounded off?
Are the walls faced on the inner surface with a smooth non-absorbent light-coloured finish impervious to water and capable of being cleaned without sustaining damage?
Are hose connections provided together with Hoses Holders for hoses Supply of hot water
For the disinfecting of vehicle wheels and other parts, on leaving the unclean sector.
Are there windows?
Are the window frames constructed of metal or other suitable alternatives?
Are the internal window-sills-Suitably sloped to prevent collection of dust and dirt? Smooth to allow easy cleaning?
Are the window coverings insect proof?
Is material of animal origin received into the premises of the sterilizing plant otherwise than into the unclean area?
Is any material of animal origin being removed from the unclean area other than through the charging apertures of the sterilizing equipment?
Are the charging apertures of the sterilizing apparatus situated in the unclean area?
Where applicable, does the unclean area have equipment to reduce the size of animal by-products?
Where applicable, does the unclean area have equipment for loading crushed animal by-products into the processing unit?
Other remarks:

Major and critical non-conformances

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Temperature controlled area

General Temperature controlled area

Area identification:
Temperature
Time of reading
Is equipment in good working order and maintained well
No build up of ice or snow?
No ice around the door?
Is there enough ventilation?
Is there enough light?
Is there separate colour-coded cleaning equipment?

Walls

Are they smooth, rust - free, non - toxic, cleanable and non – absorbent
No open joints or open seams?

Ceilings

No open joints or open seams?
Are they smooth, rust - free, non - toxic, cleanable and non – absorbent
Are there indications of condensation?

Floors

Are they smooth, rust - free, non - toxic, cleanable and non – absorbent
No open joints or open seams?
Any signs of water pooling

Product handling

Is there no product on the floor?
Are the containers not rusted or damaged?
Are there leaking containers?
Is the first expired first out principal followed?
Is all product or ingredients identified?

Major and critical non-conformances

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Staff amenities

Staff amenity

Select an area

Canteen

Staff amenity general

Name of area:
Is the area clean?
Is the area large enough for the number of people to use it?
Is there separate colour-coded cleaning equipment?
Are there hand wash basins?
Are the taps foot or knee operated?
Is the antibacterial soap?
Is there a suitable method to dry hands?

Canteen specific

Major and critical non-conformances

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Entrance lobby

Staff amenity general

Name of area:
Is the area clean?
Is the area large enough for the number of people to use it?
Is there separate colour-coded cleaning equipment?
Are there hand wash basins?
Are the taps foot or knee operated?
Is the antibacterial soap?
Is there a suitable method to dry hands?

Entrance lobby specific

Major and critical non-conformances

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Staff amenity general

Name of area:
Is the area clean?
Is the area large enough for the number of people to use it?
Is there separate colour-coded cleaning equipment?
Are there hand wash basins?
Is there hot and cold water?
Are the taps foot or knee operated?
Is the antibacterial soap?
Is there a suitable method to dry hands?

Toilet specific

Is the entrance to the bathroom off the production floor?
Was there sufficient toilet paper
Are there showers?

Non-conformance

Are there any major or critical non-conformance?
Add non-conformance?
Is the non-conformance major or critical?

Major non-conformance

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Critical non-conformance:

Describe the non-conformance:
Enter the action that was agreed to correct the non-conformance
Enter the date when corrective action should have taken place:
Signature of company representative
Enter the regulatory reference if applicable:

Bathroom

Labelling

EU requirements

Is category 3 material identifiable & separate during transport and collection and marked as “not for human consumption”
Is the name and address of the feed manufacturing establishment of origin, marked clearly and legibly?
Is the fish and derived products from fish intended for feed for fish?
In the case of fishmeal from farmed fish which is intended for feeding to farmed fish of another species, the scientific name of the species of origin
in the case of fish meal from wild fish, bearing the words ‘contains fish meal from wild fish only – may be used for the feeding of farmed fish of all species’;
in the case of fish meal from farmed fish, bearing the words ‘contains fish meal from farmed fish of the […] species only – may only be used for the feeding of farmed fish of other fish species’
in the case of fish meal from wild fish and from farmed fish, bearing the words ‘contains fish meal from wild fish and farmed fish of the […] species – may only be used for the feeding of farmed fish of other fish species’
Species of origin, including an indication of whether the aquatic animals were caught in the wild or produced in aquaculture.

South African requirements

Does the label contain:
Name of feed/pet food?
Registration number and reference to act 36 of 1947 (V number)?
Complete composition?
Weight/ mass of the container?
Name and address of the registration holder?
Batch number/ date of manufacture/ expiry date/ Best before date.
Withdrawal period for controlled substance
Levels of addition of controlled substances

Laboratory

Laboratory
Own Laboratory?
Accredited?
Accredited by?
Accredited for?
Name:
Is the lab equipped?
Approved by CA?
Does the lab have enough capacity?

Sterilizing plant check sheet - VPN 43

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Working hours

General

Layout Map

Non-conformance

Major non-conformance

Critical non-conformance:

Notes:

Raw materials

Controlled substances

GMOs

Declaration by establishment:

Declaration by auditor

Training

Training:

Cleaning team training:

Personal hygiene training

Non-conformance

Major non-conformance

Critical non-conformance:

Notes:

Personnel practices:

Protective clothing:

Non-conformance

Major non-conformance

Critical non-conformance:

Notes:

Hand washing:

Non-conformance

Major non-conformance

Critical non-conformance:

Notes:

Cleaning and sanitation:

Non-conformance

Major non-conformance

Critical non-conformance:

Notes:

Soap/ toilet paper/ disposable Towels:

Notes:

Pest control:

Non-conformance

Major non-conformance

Critical non-conformance:

Notes:

Construction and maintenance:

Non-conformance

Major non-conformance

Critical non-conformance:

Notes:

Waste disposal:

Non-conformance

Major non-conformance

Critical non-conformance:

Notes:

Contact wrapping and packing materials:

Non-conformance

Major non-conformance

Critical non-conformance:

Notes:

Water quality

Non-conformnce

Major non-conformance

Critical non-conformance:

Notes:

Dress code and code of conduct:

Major non-conformance

Critical non-conformance:

Notes:

Medical fitness of staff:

Daily medical checks:

Non-conformance

Major non-conformance

Critical non-conformance:

Hazard analysis and control:

Critical limmits

EU Methods

EU method 7