Information
-
Document No.
-
Audit Title
-
Client / Site
-
Conducted on
-
Prepared by
-
Location
-
Personnel
14.1 - FOREIGN BODY CONTROLS & RISK ASSESSMENT
-
The site must have effective procedures in place to eliminate (so far as practically possible) potential foreign body hazards
-
The site must have a documented risk assessment and corresponding policies and procedures for potential foreign body hazards including:
-
Glass and hard plastic
-
Wood
-
Metal
-
Paper
-
String
-
Tape
-
Maintenance debris
-
Personal effects
14.2 - GLASS & HARD CLEAR PLASTIC
-
Glass in production and storage areas must be replaced with suitable alternatives where possible
-
If glass cannot be replaced, glass items must be protected
14.3 - GLM: NEW EQUIPMENT
-
Introduction of new equipment or modification to existing equipment must eliminate glass and clear plastic where possible.
14.4 - GLM: REGISTER
-
All glass and hard clear plastic in production and storage areas must be listed on a register
-
Aspirational - brittle coloured plastics are considered for inclusion in the register, where they pose a risk of product contamination.
14.5 - GLASS AUDITS
-
Audits must be completed on all registered items at a frequency determined by risk assessment
-
Audit must record the condition of the item eg intact, broken, damaged but intact, undamaged but not working
-
Any issues raised must be investigated to establish if the glass breakage procedure has been followed and if not whether product has been put at risk
-
A risk assessment must be completed to determine how quickly repairs must be made
14.6 - GLASS BREAKAGE
-
A detailed procedure must be in place for the management of glass and hard plastic breakages - this must include:
-
Stopping of production
-
Restriction of movement through the affected area
-
Quarantine of affected materials
-
Report to management
-
Clean up of breakage and disposal / cleaning of cleaning equipment
-
Safe removal of glass from area
-
Repair or replacement of damaged item
-
The checking of PPE including footwear and changing if necessary
-
Completion of an incident log and sign off that production can restart, by a responsible / senior person
-
A sample of broken glass must be retained in a safe manner
-
Corrective action to prevent reoccurrence
14.7 - TRAINING
-
All employees must be briefed on the glass breakage procedure at induction
-
All production / hygiene managers and engineers must be trained to understand and apply the glass breakage procedure
14.8 - WOOD
-
The use of wood within the site production and storage areas where possible must be eliminated<br>(Hand tools, pencils, clip boards, furniture, brooms)
-
Where wood can not be eliminated in production and storage areas it must be minimised and suitably controlled - controls may include:
-
Layer separation between pallets and product
-
Coverage of materials stored under wooden pallets on racking systems
-
Broken pallets removed from system
-
Demarcation of where wooden pallets are or are not permitted within the site
14.9 - WOOD (2)
-
Wood must not be permitted in open food areas (medium) areas
-
Where wood is used in the process it must be controlled (eg pallets)
-
Sites must strive to eliminate all wood in processing areas and must be able to demonstrate that alternatives have been evaluated and why these options were not suitable
-
Controls for wood used in medium risk areas must be based on risk assessment. They must include:
-
Intake checks
-
Inspection for splinters / damage
-
Procedures for handling of breakage
14.10 - WOOD (3)
-
Wooden pallets destined for Tesco depots, must be in a good condition and not pose a contamination risk
14.11 - METAL CONTROL
-
There must be appropriate systems in place for the prevention of metal contamination
14.12 - METAL CONTROL (2)
-
Where metal is used in the process or integral to the product (bag clips, cans, packaging) it must be suitably controlled
14.13 - EQUIPMENT (METAL)
-
Knife, blade, scissors and needle control must be in place and include:
-
Only company issue, captive, identified and registered knives, blades and scissors must be used
-
All knives / scissors issued will be individually numbered to ensure they can be accounted for
-
Snap blade knives must not be used
-
Knives, blades and scissors must only be used for the task for which they were designed
-
Equipment must be accounted for and the condition checked and recorded (minimum start and end of production / shift)
-
In the event of breakage or loss, all parts must be accounted for and the incident logged - corrective action must be taken to prevent reoccurrence
-
A procedure must be in place for disposing of used knives
-
Knives and blades must not be stored in personal lockers - should be stored on shadow boards, magnetic holders ie. secured clean storage
14.14 - ENGINEERING (METAL)
-
Engineering activities must be controlled to avoid compromising product safety or quality
-
The following controls must be in place: (medium areas)
-
Start up checks of equipment must identify damaged or missing parts
-
In the event of damage or loss, all parts must be accounted for and the incident logged - corrective action must be taken to prevent reoccurrence
-
Potential transfer of metal contamination from engineering areas must be suitably controlled (eg swarf mats)
-
Wire brushes and scourers must be in a good condition and stored away from the production process or below product height when not in use
-
Mobile engineering work stations must not be used in open food areas
14.15 - FOREIGN BODY CONTROL
-
To minimise the risk of contamination from clear plastic liners and bags of a contrasting colour must be used where possible
14.16 - FOREIGN BODY CONTROL (2)
-
Bags and film gauges must be specified and be appropriate to avoid potential entrapment or tearing
14.17 - FOREIGN BODY CONTROL (3)
-
All unnecessary packaging must be removed prior to transfer of materials into production areas (traceability must be maintained)
14.18 - FOREIGN BODY CONTROL (4)
-
All wrapping must be removed from materials before cutting
14.19 - FOREIGN BODY CONTROL (5)
-
Inspection procedures must ensure that all entrapped packaging materials are removed during decanting of materials eg frozen
-
If entrapped packaging is identified, corrective action must be taken to remove the packaging prior to the material being used in production or the material must be rejected
14.20 - FOREIGN BODY CONTROL (6)
-
Opening and re-sealing of packaging must minimise the risk of potential contamination
-
A bag opening procedure must be in place and followed
14.21 - FOREIGN BODY CONTROL (7)
-
Correct grade, colour and quality of material must be selected for each application eg factory containers and PPE
14.22 - FOREIGN BODY CONTROL (8)
-
All damaged food / ingredient containers and trays must be removed from the system and corrective action implemented to prevent reoccurrence
14.23 - FOREIGN BODY CONTROL (9)
-
The use of food containers (bottles/pots/boxes) to store other materials eg nuts/bolts/chemicals must not be permitted
14.24 - MISCELLANEOUS ITEMS
-
All pens used within production, storage and packing areas must be site issued, one piece and of contrasting colour to product
-
Staples / staplers are not permitted in production, packaging or storage areas - including offices
-
Drawing pins are not permitted in production, packaging or storage areas - including offices
-
Hole punches are not permitted in production, packaging or storage areas - exception 1 per office clearly labelled / controlled not to leave office.
-
The number of miscellaneous items must be kept to a minimum
-
Required miscellaneous items must be of a contrasting colour and managed Eg calculators, rulers.
14.25 - FOREIGN BODY CONTROL (10)
-
The type condition and location of any labels used must not pose a risk of contamination
-
Aspirational - Paper labels in open food areas are kept to a minimum
14.26 - FOREIGN BODY CONTROL (11)
-
Aspirational - where FB detection equipment is in place, traceability labels/tags in open food areas are detectable
14.27 - FOREIGN BODY CONTROL (12)
-
All signage must be secure and effectively sealed against the wall to minimise risk of debris collecting behind
-
All signage must be washable
-
Aspirational - magnetic signage in use
14.28 - CARDBOARD CONTROL
-
The use of cardboard in production areas must be managed / controlled
-
Cardboard boxes are opened correctly to prevent ripping
-
Storage and packaging areas are regularly swept to remove card shards
-
Medium - risk assessment must be conducted prior to the use of cardboard in production areas
14.29 - DE-BOXING / DE-BAGGING
-
A procedure must be in place for the de-boxing and debagging of raw materials and packaging, which aims to minimise the risk of contamination
-
Training of procedure must be documented
14.30 - DE-BOXING / DE-BAGGING (2)
-
High - cardboard / paper sacks must not be used within high risk / high care areas
14.31 - FOREIGN BODY AUDITS
-
Foreign body audits must be completed at a frequency based on risk
