Information
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Document No.
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Audit Title
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Client / Site
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Conducted on
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Prepared by
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Location
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Personnel
15.1 - METAL DETECTION / X-RAY
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All products must be examined through a metal detection or X-ray detection system
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Documented justification, based on risk assessment must be given if detection is not in place (agreed with Tesco TM)
15.2 - TESCO COP 375
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All sites must comply with the requirements of Tesco COP 375 - FB detection systems:
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Reject log completed - rejects passed back through line 3 times, records kept
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Memory test completed at start and end of shift
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Consecutive test completed at start and end of shift, and minimum hourly during the shift
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Test pieces must be controlled - manufactured with serial number / issued with certificate
15.3 - EQUIPMENT
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Foreign body detection equipment must be specified as appropriate for the products that are being examined
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Equipment must be upgraded to improve detection sensitivity where advances in detection are developed
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The operation and sensitivity of the detector in use must be well understood by relevant site personnel
15.4 - EQUIPMENT - METAL DETECTORS
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All metal detectors must have the capability of detecting:
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Ferrous
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Non-ferrous
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Stainless steal
15.5 - EQUIPMENT - FOREIGN BODY DETECTION
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All foreign body detectors must be located as close as possible to the finished packaging point
15.6 - EQUIPMENT - FOREIGN BODY DETECTION (2)
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All foreign body detectors must have adequate security devices, so only authorised personnel have access to alter settings
15.7 - EQUIPMENT - CONVEYOR SYSTEMS
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A conveyor type detection system must have:
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An effective automatic rejection system
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A locked box to receive rejected product
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A fully enclosed area around the search head and rejection box
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A visual or audio alarm system in the event of detection
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Aspirational - foreign body detector systems include:
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A data capture system to show pack numbers checked
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The number of rejects, number and type of tests
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Foreign body detector system highlights when tests are due
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Visual or audible alarm system in the event of line fault and fail safe activation
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The system stops if a test has not been completed
15.8 - EQUIPMENT - IN LINE SYSTEMS
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In line metal detectors (eg pipe detectors) must have a visual or audible alarm
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In line metal detectors (eg pipe detectors) must reject product into a dedicated container
15.9 - EQUIPMENT
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The foreign body detection system must be serviced at regular intervals, either by equipment manufacturer or trained contractors (minimum annually)
15.10 - TESTING OF EQUIPMENT
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The foreign body detector must be fully operational at the start of production
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An effective testing method must be in place and all checks must be documented
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Detectors must be checked at the beginning and end of production, and minimum hourly during the run
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The test pieces must be placed in the worst case scenario area - on advice from equipment manufacturer.
15.11 - FAIL SAFE SYSTEMS
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Detector fail safe systems where fitted must be challenged at start and end of day to make sure they are effective - fail safe systems / checks should include:
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Reject confirmation - start / end production
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Bin full - start / end production
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Air pressure low - start / end production
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Search head failure - start / end production
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Back-up sensor - start / end production
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Photo electric cell pre search head - start / end production
15.12 - PLASTERS
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Each batch of detectable plasters must be checked to ensure they are detected by the lowest sensitivity X-ray
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Plaster checks must be completed by placing plaster in the product
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Records must be kept of dectable plaster checks
15.13 - DETECTOR FAILURE
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In the event of a FB detector failing (test piece/failure to reject product) all product since last good check must be isolated and retested though a unit that has been confirmed to be working correctly
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A detailed procedure must be in place to handle incidents when FB's are found in product
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A full investigation must take place to ensure the source of contamination is identified and the risk of other materials being contaminated must be assessed
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Corrective actions must be put in place to prevent a reoccurrence - details of investigation recorded
15.14 - TRAINING
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All staff involved with FB detection must be trained in technical and operational requirements
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All staff involved with FB detection must be trained in principles of FB detection to ensure full understanding of the purpose
15.15 - SIEVING / FILTERING RISK ASSESSMENT
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Risk assessments must be completed to determine whether a particular material requires sieving / filtering (including liquids)
15.16 - SIEVING
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Where sieves / filters are used these must be metal detectable or of a contrasting colour to the food
15.17 - EQUIPMENT
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Equipment used for sieving / filtering must have written inspection procedures
15.18 - EQUIPMENT (2)
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Sieving / filtering equipment must be inspected for integrity at pre-defined intervals as identified in the risk assessment and recorded
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Equipment must be accessible to enable inspection
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Mobile equipment must be uniquely identified to ensure that the integrity of each sieve is being maintained
15.19 - PREVENTATIVE MAINTENANCE
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Sieves and filters must be included on the preventative maintenance plan
15.20 - TRAINING
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Training of personnel operating or inspecting the sieving / filtering equipment must take place
15.21 - TRACEABILITY
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Records must be in place to demonstrate when ingredients have been sieved / filtered (traceable to batch level)
15.22 - STORAGE
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Stored sieved ingredients must be protected to prevent post sieving contamination
15.23 - SIEVING
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A sieve matrix must be in place detailing the type of material, sieve size, frequency of inspection and sieve location
15.24 - FOREIGN BODIES
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Procedures must be in place for actions when foreign bodies are found
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A full investigation must take place to ensure the source of contamination is identified and corrective action plan implemented (and product dealt with in appropriate manner)
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Details of the investigation must be recorded
15.25 - SIEVE TAILINGS
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Sieve tailings must be checked and recorded at regular intervals as defined in the risk assessment
