GUIDELINES FOR IMPLEMTING GMP IN FOOD PROCESSING Food Handling practices 5. 1 Use of colour coded equipment 5.1.1 Equipment used in different areas of a factory should be colour coded or clearly dentified in such a manner as to designate that department and to prevent the risk of cross contamination e. g. chopping boards, knives and product trays used in the raw material area must not be used in the work in progress or finished product sections Auditors Recommendations. Look At: Look For. Equipment Identification Equipment colour coded clearly or uniquely identified for intended use 5.1.2 Each department should have an inventory of all colour coded or uniquely identified equipment, which is checked daily and any damaged or broken items replaced Auditors Recommendations Look At Look For. Equipment Identification and Equipment colour coded or uniquely identified for intended use traceability Records of equipment and traceability 5.1.3 Each department should be supplied with sufficient colour coded or uniquely identified equipment to eliminate the need to"borrow items from other areas, even on a temporary basis Auditors Recommendations Look At Look For Equipment Identification and Equipment colour coded clearly or uniquely identified for intended use traceability Records of equipment and traceability 5.1. 4 The use of brightly coloured coded equipment will significantly reduce the potential for foreign body contamination as splinters of it would be easily identified in the product Auditor's Recommendations Look At: Look For. Equipment Identification Equipment colour coded clearly to identify intended use
GUIDELINES FOR IMPLEMTING GMP IN FOOD PROCESSING 5. Food Handling Practices 5.1 Use of colour coded equipment 5.1.1 Equipment used in different areas of a factory should be colour coded or clearly dentified in such a manner as to designate that department and to prevent the risk of cross contamination e.g. chopping boards, knives and product trays used in the raw material area must not be used in the work in progress or finished product sections. Auditor’s Recommendations: Look At: Look For: Equipment Identification Equipment colour coded clearly or uniquely identified for intended use 5.1.2 Each department should have an inventory of all colour coded or uniquely identified equipment, which is checked daily and any damaged or broken items replaced. Auditor’s Recommendations: Look At: Look For: Equipment Identification and traceability Equipment colour coded or uniquely identified for intended use Records of equipment and traceability 5.1.3 Each department should be supplied with sufficient colour coded or uniiquely identified equipment to eliminate the need to “borrow” items from other areas, even on a temporary basis. Auditor’s Recommendations: Look At: Look For: Equipment Identification and traceability Equipment colour coded clearly or uniquely identified for intended use Records of equipment and traceability 5.1.4 The use of brightly coloured coded equipment will significantly reduce the potential for foreign body contamination as splinters of it would be easily identified in the product. Auditor’s Recommendations: Look At: Look For: Equipment Identification Equipment colour coded clearly to identify intended use
5.2 Adequate control of product containers 5.2.1 All product containers, whether for raw materials, work in progress or finished product, must be clean and in good condition to prevent the risk of foreign body contamination Auditors recommendations Look At Look For. Equipment Cleaning records for containers aw Material/ Finished Suitability of containers for intended use product conveyance Non-conformance and corrective action reports 5.2.2 Product containers must give the product adequate protection from external sources Auditors Recommendations. Look At: Look For. ent Cleaning records for containers Raw Material Finished Suitability of containers for intended use Non-conformance and corrective action reports Container protection 5.2.3 All product containers must be held off the floor e.g by the use of plastic pallets, plastic wheels to prevent contamination from the floor and to allow access for "clean as you go"in the event of product Auditor's Recommendations. Look At Look For Container Storage Storage to housekeeping and food safety practices Cleaning records for storage facilities 5.2.4 Product containers must not be stored against walls because of the potential foreign body risk, damage to the wall and access for cleaning Auditors recommendations Look At: Look For Product Contamination Non conformance records Foreign Body Records Risk Assessment
5.2 Adequate control of product containers 5.2.1 All product containers, whether for raw materials, work in progress or finished product, must be clean and in good condition to prevent the risk of foreign body contamination. Auditor’s Recommendations: Look At: Look For: Equipment Raw Material / Finished product conveyance Cleaning records for containers Suitability of containers for intended use Non-conformance and corrective action reports 5.2.2 Product containers must give the product adequate protection from external sources. Auditor’s Recommendations: Look At: Look For: Equipment Raw Material / Finished product conveyance Cleaning records for containers Suitability of containers for intended use Non-conformance and corrective action reports Container protection 5.2.3 All product containers must be held off the floor e.g by the use of plastic pallets, plastic wheels to prevent contamination from the floor and to allow access for “clean as you go” in the event of product spillage’s. Auditor’s Recommendations: Look At: Look For: Container Storage Storage to housekeeping and food safety practices Cleaning records for storage facilities 5.2.4 Product containers must not be stored against walls because of the potential foreign body risk, damage to the wall and access for cleaning. Auditor’s Recommendations: Look At: Look For: Product Contamination Non conformance records Foreign Body Records Risk Assessment
5.3 Accountability for ingredients in production-full traceability 5.3.1 It is recommended that all ingredients used in production should have a raw material batch code, to identify them in storage and processing, and accompanying documentation. (This also includes packaging) Auditors Recommendations. Look At: Look For. Product Identification and ldentification codes to all product with records for traceability Traceability 5.3.2 Ingredients should be transported within the factory premises in such a way that their identities are not Auditors Recommendations Look At: Look For. Product fication and ldentification codes to all product with records for traceability Tracert 5.3.3 There should be a formalised procedure for the issue of food ingredients from stores indicating the amount issued batch code and date of issue Auditors Recommendations Look At Look For. Product ldentification and ldentification codes to all product with records for traceability Traceability Records of issue to production 5.3.4 Where the addition of batch quantities of ingredients to a batch is carried out manually by an operator the addition of each ingredient to the batch should be recorded at the time of manufacturing to minimise the risk of accidental omission and to ensure traceability of ingredients Auditors Recommendations Look At Look For. Product Identification and ldentification codes to all product with records for traceability Traceability Manufacturing Production records 5.3.5 Where the process involves a"resting"stage or delay with work in progress/part processed materials they must be given a reference code Auditors Recommendations Look At: Look For Product Identification and ldentification of all products whether raw, in-production or finished product Traceability
5.3 Accountability for ingredients in production - full traceability 5.3.1 It is recommended that all ingredients used in production should have a raw material batch code, to identify them in storage and processing, and accompanying documentation. (This also includes packaging). Auditor’s Recommendations: Look At: Look For: Product Identification and Traceability Identification codes to all product with records for traceability 5.3.2 Ingredients should be transported within the factory premises in such a way that their identities are not lost. Auditor’s Recommendations: Look At: Look For: Product Identification and Traceability Identification codes to all product with records for traceability 5.3.3 There should be a formalised procedure for the issue of food ingredients from stores indicating the amount issued, batch code and date of issue. Auditor’s Recommendations: Look At: Look For: Product Identification and Traceability Identification codes to all product with records for traceability Records of issue to production 5.3.4 Where the addition of batch quantities of ingredients to a batch is carried out manually by an operator, the addition of each ingredient to the batch should be recorded at the time of manufacturing, to minimise the risk of accidental omission and to ensure traceability of ingredients. Auditor’s Recommendations: Look At: Look For: Product Identification and Traceability Identification codes to all product with records for traceability Manufacturing / Production records 5.3.5 Where the process involves a “resting” stage or delay with work in progress/part processed materials, they must be given a reference code. Auditor’s Recommendations: Look At: Look For: Product Identification and Traceability Identification of all products whether raw, in-production or finished product
5.3.6 The company should have sufficient documentation so that any batch of finished product can be correlated with the individual deliveries of raw materials used in manufacturing and with the corresponding laboratory records. (This is essential in the event of a product recall) Auditors Recommendations Look At Look For Product Identification and Records of traceability Traceability Records of Laboratory tests and results Laboratory Test Records 5.4 Temperature control disciplines 5.4.1 Where hand held digital thermometers are used to check temperatures they must be cleaned and sterilised in between use, to prevent cross contamination Auditors Recommendations Look At: Look For Temperature Control Use of suitable equipment and records maintained Cleaning procedure and records Provision of sterilisation facility suitable for thermometers 5.4.2 Hand held thermometers should be designated to a particular department and should be suitably accurate and precise for the operation being carried out Auditors recommendations Look At Look For Temperature Contro Use of suitable equipment and records maintained 5.4.3 Where temperatures are critical to the process e.g. during cooking of batch recipes, chilling and storage, they should be monitored at an agreed frequency, recorded and signed Auditors Recommendations Look At Look For Temperature Control Use of suitable equipment and records maintained Frequency of recording or use of control charts Completion of temperature records
5.3.6 The company should have sufficient documentation so that any batch of finished product can be correlated with the individual deliveries of raw materials used in manufacturing and with the corresponding laboratory records. (This is essential in the event of a product recall). Auditor’s Recommendations: Look At: Look For: Product Identification and Traceability Laboratory Test Records Records of traceability Records of Laboratory tests and results 5.4 Temperature control disciplines 5.4.1 Where hand held digital thermometers are used to check temperatures they must be cleaned and sterilised in between use, to prevent cross contamination. Auditor’s Recommendations: Look At: Look For: Temperature Control Use of suitable equipment and records maintained Cleaning procedure and records Provision of sterilisation facility suitable for thermometers 5.4.2 Hand held thermometers should be designated to a particular department and should be suitably accurate and precise for the operation being carried out. Auditor’s Recommendations: Look At: Look For: Temperature Control Use of suitable equipment and records maintained 5.4.3 Where temperatures are critical to the process e.g. during cooking of batch recipes, chilling and storage, they should be monitored at an agreed frequency, recorded and signed. Auditor’s Recommendations: Look At: Look For: Temperature Control Use of suitable equipment and records maintained Frequency of recording or use of control charts Completion of temperature records
5. 4. 4 All temperature recording equipment must be regularly calibrated against a given standard and maintained in good condition. Any temperature discrepancies of manual checking against automatic temperature monitoring must be investigated Auditors recommendations Look At Look For Temperature Contro Use of suitably precise equipment Calibration and Testing Frequency of calibration Records of maintenance 5.5 Risk assessment and HAccP documentation 5.5. 1 A system of Hazard Analysis and Critical Control points should be established and all appropriate process flow charts and documentation to go with it should be available Auditors Recommendations: Look At: Look For HACCP System and Plan Establishment of the HACCP principles with relevant material accessible with suitable validation and verification of the plan 5.5.2 There should be evidence that the HACCP system is regularly reviewed and that problems highlighted as a result of internal audits are actioned accordingly Auditor's Recommendations. Look At Look For HACCP System and Plan Internal Quality Audit Records Non conformance and corrective action reports indicate activities actioned onitoring frequency established 5.5. 3 Where the product development programme introduces a new type of product, with different manufacturing parameters, the HACCP system should be implemented prior to product launch Auditors Recommendations Look At: Look For. New Product Development identified new product activities HACCP System and Plan Implementation of HACCP plan to meet new product demands
5.4.4 All temperature recording equipment must be regularly calibrated against a given standard and maintained in good condition. Any temperature discrepancies of manual checking against automatic temperature monitoring must be investigated. Auditor’s Recommendations: Look At: Look For: Temperature Control Calibration and Testing Use of suitably precise equipment Frequency of calibration Records of maintenance 5.5 Risk assessment and HACCP documentation 5.5.1 A system of Hazard Analysis and Critical Control points should be established and all appropriate process flow charts and documentation to go with it should be available. Auditor’s Recommendations: Look At: Look For: HACCP System and Plan Establishment of the HACCP principles with relevant material accessible with suitable validation and verification of the plan 5.5.2 There should be evidence that the HACCP system is regularly reviewed and that problems highlighted as a result of internal audits are actioned accordingly. Auditor’s Recommendations: Look At: Look For: HACCP System and Plan Internal Quality Audit Records Non conformance and corrective action reports indicate activities actioned Monitoring frequency established 5.5.3 Where the product development programme introduces a new type of product, with different manufacturing parameters, the HACCP system should be implemented prior to product launch. Auditor’s Recommendations: Look At: Look For: New Product Development HACCP System and Plan Identified new product activities Implementation of HACCP plan to meet new product demands