CTA 023 CTS Section Three Site Standards

8/3/2019 CTA 023 CTS Section Three Site Standards

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CTS Section Three Site

Standards

Document Ref CTA 023Date 05/06/2009Version No 005Author J BarnettAuthorised By D Raine

CLAUSE CLAUSE DETAILS

External Standards

3.1

STATEMENT OF INTENT: The site shall be of suitable size, location, construction anddesign, to facilitate maintenance, to prevent contamination and enable the production ofsafe and legal finished products.

3.1.1

Premier Foods shall ensure it conforms to local regulations including registration and / orapproval of premises.

3.1.2

Consideration shall be given to local activities and environment, which may have anadverse impact on finished product integrity, and measures shall be taken to preventcontamination. Where measures have been put in place to protect the site from anypotential contaminants, these shall be regularly reviewed to ensure they continue to beeffective e.g. dust or odour.

3.1.3

The site boundaries shall be clearly defined.

3.1.4

The external areas shall be maintained in good order to an appropriate standard. Wherebuildings are surrounded by grassed or planted areas, these shall be regularly tendedand well maintained. The condition of the site shall be included within the internal auditprocess. All roadways and paths within the perimeter shall be concreted, paved,tarmaced, well drained and maintained in good repair

3.1.5

External traffic routes, under site control, shall be suitably surfaced and maintained ingood repair to avoid contamination of the product.

3.1.6

Perimeter areas shall be kept clean and free from rubbish, overgrown vegetation anddisused equipment.

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3.1.7

The building fabric shall be maintained to minimise potential for product contaminatione.g. pipe work shall be appropriately sealed to prevent pest entry, ingress of water and

other contaminants.

3.1.8

The perimeter must be baited against rodents.

3.1.9

A clean and unobstructed area shall be provided along external walls of buildings usedfor production and storage. Where there are adjoining walls, procedures shall be inplace to retain an appropriate level of product protection and cleanliness.

3.1.10

Where natural drainage is inadequate, external drainage shall be installed. The potentialrisk of flooding shall also be considered.

Security

3.2

STATEMENT OF INTENT: Security shall be maintained at all times to prevent access ofunauthorised persons to production and storage areas.

3.2.1

Access to the site by employees, contractors and visitors shall be controlled and a visitorreporting system shall be in place.

3.2.2

Staff shall be trained in site security procedures and encouraged to challengeunidentified or unknown visitors.

3.2.3

Measures shall be in place to maintain site security and to ensure only authorised staffhave access to production and storage areas via designated access points. Areas shallbe assessed according to risk; sensitive or restricted areas shall be defined, clearlymarked, monitored and controlled.




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3.2.4

Based on risk assessment, procedures shall be in place to ensure the secure storage ofall materials including ingredients, packaging chemicals and equipment.

3.2.5

Procedures shall be in place to ensure that finished product is held under secure storageand transportation conditions e.g. tamper evident packaging, contractual handlingagreements.

3.2.6

Boundary fences, doors and door locks must be maintained and in good repair.

3.2.7

All external storage units, silos, refrigerators and freezers must be fitted with locks andremain locked when not in use.

3.2.8

Where required by legislation, the site shall be registered with, or approved by, the

appropriate authority.

3.2.9

Dogs and other domestic animals are not permitted on sites. Where guard dogs areused for security, these must be under the control of the security personnel and not freerunning.

Internal Site Standards

3.3.1

FUNDAMENTAL CLAUSE: Premises and plant shall be designed, constructed andmaintained and procedures shall be in place to control the risk of product contaminationand to comply with all relevant legislation.




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3.3.1.1

Premises shall allow sufficient working space and storage capacity to enable alloperations to be carried out properly under safe hygienic conditions.

3.3.1.2

Temporary structures constructed during building work or refurbishment etc shall bedesigned and located to avoid pest harbourage and potential contamination of products.

3.3.1.3

The building shall be fully proofed against pests with all areas readily accessible for pestcontrol inspections. Health and safety procedures must be followed when accessingareas.

3.3.1.4

The process flow from intake to dispatch shall be arranged to minimise the risk ofproduct contamination. Product crossover shall be minimised.

3.3.1.5

Physical barriers or demonstrably effective procedures shall be in place to minimise therisk of contamination of raw materials, intermediate / semi processed products,packaging and finished products with particular consideration given to special handlingrequirements for specific materials.

3.3.1.6

Any conveyances used in the transport of food, e.g. trolleys, trays and crates shall besegregated so that those used for raw materials will not be used for the transport offinished products.

3.3.1.7

All equipment used in the high care area must be dedicated (including engineering).

3.3.1.8

The systems of working shall be such to reduce any potential physical, chemical(including allergens) or microbiological contamination risks.




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3.3.1.9

Offices within production and storage areas shall be controlled and managed to ensurethey pose no risk to product. Equipment must be kept to a minimum to allow easy

cleaning. Eating and drinking shall not be permitted in these offices.

3.3.1.10

Segregation shall take into account the flow of product, nature of materials, equipment,personnel, waste, airflow, air quality and services provision.

3.3.1.11

There shall be effective segregation in place to minimise the risk of productcontamination where specific handling requirements are required, e.g. allergens, or

identity preserved products.

3.3.1.12

Based on risk assessment, facilities for tray and utensil washing and general purposecleaning shall, where appropriate, be adequately segregated from production activities.The cleaning of production utensils shall be carried out in segregated areas or at specifictime periods separated from the production process. If this is not possible, theseoperations shall be controlled as to not affect the product.

Adequate segregated storage space shall be available for both dirty and clean utensils.

The facilities shall be supplied with both hot and cold running water and a detergentdosing system where appropriate. There shall be adequate drainage. Provision shall be made for soaking, cleaning and rinsing. The area shall be adequately ventilated with extraction canopies if necessary. Automated utensil-wash units shall be assessed before use as to the correctoperational procedures and conditions of temperature, cleaning chemicals and timerequired.

3.3.1.13

Cleaning and inspection of areas and equipment shall be aided by the avoidance ofobstructions and where appropriate the provision of adequate spaces.

3.3.1.14

Where high-risk products are manufactured, there shall be physical segregation betweenprocessing and finished product handling areas. This high risk area shall be fabricatedand designed to a high standard of hygiene, and practices shall be in place to controlingredients, equipment, packaging, environment and personnel to preventcontamination.




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3.3.1.15

In high-care areas where there is a significant risk of contamination of chilled ready toeat/heat products by pathogenic micro-organisms, the processing or handling of food in

these areas shall be appropriate to minimise product contamination by such micro-organisms.

3.3.1.16

Barriers shall be complete from floor to ceiling with the only breaks at the agreedcontrolled points (e.g. hatchways for packaging, fryer/travelling oven outlets into highcare).

3.3.1.17

The design layout and construction of the premises shall ensure there is effectiveseparation between low care and high care areas to prevent risks of cross contaminationfrom the low care environment, low care materials or operators. This shall includemovement of ingredients/raw materials, packaging, equipment, personnel,water/drainage and airflow.

3.3.1.18

There shall be no entrances directly from raw protein handling areas to high care areas.

3.3.1.19

A risk assessment must be carried out on all food ingredients, equipment and othermaterials which are to be transferred into high care areas to ensure that suitable andeffective methods of transfer are used. The controls implemented as a result of this riskassessment shall be validated, verified and monitored.

3.3.1.20

Where spices and other dried ingredients (including heat treated spices) with a knownmicrobiological risk are being used, these shall be heat treated into high care. Wherethis is not possible an alternative validated biocidal regime must be in place (e.g.acidification).

3.3.1.21

Packaging materials which have been microbiologically decontaminated shall beprotected from re infection prior to entry into the high care area.




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3.3.1.22

The location of all transfer points shall not compromise high-risk and low-risksegregation and practices shall be in place to minimise risk of product contamination,

e.g. disinfection.

3.3.1.23

Disinfecting soak tanks or spray tunnels must use an approved terminal disinfectant at aminimum 1% concentration, or 100ppm free chlorine. Disinfectant spray systems shalloperate automatically when the conveyor is switched on. Suitable controls must beoperated to ensure equipment is kept in good working order, spray nozzles remain clear,and chemical concentrations are maintained at the correct level.

3.3.1.24

Controls for cooking or blanching equipment must be sited to be accessible for and usedonly by personnel in only one of the areas (high care or low care). They must not beaccessible to both sides.

3.3.1.25

Any continuous band conveyors shall not bridge the low/high care barrier, but mustbreak at the dividing line.

3.3.1.26

Equipment shall not be transferred across the low care/high care barrier. Where this isunavoidable, heat treatment by a steam cabinet or oven must be used.

3.3.1.27

Utensils must not be passed in either direction across the low care/high care barrier.

3.3.1.28

Where appropriate, e.g. high risk areas, positive air pressure systems must be in place.High risk production areas must maintain a positive pressure to prevent ingress ofcontaminants from outside. The air should be filtered to appropriate microbiologicalstandards. (Also see CCFRA Guideline No.12).




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Fabrication

3.3.2.1

STATEMENT OF INTENT: The fabrication of the site, buildings and facilities shall besuitable for the intended purpose. All internal surfaces shall be impervious, easy toclean and in sound condition.

Fabrication - Walls

3.3.2.1.1

Walls shall be designed, constructed, finished and maintained to prevent the

accumulation of dirt, minimise condensation and mould growth, and facilitate cleaning.

3.3.2.1.2

Floor/wall and similar junctions shall be coved. Severe angling shall be avoided.

3.3.2.1.3

Walls shall be adequately protected against any mechanical damage (e.g. bump-bars).

3.3.2.1.4

Cavity wall construction shall be avoided. Where unavoidable, suitable access shall beprovided for pest control purposes.

Fabrication - Floors

3.3.2.2.1

Floors shall be designed to meet the demands of the process, and withstand cleaningmaterials and methods. They shall be impervious and maintained in good repair.

3.3.2.2.2

Drainage, including drains from laboratories, where provided, shall be sited, designedand maintained to minimise risk of product contamination and not compromise productsafety. Machinery and piping shall be arranged so that, wherever feasible, processwaste water goes directly to drain.

3.3.2.2.3

Drains shall be accessible for cleaning and fitted with screens or traps to prevent pestentry.

3.3.2.2.4 There shall be a drain plan in place for the entire site, including the external areas.




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3.3.2.2.5

Drainage systems for high care and low care areas shall be totally independent, andshall only join outside the building. It must not be possible for any back-flow to occur.

3.3.2.2.6

Drains from laboratories shall not present a risk to products.

3.3.2.2.7

Where significant amounts of water are used, or direct piping to drain is not feasible,floors shall have adequate falls to cope with the flow of any water or effluent towards

suitable drainage. In low care areas this fall shall be away from the high care barrier.

Fabrication - Ceilings

3.3.2.3.1

Ceilings and overheads shall be designed, constructed, finished and maintained toprevent the accumulation of dirt, minimise condensation and mould growth, and facilitatecleaning.

3.3.2.3.2

Where suspended ceilings are used, adequate access to the void shall be provided tofacilitate cleaning, maintenance of services and inspection for pest activity.

Fabrication - Windows

3.3.2.4.1

Where there is a risk to product, windows and roof glazing, which are designed to beopened for ventilation purposes, shall be adequately screened to prevent the ingress ofpests. Screening shall be well fitted and removable to allow cleaning.

3.3.2.4.2Window sills shall be sloped to prevent use as shelves.

3.3.2.4.3 Wooden window frames are not recommended. Where used, they shall be

painted/sealed to facilitate cleaning, and shall be free from damage and rot.




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3.3.2.4.4

Where they pose a risk to product glass windows shall be protected against breakage.

Fabrication - Doors

3.3.2.5.1

Where external doors to raw material handling, processing, packing and storage areasare opened, suitable precautions shall be taken to prevent pest ingress. Doors and docklevellers in these areas shall be close fitting or adequately proofed.

3.3.2.5.2

Door surfaces shall be adequately protected against mechanical damage (e.g. metalkick-plates). Wooden doors and door frames shall be painted/sealed to facilitatecleaning, and shall be free from damage and rot.

3.3.2.5.3

Doors shall be in good condition and easy to clean and disinfect, where required.

3.3.2.5.4

For High Care / Risk areas fire exits must be alarmed or tamper evident

3.3.2.5.5

Where removable wall sections (pod doors) are used between high care/risk and lowcare wall for occasional access, these must be close fitting and sealed each time afteropening. A full deep clean of the high care/risk area must be undertaken if removedbefore production re-commences.

Fabrication - Lighting

3.3.2.6.1

Suitable and sufficient lighting shall be provided for a safe working environment, correctoperation of processes, inspection of product and effective cleaning. Lighting in allareas of the premises shall be sufficient to enable product inspection and cleaningactivities to be carried out effectively




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3.3.2.6.2

All bulbs and strip lights, including those on electric fly killer units, where they constitutea risk to products, shall be protected by shatterproof plastic diffusers, sleeve covers, or

with a shatterproof protective coating. Sheathed bulbs shall be adequately marked as totheir protected status. Where full protection cannot be provided alternative managementsuch as wire mesh screens or monitoring procedures shall be in place.

3.3.2.6.3

For high temperature lights, where plastic covers are not viable, a fine mesh metalscreen shall be fitted. Where full protection cannot be provided the glass managementsystem shall take this into account

Fabrication

3.3.2.7

Where appropriate all internal surfaces should be of a light colour such that the standardof cleanliness can be demonstrated.

3.3.2.8

Fabrication joints must be sealed, free from mould, and pose no foreign body risks

Air conditioning / Ventilation

3.3.2.9.1

Adequate ventilation and extraction shall be provided in product storage and processingenvironments to prevent condensation or excessive dust.

3.3.2.9.2

A risk assessment shall be undertaken to assess the need to provide air filtration orscreening to the production area. Where air filtration is required this shall be subject to

regular maintenance.

3.3.2.9.3

Where the process requires screened or filtered air, the equipment used for this purposeshall be easily accessible, adequately maintained and cleaned.

3.3.2.9.4

Where appropriate, positive air pressure systems shall be in place.

3.3.2.9.5 Ventilation / air supply must be adequate for the production process and must not be apotential source of product contamination.




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3.3.2.9.6

Natural air flow is not sufficient where processing dissipates heat, steam or dust or inhigh risk areas. Ventilation should not rely on open doors or windows.

3.3.2.9.7

Air intake equipment must be designed to incorporate filters or mesh to prevent ingressof dirt/insects. Air intakes must be sited away from potential taint or pollution sources.

3.3.2.9.8

Airflow must pass from clean or high risks areas to dirty or low risk areas.

3.3.2.9.9

Ducting should be designed to reduce dust lodging and facilitate cleaning.

3.3.2.9.10

Processes which give off steam or other vapours must be effectively hooded and fittedwith adequate extraction equipment. It is essential that condensation does not dripdirectly onto product or equipment, but is adequately channelled to a drain. Suchequipment must be capable of accommodating surges, e.g. opening of oven doors orkettle lids.

3.3.2.9.11

Fans and condensers should be positioned outside production areas and must beincluded on a regular cleaning and maintenance schedule.

3.3.2.9.12

Condensate from extraction systems, chillers or evaporators must be plumbed directly tothe drain. There must be access for regular sanitising of the evaporator, drip tray anddrainage system. Particular attention should be paid to the risk of back-syphoning ofcondensate water from refrigeration equipment drain systems.

3.3.2.9.13 All air supplies which come into direct contact with product, materials or process linesmust be fitted with adequate water and oil traps and where applicable, must also befiltered to prevent microbial contamination.




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3.3.2.9.14

For high care / risk areas air filtration must be in place, regularly maintained andincorporate the following requirements

Positive air pressure, supported by a site study to measure air pressure Risk assessed filter sizes appropriate to the potential contamination likely to beencountered from the local environment Air socks in use must be cleaned and maintained at defined frequencies, adequateenough to prevent build up of debris / mould. Air socks shall be identified for rotation.

Utilities

3.4

STATEMENT OF INTENT: All utilities to and within the production and storage areasshall be designed, constructed, maintained and monitored to effectively control the riskof product contamination.

3.4.1

All water used as a raw material in the manufacture of processed food, the preparationof primary product, or for equipment or plant cleaning shall be supplied in sufficient

quantity, be potable or pose no risk of contamination according to applicable legislation,either being drawn from mains supply or suitably treated according to its source.

3.4.1.1.

Certificates of potability from the local water provider shall be held, however based onrisk assessment it may be necessary for additional testing to be undertaken.

3.4.2

Where water is used for primary washing of raw materials prior to the manufacture ofprocessed food and where potable water is not used, procedures shall be in place tominimise the risk of contamination of semi-processed or processed product.

3.4.3

Water tanks shall be of adequate capacity, tightly lidded, and lined internally withsuitable materials.

3.4.4 Water tanks shall be regularly inspected for cleanliness and foreign body contamination,and included on the site cleaning schedule. Details of checks and inspections shall berecorded.




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3.4.5

All water tanks shall be identified with a number and labelled accordingly together withdetails of where the water is being fed to. A plan of the water storage and distributionsystem shall be maintained on site. This plan shall show both potable, and non-potablewater lines.

3.4.6

Redundant water pipework and other services shall be removed to avoid deadlegs.

3.4.7

Water softeners shall be carefully maintained in accordance with manufacturersinstructions. Records of all inspections/maintenance work shall be maintained.

3.4.8

Based on risk assessment, the microbiological and chemical quality of water, steam, ice,air, compressed air or other gas that comes into direct contact with the food orpackaging, that in itself does not constitute an ingredient, shall be regularly monitored,on a risk assessment basis, shall comply with relevant legal regulations and shall

present no risk to product safety or quality.

3.4.8.1

A suitable programme of microbiological testing of water supplies to include criticalpoints of use and bulk storage tanks shall be in use.

3.4.8.2

Water used as an ingredient without further heat processing, or in direct contact withhigh care food (e.g. component cooling/washing) shall be subject to a weeklyprogramme of microbiological sampling and analysis.

3.4.9

Pipes, cables and similar shall be situated far enough from the wall, and off the floor toallow adequate access for cleaning.

3.4.10

Electrical cables shall be carried on an open tray rather than in enclosed units. All cable

ties shall be secured and made good in order to reduce the risk of contamination.




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3.4.11

Adequate access shall be provided to the base of all lift shafts for pest control andcleaning purposes.

3.4.12

Where borehole water is used, effective systems for the management and monitoringshall be in place.

Equipment

3.5

STATEMENT OF INTENT: Equipment shall be suitably designed for the intendedpurpose and shall be used so as to minimise the risk of contamination of product.

3.5.1

All equipment shall be properly specified before purchase, constructed of appropriatematerials, be of a suitable design to ensure it can be effectively cleaned and shall betested and commissioned prior to use

3.5.2

Equipment shall be positioned and designed / engineered so as to give access under,inside and around it for ease of routine cleaning, inspection and servicing, or wherepermanently sited shall be properly secured and sealed to the floor. It shall also bedemonstrated that routine cleaning procedures minimise the risk of contamination

3.5.3

Certificates of conformity or other evidence shall be available for equipment in direct

contact with food to confirm its suitability for use, e.g. conveyor belts.

3.5.4

There shall be start up checks of equipment to check for missing or damaged parts

3.5.5 Any replacement of, repairs to, or modifications of existing equipment, shall bedocumented and agreed with the appropriate competent site technical/HACCP

representative to ensure that the changes do not compromise product safety. Whererequired this shall prompt a review of the HACCP plan. Any replacements, modificationsor major repairs/changes shall be highlighted at the daily site meetings.




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3.5.6

Non-flaking, corrosion resistant materials shall be used on equipment in order to preventproduct contamination. Where this is unavoidable, these materials must be maintainedin good condition so as not to pose a foreign body hazard.

3.5.7

Food contact surfaces shall where possible be smooth, non-porous and inert to the food

being produced, unless a documented risk assessment has been undertaken and noother materials have been highlighted as suitable for the specific process

3.5.8

Parts susceptible to wearing on mechanical equipment e.g. belts brushes and scrapersthat come into contact with food shall be made of a contrasting colour to the food and beregularly inspected for wear and damage. Parts may be converted to a contrastingcolour on a replacement basis.

3.5.9

Wherever possible nuts, bolts, washers and sieve mesh etc. used on food processingequipment shall be made from magnetic stainless steel. Where aluminium washers arenecessary, these shall be nickel coated.

3.5.10All welding shall be continuous, and ground smooth.

3.5.11Use shall be made of Nylock type nuts wherever possible or similar secure fittings.

3.5.12

Wooden equipment and utensils shall not be used in areas where exposed product isprocessed or stored. Where this is unavoidable, and the risk is managed the conditionof the wood shall be subject to regular documented checks to ensure that it is in goodorder and clean.

3.5.13 Glass equipment or equipment containing glass shall not be used. Where the use ofsuch equipment is unavoidable, it must be protected.




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3.5.14

Mobile equipment such as Fork Lift Trucks, scissor lifts, pallet trucks and ladders shallbe maintained and stored in a suitable area when not in use.

3.5.15

Battery charging equipment shall not be stored in open food areas. Mobile equipmente.g. forklift trucks and pallet trucks that are used in open food areas must not be usedoutside.

3.5.16

Only food grade lubricants shall be used in processing equipment where there is a riskof the lubricant coming into contact with the food material.

3.5.17

Motors and similar equipment shall be sited so that there is no danger of oil or greasecontaminating food.

3.5.18

Disused or obsolete equipment shall be removed from production environment. Where itremains in production, it shall be stored in an orderly fashion, permitting access forroutine, documented cleaning and pest control measures.

3.5.19

Disused or obsolete equipment stored externally shall be adequately segregated fromother areas, and maintained from encroachment of refuse, weeds and infestation.

3.5.20

Internal areas used for storage of disused or obsolete equipment or large spares shallbe subject to good standards of housekeeping and hygiene including appropriate pestcontrol measures.

Maintenance

3.6 STATEMENT OF INTENT: A documented system of planned maintenance shall be inplace covering all items of equipment and plant which are critical to product safety,legality and quality.




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3.6.1

Equipment, including fixtures and fittings, shall be maintained in such a condition as tominimise the risk of product contamination.

3.6.2

Arrangements shall be in place to ensure that maintenance tasks are raised andcompleted on time, and highlighted if they are not carried out for any reason.

3.6.2.1

A system shall be in place to prioritise any repairs which may impact on food safetylegality or quality.

3.6.2.2

Repairs must be completed within an agreed timescale and recorded.

3.6.3

Instructions shall be available indicating what should be done during plannedmaintenance, and engineers shall be trained in planned maintenance procedures.Planned maintenance tasks shall be recorded.

3.6.4

Frequent checks shall be made on critical machinery components such as slicer andmincer blades. These checks shall be documented together with a record of anynecessary corrective action taken.

3.6.5

When commissioning new equipment and plant, a maintenance programme shall beestablished and put into place based on risk assessment.

3.6.6

The company shall ensure that the safety or legality of product is not jeopardised duringmaintenance and cleaning operations.

3.6.7 In addition to any planned maintenance programme, where there is a risk of productcontamination by foreign bodies arising from equipment failure, the equipment shall beinspected at pre-determined intervals, actions and inspection results documented.




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3.6.8

Wherever possible engineering work shall take place outside production areas, andpreferably in the engineering workshop. Welding, drilling, riveting and soldering mustnot take place on plant being used for production or any plant immediately adjacentunless suitable hygienic screening is in place.

3.6.9

Engineers carrying out repairs on production lines shall be provided with an enclosedmetal or plastic box for tools, nuts, bolts and screws etc. Magnetic trays or other clearly

marked containers shall be used to contain fixings removed or replaced duringengineering work.

3.6.10

Engineers tools shall be kept clean and maintained to prevent contamination risks.Tools shall remain captive to site or adequately cleaned prior to transferring into openfood areas.

3.6.10.1

For high risk / high care areas tools shall remain captive to the area or be disinfectedprior to transfer into the area.

3.6.11

Engineers tool boxes shall be kept clean internally and free from unnecessaryextraneous matter which could be hazardous to production.

3.6.12

Engineers tool boxes shall not come into contact with food contact surfaces. Whereappropriate wheeled engineers tool boxes shall be used.

3.6.13

Missing fittings on equipment shall be accounted for and/or replaced.

3.6.14 Cleaning or replacing light fittings, glass or brittle plastics shall be done in a manner thatwill minimise the potential for product contamination.




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3.6.21

Workshops and engineering equipment shall be maintained in a clean condition.Workshops shall be controlled to prevent contamination risks to the product, cleaned on

a regular basis, and clean as you go principles shall be adopted to keep swarf and metaldebris to a minimum. This may include provision of swarf mats where opening ontoproduction areas. Engineering spares and equipment shall be stored off the floor.Engineering areas shall be covered by the Pest Prevention Programme, and also beincluded ion the internal audit schedule.

3.6.22

A suitable foot scraper mat shall be fitted at the main exit from the workshop

3.6.23

Suitable PPE or work wear shall be provided to personnel involved in the cutting,grinding and drilling of metal to reduce the risk of contamination.

3.6.24

Materials used for equipment and plant maintenance and that pose a risk by direct or

indirect contact with raw materials, intermediate and finished product , such aslubricating oils and paints, shall be suitable for the intended use e.g. food grade oils, nontoxic paints.

3.6.25

Production or food containers must not be used for general storage in engineeringareas.

Staff Facilities & Catering Facilities

3.7

STATEMENT OF INTENT: Staff facilities shall be sufficient to accommodate therequired number of personnel, designed and operated to minimise the risk or productcontamination. Such facilities should be kept in good and clean condition. Suitable stafffacilities shall be provided to include toilets, rest room/canteen, changing/locker roomsand first aid resource.




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3.7.1

The risk of product contamination from staff facilities shall be subject to a documentedevaluation based on risk assessment and appropriate controls applied.

3.7.2

Designated changing facilities shall be provided for all personnel, whether staff, visitor orcontractor. Where appropriate, these shall be sited to allow direct access to theproduction, packing or storage areas without recourse to any external area. Where thisis not possible, risk assessment shall be carried out and procedures implementedaccordingly e.g. the provision of cleaning facilities for footwear.

3.7.3

Changing facilities where staff are required to change footwear must be kept clean andbe dried after cleaning

3.7.4

Storage facilities shall be provided for all personnel who work in raw-material handling,processing, preparation, packing and storage areas. These shall be of sufficient size toaccommodate all reasonable personal items.

3.7.4.1

Where lockers are provided these shall be kept clean and in good condition, regularlycleared and not used for the storage of food.

3.7.4.2

Lockers in high risk areas or businesses shall have sloping tops and be raised off thefloor to facilitate cleaning and prevent the accumulation of rubbish.

3.7.5

Storage areas for workwear, and laundry areas must be clean, protected fromcontamination and adequate for the number of staff on site.




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3.7.6

Suitable and sufficient hand washing facilities shall be provided at access to theproduction area, and at other appropriate points within production areas, particularly

areas where more frequent hand washing is necessary. Hand wash basins shall bepositioned to avoid the risk of aerosols in production areas, but shall be easilyaccessible. Such hand wash facilities shall provide as a minimum:

sufficient quantity of water at an appropriate hand hot temperature liquid soap which is odourless and bactericidal single use towels or suitably designed and located air driers. Waste receptacles shallnot be hand operated and shall be suitably sited to ensure water drips do not makefloors wet/dirty. appropriate instructions for use (including consideration of appropriate language) Where used nail brushes shall be stored in sanitiser Hands free operation for use of taps and disposal of towels

Where high risk food products are handled, the following additional requirements shallbe provided: water taps with hand free operation hand disinfection

For non-production areas it may be suitable to use sanitiser in place of hand washingstations

3.7.7

All staff shall be fully trained in effective hand washing disciplines.

3.7.8

Footbaths are not permitted. Good footwear hygiene shall be achieved by the provisionof dedicated footwear, supported by boot/shoe cleaning regimes.

3.7.9

Toilets shall be adequately segregated from production, packing and storage areas andshall not open directly into production, packing and storage areas. Toilets shall beprovided with hand-washing facilities comprising:

basins with soap and water at a suitable temperature adequate hand drying facilities advisory signs to prompt hand washing (including consideration of appropriatelanguage)

Where hand-washing facilities within toilets are the only facilities provided before re-entering production, then the hand wash facility requirements of 3.7.4 shall apply.




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3.7.10

Designated controlled smoking areas shall be isolated from production areas to anextent that ensures smoke cannot reach the product. Where smoking is allowed under

national law, sufficient extraction to the exterior of the building shall be ensured.Adequate arrangements for dealing with smokers waste shall also be provided atsmoking facilities, both inside and at exterior locations. Facilities shall be available, withadequate reminders, for hand washing after smoking.

3.7.11

Consumption and storage of food shall only be in designated areas and shall not bepermitted in production or storage areas.

3.7.12

All food brought into manufacturing premises by staff shall be appropriately stored in aclean and hygienic state. Refrigeration shall be provided and temperature monitored toensure safe storage conditions. No food shall be taken into storage, processing orproduction areas.

3.7.13

Equipment provided for refreshment storage or preparation (e.g. microwaves or toasters)must be regularly inspected and cleaned.

3.7.14

Where catering facilities are provided, these shall be suitably controlled to preventcontamination of product and to minimise the risk of food poisoning of employees. Thecatering facility shall have a HACCP system in place. Where this is managed by acontractor this must be reviewed by a technically competent person on site.

3.7.15

The catering facilities shall be separate from production, packing and storage areas.

3.7.16

A technically competent person shall audit the canteen and vending machine facilitiesregularly to ensure that they are being run hygienically and with food safety in mind.

3.7.17 Canteen staff shall not present a risk to food which they are preparing or serving and

shall not contradict the site rules for protective clothing and food hygiene, to this endcanteen staff shall have medical screening prior to commencement of work be suitably trained in basic food hygiene. Comply with the sites personal hygiene and workwear rules.




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3.7.18

Where eating of food is allowed outside during breaks, this shall be done in suitabledesignated areas with appropriate control of waste.

3.7.19

Where an operation involving high-risk products (refer to glossary) exists, personnelshall enter via a specially designated changing facility, and shall follow specified

procedures for applying visually distinctive clean overalls, headwear and footwear.

3.7.19.1

This clothing shall be removed only in specially designated areas.

3.7.20

Outdoor clothing and other personal items shall be stored separately from workwearwithin the changing facilities.

3.7.20.1

Personal outdoor shoes must be segregated from site-dedicated footwear provided forinternal factory areas

3.7.21

Hand washing facilities should preferably be in full view of the production process with

guide rails to channel personnel past the hand wash basins.

3.7.22

Facilities for visitors and contractors shall be such as to enable compliance with PremierFoods hygiene policy.

Physical & Chemical Product Contamination

3.8.1 STATEMENT OF INTENT: Appropriate facilities and procedures shall be in place tocontrol the risk of physical or chemical contamination of product.




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3.8.1.1

Based on risk assessment Premier Foods shall identify, control and manage anypotential risks from chemical, physical or taint contamination. This may include risksassociated with: Storage Production operation or processes or machinery Any maintenance or building work carried out Hygiene and cleaning operations

These shall be verified through regular site audits carried out at a frequency determinedby risk analysis.

3.8.1.2

A nominated senior manager shall be responsible for ensuring that foreign matterprevention control systems are effective. Preventative actions shall be taken within areasonable and practical timeframe.

3.8.1.3

Once potential foreign matter contaminants or points where contamination could occurhave been identified, action shall be taken to permanently eliminate the hazards, or toput in place appropriate control systems, i.e.

Pre-start line checks against an inventory of identified hazards Engineers checks on critical elements of equipment e.g. condition of bearings, pointsof likely abrasion due to metal on metal contact, oil seals, utensils, product containersand small consumable items. All such checks shall be fully documented together with details of any necessarycorrective action taken.

3.8.1.4

Appropriate measures shall be in place to remove any foreign matter contamination from

incoming raw materials.

3.8.1.5

Inspection procedures must be in place to ensure entrapped packaging materials areremoved or during decanting, cutting or unwrapping of raw materials.

3.8.1.6 Outer ingredient packaging should be removed in a dedicated area. Cardboard / paper sacks must not be used in high care / high risk areas.




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3.8.1.7

Bulk storage systems should be designed so as to eliminate the possibility of crosscontamination.

3.8.1.8

Food containers shall be maintained in good condition without damage, and shall onlybe used for their intended use and not used to store other materials such as nuts andbolts, stationery etc.

3.8.1.9

Appropriate storage facilities shall be provided for the control and storage of chemicals.These shall be secured and ensure that non-food chemicals are not stored with food orpackaging materials.

3.8.1.10

Potential contamination risk from building fabric and overhead structures shall becontrolled through regular documented audits and corrective action taken to minimiserisk of product contamination.

3.8.1.11

Food contact conveyor belts must be checked for fraying on a daily basis or prior to startup.

3.8.1.12

All work in progress and ingredients must be labelled, identified and kept covered when

not in use.

3.8.1.13

Incompatible materials, e.g. volatile flavourings and high-fat foods, shall be stored in anappropriate manner to prevent contamination.

3.8.1.14 Pens, calculators, rulers and other stationery shall be kept to a minimum in production

areas. Pens where required for use within production areas shall company issued, be ofone piece construction, of contrasting colour and metal detectable where appropriate.




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Sieving and Filtering

3.8.2.1

Filters, sieves and magnets used for foreign body control shall be regularly inspectedand properly maintained. Such activities shall be recorded and investigated.

3.8.2.2

Based on risk assessment, procedures shall be implemented to minimise foreign bodycontamination of packaging during filling operations, e.g. covered conveyors, containerinversion and foreign body removal through rinsing or air jets.

3.8.2.3

Sieving and filtering will allow the removal of foreign bodies. At all times in the case ofsieves, the smallest size possible shall be used with agitation assistance

3.8.2.4

In cases where the raw material particulate is large, an inspection table or similar shallbe used.

3.8.2.5

Sieves and filters shall be metal detectable where possible. They shall be magnetic andnon corrodible. If a nylon sieve is used it shall be coloured to contrast with the productbeing sieved and an inspection system shall be incorporated to minimise the risk ofcontamination from the nylon. Electronic sensing devices shall be used where humanfrequent inspection is difficult.

3.8.2.6

Mesh size and sieve types shall be agreed with customers where applicable.

3.8.2.7 The layout of sieving rooms/areas shall segregate sieved from unsieved ingredients tominimise post-sieving contamination.




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3.8.2.8

Spare sieve plates or screens of the correct size shall be available on site.

3.8.2.9

Sieves shall be arranged so they completely cover the container being sieved into.

3.8.2.10

Sieves shall be properly stored off the floor when not in use.

3.8.2.11

Containers of sieved ingredients shall be covered and labelled with full traceability anduse by information where appropriate.

3.8.2.12

A risk assessment shall be carried out to determine whether or nor a particular materialrequires sieving. The following shall be considered;

The level of checks/controls in place at a suppliers premises. The history of thesupplier shall also be considered and documented. The packaging format of the material e.g. bag, box or bulk. Whether the raw materials characteristic will be dramatically changed thereforeaffecting final product quality. The risk from dust generation from an (a) Health & Safety aspect, (b) Crosscontamination e.g. allergens shall be considered.

3.8.2.13

A full HACCP analysis shall be carried out on the process to determine the risksassociated with raw material from intake to dispatch.

3.8.2.14

Sieving/filtering shall take place at the most appropriate point in the process based onrisk assessment and discussion with customers where relevant.




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3.8.2.15

Management systems and documented procedures shall be in place for operatingsieving/filtering control points.

3.8.2.16

Equipment used for sieving/filtering shall have inspection procedures so that it does notbecome a foreign body hazard in itself. In addition pre-determined actions shall bedocumented in the case of a sieve/filter becoming damaged. Photographic evidence ofthe sieve/filter failure shall be retained for reference.

3.8.2.17

The equipment shall be on a regular and appropriate preventative maintenanceschedule and sieves/filters shall be uniquely identified. This shall include mobileequipment.

3.8.2.18

Training for staff operating and inspecting the equipment shall take place. Documentedevidence of training shall be available. Training of staff shall be reviewed regularly(minimum annually).

3.8.2.19

Only designated personnel shall be responsible for issuing sieves and filters.

3.8.2.20

Full process records and traceability systems shall be in place at all sieving/filtering

stages.

3.8.2.21

A sieve matrix which details types of material, sieve size, frequency of inspection andsieve location shall form part of the sieving controls.

3.8.2.22 Action procedures shall be in place for when foreign bodies are found. A fullinvestigation shall take place to ensure that the contamination source is identified.Details of the investigation shall be documented on an incident log.




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3.8.2.23

Sieve tailings shall be checked at regular intervals as defined by the risk assessmentand type of process.

3.8.2.24

Where sieving/filtering takes place, the material shall then pass over/through a suitablemagnet. A procedure for the operation, cleaning and inspection of the magnet shall bein place. All tailings shall be inspected and a magnet passed across the material. This

shall then be recorded on an incident log.

Chemical

3.8.3.1

A chemical control procedure shall be in place which manages the use, storage andhandling of non-food chemicals. This shall include:

approved purchase availability of material safety data sheets and specifications where appropriate, confirmed suitability for food use strong scented products shall not be used identification of chemicals at all times segregated and secure storage with restricted access to authorised personnel use by trained personnel only all chemicals must be used in accordance with written instructions relevant to the area.

Wood

3.8.4.1

In areas where a risk assessment has identified the potential for product contaminationfrom wood, the use of wood shall be excluded. Where the use of wood cannot beavoided and the risk is managed, the condition of wood shall be regularly checked toensure it is in good order and clean.

3.8.4.1.1 There shall be a documented evaluation to demonstrate the assessment of alternativesto wood and why these were unsuitable replacements.




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3.8.4.2

The use of wooden handled tools shall be avoided where possible. If the use of woodcannot be avoided and the risk is managed, the condition of the wood shall be inspectedafter each use for damage, and reported to the responsible site technical person if anydamage has occurred.

3.8.4.3

Broken or damaged wooden structures shall be repaired and all wood debris removedas soon as is possible. Wood chips shall be swept up immediately to avoid their transferto production areas.

3.8.4.4

Where ingredients are stored on wooden pallets, they shall be transferred onto plasticpallets prior to entry into the weighing/production areas of the factory. Baggedingredients shall be interleaved from wooden pallets by slip-sheets.

3.8.4.5

Any wooden pallets in use on the site shall be clean, sound and in good repair.

Glass, Brittle & Hard Plastic, Ceramics & Similar Materials

3.8.5.1

The site shall have a documented Glass and Hard Plastics Policy setting out the

company rules regarding the control of these materials in the factory. This must alsoinclude the companys intentions, regarding any future refurbishment or purchase of newequipment, to remove the use of glass where possible. The policy shall be briefed to allpersonnel at induction including contractors.

3.8.5.2

The policy shall be the responsibility of a nominated senior manager, who should ensurethat its requirements are fully implemented.




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3.8.5.3

The policy shall extend to all food processing areas and storage areas including thoseassociated with production e.g. production offices, corridors, loading bays, engineering,

equipment washing and staff facility areas of the site, and areas where there is apotential route for contamination into the above areas.

3.8.5.4

In areas where a risk analysis has identified a potential for product contamination fromglass, the presence of glass shall be excluded. Where this cannot be avoided, but therisk is managed, glass shall be protected against breakage.

3.8.5.5

Any remaining glass in production, storage, maintenance, staff facility and equipmentwashing areas must be replaced with a suitable alternative material or where this is notpossible, a shatter resistant film shall be applied on the surface facing the food area.

3.8.5.6

Where glass in food vessels cannot be replaced, then it shall be toughened and conform

to British Standard 3463 (1975) 1988: Specification for Observation and Gauge Glassesfor Pressure Vessels, or DIN 7090/8902 which set the standards for pressure resistantsight glasses, or equivalent standard.

3.8.5.7

Light fittings in all food processing areas and storage areas including those described in3.8.5.3 shall be protected against damage. Fluorescent tubes including tubes inelectronic fly-killing units, shall be provided with a protective shatter resistant outersheath, or housed in a protective fitting.

3.8.5.8

Where possible, glass replacement shall be carried out after production in order to limitthe possibility of product contamination. A senior manager shall be informed of the workto take place and agree the arrangements for when and how the work should proceed.Records shall be kept of any glass replacement work in production areas.

3.8.5.9 The use of glass mirrors in changing rooms should be avoided, where this is notpossible the requirements of 3.8.5.5 shall be applied.




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3.8.5.10

Ingredients shall not be delivered in glass containers unless totally unavoidable. Thesedeliveries shall be either sieved or filtered into a plastic container, in a designated area,prior to transferring to production.

3.8.5.11

Glass food and drinks containers (including Thermos-type flasks) shall not be taken intoany all food processing areas and storage areas including those listed in 3.8.5.3 unlessrequired as a final packing container. Any exceptions shall be approved in writing by theresponsible senior factory manager.

3.8.5.12

Where glass containers are used as a packaging medium, detailed procedures mustexist covering

Intake checks of glass General handling requirements Breakages on line particularly in filling and lidding / capping equipment.

3.8.5.13

Where sites produce in both glass and other media, the operations shall be physicallyseparated.

3.8.5.14

Documented procedures for handling glass, brittle or hard plastic, ceramic or othersimilar materials shall be in place and implemented to ensure that necessaryprecautions are taken. Procedures shall include:

List of items (glass register) detailing location, type and condition. Proximity to ingredients/raw materials, product, packaging or equipment. Recorded checks (audit) of condition of items carried out at a specified frequencybased on risk analysis. Details on cleaning or replacing items to minimise potential for product contamination

3.8.5.15

The risk assessment shall be used to form the basis for determining subsequent actionsuch as replacement, protection and monitoring the condition of the glass/glass-likematerial as appropriate. This shall be carried out and signed off by the nominated senior

manager or deputy.




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3.8.5.16

Glass windows shall be part of the documented risk assessment to determine the risk ofproduct contamination in the event of breakage. Where such a risk determines no

requirement to add a shatter-resistant film, this should be agreed with customertechnologists where the customer requires this.

3.8.5.17

The glass register shall be reviewed on a regular basis, and in the event of change toequipment or fabrication of the area.

3.8.5.18

There shall be a regular audit at a frequency determined by risk assessment. Allfindings, from audits, shall be recorded with corrective action as necessary.

3.8.5.18.1

Where required by specific customers glass and glass-like materials sited directly on,over or adjacent to production lines, food processing equipment, and in areas whereproducts or ingredients are exposed shall be inspected daily.

3.8.5.19

Based on risk assessment, documented procedures shall be in place detailing the actionto be taken in case of breakage of glass, brittle or hard plastic, including glass packagingand similar material. This shall include:

Stopping or isolation of production Restriction of movement through the affected area Reporting to management Quarantining the products and production area that were potentially affected Clean up of breakage, safe removal and disposal of breakage from area

Cleaning the production area Repair or replacement of the broken item (where necessary) Inspection of the production area and authorisation to continue production Changing work-wear and inspection of footwear Specifying those staff authorised to carry out the above points Recording the breakage incident and if appropriate the retention of a sample of brokenmaterial Where appropriate the corrective action to prevent re-occurrence

3.8.5.20 All breakages that pose risk of product contamination shall be recorded in an incidentreport.




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3.8.5.21

All equipment used to clean up a glass spillage shall be either dedicated or single use.Single use equipment shall be immediately disposed of with the glass outside thefactory. Dedicated equipment shall be locked away when not in use. Vacuum cleanersshall not be used for glass clean-up operations unless dedicated for this use and markedaccordingly.

3.8.5.22

Glass breakages in areas not associated with production or storage shall be dealt with

on a risk assessment basis, and the incident details recorded.

3.8.5.23

Where practical, broken glass fragments shall be pieced back together to try todetermine whether all of the glass has been accounted for.

3.8.5.24

All production / hygiene managers must be trained to understand and apply the glass

breakage procedure

Metal Control

3.8.6.1

There shall be a documented policy for the control of the use of sharp metal implementsincluding knives, scissors cutting blades on equipment, needles and wires. This shallinclude suitable control both into and out of the factory and safe disposal of suchequipment in a sealable container when no longer usable.

3.8.6.2

Snap-off blade knives shall not be used.

3.8.6.3

All non production blades, equipment and tools shall not be left in a position that allowsthem to contaminate the product.




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3.8.6.4

Any filters and sieves used for foreign body control shall be regularly inspected andproperly maintained. Such activities shall be recorded and investigated.

3.8.6.5

Suitable alternatives to metal document staples shall be used to secure multiple pagedocuments used in production areas.

3.8.6.6

Where staples or other items are used which are likely to cause contamination inpackaging, appropriate precautions shall be taken to minimise the risk of product

contamination.

3.8.6.7

Drawing pins and paperclips should be excluded from production areas, and controlledin non-production areas to ensure risk of contamination is adequately managed

Housekeeping & Hygiene

3.9

FUNDAMENTAL CLAUSE: Housekeeping and cleaning systems shall be in place whichensure appropriate standards of hygiene are maintained at all times and that risk ofcontamination is minimised.

3.9.1

All employees must employ a clean as you go policy and are responsible for keepingtheir cleaning equipment in good repair and hygienic condition.

3.9.2 Documented cleaning schedules shall be in place and maintained for the building,services, plant and all equipment. Cleaning schedules shall include the followinginformation: responsibility for cleaning item/area for cleaning frequency of cleaning instructions for dismantling equipment including any necessary engineering assistance.Photographs shall be used, where relevant, e.g. more complex items of equipment.

method of cleaning and equipment to be used cleaning materials to be used, concentrations and contact time cleaning records and responsibility for verification key points for final inspection




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3.9.3

Cleaning frequencies shall be determined according to experience and based on all

relevant parameters (e.g. results of visual cleaning checks, microbiological testing,internal audits, and pest control inspections). There shall be target dates set forcleaning for tasks done on a less frequent basis.

3.9.4

Designated cleaning areas must be kept in a hygienic condition with obvious flow ofequipment from dirty to clean.

3.9.4.1

High care areas must have their own cleaning facility and items must not be returnedfrom the high care area to the low care area for cleaning unless they pass through aheating or disinfection process on return to high care.

3.9.5

Production equipment must be cleaned off the floor on racks or stands stored in a manner which prevents re-contamination

for high care areas, re-disinfected immediately prior to use if previously held in storage

3.9.6

Trays for holding product, work in progress, rework, or rejects must not be stored on thefloor.

3.9.7 Sinks for cleaning production equipment must be identified and separate to floorcleaning equipment.




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3.9.8

Tray and rack washing equipment must be operating at the correct temperature and withcorrect chemical type and dilution. for high care areas tray and rack washing equipment must be of suitable constructionand be monitored and verified. The frequency of monitoring must determined by a formalstudy, or based on recommendation from suppliers.

3.9.9

Work instructions shall be regularly reviewed and updated where necessary and shall beavailable on the factory floor for reference by cleaning staff.

3.9.10

Records shall be kept of the actual date that cleaning was carried out and shall besigned off by the person who carried out the cleaning. Verification that the cleaningactivity has been carried out shall be made by a member of the supervision team.Records of this shall be kept; this may take the form of countersigning a sample ofcleaning records.

3.9.11

Where cleaning has not been carried out for any reason there shall be a note ofexplanation and corrective action included in the cleaning records.

3.9.12

Cleaning and housekeeping shall be carried out by trained personnel in accordance withdocumented procedures and records maintained.

3.9.13

Cleaning chemicals and equipment shall be: fit for purpose suitably identified for intended use e.g. colour coded or labelled stored in hygienic manner to prevent contamination, in a segregated area

3.9.14

Brush stocks shall be made from solid materials such as polypropylene (not wood).Foamed construction is not recommended as it breaks more easily and is more prone to

contamination.




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3.9.15

Brush filaments shall be suitable for use, coloured, of non-animal origin and shall befirmly secured.

3.9.16

Sweeping brush handles and squeegees shall be of anodised aluminium and securelyattached to the stock. Colour coded plastic sleeves are not recommended due to thepotential for foreign body contamination.

3.9.17

Equipment such as hand held scrapers which will be in direct food contact shall beconstructed of materials that are robust and suitable for the application. They shall becoloured to contrast with food products.

3.9.18

Squeegees shall be constructed in such a way that they can be easily cleaned anddisinfected.

3.9.19

Shovels made of plastic shall be of one piece construction. Stainless steel shovels shallhave metal to metal joints only and shall be continuously welded with a smooth finish.

3.9.20

Mobile vacuum cleaners shall be regularly cleaned and the flexible pipework kept ingood order. Damaged suction pipes/tooling shall be replaced or appropriately repaired.The use of tape is not an acceptable method of repair.

3.9.21

When items of cleaning equipment become damaged they shall be replaced. Thecondition of cleaning equipment shall be included in hygiene self-audits.

3.9.22 Cleaning equipment shall be colour coded to distinguish between the following uses;

Food contact/production equipment surfaces. Floors Toilets Engineering

Non-food areas, corridors, external areas. Allergens (where required)

Colour coding requirements shall be clearly displayed with the equipment




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3.9.23

It may be necessary to use colour coded equipment in different areas of food productione.g. high care and low risk areas.

3.9.24

Where possible the principles of colour coding shall be extended to all items of cleaningequipment e.g. mop buckets, brush handles, scouring pads and cleaning cloths.

3.9.25

A system of ensuring all new cleaning equipment is clean before use shall be in place.Where required equipment shall be disinfected before use. Any labels shall be removed.

3.9.26

All cleaning equipment shall be cleaned after each use and always stored in a cleanedcondition.

3.9.27

Appropriate non-food tainting chemicals shall be used for cleaning and disinfecting theequipment.

3.9.28

Mops shall not be used in open food areas. Where mops are permitted through use ofconcession and appropriate customer technical approval, the heads shall be eitherrenewed daily or, after use, washed, disinfected and allowed to air dry.

3.9.29 Where microbiologically vulnerable food products are manufactured and cleaning

equipment needs to be regularly cleaned, all parts of the equipment, (including handles)shall be fully disinfected for sufficient contact time.




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3.9.30

Cleaning equipment shall be stored separately, in accordance with colour coding toprevent risks of cross contamination.

3.9.31

All cleaning equipment shall be stored off the floor in a suitable area designated for thepurpose.

3.9.32

Brushes, squeegees, mops etc shall be stored head down to prevent contamination ofhandles.

3.9.33

In areas where microbiologically vulnerable products are manufactured, the heads andhandles of equipment such as squeegees shall be stored fully submerged in disinfectantsolution when not in use. In dry areas this equipment shall be cleaned and stored dry.

3.9.34

Cleaning chemicals shall be suitable for use in food manufacturing environments, fit for purpose. stored in a restricted access area with suitable spillage containment facility suitably labelled controlled in use and storage according to manufacturer instructions. Storage in production areas must be minimised and secured.

3.9.35

Control of Substances Hazardous to Health (COSHH) details must be available for allchemicals used on site.

3.9.36

Pine or phenolic based chemicals shall not be stored or used on site, includingamenity/toilet areas.




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3.9.37

Automatic chemical dosing systems must be regularly monitored, to ensure adequatedosing. Where automatic recording devices are in place, the records must be kept for

an appropriate period of time in order to demonstrate due diligence.

3.9.38

Where manual make-up of concentrations is carried out, the vessels containing thesolution shall be appropriately labelled.

3.9.39

Cleaning practices shall be completed to minimise risk of contamination. To this endcleaning must always be performed in a logical sequence, based on risk.

3.9.40

Disinfection processes, where applicable, shall be in place to effectively controlmicrobiological risk. These processes shall be documented and the effectiveness of thedisinfection process verified on a regular basis based upon risk assessment.

3.9.41

Dry cleaning methods shall make use of suitable vacuum equipment. The use ofpressurised air-lines for cleaning shall be avoided due to the potential for spreadingdebris, food particles and infestation.

3.9.42

High pressure water hoses shall not be used due to the potential for contamination of

foods and equipment surfaces from aerosols. Where the use of hoses is unavoidable,they shall be of low pressure and high volume. Hoses shall be regularly cleanedincluding retractable types. Hose and cleaning lance ends must not be left on the floor orin tanks when not in use.

3.9.43

Clothing used for cleaning tasks shall be colour coded and adequately separatedthrough laundering and return delivery systems, e.g. low risk areas, high care areas.




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3.9.44

Staff, who clean toilet areas as well as food handling areas shall ensure that they weardedicated clothing for the cleaning of toilet areas, and this is changed accordingly when

entering food handling areas. This clothing shall be changed at least daily and storedseparately from food handlers protective clothing.

3.9.45

The effectiveness of the cleaning and sanitation procedures (including those carried outby contractors) shall be verified and recorded. Corrective actions shall be documented.

3.9.46

Independent member of the factory management team, who has a sound knowledge ofthe factory and standards required, shall check finished cleaning standards at anappropriate frequency.

3.9.46.1

Checks may take the form of a sample of all finished cleaning tasks. Where thisapproach is taken, sampling shall be organised such that over an appropriate timeperiod, every cleaning task is checked.

3.9.46.2

Where products are microbiologically sensitive, checks shall include swabbing/rinsewaters/contact plates/bioluminescence, following the completion of cleaning. All resultsmust be recorded and action taken as necessary.

3.9.46.3

ATP Bioluminescence techniques must only be used for the swabbing of surfaces afteradequate validation work. Records must be kept from the validation process to confirmthis.

3.9.46.4

Records of checks, including corrective action in the event of unsatisfactory standardsshall be maintained.




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3.9.47

Areas selected for microbiological monitoring must be carefully chosen, so that theyrepresent the critical control points of a particular process. A schematic diagram of the

locations where the swabs are taken must be based upon risk assessment. Areas mayinclude but will not be limited to;

Entrance and exits Structural parts such as pillars Refrigerators and associated condensate. Contact surfaces including door handles Areas where open product comes into contact with a surface e.g. conveyor belts

3.9.48

In high care areas the efficiency of cleaning must be monitored by microbiologicalmonitoring of food contact, non food contact surfaces and personnel.

3.9.49

Production environments for products that are susceptible to Listeria contamination mustbe subject to Listeria testing. These areas must be represented on a schematicdiagram.

3.9.50

All swabs must be examined and compared to the standards laid down in the companyshygiene schedule. Individual results and trend analysis must be used to identify requiredaction.

3.9.51

Validation of cleaning and disinfection procedures shall be completed and they shall beamended when circumstances change e.g. building or maintenance work, new productsor equipment etc.

Clean In Place (CIP) Systems

3.9.2

STATEMENT OF INTENT: Where food processing systems are cleaned in place (CIP)the CIP facilities shall de designed, monitored and maintained to ensure effectiveoperation to ensure consistently clean and safe food production. Consideration shall begiven to frequency, cycle time, temperature, chemical concentration and spray balllocation and coverage. CIP shall have adequate separation from active product lines.




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3.9.2.1

Design and installation of the system shall be to a clear specification. Any changes tothe system shall be documented and shall only take place involving appropriately

qualified staff and/or the system supplying company.

3.9.2.2

Where the process involves heat treatment for product safety e.g. pasteurisation, thereshall be no cross connections between raw and post heat treatment equipment andpipelines. With the exception of total loss CIP systems this necessitates separate CIPsystems for raw and post heat treatment equipment.

3.9.2.3

All pipework shall be readily identifiable as containing raw product, post heat treatedproduct or CIP solution and shall show the direction of flow.

3.9.2.4

There shall be a physical break between product pipes and CIP pipes. Separation by asingle valve shall not be acceptable unless it is of a recognised mix-proof construction.

3.9.2.5

CIP route selection shall have either key piece security, mix proof routing valves, orwhere several routes are cleaned by one CIP set, via a flow plate. These shall bevalidated by proximity switches. Flow plates shall clearly identify routes made by swingbend connections

3.9.2.6

Low level signals from vessels and automatic product routing valves shall be presentand shall interface with the CIP control system and food process control system.

3.9.2.7

The quality of water supplied shall comply with customer/legal requirements. Steamused for cleaning shall be filtered through a fine mesh proprietary filter and shall be freefrom boiler treatment carry over. Means of sampling the steam or condensate shall bepresent.

3.9.2.8 Air used to purge product from pipes shall be filtered to sterility, which shall be routinely

monitored.




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3.9.2.9

All CIP systems shall incorporate;- Temperature measuring device on the detergent return line- High and low level temperature alarms.- Conductivity cells on CIP return and in detergent holding tank.- Access for conductivity cell cleaning and maintenance.- High and low level detergent concentration and tank level alarms.- Devices to ensure adequate flow is maintained.- Return flow measurement device on return line to ensure circuit is made.- Suitable access to all CIP tanks.

3.9.2.10

Automatic systems shall stop or go into hold condition if the correct parameters are notmet. Where a system is manual all cleaning parameters shall be monitored andrecorded on each clean.

3.9.2.11

To monitor correct plant operation, CIP systems shall also have automatic recordingdevices to visually display time, temperature, flow rate and sequence of cleaning cycle.The system shall be able to identify which route has been recorded.

3.9.2.12

CIP systems that are either fully automatic or fully manually operated are preferred.Semi-automatic systems should be avoided.

3.9.2.13

Where food processing equipment is not specifically designed for CIP or where the use

of a mobile CIP unit is proposed, the advice of a reputable engineering company withappropriate CIP expertise, or a reputable cleaning chemical company shall be sought.

3.9.2.14

The diameter of the pipework shall be the same throughout the cleaning circuit. Wherethis is not possible the flow rate shall be determined at the largest pipe diameter.

3.9.2.15 Welded pipework connections shall have a smooth internal finish. Where unions arerequired, they shall be of a recognised hygienic type. Valves on the CIP circuit shall alsobe capable of being cleaned in place. Plug cock valves and most types of ball valvesshall not be used.




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3.9.2.16

Dead-legs shall be avoided where possible. Where unavoidable, the length shall not begreater than 1.5 times diameter of the pipe. Pipework configuration shall enableeffective drainage.

3.9.2.17

CIP pumps shall be sized to ensure a minimum flow rate of 1.5m/sec in the largest pipediameter in the system.

3.9.2.18

A stainless steel strainer and a pressure gauge shall be in place in the detergent deliveryline just after the delivery pump. It shall be regularly checked and cleaned.

3.9.2.19

All spray devices shall be designed to be fit for purpose and to ensure total coverage ofall surfaces and fittings. They shall also be readily removable for inspection andcleaning.

3.9.2.20

Adequate sampl

Documents

CTA 023 CTS Section Three Site Standards