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23-07-2019 and 24-07-2019Date of audit:
CHOCOLAND a.s.Audited company:
Final Audit Report
IFS FoodVersion 6.1
Bureau Veritas Certification Denmark A/SOldenborggade 25
7000 FredericiaDenmark
Page 1 of 81CHOCOLAND a.s.
Fax:
0042 321 723 440
Phone:
0042 602728120
Fax:Phone:
EAN Code/ UCC GlobalLocation Number:
COID: 28843
CHOCOLAND a.s.
Name and address of the audited site:
Ovčárecká 305
28002 Kolín
Czechia
Name and address of the company (or headquarter):
Bureau VeritasCertification DenmarkA/S / PavlaHumpolikova
CB and auditor ofprevious audit:
10-08-2018
Date of previous audit:Date/time of current audit:
23-07-2019 (09:00-18:30)24-07-2019 (09:00-18:30)
Co-auditor:
Mrs. Jitka Vokurková
Lead Auditor:
Trainee(s):
Audit details
IFS FoodVersion 6.1, November 2017
Audit Overview
Technology scope(s): C, D, F
Product scope(s): 6
Production of confectionery intermediate products (spreads, soya mill products, fillers, toppings, pastes),
confectionery products (nut spreads, coated nuts, sticks, coated sticks, chocolate, chocolate figurines,advent calendar) and special products (sports sticks).
Products are packed in Al, PP or PS foils, PP bags, PP buckets and cups, PET boxes, PE tubes and trays,paper bags and glass cups.
Beside own production, company has outsourced processes and/or products.
Scope of audit
Page 2 of 81CHOCOLAND a.s.
1110987654321
Scopes and processing steps
P1A
P2B
P3C
P4C
P5C
P6D
P7D
P8E
P9E
P10E
P11F
P12F
P13F
* The explanation of the product scopes and processing steps are listed separately
Pet food11
Dry products, other ingredients and supplements10
Oils and fats9
Beverages8
Combined Products7
Grain products, cereals, industrial bakery and pastry, confectionary, snacks6
Fruit and vegetables5
Dairy products4
Egg and egg products3
Fish and fish products2
Red and white meat, poultry and meat products1
Scope descriptionScope
Scope explanation
Page 3 of 81CHOCOLAND a.s.
Distillation, purification, steaming, damping, hydrogenating, millingP13
Coating, breading, battering, cutting, slicing, dicing, dismembering, mixing/blending, stuffing, slaughtering,sorting, manipulation, packaging. Storing under controlled conditions (atmosphere) except temperature
P12
Cooking, baking, bottling, filling of viscous products, brewing, fermentation (e.g. wine), drying, frying,roasting, extrusion, churning
P11
Specific separation techniques: e.g. filtration like reverse osmoses, use of active charcoalP10
Processes to prevent product contamination esp. microbiological contamination, by means of high hygienecontrol and/or specific infrastructure during handling, treatment and/or processing e.g. clean room
technology, „white room“, controlled working room temperature for food safety purpose, disinfection aftercleaning, positive air pressure systems (like filtration below 10μm)
P9
Packing MAP, Packing under vacuumP8
Antimicrobial dipping/ spraying, fumigationP7
Freezing (at least –18 °C) including storage. Quick freezing, Cooling, chilling processes and respective coolstoring
P6
Evaporation/ dehydration, vacuum filtration, freeze drying, microfiltration (less than 10 µ mesh size)P5
Preserving: Salting, marinating, sugaring, acidifying/ pickling, curing, smoking, etc. Fermentation/ acidificationP4
Irradiation of foodP3
Thermal pasteurisation, UHT/ aseptic filling; hot filling; Other pasteurisation techniques e.g. high pressurepasteurisation, microwave
P2
Sterilisation (e.g. cans)P1
Processing step descriptionProcessing
step
Processing step explanation
Page 4 of 81CHOCOLAND a.s.
Closingmeeting
Siteassessment
(Audit)
Documenta-tion review
Openingmeeting
Position:Name:
Audit participants
Plant ManagerPavel Mráz
Quality managerZuzana Dubská
ProductionManager
Miroslav Mikovec
Head of productionno. 202
Lenka Němcová
Technicianmanager
Martin Polák
Technical managerJan Malíř
Head of productionno. 203
IvanaWiedermannová
Head of Designand Development
Eliška Břinčilová
Dispatch ManagerJana Věříšová
Dispatch operatorJana Pesslová
Dispatch operatorPetra Dušková
TechnologistMiloslava Cézová
LaboratoryBarboraMelicharová
LaboratoryIrena Jirsová
Page 5 of 81CHOCOLAND a.s.
Next auditbetween 21-06-2020 and 30-08-
2020
As a result of the audit performed on 23-07-2019 and 24-07-2019, „Bureau Veritas Certification Denmark A/S“ found that the processing activities of CHOCOLAND a.s. for the above mentioned scope of audit comply with the requirements set out in the IFS Food 6.1, Version 6.1, at Higher Level, with a score of 96,78%.
Final result of audit
Page 6 of 81CHOCOLAND a.s.
COID number: 28843.
Veterinary number of the company is: Company has no veterinary control number (vegetable produ-cts).
Company is registered under state authority “Czech Agriculture and Food Inspection Authority”.
1) The production in site Kolin was started in 1894, from the year 1992 the factory was part of Nestle company, in 1998 new company was formed ALTIS Kolin s.r.o. which was in 2011 bought by company Chocoland Beri a.s. and produced under the name of Altis Kolin. From 1.1.2014 the company produced under the name CHOCOCLAND a.s.
2) The last investment in 2018 / 2019:
- soy mill: new metal silos instead of wooden for soy milled products and reconstruction of another appropriate equipment (internal transport of milled products)
- general reconstruction of the line for soy bars is planned in next years
3) The name and contact data of the contact person in case of emergency:
Ing. Zuzana Dubská, tel: + 420 602 728 120, email: [email protected].
4) The company´s product scope: PS 6: Grain product, cereal products, confectionary snacks.
Production is divided into 14 production lines. Product per groups:
Production of confectionery intermediate products:
-spreads,
- soya mill products,
-fillers, toppings, pastes
Production of confectionery products:
-nut spreads,
-coated nuts,
-sticks, coated sticks,
-chocolate,
-chocolate figurines,
-advent calendar
The company produces private labels for retail chains and also supplies their brand products, e.g. to
Product groups and products per group produced in the company:
Product Scope 6 Cereals - soya mill products Chocolates (bright and dark) - chocolate, chocolate figurines, advent calendars Crisps, snacks & nibbles - sticks with various fillings Flour - soy flour Others - various spreads, fillers, toppings
Company profile
Page 7 of 81CHOCOLAND a.s.
Reviewer: Lone Sandberg
Ahold, Lidl, Billa, Norma, Penny, Rosa market. Products are supplied to the Czech Republic, EU countries, Canada, USA, Japanese.
5) The company’s processes (IFS technology scopes):
C P4 – sugaring;
D P6 - chilling and cool storage,
F P11 – bottling; filling of viscous products, roasting, conching
P12 - coating, mixing, grinding, sorting and packing,
P13 - milling
6) Trade products (already processed): Company trades with products: box of chocolates, pralines, biscuits, waffle under the name of producer.
7) Employees: there are 200 own employees and 27 agency workers. They work in 1 or 1-3 shifts, 5-7 days a week.
8) Outsourced products:
Chocolate pralines with fillings, pralines are supplied in primary packaging and the company packed them into secondary packaging.
Filled candies and hard candies, candies are supplied in primary packaging and the company packed them into secondary packaging.
Three types of biscuits: Biscuit with caramel cream, Belgian chocolate and choco drage and Biscuit with milk cream, Belgian chocolate and choco drage and Biscuit with coconut cream, Belgian chocolate and choco drage - supplied in primary packaging and secondary packing and the company finally packed and labelled them.
Chocolate Lentils are supplied in bulk to the company, handled as open products and packed into primary and other packaging. The supplier is IFS certified.
Almost all suppliers of these products are IFS certified – now 9; two others not and audit is planned. 9) Sub-contracted part(s) of the process: N/A.
10) External services: transport, metrology, accredited analysis, store, pest control
11) The site area of the plant in square meters: area 9150 m2. Three production buildings: no. 201 (soy mill, roasting, production of chocolate and peanuts spreads); no. 202 (production of soy bars); no. 203 (chocolate production).
12) The company does not use IFS logo.
13) The reasons for reduction: Time was not reduced.
14) There are no seasonal breaks.
14) There is no sub-company.
15) Other certification scheme: ISO 22000, ISO 14001, ISO 18001, certification body Bureau Veritas Czech Republic.
Page 8 of 81CHOCOLAND a.s.
9150Size of the company in square metres:
Ing. Zuzana Dubská, tel: + 420 602 728 120, email:[email protected]
IFS Contact Person:
Number of seasonal workers:
Number of part-time workers:
Number of full-time workers:
227Total number of employees:
Additional audit data
368465041038042231107407675121081448113234
COID of these companies:
Almost all products are produced in IFS certificated companies, 2companies not and audits are planned this year1) HDI S.p.A. Holding Dolciaria Italiana, IFS certified, COID 36846(Chocolate pralines)2) Klett Schokolade GmbH &CO KG, IFS certified COID 504(Chocolate pieces/figurines)3) Carletti A/S, IFS certified, COID 10380 (Chocolate Lentils)4) Banketbakkerij Nora B.V., IFS certified COID 42231 (biscuits)5) Franz Hauswirth Ges m.b.H, IFS certified, COID 10740 (Chocolatepieces/figurines)6) Eichetti Confect spezialitäten, A. Eichelmann GmbH&CO KG, IFScertifed, COID 7675 (Ice chocolate)7) Belgian Chocolate Group NV, IFS certified COID 12108(Chocolate)8) Delafaille N.V., IFS certified, COID 14481 (Chocolate pralines)9) Steenland Chocolate B.V., IFS certified COID 13234 (Chocolatepieces)10) ChocoSuc Partner s.r.o without IFS certification, 2 nd party auditis planned, (Chocolate bars)11) T-Severka spol s.r.o., without IFS, 2 na party audit is planned(Chocolate pieces, figurines, pralines
Description and certification status:
11Number of subcontractors:
These outsourced products are used :1) products are produced andpacked into primary packaging in outsourced company and companyChocoland ensured secondary packaging (products: Chocolatepralines and figurines, candies, 2) products are produced and packedinto bulk in outsourced company and company Chocoland ensuredprimary and secondary packaging (products: Chocolate Lentils)3)products are produced and packed into primary and secondarypackaging in outsourced company (products: biscuits)
Outsourced processes explanation:
yesOutsourced processes and/or products:
Outsourced processes and/or products
Audit data
Page 9 of 81CHOCOLAND a.s.
Explanations regarding the audit report
N/A requirements will beexcluded from the finalscoring
Not applicableRequirement not applicable for a company
N/A
50 % of the possible totalamount of points issubtracted
The KO requirement has not been implementedKO requirement scoredwith a D
15% of the possible totalamount of points issubtracted
When there is a substantial failure to meet therequirements of the Standard, which includesfood safety and/or the legal requirements of theproduction and destination countries. A majorcan also be given when the identified non-conformity can lead to a serious health hazard.A major can be given to any requirement whichis not defined as KO.
Major
-20 pointsRequirement has not been implementedD (deviation)
5 pointsSmall part of the requirement has beenimplemented
C (deviation)
15 pointsAlmost full complianceKO requirementscored with a B
15 pointsAlmost full complianceB (deviation)
20 pointsFull complianceA
PointsExplanationResult
Evaluation of requirements
Page 10 of 81CHOCOLAND a.s.
Yes, certificate athigher level, 12months validity
Report includingaction plan gives
status
Send completedaction plan within
2 weeks ofreceiving thepreliminarily
report.
Approved athigher IFS Foodlevel after receiptof the action plan
Total score is ≥ 95%
Yes, certificate atfoundation level,
12 months validity
Report includingaction plan gives
status
Send completedaction plan within
2 weeks ofreceiving thepreliminarily
report.
Approved atfoundation IFSFood level afterreceipt of theaction plan
Total score is ≥ 75% and < 95%
Certificate atfoundation level, if
the Major non-conformity is
finally solved ascontrolled during
the follow-up audit
Report includingaction plan gives
status
Send completedaction plan within
2 weeks ofreceiving thepreliminarily
report. Follow-upaudit max. 6
months after theaudit date
Not approvedunless further
actions taken andvalidated afterfollow-up audit
Max 1 Major andtotal score ≥ 75%
NoReport gives
status
Actions and newinitial audit to be
agreed uponNot approved
> 1 Major and/ortotal score < 75%
NoReport gives
status
Actions and newinitial audit to be
agreed uponNot approved
At least 1 KOscored with D
CertificateReport formAction companyStatusAudit result
Scoring and awarding of certificates
Page 11 of 81CHOCOLAND a.s.
108000N/A
000000D
026000C
0011000B
743120283322A
000000Majors
000000KO
Chapter 6
Food defense
Chapter 5
Measurements,analyses,
improvements
Chapter 4
Planning andproduction
process
Chapter 3
Resourcemanagement
Chapter 2
Quality andFood safety
managementsystem
Chapter 1
Seniormanagementresponsibility
Summary:
Audit report
IFS FoodVersion 6.1, November 2017
The processing activities of company „CHOCOLAND a.s.“ met the requirements of the IFS Food, Version 6.1.
The company passed with a score of 96,78% at:
Result:
Date of renewal audit: between the 21-06-2020 and the 30-08-2020.
Higher Level
96,78 %
Page 12 of 81CHOCOLAND a.s.
N/A
Observations regarding KO's and Majors:
Page 13 of 81CHOCOLAND a.s.
Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Total
0,00
20,00
40,00
60,00
80,00
100,00100 100 100
94,71 96,67100
96,78
General summary table for all chapters:
All senior managers and head workers proved adequate understanding of the system and its requirements. Documents and records are maintained and kept well despite some deviations were found. The big advantage is established and maintained certified integrated system according to ISO norms.Level of infrastructure and hygiene of production and storage premise was good, despite a lot of deviations raised mainly on infrastructure (given by "older" buildings), but significant improvement since last audit was evident mainly in reconstruction of soy mill technology - replacement of wooden silos for metal ones and other appropriate renovation of mill equipment. The factory is continuously reconstructed in general. New investment into new production continuous line for soy sticks in next years was explained during the opening-meeting . Company has internal laboratory which is equipped for basic MB, CH and PH analysis. Quality manager Mrs. Zuzana Dubská well proved experience and knowledge in production practice and food safety systems. Food fraud issue was taken into account, the risk assessment was performed - laboratory analysis and visual checks of RM are implemented. The company determined 2 main CCPs: CCP Metal detection and CCP receipt of raw materials. Since last audit and recall in last year all pallets with peanuts are analyzed on afla toxins in accredited laboratory.The hazard analysis regarding foreign body was elaborated. There are metal detectors managed as CCPs, sieves and magnets in place managed as CPs. Only two complaints on foreign bodies in this year. The system of traceability was proved, and traceability test was carried out in short time and accurately. It was well presented and documented. IS Helios is in place.The overall result is "higher level", the company was very good prepared for the renewal IFS audit.There were 11 B and 8 C deviations raised.No deviation in Chapter 1. No deviation in Chapter 2.No deviation in Chapter 3.There were 17 deviations identified in Chapter 4, there were raised on obsolete parameters in customer contract, 7 raised on shortcomings in construction requirements, one raised on inappropriate cleaning, 3 on foreign body management, two on pest control, inadequate storage conditions, 2 on condition of equipment and maintenance. There were 2 deviations identified in Chapter 5, both on failures in metrology. No deviation in Chapter 6.
Overall summary of the audit:
Page 14 of 81CHOCOLAND a.s.
Corrective actions from last audit were implemented and were effective, checked during site inspection and documentation checks. 'Some deviations were raised on same clause as last year: req. 4.9.3.1, 4.9.4.1 and 4.17.4 but concerned another places, previous were repaired. One deviation on req. 4.9.5.1 concerned another topic than last year.
Description of follow up of corrective actions from the previous audit:
Page 15 of 81CHOCOLAND a.s.
Summary of all Chapter 1 deviations and non-conformities found:
Chapter 1: Senior management responsibility
ExplanationEvalua-tion
IFS requirementsReferenceNr.
No non-conformities found.
Page 16 of 81CHOCOLAND a.s.
Summary of all Chapter 2 deviations and non-conformities found:
Chapter 2: Quality and food safety management system
ExplanationEvalua-tion
IFS requirementsReferenceNr.
No non-conformities found.
Page 17 of 81CHOCOLAND a.s.
Summary of all Chapter 3 deviations and non-conformities found:
Chapter 3: Resource management
ExplanationEvalua-tion
IFS requirementsReferenceNr.
No non-conformities found.
Page 18 of 81CHOCOLAND a.s.
Summary of all Chapter 4 deviations and non-conformities found:
Chapter 4: Planning and Production Process
ExplanationEvalua-tion
IFS requirementsReferenceNr.
Specifikace pro FN Martius odsouhlasená s LIDL , 1.7.2019: nesoulad ve složení (např. uvedeno 6% kakaa, bez aromat) se stávajícím značením na obale (5,2 % kakao, aroma).
Specification for FN Martius agreed with LIDL, 1.7.2019 non-compliance in composition (eg. 6% cocoa, not added flavor) with existing product labeling (5,2% cocoa, flavor).
CThe specification controlprocedure shall include theupdate of finished productspecification in case of anymodification:- of raw material- of formula/recipe- of process with influence onthe final products- of packaging with influenceon the final products.
4.2.1.61
Stěny celkově v horším stavu na odhořčárně.
Díry v dlaždicích po hmoždinkách na pytlování - arašídy.
Walls are generally in worse condition on soya beans preparing area "odhořčárna".
Holes in tiles after previous dowels - peanuts bagging area.
BThe surfaces of walls shall bein a good condition and easy toclean; they shall be imperviousand wear-resistant.
4.9.2.22
Podlahy celkově v horším stavu - výroba: sojové tyčinky a budova 203, 1.patro (kovová podlaha a betonový přechod).Opravy plánovány, především s ohledem na modernizaci linky na sojové tyčinky.
Floors generally in a worse condition - production of soy bars and building 203, 1st floor (metal floor and concrete transition).Repairs planned, especially with regard to the modernization of the soya bar line.
BFloor covering shall bedesigned to meet productionrequirements and shall be ingood condition and easy toclean. Surfaces shall beimpervious and wear-resistant.
4.9.3.13
Poškození stropu včetně nezakrytého otvoru na dílně "nugeta".
Damaged ceiling, including the open hole at "nugget" production area.
BCeilings (or, where no ceilingsexist, the inside of roofs) andoverhead fixtures (incl. piping,cableway, lamps etc.) shall beconstructed to minimise theaccumulation of dirt and shallnot pose any risk of physicaland/or microbiologicalcontamination.
4.9.4.14
Poškozené rámy oken na odhořčárně.
Damaged window frames on soya beans preparing area "odhořčárna".
BWindows and other openingsshall be designed andconstructed to avoid theaccumulation of dirt and shallbe maintained in goodcondition.
4.9.5.15
Page 19 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
Některá okna v místech otevřeného produktu nejsou chráněna proti rozbití. Např. skleněné okno v blízkostí máčení persiko.
Some windows in open product areas are not protected against breakage. E.g. glass window near the soaking of Persiko
CIn areas where unpackagedproduct is handled, windowsshall be protected againstbreakage.
4.9.5.46
Netěsná plechová vrata - sklad polotovarů Jambor.
Untight sheet metal doors - Jambor semi-finishedproduct storage area.
BExternal doors and gates shallbe constructed to prevent theingress of pests; if possible,they shall be self-closing.
4.9.6.27
Klimatizační zařízení - arašidky ; nevhodné umístění svítidel v těsné blízkosti jednotek a svod kondenzátu přímo do umyvadla. Nejsou obecně jasné důkazy o výměně nebo čištění filtrů klimatizačních jednotek, doloženy pouze pravidelné revize těsnosti - kontroly úniků chladiva.
Air conditionig equipment - "arašídky" production area; improper placement of lightings closely to AC units and condensate drain directly into the sink.There is generally no clear evidence of replacement or cleaning of air conditioner filters,only periodic leakage revisions.
BAir conditioning equipment andartificially generated airflowshall not lead to any productsafety or quality risks.
4.9.8.38
Některá zařízení a jejich hůře dostupná místa nebyla řádně vyčištěna v době auditu:- Z míchačky zespodu- tvarovací a máčecí stroj uvniř a pod linkou- dále znečištěná stěna za vývěskami na dílně pytlování - arašídy- znečištěná podlaha na odhorčárně; u zásobníku a namáčení persiko byla na zemi rozsypána jádra podzemnice.
Some production equiment and their harder to access places were not properly cleaned at the time of the audit:- "Z" blenders (bottom part)- Forming and dipping machine inside and below the line- the dirty wall behind the information boards in the peanut bagging area- dirty floor in soya beans preparing area "odhořčárna", spilled peanuts near the hopper and soaking of persiko
CBased on hazard analysis andassessment of associatedrisks, cleaning and disinfectionschedules shall be availableand implemented. These shallspecify:- objectives- responsibilities- the products used and theirinstructions for use- the areas to be cleanedand/or disinfected- cleaning frequency- documentation requirements- hazard symbols (ifnecessary).
4.10.19
Page 20 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
Zkouška detektoru na sojových sucích nebyla zcela přesná - test proběhl bez produktů, nebylo zkoušeno vyřazení.Test detektoru na arašídkách - po testu s etalony nebyly zkoušené vyřazené výrobky znovu prověřeny MD.
The detector testing on soy bars was not entirely accurate - the test was carried out without products, and no rejection machanisms was tested.The detector testing "arašídky"- after testing with standards the tested rejected products were not re-tested by the metal detector.
CThe appropriate accuracy ofdetectors shall be specified.Checks of proper function ofdetectors shall be carried outregularly. In case ofmalfunction or failure of ametal and/or foreign materialdetector, corrective actionsshall be defined, implementedand documented.
4.12.510
Měření síly magnetů bylo provedeno, avšak získané hodnoty nebyly dosud zanalyzovány s ohledem na umístění magnetu (tj. zda se jedná o koncový magnet nebo sekvenci několika magnetů či zda je zařazeno v kombinaci se sítem či MD) a s ohledem na typ magnetu.
Magnet strength measurements have been performed, but the values obtained have not yet been analyzed with respect to magnet placement (ie whether it is an end magnet or a sequence of several magnets, or whether it is combined with a sieve or a MD) and with respect to the type of magnet.
BIn cases where specialequipment or methods areused to detect foreign material,these shall be properlyvalidated and maintained.
4.12.611
Rozbití několika krytů svítidel na dílně adventních kalendářů (budova 203), třebaže záznamy z 22.7. nevykazovaly žádné evidentní poškození krytů.
Breaking of several lighting covers in the advent calendar prod.area (building 203), although records from 22.7. showed no evident damage on these covers.
BBreakages of glass and brittlematerial shall be recorded.Exceptions shall be justifiedand documented.
4.12.912
Page 21 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
External company DERATOR s.r.o. is used. Contract from 22.6.2017. Visits are ensured monthly and 2 times a year gassing is ensured.The firm is certified according the standard CEPA ČSN 16 636 (certificate from 6.9.2017).
Enclosed:- records of visits: 26.4.2019, 31.5.2019, 27.6.2019 (only outdoor baits are taken, sporadic occurence of moths - preventive gassing 4.7.2019)
86 pcs of non toxic bites DETEX35 pcs toxic bites STORM44 pcs insects bites69 pcs glue bites (insects)10 pcs fly killer 29 bites "živolovky"
MSDS for used agents: Uragan D2-Bluefume, 1.3.2017, Aquapy 1.4.2014, Effect Ultimate professional 15.1.2015.
Odchylka: Ojedinělý výskyt zavíječe na budově 201 a 203.
Deviation: Sporadic occurence of moths at the 201 and also 203 building.
BThe company shall have a pestcontrol system in place whichis in compliance with locallegal requirements, taking intoaccount, as a minimum:- the factory environment(potential pests)- site plan with area forapplication (bait map)- identification of the baits onsite- responsibilities, in-house/external- used products/agents andtheir instructions for use andsafety- the frequency of inspections.The pest control system shallbe based on hazard analysisand assessment of associatedrisks.
4.13.113
Nejsou k dispozici důkazy o výměně UV trubic z elektrických lapačů hmyzu.
There is no evidence of replacement of UV tubes in electric fly killers.
BBaits, traps and insectexterminators shall befunctioning, shall be insufficient numbers and shall beplaced in an appropriateposition. They shall beconstructed and positioned asnot to cause any contaminationrisk.
4.13.414
Page 22 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
Skladovací podmínky pro suroviny neodpovídaly v době auditu stanoveným limitům či požadavkům uvedeným ve specifikacích surovin (sklad Jambor: 22,9°C, sklad 3: 22°C a sklad 4: 24,5°a sklad Betoňák : 27,6 °C). Zápisy teplot probíhají vždy jednou denně ráno, kdy teploty většnou odpovídají. Ačkoliv pro tyty případy byla vytvořena analýza a definována nápravná opatření, nejsou reálně opatření zřejmě z tohoto důvodu iniciována.
Nezakryté nepoužívané primární obaly v otevřeném regálu linky - arašídky.
Storage conditions for some raw materials did not comply with the limits or requirements specified in the raw material specifications at the time of the audit (Jambor warehouse: 22.9 ° C, warehouse 3: 22 ° C and warehouse 4: 24.5 ° and Betoňák warehouse: 27.6 ° C ). The temperature is recorded every day in the morning, when the temperatures mostly correspond.Although analysis and corrective action is defined for these cases, the real corrective actiondo not seem to be initiated for this reason.
Uncovered unused primary packaging in the open shelf of the packing line "arašídky". .
CThe storage conditions of rawmaterials, semi-processed andfinished products as well aspackaging shall in each casecorrespond to productrequirements (e.g.refrigeration, protective covers)and shall not be detrimental toother products.
4.14.215
V plánu údržby nejsou zahrnuty všechny metal detektory. Není důkaz o výměně filtru na vyfukovacím zařízení u MD na výrobě soj. suků.
Not all metal detectors are included in the maintenance plan. There is no evidence of replacing the filter on the blower of MD at soy bars production.
BAn adequate system ofmaintenance shall be in place,maintained and documented,covering all critical equipment(incl. transport) for compliancewith product requirements.This applies both for internaland external maintenanceactivities.
4.16.116
Třepení bílého dopravníku na balení Arašídky.
Fraying of white transport belt intended for product dosing and packing "Arašídky".
Značně poškozený pás - soj. tyčinky v polevě (Martius...).
Significantly damaged belt - soy bars in topping (Martius ...). .
Drobné poškození nožů na odhorčárně (špičky).
Damaged knives (tips) at the soy beans preparing area "odhořčárna".
CThe company shall ensure thatall product equipment is ingood condition without anynegative influence on foodsafety.
4.17.417
Page 23 of 81CHOCOLAND a.s.
Summary of all Chapter 5 deviations and non-conformities found:
Chapter 5: Measurements, analyses, improvements
ExplanationEvalua-tion
IFS requirementsReferenceNr.
Nevypovídající identifikace teploměrů a vlhkoměrů na skladech s ohledem na označení v Seznamu měřidel. Ve skutečosti má jedno měřidlo 2 kalibrační listy, to však na štítku měřidla a v samotném Seznamu není zohledněno.
Incorrect identification of thermometers and hygrometers in warehouses with respect to marking in the List of measuring devices. In fact, one device has 2 calibration protocols, but this is not reflected directly on the device label and in the List itself.
CThe company shall identify themeasuring and monitoringdevices required to ensurecompliance with productrequirements. These devicesshall be recorded on adocument and clearlyidentified.
5.4.11
Chyběl důkaz o kalibraci teploměru 2018/3153 umístěném ve skladu. Teploměr na expedici používaný ke kontrole nachlazení prostoru vozidla před nakládkou nebyl v Seznamu měřidel, označený nejasně evidenčním číslem 79, nebyla doložena kalibrace.
Měřidla např. teploměry, které jsou součástí technologie a slouží k monitoringu CP, nejsou evidována a není stanoven způsob jejich kontroly.
There was no evidence of calibration of the 2018/3153 thermometer located in the warehouse.The thermometer placed in the dispatch area used to control the cooling of vehicle before loading was not inclidet in the List of measuring devices, identified by an unclear registration number 79, no calibration was provided.
Measuring devices such as thermometers, which are part of the technology and are used for CP monitoring, are not registered and the method of their control is not specified.
CAll measuring devices shall bechecked, adjusted andcalibrated, under a monitoringsystem, at specified intervalsand in accordance with definedrecognised standard/methods.The results of the checks,adjustments and calibrationsshall be documented. Wherenecessary, corrective actionson devices and, if necessary,on process and products shallbe carried out.
5.4.22
Page 24 of 81CHOCOLAND a.s.
Summary of all Chapter 6 deviations and non-conformities found:
Chapter 6: Food defense
ExplanationEvalua-tion
IFS requirementsReferenceNr.
No non-conformities found.
Page 25 of 81CHOCOLAND a.s.
Report of the N/A evaluations
ExplanationEvalua-tion
IFS requirementsReferenceNr.
Outdoor storage is not used.N/AOutdoor storage shall be keptto a minimum. Where goodsare stored outside, hazardanalysis and assessment ofassociated risks shall beundertaken in order to ensurethat there is no risk ofcontamination or adverseeffect on quality and foodsafety.
4.7.31
No such equipment in placeN/ADust extraction equipmentshall be installed in areaswhere considerable amountsof dust are generated.
4.9.8.42
Recycled water is not used.N/ARecycled water which is usedin the process shall not posea contamination risk. Thewater shall comply withapplicable legal requirementsfor potable water; records ofcompliance testing shall beavailable.
4.9.9.23
Non-potable water is not used.N/ANon-potable water shall betransported in separate,properly marked piping. Suchpiping shall not be connectedto the drinking water system,or allow the possibility ofreflux to contaminate potablewater sources or the factoryenvironment.
4.9.9.44
Compressed air is not in direct contact with food or primary packaging material.
N/AThe quality of compressed airthat comes in direct contactwith food or primarypackaging material shall bemonitored based on hazardanalysis and assessment ofassociated risks.
4.9.10.15
External companies are not used.N/AWhere a company hires athird-party service provider forcleaning and disinfectionactivities, all requirementsspecified within section 4.10shall be clearly defined in therespective contract.
4.10.106
Page 26 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
No GMO raw materials used. Based on specifications of raw materials - declarations of suppliers were submitted.
N/AThere shall be adequateprocedures to ensure thatwhere products consisting ofor containing GMOs aremanufactured, contaminationof non-GMO products isavoided. Adequate controlmeasures shall be in place toavoid GMO crosscontamination. Theeffectiveness of theseprocedures shall bemonitored by testing.
4.19.37
No GMO raw materials used. Based on specifications of raw materials - declarations of suppliers were submitted.
N/AFinished products containingGMOs or labelled as notcontaining GMOs shall bedeclared in accordance withcurrent legal requirements.Delivery documents shallinclude the correspondingreference to GMOs.
4.19.48
No legislation requirementN/AIf legislation makesregistration or onsiteinspections necessary,evidence shall be provided.
6.1.39
Page 27 of 81CHOCOLAND a.s.
Detailed audit report
ExplanationEvalua-tion
IFS requirementsReferenceNr.
Senior ManagementResponsibility
11
Corporate policy/Corporateprinciples
1.12
Enclosed Quality Policy from 17.5.2019AThe senior management shalldraw up and implement acorporate policy. This shallconsider as a minimum:- customer focus- environmental responsibility- sustainability- ethics and personnelresponsibility- product requirements(includes: product safety,quality, legality, process andspecification).The corporate policy shall becommunicated to allemployees.
1.1.13
AThe content of the corporatepolicy shall have been brokendown into specific objectivesfor the related departments.The responsibility and the timescale for achievement shall bedefined for each department ofthe company.
1.1.24
AFrom the corporate policy, thequality and food safetyobjectives shall becommunicated to theemployees in the respectivedepartments and shall beeffectively implemented.
1.1.35
Within management review - last on 16.7.2019AThe senior management shallensure that the achievement ofall objectives is regularlyreviewed, as a minimum atleast once a year.
1.1.46
Plant manager meetings - weekly.AAll relevant information relatedto food safety and quality shallbe communicated effectivelyand in a timely manner to therelevant personnel.
1.1.57
Corporate structure1.28
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
AAn organisation chart shall beavailable showing the structureof the company.
1.2.19
ACompetences andresponsibilities, includingdeputation of responsibilityshall be clearly laid down.
1.2.210
AJob descriptions with clearlydefined responsibilities shallexist and shall be applicablefor employees whose work hasan effect on productrequirements.
1.2.311
AKO n°1: The seniormanagement shall ensure thatemployees are aware of theirresponsibilities related to foodsafety and quality and thatmechanisms are in place tomonitor the effectiveness oftheir operations. Suchmechanisms shall be clearlyidentified and documented.
1.2.4KO
12
AEmployees with influence onproduct requirements shall beaware of their responsibilities,and shall be able todemonstrate theirunderstanding of theirresponsibilities.
1.2.513
Ing. Zuzana Dubská, 1.10.2013AThe company shall have anIFS representative nominatedby senior management.
1.2.614
AThe senior management shallprovide sufficient and relevantresources to meet the productrequirements.
1.2.715
AThe department responsiblefor quality and food safetymanagement shall have adirect reporting relationship tothe senior management.
1.2.816
AThe company shall ensure thatall processes (documentedand undocumented) are knownby the relevant personnel andare applied consistently.
1.2.917
Page 29 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
quality managerAThe company shall have asystem in place to ensure thatit is kept informed of allrelevant legislation on foodsafety and quality issues,scientific and technicaldevelopments and industrycodes of practice.
1.2.1018
AThe company shall inform itscustomers, as soon aspossible, of any issue relatedto product specification, inparticular of all non-conformity(ies) identified by competentauthorities related to productswhich could have, has or hashad a defined impact on safetyand/or legality of respectiveproducts. This could include,but are not limited tocautionary issues.
1.2.1119
Customer focus1.320
AA documented procedure shallbe in place to identifyfundamental needs andexpectations of customers.
1.3.121
AThe results of this procedureshall be evaluated andconsidered to determinequality and food safetyobjectives.
1.3.222
Management review1.423
Once per year - last on 16.7.2019ASenior management shallensure that the quality andfood safety managementsystems are reviewed at leastannually or more frequently ifchanges occur. Such reviewsshall contain, at least, resultsof audits, customer feedbacks,process compliance andproduct conformity, status ofpreventive and correctiveactions, follow up actions fromprevious management reviews,changes that could affect thefood safety and qualitymanagement systems andrecommendations forimprovement.
1.4.124
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
AThis review shall include theevaluation of measures for thecontrol of the quality and foodsafety management systemand for the continuousimprovement process.
1.4.225
during site inspectionsAThe company shall identify andreview regularly (e.g. byinternal audits or on-siteinspection) the infrastructureneeded to achieve conformityto product requirements. Thisshall include, as a minimum,the following:- buildings- supply systems- machines and equipment- transport.The results of the review shallbe considered, with dueconsideration to risk, forinvestment planning.
1.4.326
during sites inspectionsAThe company shall identify andreview regularly (e.g. byinternal audits or on-siteinspection) the workenvironment needed toachieve conformity to productrequirements. This shallinclude, as a minimum thefollowing:- staff facilities- environmental conditions- hygienic conditions- workplace design- external influences (e.g.noise, vibration).The results of the review shallbe considered, with dueconsideration to risk forinvestment planning.
1.4.427
Quality and Food SafetyManagement System
228
Quality management2.129
Documentation requirements2.1.130
Quality manual: "Příručka bezpečnosti a kvality potravin, 17.5.2019 (revision in personall isse).
AThe system for food safety andquality management shall bedocumented and implemented,and shall be retained in onelocation (food safety andquality manual or electronicdocumented system).
2.1.1.131
Page 31 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
OS 4.2.3 "Řízení dokumentů", 26.9.2016AA documented procedure shallexist for the control ofdocuments and theiramendments.
2.1.1.232
AAll documents shall be clearlylegible, unambiguous andcomprehensive. They shall beavailable to relevant personnelat all times.
2.1.1.333
AAll documents which arenecessary for compliance withthe product requirements shallbe available in their latestversion.
2.1.1.434
The sheet of amendments is part of each document.
AThe reason for anyamendments to documentscritical for the productrequirements shall berecorded.
2.1.1.535
Record keeping2.1.236
.AAll relevant records necessaryfor the product requirementsshall be complete, detailed andmaintained and shall beavailable on request.
2.1.2.137
ARecords shall be legible andgenuine. They shall bemaintained in a way thatsubsequent manipulation ofrecords is prohibited.
2.1.2.238
AAll records shall be kept inaccordance with legalrequirements and for aminimum of one year after theshelf life. For products whichhave no shelf life, the durationof record keeping shall bejustified and this justificationshall be documented.
2.1.2.339
AAny amendments to recordsshall only be carried out byauthorised persons.
2.1.2.440
ARecords shall be securelystored and easily accessible.
2.1.2.541
Food safety Management2.242
HACCP system2.2.143
Page 32 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
Document "HACCP manual ", 13.5.2019.Eight HACCP studies:- Mlýnská výroba (Mill production) - Pomazánky, polevy, čokoláda (fillers, toppings, pastes, chocolate)- Dražé (pellet)- Tyčinky (Sticks)- Duté figurky (chocolate figurines)- Formované cukrovinky (confectionery products)- Balení (packaging)- Skladování (storage)
AThe basis of the company’sfood safety control systemshall be a fully implemented,systematic and comprehensiveHACCP system, based uponthe Codex Alimentariusprinciples. It shall take intoaccount any legalrequirements of the productionand destination countrieswhich may go beyond suchprinciples. The HACCP systemshall be implemented at eachproduction site.
2.2.1.144
AThe HACCP system shallcover all raw materials,products or product groups aswell as every process fromgoods into dispatch, includingproduct development andproduct packaging.
2.2.1.245
AThe company shall ensure thatthe HACCP system is basedupon scientific literature, ortechnical verified specificationsrelating to the manufacturedproducts and procedures. Thisshall be maintained in line withnew technical processdevelopment.
2.2.1.346
During HACCP team meetings last on 12.7.2019
AHACCP system shall bereviewed and necessarychanges shall be made whenany modification is made in theproduct, process or any step.
2.2.1.447
HACCP team2.2.248
Enclosed appointment from:Team leader: Petr Richtr, 3.1.2017members:Ing. Dubská, 1.10.2013Lenka Němcová, 14.0.2015Ivana Wiedermanová, 27.7.2017Kateřina Pokorná, 21.3.2018Jaroslav Jedlička, 5.12.2017Jana Věříšová, 1.6.2009Eliška Břinčilová, 5.4.2017Jan Malř, 27.7.2017Martin Polák, 27.7.2017
Since 13.5.2019 new members: Mr. Mikovec, Mr.Lipenský
AAssemble HACCP team (CAStep 1)The HACCP team shall bemultidisciplinary and includeoperational staff. Personnelappointed as HACCP teammembers shall have specificknowledge of HACCP, productand process knowledge andthe associated hazards. Wherecompetent knowledge is notavailable, external expertadvice shall be obtained.
2.2.2.149
Page 33 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
AThose responsible for thedevelopment and maintenanceof the HACCP system shallhave an internal team leaderand shall have receivedadequate training in theapplication of the HACCPprinciples.
2.2.2.250
AThe HACCP team shall havestrong senior managementsupport and shall be wellknown and established acrossthe whole facility.
2.2.2.351
HACCP analysis2.2.352
Descriptions of products is in HACCP manual and in product specifications.
ADescribe product (CA Step 2)A full description of the productincluding all relevantinformation on product safetyexists such as:- composition- physical, organoleptic,chemical and microbiologicalparameters- legal requirements for thefood safety of the product- methods of treatment- packaging- durability (shelf life)- conditions for storage,method of transport anddistribution.
2.2.3.153
AIdentify intended use (CA Step3)The intended use of theproduct shall be described inrelation to the expected use ofthe product by the endconsumer, taking into accountvulnerable groups ofconsumers.
2.2.3.254
Page 34 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
There are 20 flow diagrams:Hrudky, polevy, pochoutky, 10.6.2016Sójové boby, 24.7.2017Kulér, griliáš, 22.4.2016Arašídy v cukru, 276.2018Máčené výrobky, 31.8.2015Máčené tyčinky-nová linka, 12.4.2016Skladování surovin a obalů, 15.2.2016Příjem surovin a obalového materiálu, 1.6.2018Hmoty, 20.4.2016Pražení, 19.1.2018Protlačované tyčinky, 25.2.2016Formované cukrovinky, 28.4.2015Skladování hotových výrobků a polotovarů, 3.4.2014Pomazánky, 18.1.2016Kávová pasta, 18.5.2015Mletí cukru, 7.10.2015Kompletace kolekcí a dalších výrobků, 25.5.2016Nalévání figurek a výrobků do blistrů, 10.7.2018Bílá linka, 26.6.2018
AConstruct flow diagram (CAStep 4)A flow diagram shall exist foreach product, or productgroup, and for all variations ofthe processes and sub-processes (including reworkand reprocessing). The flowdiagram shall be dated, andclearly identify each CCP withthe number assigned to it. Inthe event of any changes theflow diagram shall be updated.
2.2.3.355
ensured contionously and at least all flow diagram are confirmed at HACCP meeting, last,
11.7.2019 (new sieves at mill production "prosévačka")
AOn-site confirmation of the flowdiagram (CA Step 5)The HACCP team shall verifythe flow diagram, by on-sitechecks, at all operation stages.Amendments to the diagramshall be made, whereappropriate.
2.2.3.456
Conduct a hazard analysis foreach step (CA Step 6 –Principle 1)
2.2.3.557
AA hazard analysis shall beavailable for all physical,chemical and biologicalhazards, including allergens,which may reasonably beexpected.
2.2.3.5.158
probability (P) 1-3, severity (S) 1-3result:: 1-2 = GMP, 2-4=CP, 5-6=CCP.
AThe hazard analysis shallconsider the likely occurrenceof hazards and severity of theiradverse health effects.
2.2.3.5.259
Determine critical controlpoints (CA Step 7 – Principle2)
2.2.3.660
AThe determination of relevantcritical control points (CCP's)shall be facilitated by theapplication of a decision tree orother tool(s), whichdemonstrates a logicalreasoned approach.
2.2.3.6.161
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
CP´s are determined - eg.: dosage, magnets, temperatures, softness, sieves, labeling, type of packaging material, weight.Monitoring is ensured.
AFor all steps which areimportant for food safety, butwhich are not CCP’s, thecompany shall implement anddocument control points (CP’s). Appropriate control measuresshall be implemented.
2.2.3.6.262
Page 36 of 81CHOCOLAND a.s.
ExplanationEvalua-tion
IFS requirementsReferenceNr.
Checked 2 types of CCP were determined:- metal detectors
- income of raw materials: milk products, cocoa, emulg. fats, hazelnut paste (Salmonella)- income of packaging material (labeling - especially declaration of allergens) - income of peanuts (aflatoxins).
These CCP´s were determined (12 CCP´s)
CCP Metal detectors:- Step: after packing-Parameter: proper function of detectors, detection of foreign bodies
CCP 1- Metal detector - process: "Pomazánky, vaničky", limits: 1,5 mm Fe, 2,0 mm S/SCCP 2 – Metal detector - process: "Pomazányk, dozy, tuby, kelímky", limits: 1,5 mm Fe, 2,0 mm S/S, 2 mm nonFeCCP 4- Metal detector- process: "Pomazánky sklo", limits: 1,5 mm Fe, 2,0 mm S/S, 2 mm nonFeCCP 5 -Metal detector- process: "Arašídy v cukru", limits: 1 mm Fe, 1,2 nonFe, 1,5 mm S/S, 1,5CCP 6 - Metal detektor- process: "Sojove tyčinky", limits: 1,5 mm Fe, 2 and 2,5 mm S/S, 2 mm nonFeCCP 7 - Metal detektor- process: "Sojové mlýnské výrobky", limits: 1,5 mm Fe, 2,0 mm S/SCCP 9 - Metal detektor- process: "Čokolády, polevy, pochoutky", limits: 1,5 mm Fe, 2,0 mm S/SCCP 10 - Metal detektor- process: "Hmotárna - tyčinky", limits: 1,5 mm Fe, 2,0 mm S/S, 2,0 mm nonFeCCP 11 - Metal detektor- process: "máčené tyčinky", limits: 1,5 mm Fe, 2,5 mm S/S, 1,5 mm nonFeCCP 14 - Metal detektor- process: "Adventní kalendáře, figurky", limits: 1,5 mm Fe, 2,0 mm S/S, 2,5 mm nonFe
CCP (no. 18) Income of raw materials and packaging, check of atest / or test of every batch or receive on specific parameter- Income of packaging material, check of labeling the presence of allergens
- Income of cocoa powder, some milk dry products, hazelnut paste, emulg. fats - Salmonella, limits: negative- Income of peanuts; every pallet is tested on aflatoxin B1 and suma aflatoxins
AEstablish critical limits for eachCCP (CA Step 8 – Principle 3)For each CCP, the appropriatecritical limits shall be definedand validated in order toclearly identify when a processis out of control.
2.2.3.763
Establish a monitoring systemfor each CCP (CA Step 9 –Principle 4)
2.2.3.864
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
CCP 1 - 14 Metal detectors: each hour
testing by operators, written records. CCP 18 - Income of packaging material, check of labeling - each first supply of packaging material
CCP 18 - Income of some cocoa, milk products and fats - Salmonella, certificate of analyses with each supplyCCP 18 - Income of peanuts, every pallet is tested on aflatoxin B1, suma aflatoxins in accredited laboratory, release based on results.
AKO N° 2: Specific monitoringprocedures shall beestablished for each CCP todetect any loss of control atthat CCP. Records ofmonitoring shall be maintainedfor a relevant period. Eachdefined CCP shall be undercontrol. Monitoring and controlof each CCP shall bedemonstrated by records. Therecords shall specify theperson responsible as well asthe date and result of themonitoring activities.
2.2.3.8.1KO
65
Trainining in CCPs monitoring checked for:Mrs. Šípková (metal detection): 11.4.2018Mrs. Pokorná (MD): 4.6.2019Mrs. Vondráčková (MD): 15.5.2019
AThe operative personnel incharge of the monitoring ofCCP’s shall have receivedspecific training/instruction.
2.2.3.8.266
ARecords of CCP’s monitoringshall be checked.
2.2.3.8.367
AThe CP’s shall be monitoredand this monitoring shall berecorded.
2.2.3.8.468
AEstablish corrective actions(CA Step 10 – Principle 5)In the event that the monitoringindicates that a particular CCPor CP is not under control,adequate corrective actionsshall be taken anddocumented. Such correctiveactions shall also take intoaccount any non-conformingproducts.
2.2.3.969
AEstablish verificationprocedures (CA Step 11 –Principle 6)Procedures of verification shallbe established to confirm thatthe HACCP system is effective.Verification of the HACCPsystem shall be performed atleast once a year. Examples ofverification activities include:- internal audits- analysis- sampling- evaluations- complaint by authorities andcustomers.The results of this verificationshall be incorporated into theHACCP system.
2.2.3.1070
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
AEstablish documentation andrecord keeping (CA Step 12 –Principle 7)Documentation shall beavailable covering allprocesses, procedures, controlmeasures and records.Documentation and recordkeeping shall be appropriate tothe nature and size of thecompany.
2.2.3.1171
Resource Management372
Human resourcesmanagement
3.173
AAll personnel performing workthat affects product safety,legality and quality shall havethe required competence byeducation, work experienceand/or training, commensuratewith their role, based onhazard analysis andassessment of associatedrisks.
3.1.174
Human resources3.275
Personnel hygiene3.2.176
Procedure PP 01/03 : "GMP a GHP pro výrobní, skladovací a ostatní prostory", 3.10.2016
AThere shall be documentedrequirements relating topersonnel hygiene. Theseinclude, as a minimum, thefollowing fields:- protective clothing- hand washing anddisinfection- eating and drinking- smoking- actions to be taken in case ofcuts or skin abrasions- fingernails, jewellery andpersonal belongings- hair and beards.The requirements shall bebased on hazard analysis andassessment of associated risksin relation to product andprocess.
3.2.1.177
AKO N° 3: The requirements forpersonnel hygiene shall be inplace and applied by allrelevant personnel, contractorsand visitors.
3.2.1.2KO
78
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IFS requirementsReferenceNr.
ACompliance with personnelhygiene requirements shall bechecked regularly.
3.2.1.379
AVisible jewellery (incl. piercing)and watches shall not be worn.Any exceptions shall havebeen comprehensivelyevaluated by hazard analysisand assessment of associatedrisks in relation to product andprocess. This shall beeffectively managed.
3.2.1.480
Blue plasters are used.ACuts and skin abrasions shallbe covered by a colouredplaster/bandage (different fromthe product colour) –containing a metal strip, whereappropriate – and in case ofhand injuries, in addition to aplaster/bandage, a single useglove shall be worn.
3.2.1.581
Protective clothing forpersonnel, contractors andvisitors
3.2.282
ACompany procedures shallexist to ensure that allpersonnel, contractors andvisitors are aware of the rulesregarding the management ofwearing and changing ofprotective clothing in specifiedareas in accordance withproduct requirements.
3.2.2.183
AIn work areas where wearingheadgear and/or beard snood(coverings) is required, the hairshall be covered completely,so that product contaminationis prevented.
3.2.2.284
AClearly defined usage rulesshall exist for workareas/activities where it isrequired to wear gloves(coloured differently from theproduct colour). Compliancewith these rules shall bechecked on a regular basis.
3.2.2.385
ASuitable protective clothingshall be available in sufficientquantity for each employee.
3.2.2.486
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
Clothing is washed by employees according to procedure, 2/2010 "Praní oděvů" 19.7.2016.
AAll protective clothing shall bethoroughly and regularlylaundered. Hazard analysisand assessment of associatedrisks, together withconsideration given to theprocesses and products of thecompany shall determine ifclothing shall be washed by acontract laundry, on sitelaundry or by the employee.
3.2.2.587
Procedure ,2/2010 "Praní oděvů" 19.7.2016.AGuidelines shall exist forlaundering of protectiveclothing and a procedure shallbe in place for checking itscleanliness.
3.2.2.688
Procedures applicable toinfectious diseases
3.2.389
AThere shall be written andcommunicated measures forpersonnel, contractors andvisitors to declare anyinfectious disease which mayhave an impact on food safety.In case of declaration ofinfectious disease, actionsshall be taken in order tominimize risk of contaminationof products.
3.2.3.190
Training and instruction3.391
AThe company shall implementdocumented training and/orinstruction programs withrespect to the productrequirements and the trainingneeds of the employees basedon their job and shall include:- training contents- training frequency- employee’s task- languages- qualified trainer/tutor- evaluation methodology.
3.3.192
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IFS requirementsReferenceNr.
AThe documented trainingand/or instruction shall apply toall personnel, includingseasonal and temporaryworkers and employees fromexternal companies, employedin the respective work area.Upon employment, and beforecommencing work, they shallbe trained in accordance withthe documentedtraining/instruction programs.
3.3.293
Enclosed record of general training from 24.5.2019 (HACCP, GHP/GMP) + knowledge tests, checked for employees: Mrs. Pokorná, Nadia Vasylieva, Mrs. Vondráčková, Mrs. Wiedermanová, Mr. Pukshyn, Mrs. B. Šípková, Mrs. Kazimíra Šimůnková
Checked contract with personal agency: Plasha, contract 1.4.2019
ARecords shall be available ofall training/instruction events,stating:- list of participants (this shallinclude their signature)- date- duration- contents of training- name of trainer/tutor.There shall be a procedure orprogram in place to prove theeffectiveness of the trainingand/or instruction programs.
3.3.394
AThe contents of training and/orinstruction shall be reviewedand updated regularly and takeinto account company’sspecific issues, food safety,food related legal requirementsand product/processmodifications.
3.3.495
Sanitary facilities, equipmentfor personnel hygiene and stafffacilities
3.496
AThe company shall providestaff facilities, which shall beproportional in size, equippedfor the number of personneland designed and operated soas to minimise food safetyrisks. Such facilities shall bekept in clean and goodcondition.
3.4.197
AThe risk of productcontamination by foreignmaterial from staff facilitiesshall be evaluated andminimised. Consideration shallalso be given to food broughtto work by personnel andpersonal belongings.
3.4.298
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AThere shall be in place rulesand facilities to ensure thecorrect management forpersonnel belongings and forfood brought to work bypersonnel, food coming fromdining room and from vendingmachines. The food shall onlybe stored and/or used indesignated areas.
3.4.399
AThe company shall providesuitable changing rooms forpersonnel, contractors andvisitors. Where necessary,outdoor clothing and protectiveclothing shall be storedseparately.
3.4.4100
AToilets shall not have directaccess to an area where foodproducts are handled. Thetoilets shall be equipped withadequate hand washingfacilities. Sanitary facilitiesshall have adequate natural ormechanical ventilation.Mechanical airflow from acontaminated area to a cleanarea shall be avoided.
3.4.5101
AAdequate hand hygienefacilities shall be provided ataccess points to and withinproduction areas, as well as atstaff facilities. Based on hazardanalysis and assessment ofassociated risks, further areas(e.g. packaging area) shall besimilarly equipped.
3.4.6102
AHand washing facilities shallprovide as a minimum:- running potable water at anappropriate temperature- liquid soap- appropriate equipment forhand drying.
3.4.7103
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AWhere highly perishable foodproducts are handled, thefollowing additionalrequirements regarding handhygiene shall also be provided:- hand contact-free fittings- hand disinfection- adequate hygiene equipment- signage highlighting handhygiene requirements- waste container with handcontact-free opening.
3.4.8104
MiBI swabs (internally), Enterobacteriacae - monthly (22.7., 10.6., 14.5.2019)
ABased on hazard analysis andassessment of associatedrisks, there shall be a programto control effectiveness of handhygiene.
3.4.9105
AChanging rooms shall besituated so that they allowdirect access to the areaswhere food products arehandled. Based on hazardanalysis and assessment ofassociated risks, exceptionsshall be justified and managed.
3.4.10106
AWhere the hazard analysis andassessment of associated risksshow the necessity, cleaningfacilities shall be available andused for boots, shoes andfurther protective clothing.
3.4.11107
Planning and ProductionProcess
4108
Contract agreement4.1109
Checked contract:
LIDL Složení/Zaručená jakost ,1.7.2019 and Deklarační list 10.1.2018
AThe requirements which aredefined between the contractpartners shall be established,agreed upon and reviewedconcerning their acceptabilitybefore a supply agreement isconcluded. All clauses relatedto quality and food safety shallbe known and communicatedto each relevant department.
4.1.1110
AChanges of existingcontractual agreements shallbe documented andcommunicated between thecontract partners.
4.1.2111
Specifications and formulas4.2112
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Specifications4.2.1113
there are about 95 ready products, 51 semi-products
ASpecifications shall beavailable and in place for allfinished products. They shallbe up to date, unambiguousand be in compliance withlegal and customerrequirements.
4.2.1.1114
Specifications of raw materials checked during the audit:
Bakers cake SG 084, Vandermoortele, 4.6.2019, IFS and BRC, questionnaire (Q) 14.5.2019Aroma Ruma, Silesia, 5.6.2019, BRC, Q 21.6.2019Kokosové aroma 711, Aroko, 7.1.2019 FSSC 22000Sušená Syrovátka, sladká, Eligo, 24.6.2019, FSSC 22000 Sojové boby, Netagro, 18.10.2018, Q 17.4.2019Natural cococa powder, Theobroma, 17.2.2017 FSSC 2200Mléčná Cokoláda, Gryf CA, 7.6.2019, FSSC 22000, Q 7.6.2019 Jádra podzemnice olejné, Aldebaran Commmodity, 16.12.2018, Argentina, China, ISO 22000PackagingChristel 300g, Vetropack, 7.6.2019, DofC 1.3.2019, Analytical report, 26.7.2017Komelis Caps and Closures, spec. 5,6.2019, Dof C3407PPEE All Closures, 5.6.2019Tech spec TAPAFOL BOPP 20mik + BOPP 35 mik, 1.3.2019, Dof C, 31.5.2019 BRC /IOP
AKO N° 4: Specifications shallbe available and in place for allraw materials (rawmaterials/ingredients,additives, packaging materials,rework). Specifications shall beup to date, unambiguous andbe in compliance with legalrequirements and, if existing,with customer requirements.
4.2.1.2KO
115
Checked signed customer specifications:
LIDL Marcius 100g, 1.7.2019LIDL Sojový kmen, 1.7.2019Nugeta 340 g Nestle, 17.5.2017Specifikace Zebra, Milch Chocolate, 62,5 g pytlík (5 figurek), March 2018
Internal specifications: Arašídová pomazánka 32% arašídů, 22.5.2018Kakaová tyčinka s náplní s příchutí vaj. likér, 24.6.2019Tuby lískooříšková pomazánka, 6.5.2015
AWhere required by customers,product specifications shall beformally agreed.
4.2.1.3116
ASpecifications and/or theircontents shall be provided inthe relevant location andaccessible to all relevantpersonnel.
4.2.1.4117
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AThere shall be a procedure forthe creation, the modificationand approval of specificationsfor all parts of the process,which shall include thepreliminary acceptance of thecustomer, if specifications havebeen agreed with customers.
4.2.1.5118
Specifikace pro FN Martius odsouhlasená s LIDL , 1.7.2019: nesoulad ve složení (např. uvedeno 6% kakaa, bez aromat) se stávajícím značením na obale (5,2 % kakao, aroma).
Specification for FN Martius agreed with LIDL, 1.7.2019 non-compliance in composition (eg. 6% cocoa, not added flavor) with existing product labeling (5,2% cocoa, flavor).
CThe specification controlprocedure shall include theupdate of finished productspecification in case of anymodification:- of raw material- of formula/recipe- of process with influence onthe final products- of packaging with influenceon the final products.
4.2.1.6119
Formula/recipes4.2.2120
No special technological requirement.Requirements on recipe and analyses of products have some customers e.g. Nestle, LIDL.Company fulfills these requirements. Checked for LIDL in detail (recipe, specifications, labelling, contract with customer, interview with staff - sales and production dept.): product within traceability test: Fist Nice Marcius Sojariegel UTZ 100g
AKO N° 5: Where there arecustomer agreements inrelation to the productformula/recipe andtechnological requirements,these shall be complied with.
4.2.2.1KO
121
Product development/Productmodification/Modification ofproduction processes
4.3122
Procedure PP06 "Postup pro inovaci a vývoj nových výrobků", 13.8.2015.In 2018: 14 projects
Checked project V08/2018 "Jsem kokosová plněná"
AA procedure for productdevelopment shall be in placewhich incorporates the hazardanalysis principles, inaccordance with the HACCPsystem.
4.3.1123
AProduct formulation,manufacturing processes,process parameters and thefulfilment of productrequirements shall beestablished and shall havebeen assured by factory trialsand product testing.
4.3.2124
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AShelf life tests or adequateprocesses shall be carried outand consideration given toproduct formulation,packaging, manufacturing anddeclared conditions; “Use by”or “Best before” dates shall beestablished accordingly.
4.3.3125
AWhen establishing andvalidating the shelf life of theproduct (including long shelflife product i.e. labelled with a“best before date”), the resultsof organoleptic tests shall alsobe taken into account.
4.3.4126
AProduct development shallconsider the results oforganoleptic assessments.
4.3.5127
AA process shall be in place toensure that labelling complieswith current legislation ofdestination country andcustomer requirements.
4.3.6128
ARecommendations forpreparation and/or use of thefood products shall beestablished. Whereappropriate, customerrequirements shall be included.
4.3.7129
9.4.19 122147/19 Smile kokosová tyčinka, vit. C B1 a B2
AThe company shalldemonstrate through studiesand/or perform relevant tests inorder to validate nutritionalinformation or claims which arementioned on labelling. Thisapplies both for a new productand during all its period of sale.
4.3.8130
AThe progress and results ofproduct development shall beproperly recorded.
4.3.9131
AThe company shall ensure thatin the event of changes toproduct formulation, includingrework and packagingmaterial, processcharacteristics are reviewed inorder to assure that productrequirements are compliedwith.
4.3.10132
Purchasing4.4133
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Procedure OS 7.4 Purchasing, 1.2.2017AThe company shall controlpurchasing processes toensure that all externallysourced materials andservices, which have an impacton food safety and quality,conform to requirements.Where a company chooses tooutsource any process thatmay have an impact on foodsafety and quality, thecompany shall ensure controlover such processes. Controlof such outsourced processesshall be identified anddocumented within the foodsafety and qualitymanagement system.
4.4.1134
AThere shall be a procedure forapproval and monitoring ofsuppliers (internal andexternal), outsourcedproduction or part of it.
4.4.2135
Each supplier has its own sheet.Criteria: quality, delivery, approach to complaints, documents to supply, sent questionnaires, GFSI / other certifications.
AThe approval and monitoringprocedure shall contain clearassessment criteria such as:audits, certificates of analysis,supplier reliability andcomplaints, as well as requiredperformance standards.
4.4.3136
Ensured annually - last 30.6.2019AThe results of suppliers’assessments shall be reviewedregularly and this review shallbe based on hazard analysisand assessment of associatedrisks. There shall be records ofthe reviews and of the actionstaken as a consequence ofassessment.
4.4.4137
Checked eg CofA: Atest Barry Callebaut kakao, 11-10-2018 a atest Tulip cocoa, 20.2.2018 – Salmonella negat,
AThe purchased products shallbe checked in accordance withthe existing specifications andtheir authenticity, based onhazard analysis andassessment of associatedrisks. The schedule of thesechecks shall, as a minimum,take into account the followingcriteria; product requirements,supplier status (according to itsassessment) and impact of thepurchased products on thefinished product. The originshall be additionally checked, ifmentioned in the specification.
4.4.5138
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AThe purchased services shallbe checked in accordance withthe existing specifications. Theschedule of these checks shallat least take into account thefollowing items: servicerequirements, supplier status(according to its assessment)and impact of the service onthe finished product.
4.4.6139
Product packaging4.5140
Primary packaging material in place:-Al Foil, Al lids- PP foil, PS foil- PP bags,- PP buckets, PP cups, PET boxes, PVC boxes, PE Tubes+ lids- PVC trays- paper bags, paper bags with PE layer- glass
ABased on hazard analysis,assessment of associated risksand intended use, thecompany shall determine thekey parameters for thepackaging material.
4.5.1141
Primary packaging material in place:Al Foil, Al lids- PP foil, PS foil- PP bags,- PP buckets, PP cups, PET boxes, PVC boxes, PE Tubes+ lids- PVC trays- paper bags, paper bags with PE layer- glass
ADetailed specifications shallexist for all packagingmaterials which comply withthe current relevant legislation.
4.5.2142
AFor all packaging materialwhich could have an influenceon products, certificates ofconformity shall exist whichcomply with current legalrequirements. In the event thatno specific legal requirementsare applicable, evidence shallbe available to demonstratethat packaging material issuitable for use. This appliesfor packaging material whichcould have an influence on rawmaterials, semi-processed andfinished products.
4.5.3143
Enclosed declaration and analysis to primary packaging material:Christel 300g, Vetropack, 7.6.2019, DofC 1.3.2019, Analytical report, 26.7.2017Komelis Caps and Closures, spec. 5,6.2019, Dof C3407PPEE All Closures, 5.6.2019Tech spec TAPAFOL BOPP 20mik + BOPP 35 mik, 1.3.2019, Dof C, 31.5.2019 BRC /IOP
ABased on hazard analysis andassessment of associatedrisks, the company shall verifythe suitability of the packagingmaterial for each relevantproduct (e.g. organoleptictests, storage tests, chemicalanalysis, migration tests).
4.5.4144
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AThe company shall ensure thatthe packaging usedcorresponds to the productbeing packed. The use ofcorrect packaging shall beregularly checked and checksshall be documented.
4.5.5145
ALabelling information shall belegible indelible and shallcomply with agreed customerproduct specifications. Thisshall be regularly checked andchecks shall be documented.
4.5.6146
Factory location4.6147
AThe company shall investigateto what extent the factoryenvironment (e.g. ground, air)may have an adverse impacton product safety and productquality. Where it is establishedproduct safety and qualitycould be compromised,appropriate measures shall beestablished. The effectivenessof the established measuresshall be periodically reviewed(examples: extremely dusty air,strong smells).
4.6.1148
Factory Exterior4.7149
AThe factory exterior shall bemaintained to be clean andtidy.
4.7.1150
AAll external areas of the factoryshall be maintained in goodcondition. Where naturaldrainage is inadequate, asuitable drainage system shallbe installed.
4.7.2151
Outdoor storage is not used.N/AOutdoor storage shall be keptto a minimum. Where goodsare stored outside, hazardanalysis and assessment ofassociated risks shall beundertaken in order to ensurethat there is no risk ofcontamination or adverseeffect on quality and foodsafety.
4.7.3152
Plant layout and process flows4.8153
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APlans clearly describinginternal flows of finishedproducts, packaging materials,raw materials, waste,personnel, water, etc. shall bein place. A site map coveringall buildings of the facility shallbe available.
4.8.1154
AThe process flow, from receiptof goods to dispatch, shall bein place so that contaminationof raw materials, packaging,semi-processed and finishedproducts is avoided. The risk ofcross-contamination shall beminimised through effectivemeasures.
4.8.2155
AIn case of microbiologicallysensitive production areas,these shall be operated andmonitored to ensure productsafety is not compromised.
4.8.3156
ALaboratory facilities and in-process controls shall notaffect the product safety.
4.8.4157
Constructional requirementsfor production and storageareas
4.9158
Constructional requirements4.9.1159
ARooms where food productsare prepared, treated,processed and stored shall bedesigned and constructed sothat food safety is ensured.
4.9.1.1160
Walls4.9.2161
AWalls shall be designed andconstructed to prevent theaccumulation of dirt, to reducecondensation and mouldgrowth, and to facilitatecleaning.
4.9.2.1162
Stěny celkově v horším stavu na odhořčárně.
Díry v dlaždicích po hmoždinkách na pytlování - arašídy.
Walls are generally in worse condition on soya beans preparing area "odhořčárna".
Holes in tiles after previous dowels - peanuts bagging area.
BThe surfaces of walls shall bein a good condition and easy toclean; they shall be imperviousand wear-resistant.
4.9.2.2163
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AThe junctions between walls,floors and ceilings shall bedesigned to facilitate cleaning.
4.9.2.3164
Floors4.9.3165
Podlahy celkově v horším stavu - výroba: sojové tyčinky a budova 203, 1.patro (kovová podlaha a betonový přechod).Opravy plánovány, především s ohledem na modernizaci linky na sojové tyčinky.
Floors generally in a worse condition - production of soy bars and building 203, 1st floor (metal floor and concrete transition).Repairs planned, especially with regard to the modernization of the soya bar line.
BFloor covering shall bedesigned to meet productionrequirements and shall be ingood condition and easy toclean. Surfaces shall beimpervious and wear-resistant.
4.9.3.1166
AThe hygienic disposal of wastewater shall be ensured.Drainage systems shall beeasy to clean and designed tominimise the risk of productcontamination (e.g. ingress ofpests, etc.).
4.9.3.2167
AWater or other liquids shallreach drainage withoutdifficulties, using appropriatemeasures. Puddles shall beavoided.
4.9.3.3168
AIn food handling areas,machinery and piping shall bearranged so that waste water,if possible, goes directly into adrain.
4.9.3.4169
Ceilings/Overheads4.9.4170
Poškození stropu včetně nezakrytého otvoru na dílně "nugeta".
Damaged ceiling, including the open hole at "nugget" production area.
BCeilings (or, where no ceilingsexist, the inside of roofs) andoverhead fixtures (incl. piping,cableway, lamps etc.) shall beconstructed to minimise theaccumulation of dirt and shallnot pose any risk of physicaland/or microbiologicalcontamination.
4.9.4.1171
The false ceilings are checked by own janitors.AWhere false ceilings are used,an access to the void shall beprovided in order to facilitatecleaning, maintenance andinspections for pest control.
4.9.4.2172
Windows and other openings4.9.5173
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Poškozené rámy oken na odhořčárně.
Damaged window frames on soya beans preparing area "odhořčárna".
BWindows and other openingsshall be designed andconstructed to avoid theaccumulation of dirt and shallbe maintained in goodcondition.
4.9.5.1174
AWhere there is risk ofcontamination, windows androof glazing shall remainclosed and fixed duringproduction.
4.9.5.2175
AWhere windows and roofglazing are designed to beopened for ventilationpurposes, they shall be fittedwith easily removable, goodcondition pest screens or othermeasures in order to avoid anycontamination.
4.9.5.3176
Některá okna v místech otevřeného produktu nejsou chráněna proti rozbití. Např. skleněné okno v blízkostí máčení persiko.
Some windows in open product areas are not protected against breakage. E.g. glass window near the soaking of Persiko
CIn areas where unpackagedproduct is handled, windowsshall be protected againstbreakage.
4.9.5.4177
Doors and gates4.9.6178
ADoors and gates shall be ingood condition (e.g. nosplintering parts, flaking paintsor corrosion) and easy toclean.
4.9.6.1179
Netěsná plechová vrata - sklad polotovarů Jambor.
Untight sheet metal doors - Jambor semi-finished product storage area.
BExternal doors and gates shallbe constructed to prevent theingress of pests; if possible,they shall be self-closing.
4.9.6.2180
Lighting4.9.7181
AAll working areas shall haveadequate lighting.
4.9.7.1182
AAll lighting equipment shall beprotected by shatter proofcovers and installed tominimise the risk of breakage.
4.9.7.2183
Air conditioning/Ventilation4.9.8184
AAdequate natural and/orartificial ventilation shall existin all areas.
4.9.8.1185
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AIf ventilation equipments areinstalled, filters and othercomponents which requirecleaning or replacement shallbe easily accessible.
4.9.8.2186
Klimatizační zařízení - arašidky ; nevhodné umístění svítidel v těsné blízkosti jednotek a svod kondenzátu přímo do umyvadla. Nejsou obecně jasné důkazy o výměně nebo čištění filtrů klimatizačních jednotek, doloženy pouze pravidelné revize těsnosti - kontroly úniků chladiva.
Air conditionig equipment - "arašídky" production area; improper placement of lightings closely to AC units and condensate drain directly into the sink.There is generally no clear evidence of replacement or cleaning of air conditioner filters,only periodic leakage revisions.
BAir conditioning equipment andartificially generated airflowshall not lead to any productsafety or quality risks.
4.9.8.3187
No such equipment in placeN/ADust extraction equipmentshall be installed in areaswhere considerable amountsof dust are generated.
4.9.8.4188
Water supply4.9.9189
Potable water from own well and public water supply is used. Water is added into production process (production of soy sticks). Quality check (analysis according to valid national legislation No. 252/2004 Sb.) according to the annual sampling plan:- short analyses - 2 times a year, Tested parameters: MB- coliform, E.Coli, Cl. perfringens, culltiv MO 36°C and 22°C, CH - Cl, Fe, Ca, Mg, chemical oxygen consumption, NH4, NO2, NO3, taste, odour, conductivity, turbidity, Al.- warm water (Legionella) - 2 times a year- technological (duplicator) water, - 4 times per year (MB)
AWater which is used asingredient in the productionprocess, or for cleaning, shallbe of potable quality andsupplied in sufficient quantity;this also applies to steam andice used within the productionarea. A supply of potable watershall be available at all times.
4.9.9.1190
Recycled water is not used.N/ARecycled water which is usedin the process shall not pose acontamination risk. The watershall comply with applicablelegal requirements for potablewater; records of compliancetesting shall be available.
4.9.9.2191
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Last analysis (accredited lab. SVU Jihlava L1129):- short analyses (MB + CH parameters): last protocol no. 132523/19, 23.5.2019
- warm water (Legionella) protocol no. 132524/19, 23.5.2019
- technological (duplicator) water (MB parameters): protocol no. 134088/19, 30.5.2019,
AThe quality of water, steam orice shall be monitoredfollowing a risk based samplingplan.
4.9.9.3192
Non-potable water is not used.N/ANon-potable water shall betransported in separate,properly marked piping. Suchpiping shall not be connectedto the drinking water system,or allow the possibility of refluxto contaminate potable watersources or the factoryenvironment.
4.9.9.4193
Compressed air4.9.10194
Compressed air is not in direct contact with food or primary packaging material.
N/AThe quality of compressed airthat comes in direct contactwith food or primary packagingmaterial shall be monitoredbased on hazard analysis andassessment of associatedrisks.
4.9.10.1195
ACompressed air shall not posea risk of contamination.
4.9.10.2196
Cleaning and disinfection4.10197
Některá zařízení a jejich hůře dostupná místa nebyla řádně vyčištěna v době auditu:- Z míchačky zespodu- tvarovací a máčecí stroj uvniř a pod linkou- dále znečištěná stěna za vývěskami na dílně pytlování - arašídy- znečištěná podlaha na odhorčárně; u zásobníku a namáčení persiko byla na zemi rozsypána jádra podzemnice.
Some production equiment and their harder to access places were not properly cleaned at the time of the audit:- "Z" blenders (bottom part)- Forming and dipping machine inside and below the line- the dirty wall behind the information boards in the peanut bagging area- dirty floor in soya beans preparing area "odhořčárna", spilled peanuts near the hopper and soaking of persiko
CBased on hazard analysis andassessment of associatedrisks, cleaning and disinfectionschedules shall be availableand implemented. These shallspecify:- objectives- responsibilities- the products used and theirinstructions for use- the areas to be cleanedand/or disinfected- cleaning frequency- documentation requirements- hazard symbols (ifnecessary).
4.10.1198
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Procedure 01/02 "Sanitační řád", 3.8.2016.
There are 64 plans covered all spaces.
ACleaning and disinfectionschedules shall beimplemented and documented.
4.10.2199
AOnly qualified personnel shallbe allowed to undertakecleaning and disinfection. Thepersonnel shall be trained andretrained to carry out thecleaning schedules.
4.10.3200
Internal laboratory - swabs: every month (Enterobacteruacae), checked records 14.5.2019, 10.6.2019, 22.7.2019
External laboratory (SVU Olomouc, SVU Praha) - swabs weekly on SalmonellaProtocol no. 5123/19 15.7.19 stěry zařízení, Salmmonella4980/19, 4.7.19 stěry zařízení Salmonella13.6.2019 smetky - Salmonella
AThe effectiveness and safety ofthe cleaning and disinfectionmeasures, based on hazardanalysis and assessment ofassociated risks, shall beverified and documentedaccording to a samplingschedule by using appropriateprocedures. Resultantcorrective actions shall bedocumented.
4.10.4201
ACleaning and disinfectionschedules shall be reviewedand modified, if necessary, inthe event of a change toproduct, process or cleaningequipment.
4.10.5202
AThe intended use of cleaningutensils shall be clearlyidentified. Cleaning utensilsshall be used in a way to avoidcontamination.
4.10.6203
ACurrent safety data sheets(SDS) and instructions for useshall be available for chemicalsand cleaning agents.Personnel responsible forcleaning shall be able todemonstrate their knowledgeof such instructions, whichshall be always available onsite.
4.10.7204
ACleaning chemicals shall beclearly labelled, used andstored appropriately, to avoidcontamination.
4.10.8205
ACleaning activities shall becarried out in periods of non-production. If this is notpossible, these operationsshall be controlled as to notaffect the product.
4.10.9206
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External companies are not used.N/AWhere a company hires a third-party service provider forcleaning and disinfectionactivities, all requirementsspecified within section 4.10shall be clearly defined in therespective contract.
4.10.10207
Waste disposal4.11208
External firms:- AV Kolín Plasty- obec Radim- S.firma s.r.o.
AA waste managementprocedure shall exist and shallbe implemented to avoid crosscontamination.
4.11.1209
AAll current legal requirementsfor waste disposal shall bemet.
4.11.2210
AFood waste and other wasteshall be removed as quickly aspossible from areas wherefood is handled. Theaccumulation of waste shall beavoided.
4.11.3211
AWaste collection containersshall be clearly marked,suitably designed, in goodstate of repair, easy to clean,and where necessarydisinfected.
4.11.4212
AWaste collection rooms andcontainers (incl. compactors)shall be designed to be keptclean to minimise pestattraction.
4.11.5213
AWaste shall be collected inseparate containers inaccordance with the intendedmeans of disposal. Such wasteshall be disposed byauthorised third parties only.Records of waste disposalshall be kept by the company.
4.11.6214
Risk of foreign material, metal,broken glass and wood
4.12215
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HACCP Plans contain information about possible contamination.Rules for prevention are documented in "PP 02/04 "Registr skla a tříštivých materiálů, politika dřeva ve výrobě, seznam nožů a škrabek", 6.3.2018.The company uses following equipment to detect or reject materials contaminated with foreign bodies:- sieves, different mesh sizes sieves ( 1,0-6,3 mm) used for sieving of all raw materials, semi products or products - there are 20 sieves-metal detectors (12 frame detectors on lines)- 30 magnets Some products are packed in glass. Procedures are worked out:- PP 08/05 Čistící režim Plnění pomazánek do dóz a sklenic, 30.4.2015- PP 04/2009 Zásady manipulace se sklem, 7.7.2015.The record about cleaning and checks after each glass breakage is ensured.
AKO N° 6 Based on hazardanalysis and assessment ofassociated risks, proceduresshall be in place to avoidcontamination with foreignmaterial. Contaminatedproducts shall be treated asnon-conforming products.
4.12.1KO
216
AIn all areas, e.g. handling ofraw materias, processing,packing and storage, wherehazard analysis andassessment of associated riskshave identified the potential forproduct contamination, the useof wood shall be excluded.Where the use of wood cannotbe avoided, the risk shall becontrolled and the wood shallbe in good order and clean.
4.12.2217
AWhere metal- and/or otherforeign material detectors arerequired, they shall be installedto ensure maximum efficiencyof detection, in order to avoidsubsequent contamination.Detectors shall be subjected toregular maintenance to avoidmalfunction.
4.12.3218
Ensured by operators as CCP. Frequency: each hour.
APotentially contaminatedproducts shall be isolated.Access and actions for furtherhandling or checking for theseisolated products shall becarried out only by authorisedpersonnel according to definedprocedures. After this check,contaminated products shall betreated as non-conformingproducts.
4.12.4219
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Zkouška detektoru na sojových sucích nebyla zcela přesná - test proběhl bez produktů, nebylo zkoušeno vyřazení.Test detektoru na arašídkách - po testu s etalony nebyly zkoušené vyřazené výrobky znovu prověřeny MD.
The detector testing on soy bars was not entirely accurate - the test was carried out without products, and no rejection machanisms was tested.The detector testing "arašídky"- after testing with standards the tested rejected products were not re-tested by the metal detector.
CThe appropriate accuracy ofdetectors shall be specified.Checks of proper function ofdetectors shall be carried outregularly. In case ofmalfunction or failure of ametal and/or foreign materialdetector, corrective actionsshall be defined, implementedand documented.
4.12.5220
Měření síly magnetů bylo provedeno, avšak získané hodnoty nebyly dosud zanalyzovány s ohledem na umístění magnetu (tj. zda se jedná o koncový magnet nebo sekvenci několika magnetů či zda je zařazeno v kombinaci se sítem či MD) a s ohledem na typ magnetu.
Magnet strength measurements have been performed, but the values obtained have not yet been analyzed with respect to magnet placement (ie whether it is an end magnet or a sequence of several magnets, or whether it is combined with a sieve or a MD) and with respect to the type of magnet.
BIn cases where specialequipment or methods areused to detect foreign material,these shall be properlyvalidated and maintained.
4.12.6221
AIn all areas, e.g. handling ofraw materials, processing,packing and storage, wherehazard analysis andassessment of associated riskshave identified a potentialproduct contamination, thepresence of glass and brittlematerial shall be excluded.Where the presence of glassor brittle plastic cannot beavoided, appropriate measuresshall be in place to protectagainst breakage.
4.12.7222
PP 02/04 "Registr skla a tříštivých materiálů, politika dřeva ve výrobě, seznam nožů a škrabek", 6.3..2018Daily checks with records according to the Register.
AAll stationary objects made ofor incorporating glass or brittlematerial present in areas ofhandling of raw materials,processing, packing andstorage shall be listed in aspecific register, includingdetails of their exact location.An assessment of thecondition of objects on theregister shall be performed ona regular basis and recorded.Frequency of this check shallbe justified by documents.
4.12.8223
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Rozbití několika krytů svítidel na dílně adventních kalendářů (budova 203), třebaže záznamy z 22.7. nevykazovaly žádné evidentní poškození krytů.
Breaking of several lighting covers in the advent calendar prod.area (building 203), although records from 22.7. showed no evident damage on these covers.
BBreakages of glass and brittlematerial shall be recorded.Exceptions shall be justifiedand documented.
4.12.9224
Procedures are worked out:- 08/05 Čistící režim Plnění pomazánek do dóz a sklenic, 30.4.2015- PP 04/2009 Zásady manipulace se sklem, 7.7.2015.The record about cleaning and checks after each glass breakage is ensured.
AProcedures shall be in placedescribing the measures to betaken in case of breakage ofglass and/or brittle material.Such measures shall includeidentifying the scope of goodsto be isolated, specifyingauthorised personnel, cleaningthe production environmentand release of production linefor continued production.
4.12.10225
ABased on hazard analysis andassessment of associatedrisks, preventive measuresshall be in place for handling ofglass packaging, glasscontainers or other kinds ofcontainers in the productionprocess (turn over, blow, rinse,etc.). After this process stepthere shall be no further risk ofcontamination.
4.12.11226
AWhere visual inspection isused to detect foreign material,the employees shall be trainedand operative change shall beperformed at an appropriatefrequency to maximiseeffectiveness of process.
4.12.12227
Pest monitoring/Pest control4.13228
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External company DERATOR s.r.o. is used. Contract from 22.6.2017. Visits are ensured monthly and 2 times a year gassing is ensured.The firm is certified according the standard CEPA ČSN 16 636 (certificate from 6.9.2017).
Enclosed:- records of visits: 26.4.2019, 31.5.2019, 27.6.2019 (only outdoor baits are taken, sporadic occurence of moths - preventive gassing 4.7.2019)
86 pcs of non toxic bites DETEX35 pcs toxic bites STORM44 pcs insects bites69 pcs glue bites (insects)10 pcs fly killer 29 bites "živolovky"
MSDS for used agents: Uragan D2-Bluefume, 1.3.2017, Aquapy 1.4.2014, Effect Ultimate professional 15.1.2015.
Odchylka: Ojedinělý výskyt zavíječe na budově 201 a 203.
Deviation: Sporadic occurence of moths at the 201 and also 203 building.
BThe company shall have a pestcontrol system in place whichis in compliance with locallegal requirements, taking intoaccount, as a minimum:- the factory environment(potential pests)- site plan with area forapplication (bait map)- identification of the baits onsite- responsibilities, in-house/external- used products/agents andtheir instructions for use andsafety- the frequency of inspections.The pest control system shallbe based on hazard analysisand assessment of associatedrisks.
4.13.1229
Enclosed certificate of operator of external firm T.Raška 20.10.2022 (§58 odst.1), 26.11.2020 (§58 odst.2,3).
AThe company shall havequalified and trained in-housestaff and/or employ theservices of a qualified externalprovider. Where an externalprovider is used, the activitiesrequired on site shall bespecified in a written contract.
4.13.2230
APest control inspections andresulting actions shall bedocumented. Implementationof actions shall be monitoredand recorded.
4.13.3231
Nejsou k dispozici důkazy o výměně UV trubic z elektrických lapačů hmyzu.
There is no evidence of replacement of UV tubes in electric fly killers.
BBaits, traps and insectexterminators shall befunctioning, shall be insufficient numbers and shall beplaced in an appropriateposition. They shall beconstructed and positioned asnot to cause any contaminationrisk.
4.13.4232
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Procedure : PP Příjem surovin a obalového materiálu, 1.6.2018
AIncoming deliveries shall bechecked on arrival for thepresence of pests. Anyinfestation shall bedocumented and controlmeasures taken.
4.13.5233
Annual pest control evaluation report: 12.12.2018
AThe effectiveness of the pestcontrol shall be monitored withthe help of regular trendanalyses.
4.13.6234
Receipt of goods and storage4.14235
AAll incoming goods, includingpackaging materials andlabels, shall be checked forconformity againstspecifications and to adetermined inspection plan.The inspection plan shall berisk based. Test results shall bedocumented.
4.14.1236
Skladovací podmínky pro suroviny neodpovídaly v době auditu stanoveným limitům či požadavkům uvedeným ve specifikacích surovin (sklad Jambor: 22,9°C, sklad 3: 22°C a sklad 4: 24,5°a sklad Betoňák : 27,6 °C). Zápisy teplot probíhají vždy jednou denně ráno, kdy teploty většnou odpovídají. Ačkoliv pro tyty případy byla vytvořena analýza a definována nápravná opatření, nejsou reálně opatření zřejmě z tohoto důvodu iniciována.
Nezakryté nepoužívané primární obaly v otevřeném regálu linky - arašídky.
Storage conditions for some raw materials did not comply with the limits or requirements specified in the raw material specifications at the time of the audit (Jambor warehouse: 22.9 ° C, warehouse 3: 22 ° C and warehouse 4: 24.5 ° and Betoňák warehouse: 27.6 ° C ). The temperature is recorded every day in the morning, when the temperatures mostly correspond.Although analysis and corrective action is defined for these cases, the real corrective action do not seem to be initiated for this reason.
Uncovered unused primary packaging in the open shelf of the packing line "arašídky". .
CThe storage conditions of rawmaterials, semi-processed andfinished products as well aspackaging shall in each casecorrespond to productrequirements (e.g.refrigeration, protective covers)and shall not be detrimental toother products.
4.14.2237
ARaw materials, packaging,semi-processed and finishedproducts shall be stored so asto minimise the risk of crosscontamination.
4.14.3238
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AAppropriate storage facilitiesshall be available for themanagement and storage ofworking materials, processaids, and additives. Thepersonnel responsible for themanagement of storagefacilities shall be trained.
4.14.4239
AAll products shall be clearlyidentified. Use of productsshall be undertaken inaccordance with the principlesof First In/First Out and/or FirstExpired/First Out.
4.14.5240
External warehouse Nagel (IFS Logistic certified) is used. Contract ensured.
AWhere a company hires a third-party storage service provider,the service provider shall besubject to IFS Logisticsrequirements. If the third partyservice provider is not certifiedto IFS Logistics, all relevantrequirements equivalent to thecompany’s own warehousingpractices shall be fulfilled andthis shall be clearly defined inthe respective contract.
4.14.6241
Transport4.15242
.ABefore loading transportvehicles, their condition (e.g.absence of strange smells,high dust load, adversehumidity, pests, mould) shallbe checked and action taken, ifnecessary.
4.15.1243
AProcedures to preventcontamination during transportshall be implemented(food/non-food/differentcategories of goods).
4.15.2244
AWhere goods must betransported at certaintemperatures, before loading,the temperature inside thevehicle shall be checked anddocumented.
4.15.3245
AWhere goods must betransported at certaintemperatures, maintaining theadequate range oftemperatures during transportshall be ensured anddocumented.
4.15.4246
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AAdequate hygienicrequirements for all transportvehicles and equipment usedfor loading/unloading (e.g.hoses of silo installations) shallexist. There shall be records ofthe measures taken.
4.15.5247
ALoading and unloading areasshall have equipment in placeto protect transported productsfrom external influences.
4.15.6248
External firms are used e.g.:- Haná Intertrans Olomouc- Raben Logistic , contracts from 2.5.2015- Nagel Česko
AWhere a company hires a third-party transport serviceprovider, all the requirementsspecified within section 4.15shall be clearly defined in therespective contract or theservice provider shall besubject to IFS Logisticsrequirements.
4.15.7249
ASecurity of transport vehiclesshall be appropriatelymaintained.
4.15.8250
Maintenance and repair4.16251
V plánu údržby nejsou zahrnuty všechny metal detektory. Není důkaz o výměně filtru na vyfukovacím zařízení u MD na výrobě soj. suků.
Not all metal detectors are included in the maintenance plan. There is no evidence of replacing the filter on the blower of MD at soy bars production.
BAn adequate system ofmaintenance shall be in place,maintained and documented,covering all critical equipment(incl. transport) for compliancewith product requirements.This applies both for internaland external maintenanceactivities.
4.16.1252
AProduct requirements andprevention of contaminationshall be ensured during andafter maintenance and repairwork. Records of maintenanceand repair work and ofcorrective actions taken shallbe kept.
4.16.2253
AAll materials used formaintenance and repair shallbe fit for the intended use.
4.16.3254
AFailures of plant andequipment (incl. transport)covered by the maintenancesystem shall be documentedand reviewed with a view toadapting the maintenancesystem.
4.16.4255
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ATemporary repairs shall becarried out so that productrequirements are not affected.Such work shall bedocumented and a short-termdeadline set for eliminating thefault.
4.16.5256
AWhere a company hires a third-party maintenance and repairservice provider, all thecompany specifiedrequirements regardingmaterial and equipment shallbe clearly defined,documented and maintained.
4.16.6257
Equipment4.17258
AEquipment shall be suitablydesigned and specified for theintended use. Beforecommissioning, it shall beverified that the productrequirements are compliedwith.
4.17.1259
AFor all equipment and toolswith direct food contact,certificates of conformity shallexist which confirm compliancewith current legalrequirements. In case nospecific legal requirements areapplicable, evidence shall beavailable to demonstrate thatall equipment and tools aresuitable for use. This appliesfor all equipment and tools indirect contact with rawmaterials, semi-processed andfinished products.
4.17.2260
AEquipment shall be designedand located so that cleaningand maintenance operationscan be effectively performed.
4.17.3261
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Třepení bílého dopravníku na balení Arašídky.
Fraying of white transport belt intended for product dosing and packing "Arašídky".
Značně poškozený pás - soj. tyčinky v polevě (Martius...).
Significantly damaged belt - soy bars in topping (Martius ...). .
Drobné poškození nožů na odhorčárně (špičky).
Damaged knives (tips) at the soy beans preparing area "odhořčárna".
CThe company shall ensure thatall product equipment is ingood condition without anynegative influence on foodsafety.
4.17.4262
AThe company shall ensure thatin the event of changes toprocessing methods andequipment, processcharacteristics are reviewed inorder to assure that productrequirements are compliedwith.
4.17.5263
Traceability (including GMOsand allergens)
4.18264
Traceability evidence in written and electronic form IS Helios. Traceability test during the audit was carried out with the product bought by the auditor in the retail net LIDL Doksy:First Nice Marcius Sojariegel URZ 100g, product no.210000759 - batch: 20190402-1, BBD 4.2.2019.Mixing, forming: 23.1.2019, coating of sticks: 24.1.2019, packing 4.2.2019, together 3 pallets/900 kg/2520 kg.Despatch: Warehouse Nagel Olomouc, 12.2.2019, 1680 kg and 15.2.2019 840 kg. Delivery to customer:LIDL Cerhovice: 23.4.2019 840 kg, LIDL SK Nemšová 10.5.2019 840 kg, LIDL Brandýs nad Labem: 13.5.2019 840 kg. Nothing on stock.
All data about raw materials used, production and dispatch were submitted incl. results of CP and CCP monitoring, internal checks and analyses and quantity checking.
Duration 3 hrs.
AKO N° 7: A traceability systemshall be in place which enablesthe identification of product lotsand their relation to batches ofraw materials, packaging indirect contact with food,packaging intended orexpected to be in direct contactwith food. The traceabilitysystem shall incorporate allrelevant receiving processingand distribution records.Traceability shall be ensuredand documented until deliveryto the customer.
4.18.1KO
265
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ADownstream traceabilityrecords (from production sitesto the customers) shall beavailable. The timeframe forproducing these records forreview shall be compliant withcustomer’s requirements.
4.18.2266
ATraceability shall be in place toidentify the relationshipbetween batches of finalproducts and their labels.
4.18.3267
Traceability system is tested minimally annually, last on:
26.4.2019 Nugeta arašídová 42 g26.6.2019 Mléko zahuštěné slazené
AThe traceability system shallbe tested on a periodic basis -at least annually and each timetraceability system changes.The test shall verify upstreamand downstream traceability(from delivered products to rawmaterials, and vice versa),including quantity checking.Test results shall be recorded.
4.18.4268
.ATraceability shall be ensured atall stages, including work inprogress, post treatment andrework.
4.18.5269
ALabelling of semi-finished orfinished product lots shall bemade at the time when thegoods are directly packed toensure a clear traceability ofgoods. Where goods arelabelled at a later time, thetemporarily stored goods shallhave been provided with aspecific lot labelling. The shelflife (e.g. best before date) ofthe labelled goods shall becalculated from the originalproduction batch.
4.18.6270
AIf required by customer,identified samplesrepresentative for themanufacturing lot shall bestored appropriately and keptuntil expiration of the “Use by”or “Best before date” of thefinished product and ifnecessary for a determinedperiod beyond this date.
4.18.7271
Genetically modifiedorganisms (GMOs)
4.19272
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Is the company working with products consisting of GMOs, containing GMOs or produced from GMOs? : no
No GMO raw materials used. Based on specifications of raw materials (declarations of suppliers were submitted) and analyses. Soy beans are regularly analyzed.Enclosed protocols: 2261/18 GMO testing, 20.12.18 (accr. lab VuRostinné výroby, L1465), for soy beans Netagro receipt 5.11.2018
AFor products being delivered tocustomers and/or countrieswith GMO requirements, thecompany shall have in placesystems and procedures toallow the identification ofproducts consisting of GMOs,containing GMOs or producedfrom GMOs, including foodingredients, additives andflavouring(s).
4.19.1273
No GMO raw materials used. Based on specifications of raw materials (declarations of suppliers were submitted) and analyses. Soy beans are regularly analyzed.
ARaw material specificationsand delivery documentsidentifying products consistingof, being made from, orcontaining GMOs shall beavailable. The assurancesconcerning the GMO status ofthe raw materials shall beagreed by contract with thesupplier or the relevanttechnical documents shallspecify the GMO status. Thecompany shall maintain acontinuously updated listing ofall GMO raw materials used atits premises, which alsoidentifies all blends andformulas to which such GMOraw materials are added.
4.19.2274
No GMO raw materials used. Based on specifications of raw materials - declarations of suppliers were submitted.
N/AThere shall be adequateprocedures to ensure thatwhere products consisting of orcontaining GMOs aremanufactured, contaminationof non-GMO products isavoided. Adequate controlmeasures shall be in place toavoid GMO crosscontamination. Theeffectiveness of theseprocedures shall be monitoredby testing.
4.19.3275
No GMO raw materials used. Based on specifications of raw materials - declarations of suppliers were submitted.
N/AFinished products containingGMOs or labelled as notcontaining GMOs shall bedeclared in accordance withcurrent legal requirements.Delivery documents shallinclude the correspondingreference to GMOs.
4.19.4276
ACustomer requirementsconcerning the GMO status ofproducts shall be clearlyimplemented by the company.
4.19.5277
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Allergens and specificconditions of production
4.20278
Present allergens:EU Peanut and products thereof (EU) Soy and products thereof (EU) Milk and products thereof (EU) Nuts (EU) Hazelnut (EU)Non-EU Nuts Coconut (USA)
Procedure PP 04/06 "Alergeny - jejich kontrola a řízení", 26.5.2017These allergens are manipulated: peanuts, soy, milk, nuts (hazelnuts), coconut (USA). The rules for handling with allergens are in procedure PP04/06 and are ensured in practice.
ARaw material specificationsidentifying allergens requiringdeclaration that are relevant tothe country of sale of thefinished product shall beavailable. The company shallmaintain a continuously up todate listing of all raw materialscontaining allergens used at itspremises, which also identifiesall blends and formulas towhich such raw materialscontaining allergens areadded.
4.20.1279
Cleaning procedures are introduced and validated by analyses.Checked protocols regarding allergens presence:24.6.2019 139057/19 lepek, tyčinka Retro16.5.2019 138838/ 19 lepek Sojový kmen 21.3.2019 lepek Rýžový posyp
ABased on hazard analysis andassessment of associated risk,control measures shall be inplace from receipt to dispatch,to ensure that crosscontamination of products byallergens is minimised. Controlmeasures shall be verified.
4.20.2280
AFinished products containingallergens requiring declarationshall be declared inaccordance with current legalrequirements. For theadventitious or unintentionalpresence, the labelling oflegally declared allergens andtraces shall be based onhazard analysis andassessment of associatedrisks.
4.20.3281
No such requirement from customers.AWhere customers specificallyrequire that products are “freefrom” certain substances oringredients (e.g. gluten, pork,etc.), or that certain methods oftreatment or production areexcluded, verifiable proceduresshall be in place.
4.20.4282
Food Fraud4.21283
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Fraud-susceptible raw materials/products identified in the vulnerability assessment:Grains Which one(s) rice flourOthers hazelnut debrisChocolate Which one(s) chocolate, cocoa powder
Enclosed procedures:- HACCP manual (chapter 14)- PP 01/18 Prevence falšování, 1.7.2019 (food fraud assessment)- HACCP 06/05 Příjem surovin a obalových materiálů, režim kontroly, 1.6.2018The increased risk was determined for these raw materials:
- cocoa powder (the occurrence of husks, substitution), sensory tests, anal. test on theobromin, caffeine - chocolate (type of fat, substitution), ensured anal. test on theobromin, caffeine - hazelnut debris (presence of peanuts), ensured analyses- rice flour (gluten), ensured analyses
AA documented food fraudvulnerability assessment shallbe undertaken on all rawmaterials, ingredients,packaging and outsourcedprocesses, to determine therisk of fraudulent activity inrelation to substitution,mislabelling, adulteration orcounterfeiting. The criteriaconsidered within thevulnerability assessment shallbe defined.
4.21.1284
Procedure HACCP 06/05 Příjem surovin a obalových materiálů, režim kontroly, 1.6.2018
AA documented food fraudmitigation plan shall bedeveloped, with reference tothe vulnerability assessment,and implemented to controlany identified risk. Themethods of control andmonitoring shall be definedand implemented.
4.21.2285
The increased risk was determined for these raw materials:
- cocoa powder (the occurrence of husks, substitution), sensory tests, anal. test on theobromin, caffeine - chocolate (type of fat, substitution), ensured anal. test on theobromin, caffeine - hazelnut debris (presence of peanuts), ensured analyses- rice flour (gluten), ensured analyses
AIn the event of increased risk,food fraud vulnerabilityassessment shall be reviewed.Otherwise all vulnerabilityassessments shall be reviewedat least annually. Control andmonitoring requirements of thefood fraud mitigation plan shallbe reviewed and amendedwhen applicable.
4.21.3286
Measurements, Analysis,Improvements
5287
Internal audits5.1288
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Procedure OS 8 Internal audit, 18.6.2015inspections).
AKO N° 8: Effective internalaudits shall be conductedaccording to a defined agreedaudit program and shall coverat least all requirements of theIFS Standard. Scope andfrequency of internal auditsshall be determined by hazardanalysis and assessment ofassociated risks. This is alsoapplicable for off-site storagelocations owned or rented bythe company.
5.1.1KO
289
Every production area and all departments are covered. All IFS requirements are included. Critical activities are: production (covered by annual internal audits and site inspections).Checked records of IFS audit report by external auditor Ing. Petra Vysloužilová from 12.4.2019
Another audit report - ISO 22000 in place: 14.11.2018
AInternal audits of activitieswhich are critical to food safetyand product specificationsshall be carried out at leastonce a year.
5.1.2290
Certifikát Petra Vysloužilová, FSMS LA, 20-4-2018
AThe auditors shall becompetent and independentfrom the audited department.
5.1.3291
AAudit results shall becommunicated to the seniormanagement and toresponsible persons ofconcerned department.Necessary corrective actionsand a schedule forimplementation shall bedetermined and documentedand communicated to everyrelevant person.
5.1.4292
AIt shall be documented howand when the correctiveactions resulting from theinternal audits shall be verified.
5.1.5293
Site factory inspections5.2294
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Min once a month – checked records from 22.7. 2019
AFactory inspections shall beplanned and carried out (e.g.product control, hygiene,foreign material hazards,personnel hygiene andhousekeeping). The frequencyof inspections in every area(including outdoor areas) andevery single activity shall bebased on hazard analysis andassessment of associated risksand on the history of previousexperience.
5.2.1295
Process validation and control5.3296
AThe criteria for processvalidation and control shall beclearly defined.
5.3.1297
AIn circumstances where thecontrol of process and workingenvironment parameters(temperature, time, pressure,chemical properties etc.) isessential to ensure the productrequirements, such parametersshall be monitored andrecorded continuously and/orat appropriate intervals.
5.3.2298
AAll rework operations shall bevalidated, monitored anddocumented. These operationsshall not affect the productrequirements.
5.3.3299
AThere shall be appropriateprocedures for promptnotification, recording andmonitoring of equipmentmalfunction and processdeviations.
5.3.4300
AProcess validation shall beperformed using the collecteddata that is relevant for productsafety and the processes. Ifsubstantial modifications occur,a revalidation shall be carriedout.
5.3.5301
Calibration, adjustment andchecking of measuring andmonitoring devices
5.4302
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Nevypovídající identifikace teploměrů a vlhkoměrů na skladech s ohledem na označení v Seznamu měřidel. Ve skutečosti má jedno měřidlo 2 kalibrační listy, to však na štítku měřidla a v samotném Seznamu není zohledněno.
Incorrect identification of thermometers and hygrometers in warehouses with respect to marking in the List of measuring devices. In fact, one device has 2 calibration protocols, but this is not reflected directly on the device label and in the List itself.
CThe company shall identify themeasuring and monitoringdevices required to ensurecompliance with productrequirements. These devicesshall be recorded on adocument and clearlyidentified.
5.4.1303
Chyběl důkaz o kalibraci teploměru 2018/3153 umístěném ve skladu. Teploměr na expedici používaný ke kontrole nachlazení prostoru vozidla před nakládkou nebyl v Seznamu měřidel, označený nejasně evidenčním číslem 79, nebyla doložena kalibrace.
Měřidla např. teploměry, které jsou součástí technologie a slouží k monitoringu CP, nejsou evidována a není stanoven způsob jejich kontroly.
There was no evidence of calibration of the 2018/3153 thermometer located in the warehouse.The thermometer placed in the dispatch area used to control the cooling of vehicle before loading was not inclidet in the List of measuring devices, identified by an unclear registration number 79, no calibration was provided.
Measuring devices such as thermometers, which are part of the technology and are used for CP monitoring, are not registered and the method of their control is not specified.
CAll measuring devices shall bechecked, adjusted andcalibrated, under a monitoringsystem, at specified intervalsand in accordance with definedrecognised standard/methods.The results of the checks,adjustments and calibrationsshall be documented. Wherenecessary, corrective actionson devices and, if necessary,on process and products shallbe carried out.
5.4.2304
AAll measuring devices shall beused exclusively for theirdefined purpose. Where theresults of measurementsindicate a malfunction, thedevice in question shall beimmediately repaired orreplaced.
5.4.3305
AThe calibration status of themeasuring devices shall beclearly identified (labelling atthe machine or on a list of testdevices).
5.4.4306
Quantity checking (quantitycontrol/filling quantities)
5.5307
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Quantity checks: 10 final products are weighed each hour.
All scales for finished goods are legally approved every 2 years.
Symbol "e" is used for weighing of some products (private labels), certificate of "e" aproval by state authority "CMI": "Osvědčení o metrologické kontrole 1000-BZ-C0002-19, validity 19.2.2024"
AThe frequency andmethodology of quantitychecking shall be determinedso that the legal requirementsand customer specifications, orif appropriate, guidelines fornominal quantity are met.
5.5.1308
AA procedure shall exist todefine compliance criteria forlot quantity checking. Thisprocedure shall also, amongothers, take into considerationthe tare, the density and othercritical attributes.
5.5.2309
AChecks shall be implementedand recorded, according to asampling plan which ensures aproper representation of themanufacturing lot.
5.5.3310
AResults of these checks shallbe compliant with definedcriteria for all products ready tobe delivered.
5.5.4311
AFor purchased, already pre-packed products from thirdparties, there shall be evidenceabout the compliance with thelegal requirements for nominalquantity.
5.5.5312
AIf applicable, all equipmentused for final checking shall belegally approved.
5.5.6313
Product analysis5.6314
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
Analysis critical to food safety are performed both in the internal and external labs: Internal laboratory carries out following analyses: - MIBI - coliform, TPC, mould, yeast, Enterobacteriacae- dry matter, sensory tests, water activityExternal laboratories- SVÚ Jihlava (number L 1129), SVU Praha (L1176) , SVU Olomouc (L1144), Výzkumný ústav rostlinné výroby (L1465)These analyses are carried out: Salmonella spp., Enterobakteriaceae, heavy metals (Pb, Cd, Al), pesticides, GMO, mycotoxins (aflatoxins)
Internally:moisture, dry matter, fat, "de-bittering", softnessMB: enterobacteriacea, TPC, Y+M, coliform, swabs from environment, workers, clothing, fall-outs
AThere shall be proceduresensuring that all specifiedproduct requirements are met,including legal requirementsand specifications.Microbiological, physical andchemical analysis required forthat purpose shall beperformed internally and/orsubcontracted.
5.6.1315
External accredited laboratories:- SVÚ Jihlava (number L 1129), - SVU Praha (L1176) , - SVU Olomouc (L1144)- Výzkumný ústav rostlinné výroby (L1465), GMO
AAnalyses, which are relevantfor food safety, shall preferablybe performed by laboratorieshaving appropriate accreditedprograms/methods (ISO17025). If the analyses areperformed by a factory internalor a laboratory not havingappropriate accreditedprograms/methods, the resultsshall be verified on a regularbasis by laboratoriesaccredited on theseprograms/methods (ISO17025).
5.6.2316
AProcedures shall exist whichensure the reliability of theinternal analysis results on thebasis of official recognisedanalysis methods. This shallbe demonstrated by ring testsor other proficiency tests.
5.6.3317
AA test plan shall be drawn upfor internal and externalanalysis, based on hazardanalysis and assessment ofassociated risks, which coversraw materials, semi-processedand finished products as wellas processing equipments andpackaging materials, andwhere necessaryenvironmental tests. The testresults shall be documented.
5.6.4318
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
AResults of analysis shall beevaluated promptly.Appropriate correctivemeasures shall be introducedfor any unsatisfactory results.The analytical results shall bereviewed regularly in order toidentify trends. Trendsindicating potentialunsatisfactory results shall betaken into consideration.
5.6.5319
AWhere internal analysis isundertaken, qualified andtrained personnel shall be inplace, as well as appropriateequipment and premises.
5.6.6320
Checked protocols:- pesticidy hladká mouka CLPRM 25.6.2019- 1.7.2019 zásobník arašídová nugety
- enterobacteriacea 140101/19 27.6.19 Sojové vločky- Salmonella 17.6.19 400/6/2019 Nugeta arašídová, Orion hořká se sladidlem- GMO, 16.10.18 (Martius ), 2245/18, 23.10.18 - aflatoxin B1 and suma, for peanuts batch 2100D001520170,17.7.2019 , protocol 141892/19
AFor verification of finishedproduct quality, internalorganoleptic tests shall becarried out regularly. Thesetests shall be in accordancewith specifications and relatedto the impact on respectiveparameters of productcharacteristic. The results ofthese tests shall bedocumented.
5.6.7321
ABased on hazard analysis,assessment of associated risksand on any internal or externalinformation on product riskswhich may have an impact onfood safety and/or quality (incl.adulteration and fraud), thecompany shall update itscontrol plan and/or take anyappropriate measure to controlimpact on finished products.
5.6.8322
Product quarantine(blocking/hold) and productrelease
5.7323
Laboratory staff is responsible.
Relase for product "Uvolnovací protokol výrobku", Marcius 100 g, 02.2020/ 20190204-1 (senzorika, hmotnost, kontrola CCP)
5.2. 2019, kontrola e 4.2.2019 7:58 – 13:42 hod, 101 g
AA procedure shall be in place,based on hazard analysis andassessment of associatedrisks, for the quarantine(blocking/hold) and release ofall raw materials, semi-processed and finishedproducts and packagingmaterials. The procedure shallensure that only products andmaterials conforming toproduct requirements areprocessed and dispatched.
5.7.1324
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
Management of complaintsfrom authorities and customers
5.8325
Procedure OS 8.3 "Řízení neshodných produktů a reklamací", 4.1.2017
Number of complaints from customers for 2018: 65 (42 justified), main reason: packaging, labelling, MB parameters7 complaints on foreign bodies (3x wooden pieces, plastic, 2 metal, hard peanut)One recall in 2018 (aflatoxins in products)No complaints from authority.
Number of complaints from customers for 2019:42 (32 justified), main reason: sensory signs, labeling, MB parameters for enterobacteriacea in soya semi-finished products for customer Nestle2 complaints on foreign bodies: string, a piece of plastic packaging No complaint form authority.
AA system shall be in place forthe management of productcomplaints.
5.8.1326
AAll complaints shall beassessed by competent staff.Where it is justified appropriateactions shall be takenimmediately, if necessary.
5.8.2327
Well analyzed and reported.AComplaints shall be analysedwith a view to implementingpreventive actions which avoidthe recurrence of the non-conformity.
5.8.3328
AThe results of complaint dataanalysis shall be madeavailable to the relevantresponsible persons and to thesenior management.
5.8.4329
Management of incidents,product withdrawal, productrecall
5.9330
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
Procedure: "PP 01/04 Krizové řízení, stahování výrobů", 12.4.2018
AA documented procedure shallbe defined for management ofincidents and of potentialemergency situations thatimpact food safety, legality andquality. This procedure shall beimplemented and maintained.This includes as a minimum:the nomination and training ofa crisis team, an alert contactlist, sources of legal advice (ifnecessary), contactsavailability, customerinformation, and acommunication plan, includinginformation to consumers.
5.9.1331
How many recalls have been performed since the last audit : 0
How many withdrawals have been performed since the last audit : 0
No recall nor withdrawal since last audit.
last in 2018 on content of aflatoxin B1 in a finished product ( Sympathia Peanut arašídová, 400g, LIDL)
AKO N° 9: There shall be aneffective procedure for thewithdrawal and recall of allproducts, which ensures thatinvolved customers areinformed, as soon as possible.This procedure shall include aclear assignment ofresponsibilities.
5.9.2KO
332
AUpdated emergency contactdetails (such as names andphone numbers of suppliers,customers and competentauthorities) shall be available.A person of the company, whohas the authority to initiate theincident management process,shall be permanently available.
5.9.3333
Tested annually together with traceability test.AThe feasibility, effectivenessand timeliness ofimplementation of thewithdrawal procedure shall besubject to regular internaltesting, based on hazardanalysis and assessment ofassociated risks but carried outat least once a year. This shallbe carried out in a manner toensure the effectiveimplementation and operationof the procedure.
5.9.4334
Management of non-conformities and non-conforming products
5.10335
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
AA procedure shall exist for themanagement of all non-conforming raw materials, semi-finished and finished products,processing equipment andpackaging materials. This shallinclude, as a minimum:- isolation/quarantineprocedures- hazard analysis andassessment of associated risks- identification (e.g. labelling)- decision about the further use(e.g. release, rework/posttreatment, blocking,quarantine, rejection/disposal).
5.10.1336
AThe responsibilities for themanagement of non-conforming products shall beclearly identified. Theprocedure for the managementof non-conforming productsshall be understood by allrelevant employees.
5.10.2337
AWhere non-conformities arepresent, immediate correctionsshall be taken to ensure thatproduct requirements arecomplied with.
5.10.3338
AOut of specification, finalpackaged products orpackaging materials, bothrelated to private labels, shallnot be placed in the marketunder the label concerned.Exceptions shall be agreed inwriting with the contractpartners.
5.10.4339
Corrective actions5.11340
AA procedure shall be in placefor the recording and analysisof the non-conformities withthe objective to avoidrecurrences by preventiveactions and/or correctiveactions.
5.11.1341
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
AKO N° 10: Corrective actionsshall be clearly formulated,documented and undertaken,as soon as possible to avoidfurther occurrence of non-conformity. The responsibilitiesand the timescales forcorrective action shall beclearly defined. Thedocumentation shall besecurely stored, and easilyaccessible.
5.11.2KO
342
AThe performance of theimplemented corrective actionsshall be documented and theeffectiveness shall be checked.
5.11.3343
Food defense plan andexternal inspections
6344
Defense assessment6.1345
Technical managerAResponsibilities for fooddefense shall be clearlydefined. Those responsibleshall be key staff or shall haveaccess to the top managementteam. Sufficient knowledge inthis area shall bedemonstrated.
6.1.1346
Procedure: PP 03/14 "Obrana potravin", 22.5.2019.Hazard analysis is part of this procedure.Food defence is tested annually - last test 5.6.2019
AA food defense hazardanalysis and assessment ofassociated risks shall havebeen performed anddocumented. Based on thisassessment, and based on thelegal requirements, areascritical to security shall beidentified.Food defense hazard analysisand assessment of associatedrisks shall be conductedannually or upon changes thataffect food integrity.An appropriate alert systemshall be defined andperiodically tested foreffectiveness.
6.1.2347
No legislation requirementN/AIf legislation makes registrationor onsite inspectionsnecessary, evidence shall beprovided.
6.1.3348
Site Security6.2349
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ExplanationEvalua-tion
IFS requirementsReferenceNr.
ABased on a hazard analysisand assessment of associatedrisks, identified areas critical tosecurity shall be adequatelyprotected to preventunauthorized access.Access points shall becontrolled.
6.2.1350
AProcedures shall be in place toprevent tampering and/or allowidentification of signs oftampering.
6.2.2351
Personnel & Visitor Security6.3352
AVisitor policy shall containaspects of food defense plan.Delivery and loading staff incontact with the product shallbe identified and shall respectthe access rules of thecompany. Visitors and externalservice providers shall beidentified in areas with productstorage and shall be registeredat the time of access. Theyshould be informed about thesite policies and their accesscontrolled accordingly.
6.3.1353
AAll employees shall be trainedin food defense with respect tothe product requirements andthe training needs of theemployees or when significantprogram changes occur. Thetraining sessions shall bedocumented.Employee hiring andemployment terminationpractices shall considersecurity aspects as permittedby law.
6.3.2354
External Inspections6.4355
AA documented procedure shallexist for managing externalinspections and regulatoryvisits. Relevant personnel shallbe trained to execute theprocedure.
6.4.1356
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