FOOD SAFETY INSPECTION REPORT For SYSCO. #SYS-B-188 FreshPoint Nanaimo 4911 Wellington Road Nanaimo, BC V9T 2H5 Canada

Transcription

1 FOOD SAFETY INSPECTION REPORT For SYSCO #SYS-B-188 FreshPoint Nanaimo 4911 Wellington Road Nanaimo, BC V9T 2H5 Canada TYPE OF AUDIT INSPECTION DATE October 1, 2010 AIB International Inc Bakers Way PO Box 3999 Manhattan, KS ( ) ( ) Fax ( )

2 RATING A Food Safety inspection was conducted at this facility on October 1, The writer was accompanied throughout the inspection by Debbie Baildham, Office Manager. At the conclusion of the inspection, a meeting was held to discuss the observations, recommendations, and rating. Based on the observations made, the information obtained, and the criteria set forth in the AIB International Inc. Consolidated Standards for Inspection: Food Distribution Centers, the overall food safety level of this facility was considered to be: SUPERIOR (950) AIB International Inc. states that this report as dated and provided herein is to be construed as its findings and recommendations, category scores, total score, and rating. A passing score of 700 and above is not a certification of the facility, products or programs. AIB International Inc. does not accept or assume responsibility for the Prerequisite and Food Safety Programs in effect with (customer). AIB International Inc. is only reporting the food safety conditions of (customer) as of the date of this report and assumes no responsibility or liability as to whether (customer) does or does not carry out the recommendations as contained in this report. #SYS-B-188-p.1

3 RATING ANALYSIS DATE OF INSPECTION: October 1, 2010 TYPE OF INSPECTION: Unannounced OVERALL RATING: SUPERIOR OPERATIONAL METHODS AND PERSONNEL PRACTICES 200 MAINTENANCE FOR FOOD SAFETY 165 CLEANING PRACTICES 195 INTEGRATED PEST MANAGEMENT 200 ADEQUACY OF FOOD SAFETY PROGRAMS 190 TOTAL: 950 #SYS-B-188-p.2

4 Discrepancy Totals Serious Items Total: 0 Improvement Needed Items Total: 3 Unsatisfactory Items Total: 0 FACTUAL OBSERVATIONS AND SPECIFIC RECOMMENDATIONS OP = Operational Methods and Personnel Practices IPM = Integrated Pest Management MS = Maintenance for Food Safety AP = Adequacy of Prerequisite and Food Safety Programs CP = Cleaning Practices IMPROVEMENT NEEDED MS MS MS At the ceiling joint of the thirty four degree cooler, an accumulation of condensate was observed which was dripping actively onto the floor beneath. There was no product stored immediately under this drip. However, possible product contamination risk was presented. The facility was encouraged to focus efforts on the implementation of long term and sustainable repairs to this ceiling joint so as to prevent any potential risk of product contamination. (IMPROVEMENT NEEDED) A water drip was observed on the curb seam fourteen inches up the North wall of the dairy cooler behind the racking, pooling water was evident on the floor. There was no direct risk of product contamination, however potential was presented. The facility was encouraged to investigate the root cause of this drip so as to eliminate and negate any risk of mould growth or product contamination. (IMPROVEMENT NEEDED) Adequate barriers were in place to prevent rodents, insects, and birds from entering the facility. Cracks, crevices, and other pest harborages were eliminated and doors were pest-proofed to prevent pest entry. Even so, the personnel door located between tin-cats one and two was observed as propped open. Exterior doors should remain closed so as to prevent potential rodent ingress into the facility. (IMPROVEMENT NEEDED) MINOR ISSUE NOTED CP Daily housekeeping cleaning activities were carried out in a way that prevents contamination. Housekeeping activities were assigned to the appropriate department to maintain work and support areas. Even so, two soft (minorly decomposed) beets were observed under a pallet in the dry goods warehouse. Minor spills should be cleaned up promptly so as to negate any attraction by pests. #SYS-B-188-p.3

5 AP AP Specific written procedures were on file for providing food safety training to all personnel and contractors. Records of new employee training and annual refresher training were maintained for all personnel. This was last completed on June 16, Employees were monitored to assure comprehension of presented materials. Even so, the facility was encouraged to provide supplemental training regarding closing of doors when not in use to as to discourage the habit of propping doors open as referenced in the body of this report. A multidisciplinary Food Safety Committee was established to conduct monthly inspections of the entire facility. Documentation of the monthly inspections included identified observations, specific assignments, Corrective Actions, and actual accomplishments. This was last completed on September 23, Continued emphasis should be placed on ensuring that the inspections become more detailed in identifying and promptly eliminating all potential food safety hazards such as those observed during the AIB International inspection and outlined in the text of this report. COMMENT OP OP OP OP OP OP OP OP Transports, produce, dry goods,meat, and dairy goods were inspected upon receipt for cleanliness, pest activity, structural defects, or other issues that could jeopardize product integrity. Inspection documentation, including rejected shipments, was maintained. Temperature documentation was maintained on file for perishable loads of inbound materials. A reveiw of this documentation demonstrated that it was current. Food products were stored and removed from storage to prevent product contamination. Materials were stored off the floor and 18 inches (45 cm) away from the wall to facilitate cleaning, inspection, and pest control activities. Adequate space was provided for access. Receiving dates for dry goods and dates of expiration for perishable materials were used to facilitate stock rotation. Storage areas were clean, well ventilated, and dry. Materials in storage were protected against contamination. Packaging materials, toxic chemicals, and non-product materials were segregated. Ingredients, packaging supplies, and other materials were rotated on a "First-In, First-Out" basis. Pallets were clean, dry, and in good repair. When used, slip sheets provided adequate protection against product contamination. Trash, recyclables, and organic waste was stored in properly identified and covered containers. These licensed contractors managed materials. Single-service containers were not used at this facility. Dairy products such as milk, yogurt, and cheeses were held in a cooler held at 3 C as were processed meat products. #SYS-B-188-p.4

6 OP OP OP OP OP OP OP OP OP MS MS MS Incompatible materials were stored under conditions that prevented cross-contamination. Allergens were stored in designated labeled locations. Iced product was stored on the lower level of the racking in the cooler and did not appear to pose a risk of product contamination. Containers and utensils were not used for product handling at this facility. There were no processing rooms at this facility. All shipping vehicles were inspected prior to loading for cleanliness and structural defects that could jeopardize product integrity. Inspection documentation was maintained and included lot code designation, amounts, and the point of distribution to ensure traceability and recall. Trailers were locked upon departure. Temperature checks were completed prior to loading to assure that trailers were pre-cooled appropriately. Transportation breakdown procedures had been established for this facility. Adequate hand washing stations were located within washrooms and were stocked with single-use towels and pre-mixed sanitizers as appropriate. "Wash hands" signs were displayed by sinks and entries into storage areas. Washrooms, showers, and locker rooms were maintained in an acceptable sanitary condition. "Wash hands" signs were displayed in restrooms, lunchrooms, and smoking areas. Trained supervisors were in place to monitor compliance with personnel practices. Good personal hygiene practices were observed. Personnel were not observed eating, drinking, or smoking in unauthorized areas. Personal property was stored in appropriate locations defined by company policy. Effective procedures were in place to ensure that personnel with boils, sores, infected wounds, infections, or other communicable diseases were not permitted to come in contact with food as required. This information was included in the facility GMP programme to which employees were trained. All non-facility personnel, including visitors and contractors, followed the facility personnel practices requirements. Facility boundaries were defined and controlled. Measures were in place to prevent contamination from local activities or neighboring properties that could impact the facility. This facility was located adjacent to a car dealership near residential dwellings. Outside grounds were maintained in a way that prevents product contamination. Measures included, but were not limited to, managing drainage, litter, weeds, and dust and maintaining waste to eliminate pest attraction to the facility. Some measures were taken to maintain facility security. Security strategies included: fencing, controlled gate access during non-business hours, alarm system, locked doors, limited access to the facility, surveillance cameras, employee screening, awareness and training programs. #SYS-B-188-p.5

7 MS MS MS MS MS MS MS MS MS MS MS CP CP CP CP CP Adequate space was observed between equipment and structures to facilitate access for cleaning and maintenance activities. Fixtures, ducts, and pipes were properly installed and maintained to prevent contamination from leaks, condensation, or loose material. Fluorescent light tubes, light bulbs, essential glass, brittle plastics, and ceramics in the facility were of the safety type or otherwise protected from accidental breakage over exposed product storage areas. Those that could not be protected were accounted for in the Glass, Brittle Plastics, and Ceramics Program. Adequate ventilation was provided in the facility. There were no processing rooms with equipment that required the use and control of food-grade lubricants at this facility. The facility did not have any exposed recoup or processing areas that required a written temporary repair procedure for repair of these surfaces to be defined. There were no food contact surfaces at this facility. Temperature measuring devices, including thermometers and recording controls, were installed in coolers, freezers, or other temperature-controlled storage areas. Thermometres were linked to an outside alarm company and in the event of set temperatures being exceeded, facility personnel were notified and appropriate actions were taken. Transporting equipment, such as forklifts and pallet jacks, was maintained to prevent contamination of materials. Water was supplied to this facility by the City of Nanaimo. Water was not used in direct food contact applications. Hand washing facilities provided hot and cold running water. Hand washing facilities were labeled. Cleaning was done in a way that prevents contamination of raw materials, products, and equipment. Food approval documentation was not needed for cleaning chemicals and sanitizers used as there were no food contact surfaces requiring cleaning. Adequate cleaning equipment and tools were available and stored away from storage areas in a cabinet located on the loading dock. Deep cleaning of equipment and structures was conducted according to the Master Cleaning Schedule to prevent the development of microorganisms, insects, or foreign material. Periodic cleaning tasks complied with written procedures. There were no direct food contact surfaces and utensils in use at this distribution center. #SYS-B-188-p.6

8 IPM IPM IPM IPM IPM IPM IPM IPM A formal Integrated Pest Management (IPM) Program with written procedures that included requirements of the facility's Prerequisite Programs was in place. This written programme was managed by trained IPM contract personnel. An annual facility assessment that addressed all areas inside and outside of the facility was documented. This was completed on June 23, 2010 by trained IPM service personnel. The only recommendation was the addition of one additional bait station, this was added on July 7, 2010 and added to the site device map at that time. The facility did not manage their IPM Program under an alternative guideline. A signed agreement was in place with the Abell Pest Control Company to provide IPM services. A copy of the service agreement included materials, the facility name, facility contact person, frequency of services, description of services, term of contract, a current list of approved chemicals, emergency call procedures, service records to be maintained, and notification requirements for changes in materials or services. Current copies of certification or registration documents were on file for all persons providing IPM services for the facility. This included: a Certificate of Liability Insurance (valid to July 1, 2011), a Pesticide Use and Vendor Licence (issued by the British Columbia Ministry of the Environment and valid to April 1, 2014), a Pesticide Applicator Certificate (valid to October 12,2010), and evidence of GMP training provided to the IPM service technician by a third party. Current copies of the pesticide specimen labels and Material Safety Data Sheets (MSDS) were on file for pesticides listed as being applied at the facility. Contrac blox (PCP 22239) was the only rodenticide listed for use at this facility. Documentation of all pesticides, including rodenticides, applied on the premises included materials applied, registration number, target pest, amount applied, specific area where pesticide was applied, method of application, rate of application or dosage, date and time treated, and applicator's signature. The last recorded application was made on September 1, 2010 when Contrac blox (PCP 22239) was installed in exterior bait stations. Pesticides and application equipment were not stored at the facility. #SYS-B-188-p.7

9 IPM IPM IPM IPM IPM IPM IPM IPM IPM AP The outside IPM service provider left a service report after each visit. These records provided documentation of the checks and findings for pest monitoring devices, descriptions of the current levels of pest activity, and recommendations for actions needed to correct conditions allowing a potential for pest activity. A corrective action request log was used to capture information about pest sightings as well as requests for corrective actions. A review of this document showed that it was current and complete, actions appeared to be appropriate to findings. A detailed facility survey was documented and used to determine placement of all pest monitoring devices. A current site map that lists the locations of interior and exterior pest control devices was on file. This map was dated June 2010 and appeared to depict accurately the location of twenty interior rodent devices, nine bait stations, four pheromone traps, and three ILTs. Bait stations were provided for exterior rodent control. Exterior rodent monitoring devices were installed around the exterior perimeter of the facility at appropriate intervals. These stations were tamper resistant, properly positioned, anchored in place, secured, and properly labeled in compliance with regulatory requirements. Randomly examined units were clean and had been supplied with fresh bait. These were serviced on a monthly frequency by IPM service personnel, this was last completed on September 1, Mechanical rodent traps were installed to monitor rodent activity inside the facility and were properly positioned. The randomly examined traps appeared to be properly maintained. Traps were inspected on a weekly frequency by IPM service personnel, this was last completed on September 29, Insect light traps (ILTs) were used in the facility to aid in monitoring insect activity. These traps were more than 10 feet (3 meters) from exposed products. The traps were scheduled for weekly cleaning in the summer and monthly cleaning in the winter, or as dictated by climate. A record of the service, cleaning, and activity levels of each ILT was maintained. The light tubes within these units were last changed on June 23, Pheromone monitoring devices were used to monitor insect activity in this facility. These devices were properly placed and regularly inspected. Bird activity was not noted in or around the facility. Wildlife, including domestic animals, was not observed at the time of the survey. Pest habitats and pest activity were identified and eliminated. No evidence of rodent or insect activity was noted in or around the facility. The facility had a documented policy statement outlining its commitment to produce safe and legal products. #SYS-B-188-p.8

10 AP AP AP AP AP AP AP AP AP AP A current organizational chart was maintained. Responsibility and authority for ensuring food safety and defense and compliance with federal, state, local, and any other appropriate regulatory laws or guidelines were clearly assigned to the Branch Manager. The facility was licensed by the City of Nanaimo which was current for the calendar year. Based on a review of the facility and related documentation, an appropriate budget and adequate labor support appeared to be in place to maintain the timely acquisition of tools, equipment, monitoring devices, chemicals, and other required resources. Written procedures were established to define step-by-step processes to ensure product safety. Job descriptions were defined for key positions and alternates were defined. A risk-based audit of procedures was documented by competent inspectors. Audit documentation included identified observations, specific assignments, Corrective Actions, and actual accomplishments. This was completed by third party and customer audits. A written Program for evaluating Customer Complaints was established at this fresh produce distributor. The use of a customer complaint notice form captured details regarding the nature of the complaint, product, and corrective actions. The Branch Manager communicated complaint information (as appropriate) to facility personnel. A written Chemical Control Program that addresses all chemicals used in the facility was established. The warehouse manager was the designated chemical purchaser. Chemicals were stored in a locked room and an approved chemical list was posted in this room. MSDS, training, and spill containment were included in the scope of the programme. A documented Allergen Control Program was in place to address the allergens handled or stored at this facility. This included a list of allergens stored within the warehouse and procedures for transfer, handling, and clean up of spills. This procedure was posted in the warehouse at slot locations where allergens were stored. The facility had a written policy stating that no glass, brittle plastics, or ceramics were to be used in the facility, except where absolutely necessary. Included in the policy was a procedure to handle any breakage in the facility. A list of all essential glass, brittle plastics, and ceramics was developed. An audit of the glass and brittle plastics inventory list was completed each week, this was last completed on September 25, A formal documented Cleaning Program that included a Master Cleaning Schedule (MCS) for periodic cleaning assignments as well as a daily housekeeping schedule was developed and implemented in this facility. A formal Preventive Maintenance Program and work order system was used to prioritize problems in structural and equipment maintenance. #SYS-B-188-p.9

11 AP AP AP AP AP AP AP Incoming ingredients, packaging, and transports received into the facility were inspected by trained personnel according to established written procedures. Documented procedures outlined protocol for the inspection of tractor trailers. A written Regulatory Affairs and Inspections Program was on file. The Program included a list of personnel delegated to accompany all inspectors along with a company policy regarding recording devices, cameras, records, and sample taking. The facility had conducted a Site Security Assessment to identify food defense risks. The facility had developed a crisis response. A documented Traceability Program that addressed identification of lot numbers of products, rework/repack, and packaging materials was developed and in place. All finished products were coded and recorded. A written Recall/Withdrawal Program was on file. Distribution records were maintained to identify the initial point of distribution to facilitate segregation and recall of specific lots. The Recall Program was tested twice annually, and test results were documented. This was last completed on May 25, 2010 when lots of prepared salad kits were identified within the distribution network. A written Program was in place to control nonconforming products,finished products, and returned goods. Corrective Actions equal to the seriousness of the risk appeared to be taken. Programmes were established and appeared to be followed for goods returned by customers. The facility had completed a hazard analysis and it was determined that there were no CCP's in this produce and grocery distribution centre. There was no regulatory HACCP requirement at this produce distribution centre. #SYS-B-188-p.10