FOOD SAFETY INSPECTION REPORT For SYSCO. #SYS-B-141 FreshPoint - Central Florida 8801 Exchange Dr Orlando, FL

Transcription

1 FOOD SAFETY INSPECTION REPORT For SYSCO #SYS-B-141 FreshPoint - Central Florida 8801 Exchange Dr Orlando, FL TYPE OF AUDIT INSPECTION DATE April 13, 2010 AIB International Inc Bakers Way PO Box 3999 Manhattan, KS ( ) ( ) Fax ( )

2 RATING A Prerequisite and Food Safety inspection was conducted at this facility on April 13, The writer was accompanied throughout the audit by Mr. John Schafer, Warehouse Manager; Mr. Kelly Fuller, Quality Assurance Manager; Mr. Scott Crane, Pre-Cut Manager; Mr. Tony Salerni, Program Quality Manager; and Mr. Wenzell Underwood, Pre-Cut General Manager. At the conclusion of the audit, 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 Consolidated Standards for Inspection: Fresh-Cut Produce, the overall food safety level of this facility was considered to be: SUPERIOR (905) 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-141-p.1

3 RATING ANALYSIS DATE OF INSPECTION: April 13, 2010 TYPE OF INSPECTION: Unannounced OVERALL RATING: SUPERIOR OPERATIONAL METHODS AND PERSONNEL PRACTICES 190 MAINTENANCE FOR FOOD SAFETY 170 CLEANING PRACTICES 175 INTEGRATED PEST MANAGEMENT 195 ADEQUACY OF FOOD SAFETY PROGRAMS 175 TOTAL: 905 #SYS-B-141-p.2

4 Discrepancy Totals Serious Items Total: 0 Improvement Needed Items Total: 5 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 CP AP Fixtures, ducts, refrigeration units, and pipes were properly installed and maintained to prevent contamination from leaks, condensation, or loose material. There was no evidence of loose materials, such as insulation, flaking rust, and paint, in the overheads or from most production equipment in or above the product zone. However some of the safety labels on the CC machine were peeling off. The labels were located in close proximity to a product zone. It was recommended that these labels be removed to prevent possible product contamination. (IMPROVEMENT NEEDED) There were some metal shavings observed in a hollow rack end by slot number D1131 in cooler "D". It was recommended that the shavings be removed and that the rack end be capped to prevent reoccurrence. (IMPROVEMENT NEEDED) Adequate cleaning equipment and tools were available and stored away from production areas. Cleaning tools were labeled or color coded to separate them based on their intended use. Separate and distinct utensils were used to clean food contact surfaces (product zones), structures (product areas), restrooms, and floor drains. Cleaning utensils were cleaned and properly stored after use. Tools were segregated in storage to prevent cross contamination. However a green dust pan that is designated for restroom use was observed under a rack in cooler "E". It was recommended that restroom tools be properly used and stored, so as to prevent possible cross contamination issues. (IMPROVEMENT NEEDED) A formal Preventive Maintenance Program and work order system was used to prioritize problems in structural, equipment, or utensil maintenance. Written programs should included information related to post maintenance cleaning notification including tools and parts reconciliation, records of evaluation, and sign off by authorized personnel. Records should be maintained to indicate compliance to the program. It was recommended that the post maintenance cleaning and inspection program be in writing. (IMPROVEMENT NEEDED) #SYS-B-141-p.3

5 AP A Hazard Analysis Critical Control Point (HACCP) Program was developed and implemented for processes and process lines. The HACCP plan was signed and was managed by a trained HACCP team leader with assistance of HACCP trained team members. Finished Product Profiles were provided for each product produced. A current Process Flow Diagram was in place. The seven principles of HACCP were followed in the development of the HACCP Program and included a risk assessment for both the ingredients and the process. Documented training was current for most management and non-management personnel and for those with designated CCP responsibilities. The CCP's included testing of the chlorine wash water and the metal detectors. Documentation reviewed indicated compliance to the written program. It was understood that there have been no recent deviations to review. The HACCP plan also covered seafood cross docking as indicated in the separate addendum. The HACCP plan was validated by the corporate office on an annual basis. It was recommended that documented training be on file for the HACCP team to ensure all members have documented training. (IMPROVEMENT NEEDED) MINOR ISSUE NOTED OP OP IPM Loose or insecure jewelry was not observed. Personnel were not observed eating, drinking, or smoking in unauthorized areas. Personal property was stored in appropriate locations defined by company policy. However a discarded drink container was observed in a trash container by overhead door number 21 and candy wrapper was observed on forklift number 22. It was recommended that this issue be addressed with all employees to ensure compliance with GMP's and company policies. 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 by law. Cuts and grazes were covered by metal detectable bandages that were regularly tested in the metal detector. Documentation of testing was not maintained. Bandages were covered with gloves to prevent addition to product as foreign material. Written procedures for handling products that may have come in contact with blood or bodily fluids were documented. Supervisor training on recognizing the signs and symptoms of infectious disease was on file and current. It was recommended that the metal detectable band-aid checks be documented. An annual facility assessment that addressed all areas inside and outside of the facility was documented. This was conducted by trained pest control personnel. However the previous assessment was over a year old by 14 days. It was recommended that an assessment be conducted as soon as possible. This documentation was provided during the audit. #SYS-B-141-p.4

6 AP AP AP 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. It was recommended that these audits be used to identify and address food safety issues such as those observed during this audit. A risk-based audit of procedures was documented by competent inspectors. Audit documentation included identified observations, specific assignments, Corrective Actions, and actual accomplishments. The program was new and not fully formalized, however a few programs had been audited. It was recommended that the program be formalized and that all procedures are audited at least once per year. A documented Allergen Control Program was in place to address the allergens used or handled at this facility. The program addressed all elements of the standard. The facility stores and ships whole coconuts, however they had not been identified as an allergen. Although exposure was minimal at best, it was recommended that coconuts be identified in the program as an allergen. COMMENT OP OP OP OP OP Transports/containers and ingredients 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. Minimum temperature requirements were defined for perishable materials. Documentation of received material temperatures indicated compliance to requirements. Ingredients were stored and removed from storage to prevent product contamination. Materials were stored off the floor and 18 inches away from the wall to facilitate cleaning, inspection, and pest control activities. Space was provided between rows of product to allow access for cleaning and inspection. Receiving dates 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 nonproduct materials were segregated. Packaging materials, toxic chemicals, and non-product materials were segregated. Infrequently used materials, and packaging supplies were inspected on a defined frequency for evidence of infestation. An 18 inch painted inspection line was along floor wall junctions around the interior perimeter. Ingredients, packaging supplies, and other materials were rotated on a "First-In, First-Out" basis to ensure stock rotation. A formal procedure was in place to monitor and regularly inspect packaging materials that were in storage for more than 90 days. Pallets and produce bins were clean, dry, and in good repair. #SYS-B-141-p.5

7 OP OP OP OP OP OP OP OP OP OP OP Food approval documentation was on file for processing aids. These were verified for Nature Seal. Procedures were provided for transferring and handling food materials. Containers were stored off the ground, in good condition, identified and covered. Procedures for traceability were defined and followed. Procedures addressed inspection, spillage, cleaning and how packaging materials were handled prior to use in production. Foreign material control devices appropriate to the product or process equipment were provided on each production line at the last possible point. Metal detectors were used, an alarm, conveyor stop, and keyed re-start were provided. Product that are detected to have metal are immediately removed from the line and investigated by quality control. Documentation of the metal detector checks was maintained, documentation reviewed indicated compliance to the program and was up to date. The metal detector checked during the audit properly detected and rejected the provided test pieces. The metal detector was checked with ferrous, non-ferrous, and stainless steel test pieces. Trash or inedible waste was stored in properly identified and covered containers. Trash was disposed of by licensed contractors. Ingredient scoops were not used at this facility. Carryover product, work in progress, rework, and raw materials were covered and dated. The materials were minimal, properly handled, and used daily. Housekeeping activities were ongoing throughout the hours of operation in production, raw material, and support areas to maintain a sanitary working environment. Production equipment and supplies were neatly arranged. Space and storage were adequate. Portable or infrequently used equipment were not stored in production areas. Single-service containers were not reused at this facility. Containers are discarded to the trash compactor after use. Production facilities, equipment, and accessories were designed to minimize hand contact where possible and practical. Raw materials, work in progress, and finished products capable of supporting the rapid growth of pathogenic microorganisms were properly stored. Temperatures observed in the produce coolers were at 40 degrees or below, which was appropriate for the materials being stored. The processing room was maintained at 40 degrees or below. Incompatible materials were stored under conditions that prevented cross-contamination. Allergen materials were properly identified and stored, including segregation and like over like storage. Foot foam units were used at entrances to production areas. #SYS-B-141-p.6

8 OP OP OP OP OP OP OP OP MS MS Containers were constructed, handled, and maintained to prevent contamination. Misuse of containers or utensils was not observed. Snap off blades were not used 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. Locks were provided and documented for outbound materials. Temperatures of pre-cooled vehicles was documented. A written transportation breakdown procedure was in place. Adequate hand washing stations were located at appropriate locations and were stocked with single-use towels and sanitizers as appropriate. "Wash hands" signs were displayed by sinks and entries into production areas. Sanitizers are pre-mixed. Washrooms and locker rooms were maintained in an acceptable sanitary condition. "Wash hands" signs were displayed in restrooms, lunchrooms, and smoking areas. Lockers were inspected on a defined frequency and no open food or drink was allowed. Trained supervisors were in place to monitor compliance to personnel practices. Personnel were observed washing hands appropriately and good personal hygiene practices were observed. Hand washing procedures were monitored periodically for effectiveness. Personnel in the facility were wearing adequate hair and beard restraints. Their clothing and uniforms were clean and well maintained. Personnel welfare facilities allowed direct access to the facility. Tools were stored below the waist to prevent product contamination. The processing operation was not considered high risk. Controls were in place for outer garments, hand washing and sanitizing, and foot foam systems. A laundry service was used for uniform and smock laundering. All nonfacility 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. The facility is bordered by open land and a truck repair facility. 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 and equipment graveyards to eliminate pest attraction to the facility. #SYS-B-141-p.7

9 MS MS MS MS MS MS MS MS MS MS MS MS MS Some measures were taken to maintain facility security. Security strategies included fencing, controlled gate access, controlled parking, locked doors, limited access to sensitive areas, surveillance cameras, guard services, truck seals, employee screening, and awareness and training programs. Adequate space was observed between equipment and structures to facilitate access for cleaning and maintenance activities. Floors, walls, and ceilings throughout the facility were well constructed and maintained. Floor drainage was designed and maintained to allow access for cleaning and to prevent product contamination. There was no evidence of roof leakage. 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. Those that could not be protected were accounted for in the Glass, Brittle Plastics, and Ceramics Program. Lighting was adequate at the time of the audit. Adequate ventilation was provided in the facility. Filters were in place in air makeup units to remove particles of 50 microns or larger. Insect screens were provided on windows or doors used for ventilation to prevent pest entry. Fans observed were clean and were accessible for maintenance and sanitation activities. 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. There was no evidence of leaks or excessive lubrication in product zones where contamination was likely. In areas where drive motors or gearboxes were mounted over product zones, deflector plates or catch pans were intact and maintained to prevent product contamination. Food-grade lubricants were used on food processing equipment. The lubricants were properly identified and stored to prevent cross contamination issues. Operations were separated to prevent product contamination. The processing area was separate from the storage areas. Toilet rooms did not open into storage or processing areas. Facility design standards identified the appropriate materials, modification and repair procedures to reduce potential contamination, facilitate cleaning and eliminate pest harborage. Equipment and utensils were designed and constructed of materials that were easily cleaned and maintained. The facility followed a written Temporary Repair Program that defined food-grade materials appropriate for use as temporary repair materials. Food contact surfaces were smooth, corrosion-free, constructed of nontoxic material. No spot or tack welds were identified. #SYS-B-141-p.8

10 MS MS MS MS MS MS CP CP CP CP CP CP Temperature measuring devices, including thermometers, regulating, and recording controls were installed on any equipment that prevents pathogenic microorganism growth. Temperatures were monitored and attached to an alarm system, should temperatures exceed set parameters. A calibration program was in place that was traceable to a national standard. Compressed air was not used in the process. Transporting equipment, such as forklifts and pallet jacks, were maintained to prevent contamination of materials. These were maintained on the PM program. Food contact parts were stored off the floor in a clean environment. A program was in place to monitor water quality and records were provided. The program included water and ice used for food contact. Back siphonage devices were provided and records of checks of the devices was current. The city water was sampled and analyzed twice per year, and documented results were maintained. Hand washing facilities provided hot and cold running water. Hand washing facilities were labeled and separate from utensil washing facilities. Cleaning was done in a way that prevents contamination of raw materials, products, and equipment. Food approval documentation was provided for cleaning chemicals and sanitizers used to clean food contact surfaces. Chemicals were properly labeled and stored. Records of concentration testing were maintained. 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 during production. Water used for housekeeping activities was properly restricted to prevent contamination issues. 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. Maintenance cleaning appeared to be completed in a way that prevented product contamination. No maintenance debris was observed during the audit. Food contact surfaces and utensils were cleaned and sanitized as appropriate to remove contaminants. Utensils, containers, and product zones were cleaned to prevent residues from being transferred to other products. #SYS-B-141-p.9

11 IPM IPM 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. The program was written and implemented by a licensed pest control company. The facility did not manage their IPM Program under an alternative guideline. A signed agreement was in place with the Ecolab 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. The license and insurance information was current and documented GMP training was on file for the pest control personnel. 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. These were verified for Weather blox, EPA# , Advion Gel Bait, EPA# , and Demand CS, EPA# 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. Documentation indicated that pesticides were applied as per label direction. Pesticides and application equipment were not stored at the facility. 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 pest sightings log was used and quarterly trending information was provided to the facility. 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. Exterior pest monitoring devices, such as traps or 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. The bait stations examined were found to be properly maintained. The stations were serviced at least monthly. #SYS-B-141-p.10

12 IPM IPM IPM IPM IPM AP AP AP AP AP 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. Insect light traps (ILTs) were used in the facility to aid in monitoring insect activity. These traps were more than 10 feet 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 bulbs were shatter resistant and documentation was maintained of the annual bulb changes was maintained. 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. The policy was signed and was communicated to all personnel. 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 Quality Control manager. The facility was licensed by the Florida Department of Agriculture and was current. The facility remained current on industry codes of practice and technical developments, through corporate communications. 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. Written job descriptions including food safety responsibilities were developed, these included alternates in the event of absence of key personnel. These were periodically reviewed for relevance. 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. The last training is conducted at least annually and exit criteria had been established. #SYS-B-141-p.11

13 AP AP AP AP AP AP A written program for evaluating Customer Complaints was established. This program included a plan for quick distribution of complaint information to all departments responsible for implementing Prerequisite and Food Safety Programs. Complaint information was used, where appropriate, to avoid recurrence and implement ongoing improvements to product safety. Actions appropriate to the seriousness and frequency of the identified problems appeared to be carried out promptly and effectively. A written Chemical Control Program that addresses all chemicals used in the facility was established. The program addressed most elements as indicated in the standards including contractor chemicals and training. The facility established a formal Microbial Program to address microbiological analysis in the production and packaging environment. Analysis for TPC (Total Plate Count), coliforms, yeast, mold, Salmonella, E. coli, and Listeria were included as part of the testing programs. The facility conducted weekly ATP and swab testing of product contact surfaces. The facility also sent finished product out to a lab for micro testing. All sampling was sent to a certified laboratory for testing and documented results were maintained on file. The program included steps to execute if results were outside the allowed parameters. There were no instances reviewed where limits were exceeded. 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 and brittle plastics was developed and was audited routinely to ensure any accidental breakage is found and addressed. 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. The MCS specified frequency, responsibility, postcleaning evaluation techniques and Corrective Actions. Written cleaning procedures were developed for all equipment, structures, and grounds that impacted storage, processing and packaging of food products. The procedures included chemicals, concentrations, disassembly instructions, and step by step direction as they apply to each task. Conditions observed in the facility supported the documentation. Incoming raw materials, packaging, and transports received into the facility were inspected by trained personnel according to established written procedures. Procedures were in place for the receipt of trailers of dry and refrigerated products. Procedures included inspection for pests, filth, damage, seals, temperature, etc. Documentation reviewed indicated compliance of the written procedures. #SYS-B-141-p.12

14 AP AP AP AP AP AP AP AP AP A written Regulatory Affairs and Inspections Program was on file. The program included a list of personnel delegated to accompany all inspectors along with the company policy regarding recording devices, cameras, records, and sample taking. The last regulatory inspection was conducted by the Florida Department of Agriculture on March 10, The inspection resulted in a rating of "GOOD". The issue observed had been addressed. Evidence of registration under the FDA Bioterrorism Act was on file at the facility. The facility had conducted a Vulnerability Assessment to identify food defense risks. The facility had a written food defense program in place. The program included procedures, a food defense team, including roles and responsibilities. Formal food defense training had been provided for facility personnel, and food defense training had been conducted for all employees. A documented Traceability Program that addressed identification of lot numbers of raw materials, rework, food contact packaging materials, work in progress, finished product, distribution, and processing aids 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. The program addressed all the requirements of the standard. The last mock recall was conducted on March 12, A written program was in place to control nonconforming products, including work in progress, finished products, and returned goods. Corrective Actions equal to the seriousness of the risk appeared to be taken. A written program outlining the evaluation, selection, and maintenance of suppliers of goods and services that affect product quality and food safety had been implemented. The program was developed and managed at the corporate level. Appropriate specifications were on file for raw materials, food contact packaging materials, finished products, work in progress, and processing aids. These specifications were detailed to ensure compliance with relevant food safety and legislative requirements. Letters of Guarantee or Certifications for received materials and finished products were on file and current. Letters of Guarantee indicated compliance. Field and Supplier Certification Programs were in place to ensure product safety for produce and agricultural commodities. It was understood that this program was managed at the corporate level. #SYS-B-141-p.13

15 AP The facility maintained processing records that were legible, genuine, in good condition, and contained sufficient information to comply with government requirements. The facility used chlorine in the produce wash water. Records reviewed indicated compliance to the hourly testing. #SYS-B-141-p.14