AIB International Consolidated Standards for Inspection

Transcription

1 AIB International Consolidated Standards for Inspection Facility Name : FreshPoint Austin Account Number : SYS-B-207 Distribution Centers Facility Address : Springdale Rd Austin, Texas United States Dates(s) of Inspection : 30-NOV-11 Announcement Type : Unannounced Inspection Type : Scored Contacts : US Office: 1213 Bakers Way PO Box 3999, Manhattan, KS (785) (800) Fax (785) UK Office: PO Box 11, Leatherhead, Surrey, KT22 7YZ Fax Website :

2 CUSTOMER DETAILS Organization Name Account Number Products Produced FreshPoint Austin SYS-B-207 Storage and distribution of produce and dry ingredients for Food Service customers Fresh, frozen and/or canned seafood products were not stored at the time of the inspection PARTICIPANT NAMES Name Role Inspection Closing Meeting Mr Dylan Massave VP of Purchasing Yes - Mr Eric Price VP of Operations Yes Yes Mr Juan Ramirez Warehouse Supervisor Yes - Mr Tony Medina Operations Manager Yes Yes Oliver Blome Auditor Yes Yes Disclaimer: 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 the customer named on the title page of this report (the customer) AIB International Inc is only reporting the food safety conditions of the customer as of the date of this report and assumes no responsibility or liability as to whether the customer does or does not carry out the recommendations as contained in this report Page 2 of 60

3 CATEGORY SCORES Announcement Type Inspection Type Unannounced Scored Category Minor Issues Noted Improvement Needed Serious Unsatisfactory Score Operational Methods and Personnel Practices Maintenance for Food Safety Cleaning Practices Integrated Pest Management Adequacy of Prerequisite and Food Safety Programs Total Score 860 OVERALL RESULTS Rating Recognition of Accomplishment Page 3 of 60

4 OBSERVATIONS BY RISK WITHIN CATEGORY # Rating Standard Standard # # Location 1 Improvement Needed (IN) Material Inventory Raw Material Storage : Insect-susceptible materials were stored in very limited quantities Materials in storage longer than four weeks were regularly inspected However, one 25lbs bag of "PANKO" breadcrumbs, received on 6/13/2011 and stored in the Dry Area was not included in this inspection Recommendation: It was recommended that all grain based, insect susceptible materials be included in the monthly inspection to identify, address and eradicate any signs of stored product post infestation 2 Minor Issues Noted (MI) Pallets Raw Material Storage : Slipsheets were used on most pallets and between pallets to protect materials from damage However, bagged onions stored directly on wooden pallets were noted on three occasions Recommendation: Slip sheets should be provided to prevent nails and/or wood puncturing product and the potential food safety concerns associated with this 3 Improvement Needed (IN) Finished Product Transportation Loading Dock : Vehicles temperatures were checked but not recorded prior to loading Recommendation: It was recommended that vehicle temperatures be checked and recorded prior to loading to ensure that temperature requirements for perishable products are met and procedures are being followed 4 Improvement Needed (IN) Finished Product Transportation Facility Overview : Inspections of shipping vehicles prior to loading were not documented and current Recommendation: It was recommended that shipping vehicles be inspected prior to loading for vehicle integrity, cleanliness, off-odors, pest activity or other potential contaminants These inspections should be documented and verified to indicated compliance 5 Improvement Needed (IN) Overhead Structures Raw Material Storage : Standing water was noted in the northeast corner of the Overflow Room, beneath the condenser unit No product was stored in close proximity Recommendation: Although a leak on the unit connections was not noted, it was recommended that the source of the water accumulation be determined to prevent potential product safety concerns caused by overhead leakage 6 Improvement Needed (IN) Overhead Structures Raw Material Storage : Duct tape and white plastic liner was used to patch the ripped ceiling insulation in the northeast corner of the Potato Cooler, directly above stored, covered boxes with potatoes Recommendation: The insulation damage should be permanently repaired to prevent additional deterioration and potential of foreign material contamination associated with this 7 Improvement Needed (IN) Temporary Repair Materials Facility Overview : Based on the observation noted under 2613, it was recommended that the use of tape, plastic liner, string, wire, Page 4 of 60

5 cardboard etc be discouraged for temporary repairs Temporary emergency repairs should be signed/dated, brought to the attention of Management and permanently repaired in a timely manner 8 Improvement Needed (IN) Temperature Measuring Devices Facility Overview : Temperature measuring devices, such as used in Freezer M and Cooler N and critical to food safety were not calibrated to a national or recognized standard Recommendation: It was recommended that all thermometers located in cold storage areas critical to food safety be calibrated to a national standard (NIST) on a predetermined frequency This will ensure that temperature readings are accurate 9 Improvement Needed (IN) Temperature Measuring Devices Facility Overview : Temperature readings in the cold storage areas were between -2F and 37F at the time of the inspection It was explained that temperatures were monitored daily; however, temperature monitoring records for Freezer M and Cooler N were not available for review Recommendation: It was strongly recommended that temperatures in all cold storage areas critical to product safety be monitored and readings be documented Any temperature readings outside established perimeters should be followed by documented corrective actions 10 Improvement Needed (IN) Periodic (Deep) Cleaning Facility Overview : Deep cleaning of equipment and structures was to be conducted according to the Master Cleaning Schedule to prevent the development of microorganisms, insects, or foreign material However, some dried-out cilantro stems were dangling off the bottom grate for the storage rack in location I0071 Open boxes with broccoli were stored beneath this finding Recommendation: It was recommended that storage racks and other overhead structures be cleaned often enough to remove debris and other potential contaminants 11 Minor Issues Noted (MI) Trend Analysis Facility Overview : Pest-sighting logs were not reviewed on a quarterly basis to identify trends in pest activity These were reviewed during the annual assessment Recommendation: Quarterly trending should be conducted to identify any trends in pest activity and to update the IPM Program, if needed 12 Minor Issues Noted (MI) Trend Analysis Facility Overview : Corrective Actions were not consistently documented for identified issues documented on the service tickets Recommendation: Corrective actions should be documented, thus demonstrating that recommendations made by IPM personnel were being followed 13 Minor Issues Noted (MI) Pheromone Monitoring Devices Facility Overview : Pheromone monitoring was not conducted in storage areas with insect susceptible materials Recommendation: Although the facility only stored limited quantities of insect susceptible materials (rice, breadcrumbs) and no insect activity was noted, consideration should be given to placing pheromone monitoring devices in the Dry Area to detect any activity levels of stored product pests 14 Minor Issues Noted (MI) Self-Inspections Facility Overview : Monthly self-inspections of the entire facility, including the outside grounds, were conducted Recommendation: However, based on the observations made during the survey, it was recommended that future facility self-inspections Page 5 of 60

6 become more detailed in identifying potential food safety hazards such as noted and outlined in the body of this report 15 Improvement Needed (IN) Written Procedure Audits Facility Overview : A risk-based audit of procedures was not completed Moreover, it was noted that several procedures were outdated, not reflecting the recent change in Senior Management Recommendation: It was recommended that procedures be reviewed at least annually to ensure that these are still applicable and valid, as outlined in section 57 of the AIB International Standards for Inspection Moreover, current documentation should be reorganized to ensure that all programs are readily available when needed during future audits 16 Improvement Needed (IN) Allergen Control Program Facility Overview : Documented allergen awareness training for employees was not available for review Recommendation: It was recommended that allergen training be conducted and documented to ensure that employees have a general understanding of allergen handling and the potential risk of allergen contamination concerns 17 Minor Issues Noted (MI) Cleaning Program Facility Overview : The MCS specified frequency, responsibility, and post-cleaning evaluation techniques Recommendation: However, frequencies and techniques for rack cleaning should be reviewed and revised as needed to prevent future issues such as noted and described in this report 18 Improvement Needed (IN) Preventive Maintenance Program Facility Overview : A formal Preventive Maintenance Program and work order system was not available for review Recommendation: Although most maintenance tasks related to fork trucks, cooling units and structural maintenance were contracted out, it was recommended that a written program be maintained, addressing building and equipment maintenance to ensure a food safe distribution environment Page 6 of 60

7 FACILITY SPECIFIC INFORMATION Ref# Question Comments 1 (19) Does the facility use bulk dry materials? No 1a (113) If so, state the materials received, if they are sifted, screen size in the sifter, and frequency of screen checks and tailings checks N/A 2 (114) Does the facility use Bulk Liquid materials? No 2a (114) If so, comment on materials received, are strainers provided and where, frequency of strainer inspections, and documentation N/A 3 (122) Does the site have temperature controlled areas such as coolers or freezers? Yes 3a (217) If so state temperatures observed, method of monitoring such as manual or continuous, and if an alarm system is present Temperatures in the cold storage areas ranged from -2F to 37F Temperature monitoring activities were data-loggers and manual recordings Facility personnel would be notified in the event of temperature discrepancies 4 (115) Are foreign material control devices used? No 4a (115) If so, list devices used and if they are present on all lines Comment on device testing observed during the inspection N/A 5 (44) Were IPM services provided by a contractor? Yes 5a 5b (44) If so, provide name of service provider, comment on if business and PCO licenses were current If licenses were not required, was training provided and was GMP training provided (46) If pesticides were used comment on availability of MSDS and sample labels and list pesticides used in past 12 months IPM services were provided by Steritech The Business License and Applicator License were current through 7/31/2011 Liability insurance was current through 3/31/2012 GMP training for the applicator was dated 3/25/2010 Contrac Blox, EPA# ; Advance, EPA# ; Deadline Mini, EPA# ; Generation Mini Block, EPA# were applied in 2011 MSDS and sample labels were maintained 6 (52) Who has the assigned responsibility (job title) for food safety at the facility? 7 (510) Does the site have a documented Microbiological Control Program in place? The Operations Manager No Page 7 of 60

8 7a (510) If so, comment if testing is for Sanitation, Finished Product and/or Environmental and the organisms tested for N/A 7b (510) Comment if the laboratory is In-house or if an outside lab used N/A 8 (516) Has the site been inspected by a regulatory agency in the past year? Yes 8a (516) If so, indicate the date and agency that conducted the inspection and if corrective actions were documented for any findings The Austin/Travis County Health and Human Services Department conducted an inspection on 11/14/2011 No violations were documented on Form ECHU (525) Is a HACCP program in place? Yes 9a 9b (525) If so, indicate if the plan has been validated and by whom Also indicate the date of the most recent reassessment (525) Did the facility store or produce any products under regulatory HACCP guidelines? If so, list the products The plan was validated during the last assessment on 8/24/2011 by the FreshPoint San Antonio HACCP Coordinator No Page 8 of 60

9 ALL OBSERVATIONS AND RECOMMENDATIONS Unsatisfactory or Serious Items are designated in bold and italic Improvement Needed items are designated in bold Minor Issues are designated in Italics 10 Operational Methods and Personnel Practices # Standard Standard # # Risk Location 1 Rejection of Shipments Facility Overview Damaged, infested or dirty transports/containers are rejected Damaged, infested or dirty transports or containers were rejected upon receipt 2 Rejection of Shipments Facility Overview Materials shipped in damaged, infested or dirty vehicles are rejected Documentation of rejection of damaged, infested or dirty materials was included as part of the program 3 Rejection of Shipments Facility Overview Perishable or frozen materials meet specific minimum temperature requirements at points of shipment, transportation and receipt Documentation of temperature checks of frozen and perishable materials met the temperature requirements defined in the facility's program 4 Rejection of Shipments Facility Overview The facility maintains documentation of temperature checks for perishable goods at receiving points Temperature documentation appeared to be complete 5 Rejection of Shipments Facility Overview The facility maintains documentation of rejected shipments that includes defect specifications and reasons for rejection Rejection documentation, including the reason for rejection, was in place and current 6 Storage Practices Facility Overview Food products are stored and removed from storage in a manner that prevents contamination Page 9 of 60

10 Food product storage and removal was done in a way to prevent contamination 7 Storage Practices Facility Overview Receiving dates are visible on the bottom unit of the pallet or individual container Receiving dates or other viable means of stock rotation were in use at the facility 8 Storage Practices Facility Overview Materials are stored off the floor on pallets, slipsheets or stands Materials were stored off the floor 9 Storage Practices Facility Overview Materials are stored at least 18 in or 45 cm away from walls and ceilings Perimeter clearance was provided for storage of materials 10 Storage Practices Facility Overview Adequate space is maintained between rows of stored materials to allow cleaning and inspection Procedures are followed to guarantee the proper cleaning, inspection, and monitoring for pest activity in storage areas, where an 18 in or 45 cm inspection perimeter cannot be provided Adequate space for storage of materials was in place to allow access for cleaning, inspection and pest control monitoring activities 11 Storage Practices Facility Overview Receiving dates are on a permanent part of materials packaging (ie, not on stretch-wrap) Receiving dates were provided to facilitate stock rotation 12 Storage Practices Facility Overview There are at least 14 in or 35 cm of space between pallet rows Adequate clearance between pallet rows was provided 13 Storage Practices Facility Overview Storage slots and traffic lanes are provided for items stored at floor level Storage slots and traffic lanes were provided for floor level storage of materials 14 Storage Practices Facility Overview If an 18 in or 45 cm clearance from walls is impossible due to aisle widths and forklift turning space, a rack system can be installed against the wall In this case, a bottom rail is installed 18 in or 45 cm off the floor so that no pallets Page 10 of 60

11 are stored on the floor Racks were installed against the wall with sufficient clearance to allow access for cleaning, inspection and pest control monitoring activities 15 Storage Conditions Facility Overview Storage areas are clean, well ventilated, and dry Materials and packaging materials are protected from condensate, sewage, dust, dirt, chemicals or other contaminants Storage areas were clean, well ventilated, and dry Materials and packaging were protected from contaminants 16 Storage Conditions Facility Overview All toxic chemicals, including cleaning and maintenance compounds, and non-product materials, including equipment and utensils, are stored in a separate area Segregation of non-product related materials, chemicals, equipment and utensils was practiced at this facility 17 Storage Conditions Facility Overview Research and Development items and infrequently used materials and packaging supplies are regularly inspected for signs of infestation Infrequently used materials and packaging were inspected for signs of infestation on a regular basis 18 Storage Conditions Facility Overview Special handling procedures are followed for packaging materials that pose a product safety risk if mishandled (eg, aseptic or glass packaging) Failures and Corrective Actions are documented Special handling procedures were in place for packaging materials with a product safety risk 19 Storage Conditions Facility Overview Packaging is stored away from food materials and finished product in a designated area, if possible Segregation of packaging materials from food materials and finished products was observed 20 Storage Conditions Facility Overview Frozen foods are not staged for longer than 30 minutes on docks that are refrigerated to hold an air temperature not exceeding 40 Degrees F or 4 Degrees C Refrigerated docks were provided to prevent food safety issues when staging refrigerated and frozen materials 21 Storage Conditions Facility Overview If the dock is not refrigerated, products are not kept there for longer than 15 minutes Refrigerated and frozen materials were not left for excessive amounts of time to cause thawing or temperature Page 11 of 60

12 abuse of product when staged on non-refrigerated docks 22 Storage Conditions Facility Overview An 18 in or 50 cm painted inspection line is provided on the floor wall junctions around the perimeter and interior partition walls to aid in the detection of pest activity Inspection perimeters were provided to aid in the detection of pest activity on wall perimeters 23 Material Inventory Facility Overview Ingredients, packaging supplies, and other materials are rotated on a First-In, First-Out (FIFO) basis or other verifiable method (such as First Expired, First Out [FEFO]) to ensure stock rotation Ingredients and packaging materials were rotated on a First-In, First-Out basis 24 Material Inventory Improvement Needed (IN) Raw Material Storage Insect-susceptible materials in storage longer than four weeks are regularly inspected Recommendation Insect-susceptible materials were stored in very limited quantities Materials in storage longer than four weeks were regularly inspected However, one 25lbs bag of "PANKO" breadcrumbs, received on 6/13/2011 and stored in the Dry Area was not included in this inspection It was recommended that all grain based, insect susceptible materials be included in the monthly inspection to identify, address and eradicate any signs of stored product post infestation 25 Material Inventory Facility Overview The repalletizing date or inspection date is located near the original receiving date A repalletizing date was provided on inspected materials 26 Pallets Facility Overview Pallets are clean and in good repair Pallets were observed to be clean and in good repair 27 Pallets Facility Overview Pallets and other wooden surfaces are properly dried after being washed 28 Pallets Minor Issues Noted (MI) Raw Material Storage Slipsheets are placed between pallets and bags of ingredients, and between double-stacked pallets to protect ingredients from damage by the pallet Slipsheets were used on most pallets and between pallets to protect materials from damage However, bagged Page 12 of 60

13 Recommendation onions stored directly on wooden pallets were noted on three occasions Slip sheets should be provided to prevent nails and/or wood puncturing product and the potential food safety concerns associated with this 29 Designated Rework Areas Facility Overview There is a designated rework area The facility had a designated salvage/rework area 30 Designated Rework Areas Facility Overview The rework area is segregated from usable materials Rework materials were segregated from good stock 31 Designated Rework Areas Facility Overview Rework is processed weekly or as often enough to keep rework quantities at minimal levels Rework was processed to maintain quantities at minimal levels 32 Designated Rework Areas Facility Overview Rework is identified for traceability purposes Rework materials were identified to allow traceability 33 Waste Material Disposal Facility Overview Trash or inedible waste is stored in properly covered, labeled containers Trash and inedible waste was stored in covered and identified containers 34 Waste Material Disposal Facility Overview Waste containers are emptied at least daily Waste containers were emptied daily 35 Waste Material Disposal Facility Overview Trash or inedible waste does not come in contact with raw materials, work-in-progress, or finished product at any time Trash and inedible waste was segregated from raw materials and food products 36 Waste Material Disposal Facility Overview Licensed contractors remove waste, where required Licensed contractors were used to remove waste from the facility Page 13 of 60

14 37 Waste Material Disposal Facility Overview Waste disposal meets regulatory requirements Waste disposal appeared to meet regulatory requirements 38 Temperature-Sensitive Materials Facility Overview Materials, work-in-progress, and finished product capable of supporting the rapid growth of pathogenic microorganisms are properly stored Temperature-sensitive materials were found to be properly stored 39 Temperature-Sensitive Materials Facility Overview "Temperature-sensitive materials are stored to maintain the appropriate internal temperatures: -40 Degrees F or 4 Degrees C or below -140 Degrees F or 60 Degrees C or above -Or in accordance with country-specific regulation" Temperature-sensitive materials were stored to maintain appropriate internal temperatures 40 Temperature-Sensitive Materials Facility Overview Continuous recording thermometers are placed in all rooms or areas where frozen foods are stored or handled and the thermometers are calibrated and maintained Calibrated continuous recording thermometers were placed in all areas where frozen foods were stored or handled 41 Temperature-Sensitive Materials Facility Overview Freezers and coolers are provided with vinyl strip doors, self-closing devices, or other methods to maintain temperatures Freezers and coolers were provided with self-closing doors, strip curtains or other devices to maintain temperatures 42 Cross Contamination Prevention Facility Overview Incompatible materials (such as raw and cooked products) are stored under conditions that prevent cross contamination Materials appeared to be properly stored and segregated to prevent cross contamination 43 Cross Contamination Prevention Facility Overview Measures are taken to prevent cross contamination by hazardous ingredients, such as allergens The facility has defined measures in place to prevent cross contamination from hazardous ingredients, such as allergens Page 14 of 60

15 44 Cross Contamination Prevention Facility Overview Systems are set up to reduce any potential physical, chemical, or microbiological contamination risks The facility has implemented systems to reduce physical, chemical, and microbiological contamination 45 Cross Contamination Prevention Facility Overview Protective measures are provided in areas where iced down product is stored over like or dissimilar items in order to prevent melting ice from contaminating product below Protective measures were provided to prevent iced down product stored over like or dissimilar items from contaminating product below 46 Containers and Utensils Facility Overview Containers and utensils used to transport, process, hold, or store food materials are constructed, handled, and maintained in a way that prevents contamination Containers and utensils used for food materials were properly handled and maintained 47 Containers and Utensils Facility Overview Containers for food products are only used for their designated purposes No misuse of containers was noted during the inspection 48 Containers and Utensils Facility Overview Containers are legibly labeled with contents Containers were found to be properly labeled or color-coded 49 Finished Product Transportation Facility Overview Legible code marks that are easily seen by consumers are placed on all finished products Legible code marks were observed on finished products 50 Finished Product Transportation Facility Overview Code marks satisfy regulatory packaging requirements and lot definitions, and are used in the Recall Program Lot codes were provided on finished products to facilitate product recall 51 Finished Product Transportation Facility Overview Distribution records identify the initial point of distribution as per regulatory requirements Records of distribution were maintained to identify the initial point of distribution 52 Finished Product Transportation Facility Overview Page 15 of 60

16 Finished products are handled and transported in a way that prevents actual or potential contamination No issues with finished product handling or distribution practices were noted 53 Finished Product Transportation Facility Overview Finished products are loaded or transferred in covered bays or canopies to protect the products from weather damage Covers or canopies were provided to protect products from weather damage 54 Finished Product Transportation Facility Overview Temperatures of perishable and frozen products are taken and recorded upon loading Temperatures of perishable and/or frozen products were taken and recorded during loading activities 55 Finished Product Transportation Facility Overview Documentation validates that temperature-sensitive products are loaded into vehicles that are designed to sustain required temperatures during delivery 56 Finished Product Transportation Recommendation Documentation indicated that climate-controlled vehicles capable of maintaining temperatures for shipping refrigerated and/or frozen materials were used at this facility Records indicated that perishable materials were shipped in these vehicles Improvement Needed (IN) Loading Dock Temperatures of vehicles are checked and recorded before loading Vehicles temperatures were checked but not recorded prior to loading It was recommended that vehicle temperatures be checked and recorded prior to loading to ensure that temperature requirements for perishable products are met and procedures are being followed 57 Finished Product Transportation Facility Overview The facility enforces transportation breakdown procedures Written transportation breakdown procedures were on file at the facility 58 Finished Product Transportation Facility Overview Prior to loading, all shipping vehicles are inspected for cleanliness and structural defects that could jeopardize the product 59 Finished Product Transportation Shipping vehicles were inspected for cleanliness and structural issues prior to loading Improvement Needed (IN) Facility Overview Page 16 of 60

17 Shipping vehicle inspections are documented Recommendation Inspections of shipping vehicles prior to loading were not documented and current It was recommended that shipping vehicles be inspected prior to loading for vehicle integrity, cleanliness, off-odors, pest activity or other potential contaminants These inspections should be documented and verified to indicated compliance 60 Finished Product Transportation Facility Overview Local delivery trucks and route trucks are inspected and cleaned at least weekly to identify potential sources of foreign material contamination Local delivery trucks and vehicles were inspected and cleaned on a minimum of a weekly basis 61 Finished Product Transportation Facility Overview Common carriers and customers are encouraged to maintain their delivery vehicles in sanitary condition and in good repair Common carriers and customer delivery vehicles were addressed as part of the finished product transportation program 62 Finished Product Transportation Facility Overview Security seals or padlocks are provided, and their use is documented as per facility or customer requirements Documentation of the use of security seals and/or padlocks was documented per requirements 63 Finished Product Transportation Facility Overview Transport refrigeration units have recording devices Transport refrigeration units were equipped with recording devices 64 Finished Product Transportation Facility Overview Adequate free air circulation is provided all around the load during refrigerated or frozen product transportation Pallets with slipsheets or another way to allow adequate air circulation under the load are in place unless the transport has a channeled floor to maintain air circulation Free air circulation was provided via the use of pallets or channeled floors for refrigerated and/or frozen loads 65 Finished Product Transportation Facility Overview If applicable, the vehicle's refrigeration unit is turned on and the doors are closed when loading and unloading are not taking place Vehicle refrigeration units are on when loading and doors are maintained to preserve temperature integrity of the loading and unloading activities Page 17 of 60

18 66 Finished Product Transportation Facility Overview The thermostat on the vehicle's refrigeration unit is set to maintain an air temperature of 0 Degrees F or -18 Degrees C or lower for frozen food Thermostats on vehicle refrigeration units were set to maintain air temperature at 0 Degrees F/-18 Degrees C for frozen foods 67 Finished Product Transportation Facility Overview Dome lights provided in transports are shielded to prevent glass breakage No unshielded dome lights were noted in the transports inspected 68 Hand Washing Facilities Facility Overview Suitable and properly maintained hand washing facilities are located at the entrance to work areas, and at other appropriate sites Accessible and properly maintained hand washing facilities were provided 69 Hand Washing Facilities Facility Overview Single use towels or air dryers are provided at hand washing stations Single use towels and/or air dyers were used at this facility 70 Hand Washing Facilities Facility Overview Hand sanitizing stations are provided, where appropriate 71 Hand Washing Facilities Facility Overview Hand sanitizers are regularly monitored for proper concentration to ensure effectiveness 72 Hand Washing Facilities Facility Overview "Wash hands" signs appear above sinks and entries to work areas, where appropriate "Wash hands" signs were provided above sinks and in entries to work areas where appropriate 73 Hand Washing Facilities Facility Overview Dispensers for disposable paper towels are covered Hands-free design is desirable Paper towel dispensers were covered and hands-free in design 74 Washrooms, Showers and Locker Facility Overview Page 18 of 60

19 Rooms All washrooms, showers, and locker rooms are maintained in a sanitary condition Employee welfare areas were found to be clean and well maintained 75 Washrooms, Showers and Locker Facility Overview Rooms No pests or mold are present No mold or pest evidence was observed 76 Washrooms, Showers and Locker Facility Overview Rooms There are no open food or drinks in lockers or locker rooms Open food and drinks were not noted 77 Washrooms, Showers and Locker Facility Overview Rooms "Wash hands" signs are displayed in all restrooms, lunchrooms, and smoking areas "Wash hands" signs were provided in employee welfare areas 78 Washrooms, Showers and Locker Facility Overview Rooms Company-owned personnel lockers are inspected on a defined frequency 79 Personal Hygiene Facility Overview Trained supervisors are responsible for ensuring that all personnel are complying with facility polices regarding personnel practices Trained supervisors were responsible for ensuring compliance with facility personnel practice requirements 80 Personal Hygiene Facility Overview Personnel wash hands before beginning work, and after eating, drinking, smoking, using the restroom, or otherwise soiling hands Plant polices required that personnel wash hands before beginning work, and after eating, drinking, smoking, using the restroom, or otherwise soiling hands No violations of this policy were observed 81 Personal Hygiene Facility Overview Personnel are encouraged to practice good personal hygiene at all times Page 19 of 60

20 Good employee hygiene practices were noted during the inspection 82 Personal Hygiene Facility Overview Hand washing practices are checked periodically for effectiveness 83 Personal Items and Jewelry Control 84 Personal Items and Jewelry Control 85 Personal Items and Jewelry Control Hand washing practices were periodically monitored for effectiveness Facility Overview Personnel eat, drink, chew gum, and use tobacco products only in designated areas Personnel were not observed eating, drinking, or smoking in unauthorized areas Facility Overview Personal food and belongings are not brought into work or storage areas Personal property was stored in appropriate locations defined by company policy Facility Overview All personal property is stored in a designated area Designated areas for storage of personal property were provided 86 Health Conditions Facility Overview No person with boils, sores, infected wounds, or any other infections or communicable disease is permitted to contact food as defined by local or national law 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 87 Health Conditions Facility Overview All personal health cards are current and properly posted if required by local regulations Personal health cards were current and on file 88 Health Conditions Facility Overview The facility follows procedures requiring personnel, including temporary workers, to notify supervisory personnel of any relevant infectious disease or conditions to which they may have been exposed Procedures requiring personnel, including temporary workers, to notify supervisors of infections or disease that Page 20 of 60

21 that they may have been exposed to were in place 89 Non-Facility Personnel Facility Overview "Non-facility personnel conform to the facility Personnel Practices Program Non-facility personnel include but are not limited to: -Visitors -Temporary personnel -Regulatory authorities -Outside contractors -Tour groups -Family and friends of personnel" Non-facility personnel, including visitors and contractors, followed the facility personnel practices requirements 20 Maintenance for Food Safety # Standard Standard # # Risk Location 90 Facility Location Facility Overview The facility identifies and takes measures to prevent product contamination from local activities that could have adverse impacts Facility boundaries were defined and controlled 91 Facility Location Facility Overview Facility boundaries are clearly defined and controlled Boundaries were clearly defined and controlled 92 Facility Location Facility Overview Effective measures are in place to prevent product contamination from neighboring properties These measures are periodically reviewed Measures were in place to prevent contamination from local activities or neighboring properties that could impact the facility 93 Outside Grounds Facility Overview Equipment stored outside is placed to prevent pest harborage, to make the inspection process easier, and to protect equipment from deterioration and contamination Outside grounds and equipment storage was maintained in a way that prevents product contamination or pest harborage 94 Outside Grounds Facility Overview Litter and waste are removed from the property Measures included removal of litter and managing and maintaining waste to eliminate pest attraction to the facility Page 21 of 60

22 95 Outside Grounds Facility Overview Weeds and tall grass are not near the building Weeds and tall grass were not noted near the building 96 Outside Grounds Facility Overview Roads, yards, and parking areas are maintained to be free of dust, standing water, and other potential contaminants Roads, yards, and parking areas were maintained to eliminate excessive dust, standing water, or other contaminants 97 Outside Grounds Facility Overview Adequate drainage is provided for grounds, roofs, and other areas No issues with drainage from the roof, grounds, or other areas were observed 98 Outside Grounds Facility Overview Outside wet and dry waste or scrap compactors, modules, and containers are installed in a way that prevents product contamination Containers are maintained to minimize and contain leakage, and are removable so that the area can be cleaned Outdoor waste and scrap compactors were maintained to minimize leakage and were removable to facilitate cleaning 99 Outside Grounds Facility Overview Waste containers and compactors are closed or covered, and located on a concrete pad or in a manner to minimize pest attraction and harborage Waste and scrap compactors were covered and located to prevent pest attraction or harborage 100 Outside Grounds Facility Overview Outdoor equipment storage is minimal 101 Outside Grounds Facility Overview Truck bays and garage areas are maintained to prevent pest attraction or harborage Truck bays and garages examined were well maintained at the time of the inspection 102 Security Equipment Facility Overview "Physical security measures that require maintenance or design can include: -Perimeter fences -Surveillance Page 22 of 60

23 cameras -Locked doors -Security guard stations -Controlled access -Controlled bulk storage areas" Some measures were taken to maintain facility security Security strategies included fencing, locked doors, limited access to sensitive areas, surveillance cameras, truck seals, employee screening, and a visitor log 103 Layout Facility Overview Space is maintained between equipment and structures to enable cleaning and maintenance Adequate space was observed between equipment and structures to facilitate access for cleaning and maintenance activities 104 Layout Facility Overview There is adequate space to place equipment and materials Adequate space was provided between equipment and materials 105 Floors, Walls, and Ceilings Facility Overview Floors, walls, and ceilings are made of materials that are easily cleaned and kept in good repair Floors, walls, and ceilings throughout the facility were well constructed and maintained 106 Floors, Walls, and Ceilings Facility Overview Floor drains with grates are installed, maintained, and operational in all wet storage or wash areas Grated floor drains were found to be clean and in good condition 107 Floors, Walls, and Ceilings Facility Overview Floor drain grates are easily removable for cleaning and inspection Drain grates appeared to be easily removed for cleaning and inspection 108 Floors, Walls, and Ceilings Facility Overview Drainage is designed and maintained to minimize the risk of product contamination Floor drainage was designed and maintained to allow access for cleaning and to prevent product contamination 109 Floors, Walls, and Ceilings Facility Overview Access to the void in hollow or suspended ceilings is provided to facilitate cleaning, maintenance, and inspection activities Access to the void areas above the hollow or suspended ceiling was provided 110 Floors, Walls, and Ceilings Facility Overview Roof leaks are promptly identified, controlled, and repaired Page 23 of 60

24 There was no evidence of roof leakage 111 Floors, Walls, and Ceilings Facility Overview "Ceilings, overheads, and walls are designed, constructed, finished, and maintained to: -Prevent dirt accumulation -Reduce condensation and mold growth -Facilitate cleaning" Ceilings, overhead structures, and walls were found to be clean and well maintained 112 Floors, Walls, and Ceilings Facility Overview Wall/floor junctions and corners are coved to facilitate cleaning Wall/floor junctions and corners were coved to facilitate cleaning 113 Floors, Walls, and Ceilings Facility Overview Holes in wall and floor surfaces are repaired to prevent debris from lodging and to avoid pest harborage Floor and wall structures were found to be in good repair 114 Floors, Walls, and Ceilings Facility Overview Floors are designed to meet the demands of facility operations and withstand cleaning materials and methods Floors were in good condition and appeared to be designed to withstand operations and cleaning activities 115 Floors, Walls, and Ceilings Facility Overview Floors are impervious Floors were impervious 116 Floors, Walls, and Ceilings Facility Overview Floors are sloped to direct the flow of water or effluent toward drains Floors were sloped to direct flow to the drains 117 Floors, Walls, and Ceilings Facility Overview Floor drains can be easily accessed for cleaning and inspection Floor drains were easily accessible for cleaning and inspection 118 Overhead Structures Improvement Needed (IN) Raw Material Storage Fixtures, ducts, pipes, and overhead structures are installed and maintained so that drips and condensation do not contaminate foods, raw materials, or food contact surfaces Standing water was noted in the northeast corner of the Overflow Room, beneath the condenser unit No product was stored in close proximity Page 24 of 60

25 Recommendation Although a leak on the unit connections was not noted, it was recommended that the source of the water accumulation be determined to prevent potential product safety concerns caused by overhead leakage 119 Overhead Structures Facility Overview There is no flaking paint or rust on equipment or structures Only normal mild oxidation on nonfood contact surfaces is acceptable There was no evidence of flaking rust or paint in the overheads or from production equipment in or above the product zone 120 Overhead Structures Improvement Needed (IN) Raw Material Storage Other materials (such as loose insulation) do not threaten food products or food contact surfaces Recommendation 121 Glass, Brittle Plastics and Ceramics Control 122 Glass, Brittle Plastics and Ceramics Control 123 Glass, Brittle Plastics and Ceramics Control 124 Glass, Brittle Plastics and Ceramics Control Duct tape and white plastic liner was used to patch the ripped ceiling insulation in the northeast corner of the Potato Cooler, directly above stored, covered boxes with potatoes The insulation damage should be permanently repaired to prevent additional deterioration and potential of foreign material contamination associated with this Facility Overview Adequate lighting is provided in all areas Adequate lighting was observed in all areas Facility Overview Light bulbs, fixtures, windows, mirrors, skylights, and other glass suspended over exposed product, such as produce and recoup areas, are of the safety type or are otherwise protected to prevent breakage 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 Facility Overview Light fittings and glass are replaced in a way that minimizes the potential for product contamination Light fittings and other glass were replaced in a way to prevent potential product contamination Facility Overview Glass that cannot be fully protected is addressed in the Glass, Brittle Plastics, and Ceramics Program Glass that could not be protected was accounted for in the Glass, Brittle Plastics, and Ceramics Program Page 25 of 60

26 125 Glass, Brittle Plastics and Ceramics Control 126 Glass, Brittle Plastics and Ceramics Control Facility Overview Only essential glass is present in the facility If glass must be used, it is addressed by the Glass, Brittle Plastics, and Ceramics Program Essential glass present in the facility was managed as part of the Glass, Brittle Plastics, and Ceramics Program Facility Overview All light bulbs, fixtures, windows, mirrors, skylights and other glass used in storage areas where there is no product exposure are protected against breakage unless managed under the Glass, Brittle Plastics and Ceramics Program Light bulbs, fixtures, windows, skylights, etc over product areas where there was no product exposure were either protected or managed as part of the Glass, Brittle Plastics and Ceramics Program 127 Pest Prevention Facility Overview The building has barriers in place to protect against birds, rodents, insects, and other pests Adequate barriers were in place to prevent rodents, insects, and birds from entering the facility 128 Pest Prevention Facility Overview The structures are free from cracks, crevices, and pest harborages Cracks, crevices, and other pest harborages were eliminated 129 Pest Prevention Facility Overview External doors, windows, or other openings are close-fitting or otherwise pest-proofed to less than Quarter in or 6 mm Doors were pest-proofed to prevent pest entry 130 Leaks and Lubrication Facility Overview The facility prevents, identifies, and eliminates leaks and excessive lubrication There was no evidence of leaks or excessive lubrication in product zones where contamination was likely 131 Cross Contamination Prevention Facility Overview Operations are separated based on process flow, material types, equipment, personnel, airflow, air quality, and services needed Operations were separated to prevent product contamination Page 26 of 60

27 132 Cross Contamination Prevention Facility Overview The process flow, from receiving to shipping, is arranged to prevent product contamination Process flow from receiving to shipping was arranged to minimize product contamination 133 Cross Contamination Prevention Facility Overview Areas for washing and cleaning are located away from work and storage activities, where appropriate Areas for washing and cleaning were segregated from work and storage activities as appropriate 134 Cross Contamination Prevention Facility Overview Toilet rooms do not open directly into areas where exposed product may be stored Toilet rooms did not open directly into exposed product areas 135 Temporary Repair Materials Improvement Needed (IN) Facility Overview Tape, wire, string, cardboard, plastic, and other temporary materials are not used for permanent repairs If used for emergency repairs, they are dated and replaced with a permanent repair as soon as possible Based on the observation noted under 2613, it was recommended that the use of tape, plastic liner, string, wire, cardboard etc be discouraged for temporary repairs Temporary emergency repairs should be signed/dated, brought to the attention of Management and permanently repaired in a timely manner 136 Temporary Repair Materials Facility Overview Any temporary repairs on food contact surfaces are constructed of food-grade material 137 Temporary Repair Materials Facility Overview The facility maintains a record of work orders or repair requests 138 Temporary Repair Materials Facility Overview The facility follows temporary repair procedures 139 Temporary Repair Materials Facility Overview Temporary repair issues are resolved as soon as possible and practical 140 Food Contact Surface Facility Overview Page 27 of 60