Davis Fresh Technologies

Transcription

1 Davis Fresh Technologies Davis Office: 423 E Street Davis, CA Tel: Fa: Aptos Office: 8 Seascape Village Aptos, CA Tel: Fa: solutions@davisfreshtech.com Fresh-Cut Facility Audit / Pre-Assessment: Audit Audit Date & Time: PM Customer: Company Name: Contact: Position: Phone: Fa: Address: Auditor: Product(s): Facility Name: Richmond Plant Manager: Rinco Chan QA Manager: Audit Contact: Rinco Chan Phone: Fa: City/State: Richmond, BC rchan@neptunefoodservice.com Country: Canada Address: Horshoe Way City/State: Richmond, BC Critical, Essential, Significant and Minor Issues Associated to Food Safety Risks Significant Issues (S) are those that may lead to potential contamination of edible products, but are not likely to directly lead to widespread contamination or food borne illness. Most of these issues relate to record keeping and compliance with local/federal regulations, GMP s and HACCP s, which in turn probe that an efficient food safety program is in place and working effectively. Other issues relate to implementation of control measures in the field. All issues in this category must be addressed effectively to achieve certification, but they do not pose an immediate threat of widespread food borne illness. Minor Issues (M) are those that contribute to perfect a program and merit attention but are not, themselves, crucial to assuring food safety. Incomplete paper work, lapsed licenses or untested recall programs are all things that should be fied. But they do not, in themselves, pose food safety risks. We recommend mitigation actions to address unresolved issues. Disclaimer Ready Fresh Produce Ready Fresh Produce Rinco Chan QA Manager rchan@neptunefoodservice.com Horshoe Way D. Zagory Fresh-cut vegetables During our food safety risk assessments, Davis Fresh Technologies categorizes issues into four risk categories: Critical, Essential, Significant and Minor. The following are working definitions for the four categories that are based on regulatory guidelines, practical eperience and available scientific knowledge. Critical Issues (C) are those that directly and evidently lead to widespread contamination of food, likely resulting in a food borne illness outbreak. Such things as evidence of contaminated water, soil or manure with food-borne pathogens contacting edible portions of plants, and rodent or bird feces contaminating produce, packing materials or contact surfaces, can directly lead to etensive contamination of fruits and vegetables. Such risks must be addressed immediately. Essential Issues (E) are those that present a high risk of contamination of food, possibly resulting in a food borne illness outbreak under unfavorable circumstances. These issues relates to absence of adequate toilet/handwash facilities for personnel, lack of workers training on food safety and hygiene habits, improper storage of packaging material, deficient sanitation program and lack of a periodic and adequate water testing or analysis/monitoring system. These issues must be addressed promptly to minimize contamination risks and have a satisfactory food safety program in place. Davis Fresh Technologies states that the report as given herein reflects the findings at the time and date of the audit. No warranty or guarantee related to the safety of food products referred to in this audit report is either written or implied by Davis Fresh Technologies. Davis Fresh Technologies assumes no risks or liabilities associated with the advice which is or is not acted upon by the client or its contracting associates related to the growing, harvesting, cooling, handling, distribution and/or processing of food products in this report. Any action or decision undertaken by any party based on information contained in this report is under the party's sole responsibility and risk. Ready Fresh Fresh-Cut Facility Audit Page 1 of 16 (C) Davis Fresh Technologies, LLC.

2 Section Summary Results I.Prerequisite Programs A. Raw Product Sourcing & Handling % 0 B. Packaging Materials and Supplies % 0 II. Hazard Analysis III. Produce Wash Water A. Water Quality Management % 0 B. Ice Making and Storage 0 0 IV. Employee Hygiene A. Toilet Facilities % 0 B. First Aid Policies % 0 C. Educational Sessions % 0 D. Habits and Conditions % 0 V. Plant and Equipment A. Facility Design and Sanitation % 0 B. Tools & Finished Product Containers % 0 VI. Pest Control % 0 VII. Cooling System and Facility A. General Sanitation % 0 B. Maintenance and Documentation % 0 VIII.Facility Supplies & Equipment % 0 IX. Control of Allergens % 0 X. Trace Product Recall % 0 XI. Food Security Program (non-scored) N/S N/S N/S N/S OVERALL AUDIT RESULTS % 0 Total : Category: % Achieved 97.7% >95% Ecellent No. Critical Deficiencies I. Prerequisite Programs A. Raw Product Sourcing and Handling 600 e It is a company policy that all fresh fruits and vegetables that are packed, re-packed, stored or minimally processed in this facility have been grown following Good Agricultural Practices. Ready Fresh Fresh-Cut Facility Audit Page 2 of 16 (C) Davis Fresh Technologies, LLC.

3 601 s Suppliers of fresh fruits and vegetables are required to provide evidence of food safety/gap They have audits and internal program from most suppliers programs preferably in the form of Third Party Audits (through reputable auditing companies). 602 s 603 s 604 s 605* e 606 s Alternatively, suppliers of fresh fruits and vegetables are required to demonstrate compliance of Food Safety/GAP programs through buyer's Internal Food Safety/Verification Audits (show QA/verification audits on file) Alternatively, suppliers of fresh fruits and vegetables are required to provide evidence of internal Food Safety/GAP programs in the form of copies of policies, standards and/or guidance documents. Alternatively, suppliers of fresh fruits and vegetables are required to provide evidence of Food Safety/GAP programs in the form of Letters of Guarantee. There is a program of QA evaluation of raw product to reject decayed and adulterated product. Raw product is held at an appropriate temperature prior to processing e Raw and finished product are kept Mostly. There is limited separate storage area Raw Product Sourcing Section Total Ready Fresh Fresh-Cut Facility Audit Page 3 of 16 (C) Davis Fresh Technologies, LLC.

4 B. Packaging Materials and Supplies 611* e There is a QA program and procedures for inspection of all incoming packages and materials Packaging Materials and Supplies Section Total II. Hazard Analysis 620 s There is an established HACCP team, See HACCP audit. comprised of a HACCP team leader and members from different functions across the plant. At least one member has received certified HACCP training. 622 s 624 s 626 s 627 s 628 s 630 s 632 s Prerequisite programs, including SOP s, SSOP's, Environmental monitoring, etc. are written and documented. Procedures for verifying compliance with prerequisite programs are established and documented. A product description has been prepared, including a flow chart of the process. The HACCP team performed a hazard analysis that identified all of the significant chemical, physical and microbiological risks. If significant risks are identified in the hazard analysis, they are being addressed either by prerequisite programs or HACCP If applicable, CCP s (Critical Control Points) have been established. If applicable, Critical limits have been established for each CCP, and are based on scientific data, historical eperience or other reasonable information. If applicable, CCP monitoring is documented and the documentation is available for review Ready Fresh Fresh-Cut Facility Audit Page 4 of 16 (C) Davis Fresh Technologies, LLC.

5 634 s 636 s If applicable, there are written procedures for corrective actions for each CCP if monitoring shows them to be outside critical limits. The corrective action logs have been properly filled out and initialed. If applicable, the HACCP plan is reviewed, audited/verified and updated on a scheduled basis. Hazard Analysis Section Total III. Produce Wash Water A. Water Quality Management 255 e Produce wash water has been tested for coliforms and/or E. coli (Provide test result). 258* c 261 e An approved sanitizer is used in the Tsunami 100 wash water. Specify sanitizer(s). 264 e The sanitizer concentration and/or activity is measured and recorded 3 per day with titration kit. Also measure ORP and ph. frequently during production (provide documentation) 267 e 270 s 272* e 274 s 278 s Produce wash water is free of coliforms or E. coli (Provide test result). The sanitizer activity level is maintained within its effective range The sanitizer is maintained within its allowable limits (provide documentation) A water monitoring log is kept for all water sources in contact with product, including the times readings are taken, ph, chlorine or ORP levels, addition of sanitizing agents, times of water change outs and operator's signature. Re-circulated and re-used water is changed at least daily A water change log is available, and includes ph, sanitizer concentration and/or ORP test records Ready Fresh Fresh-Cut Facility Audit Page 5 of 16 (C) Davis Fresh Technologies, LLC.

6 281 e If you are using a sanitizer other than chlorine, show evidence that the sanitizer is an effective biocide under your conditions. Water Quality Management Section Total B. Ice Making and Storage 285 c The source of the water to make ice, if different than the produce wash water, is also documented to be free of coliforms and/or E. coli Ice Making and Storage Section Total 0 0 IV. Employee Hygiene A. Toilet Facilities 130 e Clean and sanitary toilet facilities are provided for all employees. 135 s 138 e 140 e There is at least one toilet per every 20 employees. Toilets are located within ¼ mile, or a five minute walk of work areas. All toilet facilities contain toilet paper. 143 e 147 e 150 s 154 s 157 e Hand washing facilities, with soap, potable water and disposable handdrying towels, are provided. Workers are observed to be washing their hands after using toilets. There are signs, in the appropriate language(s), reminding workers to wash their hands after using the toilet. Gray water is captured and disposed of away from the harvest/packing/processing area. Toilets are cleaned and sanitized daily or sufficiently often to be maintained in a clean and sanitary condition. Ready Fresh Fresh-Cut Facility Audit Page 6 of 16 (C) Davis Fresh Technologies, LLC.

7 158 s 161 s If portable hand wash water tanks are used, they are cleaned and sanitized, and the water is changed periodically. (Show documentation). A responsible individual with a checklist inspects toilet facilities daily for cleanliness and adequate supplies. (Provide documentation) Toilet Facilities Section Total B. First Aid Policies 164 s There is a first aid kit available, containing at least bandages and antiseptic cream 168* s 172 s 175 s There is a written company policy addressing procedures for handling bleeding incidents. There is a written company policy specifying that all product eposed to blood is destroyed. There is a written company policy that all equipment eposed to blood is thoroughly cleaned and sanitized before reuse. First Aid Policies Section Total C. Educational Sessions 179* e Employees are trained in food handling and food safety * e 187 s 190 s Employees are trained in personal hygiene. Food handling and personal hygiene training sessions are documented and signatures of employees in attendance at each session obtained. Supervisors are trained to recognize and look for symptoms of food borne disease (see documentation). Educational Sessions Section Total Ready Fresh Fresh-Cut Facility Audit Page 7 of 16 (C) Davis Fresh Technologies, LLC.

8 D. Habits and Conditions 195* s There is a written company policy that food and tobacco products are prohibited from areas of food handling. 196 s There is a written company policy that supervisors are instructed to ensure that employees handling produce do not have open or eposed sores or lesions on their hands 197* s 198* s 202 s 203 s 205 s 206 s 207 s 208 s 209* s 210 s 211 s There is a written company policy that employees with sores, cuts, boils, lesions, etc. on their hands have the areas covered with first aid materials and use gloves when working with raw product There is a written company policy that employees who show signs of illness are not permitted to perform job duties where they will come in direct contact with raw product Workers at food contact surfaces wear clean outer garments There is an established program for cleaning outer garments Workers remove outer garments when they leave the work area There are designated areas to hang outer garments when they are not being worn Gloves are clean and they are replaced or sanitized before each use (if applicable). Gloves are in good repair; free of holes and tears (if applicable) It is written company policy that food contact workers not wear jewelry or other loose items Workers were observed to be following the policy against wearing jewelry or other loose items Personal items are not stored in work areas Ready Fresh Fresh-Cut Facility Audit Page 8 of 16 (C) Davis Fresh Technologies, LLC.

9 212 s 213 s There are designated employee rest and eating areas Employee rest and eating areas are physically separated from food handling areas Habits and Conditions Section Total V. Plant and Equipment A. Facility Design and Equipment 300* s There are written cleaning and sanitation procedures for all food contact surfaces (SSOPs) 302 s 304 s 305 s 310 s 311 s 315 s 330 s 335 s 336* s Belts, tables, packing lines, flumes and/or conveyors are clean There are written cleaning and sanitation procedures for belts, tables, packing lines, flumes and/or conveyors. There is a written cleaning and sanitation schedule for belts, tables, packing lines, flumes and/or conveyors. All food contact surfaces made of nonporous materials All food contact surfaces are free of rust or corrosion The seams between food contact surfaces are smooth or accessible for cleaning Floors, walls, drains, and ceiling are made of materials that can be cleaned and sanitized There is a written cleaning and sanitation schedule for floors, drains, walls, and ceilings. There are written procedures for cleaning and sanitizing floors, drains, walls and ceilings 340 s Storage rooms and other areas are Some areas in packaging clean and sanitary room could be cleaned better Ready Fresh Fresh-Cut Facility Audit Page 9 of 16 (C) Davis Fresh Technologies, LLC.

10 342* s 344 s 348 s 353 s 354 s 355 s 360 s 365 c There are written cleaning and sanitation procedures for all storage rooms and storage areas There is a written sanitation schedule for all storage rooms and storage areas There is a cleaning and sanitation log for storage rooms and areas Lights have shatterproof bulbs or covers in all areas where food or packaging are handled or held. Where workers walk over product contact surfaces, those surfaces are protected by kick plates or other barriers Glass items are ecluded from packing or processing areas. Motors in food handling areas have drip pans under them The clean water and waste water systems are physically separated 368 e Finished products are physically Mostly. separated from raw and in-process product Facility Design and Sanitation Section Total B. Tools and Finished Product Containers 370 s Finished product containers and tools are color coded e 380 s 378 s 382 s 384 s Finished product containers are cleaned and sanitized periodically There is a written schedule for cleaning and sanitizing finished product containers There are written cleaning and sanitizing procedures for finished product containers Product contact tools are made of stainless steel or other cleanable material Product contact tools are clean and sanitary Ready Fresh Fresh-Cut Facility Audit Page 10 of 16 (C) Davis Fresh Technologies, LLC.

11 385 s There is a schedule for cleaning and Suggested daily sanitizer sanitizing product contact tools dip. 388 s There are written cleaning and sanitizing procedures for product contact tools 390* e All compounds used to clean finished Ecolab. product containers, food contact surfaces or tools are approved for that use by the US EPA, FDA or other appropriate agency 391 s All tools, utensils, containers and knives are stored in a place that protects them from contamination. Tools and Finished Product Containers Section Total VI. Pest Control 358 s There is a 10 foot (3 meter) wide clear area surrounding the facility to deter rodent infestation. 400 e 405 s 408* e 410 s 413 s 416 s 419 s 424 e There is no evidence of pest populations (birds, rodents, insects). Potential nesting or hiding places for pests have been eliminated and/or cleaned. Facility areas have a written and documented pest control program Non-bait traps are placed every feet inside the facility and within 10 feet of all doors. There is a map of the location of all traps There is sufficient space to inspect the traps There is a current pest control log with records of when the traps are checked Packaging material storage areas are included in the pest control program Ready Fresh Fresh-Cut Facility Audit Page 11 of 16 (C) Davis Fresh Technologies, LLC.

12 426 s 428 s Bug zappers are not placed near or above food handling areas, an are at least 30 feet away from these areas There are no bait stations inside the facility Pest Control Section Total VII. Cooling System and Facility A. General Sanitation 450 s A master cleaning and sanitizing schedule (MCS) for the facility is in place for daily, weekly, monthly and seasonal/yearly cleaning and maintenance tasks, including floors, walls and ceilings; dump areas and containers; food contact surfaces, packing lines and tables; coolers, evaporators and drip pans; drains, overhead pipes and reservoirs; equipment and tools; tunnels and dock areas; employee break areas and rest rooms, among others. 430 s 453 e Walls, floors and tunnels are cleaned and sanitized according to a documented schedule and procedures. Evaporators, cooling coils, drip pans, drains, drain lines and reservoirs are cleaned and sanitized on a scheduled basis. (Provide documentation) 455* s 458 s 461 e 464 s Written sanitizing procedures (SSOPs) have been developed for all areas of the facility A written cleaning crew checklist is current for the facility. Water from refrigeration drip pans is drained and disposed on away from food holding and preparation areas There is no evidence of dirt, mold or slime formation on the cases, cages, fans or drain pans. General Sanitation Section Total Ready Fresh Fresh-Cut Facility Audit Page 12 of 16 (C) Davis Fresh Technologies, LLC.

13 B. Maintenance and Documentation 353 s Lights have shatterproof bulbs or covers in all areas where food or packaging are handled or held. 470 s There is a cold room temperature log 472 s Temperature logs show that the proper temperature is being maintained (Note air F/ C and product F/ C) 475 s Storage racks are free of rust or other Some older racks had some contamination rust Maintenance and Documentation Section Total VIII. Facility Supplies and Equipment 480 s Cleaning equipment and tools are clean, in working order and stored properly away from food handling areas. 483 e 485 m 487 s 228 e 493 s 498 s 499 s All chemicals, waes, cleaning compounds and solvents are stored in a locked cabinet MSDSs are on file for all materials used in the facility A log or inventory of chemicals, pesticides or sanitation materials is available for review Packaging materials are stored covered and off the floor. Goods in all storage and holding areas are kept off the ground and at least 18 inches from walls to allow cleaning and inspection for pest activity Tectrol areas, load docks, blocks and shipping materials are stored and used in a way that prevents contamination. Non-product items are not stored in the cooler (e.g. fish, employee lunches, meat, drinks etc.) Ready Fresh Fresh-Cut Facility Audit Page 13 of 16 (C) Davis Fresh Technologies, LLC.

14 500* s There is a written company policy that all waes, coatings and chemicals applied to product are approved by the US EPA for their designated use and used according to the label instructions. Facility Supplies and Equipment Section Total IX. Control of Allergens 525 e Known allergens, such as tree nuts, Sufiltes are used on peanuts, eggs, wheat (hydrolyzed potatoes. This is a CCP. protein or gluten), soy (isolate or hydrolyzed protein), dairy products, shellfish and/or sulfites are not used or stored in the facility with nonallergen products. 528 s 530 s If known allergens are used, products containing them are labeled as such. If allergens are used or stored, there are written procedures for cleaning and sanitizing all allergen contact surfaces prior to handling products not labeled as containing those allergens. Control of Allergens Section Total X. Trace Product Recall 549* e A product coding system is in place, Julian date on each bag and where product or raw material is each case. coded with date of harvest and/or packing, origin (name of farm/ranch, grower, and/or packing/processor) and location, for trace back purposes 550* s There is a trace product recall system 552* m 553 m A recall action team has been designated. A product complaint log is maintained Ready Fresh Fresh-Cut Facility Audit Page 14 of 16 (C) Davis Fresh Technologies, LLC.

15 565* m 570* m 575* s The recall policy provides a description of the type of public notice and who will be responsible to speak to media if necessary. There is a customer confirmation letter that would be sent to customers in the event of a recall There is a plan for product recovery and disposition in the event of a recall m A flow chart of the recall process has been prepared 585 s A successful mock recall test has Every si months. been performed in the last 12 months Trace Product Recall Section Total XI. Food Security (non scored) YES NO N/A # C Q. 952 s Facility boundaries and restricted areas have been clearly identified as to which access is limited or controlled (i.e. by guards, access cards, fences, etc) 950 s The management has done a general Installed video cameras and security assessment of the operation, sliding gates. facility processes and machinery; identifying possible intentional contamination risks, policies and procedures addressing those potential risks, and assigning clear responsibilities to identifiable individuals. 962 s There is a descriptive plan that identifies all areas where products and ingredients are handled and stored (e.g. off-site warehouses, product chillers, controlled atmosphere storage facilities, etc). 970 s There are programs in place that Fire evacuation plan. identify procedures to follow in the event that intentional contamination involving potential infectious or toic compounds occurs within the facility. The program includes all products and ingredients involved, as well as employees and affected areas. Ready Fresh Fresh-Cut Facility Audit Page 15 of 16 (C) Davis Fresh Technologies, LLC.

16 974 s Incoming transport/delivery vehicles are controlled and inspected Receving log identified and inspects. (evidence of possible load tampering or product contamination) prior to entering the facility 980 s 983 s Incoming truck drivers, visitors, Visitors yes, driver no. contractors or deliverers are required to be registered and ID prior to entering the facility 986 s 990 s 995 s 951 s 979 s Incoming ingredients, supplies, and shipping containers are inspected and identified by approved suppliers. Tamper-evident packaging features are used and inspected when appropriate. There are controls in place to restrict access of unauthorized personnel to areas where large amount of product is eposed (holding areas, coolers, CA rooms, etc) The facility follows a prescribed procedure for identifying potential employees and for screening applicants New-employee orientation programs include emergency and security procedures for dealing with various situations (evacuation routes, bomb threats, chemical spills, reporting abnormal situations, product tampering, etc.). Documented evidence of at least annual performance reviews of the Food Security Program or Operational Risk Management process, involving management and employees, are in place. The facility maintains a list of current approved suppliers, with respective contact information Food Security Section Total N/S N/S 0 Ready Fresh Fresh-Cut Facility Audit Page 16 of 16 (C) Davis Fresh Technologies, LLC.