windward.hawaii.edu Proc Manual... · Web viewThis manual is to be used for tree nuts that may be consumed raw. Tree nuts, such as macadamia nuts, are defined as allergens by the

Your Farm’s Name

AddressCity, Hawaii Zip

Good Manufacturing PracticesFood Safety Plan

Prepared Month, Day Year

Approved month, day, year by name, title

This food safety plan is based upon the United Fresh Produce Association Harmonized Post-harvest Standards and the FDA Proposed Preventive Controls Rule.

It is oriented to Hawaii producers.1

This manual is to be used for tree nuts that may be consumed raw. Tree nuts, such as macadamia nuts, are defined as allergens by the FDA and thus require specific techniques. Tree nuts have also been implicated in foodborne illness occurrences as they may be contaminated with Salmonella sp. bacteria. The FDA is currently reviewing tree nut food safety based upon the potential for contamination.

If your tree nuts or another grower’s tree nuts are treated in some manner in your facility and/or roasted in your facility, you will need a different GMP manual. At present, there are no regulations that dictate specific requirements for growing, handling and processing macadamia nuts.

Text appearing in red gives directions or provides information. The red text should not be present in your manual. The black text is what should be present in your manual. Remember that you will probably need to change the black text in some cases to fit your specific operation.

1. General Requirements1.1. Management ResponsibilityFood Safety Policy: Facility Name is committed to producing safe products through good manufacturing and good handling practices that focus on food safety and quality. We strive to prevent microbial contamination of produce so that it is not necessary to take corrective action after a product has left our facility. We communicate this policy to our workers during training sessions and continually reinforce it during processing activities.

Disciplinary Policy: If a worker does not follow acceptable sanitary practices, he/she is verbally corrected and retrained if needed. If we see repeated lapses in good sanitary and hygienic practices from any farm worker we will move them to a part of the operation that does not involve handling the produce or they will be dismissed.

Food Safety Program Responsibility: The program described within this Food Safety Plan is the responsibility of Facility Owner Name who acts as the Food Safety Officer. He or she can be contacted at address, telephone number, email address. If this person is not available, contact Alternate Person at address, telephone number, email address.

Facility Name processes the crops listed below. Describe to whom you sell your crops (distributer, restaurant, farmers market, etc.) and how you transport them. Describe who works in the facility and if you hire any workers. Describe what work is performed by all workers (including family members, free labor, paid labor). State what animals (if any; include pets) you have on the property, how many and where they are located. For example, do you have goats, sheep, cows or similar? Are they in a location adjacent to the facility?

Crops Processed.

Crop Approximate Yearly Volume (this information is optional)Name Tons

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Name Tons

1.2. The Food Safety PlanThis food safety plan identifies all products and the materials used to process them. The plan describes physical, chemical, biological and radiological hazards that could occur and procedures for controlling them, including monitoring, verification and recordkeeping. Areas of concern include water, chemicals, cleaning and sanitation, processing environment, security and worker practices. Our plan includes policies and procedures regarding how we keep our products safe, and records that show we are following our plan. This food safety plan is reviewed and revised, if necessary, at least once every year.

1.3. Raw MaterialsMaterials and services are sourced from suppliers who are approved and subsequently monitored. Supplier materials and/or services specifications are utilized to develop initial approval requirements, and post approval monitoring requirements. An emergency approval system exists for addressing situations wherein materials and/or services are in short supply. An approved supplier list is maintained on file.

Written specifications are provided to the supplier. The supplier provides written documentation verifying that the raw material meets the specifications (Letter of Guarantee, Certificate of Analysis or similar). The supplier is placed on the approved supplier list if they can supply at least three consecutive loads that meet inspection criteria. Each shipment of raw material is inspected and if a load fails the inspection, the load is rejected and the supplier is warned that further non-compliance will result in removal from the approved supplier list. In the event that approved suppliers cannot supply the needed materials, an emergency supplier is used. The emergency supplier must submit a Letter of Guarantee or similar documents showing that the material meets specifications. Emergency suppliers are not added to the approved supplier list until they have shown that they can consistently meet specifications.

The food products processed may be consumed by the general public. However, persons having known food allergies to the listed products should avoid consumption.

1.4. Documentation and Record KeepingWritten records of all food safety activities are maintained on file. Our records include such items as this plan, maps, and forms. We keep all of our current records in binders (state other place if used; may be kept directly in a file cabinet) which are kept state where they are located. Previous records are filed in a cabinet so they are available for inspection. Our records begin in insert date, the first year we initiated our food safety plan. Records are reviewed and verified by the Food Safety Officer on at least a weekly cycle. Records related to food safety are kept for at least two years.

If your operation is classed as a “qualified facility” (fewer requirements), you still must submit certain documents to the FDA under the Proposed Preventive Controls Rule (section 117.201) when the rule becomes final in the future.

1.5. Worker Education and Training

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All workers receive training at hire and routinely thereafter. Training information is provided by various universities such as University of Hawaii, University of California, Cornell University and Penn State University. Training may also be provided by industry groups and qualified individuals. Topics include, but are not limited to, food safety policies and procedures, personal health and hygiene, health condition symptoms, product contamination and job-specific functions. Training is provided by insert name of qualified training person. Visitors and contractors must adhere to the same standards as employees.

Training activities are recorded on the training record and kept for at least two years.

1.6. TraceabilityEach product container is labeled with the following information.

Farm name and addressTracing code (crop location, crop name and type, and harvest date)

You may also want to place a code that signifies the harvest crew involved with the crop. Insert the code you use here and describe each part of the code. For example, the code might be 2014-08-11 01-03 HC1 in which 2014-08-11 is the harvest date, 01-03 is field 1 part 3, and HC1 is Harvest Crew 1. You can also use a “Julian Date” which is based upon the day of the year. For example, January 1 2014 would be 14001. December 31 2014 would be 14365.

When the product is sold, the invoice or other shipping document such as a Bill of Lading includes information on boxes shipped, to whom, the date of shipment, and the tracing code. If a product is comingled during or after harvest, the above label information for each crop is recorded for our files and also provided to the buyer. Copies of all invoices and other shipping documents are kept so that tracing can be performed adequately and efficiently.

At least once per year, a mock traceability/recall exercise is performed. This exercise tests our ability to determine how and where a certain product was grown, when it was harvested, how it was handled and to whom it was sold. Contact information for each customer is retained on file. The amount harvested must equal the amount sold to customers, minus any discarded product. The goal is to have this information ready for presentation within four hours.

1.7. Recall ProgramThe responsibility for conducting a recall is assigned to the Food Safety Officer, insert the name of the facility owner or other qualified employee assigned this duty. If a recall is determined to be needed, the Food Safety Officer contacts the buyers of the affected products. The tracing codes of the products are provided and the buyer is requested to place the product on hold so it is not sold or further distributed. The affected product may be destroyed or returned to the farm, depending upon the circumstances of the recall. The Food Safety Officer also contacts the FDA, the State Department of Agriculture and initiates a press release. The Food Safety Officer may also need to contact the attorney for the processing operation.

1.8. Corrective ActionsIf a food safety risk is discovered, corrective actions are taken to solve the problem. We document the problem, what actions taken to correct it, the party responsible for correcting the problem, and what if any

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improvements in our practices were needed to prevent future problems. Situations are re-analyzed routinely to assure compliance.

1.9. Self-auditsAn internal self-audit is completed at least annually. All aspects of the operations food safety plan are reviewed and we record any corrective actions that may have been needed. The United Fresh Produce Association Harmonized Good Agricultural Standards audit form (Post-harvest Operations) is utilized for this exercise.

1.10. ChemicalsAll agricultural chemicals (pesticides, fertilizers, sanitizers, etc.) used on the farm comply with label directions and state and federal regulations. Chemicals are stored in locked locations in closed and properly labeled containers. Application locations, dates, restricted entry hours, product, formulation, active ingredients, rates, size of area treated, quantity, type of pest, weather conditions, method of application, and name of applicator are documented.

Agricultural chemicals are applied by trained and licensed (where required) application personnel. Water used with agricultural chemicals is consistent with our water system risk assessment and water management plan. The disposal of chemicals is conducted in accordance with federal, state and local regulations.

1.11. WaterWater used for product washing, food contact surface washing, hand washing, processing and for drinking is sourced and tested as described below. If you do not wash your product or use water in processing, omit those phrases. All water must have non-detectable levels of generic Escherichia coli (E. coli) per 100 ml test sample. In addition, water used for drinking must meet the other requirements as specified by the EPA and the Safe Drinking Water Act. Testing is performed by using commercially available testing kits (see Appendix A) that meet the requirements of the Association of Official Analytical Chemists or the American Public Health Association or the FDA Bacteriological Analytical Manual. Testing may also be performed by an appropriate state licensed laboratory (insert name of laboratory). You may need to purchase drinking water to meet this standard.

You now need to select the source of your water from the information below. If you have multiple sources of water, you will need to use the text for each water source. Change the black text as required in order to describe your situation.

If you use untreated water from surface source such as a stream, river or open reservoir, use the following text. Water that comes from the river and the reservoir on our property is untreated and is tested every seven days during the growing season.

If you use untreated water from a well and the water is stored in a reservoir that is protected from runoff, use the following text. Water that comes from our well is stored in our untreated reservoir (protected against runoff water). The water is tested monthly during the growing season.

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If you use water from an untreated well, use the following text. Water from our untreated well is tested every three months during the growing season.

If you use water from a source on your property and you treat the water according to the FDA Proposed Produce Rule, use this text. Water from our insert source type is treated according to section 112.43 of the FDA Proposed Produce Rule. Describe your treatment process in detail here. Water treatment procedures are monitored routinely to ensure the water is safe for its intended use (Section 5).

If you use water supplied by a municipal drinking water system, use this text. All water used on our operation is supplied by insert the name of the supplier which is a public drinking water supplier that meets the requirements of the Safe Drinking Water Act regulations. A copy of the most recent published results as provided by the supplier is kept on file.

The water distribution system is designed to prevent cross-connections and is of sufficient capacity to handle peak operational flows. Backflow prevention devices are present, and are inspected yearly.

If you use water to wash your product and the water is NOT recirculated (single use water), use the following text. Product received in the processing facility is washed using single use water only. The water meets the specification of no detectable E. coli as described previously. Any water pooling on the floor areas is removed at least daily.

If you use water with a sanitizer to wash and sanitize your product and the water is NOT recirculated, use the following text. Product received in the processing facility is washed using single use water combined with the sanitizer insert sanitizer name. The sanitizer is maintained at the concentration of insert concentration rate. The concentration is monitored using insert test method. Note: Some methods use an ORP monitoring system. If you use that system, insert the appropriate information. The water meets the specification of no detectable E. coli as described previously. Any water pooling on the floor areas is removed at least daily.

If you use water to wash your crop and the water is recycled, you normally need to use a sanitizing agent to ensure the water is not a source of crop contamination. The water plus sanitizer also aids in sanitizing your crop. Use the following text. Product received in the processing facility is washed using recirculated water combined with the sanitizer insert sanitizer name. The sanitizer is maintained at the concentration of insert concentration rate. The concentration is monitored using insert test method. Note: Some methods use an ORP monitoring system. If you use that system, insert the appropriate information. The recirculated water is changed every insert time period. The water meets the specification of no detectable E. coli as described previously. Any water pooling on the floor areas is removed at least daily.

If you do not wash your crop and do not field pack, use this text. Product received at the processing facility is not washed. It is placed in clean uncontaminated shipping containers for sale to customers.

1.12. Containers and Bins

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All containers and bins are stored off the ground, and covered during storage to protect them from contamination. All re-useable containers that come in direct contact with the crop are inspected, cleaned and sanitized. Generally, the procedure involves flushing the container with water, washing with soap and water if needed, and rinsing with a water and sanitizer (insert sanitizer name here) mix. Some sanitizers require another rinse step – check the label. Containers are allowed to air dry before use.

The product is packed in new cardboard boxes for shipment. All packing materials are appropriate for the product and are stored off the ground and covered to prevent contamination. Further, they are inspected prior to use. Boxes are not permitted to contact the ground or floor at any time. If you use different packaging materials for shipment, describe those materials.

Workers are trained that containers and shipping boxes are never to be used for carrying or storing anything other than the designated crop.

1.13. Facility, Equipment and ToolsThe facility is designed to promote efficiency while avoiding product contamination. Insert a detailed description of the construction of the facility buildings including the packing area. Most facilities will have been built under a building permit which requires that certain basic requirements such as restrooms, lighting and ventilation be met. A flow diagram is present that shows how the product progresses through the facility.

Preventive Maintenance is performed based upon the manufacturer’s recommendations. Repair Maintenance is performed as needed. A Master Cleaning and Sanitizing Schedule is used to ensure that facility and processing related items are not a source of product contamination. Water used for cleaning and sanitizing meets the standards described earlier. Sanitizers are labeled and approved for use on food contact surfaces. Don’t use household bleach as most products are not labeled for use in a food processing facility.

Insert a description of your sanitary standard operating procedure (SSOP) for cleaning and sanitizing your equipment. If you have several types of equipment (hand tools, containers, tanks, pallets, roasting equipment, CIPs, etc.), you will need to write a detailed SSOP for each type. Be sure you state that surfaces are allowed to air dry prior to use.

1.14. StorageProduct is stored in boxes (change the text to reflect your method of product storage) placed on pallets or shelves in designated areas. Pallets and shelves are inspected, cleaned and sanitized according to the established schedule. Product stored in open boxes or containers must be covered to prevent contamination. These areas are kept clean and sanitary. Some product may be stored in refrigerated rooms to maintain product quality. Where possible, at least 12 inch space is maintained between rows of product, and between rows of product and walls to allow for cleaning and inspection.

Chemicals are stored in a labeled and locked area away from any food product. Food use lubricants are stored separately from other chemicals.

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Packing materials are stored in an assigned area that is covered to protect the items. Materials are stored off the ground on pallets and shelves.

1.15. WasteWaste materials such as trash, leaves, culls and similar items are removed from the product handling areas at least once per day. Waste containers are covered, and are emptied, cleaned and sanitized per the established schedule.

1.16. Exterior AreasExterior areas are maintained to prevent the growth of weeds and the accumulation of trash that can be a source of pest harborage and food contamination. Equipment is stored off the ground, where possible, and away from the building.

1.17. Glass and Brittle Plastic ControlOnly essential glass and plastic items are permitted in the facility. Glass items are covered with shields or protective films to contain breakage. Glass and brittle items are listed on register, and are inspected routinely.

1.18. LubricantsOnly food-grade lubricants are used on food processing and packing equipment, and on equipment that can contact the food product. Equipment leaks are repaired immediately. Leaks that cannot be prevented are contained by using drip pans.

1.19. Equipment and Tool ConstructionFood contact equipment and tools are designed for the intended use, and are constructed of food-grade materials that are easily cleaned and sanitized. Equipment is installed in a manner that allows for adequate access for cleaning and sanitation.

1.20. Temporary RepairsAny temporary repairs of food contact equipment make use of food-grade materials. Temporary repairs are replaced by permanent repairs in a timely fashion, usually within three working days.

1.21. Worker Health/Hygiene and Sanitary FacilitiesAdequate approved toilet and hand washing facilities are provided to employees and visitors as stipulated by federal, state and local regulations. The facilities are located away from food product handling areas.

The facilities are cleaned and maintained according to the established schedule. They are supplied with soap dispensers, single-use paper towel dispensers, towel disposal containers and hand washing water that meets the microbial standard previously stated. Signs stating the requirement to wash hands are posted in a language understood by the workers.

Worker training includes instructions on how to wash hands. Workers must wash their hands prior to beginning work, before donning gloves, after any use of the toilet, after any break period, after using a

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handkerchief or tissue, after sneezing or touching the face, after handling a contaminated material, after smoking, after eating or drinking, and any other time contamination could have occurred. Workers are observed to ensure they are using proper sanitary practices.

A designated area for the storage of protective clothing and work tools is provided. Workers store these items in the labeled areas during breaks, prior to using toilets and after work shifts.

Workers with diarrhea, who are vomiting, have a sore throat with fever or show other signs of illness are not allowed to handle food product. Workers must report such instances to their supervisor so they can be sent home or assigned to non-produce handling areas. Workers are trained to consider any cut or sore to be a source of contamination for another person or a food product. Injuries are reported to the supervisor or food safety officer. Minor injuries are treated using the provided first aid kit supplies, including a bandage. Bandaged injuries to a hand require that a glove be worn. Any other bandaged injuries require the worker to be reassigned to a non-food handling area or to be sent home.

Workers are required to start their work day in clean clothing. If clothes are visibly soiled, workers are required to change into clean clothes before starting work. Open toed shoes are not permitted. Workers are permitted to wear gloves if desired, but the gloves must be clean at the beginning of the day and must be changed when they are soiled to the point where the possibility of contamination exists. Gloves are required when there is a bandaged injury to the hand. Workers are permitted but not required to wear hats, caps, or aprons. However, such items must be clean so that contamination is not a concern. Employees cannot wear jewelry (including piercings), watches, pens or other items in pockets above waist or other items when working with produce. Plain wedding bands can be worn if they fit snugly. Employees are not permitted to bring personal items into the food handling and processing areas. Personal items must be stored in the designated worker break area away from food related activities.

Smoking, chewing gum, eating, and drinking are only allowed in areas we have designated for breaks. Spitting, urinating or defecating is only allowed in the toilet facilities provided. Eating is allowed only in the designated break area. Unbreakable capped or re-sealable plastic water bottles are allowed in the fields. Drinking water meeting Federal EPA standards is provided, along with single-use disposable cups. Drinking from a shared container is not permitted.

Health and hygiene policies also apply to anyone else who enters crop production areas including employees, contractors, visitors, buyers, inspectors, and auditors. Records are kept of all activities.

1.22. Temperature ControlSome crops may be stored in a refrigerated unit to maintain product quality to ensure the food is suitable for consumption. The unit is kept in a clean and sanitary manner. The temperature of the refrigerated unit is monitored at least twice daily. The desired temperature is insert number degrees F, plus or minus 2 degrees (or whatever range is applicable to your crop). Thermometers are calibrated approximately every three months using a NIST reference thermometer.

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If you do not refrigerate your crop, omit the above text and use the following. Food products are stored at ambient temperatures and no refrigeration is used.

1.23. Packing Materials SpecificationsSpecifications for packing materials are kept on file. Appropriate cardboard boxes, plastic containers and plastic bags are utilized. Products are labeled as required by federal and state regulations.

1.24. Pest and Animal ControlPest monitoring activities are conducted on a regular basis. Employees are trained to observe for pests and evidence of pests. These observations are reported to the Food Safety Officer (FSO) who ensures the situation is evaluated and corrective actions are completed. Non-toxic traps are located along the outermost walls, both on the interior and exterior. Traps are checked routinely. Evidence of pest activity is reported to the FSO for action. Trap locations and identification numbers are designated on the pest trap map kept on file.

Domestic animals, including pets, are not permitted in or around the food processing and food storage facility. Wild or feral animals are restricted from entry by the presence of fences and enclosures.

1.25. Sampling and TestingRoutine water testing is performed as described in Section 1.11.

Routine tests are performed to ensure that water and sanitizer solutions are appropriate. This testing includes solutions that contact both the food product and food-contact surfaces.

2. Packinghouse2.1. Processing ActivitiesThe incoming commodity is inspected to remove debris and damaged food product. Trash or waste products are discarded at the end of the day and disposed of properly so they do not contact the crop. The washing procedure has been evaluated, and was described previously. Damaged product and other debris are routinely removed from the washing dump tank, and disposed of properly. Product to be re-worked is stored in containers labeled for such activity. The shelling and drying of nuts you have produced on your farm are not considered to be a change to the raw nut, and thus the raw nut is not classified as a processed food. If you roast your nuts on your property, the roasting procedure changes the nuts to a processed food. Roasting requires the preparation of a HACCP plan in most cases.

In that the nuts are usually harvested from the ground, the shelling procedure may expose the edible portion (and food contact equipment) to bacterial contamination. Without a treatment process, the nuts can pose a health risk. In your risk assessment and analysis, you must be able to show how you minimize the risk of nut contamination to an acceptable level. The bacteria Salmonella is of great concern for contamination. What step or steps do you use to assure that your raw nuts are not contaminated? This process may involve the preparation of a HACCP plan, which is beyond the scope of this document as it is very site specific.

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Water used for washing meets the microbial standards described previously. Only sanitizers approved for use on the food product are used. Sanitizer concentrations and related parameters are monitored regularly. Insert text that describes in detail how the sanitizer concentration is monitored.

All instruments are calibrated on a routine basis. Insert text that describes in detail how calibration procedures are done. Instruments can be items such as thermometers, scales, pH meters, etc.

Tree nuts are considered to be allergens. The handling line and associated activities, including product storage, are confined only to the nuts that have been harvested. No other crops are handled or stored in areas wherein nuts are present. Similarly, tools and equipment are only used for handling nuts. Allergens are considered to be potential chemical hazards. If you handle other crops, you must have a detailed plan to segregate the crops for harvesting, handling and storage. This situation requires procedures to clean and sanitize all tools and equipment to ensure cross contamination does not occur. Usually, testing for the presence of allergens on the food contact surfaces is performed. These procedures are beyond the scope of this manual as they are specific to the operation.

Remove any of the text related to washing if you do not wash any product, but keep the first two sentences regarding debris and damaged product removal, and disposal.

3. Transportation3.1. Temperature ControlSome food products may be shipped in refrigerated vehicles to maintain food quality that ensures the food is suitable for consumption. The proper temperatures for pre-cooling and transport are listed below.

Crop Pre-cooling Temperature (F) Transport Temperature (F)Insert name Insert temperature Insert temperature

Temperatures are monitored routinely to ensure compliance; temperatures must be within plus or minus 2 degrees F (or whatever range is applicable to your crop). Thermometers are calibrated approximately every three months using a NIST reference thermometer.

If you do not use refrigerated vehicles, use the following text. Products are shipped at ambient temperatures and no refrigeration is required.

3.2. Equipment Sanitation and MaintenanceTrucks are inspected for cleanliness prior to loading with product. Trucks must only be used to carry produce, and the driver must present evidence of proper cleaning.

Personnel responsible for the loading and unloading of produce are trained to avoid damaging produce or packaging materials to preclude contamination. All equipment is maintained, cleaned and sanitized to prevent contamination.

4. Security11

The food crop must be protected to the extent possible. The facility is surrounded by fences and locked gates where feasible. Entry is restricted only to those persons who have been issued a key or code. Emergency contact information is posted.

5. Forms and RecordsForms and records (logs) used to record activities are attached. These forms and records are an integral part of this manual. Note that some forms and records may not be needed for your operation. The documents are in alphabetical order. Please place them in an order that functions for your operation.

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Access Key/Code RecordInsert Farm Name

Date of Issuance

Name of Person Issued Key/Code

Key/Code Type(describe access or equipment)

Date of Return

Reviewed By:

_________________________ ____________________________ Date __________________Name Signature

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Verified By:


Customer Contact ListInsert Farm Name

Customer Name Contact Name/Title Address Telephone & email

Reviewed By:


Verified By:

_________________________ ____________________________ Date __________________14

Name Signature

Employee Non-compliance RecordInsert Farm Name

This farming operation has a ‘zero tolerance’ policy for actions that result in an immediate food safety risk. ‘Zero tolerance’ means an employee found to be in violation of a policy or procedure that results in an immediate food safety risk will be terminated. An immediate food safety risk is one wherein the crop is actually and instantly contaminated (urinating, defecating, spitting, introducing foreign objects, working with open wounds, etc.). Other infractions will result in appropriate warnings and disciplinary action.

Date: _______________ Employee Name: _________________________________________ Supervisor: _____________________________________

Describe violation: _______________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Action Taken By Supervisor: _______________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________ Date: __________________________Supervisor Signature

Employee understands the significance of the violation and action taken.

_______________________________________ Date: __________________________Employee Signature

Reviewed By:


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Verified By:


Equipment/Tool/Work Area Cleaning and Sanitation RecordInsert Farm Name

Date Equipment/Tool/Work Area Name

Cleaned Sanitized Sanitizer Name Sanitizer Rate

Completed By(name)

Yes No Yes No

Corrective Actions Corrected By(name)

Date

Reviewed By:


Verified By:

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Equipment/Tool Maintenance RecordInsert Farm Name

Date: ________________ Reported By: ________________________________

Describe routine maintenance or repair needed: ________________________________________________

_______________________________________________________________________________________

Actions taken: ___________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Date completed: _________________ Completed By: ______________________________________

Equipment cleaned and sanitized after maintenance? Yes No

Comments: _____________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Reviewed By:


Verified By:

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Food Safety System ReviewInsert Farm Name

Meeting Topics

Concerns Found

Actions Completed

Reviewed By:


Verified By:


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Food Security InspectionInsert Farm Name

Page 1 of 2

A = acceptable, U = unacceptable

Inspected By Date Comments Status Corrective Action Corrected By Correction Reviewed By Date Status

A U Date Time A UManagementResponsibilities assignedEmployees trained at hire & at least annually afterBreach report formContact info postedNotification ProceduresMedia interfaceAdequate # of supervisorsTrace/Recall proceduresInspections ConductedAnnual review

EmployeesBackground checkSupervisor awarenessID badgesRestricted accessLocks replacedPersonal items restrictedPersonal Items storageHealth ConditionsTraining evaluated

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Food Security InspectionInsert Farm Name

Page 2 of 2

Inspected By Time Comments Status Corrective Action Corrected By Correction Reviewed By Date Status

A U Date Time A UVisitors

Restricted accessAnnounced

Badge/signing usePolicies enforcedRestricted on-site

FacilityPerimeter securityAlarms operational

Doors & locksVehicles lockedLoading secure

Chemical disposalChemical security

Chemical inventoryChemical access

restrictedRestricted key access

Utilities secure

Verified By:


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Glass/Brittle Plastic/Ceramic RegisterInsert Facility Name

Update this Register Monthly

Date Location ItemRecorded By

(name)

Reviewed By:


Verified By:


Master Cleaning and Sanitation Schedule22

Insert Facility Name(This schedule is only an example. Prepare one for your facility)

Location and Task Description Daily Weekly Monthly Every 6 Months

Facility in General

Clean ceilings (including air vents, lights, and pipes)

X

Clean and sanitize interior walls and doors X

Clean and sanitize restroom walls and doors X

Clean and sanitize restroom toilets, sinks, dispensers, handicap bars, door handles

X

Clean and sanitize sinks, counters, storage areas in break/lunch room

X

Clean pipes (exterior) X

Clean exterior walls and doors X

Door handles (except restroom) X

Floors (clean and sanitize) X

Drains X

Remove trash and garbage(interior receptacles)

X

Remove trash and garbage(exterior receptacles)

X

Clean stored pallets (not in use) X

Receiving

Conveyor X

Washing, Rinsing, Grading, Packing

Remove debris on or around equipment X

Clean and sanitize equipment and tools X

Clean (sanitize if possible) pallets in use X

Storage (refrigerated)

Disassemble and clean cooling coils as needed. Drain and clean pans under coils per manufacturer's instructions.

X

Notice of Unusual Occurrence and Corrective Action Document (NUOCA)

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Insert Farm Name

This form is used for unusual incidents wherein a specific corrective actions form does not exist.

Date Description of Occurrence Reported By

Corrective Action (CA)CA

Completed By

Date CA Completed

Reviewed By:

_________________________ ____________________________ __________________Name Signature Date

Verified By:

_________________________ ____________________________ __________________Name Signature

Packing Materials Inspection Record24

Insert Facility Name

Date Time ItemSupplierName

VehicleID

CommodityAcceptable*

(Yes/No)

AcceptedBy

(name)

*=materials must meet all desired specifications and not be contaminated. If material is not acceptable, enter corrective action below.


Date

Reviewed By:


Verified By:


Pest Trap Monitoring Record

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Insert Facility Name

Date Trap ID*

Comments/Issue Corrective Action (CA)CA

Completed By

Date CA Completed

*=each trap is labeled with a number.

Reviewed By:


Verified By:


Pre-operational Inspection RecordInsert Facility name

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Each time before activities begin the facility must be inspected to ensure all items are ready for use.

Date: _______________ Time: _______________

Item Acceptable Inspected ByYes No

All floors cleaned and sanitized.Drains clear.Break room clean. Trash cans emptied and labeled.Restroom clean and sanitary. Approved soap, paper towel and toilet paper dispensers full. Trash cans emptied and labeled.Pest traps present and serviced (if needed).Food contact surfaces cleaned and sanitized.Tools cleaned, sanitized and stored properly.Equipment cleaned and sanitized. Pallets clean.Hand washing water meets regulatory specifications.Drinking water meets federal EPA standards. Single use cups present.Hand washing and drinking water signs posted.Forklifts and similar clean and sanitary.Thermometers in refrigerated areas functional. Temperature correct.Packing materials safe and ready for use.First aid kit and fire extinguishers present and current.Exterior areas clean.


Date

Reviewed By:


Verified By:


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Preventive Maintenance RecordInsert Facility Name

Equipment Equip. Code

CycleD, W, M, Q, Y Maintenance Required/Instruction Date

Completed Comments/Corrective Actions Completed By

D=daily, W=weekly, M=monthly, Q=quarterly, Y=yearly

Reviewed By:


Verified By:


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Flow ChartInsert Farm Name

Prepare a flow chart as discussed in section 3.4. A hand drawn chart is acceptable.

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Processing Hazard AnalysisFacility Name

The below is an example of a hazard analysis based on the flow of product. Modify for your needs.

StepPotential Hazard

Reasonably Likely to Occur?

Decision BasisIf Likely to

Occur, What Measures to

Prevent, Control or Eliminate Hazard?

Is Step a

CCP?

Type Description

Raw product receiving

Biological Foodborne pathogens

Yes Limited possible bird/animal feces

Contaminated crop not

harvested; product washed with

sanitizer

No

Chemical Pesticide residues

No Proper application used No

Physical Foreign objects No Removed NoRadiological None No No

Conveyer belt Biological Foodborne pathogens

No SOPs, SSOPs No

Chemical Lubricants No Food-grade materials; GMP

No

Physical Foreign objects No Light shields, register; SOPs

No

Radiological None No NoDump Wash

TankBiological Foodborne

pathogensNo SOPs, SSOPs No


No


No

Radiological None No NoRinsing Biological Foodborne

pathogensNo SOPs, SSOPs


No


No

Radiological None No NoWater

EliminationBiological Foodborne



No


No

Radiological None No NoGrading Biological Foodborne



No


No

Radiological None No No

30








Is Step a

CCP?

Type Description

Packing Biological Foodborne pathogens

No SOPs, SSOPs No


No


No

Radiological None No NoProduct Storage Biological Foodborne


Chemical Sanitizers No SOPs, SSOPs NoPhysical Foreign objects No Light shields, register;

SOPsNo

Radiological None No NoShipping Biological Foodborne


Chemical Prior shipment cross

contamination

No SOPs, SSOPs No

Physical Foreign objects No SOPs NoRadiological None No No

Repack Biological Foodborne pathogens

No SOPs, SSOPs


No


No

Radiological None No NoEquipment

Washing and Sanitizing


No SOPs, SSOPs No

Chemical Sanitizers No SOPs, SSOPs NoPhysical Foreign objects No Light shields, register;

SOPsNo

Radiological None No NoEquipment

StorageBiological Foodborne



No


No


31








Is Step a

CCP?

Type Description

Packing Materials

Receiving and Storage


No SOPs, SSOPsNo

Chemical Pesticide residues

No Proper application used No

Physical Foreign objects No SOPs NoRadiological None No No

Packing Materials Use


No SOPs, SSOPs No


No


No


NOTE: if you have a step that includes a true “kill step” to eliminate or minimize a significant hazard, you may need to develop a HACCP plan which is beyond the scope of this manual.

Reviewed By:


Verified By:


32

Raw Materials Inspection RecordInsert Facility Name

Date Time CommodityGrowerName

CommodityID

VehicleID

CommodityAcceptable*

(Yes/No)

AcceptedBy

(name)

*=product must meet all desired specifications. If product is not acceptable, enter corrective action below.


Date

Reviewed By:


Verified By:


33

Refrigerated Storage Temperature RecordInsert Farm Name

Date Time Crop TemperatureReading

Temperature Correct?*

Completed By(name)

Yes No

*=if results are not correct, the temperature must be immediately adjusted. For reference, insert the required temperature ranges for the crops.


Date

Reviewed By:


Verified By:


34

Report of Food Security BreachInsert Farm Name

Date of Breach: _____________________ Time of Breach: _________________

Location involved:

______________________________________________________________________________________

______________________________________________________________________________________

Product involved:

_____________________________________________________________________________________

Equipment involved:

______________________________________________________________________________________

______________________________________________________________________________________

Personnel involved:

______________________________________________________________________________________

______________________________________________________________________________________

Corrective actions:

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

Reviewed By:


Verified By:


35

Sanitary Facilities Maintenance RecordInsert Facility Name Here

All sanitary facilities must be cleaned, sanitized and maintained at least once daily. Place a check mark in the box once the item has been serviced.

Facility Identifi-cation

Date Time Sink Toilet/

urinal

Floor Trash emptied

Toilet paper

Paper towels

Liquid/powder

soap

Hand washing

water

Drinkingwater/single

use cups

Serviced By(name)

Reviewed By:


Verified By:


Thermometer Calibration Record36

Insert Farm Name

Thermometer ID

Date Temperature Reading (F)

NIST Thermometer Reading (F)

Corrective Action Corrected By

Reviewed By:


Verified By:


Traceability and Mock Recall Exercise37

Page 1 of 2Insert Farm Name

Conducted By: _____________________________________________ Date: ___________________

Crop Name: _______________________________ Crop Code: ________________________________

Customer Name(list each customer that

purchased the crop code)

Did the Customer Respond?

(Yes or No)*

100% Reconciliation Achieved?

(Yes or No)*+

Exercise Completed Within 4 Hours?

(Yes or No)*

*= No response requires a corrective action on page 2.+=100% reconciliation means ALL product was identified and retrieved or otherwise accounted for.

Traceability and Mock Recall Exercise38

Page 2 of 2Insert Farm Name

Comments: ________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

Corrective Actions: _________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

__________________________________________________________________________________________

Reviewed By:


Verified By:


Training Record

39

Insert Farm Name

Type of Training

□ New Hire □ Quarterly □ Annual □ Other:

Training Topics: __________________________________________________________________________

Instructor: __________________________________________ Date/time: _________________________

Training Details: __________________________________________________________________________

Training Materials Used: ____________________________________________________________________

Employee SignaturesBy signing below, you are acknowledging that you have received the above training and will abide by the procedures and

requirements covered by this training.

Employee Name Signature

Reviewed By:


Verified By:


Transport Vehicle Inspection Record

40

Insert Farm Name

Date Time Crop Vehicle ID Vehicle Clean/

Sanitary?

Cleaning/Sani

Record Present

Completed By(name)

Yes No* Yes No

*=unclean vehicles cannot be accepted. Clean and sanitary means free of any evidence of contamination.


Date

Reviewed By:


Verified By:


Visitor and Contractor Record

41

Insert Farm Name

Printed Name Signature Company Person Visiting Badge #

Time in Time out

Reviewed By:


Verified By:


Water Source Treatment RecordInsert Farm Name

42

Depending upon the sanitizer used, you may need to insert additional columns. For example, chlorine would need a column for the pH as that is important to proper treatment.

Source Name Date Time Treatment Product Test Results* Tested By (name)

*=insert here the acceptable range (or ranges) for the sanitizer and other items. For example, chlorine could be 100-200 ppm at a pH of 6.5-7.0.Reviewed By:


Verified By:


Worker Health and Hygiene PracticesInsert Farm Name

43

All workers, including contractors and visitors, must abide by the below practices to avoid crop contamination.The below list is not inclusive of all situations that may impact food safety, and it may be changed at any time.

1. Unhealthy conditions such as severe coughing, runny nose, diarrhea or a communicable disease must be reported to the supervisor immediately.

2. Cuts, burns, lesions and injuries of any type must be reported to the supervisor immediately. First aid will be rendered.

3. Employees must use the sanitary facilities (toilets) for urinating and defecating, and must inform the supervisor if the facilities are dirty or need supplies.

4. Mouth and nose must be covered when coughing or sneezing (cough or sneeze into the crook of your elbow). Hands must be washed properly afterward.

5. Hands must be properly washed prior to starting work, when returning to work after a break of any kind, before donning gloves (if used) and after using the sanitary facility (toilet).

6. No spitting except into the toilet bowl in a sanitary facility.7. Smoking, using tobacco in any form, eating, drinking and chewing gum is confined to designated areas.8. Workers must bathe regularly and wear clean clothes to work each day.9. No jewelry except for a plain wedding band may be worn while working.10. Personal items must be stored in designated areas only.11. No glass, ceramic or hard plastic items may be brought to the work site.12. No personal tools or gloves may be brought to the work site.

I, ______________________________, have read and do understand the above practices. I hereby agree to Person’s Name

abide by these practices while on the property of insert name of farm.

_____________________________________________ Date: __________________________Signature

Reviewed By:


Verified By:


Appendix A

44

Water Testing

Commercially available water testing kits for generic E. coli are available from Neo-film, EasyGel, 3M Petrifilm, Bio-rad Labs, Merck and others. The procedure is described in detail in the directions supplied by each manufacturer. Licensed commercial laboratories can also be used.

45

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windward.hawaii.edu Proc Manual... · Web viewThis manual is to be used for tree nuts that may be consumed raw. Tree nuts, such as macadamia nuts, are defined as allergens by the