Standard Operating QA-SOP21 Issue Date: 16 July 2019

Standard Operating

Procedure QA-SOP21

Cleaning and Sanitation

Page: 1 of 15

Version: 11

Issue Date: 16 July 2019

Issue Date Version Amendment Compiled by Approved by

22/06/10 1 First Issue

Melinda

Chapman &

Mei Ling Wong

07/12/10 2 Added cleaning contractor Mei Ling Wong

18/07/11 3 5.11.3, 6.3 & 7.4 Change

Production Manager to Executive

Chef

Mei Ling Wong

05/12/11 4

Separate night cleaning from clean

as you go cleaning. Modified

procedure and responsibilities.

Amended job titles and structure

Mei Wong

10/01/12 5

Amend QA‐SOP21‐FOR15 Cleaning

and Sanitation Monthly Record to

QA‐SOP21‐FOR15 Cleaning and

Sanitation Monthly & Bi‐Monthly

Record

Mei Wong

10/02/12 6 Amend job titles and structure E Populin

17/10/13 7 Amend job titles and structure

E Roccasalva


Amend form names and numbers E Roccasalva


Remove e‐Water sanitiser step E Roccasalva

27/07/18 10 Amend job titles and include

Listeria management in corrective

actions

M Wong

16/07/2019 11 5.1.5 – Amend form numbers from

QA‐SOP21‐W116 to QA‐SOP‐FOR16

Amend Job titles and structures.

O Tuifangaloka

Standard Operating

Procedure QA-SOP21


Page: 2 of 15

Version: 11


1 Purpose

This SOP is to ensure that the food premises fixtures, fittings, storage areas, equipment and food

transport vehicles are maintained in a clean state and all food contact surfaces are maintained in a

clean and sanitary condition to decrease the likelihood of product contamination and ensure

compliance with HACCP and legislative requirements.

2 Scope

This SOP applies, to the food premises’ fixtures, fittings, storage areas, equipment and food transport

vehicles, to all food contact surfaces and amenities.

The Document Sponsors are the Facility Services Manager and Quality Manager.

3 References

3.1 Food Standards Australia New Zealand: Food Safety Standard 3.2.2 (19).

3.2 Codex Hazard Analysis Critical Control Point System and Guidelines for its Application.

3.3 QA‐SOP13 Operational Hygiene and GMP.

3.4 QA‐SOP20 Chemicals.

4 Definitions

‘Clean as you Go’: a policy or principle of keeping the work area clean and tidy at all times whilst

working and includes cleaning up spills, wiping down surfaces, removing waste to bins and generally

keeping the work area, tools and equipment and person to the required levels of hygiene to

production.

Cleaning: a process that removes visible contamination such as food waste, dirt and grease from a

surface. This process is usually achieved by the use of water and detergent. During the cleaning

Standard Operating

Procedure QA-SOP21


Page: 3 of 15

Version: 11


process, microorganisms will be removed but the cleaning process is not designed to destroy

microorganisms.

Sanitising: a process that destroys microorganisms, thereby reducing the numbers of

microorganisms present on a surface. This is usually achieved by the use of both heat and water, or

by chemicals.

Food Contact Surfaces: any surface or equipment used for handling food that comes into contact

with food including chopping boards, preparation surfaces, mixing bowls, storage containers,

equipment used to wash food, cooking and other processing equipment and thermometers.

Microbes: bacteria, viruses, moulds, yeasts and parasites that can only be viewed by a microscope

(microorganisms)

Pathogens: bacteria, viruses, moulds and parasites capable of causing disease.

5 Methods

5.1 Responsibility and Authority Limits

5.1.1 The cleaning contractor has been contracted to establish and implement the cleaning and

sanitation program under the directions of the Facility Services Manager.

5.1.2 The cleaning contractor is responsible for ensuring the cleaning and sanitation program is

followed to maintain the food premises fixtures, fittings, storage areas and equipment in a

clean state and all food contact surfaces in a clean and sanitary condition.

5.1.3 The Quality Department is responsible for verifying that the cleaning and sanitation program

is working through visual cleaning verification and environmental swabs.

5.1.4 Personnel nominated on the cleaning schedule are responsible for carrying out cleaning and

sanitation procedures as instructed on the Cleaning and Sanitation Schedule.

Standard Operating

Procedure QA-SOP21


Page: 4 of 15

Version: 11


5.1.5 All personnel are required to follow the company’s ‘Clean as you Go’ policy to maintain a

clean and tidy work environment. The specific responsibilities are specified in QA‐SOP21‐

FOR16 Cleaning Work Instructions and Schedule ‐ Clean as You Go.

5.1.6 Any person may identify unclean food contact surfaces or inadequate cleaning being

undertaken. In each case, the Team Leader shall be immediately notified and food contact

surfaces shall be immediately cleaned and sanitised prior to use and inadequate cleaning

practices shall be corrected.

5.2 Induction and Training

5.2.1 All personnel will be inducted in the ‘clean as you go’ policy and correct cleaning and

sanitising procedures and use of cleaning chemicals in a food production environment.

Specific training is provided to personnel responsible for cleaning and sanitising critical

equipment and high risk areas. Records of induction and training will be documented and

filed by the Administration Coordinator or delegate. Refer to QA‐SOP16 Training.

5.3 Cleaning Work Instructions and Schedule

5.3.1 A cleaning schedule and work instructions (QA‐SOP21‐W101 Cleaning Work Instructions and

Schedule ‐ Deep Cleaning & QA‐SOP21‐W103 Cleaning Work Instructions and Schedule ‐

Clean as You Go) is maintained to ensure all parts of the food premises fixtures, fittings,

equipment and all food contact surfaces are cleaned regularly and correctly. The cleaning

schedule covers:

The areas and items to be cleaned.

The method of cleaning.

Who is responsible for each cleaning task.

The frequency at which area or item is cleaned.

Standard Operating

Procedure QA-SOP21


Page: 5 of 15

Version: 11


The chemicals and tools used and any Personal Protective Equipment (PPE) to be used.

5.4 Area and Items to be Cleaned

5.4.1 The following items and areas will be included on QA‐SOP21‐WI01 Cleaning Work

Instructions and Schedule ‐ Deep Cleaning & QA‐SOP21‐WI03 Cleaning Work Instructions and

Schedule ‐ Clean as You Go :

Portable Equipment ‐ all equipment used for processing including trays, trolleys, pans,

pots, cutlery, slicers, labelling equipment, jugs, utensils, tubs, buckets, chopping

boards, scales.

Fixed Equipment ‐ racks, rails, cesars, ovens, bench tops, sinks, taps, kettles, pans,

overhead shielding, conveyors, conveyor belts, chain roller, supports, shelves and other

storage equipment, including the undersides of equipment.

Filler heads and other equipment that can trap food.

Processing areas including all walls, floors and drains, ceilings, doors and ventilation

systems.

Storage areas ‐ chillers, freezers and dry storage areas including all walls, floors, ceilings,

doors, fan units and evaporator units and trays.

Cleaning equipment – brooms, brushes, cloths, squeegees, non‐metal scourers etc.

Garbage and waste bins, and waste and recycling storage areas.

Toilet blocks, locker and change areas, lunch rooms and offices.

5.5 Food Contact Surfaces

5.5.1 All food contact surfaces of equipment must be both cleaned and sanitised. Food contact

surfaces of equipment is any surface or equipment used for handling food that comes into

Standard Operating

Procedure QA-SOP21


Page: 6 of 15

Version: 11


contact with food including chopping boards, preparation surfaces, mixing bowls, storage

containers, equipment used to wash food, cooking and other processing equipment and

thermometers.

5.5.2 Food contact surfaces must be thoroughly cleaned before the sanitising step is undertaken as

any food residue or other soil left after the cleaning process may:

Protect bacteria from the sanitation step.

React with the sanitiser making the sanitiser less effective.

5.5.3 Effective cleaning and sanitation involves the following steps:

Dry sweeping / brushing to remove loose debris.

Rinse to reduce dirt and debris.

Wash with aid of a detergent and mechanical action to lift dirt and debris from surface.

Rinse off detergent.

Sanitise.

Rinse off sanitiser (unless ‘no rinse sanitiser’, hot water at 82oC or steam is used).

Allow to dry.

Standard Operating

Procedure QA-SOP21


Page: 7 of 15

Version: 11


5.6 Cleaning and Sanitising Methods

5.6.1 Cleaning methods are determined depending on the item or areas being cleaned and may

include manual cleaning using paper towels, squeegees, brushes and non‐metal scourers,

soaking, foam and high pressure hoses.

5.6.2 Sanitising methods are determined depending on the item or area being sanitised and may

include steam (surfaces heated to a surface temperature greater than 72°C); hot water

(surfaces also heated whereby water temperature must be ≥ 82°C); and chemical sanitisers)

5.6.3 If using a commercial single use sanitiser product designed to disinfect whilst removing soils

in a single step, manufacturer’s instructions must be strictly adhered to and chemicals not

mixed with other cleaners or sanitisers.

5.6.4 Some sanitisers are ‘no rinse sanitisers’ and so the final rinse can be omitted.

5.7 Cleaning Items and Methods requiring special consideration

5.7.1 If using high pressure hoses, the force of the hose may spread materials for long distances

and from the floor onto surfaces above as aerosols. The aerosols may contaminate food or

food contact surfaces. High pressure hoses must only be used where there is no possibility of

contaminating food or sanitised food contact surfaces.

5.7.2 When cleaning drains, do not blast water into them with a spray gun as this can blast

pathogens (e.g. Listeria monocytogenes) out of the drain and into the food production

environment.

5.7.3 Staff responsible for cleaning drains must carry out proper hand washing procedures and

change clothing afterwards and cleaning of drains must not be scheduled until the end of

production.

5.8 Personnel responsible for cleaning

Standard Operating

Procedure QA-SOP21


Page: 8 of 15

Version: 11


5.8.1 All personnel will follow the “Clean As You Go” policy and be responsible for keeping the

work area, tools, equipment and person to the required levels of hygiene to produce safe

food products. Specific requirements are outlined in QA‐SOP21‐FOR04 Clean as You Go Daily

Record.

5.8.2 Community Chef’s Cleaning Team is responsible of assisting production with cleaning tasks

during the day. Specific requirements are outlined in QA‐SOP21‐FOR16 Clean as You Go Daily

Record.

5.8.3 The cleaning contractor is employed to undertake specific cleaning tasks as outlined on the

Cleaning Schedule, deep cleaning, major spills and equipment clean downs.

5.9 Cleaning Frequency

5.9.1 Cleaning frequency for food premises, fixtures, fittings, equipment and the food transport

areas of vehicles is determined to ensure there is no accumulation of:

Garbage, expect in garbage containers.

Recycled matter, except in containers.

Food waste.

Dirt.

Grease.

Other visible matter.

5.9.2 The frequency of cleaning and sanitising food contact surfaces is based on determining when

food that will come into contact with the surface is likely to be contaminated.

Standard Operating

Procedure QA-SOP21


Page: 9 of 15

Version: 11


5.9.3 A food contact surface must be cleaned and sanitised between being used for raw and ready

to eat food; however where possible, separate surfaces and equipment should be used for

raw and ready to eat foods

5.9.4 A food contact surface must be cleaned and sanitised immediately after it has been used;

that is, where there will be a delay between the current use of the surface and the next use

of the surface; and where there is a change of use, such as change of product or batch.

5.9.5 A food contact surface should be cleaned and sanitised immediately prior to use if it has not

been adequately protected since it was last cleaned and sanitised, or if cleaning records

cannot confirm the surface has been cleaned and sanitised after last use.

5.9.6 If equipment is being used for long periods with potentially hazardous food at temperatures

between 5°C and 60°C, the food contact surfaces of this equipment must be cleaned and

sanitised every 2 hours or after each type of product, whichever comes first, to prevent food

residues remaining on the surface becoming a source of contamination.

5.10 Cleaning Chemicals and Equipment

5.10.1 Cleaning chemicals used in the food premises are designed for the purpose of use within

food establishments and will not compromise the safety of the food and are suitable when

used according to label directions or specific site cleaning procedures authorised by the

approved chemical supplier. Refer QA‐SOP09‐REG01 Approved Suppliers Register and QA‐

SOP20 Chemicals

5.10.2 Current (within 5 years) Safety Data Sheets (SDS) are held for all non‐food chemicals used by

Community Chef.

5.10.3 Cleaning chemicals will be securely and separately stored away from food and food storage

areas. Chemicals must never be stored in food containers or receptacles.

Standard Operating

Procedure QA-SOP21


Page: 10 of 15

Version: 11


5.10.4 Cleaning equipment and items such as mops, cloths and sponges and other porous items can

easily harbour microbes and must be maintained in a condition which does not allow them to

become a source of contamination.

5.10.5 Cleaning equipment that is not in good condition can become a source of foreign body

contamination (e.g. loose bristles from brushes) and must be replaced if no longer in good

condition.

5.10.6 Wooden handled cleaning implements must not be used in the food production

environment.

5.10.7 Cleaning equipment are colour coded i.e. black and green are for non‐food contact surfaces

and red is for food‐contact surfaces.

5.11 Cleaning Records

5.11.1 The Cleaning Team Leader completes and signs QA‐SOP21‐FOR13 Handover Sheet indicating

that the department or plant is ready to be handed over for cleaning by the cleaning

contractor (all raw materials have been removed, etc), the date and time the department or

plant is handed over is recorded. Any items requiring attention or any deviation from the

previous day must be written down on QA‐SOP21‐FOR13 Handover Sheet.

The cleaning contractor’s Team Leader must comment on the issues raised by the

Community Chef and write down deviations that occur during the deep cleaning. The

cleaning contractor’s Team Leader will contact the relevant people if he believes that the

deviation can stop production or if it can develop into danger of any kind.

When the clean is completed and the cleaning contractor’s Team Leader and his staff have

completed the Post‐Op hygiene inspection the plant is ready to be handed back to

production. The cleaning contractor’s Team Leader will sign QA‐SOP21‐FOR13 Handover

Sheet that he has delivered the department or plant in a condition, which is acceptable to

production. Subsequently the Community Chef Cleaning Team Leader must comment and

Standard Operating

Procedure QA-SOP21


Page: 11 of 15

Version: 11


sign the QA‐SOP21‐FOR13 Handover Sheet. The cleaning contractor’s Team Leader will read

these comments when he returns to start the next cleaning shift.

5.11.2 When an item or area is cleaned during the deep cleaning, a record of this is completed and

initialled by the cleaning contractor’s Team Leader on:

QA‐SOP21‐FOR01 Deep Cleaning and Sanitation Daily Record

QA‐SOP21‐FOR14 Deep Cleaning and Sanitation Weekly Record

QA‐SOP21‐FOR15 Cleaning and Sanitation Monthly & Bi‐Monthly Record

5.11.3 The Cleaning Records are checked and signed by the Facility Services Manager and QA on a

daily basis and filed as per QA‐SOP01 Document Control.

5.11.4 When an item or area is cleaned during the day cleaning, a record of this is completed and

initialled by the Community Chef’s Cleaning Team Leader on QA‐SOP21‐FOR16 Clean as You

Go Daily Record. However, all Team Leaders are responsible to ensure that cleaning

procedures are adhered to in their area.

6 Monitoring

6.1 The cleaning contractor’s Team Leader shall monitor the cleaning process and fill in:




6.2 All Team Leaders shall monitor the “Clean as You Go” processes. The Community Chef Cleaning

Team Leader shall sign off QA‐SOP21‐FOR04 Clean as You Go Daily Record.

Standard Operating

Procedure QA-SOP21


Page: 12 of 15

Version: 11


6.3 Quality Team Member as well as the Facility Services Manager shall sign off all cleaning records

on a daily basis.

7 Corrective Action

7.1 The cleaning contractor’s Team Leader shall verify that corrective and preventive action relating

to inadequate cleaning and sanitation is carried out including discarding food products if there is

any likelihood of contamination (after consultation with the Quality Manager), ensuring the

unclean area or item is re‐cleaned according to procedures and that the responsible personnel

are addressed and, if necessary, retrained in the correct cleaning procedures with the assistance

of the Facility Services Manager or Quality Manager. Non‐conformances and follow‐up actions

taken must be recorded in QA‐SOP08‐REG01 Non‐Conformance Register by the Quality Manager

or delegate.

7.2 The cleaning contractor’s Team Leader must instigate and record corrective actions for swab

failures on QA‐SOP21‐FOR10 Swab Failures and Corrective Action.

7.3 The cleaning contractor’s Team Leader must review any cleaning issues identified on pre‐

operational inspection sheets and implement, verify and record corrective actions and sign off on

the pre‐operational inspection sheets daily.

7.4 The Facility Services Manager may submit a Deviation Sheet to the Contractor when the

Production Manager or Quality Manager considers that the services (or a component of them)

have failed to comply with the standard required on more than one occasion.

7.5 The cleaning contractor’s Team Leader must, within 1 business day of receiving a Deviation

Sheet, propose a cure plan for the rectification of the Service failure specified in that Deviation

Sheet for consideration by the Facility Services Manager.

7.6 The cleaning contractor’s Team Leader must implement or amend a cure plan to the extent

required by the Production Manager, Facility Services Manager, Quality Manager.

Standard Operating

Procedure QA-SOP21


Page: 13 of 15

Version: 11


7.7 If Listeria is detected on a food contact surface:

7.7.1 Review cleaning procedures and implement cleaning and sanitation of the food contact

surface.

7.7.2 Increase the frequency of environmental testing to at least weekly and continue to test until

the environmental swabbing program has achieved three consecutive negative results from

tests taken on separate operation days.

7.7.3 To ensure end product has not been contaminated, where a food contact surface tests

positive for Listeria that swab shall be typed in a laboratory to confirm the presence or

otherwise of L. monocytogenes. All potentially contaminated RTE product shall be held

pending the results of this test. If the presence of L. monocytogenes is confirmed, follow

Standard 1.6.1 of the Code and test and hold available product batches from the day of the

first positive L. monocytogenes environmental contamination onwards. Product batches shall

be tested for L. monocytogenes at the rate of five 25‐gram samples per batch. Composite

testing is permitted at the laboratory. Test each production batch until the environmental

swabbing program has achieved three consecutive negative results as outlined above.

7.8 If Listeria is detected on a non‐food contact surface:

7.8.1 Review cleaning procedures and implement cleaning and sanitation of the non‐food contact

surface.

7.8.2 Increase the frequency of environmental testing to weekly and continue to test until the

environmental swabbing program has achieved three consecutive negative results from tests

taken on separate operation days.

Standard Operating

Procedure QA-SOP21


Page: 14 of 15

Version: 11


8 Verification

8.1 The Community Chef Cleaning Team Leader with the assistance of all Team Leaders shall verify

the cleaning process and record the results of the verification in QA‐SOP21‐FOR16 Clean as You

Go Daily Record.

8.2 The cleaning contractor’s Team Leader shall verify the cleaning process and record the results if

the verification in:




8.3 The Quality Team shall verify the cleaning and sanitation program through regular visual

inspections and weekly microbiological environmental swabbing of food contact surfaces, and

record results on QA‐SOP21‐REG01 Swabbing Record.

8.4 Environmental swabs will be sent to the approved food microbiological laboratory as listed on

QA‐SOP09‐REG01 Approved Suppliers Register

8.5 Visual inspection and environmental swabs results are subject to internal audits and external

audits.

8.6 Findings of internal and external audits are subject to management review.

9 Documentation

9.1 QA‐SOP21‐FOR01 Deep Cleaning and Sanitation Daily Record

9.2 QA‐SOP21‐FOR14 Deep Cleaning and Sanitation Weekly Record

9.3 QA‐SOP21‐FOR15 Cleaning and Sanitation Monthly & Bi‐Monthly Record

Standard Operating

Procedure QA-SOP21


Page: 15 of 15

Version: 11


9.4 QA‐SOP21‐FOR16 Clean as You Go Daily Record

9.5 QA‐SOP21‐FOR13 Handover Sheet

9.6 QA‐SOP08‐REG01 Non‐Conformance Register.

9.7 QA‐SOP07‐FOR03 Internal Corrective Action Request.

9.8 QA‐SOP21‐REG01 Swabbing Record.

9.9 QA‐SOP21‐WI01 Cleaning Work Instructions and Schedule – Deep Cleaning

9.10 QA‐SOP21‐WI03 Cleaning Work Instructions and Schedule – Clean as You Go

9.11 QA‐SOP21‐WI02 Pre‐Operational Checks

9.12 QA‐SOP21‐WI05 Retort Pipeline Cleaning

9.13 QA‐SOP21‐WI06 Toyo Pipeline Cleaning

Standard Operating Procedure QA‐SOP09

Approved Supplier Program

Page: 1 of 14

Version: 13

Issue Date: 01/02/19



01/03/11 2 Section 5.2.2 Changed location of specifications folder.

19/08/11 3 Section 5.6 Amended Supplier Review Mei Wong

05/12/11 4

Amend job titles and structure.

Deleted Section 5.4.7.

Added CEO to Section 5.9.4.

Added Production Manager to Section 6.

Replaced “quality” with “food safety” to Section 7.1.

Section 7: Amended responsibilities as per current

practice.

Section 9: Added Issues Register – Quality.

Section 5.6.3: Amended scoring system for food safety

& quality.

Mei Wong

09/02/12 5

Amend job titles and structure.

Replaced “Production Manager” with “Quality

Manager and/or Quality Support Officer” and added

“Demi Chef” to Section 7.1.2

E Populin

7/12/12 6

Remove Approved Raw Materials Register from

Sections 5.2.1, 5.2.4, 5.4.3, 5.5.9 (replace with SysPro)

and 9.4 (replace with SysPro).

Remove Section 5.3.2

Section 5.6.3: Amended scoring system for food

safety, quality and delivery.

Section 5.9: add New Supplier Reference Checklist

Section 7.1: add Supplier Delivery Issues Register.

E Populin


15/10/13 8 Amend job titles and structure E Roccasalva



Page: 2 of 14

Version: 13


29/12/14 9 Amend job titles and structure N Chee

27/07/15 10

Section 4: Amend authorities to reflect updated

practice.

Section 5.2.2: Amend location of files from O drive to

P drive.

Section 5.3: Add risk assessment.

Section 5.6.2 Include supplier approval application.

Remove Supplier Audit. Remove AQIS approval

M Wong

E Roccasalva

19/02/16 11

Add Section 5.10 Approved Supplier Visits.

Section 3 Add OP‐SOP01 procurement Policy

Section 9 Add OPS‐SOP01 Procurement Policy

Mei Wong

24/08/17 12

5.7 Amend supplier performance measurements

calculations and change title of section to Supplier

Review for Raw Material Suppliers. Leave review as

annually.

9.6 Add QA‐SOP09‐FOR04 Supplier Approval

Application

Mei Wong

01/02/19 13

Amend job titles and structure

Section 4: Update from MSDS to SDS

3.4 SOP Supplier Selection and Management removed.

5.6.6 Minor changes to the QA‐SOP09‐FOR3 – actual

form number QA‐SOP09‐FOR02.

5.7.3 Removed; Delivery states The Production &

Planning Officer is to keep record of delivery

performances. This is no longer required.

Definition – Amend MSDS to SDS

N Chee

O Tuifangaloka



Page: 3 of 14

Version: 13


1 Purpose

The purpose of this procedure is to ensure that raw materials used in the manufacture of food at

Community Chef meet specific requirements. The quality of raw materials has an impact on the

finished product. Raw materials will only be sourced from approved suppliers whose performance is

established through compliance history or formal quality evaluation.

2 Scope

This SOP applies to the purchasing of all ingredients, packaging materials, cleaning chemicals,

cleaning equipment, pest control chemicals, cooling tower and boiler water treatment additives,

food contact materials (metals, plastics, and lubricants) used at Community Chef.

Any material used for product development and trials are excluded from this procedure.

The Document Sponsor for this procedure is the Quality Manager.

3 References

3.1 Food Standards Australia New Zealand.

3.2 Codex Hazard Analysis Critical Control Point System and Guidelines for its Application.

3.3 Memorandum for Procurement.

3.4 OPS‐SOP01 Procurement Policy

4 Definitions

Approved Supplier ‐ A supplier of raw materials or services who have been subject to an approval

process. The following supplier categories must possess these attributes:

Food – HACCP / Food Safety Certification

Services – ISO / NATA Certification



Page: 4 of 14

Version: 13


Packaging – ISO Certification

Transport – HACCP / ISO Certification

S.D.S. ‐ Safety Data Sheet ‐ Information provided by a supplier attesting to the safety standards and

requirements applicable to the material (usually chemicals). Previously known as Material Safety

Data Sheet (MSDS).

T.D.S. ‐ Technical Data Sheet ‐ Information provided by a supplier regarding the description,

functionality and Quality specification of the material.

Specification ‐ A document defining the requirements, particularly quality requirements, with which

the material must comply.

Purchaser ‐ Personnel who have purchasing authority:

Ingredients, packaging materials, consumables – The Productions Manager in consultation with

the Production Planning Officer, Finance Manager, Quality Manager and Operation Director.

Cleaning chemicals – Facility Services Manager in consultation with the Operations Director and

Quality Manager.

Maintenance items – The Facility Services Manager in consultation with the CEO.

Production consumables – Production Manager in consultation with the Production Planning

Officer and Team Leaders.

Laboratory – The Operations Director in consultation with the Quality Manager.

5 Methods

5.1 Authority Limits

5.1.1 Refer to the Procurement Policy and Memorandum for Procurement.



Page: 5 of 14

Version: 13


5.2 Approved Raw Materials Register and Approved Suppliers

5.2.1 Purchase only materials listed in Syspro and QA‐SOP20‐REG01 Approved Chemicals Register.

5.2.2 Specifications for each of these materials from each supplier are located in the Product

Specification Folder under Menu Development on the P drive.

5.2.3 The materials may be purchased only from the primary approved supplier or, in emergency

situations or for supply rotation purposes, from approved alternative suppliers recorded on

the register.

5.2.4 It is the responsibility of the Quality Department to maintain the currency of QA‐SOP09‐

REG01 Approved Supplier Register and QA‐SOP20‐REG01 Approved Chemicals Register.

5.2.5 It is the responsibility of the Productions & Planning Officer to maintain the currency of

Syspro.

5.2.6 The Quality Manager and the Operations Director shall be notified in all cases where

purchases from approved alternative suppliers are to be ordered due to the possibility that

recipe or processing adjustments may be necessary.

5.3 Risk Assessment

5.3.1 Suppliers of raw materials must be assessed according to the risk associated with the raw

material.

5.3.2 A risk assessment must be carried out using the following table:

Severity Rating Description

3 Will directly cause a food safety issue

2 May cause a food safety issue and/or quality issue

1 Unlikely to cause food safety and/or quality issues



Page: 6 of 14

Version: 13


Likelihood of Occurrence Description

3 Highly likely if control not present

2 Possible

1 Unlikely or infrequent

Assign a value to the hazard from the two above criteria and then multiply Severity Rating x

Likelihood of Occurrence to determine a risk factor. From this calculation, the possible outcomes are

1, 2, 3, 4, 6 and 9.

Hazard Severity

1

2

3

1 Very

Low

Action

Low

2 Low

Action

Priority

Low

3 Programmed

Action

Medium

1

Likelihood

of

Occurrence

2 Low

Action

Priority

Low

4 Priority

Action

Medium

6 Urgent

Priority

Action

High

2

3 Programmed

Action

Medium

6 Urgent

High

9 Critical

Action

High

3

5.3.3

Risk Level Requirement

High HACCP Certificate

Site visit



Page: 7 of 14

Version: 13


Medium HACCP Certificate

Site visit

Low HACCP Certificate

5.3.4 Risk assessments for all suppliers are located in QA‐SOP09‐REG04 Supplier Risk Assessment.

5.4 Requirements for Certificate of Analysis (C of A)

5.4.1 The Quality Manager shall decide the requirements for C of A based on the history, risk

category of the raw material, amount of usage, end use and the supplier certification such as

HACCP etc

5.4.2 At the time of ordering raw materials, if the supplier certification has expired, the Quality

Department should request an updated copy and update it in the Approved Suppliers

Register.

5.5 Specifications / Safety Data Sheets

5.5.1 All ingredients and packaging materials purchased shall comply with the current raw material

and packaging specifications.

5.5.2 The Quality Department shall maintain the specifications.

5.5.3 The Quality Department shall retain copies of material safety data sheets, where applicable.

5.5.4 SDSs are required for all chemicals used. The Quality Department shall maintain the safety

data sheets for all cleaning, pest control, boiler, cooling tower and water treatment

chemicals used on site and shall ensure QA‐SOP20‐REG01 Approved Chemicals Register is

kept up‐to‐date.

5.5.5 The Facility Services Manager shall maintain the material safety data sheets for boiler,

cooling tower and water treatment chemicals used on site and shall obtain copies of the

relevant SDS and other documentation for all chemicals required for maintenance purposes.



Page: 8 of 14

Version: 13


5.5.6 These documents are essential to ensure that ingredients, processing aids, labels, tags,

printing inks and packaging material e.g. plastic wraps that may come into contact with food

products are not a source of contamination.

5.6 New Material / Supplier Approval

5.6.1 The initial and ongoing ability of ingredient and packaging material suppliers to meet

Community Chef’s quality requirements shall be carried out before that supplier provides

materials. Refer to Procurement Memorandum. Community Chef will review the

performance of the supplier within a specified ‘trial’ period and decide upon the level of

ongoing supplier performance monitoring. Each supplier is to be reviewed at least annually.

5.6.2 All new suppliers must complete QA‐SOP09‐FOR04 Supplier Approval Application.

5.6.3 QA‐SOP09‐FOR06 New Supplier Reference Checklist may also be used if deemed necessary.

5.6.4 Acceptance of a supplier is based on a risk assessment, Procurement Memorandum and SOP

Supplier Selection and Management.

5.6.5 Acceptance of a particular product from a supplier shall consider one or more of the

following criteria:

Quality and food safety significance.

Usage level.

Cost.

History of the materials.

5.6.6 For each approved supplier QA‐SOP09‐FOR02 Supplier Approval Coversheet will be

completed by the Quality Manager outlining:

Supplier location(s) covered



Page: 9 of 14

Version: 13


Basis for approval

Product or product groups covered

Approval expiry date

5.6.7 A reference will be made in the QA‐SOP09‐REG01 Approved Supplier Register to form a

summary of suppliers approved by the process above and the expiry date of such approval.

Suppliers present in the list include suppliers providing:

Ingredients.

Packaging.

Service providers e.g. pest control, water testing.

External calibration services.

5.6.8 Where a material requested does not appear in Syspro or in the Approved Chemicals

Register i.e. its use has not been formally approved, the purchaser shall initiate the

procedure for new material approval with the assistance of the Quality Manager.

5.6.9 Where there is a request to purchase a raw material from a non‐approved supplier for that

material, the assessment must be carried out by the procurement evaluation committee.

Refer to Procurement Memorandum and SOP Supplier Selection and Management

5.7 Supplier Review for Raw Material Suppliers

5.7.1 The supplier performance rating program provides a tool to measure supplier performance.

The Production & Planning Officer, Production Manager and Quality Manager are responsible

for the implementation, management and maintenance of the performance rating system

for Community Chef suppliers. The overall process is overviewed by the Production Manager.

5.7.2 Program Parameters



Page: 10 of 14

Version: 13


Measurements compiled and reviewed annually.

Scores compiled in QA‐SOP09‐FOR05 Supplier Review.

Findings discussed in Management Review Meetings.

Ratings discussed as part of all Purchasing and/or QA meetings with suppliers.

Any incidents are addressed at the time of occurrence.

5.7.3 Performance Measurements for Raw Material Suppliers

The target score for each supplier is 75‐100%.

Food Safety (35%)

Food safety performance is measured on a scale of 1‐10.

Number of food safety issues with raw materials delivered as identified by in‐house checks

and/or routine product testing, e.g. temperature out of specifications, foreign object

contamination.

All non‐conformances are documented by CAR# in QA‐SOP08 REG01 Non‐Conformance

Register and responses filed in the Supplier CAR folder.

Each CAR warrants a deduction of 0.5 point from a maximum score of 10.

If there is a deduction of 3 points or more during the first quarter, the supplier will be

notified and a supplier audit will be conducted.

If there is a deduction of 3 points or more two quarters in a row, alternative suppliers must

be sought.

Quality (35%)

Quality performance is measured on a scale of 1‐10.



Page: 11 of 14

Version: 13


Number of quality issues with raw materials delivered e.g. gristly meat, roast meat portions

out of specifications.

Data is taken from QA‐SOP08 REG01 Non‐Conformance Register and email communication.

Each CAR warrants a deduction of 0.5 point from a maximum score of 10.

Delivery (20%)

Delivery performance is measured on a scale of 1‐10.

Measurement includes delivery issues e.g. late deliveries, short deliveries.

Service (10%)

Service performance is measured on a scale of 1‐10.

Subjective measurement that includes inquiry response time, completeness of responses,

quality of technical and QA support, flexibility in satisfying manufacturing and delivery

changes, innovative suggestions and contributions, general ease of doing business.

The Production & Planning Officer is responsible for determining this measurement with

input provided from other departments as appropriate.

5.8 Verification of Materials

5.8.1 The Quality Manager shall ensure that a clear agreement is developed with the supplier on

the methods by which conformance to Community Chef requirements may be verified.

Verification methods may include any one or more of the following:

Relying on the supplier’s quality assurance system.

Submission of specified inspection/test data (e.g. certificates of analysis) or process

control records with delivery of materials.

100% inspection/testing by the supplier.



Page: 12 of 14

Version: 13


Lot acceptance inspection/testing by sampling by the supplier.

Implementation of a formal quality assurance system as specified by Community Chef.

5.8.2 The receival storemen shall visually assess goods being received against the relevant raw

materials inspection guideline before signing acceptance of the delivery dockets in

accordance with the details outlined in QA‐SOP10 Raw Material Receival and Storage.

Inspection shall be recorded in QA‐SOP10‐FOR01 Raw Material Inspection Checklist.

5.9 Service Order Contracts

Service orders shall generally apply to the purchase of service contracts relating to:

Pest control

Waste removal

Laboratory testing

Service providers (boilers)

Casual staff agencies

5.10 Approved Supplier Visits

Supplier visits are done either:

As part of a pre‐approval assessment.

As part of a schedule.

At the Quality Manager or Operations Manager’s discretion.

As a result of a supplier non‐conformance.

6 Monitoring



Page: 13 of 14

Version: 13


6.1 Each stage of supplier approval must be monitored by the Operations Manager and Quality

Manager who shall ensure that all the required documentation is obtained.

7 Corrective Action

7.1 Supplier Corrective Action Requests

7.1.1 Where a food safety defect is noted by the receival personnel or any other personnel, the

defect shall be reported to the Quality Manager who, depending on the severity of the issue,

shall:

Arrange for the product to be placed on hold.

Complete a Corrective Action Request.

Accept the goods if the defect is deemed to have an insignificant impact on food safety

and quality.

7.1.2 When a quality defect is noted by the receival personnel or any other personnel, the defect

shall be reported to the Quality Department:

Arrange for the product to be placed on hold.

Arrange for data input in the QA‐SOP08 REG01 Non‐Conformance Register.

7.1.3 When a stock defect is noted by the receival personnel or any other personnel, the defect

shall be reported to the Production Planning Officer who shall arrange for the relevant stock

to be placed on hold and/or returned to the supplier and for replacement stock to be

ordered.

8 Verification

8.1 This SOP and accompanying documents are subject to internal and external audits.




Page: 14 of 14

Version: 13


9 Documentation

9.1 QA‐SOP09‐REG01 Approved Suppliers Register.

9.2 QA‐SOP10‐FOR01 Raw Material Inspection Checklist.

9.3 QA‐SOP20‐REG01 Approved Chemicals Register.

9.4 QA‐SOP09‐FOR02 Supplier Approval Coversheet.

9.6 QA‐SOP09‐FOR04 Supplier Approval Application

9.7 QA‐SOP09‐FOR05 Supplier Review

9.6 QA‐SOP09‐FOR06 New Supplier Reference Checklist

9.7 Supplier Corrective Action Request Folder.

9.8 OPS‐SOP01 Procurement Policy


Process Control

Page: 1 of 13

Version: 13

Issue Date: 10 Dec 2019

Issue Date Version Amendment Compiled by Approved


11/03/11 2

Section 2 – Changed document codes and

names relating to raw material receival and

dispatch.

Section 5.2.2 – Deleted Quality Manager and

added delegate for pre‐operational checks.

Deleted Assistant Team Leader.

Section 5.5.3 Added change request form

and deleted document control register.

Mei Wong

05/12/11 3 Amend job titles and structure. Mei Wong


01/06/12 5 Section 5.5.3 & 5.5.4 ‐ Amend authorisation

list on change request form E Populin




30/06/16 9 5.2 inclusion of Allergen Control (QA‐SOP27)

5.2.2‐4 Delegate can complete Daily Review E Roccasalva


18/12/17 11


Inclusion of Manufacturing Supervisor

Update Section 5.8 with statement from

SOP11

E Roccasalva


10/12/19 13


Section 5.2.2 – added Quality Officer to

GMP Inspection. Deleted Manufacturing

O Tuifangaloka


Process Control

Page: 2 of 13

Version: 13


Purpose This procedure defines the process control procedures applied in the manufacture of food at

Community Chef to ensure safety and quality of our products. Evaluation of process changes

which may impact on HACCP and the quality system shall also be defined

1 Scope

This procedure applies to the manufacture of all food products at Community Chef. It applies

to all activities from the batching of materials for production to the palletising of finished

product.

Finished product storage and distribution are defined in QA‐SOP11 Finished Product Storage

and Delivery.

Raw material receival, handling and storage are defined in QA‐SOP10 Raw Material Receival

and Storage.


Supervisor and added Production

Manager.

Section 5.5.3 – deleted Operation

Manager and added Production Manager,

deleted Administration Coordinator and

added Business Support Coordinator,

added Operation Director.

Section 5.8.2 – Deleted Operation

Manager and added Operation Director.


Process Control

Page: 3 of 13

Version: 13


2 References

2.1 Quality Manual

2.2 Food Standards Australia New Zealand

2.3 Codex Hazard Analysis Critical Control Point System and Guidelines for its Application

3 Definitions

Control Point (CP) ‐ A point in a process or as part of a support program at which some test or

inspection is required as a control for food safety reasons. Failure at a CP does not have a direct

impact on food safety.

Quality Point (QP) – A point in a process or as part of a support program at which some test or

inspection is required as a control for food quality reasons. Failure at a QP does not have a direct

impact on food quality or legislation.

Critical Control Point (CCP) ‐ A step at which control can be applied and is essential to prevent or

eliminate a food safety hazard or reduce it to an acceptable level. Failure at a CCP has direct impact

on food safety.

Quality Control Point (QCP) ‐ A step at which control can be applied and is essential to prevent or

eliminate a quality hazard or reduce it to an acceptable level. Failure at a QCP has direct impact on

food quality or legislation breach.

HACCP Plan ‐ Hazard Analysis Critical Control Point plan.

The written document, based upon the principles of HACCP, describing the procedures for assuring

the control of a specific process. It is based on ‘on‐line’ activities.

Standard Operating Procedure – A written document which supports ‘on‐line’ activities to ensure

that they function properly e.g. pest control, training.


Process Control

Page: 4 of 13

Version: 13


5 Methods

5.1 General

Process Control shall be achieved and demonstrated by implementation of the following components

of the quality plan:

Identification of the potential hazard.

Identification of control points (CPs) and quality points (QPs) and establishment of

standards, limits and specifications.

Identification of critical control points (CCPs) and quality control point (QCPs) and

establishment of standards, limits and specifications.

Documentation of a HACCP plan for the product/process.

A full validation of the process shall be made prior to initial production ensuring

worst‐case conditions are considered.

Documentation of standard operating procedures, work instructions and forms for

testing critical characteristics of the process.

Inspection and testing at each control point (CP), quality point (QP), quality control

point (QCP) and critical control point (CCP) during manufacture. Results shall be

recorded on appropriate process control sheets and verified.

Ongoing process validation shall be undertaken on a routine basis based on risk

assessment and the receipt of data indicating inconsistent or insufficient compliance

with process requirements.


Process Control

Page: 5 of 13

Version: 13


Community Chef operates a quantity control system which conforms to legal

requirements (where the product is sold) and any additional recognised industry

sector codes or specified customer requirements.

The frequency and methodology of quantity checking shall meet the requirements of

legislation governing quantity verification, irrespective of the nature of the pre‐pack

e.g. minimum weight.

Where the quantity of the product is not governed by legislative requirements, the

product must conform to customer specification requirements.

5.2 Establishment of Process Control and Specifications

5.2.1 Process control and specifications shall be established by the Quality Manager or delegate.

Controls for the following aspects shall be documented:

Raw materials ‐ issue, handling, storage and use.

Production equipment ‐ pre‐start checks and regular monitoring and control during

production.

In‐process control.

Cleaning and sanitation (QA‐SOP21).

Pest control (QA‐SOP18).

Chemicals (QA‐SOP20)

Waste management (QA‐SOP17).

Water supply (QA‐SOP19).

Training (QA‐SOP16).


Process Control

Page: 6 of 13

Version: 13


Premises and Plant Maintenance (QA‐SOP26).

Allergen Management (QA‐SOP27).

Any other input to the manufacturing process which can impact on product quality

and/or safety.

5.2.2 Process controls shall be managed and documented as follows:

Type of Process Control Completed By Frequency

Pre‐Operational Hygiene Checks Team Leader or delegate Prior to start‐up of

each shift

Sanitation and Swab Checks QA Department / delegate Weekly

GMP Inspections Quality Officer or Quality

Manager Daily

Process Inspection Team Leader, Operator or

Production Manager

Frequency depends

on the type of

inspection

Forms (respective lines/areas) including

process control sheets

Team Leader, Operator or

Production Manager

Frequency depends

on the type of process

Daily Review Quality Officer or Quality

Manager Daily

5.2.3 QA Department or delegate shall review completed forms daily. Recurring problems are

noted in the Non Conformance Register.

5.2.4 The QA Department shall verify the CCP records. Verification shall be conducted in the form

of evaluating the acceptability of the completed form and signing off.


Process Control

Page: 7 of 13

Version: 13


5.2.5 At each CP, QP, CCP and QCP, test requirements and/or inspection shall be completed as

defined in the relevant HACCP plan and/or SOP.

5.2.6 The Quality Manager or delegate shall be responsible for the establishment and

documentation of product specifications. These shall be based on customer requirements,

historical results, process capability studies, external regulatory and legal requirements.

5.2.7 Where physical or chemical aspects of raw materials, intermediate or finished product,

processes, and/or environment are critical to product safety, legality and quality, this shall be

adequately controlled, monitored and recorded.

5.2.8 Thermal processing, temperature of the freezer, chillers and Cesars are monitored by a time‐

temperature recording system which is linked to an automatic alarm system to monitor the

process status at an appropriate frequency.

5.3 HACCP Plans

5.3.1 For each product or product group, a HACCP plan shall be prepared by the Quality Manager

or delegate.

5.3.2 The HACCP plan is the written document, based upon the principles of HACCP, describing the

procedures for assuring the safety of a specific process.

5.3.3 The HACCP plan provides a systematic approach to the identification, evaluation and control

of food safety hazards based on seven principles:

Principle 1 Conduct a hazard analysis

Principle 2 Identify the critical control points

Principle 3 Establish critical limits

Principle 4 Establish monitoring procedures

Principle 5 Establish corrective actions

Principle 6 Establish verification procedures


Process Control

Page: 8 of 13

Version: 13


Principle 7 Establish record keeping procedures

5.3.4 Community Chef’s approach to HACCP is detailed in the HACCP Implementation Manual.

5.3.5 HACCP plans are to be reviewed by the Quality Manager or food safety consultant on an

annual basis or where significant changes have been made to either the:

Product, packaging, ingredients.

Process, storage or distribution methods.

Significant changes are those that will directly affect the safety or quality of the finished

products.

5.3.6 The HACCP Team shall consist of multi‐functional team of personnel. At least one member of

the team shall have attended a formal HACCP training course to ensure a thorough

understanding of the HACCP principles and their application (CODEX). The HACCP Team shall

be identified in each product manual.

5.4 Work Instructions

5.4.1 Work instructions shall be available for all processes where the absence of such instructions

could adversely affect product quality and safety.

5.4.2 Work instructions shall be available in the relevant production and service areas and may be

in any of the following formats:

Process control sheets which shall be completed by operators at predetermined

intervals and checked by Team Leaders.

Manufacturing instructions which document the series of steps necessary to ensure

the satisfactory completion of a process.


Process Control

Page: 9 of 13

Version: 13


Signs located in processing areas which shall specify particular operating

requirements.

Inclusion of Occupational Health and Safety issues associated with a work

instruction.

5.5 Process Change Control

5.5.1 The impact on HACCP plans, SOPs, process control documents and possible quality

implications must be assessed by the Production Manager and Quality Manager prior to any

changes made to the raw materials, product, CCPs, QCPs, process, storage and distribution.

5.5.2 QA‐SOP09 Approved Supplier Program and purchasing detail changes made to raw materials

and suppliers.

5.5.3 Changes to formulations must be authorised by the Production Manager, Production &

Planning Officer, Business Support Coordinator, Dietician (if applicable), Quality Manager,

Transformation Chef, Financial Controller, Operation Director and CEO (if applicable) on a

change request form.

5.5.4 Packaging changes must be authorised by the CEO, Operations Director, Facility Services

Manager, Quality Manager, Production Manager, Business Support Coordinator, Production

& Planning Officer and Financial Controller.

5.5.5 Alterations to equipment or equipment failure or process deviations are to be assessed by

the Porduction Manager and Quality Manager for impact on product safety and/or quality

and approved by the Facility Services Manager.

5.5.6 Changes shall be communicated via documentation according to the QA‐SOP01 Document

Control.


Process Control

Page: 10 of 13

Version: 13


5.5.7 In the event of changes to product formulation, processing methods, equipment or

packaging, the company shall, where appropriate, re‐establish process characteristics,

validate product data, to ensure product safety, legality and quality.

5.6 Raw Materials Control, Traceability and Stock Rotation

5.6.1 Raw materials shall be inspected and/or tested prior to use, according to QA‐SOP14

Inspection and Testing.

5.6.2 All raw materials (including unopened and partly used containers) shall be appropriately

stored and handled in production according to QA‐SOP10 Raw Material Receival and Storage.

5.6.3 Traceability of raw materials, work‐in‐progress and finished product shall be carried out

according to system procedure QA‐SOP06 Product Identification and Traceability.

5.6.4 A stock rotation system shall be in place to ensure that raw materials (at receival, storage,

thawing, assembly) and work‐in‐progress materials are used in the correct order i.e. the

oldest stock is used first and within the allocated shelf‐life/acceptable storage times. Receipt

documents and/or labelling shall facilitate correct stock rotation. The date coding must be

clear and concise and be understood by all staff.

5.7 Equipment Control and Maintenance

5.7.1 A planned maintenance program shall be in place to ensure continuing process capability.

Maintenance of plant and equipment shall be carried out according to SOP‐026 Premises and

Plant Maintenance.

5.7.2 In the case of equipment failure or process deviation, procedures shall be in place to

establish the safety status of the product, prior to release.

5.8 Release of Product for Distribution and Stock Rotation


Process Control

Page: 11 of 13

Version: 13


5.1.1 5.8.1 Community Chef shall ensure that products are not released unless all release

procedures have been followed. Goods shall be released for distribution when all CCP checks

have been completed and are appropriately verified, managed as follows:

All products can be released straight away. However if the routine microbiological results

do not comply, the company takes the risk of having products returned after further

testing.

Products shall be released on a stock rotation basis and shall be used in the correct order

and within the allocated shelf‐life. Receipt documents and/or product labelling shall

facilitate stock rotation.

5.8.2 Only authorised personnel shall release products i.e. CEO, Operations Director, Quality

Manager and Production Manager.

5.8.3 A stock rotation system is in place to ensure that finished products are dispatched in the

correct order i.e. the oldest stock is dispatched first and within the allocated shelf‐life.

Correct product labelling shall facilitate correct stock rotation. Stock rotation is maintained

by the Dispatch Team, monitored by the Dispatch Team Leader.

5.9 Non‐Conforming Product

5.9.1 Non‐conforming product will be handled according to QA‐SOP08 Control of Non‐Conforming

Products.

5.9.2 All non‐conformances shall be referred to the relevant Team Leader / Supervisor for action

without delay.

5.10 Layout of Establishment


Process Control

Page: 12 of 13

Version: 13


5.10.1 A copy of the establishment showing the location of major items of processing equipment,

receivals and despatch areas, product preparation and processing areas is held by the Facility

Services Manager.

5.10.2 On an annual basis, the establishment layout shall be reviewed for any updates that may

have occurred in the past year.

6 Monitoring

6.1 The Quality Team shall monitor process control during production and record it on QA‐

SOP13‐FOR01 GMP Checklist and review production records daily.

6.2 The Quality Manager shall monitor process control changes to ensure that it does not

impact on food quality and safety.

7 Corrective Actions

7.1 Corrective actions for any process control non‐conformance shall be discussed and

implemented by the Quality Manager or Quality Officer to the respective personnel. Any

deficiencies in process control shall be recorded in QA‐SOP08‐REG01 Non‐Conformance

Register.

8 Verification

8.1 Process control documents are subject to internal and external audits.


9 Documentation

QA‐SOP08‐REG01 Non‐Conformance Register.

QA‐SOP13‐FOR01 GMP Checklist.


Process Control

Page: 13 of 13

Version: 13


Production Records.


Inspection and Testing

Page: 1 of 9

Version: 12

Issue Date: 27 April 2020



05/12/11 2 Amended job titles and structure Mei Wong


05/09/12 4 Amend reference document names and numbers E Populin



06/01/16 7

Include Document Sponsor: Technical Manager.

Change Team Leaders to Team Leaders. Update

name of Testing Laboratory: Merieux NutriScience.

Remove 5.2.5: Supplying sample or COA with each

delivery.

Technical Manager to sign off CCPs in the absence

of Technical Officer only.

E Roccasalva


03/10/17 9

Removed obsolete QA‐SOP10‐DOC01 Raw Material

Testing Program from references and

documentation; Updated 5.1.1

Change 5.8.1 QA‐SOP11 Packaging, Handling,

Storage and Delivery to QA‐SOP11 Finished Product

Storage and Delivery

N Chee


30/10/19 11


Amend QA‐SOP20 to QA‐SOP21 Cleaning and

Sanitation

O

Tuifangaloka

27/04/20 12 Update name of Testing Laboratory: DTS Food Labs Ola T



Page: 2 of 9

Version: 12


1 Purpose

The purpose of this SOP is to document procedures for inspection and testing activities in order to

verify that the specified and regulatory requirements for product are met.

2 Scope

This procedure applies to the manufacture and warehousing of all Community Chef products from

the point of receival of raw materials to the point of dispatch of finished products.


3 References

3.01 Quality Manual

3.02 QA‐SOP15 Equipment Calibration

3.03 QA‐SOP14‐WI02 Retention Sample Collection

3.04 QA‐SOP10 Raw Materials Receival and Storage.

3.05 QA‐SOP10‐WI01 Unloading and Inspection of Raw Materials

3.06 QA‐SOP05 Process Control

3.07 QA‐SOP08 Control of Non‐conforming Product

3.08 QA‐SOP21 Cleaning and Sanitation

3.09 QA‐SOP09 Approved Supplier Program

3.10 QA‐SOP18 Pest Control



Page: 3 of 9

Version: 12


3.11 QA‐SOP23 Menu, Product & Packaging Development and Labelling.

3.12 QA‐SOP11 Finished product Storage and Delivery.



4 Definitions

Raw Materials Materials, including ingredients and packaging, used for the manufacture of

Community Chef products.

Goods Either a raw material (ingredient or packaging), work‐in‐progress or a

finished product.

Purchase order Document(s) raised to place an order with a supplier for the purchase of

materials.

Delivery Docket Document provided by the supplier with all materials sent listing description

of materials and quantities delivered.

Store person An employee who takes delivery or despatches goods.

5 Methods

5.1 General Requirements

5.1.1 Community Chef shall use QA approved raw materials that have been inspected and found to

conform to specifications.

5.1.2 Monitoring of all incoming raw materials for compliance to specification shall be specified

and based on risk assessment. The inspection method, frequency of inspection and

procedures shall be specified and documented. Suppliers of incoming materials, as



Page: 4 of 9

Version: 12


appropriate, shall provide evidence of guarantees, certifications/declarations of analysis or

certificates of conformity. Refer to QA‐SOP09 Approved Supplier Program and QA‐SOP10

Raw Material Receival and Storage.

5.1.3 The Quality Manager shall develop and maintain inspection and testing (or quality) plans,

defining the type and frequency of each test, for each product or product group.

5.1.4 The inspection and test status of work‐in‐progress, process parameters and finished product

shall be determined on a batch basis or on a periodic basis.

5.1.5 Inspection, measurement and testing equipment shall be maintained and calibrated in

accordance with QA‐SOP15 Equipment Calibration.

5.2 Inspection and Testing of Raw Materials

5.2.1 Personnel undertaking analyses shall be suitably qualified and/or trained, and shall be

competent to carry out the analyses required.

5.2.2 In determining the amount and nature of raw materials inspection and testing consideration

shall be given to the amount of control exercised at the suppliers premises and the recorded

evidence of conformance provided.

5.2.3 Visual evaluation of unopened containers/packages of raw materials upon receipt by store

personnel shall be carried out in accordance with QA‐SOP10 Raw Materials Receival and

Storage.

5.2.4 Chemical & microbiological evaluation of raw materials shall be carried out by DTS Food Labs

when the Quality Department deems it appropriate.

5.2.5 If raw materials are released for urgent production purposes prior to the normal required

verification, they shall be positively identified and recorded, in order to facilitate recovery

and replacement in the event of non‐conformance to specified requirements.



Page: 5 of 9

Version: 12


5.3 On‐Line Inspection and Testing

5.3.1 On‐Line inspection and testing shall be carried out in accordance with the following

documentation:

QA‐SOP05 Process Control and associated process control sheets and work

instructions located at critical control points and work stations.

5.3.2 In particular, processing and packing staff shall:

Conduct all tasks carefully, double checking wherever possible, especially during raw

material assembly and during calibration of testing equipment.

Treat each task as an inspection.

After conducting checks or tests and/or taking measurements, review the results

against predetermined standards.

Notify the Team Leader of any non‐conformance and commence corrective action as

per QA‐SOP08 Control of Non‐Conforming Product.

Initial each periodic process control sheet.

Where appropriate, collect and transfer test/shelf‐life/reference samples to cold

storage.

5.3.3 Team Leaders shall periodically inspect process control sheets during their respective shifts

and shall report any trends or abnormalities affecting the quality of the product to the QA

Department without delay.

5.4 Hygiene, Cleaning and Sanitation Surveys

5.4.1 Hygiene, cleaning and sanitation surveys form an integral part of the inspection and testing

regime for the manufacture of Community Chef’s products. Such surveys that consist of the



Page: 6 of 9

Version: 12


following components shall be carried out in accordance with QA‐SOP12 Operational Hygiene

and QA‐SOP20 Cleaning and Sanitation.

Surface swabs surveys.

Pre‐operational hygiene checks (by Team Leaders or delegate).

Housekeeping surveys/GMP reports (Quality Officer or delegate).

5.4.2 Corrective action required as a result of the above activities shall be carried out in

accordance with QA‐SOP08 Control of Non‐Conforming Product.

5.4.3 Pest control activities shall be conducted and recorded in the frequency and manner defined

by QA‐SOP18 Pest Control.

5.5 Inspection and Testing of Finished Product

5.5.1 The Quality Manager shall establish finished product specifications and standards, in

consultation with the Production Manager, Dietician and/or customer.

5.5.2 The frequencies and methods of inspection and testing of finished products shall be as

defined in the verification schedule in the respective HACCP Manuals.

5.5.3 Sensory evaluation of finished products shall also be conducted as per customer

requirements.

5.6 Microbiological Testing Regime & Verification

5.6.1 The laboratory carrying out the analyses i.e. the testing laboratory shall have recognised

laboratory accreditation (NATA) or operate with the requirements and principles of ISO

17025.

5.6.2 The Quality Manager shall review the trends from the microbiological testing results of

finished goods.



Page: 7 of 9

Version: 12


5.6.3 Based on the historical microbiological results and advice from the Manager in‐charge of

Microbiology at the testing laboratory, a specification for setting the acceptable criteria and

testing frequency for raw materials or finished goods shall be determined, as per QA‐SOP‐

014‐WI01 Product Testing.

5.6.4 Personnel responsible for collecting the products shall be trained and the frequency for

collection as nominated in QA‐SOP‐014‐WI01 Product Testing.

5.6.5 If the criteria for acceptance is exceeded, the Quality Manager will advise the product to be

put on either:

“Hold” status and further re‐testing will be conducted. Refer to QA‐SOP08 Control of

Non‐Conforming Product or

Cleared on the basis of previous verification studies, suggesting the product when

used by the end‐user (under recommended conditions) will be safe. In this case, the

specification limits may be reviewed.

Recalled from councils and meal recipients.

5.6.6 A further sample of the finished goods from the same batch will be sent to the laboratory for

further confirmation.

5.7 Retention Samples

5.7.1 Retention samples will be kept for products manufactured.

5.7.2 The Quality Manager shall undertake a risk assessment based on the product risk and volume

supplied to determine the number of product samples to be retained over the nominated

shelf life.

5.7.3 Products manufactured on the day for the particular product type will be retained as defined

in QA‐SOP14‐WI02 Retention Sample Collection.



Page: 8 of 9

Version: 12


5.7.4 The products will be retained for the duration of its shelf‐life under the same conditions

specified on the label, in order for investigation of potential issues pertaining to safety,

quality or regulatory compliance.

5.7.5 At the end of each month, the pallet of retained sample that has just passed its Use by Date

shall be removed and dumped.

5.8 Warehousing and Distribution

5.8.1 The Despatch store personnel shall inspect product for correctness of identification and

coding, and absence of mechanical or temperature abuse at each stage of handling, as

defined in QA‐SOP11 Finished Product Storage and Delivery.

6 Monitoring

6.1 The QA Department or delegate shall monitor the inspection and testing of raw materials,

on‐line processes, finished products, sample collection and retention sample collection. This

can be part of GMP audits, and/or on‐line monitoring activities.

6.2 Team Leaders and operators shall monitor on‐line processes and record them in the

respective forms.

7 Corrective Actions

7.1 Any deficiencies noted shall be recorded in the QA‐SOP08‐REG01 Non‐Conformance Register

and corrective actions are to be implemented by Quality Manager to respective personnel.

Refer to QA‐SOP08 Control of Non‐Conforming Product.

8 Verification

8.1 The Quality Manager or Quality Officer reviews production inspection records daily.

8.2 Inspection and testing documents and procedures are subject to internal and external audits.



Page: 9 of 9

Version: 12



9 Documentation

9.1 Each morning the Quality Officer or trained delegate shall collect, review and file process

control sheets from the previous day’s production.

9.2 The Quality Officer or trained delegate shall check that all process control sheets have been

collected and that they have been filled in correctly, legibly and completely, and that they

accurately reflect the production activities of the day concerned.

9.3 In the absence of the Quality Officer or trained delegate, the Quality Manager shall review

Critical Control Point Records and sign off confirming the product manufactured meets all

established CCPs.

9.4 Microbiological Swab Reports shall be prepared, circulated and filed by the Quality Officer or

Quality Manager.

9.5 Housekeeping Survey/GMP reports shall be prepared, circulated and filed by the Quality

Officer or Quality Manager.

9.6 All records relating to the inspection and testing of raw materials, work in progress,

processing parameters, hygiene cleaning and sanitation procedures and finished products

shall be maintained according to the QA‐SOP05 Process Control.

9.7 Delivery Dockets.


Personal Hygiene

Page: 1 of 12

Version: 9

Issue Date: 30 August 2019



09/02/12 2 Amend job titles and structures E Populin

11/10/13 3 Amend job titles and structures E Roccasalva

29/12/14 4 Amend job titles and structures N Chee

21/12/15 5 Update Leading Hand to Team

Leader E Roccasalva

19/12/16 6

Amend job titles and structures

4.5.4 Change policy: there is now a

requirement to wear a beard cover

if a beard or moustache is present

regardless of the length.

5.2 Locker inspection to be

changed to ‘routinely’.

M Wong

30/10/17 7 Amend 4.3.2 – footwear should be

of the lace up variety, not must. E Roccasalva

24/09/18 8

Amend job titles and structures

4.5.5 No jewellery policy exception

included for Staff wearing a ring

that cannot be removed.

N Chee

30/08/2019 9

Amend job title and structure

4.3.1 Administration Manager

replace with Business Support Co‐

Ordinator

O Tuifangaloka


Personal Hygiene

Page: 2 of 12

Version: 9


1 Purpose

High standards of personal hygiene and behaviour are necessary to minimise contamination, cross

contamination and thereby achieving food safety and quality. Personal hygiene includes the

cleanliness of protective clothing and personal practices. This SOP identifies and co‐ordinates

activities required to meet these standards.

2 Scope

This procedure applies to all employees, visitors and contractors entering food processing areas,

storage areas and surrounds.


3 References


3.2 VIC Food Act 1984


3.4 QA‐SOP13 Operational Hygiene and GMP.

3.5 QA‐SOP21 Cleaning and Sanitation.

3.6 QA‐SOP16‐DOC01 Production Contractors Food Handler Induction.

3.7 QA‐SOP16‐DOC02 Visitors and Office Contractors Induction.

3.8 QA‐SOP16‐DOC03 Production Contractors Non Food Handler Induction.


Personal Hygiene

Page: 3 of 12

Version: 9


4 Method


4.1.1 All personnel, visitors and contractors must be inducted in personal hygiene and the

respective forms completed and filed in the respective department. Refer to QA‐SOP16

Training.

4.2 Personal Health Requirements

4.2.1 All employees working in production areas must have a medical clearance certificate issued,

before engaging in the handling or preparation of food, showing there is no impediment to

such employment.

4.2.2 It is the responsibility of the recruitment provider to ensure that each employee is medically

certified prior to the commencement of employment.

4.2.3 Any employee suffering from an infectious disease or condition or with which they have

been in contact e.g. severe cold or flu, stomach cramps, vomiting, diarrhoea, contagious or

infectious disease, infected wounds or sores, dermatitis, rashes or skin irritations, must

notify their Supervisor prior to the commencement of work.

4.2.4 Where Community Chef is aware of any person who has entered the premises that is

suffering from a relevant infectious disease, steps shall be taken by senior management to

minimise any risk to product safety.

4.2.5 Personal medicines are not allowed in food production, storage and dispatch areas and any

part of the facility where there is a risk of contamination of the product. They should be kept

in personal lockers at all times. For employees suffering from allergies or asthma,

authorisation must be sought from their direct Supervisor and Quality Manager if they need

to carry their epipen or inhaler in the production areas.


Personal Hygiene

Page: 4 of 12

Version: 9


Absence from Work Due To Illness

4.2.6 Following an absence from work due to illness, the employee is required to complete a

Health Questionnaire (QA‐SOP12‐FOR03 Health Questionnaire – Food Handling Employees

and Contractors) prior to returning to work.

4.2.7 The completion of the Health Questionnaire aims to establish the risk of illness which could

affect the employee’s ability to handle food, as a result of communicable diseases.

4.2.8 The completion of the Health Questionnaire will result in 1 of 2 outcomes:

1/ Return to work or

2/ Medical clearance required prior to return to work.

4.2.9 A medical clearance can be obtained from an employee’s local General Practitioner / Medical

Centre or the company’s preferred Medical Service.

Visitors and Contractors

4.2.10 All visitors and contractors who will be entering food production, storage and dispatch areas

must complete a Health Questionnaire (QA‐SOP12‐FOR04 Health Questionnaire – Visitors

and Contractors (Non Food Handlers)) prior to commencement. The Health questionnaire

will be provided by the host staff member or direct Supervisor.

4.2.11 The completion of the Health Questionnaire aims to establish the risk to food safety as a

result of a prescribed health condition.

4.2.12 The completion of the Health Questionnaire will result in 1 of 2 outcomes:

1/ Commence to operate within a food production environment or

2/ Medical clearance required prior to commencement within a food production

environment.


Personal Hygiene

Page: 5 of 12

Version: 9


4.2.14 A medical clearance can be obtained from a local General Practitioner / Medical Centre.

4.3 Protective Clothing and Footwear

4.3.1 Clothing

Clean protective clothing covering personal clothing must be worn and shall be designed to

ensure product safety is not compromised e.g. no buttons are allowed.

Protective clothing must not to be worn off site and must be cleaned when excessively

contaminated or soiled.

Each employee in production will be issued with clean outer protective clothing.

Thermal insulating garments should only be worn underneath protective clothing.

No safety pins or stickers should be worn to secure clothing.

Employees who are in direct contact with food must not wear their uniforms outside.

The Business Support Co‐Ordinator must liaise with the laundry contractor to ensure that there is

an adequate supply of clean uniforms for the workers.

As a minimum, the garments are changed on a daily basis or changed as soon as they become

excessively dirty.

Dirty uniforms shall only be removed and placed in the dirty uniform bin in the designated

change room on a daily basis.

These are picked up twice per week by the approved laundry contractor. At the same time, clean

uniforms are dropped off.

Our garments are microbiologically tested annually by the laundry contractor and are washed

according to Australian Standards.


Personal Hygiene

Page: 6 of 12

Version: 9


4.3.2 Footwear

Clean steel cap footwear must be worn and cleaned when contaminated or soiled by the wearer.

Footwear must be easily cleanable, impervious and should not be of the laced up variety.

4.3.3 Hairnets

All hair shall be fully contained to prevent product contamination and hairnets shall be single

use.

Green hairnets are for personnel in receival and despatch, blue hairnets are for personnel in

fragilisation, yellow hairnets are for personnel in the transformation, assembly and retort area.

Hairnets must not be taken off in the production area.

In the case of an operator having to change from a processing job to a cleaning job, he/she can

wear the same gear but must put a red hairnet over the green, blue or yellow hairnet.

In cases where a worker is changing from a cleaning job to a processing job, the operator must

change his hairnet colour before starting the newly assigned job i.e. Food Handling workers are

not allowed to wear a red hairnet whilst processing food.

Refer to QA‐SOP05‐WI11 Colour Coding.

4.3.4 Gloves, Sleeves and Aprons

Gloves, sleeves and aprons shall be worn where indicated and must be cleaned adequately.

Disposable gloves, sleeves and aprons shall be thrown away at the end of each shift or when

dirty in the rubbish bins provided in the production area.

Gloves, sleeves or aprons must never be left on processing or packing equipment or left

unattended. Ensure that all gloves, sleeves and aprons are accounted for. Report any missing,

damaged or torn gloves and sleeves to your Supervisor immediately.


Personal Hygiene

Page: 7 of 12

Version: 9


All food handlers must dispose of and use a new pair of gloves, sleeves and disposable aprons

when:

o Prior to entering food handling areas.

o Before starting work.

o After breaks.

o After going to the toilet.

o After eating and drinking.

o After touching body parts.

o After touching / when in contact with raw food.

o After handling waste, carrying out cleaning jobs or handling dirty equipment.

o After using chemicals.

o After sneezing, coughing or nose blowing.

o Between handling different types of ingredients.

o Every 2 hours.

o Where cross‐contamination might be an issue.

Proper hand washing procedures must be carried out prior to putting gloves, sleeves and aprons

on.

Disposable gloves, sleeves and aprons must be disposed of when contaminated in the rubbish

bins provided in the production area.


Personal Hygiene

Page: 8 of 12

Version: 9


Team Leaders are responsible for ensuring and monitoring that their staff follows the glove,

sleeve and apron policy. The QA Department will perform spot checks.

Aprons are to be washed on a daily basis or if soiled during production. Disposable aprons shall

be changed whenever they become overly soiled and pose a risk of contamination to products.

Aprons must be taken off prior to leaving the work area.

4.4 Use of Lockers

4.4.1 It is the responsibility of each member of staff to ensure their lockers are kept in a neat and

tidy condition. The QA Department will perform spot checks with the employee present.

4.4.2 A personal locker is provided to each employee.

4.4.3 Perishable food must not be stored in lockers.

4.4.4 Uniforms must not be kept in personal lockers.

4.4.5 Disciplinary actions may take place if there is a failure to comply with these requirements.

4.5 Personal Hygiene

4.5.1 Hand‐washing and sanitation to be performed with E‐water:

Hands to be washed when entering the production areas.

Hands to be washed when they become contaminated.

Hands to be washed prior to handling product.

4.5.2 The cleaners will ensure the maintenance of hand wash facilities on a daily basis.

4.5.3 Fingernails shall be kept short, clean and unvarnished. False fingernails are not permitted.


Personal Hygiene

Page: 9 of 12

Version: 9


4.5.4 Personnel must be clean shaven or a beard cover must be worn if a moustache or a beard

is present.

4.5.5 No jewellery is allowed in the production areas. Exception applies to Staff wearing a ring

that cannot be removed; ring must be encased in a disposable glove when handling food.

4.5.6 Eating and drinking are prohibited in food production and handling areas, locker rooms and

changing rooms. Food tasting by Chefs and QA must follow proper tasting procedure

4.5.10.

4.5.7 Community Chef is a non‐smoking site.

4.5.8 Excessive perfume or aftershave shall not be worn.

4.5.9 Personnel must not sneeze, spit, blow or cough on food and food contact surfaces. Staff

who needs to sneeze or cough during food production should mask his/her mouth and

nose with his/her hands. They must turn their faces away from food and food contact

surfaces before they do so. They must remove and discard contaminated gloves and follow

proper hand washing and sanitising procedures. They shall wear a new pair of gloves prior

to going back to food handling.

4.5.10 Proper tasting procedures must be followed: Food handling personnel must thoroughly

wash hand and use a sanitised spoon to obtain food. If further tasting is required, staff

must use a new sanitised spoon (or disposable spoon). Hands must be thoroughly washed

after tasting.

4.5.11 Personnel must not urinate or defecate except in a toilet.

4.5.12 All cuts, grazes and abrasions must be covered with a distinctively coloured (blue)

waterproof dressing which is also metal detectable. This shall be company monitored and

issued.

4.6 Maintenance Workers


Personal Hygiene

Page: 10 of 12

Version: 9


4.6.1 All company standards and requirements as defined in company policies and standard

operating procedures also apply to Maintenance workers.

4.6.1 Procedures for maintenance and repair of the plant are described in QA‐SOP26 Premises and

Plant Maintenance.

4.6.2 Maintenance workers shall wear a red hairnet and a clean dustcoat if working on food

contact surfaces. They shall wash their hands with e‐Water and go through the footbath

prior to entry.

4.7 Visitors, Management, Office Contractors and Production Contractors (Food

Handlers and Non Food Handlers)


operating procedures also apply to visitors, management and contractors.

4.7.2 It is the responsibility of the management staff to ensure all contractors and visitors are

aware of the company standards and requirements.

4.7.3 All production contractors who will handle food must be inducted in QA‐SOP16‐DOC01

Production Contractors Food Handler Induction by the direct Supervisor.

4.7.4 All visitors must be inducted in QA‐SOP16‐DOC02 Visitors and Office Contractors Induction

by the host staff member.

4.7.5 All office contractors must be inducted in QA‐SOP16‐DOC02 Visitors and Office Contractors

Induction by the direct Supervisor.

4.7.6 All production contractors who do not handle food e.g. maintenance contractors, must be

inducted in QA‐SOP16‐DOC03 Production Contractors Non Food Handler Induction by the

responsible supervisor.


Personal Hygiene

Page: 11 of 12

Version: 9


Monitoring

5.1 The QA Department shall monitor personal hygiene requirements by doing random checks

on personnel clothing and hand washing on return from breaks and regular inspection of

personal hygiene practices in production areas. This shall be recorded in QA‐SOP13‐FOR01

GMP Checklist.

5.2 Locker inspections will be conducted by the Quality Department routinely to ensure that the

quality management system is followed and will be documented in QA‐SOP13‐REG02 Locker

Inspection.

6 Corrective Action

6.1 The Quality Manager, Management and Team Leaders shall monitor compliance of hygiene

requirements and additional training will be provided or other corrective action initiated

where necessary (Refer to QA‐SOP13 Operational Hygiene and GMP and QA‐SOP21 Cleaning

and Sanitation).

6.2 Where appropriate, re‐training of areas that have significant impacts on product safety will

be conducted. This could be initiated from customer complaint issues, audits or other

deficiencies. Records will be updated accordingly.

7 Verification

7.1 Verification of the implementation of this procedure will be via internal & external audits.

This may include review of monitoring records and procedures.

7.2 The internal and external audit findings will be discussed at Management Review Meetings.

8 Documentation



Personal Hygiene

Page: 12 of 12

Version: 9




8.4 QA‐SOP12‐FOR03 Health Questionnaire – Food Handling Employees and Contractors.

8.5 QA‐SOP12‐FOR04 Health Questionnaire – Visitors and Contractors (Non Food Handlers).

8.6 QA‐SOP13‐FOR01 GMP Checklist.


Operational Hygiene & GMP

Page: 1 of 18

Version: 9

Issue Date: 06 Aug 2019



Melinda

Chapman &

Mei Wong

05/12/11 2 Amended job titles and structure Mei Wong

09/02/12 3 Amended job titles and structure E Populin

20/05/13 4 Amended job titles and structure. Add item

to References E Populin

16/10/13 5 Amended job titles and structure E Roccasalva

31/12/14 6 Amended job titles and structure. Update

Allergen Management to include GF. E Roccasalva

03/08/15 7

Section 4.2: Add sensory evaluation

controls.

Section 4.18.3 Add non‐CC retail products

to allergen management. Section 4.19: Add

Air Quality.

Section 4.14 Amend glass policy.

Section 4.21 Include control of loose metal

objects and knives.

Section 4.16 Include Soft Plastic Policy

M Wong

22/12/16 8 Amended job titles and structure

Update dropped product policy to match

QA‐SOP17 Waste Management procedure

E Roccasalva

06/08/19 9

Amended job titles – replace Technical

Manager with Quality Manager, removed

QA & Transformation Coordinator

Corrective Action section 6.2 Replace Skills

Matrix with Internal Training Register.

Documentation section 8.4 Replace Skills

Matrix with Internal Training Register.

O Tuifangaloka



Page: 2 of 18

Version: 9


1 Purpose

High standards of operational hygiene and good manufacturing practices (GMP) are necessary to

minimise the likelihood of food safety hazards being introduced through the work environment; to

control biological, chemical, and physical contamination of the product(s), including cross‐

contamination between products; and to control food safety hazard levels in the product and

product processing environment.

Operational hygiene and good manufacturing practices includes the basic conditions and activities

necessary to maintain a hygienic environment within the food processing environment and includes

the personnel, premises, plant, services and inputs which may impact on food safety and quality.

This SOP identifies and co‐ordinates activities required to meet these standards

2 Scope

This procedure applies to any company function or department that may have an impact – directly or

indirectly – on food safety.


3 References

3.1 Food Standards Australia New Zealand and VIC Food Act 1984


3.3 QA‐SOP12 Personal Hygiene

3.4 QA‐SOP21 Cleaning and Sanitation.





Page: 3 of 18

Version: 9



3.8 QA‐SOP05‐WI16 Holding of Products from Transformation to Retorting.

3.9 QA‐SOP27 Allergen Control

4 Method


4.1.1 All personnel must be inducted in operational hygiene and good manufacturing practices and

the respective forms completed and filed in the respective department. Refer to QA‐SOP16

Training.

4.2 Food Hygiene

4.2.1 All necessary steps must be taken and policies and procedures followed to prevent

contamination of food and food contact surfaces, including but not limited to:

Ready to eat (RTE) foods / finished products must be stored separately from raw or

unwashed foods.

If RTE foods are stored within the same cold storage unit or vehicle as raw or unwashed

foods, the RTE foods must be stored above raw or unwashed foods.

Foods must be stored in waterproof, pest proof, food grade containers with well fitting

lids or in sealed food grade packaging. Food must never be stored in chemical containers.

Good personal hygiene must be practiced at all times by staff, visitors and contractors.

Refer to QA‐SOP12 Personal Hygiene.

Personnel must not move into restricted or sensitive areas unless authorised.

Pests and animals must be kept out of the food premises. Refer to QA‐SOP18 Pest

Control.



Page: 4 of 18

Version: 9


Direct human contact with food must be limited and when handling RTE foods, food

handling gloves or clean and sanitised tongs or utensils will be used.

Food handler gloves must be changed at least every 2 hours and whenever there is a

likelihood they have been contaminated or damaged. Refer to QA‐SOP12 Personal

Hygiene, 4.3.4.

Utensils and cutting boards used in fragilisation and preparation of raw foods must not be

used for RTE foods.

Any spillages of foodstuffs or waste must be cleaned up as soon as possible and all waste

food material must be suitably wrapped and placed into a waste bin as soon as possible.

Refer to QA‐SOP17 Waste Management.

Garbage and waste must be safely handled and disposed of so as not to contaminate food

or food handling personnel Refer to QA‐SOP17 Waste Management.

Chemicals must be stored in an area completely separated from the food processing

areas. Chemicals must never be stored in food containers or receptacles. Refer to QA‐

SOP20 Chemicals.

Food packaging must be kept in a clean and sanitary condition and be correctly handled

so as not to contaminate food. Refer to QA‐SOP10 Raw Material Receival and Storage.

All food storage areas, food processing areas, food contact surfaces, work surfaces, food

equipment and food handling utensils must be kept in a clean and sanitary condition.

Refer to QA‐SOP21 Cleaning and Sanitation.

Crates and cutting boards are colour coded. Refer to QA‐SOP05‐WI11 Colour Coding.

Damaged or deteriorated food handling utensils must be discarded immediately, reported

to management and not used under any circumstances.



Page: 5 of 18

Version: 9


Damaged or deteriorated equipment, fixtures or fittings must be repaired or replaced

Refer to QA‐SOP26 Premises and Plant Maintenance.

Steel wool or metal scourers must not be used in the production facility.

Personnel must take care of any knife issued to them. Knives must never be lent to other

personnel. Personnel must not take their knife off the premises, under any circumstances

and any loss or damage to the knife or knife blade must be reported immediately to the

Supervisor.

Drawing pins, staples, rubber bands, paper clips, pins and other stationery items that may

potentially contaminate food must not be brought into the food processing area or any

area where food is stored or handled.

Sticky tape / cellotape is not be used in the food production area; signs should be

laminated and adhered professionally or in such a way they pose no risk to food.

The use of any materials likely to cause product contamination in the production areas of

the facility, e.g. staples in boxes, must be brought to the attention of the Supervisor.

No welding, riveting, drilling or soldering is to be carried out on plant, which is being used

for production. Any part of the production area where construction work is being carried

out must be screened off to prevent risk of product contamination and on completion of

maintenance or construction work the area must be cleaned thoroughly and debris

disposed of. Refer to QA‐SOP26 Premises and Plant Maintenance.

Staff must not eat or taste any product being processed in the food handling zones except

for the purpose of sensory evaluation.

Sensory evaluation can be undertaken in food handling zones provided that:

- Food safety is not compromised.

- Sensory evaluation is conducted by authorised personnel.



Page: 6 of 18

Version: 9


- A high standard of hygiene is practiced by personnel conducting sensory evaluation.

- Sensory evaluation is conducted in areas equipped for the purpose.

- Equipment for sensory evaluation is sanitized, maintained and stored away from

processing equipment.

4.2.2 It is the responsibility of every employee to immediately report to the Team Leader,

Production Planning Officer, Facility Services Manager, Quality Manager or Production

Manager the discovery of contamination in any area of the processing facility that

constitutes a risk to product and / or personnel.

4.2.3 If for any reason an employee feels that they may have contaminated food, they must report

the incident to the Team Leader, Quality Manager, Production Planning Officer, Facility

Services Manager or Production Manager immediately.

4.2.4 If for any reason an employee feels that contaminated product may have been dispatched to

customer(s) they must report the incident to the Team Leader, Production Planning Officer,

Facility Services Manager, Quality Manager or Production Manager immediately.

4.2.5 All necessary steps must be taken and food process controls followed to destroy or minimise

the growth of potentially harmful microorganisms in food and on food contact surfaces,

including but not limited to:

Temperature controls for thermal processing (cooking and pasteurising) must be strictly

adhered to.

Cold ingredients must be kept at less than 5°C (Target 4°C).

If there are unforeseen delays in preparation / fragilisation, potentially hazardous food

must be returned to cold storage.

Pasteurised food must be chilled quickly as part of the retorting process. Unpasteurised

cook‐chill food must be chilled quickly using blast chillers or Finished Goods Chillers.



Page: 7 of 18

Version: 9


Dry foods must be kept dry.

All food contact surfaces must be cleaned and sanitised according to QA‐SOP21 Cleaning

and Sanitation and related Work Instructions.

Salad fruits and vegetables that are to be consumed raw and unpeeled must be washed

and sanitised.

4.2.6 It is the responsibility of every employee to immediately report to Management the

discovery of breaches in food process controls.

4.3 Staff Facilities

4.3.1 Adequate numbers of personnel hygiene facilities are located close to the points where

hygiene requirements apply and are clearly designated to ensure that an appropriate degree

of personal hygiene is maintained and to avoid contamination of materials and the

production environment.

4.3.2 Facilities are sited to enable personnel to move to the production area without

contaminating their work wear.

4.3.3 Lavatories of hygienic design areas with hand washing and drying facilities are provided in

adequate numbers at locations away from the production area.

4.3.4 Lavatories do not open directly onto production, packing or storage areas.

4.3.5 Adequate personal lockers of sufficient size to accommodate all reasonable personal items

are provided.

4.3.6 Personal lockers are separate from uniform lockers which should not be used for storage of

personal items.

4.3.7 Locker rooms are accessed without the need to enter production areas

4.3.8 Lockers are checked as required for cleanliness.



Page: 8 of 18

Version: 9


4.3.9 Eating, drinking, the storage of food and smoking is not allowed in locker rooms, production

or packing areas. Shelf stable, sealed foods only, are allowed in lockers, no perishable items.

4.3.10 All facilities and production areas entrances have hygienic hand washing and drying including

dedicated non‐hand operated wash basins and a supply of alkaline and acidic E‐water and

disposable towels.

4.3.11 Before entering any part of the manufacturing area all staff must wear suitable clean

protective clothing.

4.3.12 These will be supplied and laundered by the Community Chef.

4.3.13 Specific protective clothing is provided for visitors and contractors in all changing facilities at

production entrances.

4.3.14 Visitors and contractors must have permission from Community Chef Management to enter

food processing areas.

4.4 Use of signs

4.4.1 Appropriate food safety signage is placed throughout the food production facility to

communicate and reinforce safe food and personal hygiene practices and techniques.

4.4.2 Signs are not displayed in a manner that creates a risk of product contamination.

4.5 Staff, Visitors and Contractors Movement

4.5.1 High and low risk areas are segregated with restricted access to high risk areas and the

requirement for dedicated clothing, footwear, tools and equipment

4.5.2 Adequate security arrangements are in place with restricted site access and control of

visitors.

4.5.3 People movement is controlled to minimise risk of cross contamination.



Page: 9 of 18

Version: 9


4.6 Visitors, Management, Office Contractors and Production Contractors (Food

Handlers and Non Food Handlers)


operating procedures also apply to visitors, management and production contractors.

4.6.2 It is the responsibility of the management staff to ensure all contractors and visitors are

aware of the company standards and requirements.

4.6.3 All production contractors who will handle food must be inducted in QA‐SOP16‐DOC01

Production Contractors Food Handler Induction by the direct Supervisor.

4.6.4 All visitors must be inducted in QA‐SOP16‐DOC02 Visitors and Office Contractors Induction

by the host staff member.

4.6.5 All office contractors must be inducted in QA‐SOP16‐DOC02 Visitors and Office Contractors

Induction by the direct Supervisor.

4.6.6 All production contractors who do not handle food e.g. maintenance contractors, must be

inducted in QA‐SOP16‐DOC03 Production Contractors Non Food Handler Induction by the

responsible supervisor.

4.7 Premises Environment

4.7.1 The food processing facility is located away from:

areas which present a potential risk of contamination

environmentally polluted areas and industrial activities which pose a serious threat of

contaminating food.

areas subject to flooding unless sufficient safeguards are provided.

areas prone to infestations of pests.



Page: 10 of 18

Version: 9


areas where wastes, either solid or liquid, cannot be removed effectively.

4.7.2 Site boundaries are defined and controlled.

4.7.3 Security arrangements are in place to control access to the site.

4.7.4 Roads, yards, pathways, parking areas and vegetation areas are maintained and have

adequate drainage.

4.7.5 The site is covered by a maintenance programme Refer to QA‐SOP26 Premises and Plant

Maintenance

4.8 Premises Construction and Layout

4.8.1 Ceilings

All ceilings and their finishes are impervious and non‐absorbent, washable and easily

cleaned, non‐contaminating and non‐tainting.

Ceilings and overhead fixtures are constructed to minimize the build up of dirt and

condensation and the shedding of particles.

False ceilings have adequate access to the void for cleaning and pest management.

4.8.2 Floors

Floors are made of durable, impervious and non‐absorbent, washable and easily cleaned,

non‐contaminating and non‐tainting material.

Floors are constructed from materials that are able to withstand the cleaning methods

applied within the facility.

Floors are constructed to allow adequate drainage and cleaning.



Page: 11 of 18

Version: 9


Wall/floor junctions are design to prevent the accumulation of dirt and to be easy

cleaned.

4.8.3 Internal Walls

All internal walls and their finishes are durable, impervious and non‐absorbent, washable

and easily cleaned, non‐contaminating and non‐tainting.

Walls are constructed from materials that are able to withstand the cleaning methods

applied within the facility.

All coving is designed to prevent damage and to be easy to clean.

4.8.4 Lighting

Good lighting is maintained to ensure clean conditions, and encourage good

housekeeping

Lighting levels are > 500 Lux when an area is in use by personnel

All lights are sealed and protected by polycarbonate diffusers

4.8.5 Doors

Access to production areas is minimised.

External doors do not open directly into production areas

Doors are all:

o Tight fitting

o Easily operated

o Easy to clean



Page: 12 of 18

Version: 9


o Hygienic

o Have no exposed wood

o Self Closing

o Rapid close doors are used whenever possible

o Roller doors have rubber strips and strip brushes to ensure they are

adequately sealed

4.8.6 Internal Drains

Covered drainage in wet areas (including footbaths) is in place and provides adequate

outflow.

Internal drains are constructed and maintained to ensure they do not to leak, block,

overflow or allow access by vermin into the food premises.

4.8.7 One Way Flow

Product Process flow is logical and follows a one way flow system

Process flow is designed to prevent contamination

Operator/people movement is controlled to minimise risk of cross contamination

4.8.8 Separation High and Low

There is segregation of high and low risk areas. Access to high risk areas is restricted and

dedicated clothing, footwear, tools and equipment used.

4.8.9 Storage areas



Page: 13 of 18

Version: 9


All areas for storage of ingredients, packaging and chemicals are secured, clean,

maintained, properly enclosed and adequately ventilated

All chemicals, including cleaning and maintenance compounds, and non‐product

materials, are stored in separate locked areas

Separate areas are designated and used for storing chemicals, packaging, raw materials

and finished products to avoid cross‐contamination risks

Separate areas are maintained for rework and quarantined products

Refrigeration units for storage of chilled and frozen foods are maintained in good repair

and regular calibration of temperature gauges is undertaken

4.9 Cleaning and Sanitation

4.9.1 All equipment, utensils, food contact surfaces, strip and air curtains, floor seals, refrigeration

units, walls, floors, ceilings, storage areas, amenities, and food transport vehicles are

maintained in a clean and hygienic state in accordance with QA‐SOP21 Cleaning and

Sanitation.

4.10 Equipment

4.10.1 All equipment used to prepare, process, cool and pack food products is designed and sited to

be easily cleaned and maintained;

4.10.2 Equipment food contact surfaces are designed to be easily cleaned and sanitised. Refer QA‐

SOP21 Cleaning and Sanitation

4.11 Preventative Maintenance

4.11.1 Premises, plant and equipment is regularly assessed to ensure it is in good condition as part

of the planned maintenance program;



Page: 14 of 18

Version: 9


4.11.2 Equipment, fixtures and fittings or areas of the premises found or reported to be damaged,

broken or deteriorated are repaired or replaced. Refer QA‐SOP26 Premises and Plant

Maintenance

4.12 Waste, Rework and Work In Progress Identification and Control

4.12.1 Work‐in‐progress, material out‐of‐spec and waste are clearly identified and segregated

during production and storage. Refer to QA‐SOP17 Waste Management and QA‐SOP05‐

WII05 Work‐in‐Progress Labelling.

4.12.2 Assessments are undertaken to ensure no risk of allergens or cross contamination from

rework.

4.12.3 Waste bins are clearly identifiable from other containers and packaging.

4.12.4 Waste management systems are in place to ensure waste is identified, collected, removed

and disposed of in a manner which prevents contamination of products or the manufacturing

environment. Refer QA‐SOP17 Waste Management.

4.13 Dropped Product & Utensils

4.13.1 Packaged products which have dropped to the floor and with the integrity of the packaging

still intact are not considered as waste. All unpackaged products which have dropped onto

the ground shall be condemned and treated as waste.

4.13.2 A food processing tool or utensil that has come in contact with any non‐food grade,

contaminated or unsanitised surface shall not be re‐used until it has have been re‐cleaned

and sanitised in accordance company cleaning procedures. Refer to QA‐SOP21 Cleaning and

Sanitation and work instructions for cleaning.

4.14 Glass Policy

4.14.1 All glass objects of similar material in food handling/contact zones shall be listed in QA‐

SOP13‐REG03 Glass Register including details of their location.



Page: 15 of 18

Version: 9


4.14.2 Glass including glass equipment, utensils, containers, test tubes, China, ceramics, bristle

plastic and bottles are not permitted in the food processing, storage or handling areas

(except where the product is contained in packaging made from these materials, or

measurement instruments with glass dial covers or MIG thermometers required under

regulation).

4.14.3 Windows, MIGs, pressure gauges, glass instrument dial covers and Cesar doors are made of

glass and must be inspected during pre‐operational hygiene checks, post‐production checks

and as part of the preventive maintenance schedule. Refer to QA‐SOP13‐WI01 Glass Policy.

4.14.4 Daily GMP inspections of food handling/contact zones must be carried out to ensure they are

free of glass or other like material and to establish no changes to the condition of the objects

listed in the glass register.

4.14.5 All light fittings are covered with polycarbonate outer tubes.

4.15 Wood Policy

4.15.1 Wood is not permitted in high risk processing areas or as a food contact surface. Wood

products and wooden implements and boards must not be brought into the production

facility. Refer to QA‐SOP13‐WI02 Wood Policy.

4.15.2 Wooden pallets must be checked for their condition and must be cleaned and well

maintained.

4.16 Soft Plastic Policy

4.16.1 All soft plastics used in the production areas must be monitored and controlled. All

disposable PPE must be maintained to ensure they are intact; this includes aprons, sleeves

and gloves. Any item torn or ripped must be checked for missing plastic and disposed of in

the rubbish bin. Refer to QA‐SOP13‐WI04 Soft Plastic Policy.

4.17 Stock Rotation



Page: 16 of 18

Version: 9


4.17.1 First in, First Out (FIFO) stock rotation procedures are followed to ensure the oldest products

and materials are used first. Refer to QA‐SOP05 Process Control and work instructions for

storage.

4.18 Allergen Management

4.18.1 Community Chef has declared that all its products contain all allergens due to the nature of

the process i.e. shared equipment, ingredient change due to limited availability, no means of

segregation between products.

4.18.2 Gluten Free product range: All GF sauces for the GF range are held on a separate pallet from

other raw materials. Fragilisation, Transformation and Assembly of Gluten Free items are all

completed prior to the commencement of regular production or after adequate cleaning and

sanitation of food contact surfaces. Refer to QA‐SOP27 Allergen Control.

4.18.3 Non‐Community Chef retail product range: Products containing target allergens must not be

stored with allergen free products. Production of these products must be scheduled prior to

the commencement of regular production or after adequate cleaning and sanitation of food

contact surfaces. Refer to QA‐SOP27 Allergen Control.

4.19 Water Quality

4.19.1 Only potable water accessed from the ‘town water’ supply (City West) is used for all food

production, hand‐washing and cleaning purposes. e‐Water is also used for hand washing.

Refer to QA‐SOP19 Water Supply and QA‐SOP20 Chemicals.

4.20 Air Quality

4.20.1 Compressed air that contacts food or food contact surfaces shall be clean and present no risk

to food.

4.20.2 Compressed air systems used in the manufacturing process shall be maintained and regularly

monitored.



Page: 17 of 18

Version: 9


4.21 Transport Vehicles

4.21.1 All vehicles used for transportation of raw materials including packaging, work in progress

and finished product to the customer or further storage facility are suitable for the purpose,

maintained in good repair and in a clean and hygienic condition.

4.21.2 Refrigeration units for transporting chilled foods are maintained in good repair and regular

calibration of temperature gauges is undertaken.

4.22 Metal Contamination / Detection

4.22.1 The risk from metal contamination on the Mondini lines (where food is packed in trays) is

controlled through metal detection equipment which is operated, calibrated and maintained

in accordance with manufacturer’s instructions. Refer to QA‐SOP05‐WI08 Metal Detector

Testing.

4.22.2 Loose metal objects on equipment, equipment covers and overhead structures shall be

removed or tightly fixed so as not present a hazard.

4.22.3 Knives and cutting instruments used in processing and packaging operations shall be

controlled, kept cleaned and well maintained. Missing knives must be reported to the Team

Leader and QA department immediately.

5 Monitoring

5.1 The Quality Officer or Quality Manager shall monitor operational hygiene and GMP

requirements by undertaking daily GMP audits. This shall be recorded in QA‐SOP13‐FOR01

GMP Checklist.

6 Corrective Action

6.1 The Production Manager, Quality Manager and Team Leaders shall monitor compliance of

operational hygiene and GMP requirements and additional training will be provided or other



Page: 18 of 18

Version: 9


corrective action initiated where necessary (Refer to QA‐SOP12 Personal Hygiene and QA‐

SOP21 Cleaning and Sanitation).

6.2 Where appropriate, re‐training of areas that have significant impacts on product safety will

be conducted. This could be initiated from customer complaint issues, audits or other

deficiencies. The Internal Training Register and Records will be updated accordingly.

7 Verification

7.1 Verification of the implementation of this procedure will be via internal & external audits.

This may include review of monitoring records and procedures.

7.2 The internal and external audit findings will be discussed at Management Review Meetings.

8 Documentation




8.4 Internal Training Register.

8.5 QA‐SOP13‐FOR1 GMP Checklist.

Work Instruction QA‐SOP14‐WI01

Product Testing

Page: 1 of 7

Version: 19

Issue Date: 07 Feb 2020



04/04/11 2 Change routine testing to fortnightly instead

of weekly Mei Wong

29/07/11 3 Sensory evaluation ‐ Changed sampling plan. Mei Wong

22/08/11 4 Sensory evaluation ‐ Changed sampling plan.

Testing – changed to monthly Mei Wong

07/10/11 5 Add more details to sampling plan. Mei Wong


04/09/12 7 Amend testing on Salads and Sandwiches to

be completed by Supplier E Populin


03/09/14 9 Include gluten testing.

Amend job titles. M Wong

29/12/14 10 Add Cook‐Chill Vegetables to Table 1 E Roccasalva

06/01/16 11

Amend testing frequency to every 2 months for retorted products. Detail testing requirements for shelf life testing. Include E.coli in Table 2.

E Roccasalva

22/12/16 12 Amend person responsible to Technical

Manager E Roccasalva

15/09/17 13 Update Corrective Action E Roccasalva

03/10/17 14 Change GF testing frequency to every batch

made N Chee

03/04/18 15 Update Corrective Actions: detection of

Listeria & L. monocytogenes E Roccasalva

27/07/18 16 Update responsibilities and titles. Amend

Listeria management in corrective actions. M Wong


24/10/2019 18 Amend job titles and structure O Tuifangaloka

07/02/20 19 Amend corrective actions for Listeria. M Wong


Product Testing

Page: 2 of 7

Version: 19


Objective Ensure that all products meet the set sensory criteria,

microbiological limits and shelf‐life.

Workers Responsible

Quality Manager

Quality Officer

Location

Assembly Area

Retort Area

Finished Goods Chiller / QA Fridge

Record

QA‐SOP14‐REG01 Finished Products and Raw Materials Testing

Register

QA‐SOP08‐REG01 Non‐Conformance Register


Product Testing

Page: 3 of 7

Version: 19


Table 1: Testing Requirements and Frequency

Product When Type of Test Testing Frequency & Units Required

Person Responsible

Pasteurised Cook Chill

Products Beginning of shelf‐life TPC at 30°C for 3 days.

1 sample/product group

every 2 months

‐ Soup

‐ Main meal or Texture

Modified

‐ Side dish or Texture

Modified

‐ Dessert or Text Mod.

‐ Bulk soup

‐ Bulk main meal

‐ Bulk side dish

Quality

Officer/Quality

Manager

Non‐Pasteurised Cook

Chill Desserts Beginning of shelf‐life

TPC, Coagulase Positive

Staphylococcus,

Enterobacteriacea ,

Listeria spp.


per month i.e.

‐ Dessert: Std CUT, MM

or PUR

‐ Bulk dessert

Quality

Officer/Quality

Manager

Non‐Pasteurised Cook

Chill Vegetables Beginning of shelf‐life


Staphylococcus, Listeria

spp, Salmonella spp.


per month i.e.

‐ Cook‐chill side

vegetables

Quality

Officer/Quality

Manager

Frozen (Non‐

pasteurised) Products Beginning of shelf‐life



spp, Salmonella spp,

E.coli and Bacillus

Cereus (Rice meals

only)

Torus Pak frozen

product – annually for

each meal. Quality

Officer/Quality

Manager

Salads and

Sandwiches Beginning of shelf‐life

Coagulase Positive



E.coli.


every 2 months i.e.

alternating Salad and

sandwich monthly

Quality

Officer/Quality

Manager

All products Life of product

Organoleptic test e.g.

appearance, taste,

aroma, flavour, texture.

Buffer meals for staff

lunch. All Staff feedback


Product Testing

Page: 4 of 7

Version: 19


Product When Type of Test Testing

Frequency & Units Required

Person Responsible

All products (except

frozen)

Beginning and end of

shelf‐life

Two samples are

collected for testing at

the beginning of shelf‐

life and at the end of

shelf‐life.

Pasteurised cook chill

products: Product

storage at 4°C followed

by TPC at 30°C for 3 days.

Non‐pasteurised cook

chill main meals and

desserts: TPC, Coagulase

Positive Staphylococcus,

Enterobacteriacea,

Listeria spp.

Salads and sandwiches:

Coagulase Positive



E.coli.

Every 6 months

‐ Soup

‐ Main meal + MM or

PUR

‐ Side dish + MM or

PUR

‐ Dessert + MM or

PUR

‐ Bulk soup

‐ Bulk main meal

‐ Bulk side dish

‐ RTE Dessert + CUT,

MM or PUR

‐ Bulk RTE dessert

‐ CC Vegetables

‐ Salad

‐ Sandwich

Quality Officer/Quality

Manager

Gluten Free Products Beginning of shelf life

ELISA Criteria: <LOQ

(laboratory at 5.0 ppm,

test kit at 10 ppm)

Every batch made Quality Officer/Quality

Manager


Product Testing

Page: 5 of 7

Version: 19


Table 2 Microbiological Criteria

Category TPC/g Coagulase +ve Staph/g

Enterobacteriacea cfu/g

Salmonella spp. /25g

E.coli cfu/g

Listeria spp. /25g Bacillus Cereus cfu/g

Pasteurised Cook Chill Products

<102 N/A NA N/A N/A N/A N/A

Non‐Pasteurised Cook Chill Products

<104 <100 N/A Not

Detected N/A Not Detected N/A

Non‐Pasteurised Desserts <106 <100 <100 N/A N/A Not Detected N/A

Salads and Sandwiches NA <100 NA Not

Detected <10

Target: Not DetectedCritical limit: <100cfu/g

N/A

Frozen Meals <104 <100 NA Not

Detected <10

Target: Not Detected Critical limit: <100cfu/g

<100 (only Rice meals)

Frozen Meals (with cheese garnish)

<106 <100 NA Not

Detected <10

Target: Not DetectedCritical limit: <100cfu/g

N/A

Method

1. Wash and sanitise your hands thoroughly.

2. For pasteurised cook‐chill products: Collect and examine the samples for leakers and send them for testing at the laboratory.

3. For non‐pasteurised cook chill main meals and desserts, salads and sandwiches: Collect samples and examine the samples and send them for testing at the laboratory.

4. The Quality Manager/Quality Officer shall be responsible to coordinate the finished product sampling for microbiological testing, organoleptic tests and shelf‐life testing.

Corrective Actions

1. If products sent for testing do not meet the microbiological specifications for TPC, send another sample for testing for confirmation. Upon confirmation, implement corrective actions accordingly.

2. Reference: Standard 1.6.1 of the Code ‐ Listeria Management/Corrective Actions

If Listeria spp. are detected in a product with less than 5 days shelf life or is a frozen product:

a. Advise the laboratory to do an enumeration (<10 cfu/g).


Product Testing

Page: 6 of 7

Version: 19


b. If the count is <100cfu/g, no further action is required besides increased product testing frequency and environmental swabs requirements as explained in point (j).

c. If the count is >100cfu/g, test for Listeria monocytogenes.

d. If Listeria monocytogenes is not detected, no further action is required besides increased product testing frequency and environmental swabs requirements as explained in point (j).

e. If Listeria monocytogenes is detected, advise laboratory to do an enumeration.

f. If the count is <100cfu/g, no further action is required besides increased product testing frequency and environmental swabs requirements as explained in point (j).

g. If the count is >100cfu/g, convene the Recall Committee and follow process as outlined in QA‐SOP25 Product Recall‐Withdrawal.

h. Recall affected products. Note that products with less than 5 days shelf life will have likely already been consumed. However, affected customers must be contacted to alert them of the findings.

i. A clearance program of test and hold of each batch should be implemented until acceptable results are obtained for three consecutive batches of the affected type of product. Sampling of potentially affected product shall adhere to the sampling plan stipulated in Standard 1.6.1 of the Code, which requires product batches to be tested for L. monocytogenes at five 25‐gram samples per batch. Composite testing of these product samples is permitted at the laboratory.

j. Complete environments swabs on food contact and non‐food contact surfaces in the production area as part of the investigation of the source of contamination.

3. If Listeria spp. is detected in a chilled product with more than 5 days shelf life:

a. Test for Listeria monocytogenes.

b. If Listeria monocytogenes is not detected, no further action is required besides increased product testing frequency and environmental swabs requirements as explained in Part (e).

c. If Listeria monocytogenes is detected, convene the Recall Committee and follow process as outlined in QA‐SOP25 Product Recall‐Withdrawal.

d. Recall affected products.


Product Testing

Page: 7 of 7

Version: 19


e. A clearance program of test and hold of each batch should be implemented until acceptable results are obtained for three consecutive batches of the affected type of product. Sampling of potentially affected product shall adhere to the sampling plan stipulated in Standard 1.6.1 of the Code, which requires product batches to be tested for L. monocytogenes at five 25‐gram samples per batch. Composite testing of these product samples is permitted at the laboratory.

f. Complete environments swabs on food contact and non‐food contact surfaces in the production area as part of the investigation of the source of contamination.

4. If Listeria is detected on a food contact surface:

a. Review cleaning procedures and implement cleaning and sanitation of the food contact surface.

b. Increase the frequency of environmental testing to at least weekly and continue to test until the environmental swabbing program has achieved three consecutive negative results from tests taken on separate operation days.

c. To ensure end product has not been contaminated, where a food contact surface tests positive for Listeria that swab shall be typed in a laboratory to confirm the presence or otherwise of L. monocytogenes. All potentially contaminated RTE product shall be held pending the results of this test. If the presence of L. monocytogenes is confirmed, follow Standard 1.6.1 of the Code and test and hold available product batches from the day of the first positive L. monocytogenes environmental contamination onwards. Product batches shall be tested for L. monocytogenes at the rate of five 25‐gram samples per batch. Composite testing is permitted at the laboratory. Test each production batch until the environmental swabbing program has achieved three consecutive negative results as outlined above.

5. If Listeria is detected on a non‐food contact surface:

a. Review cleaning procedures and implement cleaning and sanitation of the non‐food contact surface.

b. Increase the frequency of environmental testing to weekly and continue to test until the environmental swabbing program has achieved three consecutive negative results from tests taken on separate operation days.

6. If the organoleptic test results do not comply with the standards, this will be assessed by the Quality Manager, Transformation Chef and Production Manager.

Documents

Standard Operating QA-SOP21 Issue Date: 16 July 2019