Jane Nock Group Technical Manager jane.nock@in2food.co.za
What we Do -1500 plus RTE,RTRH, RTC PRODUCE PREPARED FOODS LONGLIFE • • • Long Life soups Pillow Pack Salad Leaf Sandwiches & Wraps • Long Life sauces • • Prepared Vegetables Hot eating To Go products • Potato crisp Snacks • • Prepared Salads Prepared Soups • Other bases for Snacks • • Salad additions Prepared Sauces • Frozen fruit and veg • • Prepared fruit Delicatessen Products • Biscuits • • Micro leaves Ready Meals • Soft eating dried fruit • • Baby veg Quiches • Mayonnaise products • • • Strawberries Pizza’s Avocado pulp • • Seafood Avocado IQF • • Pop chips Fresh Juice • Steel cut oats • HPP Juice • Rusks • Ambient Cakes • Hot fill Juices • Donuts
Zero Tolerance is “State of Mind” ANY species of Listeria in Environment or product is an ISSUE……… We must adopt a new attitude NO ACCEPTANCE Stop concentrating on negative results…… Investigate the “Presence Results”
Past Strategies Operation Desert Operation Noah “White Snow”
Present Strategy Mandatory Listeria Management Procedures Training Listeria Champions Monthly meetings – multi-disciplined team Listeria Mapping Micro testing KPIs Risk Assessment Of: Fabric Site: Bilsthorpe Manager: Jane Nock/Ian Dorsey Start Date 31.08.12 Area Checked HAZARD Person Scheduled Re- Responsible date for assessed Dirty side Breaking Room P C M RISK Action Required Corrective Action Completed Pathogen cleaning protocol completion Risk No extraction causing condensation above P2, Currently Mar-13 Requires Capex but managed vis clean x x 4 Investigate air flues/non used extraction grills Ian Dorsey managed by overhead cleaning Replace engineers door with plastic door x x 2 New door Ian Dorsey Oct-12 Ordered Listeria / cleaning audits Put door in between low care and filter room x x 2 New door Ian Dorsey Person Scheduled Re- Responsible date for assessed Clean side Breaking Room P C M RISK Action Required Corrective Action Completed completion Risk Can we please find away of using covers instead of tape Fabric risk assessments x 2 Investigate and replace tape Ian Dorsey Nov-12 for hi-lighting trip hazards tape is unacceptable Person Scheduled Re- Responsible date for assessed Mobile Wash P C M RISK Action Required Corrective Action Completed completion Risk Extraction required X 4 Obtain quote Ian Dorsey Barrier risk assessments Cage washer investigation instead of pressure washing for x x 4 Obtain quote Ian Dorsey 2013 Person Scheduled Re- Responsible date for assessed Process room P C M RISK Action Required Corrective Action Completed completion Risk Food Safety checklist 31.08.12 Remove redundant pipes Redundant pipes looks unslightly hinders high level clean x 2 Ian Dorsey Ongoing Ongoing 2 Service valves in poor state x 2 Paint service valves Ian Dorsey 18.07.11 Ongoing 2 flaking paint on bottoms of girders and some parts of Replace/repaint stairs x 2 Ian Dorsey 18.07.11 started to Repaint 2 ceiling above plant 3 re galvanise paint Science! Rusty girders x 2 Repaint girders Ian Dorsey 18.07.11 Ongoing 2 Sky lights need cleaning on roof x x 2 Clean Ian Dorsey Sep-12 4 Lagging requires repair above tanks x Replace damaged lagging Ian Dorsey Sep-12 Person Scheduled Re- Responsible date for assessed Chills and Chill corrider P C M RISK Action Required Corrective Action Completed completion Risk 31.08.12 Main chill wall panels badly damaged cannot clean Requires Capex but x x 4 Clad in stainless Ian Dorsey ? as low risk not a 4 priority
Listeria- Hot spot Mapping
KPI- Listeria SUMMARY OF LISTERIA TESTING FOOD CONTACT NON-FOOD INGREDIENT LISTERIA FINAL PRODUCT TOTAL SWABS PREPARED PLANT PRODUCE PLANT RAW MATERIALS AVERAGE % SWABS CONTACT SWABS COMPONENTS Total tested 516 1293 299 217 626 667 190 583 Total L.spp 6 10 34 8 28 Total L.mono <10 2 0 11 4 0 0 0 3 Total L.mono 0 53 0 0 9 27 2 1 Total negative 494 1141 281 213 574 567 180 533 L.spp % fail 0% 2% 5% 4% 5% 3% L.mono <10 % fail 0% 0% 4% 2% 0% 0% 0% 1% 1% L.mono % fail 0% 4% 0% 0% 1% 4% 1% 0.2% 1% Negative % 96% 88% 94% 98% 92% 85% 95% 91% 92%
Swabbing Strip your equipment where you didn’t think possible! 70:30 RULE – Food Contact: Non Food Contact You can increase your level of testing by swabbing several areas as a composite swab Swab During production (DP) After Production (AP) but must wait 1- 2 hours after cleaning Swab could be neutralised and give you false NEGATIVE!
Control in High Care/Risk Barrier Integrity- Full wall Barriers Barrier -High Risk Facilities are fully segregated from Low care Separate personnel entrances and Change Rooms Positive Air pressure* Separate drains Colour coding equipment Captive equipment Sculleries – Non Food Contact and Food Contact Decontamination
Barrier Risk Assessments Walk barrier & mark on factory plan, type in all the points where the barrier could STEP 2A be breached Barrier Integrity Risk Assessment & Action Plan Date 24.1.13 24.1.14 Review Due What controls are in place to maintain the Supplier Riverside Bola Sokoya list is not Technologist exhaustive, barrier integrity? Signed Signed can add Is the barrier Is the Gap more Is there a Are full floor to Further If YES, detail the agreed Transfer the Is the Door Is there an Completion procedure operatives ceiling Action control points minimum alarmed airlock date action in place around the trained Required size criteria if gap required Travelling yes N/A Yes No Yes Yes No oven spray Yes No Yes No Yes Yes No look at your ambers & decide tunnel Rack Yes No Yes Yes Yes No if action is required to return improve integrity Fire Door Yes Yes Yes No Yes Yes No Wrapping Gap from Line X to be made smaller to be No N/A N/A No Yes Yes Yes Jun-13 line gaps size of largest product passing through it Air Filters N/A N/A No N/A N/A Yes No Water N/A N/A Yes N/A N/A Yes No Filters document & date any agreed action & timescales
Fabrication & Equipment Lack Low Care High Care standards Lack of full Physical barriers-Full wall barrier segregation Poor Fabrication Walls /floor junctions Drains not separate from high Care – poor design Poor Equipment design Extraction and condensation Hose pipe design – High pressure Poor Scullery Design Evaporation Chiller units Cleaning equipment Lack of new technologies
Poor Equipment Design Photos
Fabrication- Good design Stainless rack with fixed coat hooks Use of curtains for non food contact Separate flow and sinks no tray washes for Use non food contact and Food contact Services all in one place Drain design Wall floor junctions plastic bumpers
Cross Contamination by the Movement of people and equipment • Production equipment- Must be captive • Tables/stands- hollow legs • Electrical cabinets/line services • Drainage from equipment • Wheels/dolavs/pallets/Floor Lugs- stop using • Chopping boards/knives- use different colours • People- no moment from low care to high risk • Boots, hands • Separate handwashing/entrances • Space and access around / under equipment • Product movement from chillers • Equipment design • Floor to food contact- Floor Fairy! • Water! Keep as dry as possible
Fundamental Principles of Cleaning How Often • A full clean and disinfection every 24 hours • Provide the right equipment/chemicals and number of people TIME -The cleaning window may become squeezed- NEVER compromise on cleaning window ever! Having a schedule for everything - not missing tasks Organisation & sequencing of cleaning • • Engineers available for stripping equipment • Walk away standards • No partial Cleans • Challenge the standard of cleaning Sequence of cleaning Always top down, left to right, right to left. In Process Cleaning Product changeovers / high soiling lines • • Essential to keep debris and micro loading low Scheduled in production plan • Only clean when raw materials are off the line/ out of the area • Minimum use of water, even no water - sani wipes are often sufficient • Separate hygiene staff, or full change of gloves/sleeves/ bibs & hand wash
Pathogen Cleaning Protocol Alternate chemical Regime for 3 -7 Days- until 3 consecutive clear results Change detergents to break down biofilms- Caustic to an Acid based detergent- But you will still need to use degreaser first! NB You may see rise in failures when biofilms break down before improvement Alternate disinfectants increase from 1-3% to 3-5% Approved sanitisers – efficacy- proof they work! Byotrol QFS- no DDAC- Primary Sanitiser must be used Vortex- PPA Door Handles , c,,,u Betane Plus(contains DDAC so only can be used for NFC) Tego 2001- (cant get in SA) In Production additional Measures 'Military' style discipline Handle _... sanitisation 2 hourly disinfection route with 1OOppm Free Chlorine point Or (1 or 2% terminal disinfectant as above Change squeegee trough disinfectant every 2 hours Disinfectant wipe door handles every 2 hours • Record on a chart & keep on display in the relevant area
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