6. Process Control
6.1. Management of Surplus Food and Products for Animal Feed
FUNDAMENTAL
1
Clause 6.1.1
Documented process specifications and work instructions/procedures shall be available for the key processes in the production of products to ensure product safety, legality and quality. The specifications/procedures as appropriate shall include:
Outcome Docs Actions Notes
Yes No N/A
Are documented process specifications available for the key processes in the production of products to ensure:
Are work instructions/procedures available for the key processes in the production of products to ensure:
Do specifications/procedures include, as appropriate:
Are process specifications in accordance with the agreed finished product specification?
Clause 6.1.2
Where equipment settings are critical to the safety or legality of the product, changes to the equipment settings shall only be completed by trained and authorised staff. Where applicable, controls shall be password-protected or otherwise restricted.
Outcome Docs Actions Notes
Yes No N/A
Where equipment settings are critical to the safety or legality of the product, are changes to the equipment settings only completed by:
Where applicable, are controls password-protected or otherwise restricted?
Clause 6.1.3
Process monitoring, such as of temperature, time, pressure and chemical properties, shall be implemented, adequately controlled and recorded to ensure that product is produced within the required process specification.
Outcome Docs Actions Notes
Yes No N/A
Is process monitoring, such as of temperature, time, pressure and chemical properties, in order to ensure that product is produced within the required process specification:
Clause 6.1.4
In circumstances where process parameters or product quality are controlled by in-line monitoring devices, these shall be linked to a suitable failure alert system that is routinely tested.
Outcome Docs Actions Notes
Yes No N/A
In circumstances where process parameters or product quality are controlled by in-line monitoring devices, are they linked to a suitable failure alert system that is routinely tested?
Clause 6.1.5
Where variation in processing conditions may occur within equipment critical to the safety or quality of products, the processing characteristics shall be validated and verified at a frequency based on risk and performance of equipment (e.g. heat distribution in retorts, ovens and processing vessels; temperature distribution in freezers and cold stores).
Outcome Docs Actions Notes
Yes No N/A
Where variation in processing conditions may occur within equipment critical to the safety or quality of products, are the processing characteristics:
Clause 6.1.6
In the case of equipment failure or deviation of the process from specification, procedures shall be in place to establish the safety status and quality of the product to determine the action to be taken.
Outcome Docs Actions Notes
Yes No N/A
In the case of equipment failure or deviation of the process from specification, are procedures in place to establish:
6.2. Medical Screening
FUNDAMENTAL
1
Clause 6.2.1
There shall be a formal process for the allocation of packaging materials to packing lines and control in the packing area which ensures that only the packaging for immediate use is available to the packing machines.
Outcome Docs Actions Notes
Yes No N/A
Is there a formal process for:
Where offline coding or printing of packaging material occurs:
Clause 6.2.2
Documented checks of the production line shall be carried out before commencing production and following changes of product. These shall ensure that lines have been suitably cleared and are ready for production. Documented checks shall be carried out at product changes to ensure that all products and packaging from the previous production have been removed from the line before changing to the next production.
Outcome Docs Actions Notes
Yes No N/A
Are documented checks of the production line carried out:
Do these checks ensure that:
Are documented checks carried out at product changes to ensure that, before changing to the next production:
Clause 6.2.3
Procedures shall be in place to ensure that all products are packed into the correct packaging and correctly labelled. These shall include checks:
Outcome Docs Actions Notes
Yes No N/A
Are there procedures in place to ensure that all products are:
Do these procedures include checks:
Do the checks also include verification of any printing carried out at the packing stage, including, as appropriate:
Clause 6.2.4
Where online verification equipment (e.g. bar code scanners) is used to check product labels and printing, the site shall establish and implement procedures for the operation and testing of the equipment to ensure that the system is correctly set up and capable of alerting or rejecting product when packaging information is out of specification.
Outcome Docs Actions Notes
Yes No N/A
Where online verification equipment is used to check product labels, to ensure that the system is correctly set up, are there procedures:
Where online verification equipment is used to check product labels, to ensure that the system is capable of alerting or rejecting product when packaging information is out of specification, are there procedures:
Is the testing of the equipment completed:
- at a frequency based on the site's ability to identify the release of any implicated materials should the equipment fail?
- at a frequency based on the site's ability to hold the release of any implicated materials should the equipment fail?
- at a frequency based on the site's ability to prevent the release of any implicated materials should the equipment fail?
When else should testing of the equipment conducted?
Is testing of the equipment conducted at these additional points?
Are there procedures established and implemented in the event of a failure in the online verification equipment?
6.3. Metal Control
FUNDAMENTAL
1
Clause 6.3.1
The frequency and methodology of quantity checking shall meet the requirements of the appropriate legislation governing quantity verification, and records of checks shall be retained.
Outcome Docs Actions Notes
Yes No N/A
Does the frequency of quantity checking meet the requirements of the appropriate legislation governing quantity verification?
Does the methodology of quantity checking meet the requirements of the appropriate legislation governing quantity verification?
Are records of quantity checking retained?
Clause 6.3.2
Where the quantity of the product is not governed by legislative requirements (e.g. bulk quantity), the product must conform to customer requirements and records shall be maintained.
Outcome Docs Actions Notes
Yes No N/A
Where the quantity of the product is not governed by legislative requirements:
Clause 6.3.3
Where used, the site shall establish procedures for the operation and testing of online check weighers. At a minimum, this shall include:
Outcome Docs Actions Notes
Yes No N/A
Where used, are there established procedures for the:
Do these procedures include:
Which other points should be included?
Are these additional points included?
6.4. Metal Detectors and X-Ray Equipment
FUNDAMENTAL
1
Clause 6.4.1
The site shall identify and control measuring equipment used to monitor critical control points and product safety, legality and quality. This shall include, at a minimum:
Outcome Docs Actions Notes
Yes No N/A
Has the site identified measuring equipment used to monitor:
Does the site control measuring equipment used to monitor:
Is there a documented list of equipment and its location?
Is there an identification code and calibration due date?
Does this include prevention from adjustment by unauthorised staff?
Is there protection from damage, deterioration or misuse?
Which other points should be monitored?
Are these additional points monitored?
Which other points should be controlled?
Are these additional points controlled?
Clause 6.4.2
All identified measuring devices, including new equipment, shall be checked and, where necessary, adjusted:
Outcome Docs Actions Notes
Yes No N/A
Are all identified measuring devices, including new equipment:
Are results documented?
Is equipment readable?
Is equipment of a suitable accuracy for the measurements it is required to perform?
Clause 6.4.3
Reference measuring equipment shall be calibrated and traceable to a recognised national or international standard and records maintained. The uncertainty of calibration shall be considered when equipment is used to assess critical limits.
Outcome Docs Actions Notes
Yes No N/A
Is reference measuring equipment:
Are records maintained?
Is the uncertainty of calibration considered when equipment is used to assess critical limits?
Clause 6.4.4
Procedures shall be in place to record actions to be taken when the prescribed measuring devices are found not to be operating within specified limits. Where the safety or legality of products is based on equipment found to be inaccurate, action shall be taken to ensure at-risk product is not offered for sale.
Outcome Docs Actions Notes
Yes No N/A
Are procedures in place to record actions to be taken when the prescribed measuring devices are found not to be operating within specified limits?
Where the safety or legality of products is based on equipment found to be inaccurate, is action taken to ensure at-risk product is not offered for sale?