Checklist for the Auditor · ACS (Audit Checklist STANDARD) ... HACCP Pest Control Quality...

SGF/IRMA Audit Checklist STANDARD Parts 1 - 3

SGF INTERNATIONAL e. V.

No.: DOC_OP_009

Version: 3

Replaces version: 2

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Company: Country Code: SGF Factory ID: Date of audit:

Content done page

Overview / Audit Elements 2 - 3

General Information 4 - 6

ACS (Audit Checklist STANDARD) P 1 - 3 7 - 31

Summary Corrective Actions 32 - 33

Possible Comments by the Company 34

CoC Code of Conduct Checklist 35 - 36

Final Approval (access for SGF only)

Further

enclosures

General information have to be filled in once into red-framed fields information is automatically filled in on every following page

For the correctness of information

Signature SGF/IRMA Auditor Stamp + Signature SGF/IRMA Representative

Name of the SGF/IRMA Auditor Name of the SGF/IRMA Representative

Checklist for the Auditor

SGF Code ACS



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SGF Factory ID: Date of audit:

1 1.3 1.6

1.1 1.4

1.2 1.5

2 3.13 4.10

2.1 3.14 5

2.2 3.15 5.1

2.3 3.16 5.2

2.4 3.17 6

3.18 6.1

2.5 4 7

2.6 7.1

2.7 4.1

2.8 4.2

3 4.3

3.1 4.4

3.2 4.5

3.3 4.6

3.4 4.7

3.5 4.8

3.6 4.9

3.7

3.8

3.9

3.10

3.11

3.12

Part 2 / 3

Country Code:Company:

Certification Social / Ethical standards

Technical Information

Company brochure + website

General information for Parts 1, 2 and 3

Product Range

Company Information

Number of Employees

Calibration, Control of measurement and Monitoring Devices

Part 3 / 3

Overview SGF/IRMA Audit Checklist Standard on basis of the SGF-GMP Self Assessment Questionnaire (for increased food safety, in particular in the fruit juice industry)

Product Analysis

Part 1 / 3

Product Packing, Storage & Transportation

Product Packing

Information about the Quality Management Equipment & Maintenance

Quality Management System

Waste / Waste DisposalQuality Manual

Personnel Hygiene

Cleaning Schedule, Time & Temperature,

Processes & Work Flows General Traceability

Storage & Transportation

General Traceability, Allergen Risk

Control of Nonconforming Products

Documentation of Quality, Hygiene, relevant

HACCP

Pest Control

Quality management Representative Sanitary Facilities

Cleaning SchedulesAudits

Good Manufacturing Practices

Product Recall

Purchasing

Control of Product Contamination

Process / Temperature / Time Control

Training Programs Contamination Risk, Product Analysis

Control of Product Contamination: Fruit Acceptance

Control of Product Contamination: Pipelines/Hoses

Control of Product Contamination:Fruit Washing

Production Facilities: Walls

Production Facilities: Floors

Control of Product Contamination: Fruit Sorting

Premises, Grounds, Location

Control of Product Contamination: Fruit Extraction

Layout / Product Flow

Production Facilities: Building – Production Area

Production Facilities: Ventilation

Control of Product Contamination: Contamination – Maintenance

Production Facilities: Water Supply

Production Facilities: Drainage

Production Facilities: Windows

Production Facilities: Doors

Production Facilities: Ceilings

Production Facilities: Lighting



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Audit Elements

This checklist complements the regular SGF/IRMA plant inspections which include:

• Hygiene and GMP

• Sampling and Analytical examination of samples taken

- Based on authenticity criteria of the Code of Practice for Fruit Juices and Nectars

- Safety parameters like heavy metals, pesticide residues and mycotoxins

• Traceability checks

• Labelling control of semi finished goods based on the Code of Labelling (CoL)

• Control of Social and Economic Sustainability based on the Code of Conduct (CoC)



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1.11.1.1

Fruit

1.2

1.2.1

General Information

Product Range Fruit / Product range

Major fruit Minor fruit

Number of employees

Number of Employees:



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General Information

1.3 Certification

1.3.1 Certificates available:

Certificate Certificate number expiration date



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General Information

1.4 YES NO

1.4.1

DOC o1.4.2

1.4.3

1.4.4

1.4.5 Capacity:

1.4.6

1.4.7

1.4.8

1.4.9

1.5 YES NO

1.5.1

1.6 YES NO

1.6.1

Flow chart existing - made available to customers.

Please provide copy.

Technical Information Remarks

If yes, is it made available to customers

if yes capacity <40% or > 40% of total

tank capacity


tank capacity

Extraction systems

Evaporation systems

Tank capacities (total volume)

Ambient temperature tanks

Sterile tanks

Social/ethical standards Remarks

Is there a social accountability statement and policy (apart from SGF-

CoC) in place?

Deep frozen storage

Existing - please provide details

Cooling tanks

Remarks


tank capacity


tank capacity

Company brochure + website



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Company: SGF Factory ID: Date of audit:

Maximum

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points Points %

5 Points

4 Points

2 Points

1 Point

0 Points

na

Remarks:

2 130 0 0,00%

2.1 0 0

2.1.1 YES NO

2.1.2

2.1.3

The requirements are completely fulfilled

The requirements are mostly fulfilled only small non-critical deviations from standard

The requirements are mostly not fulfilled there are deviations from standard

The requirements are fulfilled only in very small instances there are significant failures and major deviations from standard

The requirements are not fulfilled at all

in case question cannot be valued

Not allowed to give 3 points!

Remarks

Country Code:

Questionnaire

Information about the Quality Management

When will it be fully implemented?

Remarks of the auditor

Result

Quality Management System

If there is no certified system in place, is one planned?

Which Standard?



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QuestionnaireRemarks of the auditor

Result

2.2 30 0 0,00%

2.2.1 5

2.2.2 5

2.2.3 5

2.2.4 5

2.2.5 5

2.2.6 5At what frequency is the HACCP system audited to ensure

its continued effectiveness?

Does the quality policy include responsibility to the

hygiene?

Is there an effective document control procedure in

place?

Quality Manual

Does a quality manual exist?

Is the quality manual up to date?

Is it available to all staff and customers?



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2.3 10 0 0,00%

2.3.1 5

2.3.2 5

2.4 30 0 0,00%

2.4.1 5

2.4.2 5

2.4.3 5

Quality Management Representative

Whom does the quality manager report to?

Documentation of Quality, Hygiene, relevant

Processes & Work FlowsIs your quality management system fully documented?

Are specifications available for all raw materials, semi-

finished products and finished products?

Are specifications available for packaging materials

suitable for foodstuff?

Is there an organisation chart available?

If yes, please check.



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2.4.4 5

2.4.5 5

2.4.6 5

2.5. 30 0 0,00%

2.5.1. 5

2.5.2!

E.C.

5

Are there cleaning schedules available?

Who is responsible for final product release?

Is there a documented procedure for the release of your

finished product?

Does the HACCP system cover all aspects of the

manufacturing process?

Has the HACCP hazard analysis taken into consideration

microbiological, chemical & physical hazards?

HACCP



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Result

2.5.3!

E.C.

5

2.5.4!

E.C.

5

2.5.5!

E.C.

5

2.5.6

DOC □

5

2.6 10 0 0,00%

2.6.1 5

Training Programs

Have critical limits been set for all the Critical Control

Points (CCPs)

Does the process flow diagramme (see question 1.4.1)

indicate location and nature of all the CCPs?

If CCPs are not in the flow diagram, please provide them

separately.

Are the CCPs registered continuously?

Are there established and suitable measures available to

handle a CCP that is out of control?

Are training programs in place for all employees?



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Result

2.6.2 5

2.7 5 0 0,00%

2.7.1 5

2.8 10 0 0,00%

2.8.1 5

2.8.2 5

Audits

Purchasing

Are workers trained and skilled on the job?

(Training control, tests, verification?)

Are there schedules for internal audits and resp. records

available?

Do you have a supplier selection procedure?

(Self-auditing questionnaire, certificates according to IFS,

BRC, HACCP, Global GAP)

Is there a special procedure in place to monitor any

outsourced production, e.g. production carried out at

other locations?

SGF member? Monitoring of sub-supplier?



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Result

2.9 5 0 0,00%

2.9.1 5

3. 230 0 0,00%

3.1 5 0 0,00%

3.1.1 5

3.2 20 0 0,00%

3.2.1 5

3.2.2 5

Final Quality Management System Evaluation

Is there a segregation between high and low risk

operations to minimise the risk of product cross

contamination?

Premises, Grounds, Location

Layout / Product flow

Does the design of the process flow, from intake to

dispatch, prevent the contamination of raw material,

packaging, intermediate/semi-processed and finished

products?

Is an effective working quality management system in

place?

Does the internal design and layout of the processing

plant permit good food hygiene practices and protection

against cross contamination of the product?

Good Manufacturing Practices



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3.2.3 5

3.2.4 5

3.3 5 0 0,00%

3.3.1 5

3.4 10 0 0,00%

3.4.1 5

3.4.2

Are walls designed, finished & maintained to prevent the

accumulation of dirt and the reduction of condensation

and mould growth?

Are the junctions between the walls and the floor sloped

to facilitate cleaning and avoid mould growth?

Is the cleaning / washing facility for crates, utensils, trays

etc. completely segregated from other production

activities?

Does production take place within closed buildings?

Production facilities: Building - Production Area

Production Facilities: Walls

Is there a segregation between filling Units?



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3.4.3 5

3.5 15 0 0,00%

3.5.1 5

3.5.2 5

3.5.3 5

Are there openings in the walls/ceilings through which

animals, insects and birds could enter the production

area?

Production Facilities: Floors

Are floors made of alkali and acid resistant material?

What is the condition of the floors?

Do the floors have sufficient slope to avoid water

stagnation?



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3.6 5 0 0,00%

3.6.1 5

3.7 5 0 0,00%

3.7.1 5

3.8 10 0 0,00%

3.8.1 5

3.8.2 5Are all glass windows either shatter-proof or protected

against breakage in other ways?

Are fly screens in place on all openable windows?

Production Facilities: Ceilings

Production Facilities: Drainage

Are ceilings designed, constructed, finished and

maintained so as to prevent the accumulation of dirt, the

reduction of condensation and mould growth and to

facilitate easy cleaning and what is the condition?

Are the drains cleaned and maintained regularly and what

is the condition?

Production Facilities: Windows



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3.9 5 0 0,00%

3.9.1 5

3.10 5 0 0,00%

3.10.1 5

3.11 10 0 0,00%

3.11.1 5

3.11.2 5

Are all access points into the production areas protected

against birds, rodents and flying insects?

Are all glass bulbs, strip lights and electric fly killer units

protected by shatter-proof plastic diffusers or sleeve

covers?

Production Facilities: Lighting

Production Facilities: Doors

Production Facilities: Ventilation

Are ventilation systems installed so that filters and other

components which require cleaning or replacement are

easy accessible?

Does adequate natural and/or artificial ventilation exist in

all areas?



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Result

3.12 10 0 0,00%

3.12.1 5

3.12.2 5

3.13 5 0 0,00%

3.13.1!

E.C.5

3.1410 0 0,00%

3.14.1!

E.C.

5

3.14.2!

E.C.

5

Production Facilities: Water Supply

Does the plant identify the measurements critical to food

safety and the measuring and monitoring devices

required to assure product safety?

Cleanliness of existing equipment

Calibration, Control of measurement and

Monitoring Devices

Equipment & Maintenance

Is all water, coming into contact with the product, potable

(including steam, ice and condensate)?

Provide details of the frequency and nature of all tests

performed on the process waters.

Are all the measuring and manufacturing devices that

have a significant role in product safety and quality

calibrated (records, calibration certificates/stamps)?



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Result

3.15 10 0 0,00%

3.15.1 5

3.15.2 5

3.16 30 0 0,00%

3.16.1 5

3.16.2 5

3.16.3 5

3.16.4 5

Are appropriate waste disposal facilities available?

Lids with labels?

Are there designated areas where smoking, eating and

drinking are allowed?

Do the Lids have labels?

Waste / Waste Disposal

Sanitary Facilities

Are changing rooms provided for workers, staff, visitors or

contractors for changing into working clothes before

production area?

Are there toilets and suitable washing facilities, including

sanitary agents, disposable towels and hand dryers

provided?

Is there a direct access to production rooms from these

facilities?



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Result

3.16.5 5

3.16.6 5

3.17 50 0 0,00%

3.17.1 5

3.17.2 YES NO

3.17.3 5

Personnel Hygiene

Are there visible "Wash Hands" instructions available

before entering the production areas?

Are there visible rules to prohibit smoking, eating and

drinking in the production area?

Are there instructions on how to be suitably dressed to

enter the production areas (aprons, head coverings,

gloves etc.)?

Are working clothes available?

If yes, are they removed after visiting high risk area?



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Result

3.17.4 5

3.17.5 5

3.17.6 5

3.17.7 5

3.17.8 5

Are aprons, head coverings, gloves being used and what is

the condition?

Must all skin defects e.g. cuts, boils, grazes be covered by

moisture-proof plasters before entering the production

areas?

Are there instructions to remove loose items when

entering the production areas e.g. jewellery, rings,

watches, pens etc.?

Is there a specially designated changing room before

entering the high risk area?

Is protective clothing laundered effectively on a regular

basis and what is the condition?



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Result

3.17.9 5

3.17.10 5

3.17.11 5

3.18 20 0 0,00%

3.18.1!

E.C.

5

3.18.2 5

How are people controlled and excluded from the

processing areas, suffering from infectious diseases

(jaundice, diarrhoea, vomiting, fever, sore throat,

discharges from ears, nose and eyes)?

Are plasters with a metalized strip used for easier

detection in the product?

Is there a pest control system implemented?

Pest Control

Is it ensured that workers handling the product have short

clean finger nails?

Are there records available about pest control AND pest

prevention?



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Result

3.18.3 5

3.18.4 5

4 130 0 0,00%

4.1 35 0 0,00%

4.1.1 5

4.1.2 5

4.1.3 5

Is vegetation allowed to grow near the production areas

that could provide cover for pests?

Do you have cleaning schedules, procedures and records

for the BUILDING (EXTERNAL)?


for EXTERIOR SURROUNDINGS

Cleaning Schedules

Cleaning Schedule, Time & Temperature,

Contamination Risk, Product Analysis

Are traps for rodents, insects and all other relevant pests

in place?

Please check the map indicating the location of all traps

and insecticutors.


for the following? BUILDING (INTERNAL)



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4.1.4!

E.C.

5

4.1.5 5

4.1.6 5

4.1.7 5

4.2 5 0 0,00%

4.2.1!

E.C.

5


for the EQUIPMENT?

How do you evaluate the effectiveness of cleaning and

disinfection agents eg against Alicyclobacillus spores?

Are there specifications available for all cleaning agents

used?

Is there secure and separate storage for chemicals and

detergents?

Do you have established time and temperature

programmes that have been shown to produce a

microbiologically stable product? With regards to: e.g.

pH of product/brix/levels and types of microorganisms in

your final products. Please check relevant

documentation.

Process / Temperature/ Time Control



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Result

4.3 10 0 0,00%

4.3.1 5

4.3.2 5

4.3.3

4.4 10 0 0,00%

4.4.1 5

4.4.2 5

Control of Product Contamination:

Fruit Acceptance

Are filters and sieves inspected regularly and records

maintained?

Control of Product Contamination

Is there a wood & glass elimination policy?

Where is the fruit for processing coming from (e.g.

packing houses, orchards, etc.)?

Is there a procedure in place to ensure traceability of the

incoming fruit and is it applied effectively?

Is there an inspection procedure for all incoming fruit

deliveries and is it applied effectively?



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Result

4.5 15 0 0,00%

4.5.1

4.5.2 5

4.5.3 5

4.5.4 5

4.6 10 0 0,00%

4.6.1 5

Control of Product Contamination: Fruit

Washing

Is there a final washing step (equivalent to potable water

quality) prior to further processing?

Does the wash water contain any added chemicals (e.g.

Chlorine, tensides etc.)?

How is the level of added chemicals controlled?

How is the quality of the final fruit cleaning water

monitored?

Are there appropriate sorting processes/equipment to

remove unsuitable fruit and foreign matter?

Control of Product Contamination:

Fruit Sorting



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Result

4.6.2 5

4.7 10 0 0,00%

4.7.1 5

4.7.2 5

4.8 5 0 0,00%

4.8.1 5

Control of Product Contamination: Pipelines/Hoses

Are there instructions available regarding the removal of

unsuitable fruit?

Are the following systems such as sieves/filters, mixing

tanks, keg filling equipment etc. closed systems?

Are pipelines and hoses clearly marked according to the

products to be conveyed?

Are they all protected against foreign matter

contamination from the environment?

Control of Product Contamination: Fruit

Extraction



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Result

4.9 10 0 0,00%

4.9.1 5

4.9.2 5

4.10 20 0 0,00%

4.10.1 5

4.10.2 5

4.10.3 5

Control of Product Contamination: Contamination –

Maintenance

Is the final product release system working effectively?

Product Analysis

Is there a system of planned maintenance in place

covering all items of equipment which are critical to

product safety, legality and quality?

Are all oils and lubricants, that could come into contact

with the product, food-grade?

Are the analyses relevant for food safety performed in a

laboratory?

How are the testing procedures validated with the

external lab?

Please check a recent comparative report.



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Result

4.10.4 5

5 40 0 0,00%

5.1 15 0 0,00%

5.1.1 5

5.1.2 5

5.1.3 5

5.1.4

DOC o

YES NO

Product Packing, Storage & Transportation

After filling are all containers individually labelled in

accordance with appropriate industry and legal

requirements?

Please provide copy of typical label.

Does the factory have a system for the management of

product complaints?

Is the filling area of non-aseptic goods segregated from

other processing areas?

Does the filling area contain all the necessary facilities to

ensure the hygiene standards, appropriate to a filling

area, can be provided?

How are packaging materials inspected, tested and stored

to ensure they remain undamaged, clean and

uncontaminated?

Product Packing



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Result

5.2 25 0 0,00%

5.2.1 5

5.2.2 5

5.2.3 5

5.2.4 5

5.2.5 5Are copies of cleaning certificates accepted?

Is it ensured that the loading temperature is in

accordance with the product specification?

Are temperatures of product deliveries maintained &

monitored during transportation correctly?

Are all checks carried out on delivery vehicles prior to

loading?

Is it ensured that only "foodstuffs only" vehicles are used

for bulk transportation?

Storage & Transportation



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Result

6 15 0 0,00%

6.1 15 0 0,00%

6.1.1 5

6.1.2 5

6.1.3 5

6.1.4

7 5 0 0,00%

7.1 5 0 0,00%

7.1.1 5

How long are the traceability records maintained?

Is there a system to check and verify traceability from the

sources of raw materials and packaging through the

production process to the shipment of the finished

product?

Is the traceability ensured when part of the product is

produced at another location?

Does the plant have a procedure for product recall?

Control of Nonconforming Products

Product Recall

Is the traceability ensured when rework of the product is

performed?

General Traceability

General Traceability, Allergen Risk



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Question No. Deadline for

Follow up

Date of

Follow up

Summary of Corrective Actions (different remarks can be combined, if suitable)

RemarkThe following corrective actions have to be carried out



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Question No. Deadline for

Follow up

Date of

Follow up

Summary of Corrective Actions (different remarks can be combined, if suitable)

The following corrective actions have to be carried out Remark



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Name / Signature of SGF contact person in the company Name / Signature of SGF/IRMA auditor

Possible Comments by the Company

SGF/IRMA Audit Checklist STANDARD Part 1 - 3


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YES

YES

CoC / Code of Conduct Checklist

Chapter Principle Control points Status/Remarks

I. Social and Economic

Sustainability

- Child labour

Child labour shall not be permitted. A Child is

defined as a person aged less than 14 years

even if the local minimum is lower. (ILO

Convention 138 and its accompanying

Recommmendation 146 on child labour as well

as ILO Convention 182 and ist accompanying

Convention 190 on the worst form of child

labour.

I.1.1. Is there any child labour or under aged

person observed during the audit in the

plant? YES/NO

NO

If yes, please comment:


II. Environmental Sustainability

- Waste water treatment

Suppliers shall identify any negative

environmental impacts of their activities, such

as water pollution.

The use of water as well as release of

wastewater shall be properly managed in

order to preserve surrounding water sources.

II.1.1. Is there any waste water treatment in

the plant? YES / NONO

If yes, please comment:

II.1.2. What was improved/ renewed in the

last 5 years?

SGF/IRMA Audit Checklist STANDARD Part 1 - 3


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YES


III. Fruit Risk Assessment

Programme for Pesticides

(FRAPP)

This question refers to the documentation

about applied pesticides sent to SGF since the

last audit. The documentation can concern the

last harvest season or the current one. For

example, during the audit 2017, processing

IRMA members should prove that they have

provided FRAPP documentation for the season

2016 or for 2017. As companies sometimes

send some documentation which is not

adapted to the FRAPP objectives (e.g. pesticide

recommendations, pesticides allowed in the

region/country or analyse results), the

company should show the last “FRAPP

Confirmation” to the auditor. This document

shows that SGF has already approved the

documentation sent.

If the company did not deliver FRAPP

documentation since the last audit, they

should shortly explain why, in order that SGF

can try to help the company in the future.

III.1.1. Did your company deliver FRAPP

documentation to SGF? If not, explain why. NO

If not, explain why:

Checklist for the Auditor · ACS (Audit Checklist STANDARD) ... HACCP Pest Control Quality...

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