Food and Beverage Plant Tour Guide
Table of Contents
Industry Factors & Products
5 Known Food Processing Issues 3-4
Top 3 Brady Products 5-6
Area Breakdown
Receiving 7-12
Ingredient Storage/Warehouse 13-14
Pre-Production Staging 15-16
Production 17-36
Packaging 37-40
Finished Good Warehouse 41-42
Shipping 43-44
Glossary of Terms
Customer Issue Priority Ranking
Primary Secondary Tertiary
2
5 Known Food Processing Issues
When touring a food and beverage facility, keep in mind these
5 key factors related to safety and productivity goals.
1. Food Safety Regulatory Compliance: Food safety is the
number one issue facing food processors. Food recalls cost
processors millions and damage brand reputation. Because
food safety directly impacts public health, government
agencies develop stringent regulations while grocery stores
often require food processors to comply with GFSI standards
to ensure food safety. To comply with these standards, food
processors must develop protocols and ensure implementation.
Most protocols live in binders on office shelves. It’s critical to
bring this information to the processing floor.
2. Food Safety Sanitation: Because of the emphasis on food
safety, sanitary processing facilities are critical. Therefore, food
processors conduct wash downs to sanitise critical areas of
their processing facility. Wash downs generally occur every
night on third shift and whenever a production line changes over
to a new product run. The area that gets washed down and the
degree of wash down will vary by type of food. Generally, meat,
dairy and seafood plants have the harshest conditions.
3. Workforce Education: Safe & efficient food production
happens on the processing floor. And the processing floor
often creates a challenging and dangerous work environment.
Therefore, it’s critical to train front-line employees on proper
procedures and protocols and then continually reinforce this
training. This can be extremely challenging at processors
with high turnover, multiple languages spoken or low reading
proficiency among front line employees.
5 KNOWN FOOD PROCESSING ISSUES 3
5 Known Food Processing Issues
4. Food Quality/Waste Reduction: Food processors aim to
make the highest quality food with the least amount of waste.
To enhance quality, processors implement standard operating
procedures to ensure consistency. They also implement
critical control points such as x-ray or metal detection to
ensure food safety. Food that doesn’t pass quality and safety
standards must be sent back to the beginning of production
for necessary re-work.
Additionally, food processors try to get the highest yield
possible. Essentially, if they start with 100 lbs / 45.3kg of
ingredients, they’d like to get as close to 100lbs / 45.3kg of
finished product as possible. However, inefficiency in the
production process can lead to lost yield.
5. Workplace Safety: Food processing plants are dangerous
places to work. In fact, it is 59% more likely to be injured in a
food processing plant compared to average private industry
manufacturing. Top contributors to injuries include exertion/
lifting, slips, trips and falls, and getting caught in machinery.
5 KNOWN FOOD PROCESSING ISSUES
4
Top 3 Brady Products
1. ToughWash™ Labels and Printer Systems
labels stand up to harsh processing environments so you can create a safer, more productive visual work environment without compromising food safety
reminders, warn of electrical hazards and call out other safety concerns at the point of concern.
2. ToughWash™ Signs and Tags
injection molded signs and tags stand up to harsh processing environments so you can create a safer, more productive visual work environment without compromising food safety
lockout tags, sanitary operating procedures, critical control point procedures, inspection tags and more
TOP 3 BRADY PRODUCTS 5
Top 3 Brady Products
3. Lockout/Tagout Solutions
& lockout tags create a best practice solution to ensure workplace safety
for sanitation and maintenance daily
TOP 3 BRADY PRODUCTS
6
RECEIVING
Access to Plant
Signage can direct drivers to the appropriate receiving doors (food vs non-food), provide standard operating procedures for delivery and detail hygiene practices that must be followed.
People ID products can be used for temporary badges and access control.
Solution
Probing Questions
■ How do you currently alert your drivers to proper procedures for delivery?
■ How do you alert drivers to any hygiene practices they should be following for delivery?
■ How do you control the access the drivers have within the plant?
7
Access to Plant
GFSI programmes and some governments
around the world require food processors
to take steps to prevent the intentional
adulteration of food through the
implementation of Food Defense plans.
Food defense plans identify potential
areas where someone could intentionally
contaminate the food supply and then
outline risk mitigation steps. This largely
stems from concerns related to
bio-terrorism within the food supply.
In receiving, truck drivers from outside
companies will be delivering food
ingredients and food processing supplies.
It’s important for food processors to identify
& verify the driver making the delivery
and control their access within the food
processing plant.
RECEIVING
8
RECEIVING
Receipt & ID
Brady printers and labels can be used to set up a colour-coded system to create visual identification of materials.
Solution
Probing Questions
■ What do you currently use for visual identification of materials to ensure plant workers know what’s in a package, when it was received and when it will expire?
■ How do you visually identify allergens?
9
Upon receipt, some companies will
use barcodes or RFID integrated into
their ERP system to identify and track
the flow of materials through storage
and into the processing environment.
However, many processors still do this
manually using visual identification.
It’s important to track food ingredients
to identify lot numbers, date/time of
receipt and presence of allergens in
the event of a recall.
GFSI schemes often single out the
tracking of allergens. Mislabelled or
misidentified allergens are the number
one reason for recalls and can have
deadly consequences for consumers.
Receipt & ID
RECEIVING
10
RECEIVING
Non-Conforming Products
Brady floor markings and signage can be used to create a visual work space that identifies proper storage areas.
Solution
Probing Questions
■ How do you identify the proper area for handling non-conforming receivables?
■ How do you identify the proper bins for disposal of packaging that might contain contaminants?
11
As part of GFSI programmes,
non-conforming products must be
identified and held in a separate
area for inspection. Non-conforming
products could include packages
with a high amount of bird droppings
on them, ripped packages, expired
ingredients, allergens or questionable
products.
Furthermore, all packaging of
materials (shrink wrap, bands,
cardboard) should have a marked
area for disposal as the packaging
could be carrying contaminants. In
some processing plants, plastic
receiving pallets will actually be
washed and sterilised.
Non-Conforming Products
RECEIVING
12
INGREDIENT STORAGE/WAREHOUSE
Storage
Brady floor markings, labels and signage can be used to create a visual work space to help with organisation and work flow.
Solution
Probing Questions
■ How do you identify storage spaces for allergens?
■ How do you identify best practices to
13
Similar to any warehouse
environment, it’s important to visually
identify appropriate storage areas
for all items. Specifically for food, it’s
essential to identify storage areas
for potential allergens, because
unidentified allergens are the leading
cause of food recalls.
To avoid any cross-contamination,
any packages that have been
compromised or have expired should
not be stored near good ingredients.
Finally, any identification that can be
used to assist with work flow to ensure
expired food from being on the shelf.
Storage
INGREDIENT STORAGE/WAREHOUSE
14
PRE-PRODUCTION STAGING
Staging
Brady floor markings, labels and signage can be used to create a visual work space to help with organisation and work flow.
Solution
Probing Questions
■ How do you visually identify appropriate staging areas for ingredients?
■ How would a mix-up in ingredients impact your food production?
15
Many processors do not have
well-marked staging areas for
materials about to go into production.
This can cause several issues:
random locations near the
processing line can create
workplace safety concerns
related to slips, trips and falls.
identified, the wrong ingredient
could be used in product
formulation, causing quality
issues, a recall or need for
re-work.
Staging
PRE-PRODUCTION STAGING
16
PRODUCTION
Wash Down and Sanitation
ToughWash™ signs can be used to provide
sanitary operating procedures for each
piece of equipment (similar to providing
visual lockout procedures).
ToughWash™ Tags can be used to identify
machine components, tools or utensils that
must be removed from the environment for
sanitisation.
Solution
Probing Questions
■ How do workers know the appropriate procedures for cleaning and sanitising equipment?
■ How do workers know if tools and utensils have been sanitised?
■ How would you benefit from having visual procedures for sanitation on each machine?
17
Because of the emphasis on food safety,
sanitary processing facilities are critical.
Therefore, food processors conduct
wash downs to sanitise critical areas of
their processing facility. Wash downs
generally occur every night on third shift
and whenever a production line changes
over to a new product run. The area that
gets washed down and the degree of wash
down will vary by type of food. Generally,
meat, dairy and seafood plants have the
harshest wash down conditions.
Wash Down and Sanitation
PRODUCTION
18
PRODUCTION
Line Clearance for Sanitation
Solution
Probing Questions
■ How do you currently document your line clearance procedures?
■ With the tightening regulations from the FDA and with GFSI, do you feel you will be required to provide a higher level of documentation going forward?
■ How would you benefit if you could prove your line clearance using electronic data?
InspectNTrack™ Software can be used to ensure a complete inspection of sanitation and provide detailed documentation that the line has been appropriately cleared for production.
19
Before food production can start each
morning, food processors must ensure that
their production line has been completely
sanitised (99.999% free of bacteria).
Additionally, processors that use allergens
on their food line must also ensure that
the sanitation process has removed any
allergen residue to eliminate
cross-contamination concerns.
To achieve these results, food processors
follow a stringent wash down process. At
the end of this process, the food processor
must check all surfaces using blacklights,
swabs for ATP and other laboratory tests to
ensure sanitation. The line cannot start until
they have clearance for sanitation.
Today, many processors manually document
this process with paper and binders.
Line Clearance for Sanitation
PRODUCTION
20
PRE-PRODUCTION STAGING
Line Clearance for Equipment
Brady signage can provide standard operating procedures for changeovers and indicate the appropriate equipment for each type of food being processed.
InpsectNTrack can verify that appropriate maintenance has been conducted on all critical equipment.
Solution
Probing Questions
■ How often do you change over the production line?
■ How do you verify you have the right equipment on the line for production?
■ How do you document maintenance of your critical equipment? Would you benefit from electronic data storage?
PRODUCTION 21
Prior to beginning production,
processors must verify that they have
the proper equipment on the production
line for the food they are about to
produce. This is very important for any
processors that run multiple products on
the same line and conduct changeovers
on the line.
Furthermore, many GFSI programmes
require processors to keep maintenance
records for all critical processing
equipment.
Line Clearance for Equipment
PRODUCTION
22
PRE-PRODUCTION STAGING
Line Clearance for Product
Brady signage can provide standard operating procedures for commissioning a line for full production.
Solution
Probing Questions
■ My understanding is that you need to run a passable product before opening full production. Would standard operating procedures on commissioning a line be of benefit?
PRODUCTION 23
Prior to the start of full production
runs, food processors must first run
a passable product through the
produced that passes inspection,
the line can then begin running at full
production.
Line Clearance for Product
PRODUCTION
24
PRE-PRODUCTION STAGING
Lockout / Tagout
VLOP Writing Services ensure that the LOTO information can be posted in an easy to understand format at the point of lockout.
Metal detectable, wash down resistant placards and tags can be used at the point of lockout without causing food safety concerns.
Solution
Probing Questions
■ Have you ever considered creating visual lockout procedures at the point of lockout?
■ Are the lockout tags you use today metal detectable?
PRODUCTION 25
environment, lockout tagout is a
standard practice in food processing.
Unlike every other manufacturing
environment, the wash down process
occurs every night and requires
the sanitation crew to disassemble
components, and lockout or tagout
equipment as needed.
Lockout / Tagout
PRODUCTION
26
PRE-PRODUCTION STAGING
Safety Signs & Labels
Metal detectable wash down resistant signs and labels can be used to alert employees of safety hazards, without causing food safety concerns.
Solution
Probing Questions
■ Do you fully label all the safety hazards in your processing environment?
■ How do the labels you use stand up to the wash down process?
■ Are your labels metal detectable?
PRODUCTION 27
Food processing environments pose
a number of safety hazards that
should be identified with appropriate
signage. Because of the hazards in
food processing, it’s 59% more likely to
be injured in food processing than the
average private manufacturing plant.
Some of these hazards include pinch
points, sharp knives, wet and slippery
floors, heavy/repetitive lifting and
confined spaces.
In a recent survey of 300 food
processors, more than 40% indicated
they had not marked all safety hazards.
Warning Signs
PRODUCTION
28
PRE-PRODUCTION STAGING
Standard Operating Procedures
Metal detectable wash down resistant signs and labels can be used to alert employees of standard operating procedures, without causing food safety concerns.
Solution
Probing Questions
■ How do you communicate operating procedures to your employees on the line?
■ How does turnover affect your ability to ensure operating procedures are being followed?
■ How would operating procedures at the point of work create efficiencies for you?
PRODUCTION
Standard Operating Procedures1. Dedicated area and sanitation (FC 3-502.12.B.5.b2. Prevention of cross-contamination (FC 3-502.12.D.2.c)3. No bare-hand contact of ready-to-eat foods (FC 3-502.12.B.5.a)4. Chilled food storage - time and temperature monitoring (FC 3-502.12.D.2.f)5. Labeling - maximum shelf life - disposition (FC 3-502.12.D.2..e)
29
Placing standard operating procedures
along the processing line can help to
ensure workers follow protocol, making
them more efficient and increasing the
chances of safe food production. This is
especially important due to the varying
education levels, spoken languages and
frequent turnover of food processors.
Product re-work can account for
significant costs and loss of time. If a
product doesn’t pass final inspection
due to improper processing, it will need
to be re-worked through the line.
Some food processors will change over
production lines. Having changeover
procedures at the point of operation can
ensure a smooth transition that allows
the line to be commissioned for food
production more quickly.
Standard Operating Procedures
PRODUCTION
30
PRE-PRODUCTION STAGING
Critical Control Point
Metal detectable, wash down resistant signs and labels can be used to alert employees of critical control points, without causing food safety concerns.
Solution
Probing Questions
■ Do you have any signage indicating your Critical Control Points (CCPs) throughout the plant?
■ Would highlighting your CCPs create awareness among your employees as to the importance of your CCPs?
PRODUCTION 31
Almost all government agencies and GFSI
programmes require food processors to
implement HACCP plans. Essentially, they
must identify all potential hazards to food
safety and then identify the critical control
point that will eliminate that risk. Examples
of critical control points could be an oven
that cooks chicken to 170°F/ 76.6°C or an
x-ray detection system or metal detection
system at the end of a food line.
To be compliant with the regulations,
each employee operating machinery at
a critical control point must be able to
communicate the appropriate information
related to the control point to an inspector.
The food processor must be able to
prove they have validated the machine is
achieving the control point and verify that
the tests have happened over time.
Critical Control Point
PRODUCTION
32
PRE-PRODUCTION STAGING
Critical Equipment Maintenance
InspectNTrack™ Software can ensure the timely maintenance and documentation for critical equipment.
Solution
Probing Questions
■ How do you currently document your equipment maintenance?
■ Are you confident the maintenance has been taking place? Can you prove it?
PRODUCTION 33
GFSI requires that any machine on
the critical equipment list must have
documented maintenance records to
ensure it’s in compliance.
Critical Equipment Maintenance
PRODUCTION
34
PRE-PRODUCTION STAGING
Pipe Marking
Pipe markers provide clear and reliable visual markings of pipe contents and direction of flow.
Solution
Probing Questions
■ Do you have any concerns with the performance of your pipe markers?
■ Would you use more pipe marking if you felt there were better solutions available?
PRODUCTION 35
Food processors may have pipes to
transport liquids. All of these pipes
should be identified with the direction
should be the marking of potable water.
Additionally, food processors often use
Ammonia to cool areas of the plant.
These pipes must be properly identified.
Pipe Marking
PRODUCTION
36
PRE-PRODUCTION STAGING
Line Clearance for Sanitation
InspectNTrack™ Software can be used to ensure a complete inspection of sanitation and provide detailed documentation that the line has been appropriately cleared for production.
Solution
Probing Questions
■ How do you currently document your line clearance procedures?
■ With the tightening regulations from the FDA and with GFSI, do you think you will need a higher level of documentation going forward?
■ How would you benefit if you could prove your line clearance using electronic data?
PACKAGING 37
Similar to the production line, packaging
lines must be completely sanitised
(99.999% free of bacteria) prior to beginning
packaging each morning. To achieve these
results, food processors follow a stringent
wash down process.
At the end of this process, the food
processor must check all surfaces using
blacklights, swabs for ATP and other
laboratory tests to ensure sanitation. The line
cannot start until they have line clearance
for sanitation.
Line Clearance for Sanitation
PACKAGING
38
PACKAGINGPRE-PRODUCTION STAGING
Line Clearance for Equipment & Supplies
Brady signage can be used to place standard operating procedures at the point of packaging, creating an efficient and thorough line changeover.
Brady floor marking and labels can be used to better identify the appropriate packaging materials to avoid mix-ups.
Solution
Probing Questions
■ How often do you change over the packaging line?
■ How do you verify you have the right equipment and labels on the line for packaging?
PACKAGING
Standard Operating Procedures1. Dedicated area and sanitation (FC 3-502.12.B.5.b2. Prevention of cross-contamination (FC 3-502.12.D.2.c)3. No bare-hand contact of ready-to-eat foods (FC 3-502.12.B.5.a)4. Chilled food storage - time and temperature monitoring (FC 3-502.12.D.2.f)5. Labeling - maximum shelf life - disposition (FC 3-502.12.D.2..e)
39
Similar to the production line,
packaging lines must be inspected
to ensure the appropriate equipment
and supplies are available for
packaging the specific product being
produced that day.
Most important is ensuring that the
correct packaging labels are on
the line. Mislabelled allergens and
ingredients are one of the biggest
because the wrong label was applied
to the product.
Line Clearance for Equipment & Supplies
PACKAGING
40
PRE-PRODUCTION STAGING
Storage
Brady floor markings, labels and signage can be used to create a visual work space to help with organisation and work flow.
Solution
Probing Questions
■ How do you currently identify proper storage areas in your warehouse for finished product?
■ Do you post instructions in your
product flow?
FINISHED GOOD WAREHOUSE 41
Similar to any warehouse
environment, it’s important to visually
identify appropriate storage areas for
all items.
To avoid sending out bad product,
any packages that have been
compromised or have expired should
not be stored near good product.
Finally, any identification that can be
used to assist with work flow to ensure
expired food from being on the shelf.
Storage
FINISHED GOOD WAREHOUSE
42
PRE-PRODUCTION STAGING
Bulk Food - Load Out
Brady signage can be used to indicate proper clothing for a sanitised load out area and standard operating procedures for load out to ensure food safety.
Solution
Probing Questions
■ How do you ensure a sanitary environment inside your load out area?
SHIPPING 43
Some processors have a “load
out” area where food is shipped
in bulk (truck or container loads).
Because the food has the potential
for exposure to contaminants when it
is transported into the bulk container,
the load out area must be highly
sanitised.
SHIPPING
Bulk Food - Load Out
44
CLP/GHS
Because of the chemicals used within the wash down environment, you will likely find a need
GENERAL PLANT NEEDS
General Plant Needs
Shadow Boards
Because of concerns with sanitation and cross-contamination, food processing plants like to have separate tools and equipment for each area of their processing plant. In order to keep track of the tools, they will often colour code them and use shadow boards to organise them in the appropriate areas of the plant.
Pipe Markers
Although pipe markers were mentioned as part of the production floor, you will find the need for pipe markers throughout the processing plant. Whether it’s to identify ammonia pipes or potable water, it’s critical to know what’s in each pipe.
45
GLOSSARY OF TERMS
REGULATORY BODIES
Codex Alimentarius:
internationally recognised standards, codes of practice, guidelines and
other recommendations relating to foods, food production and food
safety.
European Commission: Executive body of the European Union
responsible for proposing legislation, implementing decisions, upholding
the Union’s treaties and day-to-day running of the EU.
European Food Safety Authority: Provides independent scientific
advice and communication on existing and emerging risks associated
with the food chain.
Global Food Safety Institute (GFSI): A retail driven accreditation that
aims to create a global standard for food safety from farm to fork
(www.mygfsi.com).
Popular GFSI schemes include SQF, BRC, IFS and Food Safety System
Certification 22000.
United States Department of Agriculture (USDA): Responsible for
developing and executing federal government policy on farming,
agriculture, forestry and food
(www.usda.gov/wps/portal/usda/usdahome).
U.S. Food & Drug Administration (FDA): Responsible for protecting
and promoting public health through regulation and supervision of Food
Safety (www.fda.gov).
46
GLOSSARY OF TERMS
TERMS
Adenosine Triphosphate (ATP): All microorganisms use ATP for fuel.
Its presence is a good indication of biological materials. Facilities are
swabbed for ATP at the end of cleaning processes to ensure sanitation.
Adulteration: Food that has been deemed impure due to the
introduction of foreign materials.
Cleaning in Place: A mechanised system that delivers a detergent
solution, water rinse and sanitising solution to clean equipment without
using a manual wash down.
Critical Control Points: A point, step or procedure at which controls can
be applied and a food safety hazard can be prevented, eliminated or
reduced to acceptable (critical) levels. Cooking to specific temperatures
is the most common critical control point.
Enterprise Resource Planning (ERP): Management software used to
track and identify flow of materials through storage.
FIFO (First in, First Out): Food rotation system that organises and
uses food that was received earlier first, to track product expiration and
ensure safe food.
Hazard Analysis and Critical Control Point (HACCP): A systematic
preventive approach to food safety from biological, chemical and
physical hazards in production processes.
Line Clearance for Sanitation: Before food production can start, food
processors must ensure that their production line has been completely
sanitised (99.999% free of bacteria or a 5 log reduction).
Pathogens: Bacteria such as e-coli, salmonella and listeria that can
cause foodborne illnesses.
Re-Work: Processed food that does not pass quality inspections will
need to cycle through the production cycle a second time to pass
quality standards.
Wash Down Process: An aggressive cleaning process using hot,
high pressure water, chemicals and abrasives to sanitise production
equipment to reduce the risk of foodborne illnesses.
47
BRADY Africa 361 Olympic Duel, Northlands Business Park, Newmarket Road, Randburg Tel: +27 11 704 3295 Fax: +27 86 501 7775
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EUR-M-751-EN 03/03/2015
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