23 replies to this topic

[rellie]

Hi all.

I am currently reviewing our Foreign Matter Policy and am wondering if anyone would have a sample procedure I could have a look at.

Thanks

[Charles.C]

Dear rellie,

Welcome to the forum !

Foreign Matter

A little background might help ? Product ? Process ?

Rgds / Charles.C

[Dr Ajay Shah]

Hi Rellie,

Can you please enlighten us with the type of products that you are manufacturing and the process involved and am sure you will get members to respond to your query.

Regards

Ajay

[rellie]

Hi.

It is a milk manufacturing facility. The main sources of foreign matter are wood, glass and metal.

Thanks

[Zeeshan]

Hi all.

I am currently reviewing our Foreign Matter Policy and am wondering if anyone would have a sample procedure I could have a look at.

Thanks

Attached are the sample policy and a relevant format to be used in case of accidental contamination.

 Glass, Wood & Metal poilcy.pdf   35.5KB   2764 downloads

 Physical Contamination Incident Report.pdf   81.16KB   2375 downloads

Hope it helps!

Regards:
M.Zeeshan

[MQA]

I think more information should be provided in the policies.

If you don't specify the type of elements not permitted, they may be overlooked. For example, also consider for wood clipboards and utensils.

The policy should include:

• Specifically what is not permitted
• Method of control
• Corrective Actions

I like the Incident Report form though.

[Charles.C]

Dear Jakmqa,

I would hv thought it rather depends on how general you like a policy to be ?

The details are perhaps more effectively presented in the associated procedure "a la" ISO, but maybe not as per BRC ?

Additionally, the more you include, the likelier the chance of a pre-emptive auditorial strike maybe ?

Rgds / Charles.C

[MQA]

My support of more information comes from physical contamination customer complaints over the years. I think staff should specifically be told (trained) what type of elements are excluded and permitted.

Yes, we know wood, glass, plastic, or some metals are not permitted but sometimes, we can "forget" that yes, wooden clipboards are also not permitted. Being specific eliminates the forgetfulness or "I didn't think of that" or "oops".


For example:

• Wooden pallets. Permitted within the premises but not within the process areas
• Clipboards should not be wooden or plastic
• Some equipment have glass dials
• Ensure all pens supplied do not have detachable lids
• Eliminating "band-aid" solutions of string, tape, cardboard on plant and equipment
• Ensuring no staples or paperclips on paperwork by the production desk

[zoloo]

Dear,

How to control product label in the frame of ISO 22000 requirements.

Regards ,


Zoloo, from Mongolia

[Tony-C]

My support of more information comes from physical contamination customer complaints over the years.

Complaint information and examples can be useful in briefing & training staff regarding foreign body control.

I haven't seen a wooden/board clipboard for around 20 years - something like this and pens can easily be covered of in policy: "Only company issue clipboards & detectable pens permitted in production areas"

Edited by Tony-C, 01 July 2011 - 08:41 AM.

[ultramar2010]

I have something that could be usuful:

 

 

 

1. Introduction

Companyhas established, documented and implemented a foreign body detection policy for the site, which is maintained in order to meet the requirements of the Food Safety Quality Management System and ensure the safe production of products.

 

1. Policy

Glass and Brittle Plastic:

Companyis committed to reduce, and where possible eliminate, the potential of Glass, Brittle and Hard Plastic, Ceramics and Similar Materials contamination in the products, which are being processed or handled at the company’s processing and storage areas.

Companywill take all possible precautions to prevent such contamination. As a consequence, the aim of this policy is to introduce preventive measures and good manufacturing practices to ensure that risks of such contamination are minimized.

Companyhas not permitted the use of glass, plastic and ceramic items in processing and storage areas. Glass windows are not used within production and storage areas. Lighting fixtures installed within production and storage areas have appropriate shelter in case of accidental breakage of lightening source.

 

Wood:

In areas where a risk assessment has identified the potential for product contamination from wood, the use of wood will be excluded. Where the use of wood cannot be avoided, and the risk is managed, the condition of wood is regularly checked to ensure it is in good condition and clean.

 

Metal:

The use of sharp metal implements, including knives, cutting blades on equipment, needles and wires will be controlled. This includes suitable controls both into and out of the plant and warehouse, and safe disposal.

Snap-off blade knives are not permitted in processing and storage areas.

Procedures will be developed and implemented that non-production equipment and maintenance tools would not be left in a position that allows them to contaminate the product.

 

1. Scope

The scope of the Foreign Body Detection Policy only applies to machine product items. Some hand packed items are subject to manual inspection.

 

1. Legal definition

A physical hazard in food is any extraneous object or foreign matter that may cause illness or injury to the consumer.

• Foreign objects smaller than 7 mm rarely cause trauma or serious injury except in special high-risk groups, such as infants, surgery patients and the elderly.
• Glass is the most frequently reported foreign material in food to cause illness or injury.
• FDA Health Hazard Evaluation Board conclusions in cases of foreign materials (1972–1997) found that 56 percent of objects 1–6 mm in size might pose a limited acute hazard. For objects greater than 6 mm, only 2.9 percent were judged to present no hazard.

 

1. Types of Physical Hazards

The type of foreign objects in food affects the technology needed to detect it:

1. Glass: Sharp glass contamination often occurs during filling processes in glass containers if a container is accidentally broken. Another source, but less frequent, is light bulbs broken during building maintenance.
2. Metal: Sharp metal objects may include screws and equipment splinters, blades, broken veterinary needles, fragments and clippings of prior processing procedures.
3. Plastics: Soft and hard plastics may come from packaging material of an intermediary production phase.
4. Wood: Wood splinters may have their origin at the farm or may come from handling wooden pallets.
5. Stones: Small stones are more common in crops like peas or beans contaminated during harvest.

 

1. Metal Detection

Based on risk assessment the Food Safety Team has confirmed that metal detection is a crucial control measure to some processes to prevent any metal which may come in contact with the product (loose nuts and bolts etc.) from being sent out to the customer. Metal in product will affect the company’s reputation and may seriously injure the consumer if swallowed. A sensitivity and timing check is carried out before starting production and every hour throughout production to ensure the metal detector continues to work effectively. This procedure describes the testing procedure of metal detectors.

• Ferrous is both magnetic and conductive so easily detected.
• Non-ferrous is non-magnetic but a good or excellent conductor so relatively easily detected.
• Stainless steel is the most difficult contaminant to detect as it is usually non-magnetic and a poor conductor. Stainless steel comes in various grades, some of which are magnetic varying to totally non magnetic. Their conductivity also varies, but is generally low. Both of these factors contribute to poor detectability.

The test sticks used are:

3.0 mm ferrous test stick

3.0 mm non-ferrous test stick

4.0 mm stainless steel stick

The QC technician and the production operator are responsible for carrying out metal detection checks every hour. The metal detection checks are audited every month by the Quality Assurance Manager.

Monthly inspections, maintenance and calibration are done by the equipment manufacturer, authorized factory representative or trained contractor. 

 

1. Test

1. Place the wand or stick on the on the tubular plastic holder. In the same direction that the conveyor runs.
2. Pass the wand and the tubular holder through the metal detector and verify if the system is activated.
3. Repeat the same process with the rest of sticks.
4. Record the test on to the Micro-Baggers Metal Detector Log or Tunnel Heater Metal Detector Log.

 

1. Rejected Products

1. Rejected packs must be investigated.
2. Pass the rejected products through the detector positioned in the same way as they were when they originally went through the search head.
3. Then pass the same products through the search head twice more, each time positioned in different ways.
4. If at any stage the products are rejected again, it is essential to find the contaminant and identify it, and take any necessary action to ensure similar contamination does not recur.
5. Fill out the Incident Report.
6. In case of false positives due to high moisture in the sample, record the number of rejected packs per shift in the comments section, form QMR025.

 

1. If the metal detector fails to reject the testing wands

1. Stop the line and notify immediately to the supervisor.
2. Isolate all products produced since the last satisfactory test and re-screen them, using another detector functioning to the same standard as the original system on test, or the same detector after being recalibrated.
3. If the product cannot be rechecked, it will be put on hold to be metal detected later.
4. Additionally, all products produced since the last clear metal detection check must be placed on hold and rechecked.  The details must be recorded on to the Micro-Baggers Metal Detector Log or Tunnel Heater Metal Detector Log.
5. The stock may be transferred to the warehouse if there are stored, but must be retained in a segregated area.
6. The pallets must be clearly labeled with “do not use” tape and the notation NOT METAL DETECTED written on the Pallet Label.
7. As product from each pallet is prepared for passing through the detector, the existing pallet label must be removed and the pallet number, product and best before code information, transferred to a new label.
8. When the complete pallet has been passed through the detector the operator must sign the new label and enter the date and time.  The completed label is then attached to the pallet.
9. A master list of pallets must be completed indicating sequential pallet numbers, product description, date inspected (metal detection check) and signed by supervisory management.
10. Any product failing the metal detection check must be isolated and retained for inspection by the QA Manager.

 

1. Metal Detector Operation and Training

1. Only authorized personnel are permitted to operate the Metal Detector when they have fully completed their training.
2. Only authorized and trained engineers are permitted to adjust metal detector settings.
3. Records of training are fully documented and held in the Training Program Log.

[fgjuadi]

 

I have something that could be usuful:

 

Holy cow, that is useful! 

[luna_blue]

 

I have something that could be usuful:

 

 

This is really good. Thanks.

[Charles.C]

Dear ultramar,

 

Thank you for the useful Procedure.

 

I would offer a few comments / queries

 

(a)The "Policy" appears to be similar to  that attached in Post #5

 

(b) Adding  a policy statement relating to prevent/eliminate metal contamination of the finished product might be useful (ie similar to that for glass etc).

 

© The "scope" appears to additionally relate to glass, brittle plastic ....metal contaminants

 

(d) "Legal definition" - i assume this procedure was intended for USA. i don't recall seeing any FDA usage of the term "legal". can you provide a link ?

 

(e) The wand "test" procedure, eg "tubular holder", seems obscure / unorthodox, eg no product effect / detector geometry allowed for ?.

 

(f) The value of test wands seems unusually generous unless some specific product dimension / machine aperture is limiting., eg compare wand data to that in  -

http://www.ifsqn.com...indpost&p=72265

 

Thanks again,

 

Rgds / Charles.C

[dandy0215]

Could anyone help me with a preventive measure for wood contamination.  A little info: customer found wood in a combo of meat, in the middle of the combo.  I've conducted an investigation into how this could have happened and am coming up empty handed.  Is retraining of our Foreign Material SOP & responsibilities regarding inspection, monitoring, & discovery sufficient? Thank you in advance.

[LalangBird]

 

I have something that could be usuful:

 

 

 

1. Introduction

Companyhas established, documented and implemented a foreign body detection policy for the site, which is maintained in order to meet the requirements of the Food Safety Quality Management System and ensure the safe production of products.

 

1. Policy

Glass and Brittle Plastic:

Companyis committed to reduce, and where possible eliminate, the potential of Glass, Brittle and Hard Plastic, Ceramics and Similar Materials contamination in the products, which are being processed or handled at the company’s processing and storage areas.

Companywill take all possible precautions to prevent such contamination. As a consequence, the aim of this policy is to introduce preventive measures and good manufacturing practices to ensure that risks of such contamination are minimized.

Companyhas not permitted the use of glass, plastic and ceramic items in processing and storage areas. Glass windows are not used within production and storage areas. Lighting fixtures installed within production and storage areas have appropriate shelter in case of accidental breakage of lightening source.

 

Wood:

In areas where a risk assessment has identified the potential for product contamination from wood, the use of wood will be excluded. Where the use of wood cannot be avoided, and the risk is managed, the condition of wood is regularly checked to ensure it is in good condition and clean.

 

Metal:

The use of sharp metal implements, including knives, cutting blades on equipment, needles and wires will be controlled. This includes suitable controls both into and out of the plant and warehouse, and safe disposal.

Snap-off blade knives are not permitted in processing and storage areas.

Procedures will be developed and implemented that non-production equipment and maintenance tools would not be left in a position that allows them to contaminate the product.

 

1. Scope

The scope of the Foreign Body Detection Policy only applies to machine product items. Some hand packed items are subject to manual inspection.

 

1. Legal definition

A physical hazard in food is any extraneous object or foreign matter that may cause illness or injury to the consumer.

• Foreign objects smaller than 7 mm rarely cause trauma or serious injury except in special high-risk groups, such as infants, surgery patients and the elderly.
• Glass is the most frequently reported foreign material in food to cause illness or injury.
• FDA Health Hazard Evaluation Board conclusions in cases of foreign materials (1972–1997) found that 56 percent of objects 1–6 mm in size might pose a limited acute hazard. For objects greater than 6 mm, only 2.9 percent were judged to present no hazard.

 

1. Types of Physical Hazards

The type of foreign objects in food affects the technology needed to detect it:

1. Glass: Sharp glass contamination often occurs during filling processes in glass containers if a container is accidentally broken. Another source, but less frequent, is light bulbs broken during building maintenance.
2. Metal: Sharp metal objects may include screws and equipment splinters, blades, broken veterinary needles, fragments and clippings of prior processing procedures.
3. Plastics: Soft and hard plastics may come from packaging material of an intermediary production phase.
4. Wood: Wood splinters may have their origin at the farm or may come from handling wooden pallets.
5. Stones: Small stones are more common in crops like peas or beans contaminated during harvest.

 

1. Metal Detection

Based on risk assessment the Food Safety Team has confirmed that metal detection is a crucial control measure to some processes to prevent any metal which may come in contact with the product (loose nuts and bolts etc.) from being sent out to the customer. Metal in product will affect the company’s reputation and may seriously injure the consumer if swallowed. A sensitivity and timing check is carried out before starting production and every hour throughout production to ensure the metal detector continues to work effectively. This procedure describes the testing procedure of metal detectors.

• Ferrous is both magnetic and conductive so easily detected.
• Non-ferrous is non-magnetic but a good or excellent conductor so relatively easily detected.
• Stainless steel is the most difficult contaminant to detect as it is usually non-magnetic and a poor conductor. Stainless steel comes in various grades, some of which are magnetic varying to totally non magnetic. Their conductivity also varies, but is generally low. Both of these factors contribute to poor detectability.

The test sticks used are:

3.0 mm ferrous test stick

3.0 mm non-ferrous test stick

4.0 mm stainless steel stick

The QC technician and the production operator are responsible for carrying out metal detection checks every hour. The metal detection checks are audited every month by the Quality Assurance Manager.

Monthly inspections, maintenance and calibration are done by the equipment manufacturer, authorized factory representative or trained contractor. 

 

1. Test

1. Place the wand or stick on the on the tubular plastic holder. In the same direction that the conveyor runs.
2. Pass the wand and the tubular holder through the metal detector and verify if the system is activated.
3. Repeat the same process with the rest of sticks.
4. Record the test on to the Micro-Baggers Metal Detector Log or Tunnel Heater Metal Detector Log.

 

1. Rejected Products

1. Rejected packs must be investigated.
2. Pass the rejected products through the detector positioned in the same way as they were when they originally went through the search head.
3. Then pass the same products through the search head twice more, each time positioned in different ways.
4. If at any stage the products are rejected again, it is essential to find the contaminant and identify it, and take any necessary action to ensure similar contamination does not recur.
5. Fill out the Incident Report.
6. In case of false positives due to high moisture in the sample, record the number of rejected packs per shift in the comments section, form QMR025.

 

1. If the metal detector fails to reject the testing wands

1. Stop the line and notify immediately to the supervisor.
2. Isolate all products produced since the last satisfactory test and re-screen them, using another detector functioning to the same standard as the original system on test, or the same detector after being recalibrated.
3. If the product cannot be rechecked, it will be put on hold to be metal detected later.
4. Additionally, all products produced since the last clear metal detection check must be placed on hold and rechecked.  The details must be recorded on to the Micro-Baggers Metal Detector Log or Tunnel Heater Metal Detector Log.
5. The stock may be transferred to the warehouse if there are stored, but must be retained in a segregated area.
6. The pallets must be clearly labeled with “do not use” tape and the notation NOT METAL DETECTED written on the Pallet Label.
7. As product from each pallet is prepared for passing through the detector, the existing pallet label must be removed and the pallet number, product and best before code information, transferred to a new label.
8. When the complete pallet has been passed through the detector the operator must sign the new label and enter the date and time.  The completed label is then attached to the pallet.
9. A master list of pallets must be completed indicating sequential pallet numbers, product description, date inspected (metal detection check) and signed by supervisory management.
10. Any product failing the metal detection check must be isolated and retained for inspection by the QA Manager.

 

1. Metal Detector Operation and Training

1. Only authorized personnel are permitted to operate the Metal Detector when they have fully completed their training.
2. Only authorized and trained engineers are permitted to adjust metal detector settings.
3. Records of training are fully documented and held in the Training Program Log.

 

thanks for this useful guide. really helped me a lot :D

[Wasila]

 

I have something that could be usuful:

 

 

 

1. Introduction

Companyhas established, documented and implemented a foreign body detection policy for the site, which is maintained in order to meet the requirements of the Food Safety Quality Management System and ensure the safe production of products.

 

1. Policy

Glass and Brittle Plastic:

Companyis committed to reduce, and where possible eliminate, the potential of Glass, Brittle and Hard Plastic, Ceramics and Similar Materials contamination in the products, which are being processed or handled at the company’s processing and storage areas.

Companywill take all possible precautions to prevent such contamination. As a consequence, the aim of this policy is to introduce preventive measures and good manufacturing practices to ensure that risks of such contamination are minimized.

Companyhas not permitted the use of glass, plastic and ceramic items in processing and storage areas. Glass windows are not used within production and storage areas. Lighting fixtures installed within production and storage areas have appropriate shelter in case of accidental breakage of lightening source.

 

Wood:

In areas where a risk assessment has identified the potential for product contamination from wood, the use of wood will be excluded. Where the use of wood cannot be avoided, and the risk is managed, the condition of wood is regularly checked to ensure it is in good condition and clean.

 

Metal:

The use of sharp metal implements, including knives, cutting blades on equipment, needles and wires will be controlled. This includes suitable controls both into and out of the plant and warehouse, and safe disposal.

Snap-off blade knives are not permitted in processing and storage areas.

Procedures will be developed and implemented that non-production equipment and maintenance tools would not be left in a position that allows them to contaminate the product.

 

1. Scope

The scope of the Foreign Body Detection Policy only applies to machine product items. Some hand packed items are subject to manual inspection.

 

1. Legal definition

A physical hazard in food is any extraneous object or foreign matter that may cause illness or injury to the consumer.

• Foreign objects smaller than 7 mm rarely cause trauma or serious injury except in special high-risk groups, such as infants, surgery patients and the elderly.
• Glass is the most frequently reported foreign material in food to cause illness or injury.
• FDA Health Hazard Evaluation Board conclusions in cases of foreign materials (1972–1997) found that 56 percent of objects 1–6 mm in size might pose a limited acute hazard. For objects greater than 6 mm, only 2.9 percent were judged to present no hazard.

 

1. Types of Physical Hazards

The type of foreign objects in food affects the technology needed to detect it:

1. Glass: Sharp glass contamination often occurs during filling processes in glass containers if a container is accidentally broken. Another source, but less frequent, is light bulbs broken during building maintenance.
2. Metal: Sharp metal objects may include screws and equipment splinters, blades, broken veterinary needles, fragments and clippings of prior processing procedures.
3. Plastics: Soft and hard plastics may come from packaging material of an intermediary production phase.
4. Wood: Wood splinters may have their origin at the farm or may come from handling wooden pallets.
5. Stones: Small stones are more common in crops like peas or beans contaminated during harvest.

 

1. Metal Detection

Based on risk assessment the Food Safety Team has confirmed that metal detection is a crucial control measure to some processes to prevent any metal which may come in contact with the product (loose nuts and bolts etc.) from being sent out to the customer. Metal in product will affect the company’s reputation and may seriously injure the consumer if swallowed. A sensitivity and timing check is carried out before starting production and every hour throughout production to ensure the metal detector continues to work effectively. This procedure describes the testing procedure of metal detectors.

• Ferrous is both magnetic and conductive so easily detected.
• Non-ferrous is non-magnetic but a good or excellent conductor so relatively easily detected.
• Stainless steel is the most difficult contaminant to detect as it is usually non-magnetic and a poor conductor. Stainless steel comes in various grades, some of which are magnetic varying to totally non magnetic. Their conductivity also varies, but is generally low. Both of these factors contribute to poor detectability.

The test sticks used are:

3.0 mm ferrous test stick

3.0 mm non-ferrous test stick

4.0 mm stainless steel stick

The QC technician and the production operator are responsible for carrying out metal detection checks every hour. The metal detection checks are audited every month by the Quality Assurance Manager.

Monthly inspections, maintenance and calibration are done by the equipment manufacturer, authorized factory representative or trained contractor. 

 

1. Test

1. Place the wand or stick on the on the tubular plastic holder. In the same direction that the conveyor runs.
2. Pass the wand and the tubular holder through the metal detector and verify if the system is activated.
3. Repeat the same process with the rest of sticks.
4. Record the test on to the Micro-Baggers Metal Detector Log or Tunnel Heater Metal Detector Log.

 

1. Rejected Products

1. Rejected packs must be investigated.
2. Pass the rejected products through the detector positioned in the same way as they were when they originally went through the search head.
3. Then pass the same products through the search head twice more, each time positioned in different ways.
4. If at any stage the products are rejected again, it is essential to find the contaminant and identify it, and take any necessary action to ensure similar contamination does not recur.
5. Fill out the Incident Report.
6. In case of false positives due to high moisture in the sample, record the number of rejected packs per shift in the comments section, form QMR025.

 

1. If the metal detector fails to reject the testing wands

1. Stop the line and notify immediately to the supervisor.
2. Isolate all products produced since the last satisfactory test and re-screen them, using another detector functioning to the same standard as the original system on test, or the same detector after being recalibrated.
3. If the product cannot be rechecked, it will be put on hold to be metal detected later.
4. Additionally, all products produced since the last clear metal detection check must be placed on hold and rechecked.  The details must be recorded on to the Micro-Baggers Metal Detector Log or Tunnel Heater Metal Detector Log.
5. The stock may be transferred to the warehouse if there are stored, but must be retained in a segregated area.
6. The pallets must be clearly labeled with “do not use” tape and the notation NOT METAL DETECTED written on the Pallet Label.
7. As product from each pallet is prepared for passing through the detector, the existing pallet label must be removed and the pallet number, product and best before code information, transferred to a new label.
8. When the complete pallet has been passed through the detector the operator must sign the new label and enter the date and time.  The completed label is then attached to the pallet.
9. A master list of pallets must be completed indicating sequential pallet numbers, product description, date inspected (metal detection check) and signed by supervisory management.
10. Any product failing the metal detection check must be isolated and retained for inspection by the QA Manager.

 

1. Metal Detector Operation and Training

1. Only authorized personnel are permitted to operate the Metal Detector when they have fully completed their training.
2. Only authorized and trained engineers are permitted to adjust metal detector settings.
3. Records of training are fully documented and held in the Training Program Log.

 

Thank you for sharing with us.. it is helpful

[qad@kefaloscheese.com]

thank you all

[Charles.C]

 

 

1. Legal definition

A physical hazard in food is any extraneous object or foreign matter that may cause illness or injury to the consumer.

• Foreign objects smaller than 7 mm rarely cause trauma or serious injury except in special high-risk groups, such as infants, surgery patients and the elderly.
• Glass is the most frequently reported foreign material in food to cause illness or injury.
• FDA Health Hazard Evaluation Board conclusions in cases of foreign materials (1972–1997) found that 56 percent of objects 1–6 mm in size might pose a limited acute hazard. For objects greater than 6 mm, only 2.9 percent were judged to present no hazard.

 

 

 

The above perhaps justifies a little more detail.

 

Here is a statement of the Scope of the potential US Legal Consequences -

 

 FDA - Adulteration involving hard or sharp foreign objects.pdf   290.92KB   255 downloads

[ehintze731]

Question relating to this...what if you do find clear glass in your finished product or worse yet your customer does? Not from anything breaking in your facility but maybe from the origin of the product (raw farm product such as peas or lentils). How does one respond to that?

[Amrita Budhiraja]

Here you go :)  

 

.

1. Objective: This policy defines Royal Food Products is committed to control the risk of chemical or physical contamination of product particularly in raw material handling, preparation, processing, packing and storage areas.

 

1. Scope: This procedure applies to Royal Food Products.

 

1. Responsibility: Production, receiver and shippers, QA Technicians, HACCP/QA Manager

 

1. Procedure:

 

In order to ensure that facilities and procedures are in place to control the risk of chemical or physical contamination of product, senior site management team shall ensure that the following requirements are met:

 

CHEMICAL/TAINT CONTROL

 

Processes shall be in place to manage the use, storage and handling of non-food chemicals to prevent chemical contamination. These shall include, at a minimum:

• an approved list of chemicals for purchase
• availability of material safety data sheets and specifications
• confirmation of suitability for use in a food-processing environment
• avoidance of strongly scented products. Where strongly scented materials or taint forming materials must be used (e.g. for building work), appropriate precautions shall be taken to minimise the risk of product contamination.
• the labelling and/or identification of containers of chemicals at all times
• a designated storage area with restricted access to authorised personnel and chemicals should be used by trained personnel only.

 

METAL CONTROL

 

• Refer to Metal control policy and Control of Sharp Metallic Objects for the controlled use and storage of sharp metal implements including knives, cutting blades on equipment, needles and wires is in place. This shall include a record of inspection (Register of Sharp Metallic Objects). Snap-off blade knives shall not be used.
• Loose metal objects on equipment, equipment covers, and overhead structures are removed or tightly fixed so as not to present a hazard.
• The purchase of ingredients and packaging which use staples or other foreign-body hazards as part of the packaging materials shall be avoided.
• Staples, paper clips and drawing pins shall not be used in open product areas. Where staples or other items are present as packaging materials or closures, appropriate precautions shall be taken to minimise the risk of product contamination.                

 

CONTROL OF GLASS, BRITTLE PLASTIC, CERAMICS AND SIMILAR MATERIALS

 

Glass or other brittle materials shall be excluded or protected against breakage in areas where open products are handled or there is a risk of product contamination.

 

• Glass and Brittle Plastic Inspection Report includes, at a minimum:

• a list of items detailing location, number, type and condition
• recorded checks of the condition of items, carried out at a specified frequency that is based on the level of risk to the product
• details on replacing items to minimise the potential for product contamination

• RFP-PA-PR-006 Glass and Brittle Plastic Breakage Response Plan in place.
• All windows and doors at the closed area shall be coated to protect against breakage.

• Bulbs and strip lights (including those on electric fly-killer devices) are adequately protected with the light cover.
• No glass or glass packaging is permitted or used inside the plant.
• All observations shall be written on the comment’s column of RFP-PA-FO-001 Glass and Brittle Plastic Inspection Record. QA Technician shall visually inspect all items on the Glass and Brittle Plastic Inspection Record for cracks or breakage.
• Glass instrument dial covers on processing equipment and MIG or digital thermometers are inspected during pre-op inspection at the start of each shift to confirm they have not been damaged or missing.

 

WOOD CONTROL

 

Wood should not be used in open product areas except where this is a process requirement (e.g. maturation of products in wood). Where the use of wood cannot be avoided, the condition of wood shall be continually monitored to ensure it is in good condition and free from damage or splinters which could contaminate products

 

OTHER PHYSICAL CONTAMINANTS

 

Physical contamination of raw materials by raw material packaging (e.g. during debagging and de-boxing) could occur. Following measures should be taken:

• Production operators to ensure the raw material is debagged/de-boxed in dedicated area only.
• Report to supervisor if any raw material received is damaged or tampered or if the lot number is missing and place the HOLD labels on the containers where the raw materials have been decanted.
• Perform visual checks of de-boxed/ debagged raw material to ensure the products are not contaminated with foreign body or any packaging debris. If they found any physical/ foreign bodies collect and pass to the QA or HACCP Manager.
• Metal detectable pens should be used in open product areas to minimise the risk of physical contamination.
• Gaskets, rubber impellers, and other equipment made of materials that can wear or deteriorate over time are inspected on a regular frequency.
• Loose metal objects on equipment, equipment covers, and overhead structures shall be removed or tightly fixed so as not to present a hazard.

 

 

1. Deviation:

1. If the any sharp metallic objects or missing piece is not found, IMMEDIATELY report the incident to QA or HACCP or designate. Complete deviation report.
2. Refer to Management of Non-conforming Material. Product shall be placed ON HOLD until pending decision from QA personnel.
3. All the deviation shall record on the comments section on the provided form.
4. The QA Technician shall create an Inspection Work Order and assign to Department Manager to perform corrective action.

 

1. Records:

• Pre-op Inspection record
• GMP verifications
• Glass and Brittle Plastic Monthly Inspection Report

1. References:

• RFP-PA-PR-006 Glass and brittle plastic breakage response plan
• RFP-PC-PO-002 Control of sharp metallic objects
• Management of non-conformities

1. Verification:
   1. QA Personnel shall verify Pre-operational Checklists on daily basis
   2. Refer Internal Audit Program.

 

 

 

 

 

Revision History:

Date

Rev. #

Name

Details

December 23, 2021

0

Gaganreet Tiwana

New

Mar 7, 2022

1

Gaganreet Tiwana

Updated with glass and brittle plastic procedure

Nov 22, 2022

2

Amrita Budhiraja

 

Edited by Amrita Budhiraja, 22 November 2022 - 06:28 PM.

[Amrita Budhiraja]

Dear rellie,

Welcome to the forum !



A little background might help ? Product ? Process ?

Rgds / Charles.C

 

 

 

Hi do you have any record for register of Sharp Metallic Objects? 

[theocaefarmconnex]

My company runs distribution for small producers- would we need a foreign Matter Control Policy? 

[jfrey123]

My company runs distribution for small producers- would we need a foreign Matter Control Policy? 

 

Depends on your auditing scheme, but generally yes, you need a FM control program.  Having a fair amount of experience in third party food warehousing, I'd suggest your FM program state:

- Types of FM that could be introduced by your facility, and how you control those risks (keeping all product sealed in it's original packages/containers is a good control for this).

- That your company does not open any of the packages and you rely on your customer's/supplier's packaging to come in sealed.

- Your program should detail inspecting packages at receiving and shipping to ensure no breakages or leaking product is observed.  Being that you're only a distributor, the program should detail contacting the product owners for instructions on how they want exposed/open product to be handled.