Looking for a Product Changeover Checklist

Hi everyone,

I was wondering if anyone could help me with a product changeover checklist. I work at a tuna canning factory and we have about 5 different types of products and we may run 2 different products on the same day. After viewing SQF editiion 8, we saw a requirement about providing a changeover procedure. 

Regards

Hi tunaplant,

The SQF Code Edition 8 requires:

2.6.1.3 Product start up and changeover procedures during packing shall be documented and implemented to ensure that the correct product is in the correct package and with the correct label, and that the changeover is inspected and approved by an authorized person.

This process would normally involve the removal of packaged products and packaging, then the introduction of the new packaging and product with a start up check. My procedure would require clearance from QA on the first product off prior to starting production. QA checks include confirmation the product meets specification and verification of printed information where appropriate including Date coding, Batch coding, Label, Quantity declared, Bar code etc. Start ups would be also signed off by a Supervisor.

Your checklist should reflect your procedure.

Kind regards,

Tony

Is it in a packed product area or in the packing area?  The latter will include everything Tony said but may also include weight checks.  In the open product area you would want to make sure the area was sufficiently cleaned down between products (if applicable) and signed off to say it was sufficiently clean.  

As Tony has hinted at, one of the main reasons for a changeover procedure and record is packaging.  Getting the wrong packaging on a product isn't just a known issue but a sad and common fact of life.  One of the best ways to make sure this doesn't happen is to not have any packaging on the line other than the product you are packing.  This literally means removing all of the packaging from the last run, checking the line is clear then getting the packaging for the next run.  That might sound pedantic but imagine if your real of correct labels was put on top of the reel of labels from the last run?  Then, mid run, your labels are incorrect.  Of course there is an additional check at your change of reel (or should be) but if you have multiple controls in place, you are less likely to have an issue as if one fails there is another to prevent the "Swiss cheese effect".

Good point with regards to weight checks and from past experiences ensure that not just the packaging is removed but also any other ingredient/s that you have used on your previous run.

Do SQF Food Safety Standards require weight checking procedures / documentation ?

I thought BRC were the (unfortunate) exception ?

We actually do canned products, and the labeling is done after cans have cooled down from retorting. All our products contain tuna, only the species of tuna changes with some products. I added a product changeover authorized by and verified by section in one of our existing forms, which is our visual seam inspection report. Would I have to do something similar in our labeling reports as well?

Thank you all for your response