4 replies to this topic

[Quality girl]

Minor
11.1.2.1 Floors shall be constructed of smooth, dense, impact-resistant material that can be effectively graded, drained, impervious to liquid, and easily cleaned. Floors shall be sloped to floor drains at gradients suitable to allow the effective removal of all overflow or wastewater under normal working conditions.
Where floor drainage is not available, plumbed options to handle overflow or wastewater shall be in place.
Floors are not all maintained smooth, impervious to liquid and effectively drained. Evidence: Floors were oberved in multiple areas, unprocessed (raw room) chicken prep area, sanitation areas, around drains and door areas to be degraded down to aggregate. The surface of the concrete floor is no longer smooth, impervious to liquid or easily cleaned. Squeegie was observed to be used in sanitation area to removal of overflow or waste water. Routine Maintenance schedule reviewed did not include the maintenance of the floor.

Minor
11.1.7.9 Non-conforming equipment shall be identified, tagged, and/or segregated for repair or disposal in a manner that minimizes the risk of inadvertent use, improper use, or risk to the integrity of finished product. Records of the handling, corrective action, and/or
Non-conforming equipment is not clearly identified and/or segregated for repair or disposal that minimizes the risk of inadvertent use, improper use. Records of the handling or disposal of non-conforming equipment are not maintained. Evidence: The exterior of building 191 had areas where old equipment was observed stored against the building and around the exterior. Rolling metal bakers rack, metal sink, metal work station tables. Some items were noted to be covered with tarps other exposed to the elements. It was not clear whether items would be used or were to be disposed of. The site does tag metal items that are to be pick up for metal scrap for disposal by contract service. No items were observed to be tagged for disposal. Non-conforming records reviewed Jan 2023 to July 2023 "Hold and Release log"

Minor
11.5.1.5 The use of non-potable water shall be controlled such that:
i. There is no cross-contamination between potable and non-potable water lines;
ii. Non-potable water piping and outlets are clearly identified; and
iii. Hoses, taps, and other similar sources of possible contamination are designed to prevent backflow or back-siphonage.
Not all non-potable water used for sanitation, and hand washing are designed to prevent back-siphonage. Evidence: Discharge pipes from handsinks, two and three compartment sinks were observed with discharge pipes extend below the level of the opening at floor level. Drains are designed with an open catch area with a grate lower in the floor to catch debris. Proper air gap between catch area is not provided to prevent back syphoning.

Minor
11.6.1.5 Where raw materials, ingredients, packaging, equipment, and chemicals are held under temporary or overflow conditions that are not designed for the safe storage of goods, a risk analysis shall be undertaken to ensure there are no risks to the integrity of those goods, no potential for contamination or adverse effect on food safety.
A risk analysis for packaging held under temporary or overflow conditions has not been conducted to ensure there are no risks to the intergrity, no potential for contaminination or adverse effects on food safety. Evidence: The storage of packaging in a trailer between buildings 180 and 196 the back of the parking area was observed during the facility audit and flow validation. Temporary/Overflow storage is not indicated on the flow diagram for storage or in the HACCP hazard analysis. No risk analysis was undertaken by the site.

[SQFconsultant]

I'll do the first one.

Entire floor is scheduled for repair and replacement to conform with code xxx

Attached is contract with copy of disbursement.

Followup will be submitted to show pictures of new floor asap or are attached.

Look, once you go to aggregate its all over and either a full dry out and new layers on top are needed or a complete rip out if moisture is penetrating thru aggregate to sub soil or underlying structure.

[Tony-C]

Hi Quality Girl,

 

 

Welcome to the IFSQN forums.

 

For the first three it would seem that you have facility maintenance deficiencies that require further investigation to establish the root cause? With the packaging storage on the trailer, is that a regular occurrence or a one off?

 

Typical corrective actions, in all cases you need to provide evidence of action:

 

Minor

11.1.2.1 Repair the floor. Investigate why the issue was not raised in routine inspections and maintenance inspections. Add to maintenance schedule. As per Glen’s post, if you cannot complete the corrective action within 30 days you need to provide an order/contract to demonstrate commitment to the repair.

 

Minor

11.1.7.9 Dispose of rolling metal bakers rack, metal sink, metal work station tables or tag abd add to Non-conformance records. Ensure that future items are tagged and protected or disposed of.

 

Minor

11.5.1.5  Arrange for all pipes from handsinks are shortened so they are above the level of the opening at floor level. Add to regular inspections of site and equipment.

 

Minor

11.6.1.5 Carry out a risk assessment of storage of packaging on trailers (and include security of this packaging/trailer). Add temporary/overflow storage to the flow diagram for storage and consider in the HACCP hazard analysis.

 

Kind regards,

 

Tony

[Quality girl]

The root cause analysis is that the program did not specify to conduct routine maintenance on the floors hence why the degradation occurred.

Yes for the trailer it was a one time off, we did added a lock to the trailer. But since we have cámara surveillance the team left it unlocked to remove the packaging material at during the day. So we could add that this trailer needs to be locked at the end of the shift.

[PQAManager]

11.1.2.1  If you are not fixing the floor you would have to add to your sanitation program a schedule for the floors to be squeegeed.  Training and frequency need to be address too.

 

11.1.7.9 You will have to add these items to your hold and release log and update your procedure for these items to be marked in some kind of way to say they are non-conforming and will not be used back into production.

 

11.5.1.5 Maintenance or a plumper is going to have to fix this and you can provide pictures of it fixed for evidence, work orders, P.O...

 

11.6.1.6 Temporary/Overflow storage needs indicated on the flow diagram for storage or in the HACCP hazard analysis. A risk analysis needs to be done as well.