6.1 Control of operations
The site shall operate to procedures and/or work instructions that ensure the production of consistently safe and legal product with the desired quality characteristics, in full compliance with the HACCP food safety plan.
6.1.1Documented process specifications and work instructions/procedures shall be available for the key processes in the production of products to ensure product safety, legality and quality. The specifications/procedures as appropriate shall include:
recipes –including identification of any allergens
mixing instructions, speed, time
equipment process settings
cooking times and temperatures
cooling times and temperatures
coding and shelf-life marking
any additional critical control points identified in the HACCP or food safety plan
Process specifications shall be in accordance with the agreed finished product specification
6.1.2Where equipment settings are critical to the safety or legality of the product, changes to the equipment settings shall only be completed by trained and authorised staff. Where applicable, controls shall be password-protected or otherwise restricted.
6.1.3 Process monitoring, such as of temperature, time, pressure and chemical properties, shall be implemented, adequately controlled and recorded to ensure that product is produced within the required process specification.
6.1.4 In circumstances where process parameters or product quality are controlled by in-line monitoring devices, these shall be linked to a suitable failure alert system that is routinely tested.
6.1.5 Where variation in processing conditions may occur within equipment critical to the safety or quality of products, the processing characteristics shall be validated and verified at a frequency based on risk and performance of equipment
6.1.6 In the case of equipment failure or deviation of the process from specification, procedures shall be in place to establish the safety status and quality of the product to determine the action to be taken.
6.2 Labeling and pack control
The management controls of product labelling activities shall ensure that products will be correctly labelled and coded.
6.2.1 There shall be a formal process for the allocation of packaging materials to packing lines and control in the packing area which ensures that only the packaging for immediate use is available to the packing machines.
Where offline coding or printing of packaging materials occurs:
setting and amendments to the printer parameters (e.g. the input of, or changes to, date codes) shall only be completed by an authorized member of staff
controls shall be in place to ensure that only correctly printed material is available at the packing machines.
6.2.2 Documented checks of the production line shall be carried out before commencing production and following changes of product. These shall ensure that lines have been suitably cleared and are ready for production.
Documented checks shall be carried out at product changes to ensure that all products and packaging from the previous production have been removed from the line before changing to the next production.
6.2.3 Procedures shall be in place to ensure that all products are packed into the correct packaging and correctly labelled. These shall include checks:
at the start of packing
during the packing run
when changing batches of packaging materials
at the end of each production run.
The checks shall also include verification of any printing carried out at the packing stage including, as appropriate:
country of origin
6.2.4Where online verification equipment (e.g. bar code scanners) is used to check product labels and printing, the site shall establish and implement procedures for the operation and testing of the equipment to ensure that the system is correctly set up
At a minimum, testing of the equipment shall be completed at:
the start of the packing run
the end of the packing run
a frequency based on the site’s ability to identify, hold and prevent the release of any implicated materials should the equipment fail (e.g. during the packing run or when changing batches of packaging materials).
The site shall establish and implement procedures in the event of a failure in the online verification equipment (e.g. a documented and trained manual checking procedure).
6.3 Quantity –weight, volume and number control
The site shall operate a quantity control system which conforms to legal requirements in the country where the product is sold and any additional industry sector codes or specified customer requirements.
6.3.1 The frequency and methodology of quantity checking shall meet the requirements of the appropriate legislation governing quantity verification, and records of checks shall be retained.
6.3.2 Where the quantity of the product is not governed by legislative requirements (e.g. bulk quantity), the product must conform to customer requirements and records shall be maintained.
6.3.3 Where used, the site shall establish procedures for the operation and testing of online check weighers. At a minimum, this shall include:
consideration of any legal requirements
responsibilities for testing the equipmen
operating effectiveness and any variations for particular products
methods and frequency of testing the check weighs
6.4Calibration and control of measuring and monitoring devices
The site shall be able to demonstrate that measuring equipment is sufficiently accurate and reliable to provide confidence in measurement results.
6.4.1The site shall identify and control measuring equipment used to monitor critical control points and product safety, legality and quality.This shall include, at a minimum:
a documented list of equipment and its location
an identification code and calibration due date
prevention from adjustment by unauthorised staff
protection from damage, deterioration or misuse.
6.4.2 All identified measuring devices, including new equipment, shall be checked and, where necessary, adjusted:
at a predetermined frequency, based on risk assessment
to a defined method traceable to a recognised national or international standard where possible.
Results shall be documented. Equipment shall be readable and be of a suitable accuracy for the measurements it is required to perform.
6.4.3 Reference measuring equipment shall be calibrated and traceable to a recognised national or international standard and records maintained. The uncertainty of calibration shall be considered when equipment is used to assess critical limits.
6.4.4 Procedures shall be in place to record actions to be taken when the prescribed measuring devices are found not to be operating within specified limits. Where the safety or legality of products is based on equipment found to be inaccurate, action sha