CONFIDENTIAL

Initial Certification Audit

ISO 22000 Food Safety Management System

Prepared for: Garudafood Putra Putri Jaya, PT Coated

Peanut and Snack Division
Report Date: 19/05/2017
Address Jl. Raya Pati Juana KM 2.3 Pati, Jawa Tengah, 59151 Indonesia
City Pati
Postcode 59151
Country Indonesia
Key Contact E-mail aji.yulianto@garudafood.co.id

GP 4105
Issue n: 10
 Food Safety Management System and
Quality Management Certification
Stage 1 Audit Report

ISO 22000:2005
FSSC 22000:2013 [Food] FSSC 22000:2013 [Food Packaging]
HACCP Codex Alimentarius GMP Codex Alimentarius
Additional Standard(s): FSSC 22000 [Animal Food & Feed]
ISO/TS 22002-1 PAS 223:2011 PAS 222:2011
ISO 9001:2008 ISO 14001:2004 OHSAS 18001:2007
others please specify
Accreditation Body(s) : UKAS
Site(s) audited: Address as above
Site Food Safety Team
Client Representative: Mr. Aji Yulianto Mr. Aji Yulianto
Leader:
17-May-17
Last Date of Previous Click here to enter a
Date(s) of audit(s): 18-May-17
Audit date.
19-May-17

Certificate Expiry
Total Man Hours 24 Date:
EAC Code: 03 NACE Code: 15.8
C4c - Grain products
Food Sector Category: /cereals /biscuit /flour No. HACCP Plans: 7
/confectionery /snack
FTE: 2350
No. of Employees: No. of Shifts: 3
Other:
Anggirasti Additional team
Lead auditor: Titiek S. Sudarti
(anggi.rasti@sgs.com) member(s):
Additional attendees
N/A
and roles

Manufacturing of Coated Peanut, Wheat/Corn Snack, Crisp, Extruded

Scope of certification
Snack, Instant Popcorn, and Packing of Cassava Chips

INDIV seasoning production and storage (the entity is clearly separated with
Exclusions from Scope
different managerial)
Company profile include brief history, customer base, product types, production lines,
site layout
Factory was established on 1998, with land area 121,411 m2 and building size 50,310
m2. This factory operated 4 line of coated peanut and 5 line for snack production
Description of Type of product: Coated peanut (kacang atom, kacang kedelai salut tepung, kacang
Organisation telur, and kacang salut panggang), snack (pilus), potato crisp, chocolate flavour extruded
snack, instant popcorn, and packing of cassava chips.

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CONFIDENTIAL Document: GP 4105 Issue n: 10 Page n: 2 of 8
 Food Safety Management System and
Quality Management Certification
Stage 1 Audit Report

1. AUDIT OBJECTIVES
The objectives of this audit were:

to confirm that the management system has been planned to conform with all the requirements of the
audit standard;

to confirm that the management system is designed to achieve the organizations policy objectives;

to evaluate the capability of the management system to manage compliance with statutory, regulatory
and contractual requirements;

to confirm the planned arrangements for the Stage 2 audit.

2. AUDIT SCOPE

Has this scope been amended as a result of this audit? Yes

Note: If scope has been amended, the Lead Auditor shall review if the changes require a new
contract review e.g. audit time is sufficient, audit team is qualified for the new sector(s) within
the scope of audit.

Does the scope amendment require new contract review? No

This is a multi-site audit and an Appendix listing all relevant sites and/or remote locations has
No
been established (attached) and agreed with the client

For integrated audits, confirm the current level of the clients IMS integration N/A

Has a part of this Stage 1 Audit been conduct off-site? No

3. CRITICAL AUDIT FINDINGS

The following findings, if not appropriately addressed, could result in critical / major nonconformities being
identified at the Stage 2 audit.

Clause Finding Planned Action of Client

Food safety Team
7.2.3.a Lay out showing flow movement of
personnel, materials and finished goods,
are not available. Further review shall be
conducted to assess and take action for
potential contamination to product and
process. Hygiene level have to reflected on
the lay out.
7.2.3. g. Personnel who will enter to Gudang Unit 3
shall pass through processing area
(coating area). It will lead potential cross
contamination

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 Food Safety Management System and
Quality Management Certification
Stage 1 Audit Report

7.2.3. j There are no specific workwear provided

for visitor who are entering processing
area.
7.3.3.1 Hazard louse (kutu) was not identified on
raw material ose (peanut kernel) since
there was fumigation process on
quarantine warehouse.
7.4.3 Hazard assessment of physical hazard
stone on de-stoner process was not
correct, question 2: should be yes since
de-stoner process is designed for stone
removal, and it will be CCP. At the next
processing step, if the manual sortation
process will be designed for stone removal
then the de-stoner process will be OPRP
and manual sortation will be CCP
7.4.3 Hazard assessment of material modified
starch and hazard analysis of material
incoming for kacang atom product is not
correct, i.e.: severity of Salmonella is Low,
according to hazard severity category on
HACCP manual it should be high
7.4.3 Hazard assessment of coating process
Kacang atom defined severity of
microbiological hazard E coli is high and
the probability is low. According to HACCP
manual the hazard should be significant
but it was defined as non-significant
hazard.
7.4.3 Hazard assessment of UV sterilization step
on process water preparation and
moulding and cutting step on pilus
production defined severity of
microbiological hazard E coli is high and
the probability is low. According to HACCP
manual the hazard should be significant
but it was defined as non-significant
hazard.
7.4.3 Physical hazard of pieces of cutter on
molding and cutting step of pilus
production was significant and the
decision tree question is Y-T-Y-Y and
should be OPRP but it was defined as
PRP.
8.2 Critical limit for CCP frying temperature on
Kacang atom production was min 120,
however validation data is conducted on
150-152C
7.8 Verification record of metal detector on
Extruded snack production was conducted
with sensitivity 75%, however standard of
sensitivity is 95%
7.3.5.1 Mixing of slurry seasoning was not included
on Flow diagram of Pilus production (MM.01-

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 Food Safety Management System and
Quality Management Certification
Stage 1 Audit Report

01.5.0.4)
7.3.5.1 Flow diagram of Pilus Rasa pedas (MM.01-
01.5.0.4) stated there was metal detector after
cooling step, however metal detector unit was
not available on pilus line

Production
7.2.3 Waste removal access to main production
corridor is not properly closed, there was
no door installed it only covered by plastic
curtain.
7.6.4 X ray rejection system on coated peanut
line was not properly functioned, sample
product with metal pieces was not
removed from conveyor line during
performance testing.
7.2.3 Found some floor was broken in area as
follow:
- onion preparation on production
coated peanut
- Gudang bahan baku unit 3 and
Gudang formula non AC

HRD/ HCS
7.2.3.j Action was not taken for people who are
indicated infectious disease at medical check
up May 2017. Those people are still working
in area which activity may cause product
contaminated, e.g. Coating operators (4
people indicated HbSAg+ and 2 people TB
positive), picker manual (3 people indicated
HbSAg+ and 3 people TB positive.
7.2.3.j Many employee working in factory at several
level and several areas, are having no health
status records since they joined the company.
6.2.2 Standard competencies were not fulfilled for
several position in organization, e.g. QC
Section Head requirement is S1 Food
Technology, Chemical, Agronomy, but actual
personnel is Diploma Electro; Coating
Operators shall able to distinguish colour, but
actual several Coating Operators are colour
blind.
Pest Control
7.2.3 There was no operational permit for PCO as
pest control provider from Dinas Kesehatan
Kabupaten Pati

4. NON CRITICAL AUDIT FINDINGS

The following findings, if not appropriately addressed, could lead to weaknesses being identified at the Stage 2
audit.

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Quality Management Certification
Stage 1 Audit Report

Clause Finding
Food Safety Team
5.8.2 Effectiveness of mock-recall was not reported during Management Review.

Production Coated peanut

7.2.3 Found some project material and unused machinery was stored beside main corridor, it was
potential for pest manifestation
7.2.3 Hose for process water in onion preparation was not covered when not in used and some was
stored on floor
7.2.3 Wet cleaning activity (mopping) during processing on flour shifting is not effective since wet
condition will remaining flour deposit
7.2.3 It was found condition of some container cover for flour and seasoning storage was broken and
chipped
7.2.3 Cable tray along the wall on roast coated peanut (kacang atom panggang) packing room is
uncovered. Seen some product was remaining inside and there was nut and bold stored in the
cable tray corner.
7.2.3 It was found cobweb deposited above auto packing machine on roast coated peanut
production.
7.6.4 Method of monitoring of X ray on HACCP Plan Kacang panggang rasa bawang required
monitoring of rejection air pressure min 4 bar, however there was no device for measuring the
rejection air pressure on site.

Production Snack
7.2.3 Slurry seasoning mixing tank and water storage tank on pilus seasoning preparation line was
uncovered
7.2.3 Some of hopper for finish product on pilus packing line is uncovered
7.2.3 Wall beside potato crisp production line is under construction
7.2.3 During onsite verification to potato crisp molding machine feeder, It was found mixed flour
material inside container was uncovered.

Packaging material warehouse

7.2.3 It was found net between ceiling and wall above packaging material warehouse was torn is
some point.

Raw material & Essential material warehouse

7.2.3 There was some gap on wall covering plate above raw material warehouse (Gudang bahan
Baku unit 4)

Finish Goods Warehouse

7.2.3 It was found food packaging waste remaining below packing conveyor.
7.2.3 There was no dedicated location for employee to drinking clear water on finished good packing
area, the water container was stored nearby packing conveyor
7.2.3 Production area and finish good warehouse was not properly segregated, wall beside X ray
station was opened

Utility
7.2.3 During verification to water treatment WT2 plant it was found the pressure indicator of cartridge
filter is pointed on 2.1 bar, standard parameter was maximum 2 bar.
7.2.3 TDS value after resin filter on water treatment WT1 is 130 ppm, standard parameter was
maximum 70 ppm

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Stage 1 Audit Report

Pest Control
7.2.3 Specification of organic repellent applied by PCO pest control provider at 16/05/2017 was not
available.
7.2.3 It was found number of bait block for rodent bait station (RBS) unit was not applied according
to requirement, i.e.: Usage instruction required two block have to applied on each station,
however RBS no 23,26,38 and 40 was filled with single block of bait
7.2.3 Report of spraying from PCO and Nu pest control provider was not clearly defined number of
solvent (water) used for diluted the pesticide to ensure it was applied with correct concentration

External Premises
7.2.3 Outside area near by water treatment plant and backside of material warehouse area found not
properly maintained, scrap from project and ex machinery was potential as pest manifestation
area.
Purchasing
7.2.3 CV Kuda Mas (suppliers of ose/raw peanuts) was not registered as approved supplier in
HACCP. PO 4300531234 is extraordinary release because raw peanuts were contaminated
(insect/beetles).

5. AUDIT CONCLUSIONS

The Stage 1 audit was successful in meeting the stated objectives: Yes
The stage 1 audit was limited in time and scope to the stated objectives and it is possible that
additional weaknesses will be identified during future audit activities. With consideration to the
findings identified in section 3 and 4 of this report, the overall conclusions of the audit are as follows:
The management system has been planned to conform with all the requirements of the
Yes
audit standard:
The management system is designed to achieve the organisations policy and/or food
Yes
safety policy objectives:
Based on the information provided, the system is designed to identify and manage
Yes
compliance with statutory, regulatory and contractual requirements:
The internal audit and management review planning assure appropriate coverage prior
Yes
to the Stage 2 Audit
The Prerequisite programs (PRP(s)) are sufficiently described: Yes
The stage 1 audit took place on site and during a short factory tour the elements of the No
Prerequisite program (PRP) shown to be sufficiently controlled.

The Preliminary steps to enable the Hazard analysis are sufficiently described Yes
In the Hazard analysis the relevant hazards have been identified and the degree of
No
control required to ensure food safety has been determined.
Methodology and parameters used for selection/categorization between OPRP and
Yes
CCP are specified in documents and the result of assessment are recorded

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 Food Safety Management System and
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Stage 1 Audit Report

Please provide detail:

Control measure for significant hazard (as result from hazard assessment based on severity and likelihood),
was categorized considering type of activity weather is part of PRP. If control measure is part of PRP or
control measure still has subsequent control, it is categorized as OPRP.
Control measure for significant hazard which are considered as specific activity, is assessed using decision
tree. Steps which are specifically designed to reduce hazard or as last step to reduce hazard, it is categorized
as CCP, other is categorized as OPRP
The HACCP plan has been documented and includes the specific requirements for
Yes
each identified CCP
Verification, validation and management review planning assure appropriate coverage
Yes
prior to the Stage 2 Audit:
The traceability system described enable the identification of product lots and their
Yes
relation with batches of raw materials, processing and delivery records
The methods to handle potentially unsafe products are described, including
Yes
withdrawals and management of emergency situations
Any scope exclusions are appropriate and justified: Yes
The Stage 2 audit should proceed as presently planned based on the result of this
Yes
Stage 1 audit :
If Yes selected above and critical findings raised, justify why S2 will continue as planned:
Based on demonstrated knowledge and commitment of client from the audit, it is determined the
actions raised can be completed effectively in the time frame prior to Stage 2 commencement
Choose an item.
Other:
If No selected above, provide details of newly agreed audit date and justification as to why audit will
then proceed at that time:

Comments or details of necessary changes to the stage 2 audit plan:

Stage 2 audit can conducted after organization effectively closed out the critical audit finding

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