Quality & Food Safety Manual

FOOD SAFETY & QUALITY MANUAL
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Position: Quality Systems Coordinator
Issue Date: 06/02/2012 1 of 23 Doc ref: QM01
QUALITY & FOOD SAFETY MANUAL
Wilverley Trading Estate 813/815 Bath Road Brislington Bristol BS4 5NL

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Contents Section Introduction 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Senior Management Commitment and Continual Improvement The Food Safety Plan HACCP Food Safety and Quality Management System Site Standards Product Control Process Control Personnel BRC & ISO9001 Comparison Item Page 3 4 6 6 11 14 18 19 21

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Introduction (ISO 9001:2008 section 4.1)

This Food Safety & Quality Management System has been written to provide the reader with an overview of the company's Food Safety system in addition to the Quality System and to express its commitment to providing safe, quality & legal products and services and achieving customer satisfaction. The Food Safety & Quality Management System has been developed around HACCP principles, which is considered to be fundamental to the implementation of the system. This manual has been prepared to satisfy the requirements of ISO 9001:2008 & the Global Food Safety Standard (BRC) Issue 5 for the activities carried out at TasteTech Limited. The scope of the quality management system is the design, manufacture and supply of encapsulated, spray dried and liquid food flavourings and encapsulated ingredients in bulk packs (>5.0kg) and sold via business to business transactions. Non-food products produced in unit 6 do not form part of the BRC scope TasteTech Limited, through the offices of the Managing Director, is committed to maintaining an effective Food Safety & Quality Management System. Senior Management of the organisation ensures that all employees are aware of the need to meet customer and regulatory requirements and that the necessary resources are available. The currency of the Quality Policy and objectives are maintained by regular management review. Wherever possible, quality controls have been integrated into existing systems (environment, health and safety) and cross-referenced for ease of interpretation. The effective implementation of the Food Safety & Quality Management System will be verified by regular inspections, reviews and audits that will compare management practice against the requirements of the written procedures on Food Safety & Quality Management System standards. Corrective action will be taken where necessary and will be subsequently reviewed for effectiveness.
Organisation Profile
TasteTech Limited was founded in November 1992 at the present site by the current Board of Directors to take advantage of controlled flavour & ingredient release concept to enhance, produce and market scientifically developed flavour blends & ingredients for the food production industry. Evolvement during experimentation allowed the design and development of controlled release technology (CR) to create microencapsulated free-flowing powder based flavourings & ingredients that are engineered to suit a wide range of food production methods. The company is proud of its record in the design and development, the production and supply of high quality food flavourings & ingredients to many of the leading food manufacturers, who are located both in the United Kingdom and overseas. Quality is a discipline central to all aspects of the company structure and operation. It is the aim and responsibility of personnel at all levels to provide customer satisfaction first time, every time. In support of its status in this highly specialised field, the company is a member of Leatherhead Food International (LFI), the British Essential Oils Association, (BEOA), the Food Additives and Ingredients Association (FAIA), the British Essence Manufacturers Association (BEMA), Campden BRI and other relevant bodies. The company is committed to providing their customers with a high quality product at the most competitive price and the best possible level of service at all times. All members of staff have been consulted and agree that working to the highest standards of the industry is the key to a successful company, and therefore, such standards are a mandatory requirement at TasteTech Limited.

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An essential requirement of the continuing maintenance and development of the Companys quality objectives is the installation and maintenance of a Food Safety & Quality Management System registered to BS EN ISO 9001:2008 status & BRC Global Standard for Food Safety (issue 5). As the encapsulated ingredients and flavourings are designed and used in food applications TasteTech has developed and will continuously improve food safety with the implementation and maintenance of the BRC Global Standard for Food Safety (issue 5).
Company Profile
It is the companys policy to operate and comply fully with the BS EN ISO 9001:2008 Standard & the Global Standard for Food Safety Issue 5 through registration, internal annual review and independent external audit. It is the companys belief that in operating to these standards, it will meet the requirements of its customers and that of the Industry. The company is committed to ensuring that its customers receive the service that they expect, at the agreed time, and that all personnel will be trained to ensure that they work in a safe, responsible and professional manner.
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1.0 Senior Management Commitment and Continual Improvement (ISO 9001:2008 section 5.1 & 6)
Senior Management of the organisation ensures that all employees are aware of the need to meet customer and regulatory requirements and that the necessary resources are available and are committed to the implementation of the Global Standard for Food Safety and continual improvement of the site quality management system. The currency of the Quality Policy and objectives are maintained by regular management review. The Quality Management System is administered in a manner to offer continual improvement having regard to statements in its Quality Policy, objectives (QMF112), audit results, data analysis, corrective and preventive action and management review. Data referring to product quality problems is collected and analysed and where changes to the Quality Management System offer improvements, these changes are introduced. Areas for attention are customer complaints, meeting the customers needs, product characteristics and supplier performance.
1.1.1 Food Safety & Quality Policy (ISO 9001:2008 sections 4.2.1, 4.2.2 & 5.3)
A Quality Policy has been prepared and approved by the Managing Director to demonstrate the companys intention to meet its obligation to produce safe and legal products to the specified quality and its responsibility to its customers. The policy is formally reviewed at least once a year to consider its continuing applicability and where necessary it is revised to reflect changes to the company's policies and objectives. The revised policy is approved by the Managing Director before being re-issued. The Quality Policy is communicated as appropriate throughout the organisation. 1.1.2 Food Safety & Quality Objectives
The senior management ensures that clear objectives are defined to maintain and improve the safety; legality and quality of the products manufactured. Quality objectives are reviewed for continuing suitability and communicated as appropriate throughout the Organisation (QMF112).

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1.1.3 Management Review (ISO 9001:2008 section 5.6)

The Food Safety & Quality Management System is reviewed at planned intervals, usually annually, by the senior management to ensure its continuing suitability, adequacy and effectiveness & to evaluate the site performance against the Global Standard for Food Safety and the quality objectives. The review includes the evaluation of current performance and improvement opportunities related to: audits (internal, customer and certification body audits); customer feedback (including complaints); HACCP System; follow up from previous meetings; incidents, Corrective actions, out of spec results and non-conformances and Resource requirements.
The results of activity arising from review meetings where resources, the Food Safety & Quality Management System and its processes and improvements to products related to Customer requirements, would be an essential part of the review process. All results of management review activity are recorded. Decisions and agreed actions as a result of the review process, with target dates and responsibilities for their implementation, are communicated to the appropriate member of the team. Actions are followed up by the Quality Representative to ensure timely and effective completion. 1.1.4 Senior managers attend a Management Meeting on a monthly basis as a minimum. Minutes of these meeting are recorded and available for scrutiny
1.1.5 Resource Management (ISO 9001:2008 section 6)

The Organisation has ensured that the necessary resources needed to implement and improve the Food Safety & Quality Management System and to address customer satisfaction are available. Where personnel are assigned responsibilities affecting product conformity, the organisation has ensured that they are competent on the basis of applicable education, training, skills and experience. The organisation has identified the training needs for quality related activities and provides training to satisfy these needs. Performance is evaluated and appropriate training records are maintained. Suitable equipped workplaces with appropriate hardware and software with supporting services are provided. All aspects of the human and physical factors of the working environment that affect conformity of product or service have been identified and are managed

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1.1.6
In support of its status in a highly specialised field, the company is a member of Leatherhead Food International (LFI), the British Essential Oils Association, (BEOA), the Food Additives and Ingredients Association (FAIA), the British Essence Manufacturers Association (BEMA), Campden BRI and other relevant bodies. The company receives legislative information from BEMA & FAIA and subscribes to food safety alerts from the FSA. The trade press, such as Food Manufacture, and our membership of LFI & Campden BRI ensures that we are kept informed of scientific and technological developments within the industry. This includes subscribing to LFIs Regulatory Advisor Service covering legislation both home and overseas. A genuine, hard copy of the most up to date issue of the Global Standard for Food Safety is kept on site. To ensure compliance to the Global Standard for Food Safety we ensure that recertification audits are booked on or before the audit due date indicated on the certificate The most senior production/operations manager attend both opening and closing meeting of the audit for Global Standard for Food Safety certification with relevant departmental, or their deputies, also available as required.
1.1.7
1.1.8
1.1.9
1.1.10 All root causes of non-conformances identified at the previous audit against Global Standard for Food Safety will be effectively addressed to prevent recurrence.
1.2 Organisational Structure, responsibilities and management authority (ISO 9001:2008 section 5.5)
Food Safety & Quality management functions and their interrelationships are shown in the organisation chart (QMF98). In addition Job Descriptions for each position in the company have been prepared and communicated to all staff to ensure clear understanding and effective management of the food safety & quality management system. There is a programme of staff review, companywide, which takes place on an annual basis. This ensures that the needs of the business and the individual are aligned as closely as possible. A succession chart in place that ensures the absence of key members of staff is covered (QMF57). Elements of the Food Safety & Quality Management System have been defined and communicated wherever quality is affected. Representatives have been appointed, from within the organisation, which have the authority and responsibility to ensure that the Food Safety & Quality Management System is established and maintained, and that reports on the performance of the system and any needs for improvement are made available to the Quality Representative. The significance of meeting Customer requirements is understood. Communication between all levels and functions are set to ensure the effectiveness of the processes of the Food Safety & Quality Management System.
2.0
The Food Safety Plan - HACCP

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A HACCP system is applied through the entire production process from raw material selection to despatch of final product to customer, and is implemented through our Food Safety system. The system has been compiled with the help of relevant legislation and codes of practice such as the Codex Alimentarius HACCP System and guidelines for its application Rev 4 2003. Primary responsibility for the operation and maintenance of the HACCP system will be with the Technical Manager with the assistance of the HACCP team leader and HACCP team. The HACCP team is multi disciplined and have received training in Hazard Analysis Principles and/or have suitable relevant experience of the food industry to enable successful implementation of the 7 HACCP principles. There is a pre-requisite programme in place at TasteTech that includes GMP and supports the HACCP system. The HACCP is based on risk assessment and the implementation of the 7 HACCP principles. It is generic being based on the processes employed on site. All new products are assessed at the development stage. Records demonstrating conformance are in place and a system of effective corrective actions, resulting from being out of specification (non-conformances), is maintained.
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3.0 3.1
Food Safety & Quality Management System Food Safety & Quality Manual (ISO 9001:2008 section 4.2.2)
The organisation has prepared and maintains a controlled Food Safety & Quality Manual that defines the scope of its activities, justifying any exclusion, supported by referenced documented procedures and work instructions as well as other referenced material. It is appropriate to the size of the organisation, available to all staff, electronically with a printed master copy, and must be read in conjunction with other quality management documentation.
3.2
General Documentation Requirements (ISO 9001:2008 section 4.2 & 7.2)

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Diagram demonstrating the relationships between Quality Management Procedures at TasteTech Ltd MANAGEMENT COMMITMENT
BRC & ISO9001 Compliance Health & Safety Compliance
Legal / regulatory compliance
Quality Policy (POL01)
Provision of resources (PRM03)
Staff training (PRM03)
Continual improvement (PRM11)
Customer Satisfaction (PRM04)
No
No
First orders (PRM04)
CUSTOMER
Sample request (PRM04) Yes
Repeat Orders Sales order processing & planning (PRM04 & 05)
Yes
Yes
Receive sample request from customer (PRM12 & PRM04)
Receive customer order (PRM04) Push development recipe up to production (PRM12)

Obtain required materials and schedule order (PRM06)
Receive customer order (PRM04) Obtain required materials and schedule order (PRM06) Make product and carry out QC checks (PRM18) Pack and despatch product and final QC despatch checks (PRM18 & PRM05)
Pack and despatch sample to customer, issue product specification (PRM05) Customer evaluates sample Respond to customer as necessary e.g. provide quotation, make another sample or first order production (PRM04)
Make product and carry out QC checks (PRM18) Pack and despatch product and final QC despatch checks (PRM18 & PRM05) Invoice customer
Invoice customer
Control of production equipment (PRM19)
Control of quality system documents (PRM01)
Process Control (PRM05)
Quality system audits (PRM08)
Care of customer property (PRMO5)
Control of nonconforming product (PRM09)
Measuring and analysing performance (PRM11)
Management Review (PRM02)
SYSTEM SUPPORT

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Documentation structure
The Quality Policy expresses the quality aspirations of the Directors/Senior Managers and demonstrates to all interested parties the managements commitment to providing safe & quality products, continual improvement, achieving and exceeding customer expectations and compliance with applicable legal and industry requirements.
Level 1
The Food Safety & Quality Management Manual provides an overview of the companys food safety & quality management system. It includes information about the companys organisational structure, responsibilities and operations and is approved by the Managing Director.
Level 2
Level 3
Process and procedural documents specify how to control processes and other activities. They are reviewed and approved by the Technical Manager before their initial release.
Level 4
Work instructions provide specific detail about how to perform complicated tasks. They take many forms including detailed written instructions and checklists. They are reviewed and approved by dept manager before their initial release. Forms, industry regulations, statutory requirements, standards and marketing brochures etc. Internally originated documents are reviewed and approved by the Technical Manager before initial release. Externally originated documents are controlled to ensure that information is up to date.
Level 5
3.2.1 A documented procedure ensures that all relevant quality documentation, critical to
food safety, legality & quality, is controlled, adequate and is reviewed, updated and approved as necessary. The status of the documents is identified and they are legible and retrievable and located where required within the organisation. Where documents, that affect the Quality Management System, originate from outside of the organisation, the relevant documents are identified and their distribution controlled. Obsolete documents are clearly identified to prevent unintended use. Records are maintained of the reasons for changes or amendments to documents critical to food safety, legality and quality. Procedures are in place for the identification, storage, retrieval, protection, retention time and disposition of quality records. All appropriate documents are suitably authorised.
3.3
Quality records demonstrate compliance with the quality management system including any industry, legal and customer requirements. A procedure has been written to ensure records are legible, complete and suitably stored to prevent damage, unauthorised access and to enable easy retrieval. The period of retention for records relates to the product shelf life and takes in to account any legal, industry, customer specific and internal requirements 3.4 Internal Audit (ISO 9001:2008 section 8.2.2)
Suitably trained and impartial personnel conduct periodic independent internal audits on a planned basis. All aspects of internal audits are recorded and reviewed and timely corrective action taken where necessary. Frequency of internal audits is based on risk assessment of the hazards associated with the area to be audited and review of previous audits and other relevant information.

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3.5 7.4)
Supplier Approval and Performance Monitoring (ISO 9001:2008 section
The organisation controls its purchasing function to ensure that the purchased product conforms to requirements (product safety, legality & quality). Suppliers are selected against defined criteria and are subject to planned review and evaluation. The results of evaluations and follow up actions are recorded. Purchasing documents are reviewed before release for the adequacy of information on product, procedures, processes, equipment and personnel. The organisation verifies purchased products and where verification takes place at the suppliers premises, details of the arrangements and the method of release are specified. A procedure is also in place that defines how exceptions are handled where the approval of a supplier, by audit or monitoring, has not been undertaken or is incomplete. The performance of suppliers has been established as well as trial periods for all new suppliers.
3.6
Specifications are available for all raw materials including packaging, intermediates and finished products as well as those product/services which could affect the integrity of the finished product, such as liquid nitrogen. Where applicable all specifications comply with relevant safety and legislative requirements (e.g. REGULATION (EC) No 1334/2008). Agreement and authorisation of finished product specifications is sought from customers and sign off is requested, however we inform our customers that if the specification sent is not signed and a copy returned to TasteTech within 14 days of receipt that this constitutes acceptance. Records are maintained of the reasons for changes or amendments to Specifications. All finished product specifications are available electronically via the TT server. 3.7 Corrective and Preventative Action (ISO 9001:2008 section 8.5.2 & 8.5.3)
Procedures for implementing corrective & preventive action have been documented and implemented. Appropriate action is taken as soon as possible and within appropriate timescales to rectify faults and prevent their recurrence. Requirements for identifying faults and determining their cause, with appropriate corrective action, are covered and recorded, with responsibilities and accountabilities assigned, and the results reviewed for effectiveness. The Organisation identifies preventive actions to avoid the recurrence of non-conformities, and the results of such actions are recorded and reviewed for effectiveness.
3.8
Control of Non-conforming Product (ISO 9001:2008 Section 8.3)
The Organisation preserves the conformity of the product or service from receipt of order to delivery. Procedures for ensuring that nonconforming products are controlled to prevent use or delivery have been established and documented. Control includes identification by clear labelling & isolation (where practical) of the nonconforming product, maintaining records and notifying interested parties. Nonconforming products are assessed to determine the appropriate corrective action. This can include re-working, returning to the supplier, obtaining customer approval (concession), recall and disposal. Replaced and re-worked products are subject to normal verification methods before being further processed.

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Procedures have been established to ensure that suspect or nonconforming product can be recalled after despatch from the factory. This procedure is tested at least once a year and is scheduled through the audit programme.
3.9
Traceability (ISO 9001:2008 section 7.5.3)
In any food manufacturing organisation it is important that the ingredients and primary packing materials can be traced given the details of the final product and that the final product can be traced given a list of ingredients. On delivery, all raw materials and primary packaging are allocated an internal lot number, which corresponds to the suppliers lot number/batch number/best before date, via Unity. Where appropriate, the organisation identifies the product throughout the production and service activities and identifies its status with respect to measuring and monitoring activity throughout product realisation. Where traceability is required, the unique identification of the product is controlled and recorded. Products manufactured at TasteTech are generally made to order. As each product is ordered it is given a unique works order number via the Unity System. This follows the product through the factory. When the works order is raised, raw material lot numbers are allocated, by Unity, for each batch to be made. The internal lot number of the primary packaging used for each batch is also recorded on the works order QMF12. Any re-work used is handled through the system in the same way as a raw material. The system is tested on a regular basis as part of the internal audit schedule and includes a mass balance exercise. Where customer property for inclusion in the product comes within the Organisation control, it is identified, verified, maintained and protected with details of adverse condition reported to the customer.
3.10
Complaint Handling (ISO 9001:2008 section 7.2.3)
There is a well-established system for the receiving, investigation and the determination of corrective actions for customer complaints. They are reviewed as part of the quality system reviews and improvements can be implemented to ensure product safety and legality is achieved.
3.11
Management of Incidents, Product Withdrawal & Product Recall
In the event of a non-conforming product reaching the Customer, appropriate corrective action is taken in the form a product recall. The procedure that is in place effectively manages any incident concerned with the recall or withdrawal of a product. This procedure includes a list of qualifying events: The product recall procedure is tested on a regular basis as part of our internal audit programme and reviewed at quality system review meetings.

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3.4 Contract Review & Customer Focus (ISO 9001:2008 section 5.2, 7.2, 7.2.3, 8.2.1 & 8.2.3)
The organisation has clearly identified those individuals responsible for effective communication with customers and has effective systems for communication in place. Customer needs and expectations are determined, and fulfilled to meet customer satisfaction. Due consideration is given to development, product and product manufacture, service, specification, regulatory and legal requirements. The organisation reviews its customers needs and determines any additional requirements for each contract or order. Where no customer requirements are documented, details are confirmed before acceptance. Any changes to contracts or quotations are resolved before proceeding, and the companys ability to meet the defined requirements is confirmed. The customer is kept informed of product information, enquiries, order changes or amendments and progress on customer complaints Clear methods have been established to audit customer satisfaction and any failures to meet organisation standards (such as monitoring of customer complaints). Processes affecting customer requirements are periodically reviewed to ensure that the intended purpose is being met.
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4.0 4.1
Site Standards External Standards
The manufacturing facility is approximately 35 years old and the fabric is deemed suitable for the production of food products. It is situated on the edge of an established urban trading estate. At present there are no other operations in close proximity to the site that would impact with regards to potential contaminants and should this situation change all relevant factors will be reviewed accordingly. The grounds are well maintained and have adequate drainage. Air scrubbers are located at each production unit. These de-odorise air to the atmosphere. The condition of the grounds is routinely assessed by the means of the monthly hygiene and fabric audit. Action is taken as necessary to ensure the site continues to meet operational and legislative requirements.
4.2
Security

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It is the policy of TasteTech Ltd that all raw materials, product and sensitive areas are secure. Locked coded entry points achieve this. The access of unauthorised persons to production and storage areas must be prevented. All staff have received training in the site security policy and the way in which they should deal with any unauthorised person found on site
4.3
Internal Site Standards
The flow of the process is deemed satisfactory so as to minimise the risk of product contamination. There is no requirement at present for high/low risk segregation. The cleaning of production utensils is carried out in a separate wash-up area. All other plant and machinery is cleaned in situ. The internal working environment and storage capacity is sufficient to enable all operations to be carried out properly and under safe, hygienic conditions. We have specified procedures for the handling and processing of allergenic materials as per the requirements of section 5.2 We have specified procedures for the handling and processing of organic materials as per the requirements of our Soil Association approval.
4.4
Utilities
All site water is sourced from the mains and is supplied by Bristol Water. Zone results are obtained from Bristol Water on an annual basis. Where water is used as an ingredient, for equipment and hand washing it is tested annually by an external laboratory. Liquid nitrogen is used and comes into contact with those products produced on our CR300 plant. The microbiological and chemical quality of the liquid nitrogen and water has been duly risk assessed.
4.5
Equipment
Procedures are in place to ensure that all new equipment is purchased to specification (that it is suitably designed for the intended purpose and so to minimise the risk of contamination of product) and that it is commissioned prior to use
4.6
Maintenance
A system of planned maintenance is in place for all items of plant and equipment, particularly those critical to product safety, legality and quality. Procedures are in place to ensure product safety or legality is not put at risk during maintenance operations, including cleaning or replacing of light fittings. Where practical, maintenance work is undertaken in a non-production area or if this not practical then production within a 5 metre radius is halted and the area screened off or the work is carried out outside of production hours, with usual precautionary measures in place to prevent contamination of surrounding areas. All maintenance work on site is followed by a documented hygiene clearance procedure (QMF60). Entry to the on site engineers workshop is restricted to authorised personnel by the use of a coded locked door.
4.7
Staff Facilities

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There are adequate changing facilities on the ground floor, where all staff, contractors and visitors change into permitted work wear prior to admission to production. Staff are able to store personal belongings in lockers, separate from work wear. Toilet facilities are completely separate and segregated from production. A rest room facility is provided with a refrigerator and hot water for drinks as well as appropriate waste receptacles. The refrigerator temperatures are checked once a week. Smoking is restricted to an external designated area. There are adequate hand washing facilities throughout the factory.
4.8
Chemical & Physical Product Contamination Control
The company has carried out a risk assessment so as to identify, control and manage potential risks derived from chemical, physical or taint contamination. This has been accomplished through the HACCP system All cleaning chemicals at TasteTech are suitably controlled. All bulk containers of detergent are stored on bunded pallets on delivery to TasteTech. The taps are padlocked and key use restricted. All Chemicals for use in the air scrubbers are stored outside in the lockable compound. Again keys are restricted. All janitorial cleaning chemicals are stored in the cleaning material store cupboard, which has a restricted coded lock, on delivery. Access to all cleaning chemicals is restricted to trained personnel ONLY. All lubricants, etc used on site are approved by NSF International and are suitably stored. Where practical, maintenance work is undertaken in a non-production area or if this not practical then production within a 5 metre radius is halted and the area screened off or the work is carried out outside of production hours. The condition of the building fabric & equipment is monitored via the monthly hygiene audit to reduce the risk of contamination from these items. It is the intention of TasteTech Limited not to use any Glass or Hard Plastics in production, warehouse or despatch areas, apart from those items listed on the Glass & Hard Plastics Register. The condition of the items on the Glass & Hard Plastics Register is audited routinely and should any breakages occur the necessary control procedures are in place to ensure any product within the vicinity is quarantined and assessed accordingly. We take all possible precautions to avoid the ingress of glass into our production areas thereby reducing the risk of contaminating our products. We have extended this policy to cover brittle plastic as the appearance of this in food causes the consumer as much concern as glass. All Glass and Brittle plastic items in the factory have been identified and listed on a register in the relevant locations. All checks are recorded on the relevant glass audit log. Any action required is also recorded on the glass audit log e.g. Broken items are removed and repaired or replaced or if the item is cracked then it is recorded that the item is to be monitored. Once the actions are completed they are dated and initialled by the repairer, then verified by the auditor. There is a written procedure for handling glass & brittle plastic breakages on site and it details what must happen in the event of such a breakage and the precautions to be taken. These breakages are reported on a glass breakage report. It is the intention of TasteTech Limited not to use anything other than essential wooden items in productions areas. Essential covers items such as original building fixtures, e.g. internal window frames, doors and raw material pallets. Only complete pallets of raw materials packed on wooden pallets are permitted in production areas. Other raw materials are provided on plastic transit pallets. Wooden pallets are not permitted to be lifted at, or near, blending or finished product outlet areas.

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Sieves are utilised at the identified CCP and as such are inspected both before and after use for signs of damage as well as foreign bodies. Any foreign bodies found as a result of this process step (packing) are recorded and investigated as a matter of course.
4.9
Housekeeping and Hygiene
The cleaning chemicals used in the factory are supplied by approved suppliers. There are documented cleaning schedules, records & methods in place for building, plant and equipment. The chemicals provided by approved suppliers are suitable for food use, nontainting as long as they are used at the correct levels. Concentration checks are carried out to ensure cleaning efficiency & the risk of contamination from the chemical is minimised. Factory hygiene is routinely checked on a monthly basis as part of the Hygiene Audit QMF49.
4.10
Waste/Waste Disposal
Waste materials are removed from site on a regular basis (at least weekly) by a licensed contractor. All Waste materials in the factory are collected in specified red bins/wire cages and are then transferred to the external skip. The external waste material skip is covered when not in use. If hazardous chemical waste requires disposal for reasons such as nonconformance, etc then the Technical Information Manager will make special arrangements.
4.11
Pest Control
TasteTech use the services of a reputable pest contractor to ensure that the site is kept pest free. This is achieved by regular inspections, advice and checks by the pest control contractor. We have contracted to a premier service as defined in the pest control manual & records are kept. This service provides 8 technician visits per year, 4 biologist visits per year, 4 Electronic Fly Killer (EFK) services per year.
4.12
Storage & Transport
TasteTech employs the services of approved third party hauliers for the transportation of the finished goods to the customer. A code of practice as per the requirements of 4.12 of the Global Food Safety Standard has been drawn up and all third party hauliers are required to sign it as part of their approval. TasteTech does not currently use third party storage facilities, however if they are required in the future all necessary checks and approvals will be carried out as needed. The storemen check the condition of delivery vehicles for cleanliness, etc reporting exceptions. The third party haulier vehicles are also checked for cleanliness, etc
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5.0
Product Control (ISO 9001:2008 section 7.0 & 7.5)
The production process for the Organisations products and services is planned and documented as defined in the Food Safety & Quality Management System. Quality objectives, resources, processes and documentation needs are clearly stated with acceptable criteria for verification and validation. Records appropriate to the level of confidence required for the process and the product or service are maintained. Production and services are controlled through product specifications and work instructions. Where Customer property for inclusion in the product comes within the Organisation control, it is identified, verified, maintained and protected with details of adverse condition reported to the Customer.

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Where verification of product or service cannot be ensured during the process by measuring and monitoring, control is exercised by qualification of the process, equipment and personnel through defined methods procedures and records, and re-validation if required.
5.1
Product Design/Development (ISO 9001:2008 section 7.3)
All development activities have been defined and planned to ensure product design/development is undertaken in a controlled manner and that customers receive a satisfactory service. Planning includes establishing responsibilities for development activities as well as the lines of communication between customers, development staff and other staff who interface between them. Design and development initiatives will normally be launched following a direct request from a customer or by the companys foresight in the identification of an opportunity to introduce an innovative product to the food production market. Information relating to product development requirements is recorded and includes requirements specified by the customer as well as information gained from developing similar products in the past.
All necessary information relating to the sample requirements are defined within the appropriate development documentation and are reviewed for adequacy at the start and during the development process. The need to obtain, record and review sample requirements have been defined in the applicable quality management procedures. Development outputs are clearly documented in the form of a specification and will be offered to the customer as samples. Each product is given a unique code from the development module in Unity, which cannot be transferred to any other formulation. The requirement to prepare and control development formulations and records within Unity, other necessary development information and is specified in the relevant quality management procedures. Requirements specified by the customer are reviewed to ensure they are adequate and achievable. As necessary, the customer is advised whenever their requirements are considered to be unachievable or will not provide a satisfactory outcome for the application intended. Sample development progress is monitored to ensure that samples reach the customer in a timely manner and in compliance with the customers requirements. Samples are evaluated at appropriate stages during development to check they comply with the original development requirements and statutory requirements. Evaluation can include flavour, aroma, appearance (colour/particulate size). Where necessary formulations are modified and samples re-evaluated until the required characteristics of the customers brief are achieved. Customers validate samples by the most appropriate means. This can be by assessing characteristics such as appearance (colour/particulate size), flavour, aroma and performance before and/or after introducing the sample into the intended application. The results of customer validation can initiate development input where the customer requires a formulation to be modified. Changes to formulation under development are controlled via the Development Module in Unity to ensure there is a complete history of the products development. The development number drawn from the Development Module of Unity will be changed to a production

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number in the event that the Customer places a confirmed order for the developed formulation or if a production trial is required. Changes to formulations that have already been released for production purposes result in a new formulation being developed as described above. Live formulations are reviewed on a regular basis for continued production / use and suspended if not. Where appropriate factory trials are carried out either at the request of production, in the event of a product being developed that may cause processing issues; at customers request or a where need has identified by development or technical. As the development team work closely with production and technical at TasteTech they are aware of which raw materials will work in which processes. At TasteTech there are standard processes for manufacture and our product design fits in to these categories. HACCP risk assessment is dealt with as part of the Development Module within Unity where products are assessed against our generic HACCP plans. If at this stage they do not fit or have raw materials that have inherent risks associated with them then the HACCP team will convene to assess the product on an individual basis. Shelf life is based on historical data.
5.2
Handling Requirements for Specific Materials
TasteTech Ltd recognises the requirement to conduct business in such a way as to minimise the risk of allergen contamination. All aspects of Directive 2000/13/EC and its amendments are acknowledged. It is the intention of TasteTech Ltd to minimise risk by: Effective screening of all new raw materials. Ongoing monitoring of current raw material list. Identification of all current and suspected allergens, including re-work and work in progress. Effective, safe controlled storage of any identified allergens, including re-work and work in progress. Comprehensive cleaning techniques for plant and equipment. Allergen risks, where applicable, effectively communicated to relevant customers.
5.3
Foreign Body Detection
In the main, finished products produced at TasteTech are sieved rather than metal detected and it has been determined that it is a CCP by means of risk assessment. Only product produced on the CR300 plant is metal detected, in addition to sieving, also by means of risk assessment. With advice from the metal detector manufacturer the limits for detection have been established as being 3mm ferrous, 4.5mm non-ferrous and 4mm stainless steel. It is important to note that our pack size (up to 25kg) was instrumental in the setting of the limits. The metal detector is a belt stop and alarm type and any products found to be contaminated with metal is dealt with as non-conforming product. The metal detection procedure deals with operation, monitoring, corrective action and calibration. In addition, all knives in use at TasteTech, are checked regularly during use and recorded on the appropriate records. Factory fabric is routinely checked on a monthly basis as part of the Hygiene and Fabric Audit.

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5.4
Product Packaging
TasteTech holds specifications for all packaging materials used on site. For those materials in contact with foods we have received confirmation, from the suppliers, that they conform to the Commission Directive 2002/72/EC (amended by Commission Directive 2008/39/EC ) and are deemed suitable for food use. At the goods in stage, packaging materials are checked for size (as ordered), cleanliness and free from odour and for boxes that they are staple free. In storage, packaging materials are separated from raw materials in the ambient storage area.
5.5
Product Inspection and Analysis (ISO 9001:2008 Section 8.1, 8.2 & 8.2.4)
Measuring and monitoring of the product throughout the process is designed to ensure the finished item meets specification and authorised personnel control its release. On delivery all raw materials undergo assessment, including for example taste and visual inspection. Certificates of analysis are obtained from the raw material suppliers. These are received either by fax, email or as part of the delivery paperwork.
All finished product undergoes organoleptic and, depending on the product, chemical analysis against product specification thus forming part of positive release. Due to the nature of the finished products (in the main chemicals themselves are not likely to support microbial growth) only 2 products, at random on a monthly basis, are sent for microbiological analysis unless specifically requested by a customer. All microbiological analysis is conducted on behalf of TasteTech by a UKAS accredited laboratory. The cleanliness of equipment and utensils is monitored using the Accupoint ATP system against a monthly schedule and factory drains are monitored for Listeria, where applicable. Random samples of finished product are tested annually, unless required more frequently by customers, for heavy metals and for pesticide residues, on a random basis (where applicable). These analyses are also carried out at UKAS accredited laboratories. Records of all internal and external analyses are kept in accordance with the document control procedure PRM01 & results monitored for adverse trends. If out of spec product is highlighted the non-conforming product procedure is implemented. All internal test methods used are documented and based on recognised standard & industry standard methods. As all the external laboratory facilities employed by TasteTech are UKAS accredited the staff are deemed suitably qualified/trained and competent to carry out the analyses required. All staff employed by TasteTech to conduct internal laboratory analyses are suitably trained and ring testing is carried out annually or as part of new employee review to ensure proficiency. All laboratory equipment is maintained and calibrated where appropriate.
5.7
Product Release (ISO 9001:2008 Section 7.5.1)
Product release, post delivery and delivery processes are defined by way of procedures and work instructions. All finished product undergoes organoleptic and depending on the product, chemical analysis against product specification thus forming part of positive release. Only those products that conform are released. Finished product is released by authorized staff ONLY
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6.0 6.1
Process Control Control of Operations (ISO 9001:2008 section 7.5)
All production activities are planned and carried out under controlled conditions to ensure that products comply with customer order, product safety, and legality and quality requirements. Control includes the implementation of HACCP principles, including review on an annual basis or sooner as per the review criteria (refer to HACCP Manual). Production and services are controlled through product specifications and work instructions. Suitable equipment is used and properly maintained with the use of specified measuring and monitoring equipment and activities. Product release, post delivery and delivery processes are defined.
6.2
Quantity Weight, Volume & Number Control
Where appropriate all requirements of current weights and measures legislation are met accordingly. In the main, finished product is packed to minimum weight.
6.3 Calibration and Control of Measuring and Monitoring Devices/Equipment and Software (ISO 9001:2008 section 7.6)
All measurements that relate to product conformance are specified within the appropriate documentation. This includes measurements associated with checking received products as well as in-process and final verification. Equipment & software used for measuring and monitoring product conformance is controlled to ensure it is capable of providing consistent and reliable results. Control includes as appropriate routine calibration and testing using devices traceable to international / national standards, the safeguarding of equipment from unapproved adjustments, protection during storage, handling and maintenance. Records of inspection, measuring and test equipment and software are maintained and indicate calibration/testing history and calibration/test status. Where appropriate, instructions are available that specify how to perform calibrations and/or tests on equipment calibrated or tested in-house. Calibration/test records are traceable to national or international standards at a pre-determined frequency and by trained personnel. Where applicable the equipment & software are protected against random adjustments, damage and deterioration If defective inspection, measuring and test equipment identified as such, is not returned to the supplier for repair or a service engineer called to site; it is immediately discarded to prevent accidental use. Consideration is given to any impact the defective equipment may have had upon product quality and where necessary products which may have been affected are re-checked to confirm or otherwise their acceptability.
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7.0 7.1
Personnel Training
Only members of staff that have the necessary education, training, skills and experience are assigned responsibilities that affect quality management activities and/or customer satisfaction. Applicants are evaluated during the recruitment process to consider whether they have the necessary attributes to fulfil the job requirements. All employees are inducted on joining the company to ensure they have a clear understanding of the quality management system and their responsibilities. Staff competency is monitored on an ongoing basis (via appraisal) and further training is identified & provided as necessary to ensure they remain competent and able to perform their responsibilities effectively. The effectiveness of the training is evaluated with records of training being maintained and used to assist with determining further development requirements. General training needs are discussed during Management Review meetings to consider whether new skills are needed to meet current or future demands of the company and/or changing technologies All training is carried out in accordance with the Resource Procedure PRM03 and records held. As a minimum, records must show name of trainee, date and duration of training, name of course, training provider and confirmation of attendance. All food handlers are supervised and instructed and/or trained in food hygiene & allergen handling matters commensurate with their work activity. Those responsible for the development and maintenance of the HACCP plan will receive adequate training in the application of the HACCP principles.
7.2
Access & Movement of Personnel
There are detailed plans of the site on file, depicting routes for personnel, product & waste, including access points. Coded entry locks secure access points to prevent unauthorised access. Visitors are made aware of our requirements.
7.3
Personal Hygiene
We have documented our hygiene standards in accordance with the Global Standard for Food Safety requirements and due diligence and this covers visitors, employees and contractors. Hand cleanliness of food handlers is checked periodically by way of swabbing and analysing for St. aureus & E.coli. The employee rules are covered in PRW28, the employee health and hygiene policy QMF55 & visitors and contractors in the Visitor Health and Hygiene Policy QMF56. All plasters that are purchased by the company are blue and metal detectable. Each batch is checked via the metal detector and recorded & those batches that are not detectable are rejected. The issue of these plasters is also controlled. Personal medicines are controlled and only permitted in production areas with explicit written approval of the Technical Manager.

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7.4
Medical Screening
It is the policy of TasteTech Ltd to ensure that any medical issue that may have a bearing on either the welfare of the staff or the safety of the products and consumers should be dealt with by set procedures. These include the following: 1. Pre-employment health questionnaire QMF77 to screen new employees prior to commencing working with food (as recommended by the FSA Food Handlers: Fitness to Work) 2. Option of Company medical either with a company appointed GP or employees own. To exceed the requirements of the relevant EC legislation. 3. Return from Absence (post holiday or illness) questionnaire QMF76 to ensure that travel abroad or reasons for illness do not put potential risk on the products or other staff. All employees are required to report all incidences of diarrhoea & vomiting 4. Visitors, temporary employees and contractors are required to complete a Visitor Health Questionnaire QMF78 before admittance to the production facility.
7.5
Protective Clothing
TasteTech provides all work wear worn in factory areas to protect the product from contamination from personal clothing. Employees are instructed in the correct manner for wearing work wear and that care should be taken to ensure that there are no loose threads, studs, etc. that could fall into a product. Also that sleeves must cover any personal clothing underneath. Workwear is kept as clean as is practical and changed on a daily basis. Disposable metal detectable Mob Hats are worn as product protection, to minimise any risk of hairs getting into the product. They are worn to cover ALL hair and the ears. A NEW hat is worn every day. It is deemed not necessary to remove the hat during the day UNLESS employees are leaving the site or going to their car for break times. If this is the case the hat is disposed of before leaving the changing room and replaced with a new one when ready to re-enter production to start work again. Employees are permitted to wear the same hat all day and can wear them when visiting the toilet, the canteen, the offices or going outside for a cigarette. All hats are disposed of at the end of the shift. All work wear in use at TasteTech is laundered by Brislington Laundry. TasteTech will issue all new employees safety footwear and replace worn footwear of existing employees with leather shoes or white wellingtons both with steel toecaps. Company issue footwear (ONLY) must be worn in production areas. For visitors flat, sensible shoes must be worn & persons wearing high heels will not be allowed access to the stores or production area. Blue gloves and blue aprons must be worn, at all times, by staff working with open product. Gloves are changed at regular intervals and not re-used. Aprons must be discarded at breaktimes, at toilet breaks and when changing jobs. Red aprons are available for production duties involving allergens.
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ISO 9001:2008 versus Global Standard for Food Safety Issue 5
ISO 9001:2008 4 Quality Management System 4.1 General Requirements 4.2 Documentation Requirements 4.2.1 General 4.2.2 Quality Manual 4.2.3 Control of Documents 4.2.4 Control of Records 5 Management Responsibility 5.1 Management Commitment 5.2 Customer Focus 5.3 Quality Policy 5.4 Planning 5.4.1 Quality Objectives 5.4.2 Quality Management System Planning 5.5 Responsibility, Authority & Communication 5.5.1 Responsibility & Authority 5.5.2 Management Representative 5.5.3 Internal Communication 5.6 Management Review 5.6.1 General 5.6.2 Review Input 5.6.3 Review Output 6 Resource Management 6.1 Provision of Resources 6.2 Human Resources 6.2.1 General 6.2.2 Competence, Awareness & Training 6.3 Infrastructure 6.4 Work Environment 7 Product Realization 7.1 Planning of Product Realization 7.2 Customer Related Processes 7.2.1 Determination of Requirements Related to the Product
BRC Global Standard for food Safety (issue 5) 1.0 1.0 3.7 3.7, 3.1, 3.2 3.2, 3.2.1, 3.2.2 3.7.1, 3.7.2 3.7.3 1.0 1.0, 3.3.5 3.4 3.1, 3.1.1 1.3 1.0 3.3 3.3, 3.3.3 3.3.2 1.2, 3.3.1, 3.3.3, 3.3.2 1.4, 1.5 1.6 1.7 1.8, 1.9, 1.13 1.0 1.1 7.0, 7.1 7.0, 7.1 7.0, 7.1, 7.1.3, 7.1.4, 7.1.5 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7 5.0 3.4.2, 3.7.2.3 -

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ISO 9001:2008 7.2.2 Review of Requirements Related to the Product 7.2.3 Customer Communication 7.3 Design & Development 7.3.1 Design & Development Planning 7.3.2 Design & Development Inputs 7.3.3 Design & Development Outputs 7.3.4 Design & Development Review 7.3.5 Design & Development Verification 7.3.6 Design & Development Validation 7.3.7 Control of Design & Development Changes 7.4 Purchasing 7.4.1 Purchasing Process 7.4.2 Purchasing Information 7.4.3 Verification of Purchased Product 7.5 Production & Service Provision 7.5.1 Control of Production & Service Provision 7.5.2 Validation of Processes for Production & Service Provision 7.5.3 Identification & Traceability 7.5.4 Customer Property 7.5.5 Preservation of Product 7.6 Control of Monitoring & Measuring Equipment & Software Measurement, Analysis & Improvement 8.1 General 8.2 Monitoring & Measurement 8.2.1 Customer Satisfaction 8.2.2 Internal Audit 8.2.3 Monitoring & Measurement of Processes 8.2.4 Monitoring & Measurement of Product 8.3 Control of Non Conforming Product 8.4 Analysis of Data 8.5 Improvement 8.5.1 Continual Improvement 8.5.2 Corrective Action 8.5.3 Preventative Action
BRC Global Standard for food Safety (issue 5) 5.1.8 3.10, 3.4.1 5.1 5.1.1 5.1 5.1.3, 5.1.4, 5.1.5, 5.1.6, 5.1.7 5.1.8 5.1.8, 5.1.1 5.1.2 6.1.8, 5.1.8, 5.1.1 3.6 3.6, 3.6.3, 3.6.4 3.6.1 3.6.2 6.1 6.1, 5.7 6.1.1, 6.1.2, 6.1.3, 6.1.5 3.9 4.12 6.3 1.0, 5.5 3.4.3, 3.4.4 3.5 6.0, 6.1, 1.3, 3.4.4 5.5, 5.5.1, 5.5.2 5.6, 3.11 1.0 1.0 1.0 3.8, 3.11 3.8, 3.11

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FOOD SAFETY & QUALITY MANUAL

Issue Date: 06/02/2012 1 of 23 Doc ref: QM01