The Regulatory Agencies Include

POLICY TITLE
QA/QC Program / Approval
Plant Manager / Policy/Procedure #
C - 001
Approval / Date Issued:
July 24, 1008
AUTHORIZED FOR USE AT
COMPANY XYZ / Issued By: / Supersedes:
New

I.INTRODUCTION

COMPANY XYZ is dedicated to the quality and safety of the products produced. It is every employee’s responsibility to minimize the risk that products under their responsibility will be subject to adulteration.

II.OBJECTIVE

Employ a Quality Control Program, using acceptable chemical, microbiological, physical, or other relevant inspection and testing procedures, covering all aspects of production, storage, transportation, sanitation, and maintenance to ensure the marketing of the wholesome finished food products with superior quality and is in compliance with regulatory requirements.

The regulatory agencies include:

Fraser Health Authority

Canadian Food Inspection Agency (federal)

Third Party Auditor

NSF

FDA

III.DEFINITIONS

Quality Control – A systematic set of procedures within the HACCP system that ensure food products meet product specifications for quality.

GMP - Good Manufacturing Procedures

HACCP - Hazard Analysis and Critical Control Point. A system that identifies, evaluates and controls hazards significant to food safety.

Critical Limit - A criterion that separates acceptability from unacceptability.

IV.REFERENCES

Industry Guidelines
NSF
Canadian Drinking Water Guideline
FDA

V.POLICY

The following programs and procedures are being developed and implemented in order to accomplish the objective.

GMP (pre-requisite) program
SOPs in processing
SSOPs
HACCP program
Allergen Control Program
Coding Policy
Food Security Program
Hazards Control Program
Hold Policy
Raw material Policy
Supplier Approval Policy
Equipment Approval Policy
Lab test Program
Product Specification Policy and Monitoring
Sensory Evaluation Program
Glass Control Policy

Combining these programs/policies will increase the total process control system and help continue to produce highest quality products possible. The activities of these programs/policies are addressed in detail in each program/policy.

QC Testing

TEST / Standard / Frequency / Record
Complete analysis ( Inorganic chemical, Organic Chemical, physical, Microbiological) / Canadian Drinking Water Guideline / NSF) / 1 every year / Water analysis
Radiological / NSF / 1 every 4 years / Water analysis
Trihalomethanes / Quarterly
Bacteria Finished Water
Plate Count / <200 / Sample for 90% of samples / Daily in House Weekly by accredited Lab / Micro record
Coliform / <1 / 100 ml (membrane filter) / Daily in House
Weekly by accredited lab
Bacteria Source Water ( Spring & Municipal)
Coliform / <1 / 100 ml (membrane filter) / Daily in House
Weekly by accredited lab
Bacteria Closures
TPC / < or = 1 per cm2 / Quarterly on 4 of each closure
Coliform / absent / Quarterly on 4 of each closure
Container Bacteria
TPC / < or = 1 per ml / Quarterly on 4 of each container
Coliform / absent / Quarterly on 4 of each container
Container Fill
Weight / Volume / Equal to declared net content or net content plus / Daily for each size package
pH – Finished Water
Spring Water / Hourly
RO Water / Hourly
Flavoured Water / Hourly
Ozone
Pre – Ozonation / 0.08 – 0.13 / Start Up
Contact Tank / 0.3 – 0.4 / Hourly
Residual in Bottle / 0.2 – 0.3 / Twice per product per Day
Taste
Finished Water / pleasant / Start up & Hourly
Chloride
RO Finished Water
TDS
Spring Source water / Start Up
Spring Finished Water / Start Up & Hourly
Flavoured Water / Start Up & Hourly
RO Finished Water / Start Up & Hourly

QC ACTIVITIES:

Following QC. Activities are conducted as a tool to ensure effective implementation of GMPs, Pre-requisite Programs and HACCP. Thus, producing wholesome and safe products that are of good and consistent quality.
Q.C. Activities / Frequencies / Records
Monitor Pre-Op and verify corrective actions are being followed -up on correcting deficiencies / 1x daily / Pre-Op
On site verification & monitoring of employees are following protocols of GMP, Pre-requisite and HACCP / 2 x daily / Daily Monitoring
Initiate CAR / WOR and follow up on required actions / On going / CAR / WOR
Conduct quarterly self audit and follow up with corrective actions / 1x quarterly / Audit
Calibrate equipments / instruments. e.g. Thermometer / scales
/pH meter/TDS Meter / 1 x weekly / Calibration
Monitor production SOPs are being followed and verify daily CCP's records ensuring limits are being met / 3x daily / CCP's
Monitor and verify corrective actions are being taken for any CCP not meeting Critical limits. / 1x daily / CCP's
Inspect pest control devices and assess whether infestation occurs in plant / 1x monthly / Pest Control
Inspect incoming materials and ensure shipper/receiver is working according to Material Control Program and record accordingly / As receiving / Receiving
Do plant operation inspection and on site verification 1x a day minimum / 1x daily / Daily Monitoring
Review and verify daily Production Record, Sanitation, Shipping & Receiving records & sign off / 1 x daily / Various Records
Inspect outgoing shipment and record accordingly / as shipping / Shipping
Inspect processing operations ensuring no contaminations and proper materials are being used / 1x daily / Daily Monitoring
Monitor and verify metal detectors are functioning properly and all products are being checked. Deal with suspect products. / 1 x daily / Metal Detector
Monitor and verify allergen control procedures are in place and no contamination would result. / 1 x daily / Daily Monitoring
Inspect correct products with correct labeling with correct lot and date being produced. / 1x daily / Daily Monitoring
Inspect correct chemicals and correct concentration are in use / 1 x daily / Chemical Mixing
Conduct Taste and Organoleptic testing / 3 x daily / Taste Evaluation
Conduct outside premises inspection and follow up on corrective actions / 1 x weekly / Outside INSP report
Initiate Hold procedures for questionable products and investigate cause follow by corrective and preventive actions / As required / Hold Record
Release or dispose products that are on "Hold" when investigation completes / As required / Hold Record
Conduct Sampling and testing of products / materials for microbiological analysis / 1 x weekly / Micro. Test
Conduct equipment swab test / 1 x monthly / Micro. Test
Check Air Quality / 1 x year / Micro Test
Review, organize and file all documents / 1 x daily / Various Records
Review and verify raw material specifications. Maintain up-date on approved supplier/ materials file. / on going / Raw Mat. Spec.
Monitor and verify washing, cleaning and sanitizing (plant,& equipments) operations / 1x daily / Daily Monitoring
Conduct monthly inspection (on site) of QA Food Safety System. Record all deviation and coordinate corrective actions / 1xmonthly / Monthly Inspection
Conduct monthly Food Safety meeting and record on minute book. / 1 x monthly / Food Safety meeting minute
Other QA activities
Printing of labels and keep a record of it. / As required / Label Log
Evaluate micro results and initiate necessary corrective actions / Every test result / Micr. Test
Investigate & correct various product defect problems as they occur / As required / CAR / WOR
Investigate defective raw materials, assess risk and initiate necessary Corrective Actions / As required / Hold Record
Month end Micro Report / 1x monthly / Micr. Test
Resolve customer complaints / As required / Customer Complaint
Ensure equipment cleaning & sanitation supplies are always available / on going
Liaison with inspectors / on going
Follow up & insure inspector recommendations are completed / on going / CAR / WOR
Update QC procedures as required / on going / QC
Create QC procedures as required & maintain QC/QA manual / on going / QC
Liaison with Pest Control contractor and monitor pest control program. Verify pest control operator’s performance. / on going / pest control
Review, validate & revise HACCP / Quarterly / HACCP
Review and revise Product Listing / As required / Product List
Review and revise product Formulation / labels / As required / Product Spec.
Review / revise and validate HACCP plans every six months / 1 x six monthly / HACCP
Liaise with government, customers and industry and ensure in compliance with government regulations and customers’ requirements. / On going / Various files
Record any changes, (Pre-requisite, HACCP, procedures, documents, product spec, label, raw materials etc.) in HACCP Maintenance LOG and up-date changes in respective files. / on going
Conduct employees training / New hire and on going job / Personnel Training
Safety activities
Conduct Plant audits / 1 x monthly
Arrange safety meetings / 1 x monthly
Monitor safety poster program / on going
Investigate accidents / As required
Write accident reports / As required
Follow up on accident report recommendation's' / As required
Follow up on safety committee recommendations / As required
Complete WCB claims & submit / As required
Monitor WCB claims till return to work / As required
Liaison with WCB adjudicators / As required
Liaison with inspectors / As required
Follow up & insure inspector recommendations are completed / As required
Arrange & conduct periodic employee safety meetings / As required
Conduct annual WHMIS training / As required
Order safety supplies / As required
Monitor safety supplies / As required
Monitor first aid stations / As required
Monitor noise levels & record / As required
Continuous observation for unsafe conditions & acts / As required
Arrange pertinent professional safety training / As required
Update safety procedures & policies as required / As required
Create safety procedures & policies as required / As required
Miscellaneous activities
Arrange garbage disposal / on going
Arrange uniform service / on going

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