Produce Packhouse Standard V1.2 (414).pdf

Produce Packhouse StandardAuthor: Terry Wilde Applicable to: Product: Produce Country: Group Date Issued: October 2010 Date Revised: Revision Due: October 2012 Legal and Technical Document Matrix No: 414 © Tesco Stores Ltd. All Rights Reserved. This document is supplied by Tesco for use of the immediate recipient Produce Packhouse Standard Version 1.2 Tesco Produce Packhouse Standard Version 1.2 Page 1 of 72 CONTENTS Introduction to the Produce Packhouse Standard Site Audit Section 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 HACCP Finished Product Specifications Raw Material and Secondary Site Management Packaging External Areas and Site Security Design and Construction of Premises Design and Construction of Equipment Employee Facilities and Personal Protective Equipment Factory Hygiene Personal Hygiene Process Controls Traceability Allergen Control Foreign Body Controls Foreign Body Detection Inspection and Analysis Water and Waste Water Management Product Labelling and Coding Weight, Volume and Count Checks Training Page 6 10 12 15 18 20 22 23 27 30 32 34 35 36 39 41 42 44 46 48 Quality Systems Audit 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Quality Management System Product Development Product Recall/Incident Management Internal Audits Customer Complaints Pest Control Maintenance Calibration Cleaning Programme Transport Medical Screening Employment Agencies Environment Ethical Trading Management Controls 49 50 51 53 54 55 59 61 63 64 65 66 69 70 71 72 Glossary Tesco Produce Packhouse Standard Version 1.2 Page 2 of 72 Introduction to the Tesco Produce Packhouse Standard Aim Tesco is committed to ensuring all Tesco brand products produced by suppliers are safe, meet legal requirements and are of the agreed quality. Suppliers must meet Tesco Ethical Requirements (Tesco Ethical Trading Code of Practice – Document No 388). Objective The Tesco Produce Packhouse Standard (TPPS) sets out the requirements to which suppliers must comply. In some product areas there are additional requirements as detailed in codes of practice. In no circumstance does compliance to the standard replace the need for compliance to relevant legal standards in the country of manufacture or the intended country of sale. Compliance to the standard is in addition to the duty held by the supplier to produce safe and legal food. Scope The detail contained in the TPPS is applicable to all fresh primary produce suppliers to Tesco. Although identified as a Produce Packhouse Standard, this document applies equally to sites which pack in fields and tunnels etc. The standard may also be used for secondary produce suppliers where required. The Standard Structure The Sections and Layout The standard documents Tesco requirements for the Good Manufacturing Practice (GMP) for food. It is divided into sections by subject. Aspiration Some sections have additional elements which Tesco believe will help move standards forward within the supply base. These are not prescribed requirements but will be viewed favourably by Tesco if implemented. What Good Looks Like In many sections examples are given of how a requirement may be met under the heading of What Good Looks Like (WGLL). This is intended to provide guidance and clarification of what is required. Due to the variability of the processes and premises at supplying factories, compliance to ‘WGLL’ may not ensure total compliance to a requirement. The supplier must determine the most effective method of complying with Tesco requirements and be able to demonstrate this during a Tesco audit. It should be noted however that ‘WGLL’ are not aspirations. All on-site traceability records must be available within 4 hours from request. This requirement will be challenged during the audit process through the traceability exercise. It is accepted that in certain circumstances farm records may take longer to present (e.g. UK primary packer, New Zealand Growers). A maximum of 24 hours will Tesco Produce Packhouse Standard Version 1.2 Page 3 of 72 Major – A deficiency which requires prompt attention to prevent a potential food safety failure or legal issue from arising. sites will receive a specific rating. In instances where a site has not previously worked with Tesco and is being audited as part of the initial approval process. where this failure may potentially put customers or the Tesco brand integrity at risk. the UK. The TPPS may also make reference to additional Tesco Codes of Practice (COP). This COP may also only be applicable to factories supplying products to Tesco stores in specific countries e. the site will be rated as either Approved or Not Approved. but all suppliers must be identified within the 4 hours.g. and will note the specific country / countries where it is applicable Tesco Produce Packhouse Standard Version 1. There is a likelihood that some non-conformances will be raised through the audit and these will be categorized as: • • Critical . • Depending on the category of non conformances and numbers identified. where this failure puts the customer and or Tesco brand integrity at risk. Sites that receive a ‘Not Satisfactory’ rating will need to immediately contact their TTM. Country Specific Requirements Although this TPPS is a ‘Group’ document i.e. a small number of the clauses may apply only to factories supplying products to Tesco stores in specific countries e. in the UK. Minor – A deficiency which requires attention to improve Good Manufacturing Practice standards.2 Page 4 of 72 . Information on the Tesco audit process can be found on the Tesco Technical Library (TTL) or from your TTM.g. Due Diligence documentation (our ability to defend a legal challenge) or to achieve compliance with Tesco standards.be allowed to submit documentation. • • • • • Blue = Green = Amber = Double Amber = Red = Satisfactory Satisfactory Improvement needed Improvement needed Not Satisfactory Note. Auditing of the Standard Tesco will undertake regular audits against this standard and will determine the degree of compliance to each section. Double Amber status is used for sites which have consecutive Ambers and those which have been Red then Amber.Failure to meet a food safety standard or a legal standard. it applies globally. Tesco Produce Packhouse Standard Version 1.2 Page 5 of 72 . Glossary A glossary has been provided to help with the understanding of Tesco terminology. Primary Site etc. are checked to ensure understanding in the context of this standard. Feedback on the standard or any questions should be directed to the relevant TTM or the Tesco Product Integrity Unit .g.Review The contents of the standard will be regularly reviewed and amended as required.tesco.PIU.com Training Speak to your Tesco Technical Manager for information on TPPS training and availability. It is recommended that the meaning of specific terms e.services@uk. They may include (not an exhaustive list) e. 1. The HACCP Plan must be developed using Codex Alimentarius HACCP principles with reference to relevant legislation. These cover good manufacturing practices throughout the site. A programme of refresher training to ensure up to date knowledge.2 Page 6 of 72 . accurate HACCP Plan must be in place. expert advice may be obtained from other sources. 1.3 Pre-requisite Programmes Tesco Produce Packhouse Standard Version 1.Section 1 Section No. The HACCP system should be developed by a multi-disciplinary team which must have product specific knowledge and expertise.2 HACCP Team The team should include members from at least the following disciplines: • • • Technical/QA Production ( Pack house facing) Engineering (Equipment functionality) Refresher training should include Pesticide monitoring programme. All environmental and operational controls that are necessary to produce safe and legal food products must be in place. If internal expertise is not available. At least one member of the team must have completed a recognised qualification (minimum Intermediate HACCP or equivalent) and the other members must be suitably trained. Tesco Codes of Practice and industry guidance. What Good Looks Like 1. should be considered. The operation of the HACCP system must remain the responsibility of the site. Intermediate level training would consist of a 2 day training course with a mandatory examination at the end.g.1 Hazard Analysis & Critical Control Points (HACCP) Item HACCP Plan Detail An effective.: • Personal Hygiene • Staff Training • Pest Control • Pesticide monitoring programme • Cleaning procedures • Glass/hard plastic control • Waste control • Maintenance Procedures The control measures and monitoring procedures for the pre-requisite programme must be clearly identified and documented. g. exist which can be applied to prevent. This information should be clearly documented within the scope of the study. This may be generic but it is critical that all process steps are included and identified by product.9.1. The diagram must be verified within the production area. there should be records of each process step indicating the hazards and showing the decision tree answers that determine whether it is a CCP. microbiological or foreign bodies • Potential for adulteration/deliberate contamination The team must assess whether an existing pre-requisite adequately controls the hazard identified. eliminate or reduce the risk to acceptable levels. rework and waste must be constructed.5 The intended use of the product must be defined. detailing the end user or consumer and suitability for vulnerable groups must be considered e. eliminated or reduced to acceptable levels. The HACCP team must conduct a hazard analysis to identify hazards which need to be prevented. The team must then consider for the remaining hazards what control measures. and allergy sufferers.4 Product & Intended Use Flow Diagram 1. if any. All potential hazards that may be reasonably expected to occur for each process step and product must be identified. 1. elderly. Coliform presence/growth in wash water 1. In some cases it is very possible that some produce packing facilities will have no CCPs Tesco Produce Packhouse Standard Version 1. infants.9 Determination of CCPs In combination with point 1.2 Page 7 of 72 . The Codex decision tree or equivalent must be used to determine if control measures are CCPs (Critical Control Points). Hazards identified must be specific to the process step.7 Hazard Analysis Records for this analysis should be kept in combination with point 1.6 Hazards Example. If no control measures can be identified the product/process must be modified so a control measure can be applied.8 Control Measures 1. generic descriptions such as ‘foreign body’ and ‘micro organisms’ are not sufficient. A flow diagram covering all steps of the product process operation including water. 1.7. The hazard analysis must include: • Likely occurrence and severity • Survival or multiplication of micro-organisms • Presence of chemicals. The monitoring system must be able to demonstrate control and detect loss of control of CCPs. Critical limits must be measurable and justification for their use must be documented. that individuals are actually following the stated procedures and secondly that the whole system including the pre-requisite programme is operating Tesco Produce Packhouse Standard Version 1. Monitoring procedures must be established for each CCP to ensure compliance with the critical limits. tolerance of temperature probes.11 Monitoring 1. it must not be supplied to Tesco without first discussing the issue relevant Tesco TM.14 Training 1.15 Verification Internal workshops to train HACCP thinking for all individuals involved in monitoring. Product or materials must be disposed of if the safety of the product is in doubt. The process must be capable of operating consistently within the defined limits. isolated and a full risk assessment completed. the corrective actions to be taken when a CCP deviates from critical limits must be detailed and documented by the HACCP team. This may include: • Internal audits In some produce packing sites no CCP`s may be applicable. If the risk assessment deems the product to be safe. Monitoring records must be signed by the person doing the monitoring and then verified by an authorised person.12 1. The precision limits and tolerances of the monitoring equipment must be considered when defining limits e. Personnel in the factory who monitor CCPs must have an understanding of HACCP and have specific training against the latest version of the relevant monitoring procedure.2 Page 8 of 72 .10 Critical Limits Critical limits must be defined and validated to ensure that the product is safe.13 Monitoring Records Corrective Actions 1. The verification would demonstrate a full understanding by firstly demonstrating conformance i.g. The corrective actions must ensure that the CCP has been brought under control and any material that may have been produced whilst the CCP was not in control must be identified. Monitoring procedures must contain details on how the measurements are taken and the frequency. 1.1. These workshops would use relevant case studies.e. The operation of the HACCP plan must be verified to confirm that it is effective. Where CCPs are identified. This may include changes in: • Process steps • Supply or specification of raw materials • Ingredients/recipe • Packaging. storage or distribution etc.16 Review • Review of customer complaints • Review of hazard measurements e.1. Tesco Produce Packhouse Standard Version 1. effectively.2 Page 9 of 72 .g. microbiological results. The HACCP plan must be reviewed at a pre-determined frequency (minimum annually) or prior to changes of product/process which may affect product safety. 2 Review The most current version of the master specification must have been supplier accepted and the supplier specification must be active and accepted. Photo standards will be of adequate quality and size. They should be clearly visible by production staff.2 Page 10 of 72 . 2. The person responsible for specification approval must have attended Tesco specification training. Spec Type. including: • • • My Workspace Alerts Audits & Visits The Lead TM must ensure that the most up to date specification is always in use and cascades the information to the correct person /department in a timely manner.g. 2.3 Tesco Technical Library: Supplier & Sites Area 2. Current fresh specs available for all lines supplied based on the current master version. Tesco Produce Packhouse Standard Version 1. Primary sites must have unique site codes.Section 2 Section No. 2. Plant Approval No. Contact Roles and Details. Copies of the specifications must be accessible on all production sites. Factory specification including any photographic quality standards will be available during each production run. Address. What Good Looks Like All supplier specifications should be accepted (Where secondary sites are used summary specifications are allowed providing they contain all key product quality parameters). All details of the Supplier and the Site Record must be complete and accurate. Specifications must be agreed in writing by both parties (electronic signatures are acceptable). Telephone.4 Tesco Technical Library: My Workspace Alerts Audits & Visits Document Library The nominated person will have access to One Team. e. The supplier must ensure that a nominated person is responsible for the Technical Library and has been on Tesco training to ensure that they are conversant in key functionality. A system must be in place to review and update the information. Tesco Technical Library specifications must be completed to Gold Standard as defined in the User Guides.1 Finished Product Specifications & Tesco Technical Library* Item Agreed Specifications Detail Agreed Tesco Specifications must be active on the Tesco Technical Library for all launched products. Approved sources lists must be attached to each primary site as approved by Tesco TM. • Document Library Where a supplier has multiple sites. The supplier must ensure that processes are in place to monitor compliance standards across all the supply sites. Tesco Produce Packhouse Standard Version 1.2 Page 11 of 72 . *Currently the requirements specific to the TTL are applicable to sites and suppliers supplying Tesco businesses in the UK. the nominated responsible person must ensure that all relevant information and access has been cascaded to all sites. ROI and USA. Where sites produce products for more than one country. they may also be required to use the TTL and comply with the additional clauses listed. For guidance speak to your Tesco Technical Manager. Minimum annually.2 Page 12 of 72 .1 Raw Material and Secondary Site Management Item Supplier Approval and Management Detail Any secondary site and/or contract packer must be approved and have ongoing audits by the primary supplier site. 3. 3. • • It is the primary site and not the Agent/Importer that must be approved The Agent may be assessed by the Tesco supplier as competent to manage approval of the raw material site 3.Section 3 Section No. Audits must be completed against a format which encompasses the principles of the Tesco Produce Packhouse Standard or relevant GAP certification (Nurture in UK/ROI and Primus in USA) including management of non-conformance and verification. Where supplier approval assessment indicates that certification to a third party food standard is sufficient then the valid certificate. based on: • • • Inherent quality. This data would form part of the audit schedule and intake quality checks required. Supplier audits must be completed by trained auditors with an understanding of the processes and the risks associated with the product area / site being assessed Where raw materials are supplied via an Agent/Importer. An effective raw material and supplier control system must be in place for all raw materials.4 Tesco Produce Packhouse Standard Version 1. Details of suppliers and the raw materials supplied must be kept on an approved supplier list.2 Approved Supplier List Trained Auditors Agents & Importers For Produce an approved supplier list or approved sources list is maintained. All raw material suppliers must be risk-assessed.3 3. chemical contamination (including pesticides) and microbiological risk associated with the product Volume of product supplied Supplier history What Good Looks Like A risk assessment value would be generated based on • • • Inherent risk of the Product Number / volume of product supplied Supplier history Each supplier would be rated and this value would determine the need for audit and the audit frequency. audit report and corrective action summary must be available on site. Third party audits should be retained and tracked Raw material supplier risk assessments must be reviewed annually. Raw materials must be sourced only from approved suppliers. All product lines supplied to Tesco should be included on an annual testing matrix.11 Tesco Produce Packhouse Standard Version 1. Checks must include (where applicable): Hygiene condition of vehicle Packaging integrity Evidence of pest infestation (low levels may be acceptable in some produce materials) • Date/Lot coding • Temperature (where required) • Product inspection to demonstrate compliance to specification (which must be agreed and include quality standards) • Pallet condition A Stock rotation system must be in place to ensure that raw materials are used within agreed shelf-life. Testing will be dependant on a number of factors:e.10 3.3. must be suitably segregated to reduce the risk of cross contamination or taint. • • • • Refer to PPPL's for chemicals allowed for country applicable.g. Allergenic. Sensitive materials e.7 Stock Rotation 3. onions. whether or not testing is done at source.g.6 Intake Checks Based on risk assessment checks may also include: • • Product sampling for retention Product testing (microbiological / chemical / physical /organoleptic) Where harvested product is brought in to the facility in bulk the raw material check must take place through out the production run.8 Part-Used Raw Materials Segregation of Sensitive Materials Non Conforming Materials Supplier Monitoring The exception is where raw product is stored in bulk or used at point of production in bulk i. All raw materials (Product & Packaging) must be checked by trained staff on receipt according to documented procedures. Non Conforming materials must be rejected at intake.2 Page 13 of 72 . A supplier risk assessment must define if a Pesticide Residue analysis is required. Opened or part used boxes/containers of raw materials must be effectively re-sealed and labelled. organic and materials susceptible to other pungent materials (due to potential taint risk).5 Certificates of Analysis / Conformance The Agent/Importer has to audit the packhouse/field operations and sources to the principles of this standard & ensure GAP compliance for Nurture in the UK/ROI and Primus in the USA are adhered to. Oldest material should be used first unless other quality parameters are more urgent. Raw material (Product & Packaging) supplier performance must be reviewed minimum annually. Where this is not possible the Hold and Release procedure must be followed. raw material may not be used until the details on the certificate have been checked by an appropriate senior technical person qualified and accountable for the business. is pesticide used etc 3.e Part used boxes of potatoes. in agreement with the Tesco TM. brassica 3. Where a pesticide Analysis is required.9 3. 3. Intake records must be retained. Intake records must be retained. Checks must include: • Hygiene condition of vehicle • Packaging integrity & pallet condition • Evidence of pest infestation • Date coding & Lot/batch coding • Temperature (where required) • Product inspection demonstrating compliance to specification (must be agreed & include quality standards) 3.2 Page 14 of 72 .This should include results of: • Risk assessment • Intake inspections • Testing • Delivery performance All products must be checked by trained staff on receipt according to documented procedures.12 Intake Checks For Products From Secondary Sites and/or Contract Packers Based on risk assessment checks may also include: • • Product sampling for retention Product testing (microbiological/chemical/ physical/organoleptic) Tesco Produce Packhouse Standard Version 1. 4. BRC-IOP (certificate date still current) Supplier self audit report which has been reviewed and corrective actions followed up What Good Looks Like 4. Audit reports must be available on site along with a corrective action plan. then a valid certificate and audit report must be available on site.1 Packaging Item Supplier Risk Assessment Detail An effective packaging and/or pack inserts supplier control system must be in place for all packaging. 4. Suppliers of Food contact packaging and/or pack inserts must have BRC/IOP certification or a similar accreditation complying with local legislation in country of retail.g.2 Page 15 of 72 . Audits must be completed against good manufacturing principles.4 Audit Requirement If risk assessment indicates that a site audit is required. 4. Approval may include a combination of: • • • Approved site audit report Valid 3rd party certificate e. a Supplier Self Audit may be used. All packaging suppliers must be risk-assessed. an audit may be waived.3 Supplier Approval All packaging suppliers must have a traceability system in place to trace packaging. based on: • Contact with food • Volume of product supplied • Supplier history • Certification to BRC IOP (where possible) The packaging supplier risk assessments must be reviewed on an annual basis.Section 4 Section No. Tesco Produce Packhouse Standard Version 1. confirming safety of packaging (and packaging production methods) or must have been physically audited.2 Supplier Approval If the supplier approval system indicates a low risk. Provided the response to this is satisfactory. A supplier approval system must be in place for all packaging. the site must be audited before supply commences. If the supplier approval system indicates that certification to a third party standard is sufficient. and then according to an audit schedule. 8 Non Conforming Tesco Produce Packhouse Standard Version 1. The same applies if 4 major non conformances found. Checks must include: Hygiene condition of vehicle Packaging integrity (unopened prior to acceptance/ not damaged or tampered with) • Evidence of pest infestation • Date/Lot coding • Product inspection upon opening to demonstrate compliance to specification • Pallet condition • Print quality/colour against given reference code or number Non Conforming materials must be rejected at intake. temperature/humidity • Confirmation of migration test results All packaging must be checked by trained staff on receipt according to documented procedures. which could impact on Tesco products in the supply chain. If a critical non-compliance is found at a site that is an existing supplier.g. Intake records must be retained. Print text is checked against the packaging library every new print run. Specifications should include the following information where relevant: Material composition Dimensions including thickness and gauge Colour Suitability for use in different storage / handling conditions e. Where this is not • • • • • • 4. 4.5 4. then supply must not commence until the corrective action has been completed and verified.6 Approved Supplier List Specifications Both parties have signed and dated the specification.If a critical non-compliance is found at a site that is being audited prior to commencement of supply. Details of suppliers and the packaging supplied must be kept on an approved supplier list. 4. Timescales and corrective actions must be agreed by both parties. All suppliers must be approved. Packaging specifications must be agreed by both parties. The completion of corrective actions must be verified within the agreed timescale. A copy of the audit report must be accessible on site with details of corrective actions.7 Intake Checks A controlled packaging library is retained. Tesco must be informed immediately.2 Page 16 of 72 . The same applies if 4 major non conformances found. Tesco Produce Packhouse Standard Version 1. Packaging must be stored in a designated area and be suitably covered to protect from contamination.9 Storage Where packaging is brought to the area of production on a daily basis then suitable designated and fit for purpose storage must be available.Materials possible the Hold and Release procedure must be followed. The Hold and Release procedure must be used for obsolete packaging materials. Part used packaging which is returned for storage must be suitably covered to prevent from contamination 4. Similar packaging must be stored separately to prevent incorrect use.2 Page 17 of 72 . 3 Grass / Planted Areas 5. Rig packing units should not be left unsecured for extended periods. All visitors and contractors must sign in.g. Where unavoidable.2 External Areas and Site Security Item Site Boundaries External Maintenance Detail A site plan must be available on site. 5.5 External Storage of Raw Materials. This includes all Tesco reusable product crates/trays. 5. packaging and equipment where it comes in direct contact with the product must not be stored outside. vegetation must be kept trimmed and clear from the building (Approximately 1 metre clearance. items must be protected from deterioration. External areas must be kept free from items that could provide potential pest harbourage. site is rented or neighbouring site is close and they don’t keep vegetation at bay) there should be evidence of persistent communications and management of potential issues.7 Photographic / Recording Equipment Control of Visitors. A system must be in place to manage contractors and a manager must be accountable for their movements. 5. contamination. All visitors in production areas must be accompanied at all times. Only equipment authorised by the site must be permitted on site. pests and must be inspected prior to use.1 5. Packaging. Proof of identity will be required when persons are unknown to the business.4 External Storage Units External units (including containers and tanks) must be kept locked and have restricted access.Section 5 Section No. Equipment No packaging should be stored on external rigs/tables/trolleys other than that needed for that day’s production. Rigs/mobile packing units should not be stored adjacent to spraying equipment. rigs are stored safely and securely avoiding any possible forms of contamination.6 5. Ensure that when not in use due to season end or extended down time. The use of photographic/recording equipment must be controlled. Tesco Produce Packhouse Standard Version 1. Raw materials. Where this is out of the sites control (e. What Good Looks Like Redundant machinery and /or equipment stored outside should not pose a harbourage issue 5. The yard area should have adequate drainage to prevent pooling of water & allow for cleaning. Contractors Visitor/contractor procedures include a declaration of any intended use of photographic/recording equipment. Entrance to the site via a manned security barrier/check point. When present. Tesco trays should not be left uncontrolled in open field areas overnight.2 Page 18 of 72 . to prevent pest harbourage). 5. Guard dogs (if utilised) must be under the control of security guards and not free running.8 Control of Employees Access to production and storage areas must be restricted to authorised personnel i. employees and visitors.2 Page 19 of 72 . Security guard is on site. 5. Tesco Produce Packhouse Standard Version 1.e. Employees should be encouraged to challenge unknown lone visitors.9 Guard Dogs Dogs and other animals should not be present around the site (see section 26). 6. kept clean and effectively proofed against pests. as these do not trail over forklift trucks and products and are therefore easier to keep clean and less prone to damage.4 6. If strip curtains are fitted. Tesco Produce Packhouse Standard Version 1.3 6. must be suitably proofed to prevent pest entry (including canteens.2 Page 20 of 72 . Glass windows and doors in the production and storage areas must be protected from breakage. A risk assessment must be completed on surrounding areas to establish the potential risk of transfer. What Good Looks Like Where external packing takes place -Field rigs /orchards/tunnels etc. Sinks in production areas must not be constructed from porous or breakable material. Then fabrication must be suitable and not pose a risk to the product from any form of contamination. or allowing free access to birds) Strip curtains should be full length and intact. floors. 6. 6.6 Windows 6.2 Internal Structure Walls. doors not being left open for long periods to temperature controlled areas. ceilings. they must be maintained. Floors must have adequate slope to drainage and not form pools of water.5 Floor Gradients Drains Windows 6. drains and doors must be designed and maintained to allow effective cleaning.e. weather proof and pest proof.1 Design and Construction of Premises Item External Structure & Fabric Detail The structure and fabric of the building/packing rig must be suitable for use. Windows designed to be open.7 External Doors Good door control should be in place (i. They must be maintained in a good condition to prevent foreign body risks. toilets and locker facilities if connected directly to the production facility). All external doors must be kept closed when not in use and effectively proofed against pests. Curtains which part (slide) on opening of main door are preferred.Section 6 Section No. Drains must be accessible for cleaning and fitted with screens or traps to prevent pest entry. Ventilation and extraction systems must be effective at preventing excessive dust and pest entry. 6. these doors can be opened to provide ventilation. Materials must not be stored directly against the walls to allow inspection. These doors must not however be used as personnel routes other than in emergency situations Fire exits must be identified and controlled.6.11 Ventilation and Extraction Services 6. Offices should have basic equipment (desk. factory issue pens. Equipment must be kept to a minimum to allow easy cleaning. no drawing pins etc) Tesco Produce Packhouse Standard Version 1. storage.g.12 Storage Areas The ability to clean behind the stored packaging is essential and a clear line of sight away from the wall maintained 6. with the exception of plain drinking water. Doors to temperature controlled areas should be automatic closing or alarmed if not closed. Storage areas must be fit for purpose and maintained in a clean/hygienic condition. All services (pipe work for water/gas/compressed air.13 6. ASPIRATION Offices within production / storage areas must be managed so that they do not pose a risk to product. fire extinguishers/sprinkler systems etc) should be designed from material suitable for the purpose and appropriate to the area where used. 6. cups. Eating and drinking is not permitted in these offices. Stationary items should be consistent with site rules and GMP (e. They should not be adorned with personal items (e. Similarly if heating is provided. Adequate lighting must be in place above product inspection areas. electrical cabling/conduit/sockets.15 Temperature Controlled Areas Temperature Controlled Areas Production Offices . collectables.10 6. chair.2 Page 21 of 72 . ventilation ducting. intact and allow easy and effective cleaning.g. no staples.9 Lighting Lighting in all areas must enable safe working and good visibility. (Health and Safety requirements in the country of manufacture must be adhered to). bottles etc. Condensate pipes must flow to drain and not drip on product.14 6. computer etc) of an easy to clean construction. Roller doors and shutters should not be left open allowing possible pest ingress and act as thoroughfare for any personnel If a close fitting mesh screen is in place. Lights must be protected by shatter proof covers and or sleeves. compressors/pumps.8 External Doors Any external doors in open food handling areas must be intact and kept closed during production. Section 7 Section No.2 Page 22 of 72 . work in progress packaging/trays. Rigs/trolleys should be numbered to allow for an inventory to be made to aid routine maintenance 7. 7. production belts.3 Construction Construction 7. chopping boards. A written declaration of compliance must be available. must be of a contrasting colour to the food and be regularly inspected for wear and damage.2 7.7 Charging Equipment Battery charging equipment must not be stored in production areas. 7. scissor lifts and ladders must be clean.g. as applied in the country of manufacture and intended country of sale. Equipment must be sited to give access under. brushes and scrapers that come into contact with food. forklift trucks. Wood is not a preferred material.4 Construction 7. Mobile equipment should be stored away from packaging and produce. Parts susceptible to wearing on mechanical equipment e. fans. inside and around to allow cleaning and servicing. Tractors. It must be maintained in a good condition to prevent foreign body risks. pallet trucks. Mobile equipment e. belts. Tesco Produce Packhouse Standard Version 1. maintained and stored in a suitable area when not in use. Tractors should be numbered to ensure all are accounted for under routine maintenance. especially where the tractor straddles open packed crop (oil or hydraulic fluid leaks).5 7.g. when not in use.g. ASPIRATION All food contact materials e. What Good Looks Like Equipment must be constructed from materials that are not susceptible to damage under normal usage and cleaning. No flaking paint or lead based paints should be evident. gas heaters.1 Design and Construction of Equipment Item Design and Construction Detail All equipment must be designed and constructed to enable hygienic cleaning and maintenance.6 Location Mobile Equipment Equipment must be constructed from materials that are not susceptible to damage under normal usage and cleaning. food contact utensils etc must comply with legislation for “material and articles intended to come in contact with food" Regulations (EC) 1935/2004 or equivalent. Section 8 Section No. 8.1 Employee Facilities and Personal Protective Equipment Item Employee Facilities Detail Employee facilities (including rest area, toilets, and locker areas and changing areas) must be provided and maintained in a clean and hygienic condition. Smoking areas where provided, must comply with in country legislation. Where provided they must be maintained in a clean condition and have bins for the tabs / butts (to prevent transfer into the factory on soles of shoes). No tabs / butts can be disposed of on the floor. All sites must have a dedicated space to allow employees to leave their own belongings and to change into and out of protective clothing. Field workers should have suitable storage facilities. Facilities must be provided for the collection of used/dirty work wear (adequate for the number of staff on site). Storage areas for work wear and laundry areas must be clean and protected from contamination (and adequate for the number of staff on site). Personal outdoor clothing must be segregated from work wear. Lockers must be kept clean and in good condition. Lockers must be cleared regularly and not used to store food. What Good Looks Like Separate facilities are provided where appropriate 8.2 Employee Facilities No personal items should be carried by staff. Facilities should be secure, giving staff (including agency and temporary workers) the confidence to leave their belongings. 8.3 Employee Facilities Employee Facilities 8.4 Lockers are clearly partitioned to segregate items. Items such as baseball caps, supplier tee-shirts and fleeces may be acceptable in base areas. Hooks are provided outside lockers for work wear. Canteen facilities should be used for storing workers ambient food items. Where field based, food should remain in the workers vehicle, vehicles should not be parked in the field or on the headland unless doing so aids health and safety and facilitates road access. 8.5 8.6 Employee Facilities Employee Facilities Where staff are required to change footwear floors must be kept clean and be dried adequate after cleaning. Toilets must be segregated from production and storage areas by a minimum of 2 doors with an intervening ventilated space. Toilets must be ‘fit for purpose’ for the ethnicity of staff. Tesco Produce Packhouse Standard Version 1.2 Page 23 of 72 • • • • • The doors must be self closing. The toilet area must be ventilated. Hand wash sinks and drying facilities must be present. Hand washing signs must be displayed in toilet areas. Coat hooks must be located outside the toilet area. Rig packing toilets are generally mobile units and therefore with the exception of the 2 doors with ventilated space between and self closing doors all other requirements should be complied with. 8.7 Employee Facilities Canteen / Rest Area 8.8 The requirement for Rig packing is that the toilets must be within 500m of the work area. Where showers are provided for employees there must be a system in place to ensure the shower heads do not pose a potential contamination / health risk to employees e.g. Health and Safety Legionella controls. Sites providing food service must complete a documented HACCP for this service. If a contractor is used, their HACCP must be reviewed. Basic hygiene and food safety audits must be completed on a scheduled basis by an appropriately trained person. Canteen staff must have medical screening prior to commencement of work and be suitably trained in basic food hygiene. Hairnets covering ears must be worn. Hygienic storage facilities, including refrigeration must be provided for employees bringing their own food. The temperature of refrigeration equipment must be monitored. Where preparation equipment (e.g. microwave) is provided it must be inspected and cleaned regularly. Consumption and storage of food must only be in designated areas. Field workers should not have food or drink within their working environment. Head covering must be worn by all personnel. (If food is not exposed, hair nets and beard snoods are not required). Legionnaires’ Disease: The control of Legionella bacteria in water systems. Approved Code of Practice and Guidance 2000 (www.hse.gov.uk) 8.9 8.10 Canteen / Rest Area Canteen / Rest Appropriate person should hold a certificate in food hygiene 8.11 Canteen / Rest Area A scheduled temperature check on refrigeration equipment is undertaken. A cool box may be provided to allow staff to leave their lunch in a hygienic location. PPE lockers should not be used to store food. However, food can be stored in personal lockers providing the lockers are part of the cleaning schedule with a defined frequency. For product sold loose, hair need not be fully contained and a clean company issue hat that is regularly laundered / disposable would suffice. For product that is packaged and the consumer is unlikely to wash before use (in spite of label instructions), full head covering that is disposable 8.12 Head Covering Tesco Produce Packhouse Standard Version 1.2 Page 24 of 72 and fully encloses the hair must be worn. Both above Applicable to in field operations and production areas. Different coloured gloves/ coats/footwear or coloured collars on coats may be used to aid specific staff roles. Items such as baseball caps and fleeces are acceptable. Protective clothing must be free from external pockets, buttons and not have access to own pockets. 8.14 8.15 Protective Clothing Protective Clothing Laundry Coats/jackets must be removed before entering toilets, canteen/rest areas, smoking areas and offices (outside production areas). Frequency of changing protective clothing (including re-usable aprons, gloves, high visibility vests and hard hats) and disposable items must be defined and verified. Effective laundering of protective clothing must be completed in a hygienic environment and verified. Non- perfumed detergent to be used. Protective clothing for engineering, hygiene (and where applicable laboratory) staff must be laundered separately to food production work wear to prevent possible foreign body contamination. This may be in house or by an external company. In certain circumstances home laundry programmes and line drying may be permitted with approval of Tesco TM. Staff should not wear PPE to and from work. Suitable footwear must be worn (No open toes or high heels). Footwear must be kept clean. Where automated boot washing or footbaths are used, these must not be positioned in production areas and must be cleaned to an adequate frequency. Where auto-dosing of chemical is incorporated, the concentration should 8.13 Protective Clothing Where protective clothing is supplied it must be worn to minimise the risk of product contamination. Protective clothing must be visually distinctive for staff in specific areas/roles where appropriate i.e. maintenance and cleaning personnel. Protective clothing must be maintained in good condition. Frequency determined by visual assessment. 8.16 Where external laundry providers are utilised, these should be approved and a specification for the garments held. Effective laundering by visual assessment of PPE. 8.17 8.18 Footwear Boot washing Boot washers and footbaths do not negate the need for scheduled cleaning. Tesco Produce Packhouse Standard Version 1.2 Page 25 of 72 be regularly monitored. i. 8.e. hair covering must be put on first and taken off last.2 Page 26 of 72 .19 Changing Procedure Where hair must be fully captured in appropriate head coverings. Tesco Produce Packhouse Standard Version 1. the changing procedure must protect PPE from hair contamination. Hoses / cleaning lance ends must not be left on the floor or in tanks when not in use. Cleaning equipment used for toilets must be segregated and visually distinctive.2 Page 27 of 72 . Separate equipment must be used for food contact and floor cleaning. Wall mounted cleaning equipment must be returned in a clean condition. 5. Methods of cleaning must not pose a risk of contamination or generate aerosols. 9. Dry cleaning e.Section 9 Section No. 9.5 Cleaning Equipment Tesco Produce Packhouse Standard Version 1. What Good Looks Like E. High pressure lines (>80 psi.4 Cleaning Equipment 9.g. 5.e. Where in place. brushing may be sufficient in some produce facilities 9.5 bar. Cleaning equipment may be differentiated visually by type and or colour.g.2 Factory Hygiene Item General Hygiene General Hygiene Detail Equipment and facilities must be maintained in a clean condition appropriate to its function (also see section 29 Cleaning Programme). The site must operate a ‘Clean as You Go’ Policy with personnel responsible for maintaining a clean and tidy working area. Graders cleaned at a frequency appropriate to prevent excessive build up of contaminants. which could contaminate nearby products or surfaces.1 9. in a good condition and stored away from product and production lines. Cleaning equipment must be fit for purpose Cleaning equipment must not be stored in contact with the floor. (they must be clean.g.3 Cleaning Equipment (e. heat set bristle brushes used for food contact surfaces) Mops are permitted in open food areas but must be controlled. These must be stored separately from one another. i.6 Kg/cm) do not need backflow protection. Hoses and chemical dosing equipment fitted to water supply must have back flow prevention devices installed. colour coding of cleaning equipment must be prominently displayed with equipment. Where floor cleaning equipment is wall mounted it must be stored handles up. Waste and effluent management must comply with local enforcement requirements. no phenolic or scented products.9 9. Facilities should be in place for segregation and collection of recyclable materials. not on the floor). Tesco Produce Packhouse Standard Version 1. All containers for cleaning chemicals must be correctly labelled and used for their intended purpose only.13 9. They must be managed to ensure a tidy pest free environment. It is recognised that not all sites allow staff sales or giveaway. on racks or stands. the Tesco branding and barcode must be masked by an indelible marker or a non strip label.4) Chemical dilution checks must be completed at a defined frequency for all dosed equipment (manual/automatic) based on risk assessment.8 9. Chemicals must be separated in storage to prevent accident e. Cleaning chemical storage in production areas must be kept to a minimum.11 9. Where pallets are used to store these trays. However where allowed it should be controlled.10 9. Waste trays /containers should be a solid type of tray with no holes and a different colour to those used in food production. Trays of Work In Progress or finished product must not be placed directly on the floor (even if dirty and waiting cleaning). In cases where it is not possible to remove the packaging. Tray wash equipment must be operating at the correct temperature with correct chemical type and dilution. Clear signage must be in place.g. Equipment must be kept off the floor (e. External waste containers must be covered and segregated. ASPIRATION Where staff sales or free product to employees is instigated a sales policy should be in place. (see clause 29.2 Page 28 of 72 .7 9. these should be clean and free of potential contamination. acids / chlorine based chemicals.9. 9.12 Cleaning Chemicals Cleaning Chemicals Cleaning Chemicals Production Equipment Tray Wash Production Trays 9.16 Waste Waste Waste Waste/ Staff Sales Cleaning chemicals must be used according to the manufacturers’ instructions including temperature and dilution. This is Any rejected Tesco labelled product must be securely disposed of through a Tesco authorised route or the Tesco packaging must be removed.g. The site should have full control over surplus stock and know the quantities of product.14 9.15 9. Prior to any surplus labelled stock being made available for purchase the Tesco brand must be removed.6 Cleaning Chemicals Cleaning chemicals must be suitable for a food environment e.g. Health & Safety guidelines must be followed. Fare share 1st and Company Shop Ltd are the two authorised routes for disposal of surplus stock in the UK.particularly important for traceability and or product recall. Tesco Produce Packhouse Standard Version 1.2 Page 29 of 72 . Fareshare 1st is a national charity that redistributes the food through a community network to disadvantaged people). (UK Only – If product is not stripped. understand and accept health.Section 10 Section No. 10. Procedures must be in place to highlight if a plaster is lost and prompt an investigation to ensure that the plaster has not contaminated product must be completed. including visitors and contractors. Fingernails must be kept short. All cuts and grazes on exposed skin must be covered by a waterproof blue metal detectable plaster / wound dressing provided by the factory and issued by an authorised person (a log must be kept). What Good Looks Like 10. Food / drink must not be consumed in production and storage areas (except water when provided by site).g. Wet hands 2. touching the floor. hygiene and safety rules prior to entering the production area.3 Hand Washing 10.7 10. coughing /sneezing into hands. Spitting must be prohibited in all areas. tying laces or handling unsuitable materials (this is not an exhaustive list). There should be plaster reconciliation at the end of the day or shift. applying sun cream.4 10.5 10. clean and unvarnished. touching the face / nose. Despatch Personnel must not cough or sneeze over materials or products. Where metal detection is not used on site.8 Plaster Control Personal Hygiene Tesco Produce Packhouse Standard Version 1.2 Hand Washing 1. Rinse with water 5. Visitors and contractors must be required to read. the plaster does not need to be metal detectable but must still be blue. Personal hygiene standards must be documented and followed by all personnel.repeat each area 5 times. Hand washing or sanitising must be completed on entry to food handling areas e.2) when they commence work but may subsequently use hand sanitizer on entry to non food handling areas e. (packhouses/packing rigs etc) and after the following: eating. 4.6 Hygiene Procedure Hygiene Procedure Plaster Control A plaster register must be in use to cover the issuing and return of all issued blue plasters. smoking.1 Personal Hygiene Item Personal Hygiene Detail Effective personal hygiene standards must be in place at the site. Rub palms and back of hands/ thumbs and between fingers . Apply soap 3. 10. using the toilet. Dry hands 10. Non food handlers must wash hands (as per clause 10.g.2 Page 30 of 72 . 14 Personal Hygiene Personal Hygiene Personal Hygiene Personal Hygiene Personal Hygiene Jewellery All personnel must have a good standard of personal hygiene.10 10. 10.13 10. In these circumstances a risk assessment must be completed and the permitted jewellery must be strictly controlled. Personal clothing should not pose a potential foreign body risk e. Jewellery must not be worn.e. keys. sleeves and or gloves) Tesco Produce Packhouse Standard Version 1. Procedures must be in place for the breakage/loss of glasses and contact lenses.11 10. Cufflinks and tie pins must be considered as jewellery. Watches must not be worn or brought into production and storage areas. personal mobile phones and coins) must not be taken into production and storage areas.15 Jewellery Jewellery should be suitably covered by the PPE (coat.g. Excessive perfume or aftershave must not be worn.individual's locker key will be only permitted item and or religious jewellery Mobile or self propelled packing stations have the same standards and requirements as packhouses. Additional jewellery may be permitted if it is worn for medical or religious reasons. Exception . False eye lashes or excessive facial make-up must not be worn.9 10. Personal items (e.2 Page 31 of 72 .False fingernails must not be permitted. decorative items such as sequins should not be sown on garments. with the exception of a single plain band ring (i. Others rings and studs in exposed parts of the body must not be worn. or plain sleeper/stud earrings.12 10. Staff such as picker in field situations where they do not pose a risk to finished product should be risk assessed if any jewellery is to be allowed. no stone settings and one piece).g. 10. 8 Temperature Control Systems for managing minimum and maximum shelf-life when delivered to Tesco must be in place (e.5 11.g. A defined area must be identified and marked out for the storage of quarantined finished product.6 All decisions must be risk assessed in line with the nature of the incident.g.2 Process Deviation Hold and Release 11. Tesco must be notified immediately of any illegal and or unsafe products which have been produced and despatched. Temperatures must be retained within the set quality parameters for the relevant product. must be controlled. A documented ‘Hold and Release’ procedure must be in place to manage non conforming materials or products. then corrective action must be taken and documented. re-grade or reject it What Good Looks Like Product should never be re-worked following a Tesco rejection for quality. this must include: • • • • • The nature of the incident Time and date material or product is put on hold or quarantined How it is identified The method to ensure all affected product has been isolated How and who has the authority to release the product. A temperature monitoring system must be in place e. 11.g. In some instances e. As a minimum. Product stock rotation may be determined by maturity rather than strict “First In First Out” Evidence of decision-making on stock usage should be available Ensure retention periods and storage conditions for samples have been agreed with the Tesco TM. Tesco Produce Packhouse Standard Version 1. Procedures must be in place to ensure materials and products are used in the correct order and within the allocated shelf-life.4 Hold and Release Product Control Product Control 11. This can be via portable/retractable barriers. when received by Tesco). when they are critical to product safety.1 Process Controls Item Process Control Detail Raw materials. processes and equipment. 11.7 Shelf Life 11.2 Page 32 of 72 . 11. If the product deviates from the agreed specification the Tesco TM must be notified. maturity may be used to determine order of use. manual documented checks.3 11.g. work in progress. legality or quality.Section 11 Section No. Underweight packs may get re-worked. monitored and recorded. If the product deviates from specification / procedure. The exception is e. minimum number of days a product must have until the end of its shelf life. with fresh produce. finished product. Tesco Produce Packhouse Standard Version 1.g. Procedures must be in place to take appropriate corrective action for the handling of raw material/product when the storage temperature is outside the specified tolerance.11 Product Control The system should be able to account for when temperatures fall outside of the set ranges. pungent materials (due to taint).11.10 11. (Also reference section 13). Product segregation during processing and storage must be in place for the control of materials with special handling requirements e.2 Page 33 of 72 . organic. allergenic. At start up and changeovers production lines must be clear of all previous product and packaging.9 Temperature Control Product Control 11. Traceability exercises should be completed within 4 hours. Tesco Produce Packhouse Standard Version 1. packaging and finished products (minimum twice per year). Farm records may take longer with a maximum of 24 hours but all suppliers must be identified within the 4 hours. Where membership of a specific scheme requires additional traceability exercises (e.2 Page 34 of 72 . work in progress and packaging used. 12. What Good Looks Like 12.2 12. some agricultural schemes) the minimum requirement would be based on the specific scheme.Section 12 Section No.g.3 Traceability System The trace from origin of raw materials to finished products.1 Traceability Item Traceability System Traceability System Detail Procedures must be in place to enable traceability of product from a finished pack back to all processes involved in the manufacture including the raw materials. takes less than 4hrs to gather relevant evidence for presentation. including records of all critical processes. The factory must be able to demonstrate that traceability procedures work effectively by completing traceability challenges on raw materials. g. All sites must have a written allergen risk assessment which includes details of all processes. Information must be obtained from all raw material suppliers concerning all Tesco recognised allergens or sensitive materials they handle on site. Where allergens are used. If the Risk Assessment forms part of the HACCP it will need to be clearly demonstrated. allergens should be scheduled at the end of the production period or alternatively product lines not containing allergens. Utensils used in preparation or associated with allergens must be dedicated and colour coded in raw material areas/and external packing rigs. 13. through wearing/using coloured disposable protective equipment (and cleaning materials) ASPIRATION What Good Looks Like Allergens risk assessed individually. All equipment (including production lines and utensils) used for production of allergenic products must be chemically cleaned (dismantled where possible) prior to production of non-allergenic product. The effectiveness of the cleaning process must be verified (test kits for a number of specific allergens are available).6 Equipment Where allergenic products are harvested and/or packed clarification by use of different coloured utensils for the above should be instigated. If dedicated lines (for allergens) are not in place. no grouping or hierarchy.Section 13 Section No.Allergen Control and Tesco Requirements in the Tesco Code Of Practice 117 . 13. Allergens and sensitive raw materials must be stored in a segregated marked area (nuts must be stored in a restricted access area).9 Personnel Tesco Produce Packhouse Standard Version 1. All staff (including agency) must receive allergen training as part of the site induction. Where allergens are used or stored the risk assessment must establish the potential for cross contamination. Personnel working with allergenic product should be clearly identifiable e. run on clean lines at start of a shift.5 Specifications Storage Equipment Cleaning 13.4 13. products and allergens used on site.1 Allergen Control Item Allergen COP Detail All sites must comply with the requirements as detailed in Tesco Code Of Practice 376 . 13. The risk assessment must include all processes and areas of the factory.8 Personnel 13.7 Segregation 13. staff must be aware of the risks regarding cross contamination.2 Allergen Controls 13.3 13.Nuts.2 Page 35 of 72 . Audits must be completed on all registered items at a frequency determined by risk assessment. If this is not possible. whether product has been put at risk. paper.Section 14 Section No.g. hard plastic. 14. Glass in production and storage areas must be replaced with suitable alternatives. broken. All glass and hard clear plastic in production and storage areas must be listed on a register. This should include: • • • • • • • • Stopping of production Restriction of movement through the affected area Quarantine of affected materials Report to management Clean up of breakage and disposal/cleaning of cleaning equipment Safe removal of glass from area Repair or replacement of damaged item The checking of PPE (including footwear) and changing if necessary What Good Looks Like Where finished product or raw material is handled or stored within an area without adequate controls.2 Glass 14. A detailed procedure must be in place for the management of glass and hard plastic breakages. string. 14. damaged but intact. A risk assessment must be completed to determine how quickly repairs must be made.4 Register Glass Audits Glass audits should include rig packing equipment (i. undamaged but not working. pallet toppers must be used. the glass items must be protected. tractor and trailer). E. personal effects etc.e.2 Page 36 of 72 . Any issues raised must be investigated to establish if the glass breakage procedure has been followed and if not.g.3 14. What equipment is used for the clean up of breakage? (a specific colour.5 Glass Breakage The site has a procedure that follows a logical sequence and has sufficient detail to manage the incident. including glass. intact. maintenance debris. The audit must record the condition of the item e. type or dedicated for glass breakage only) How it’s to be used? (glass maybe on equipment and floor) What happens with equipment after use (cleaned and returned to an office or disposed?) In Field operations it is sensible to quarantine areas in block/row form rather than areas of circumference. metal. tape. wood.1 Foreign Body (FB) Controls Item FB Controls & Risk Assessment Detail The site must have a documented risk assessment and corresponding policies and procedures for all potential foreign body hazards. Tesco Produce Packhouse Standard Version 1. where possible. 14. 2 Page 37 of 72 . Knife. All knives / scissors issued will be individually numbered to ensure they can be accounted for including knives used in fields.7 Wood 14.8 14. based on a robust risk assessment may include: • Layer separation between pallets and product • Coverage of materials stored under wooden pallets on racking systems • Broken pallets removed from the system • Demarcation of where wooden pallets are permitted within the site • Wooden boxes where used are in good condition and/or there is a system of repair (e. clip boards. Corrective action must be taken to prevent re-occurrence Knife and blade sharpening must take place away from production areas and equipment must be returned in a clean condition Controls. pencils.g. There must be appropriate systems in place for the prevention of metal contamination. brooms etc).14. Potato or Onion boxes) No sticking out nails or screws. Tesco Produce Packhouse Standard Version 1. no partially attached slats that may detach in normal use. Apple. • 14. furniture. must be in a good condition and not pose a contamination risk. it must be minimised and suitably controlled. Where wood cannot be eliminated in production and storage areas e.6 Training Completion of an incident log and sign off that production can restart • A sample of broken glass should be retained in a safe manner • Corrective Action to prevent reoccurrence All employees must be briefed on the glass breakage procedure at induction.g. use of pallets. All production/hygiene managers must be trained to understand and apply the glass breakage procedure.g.9 14.10 Wood Metal Control Equipment Wooden pallets destined for Tesco depots. blade. scissors and needle control must be in place and include: • • • • • • Only company issue. all parts must be accounted for and the incident logged. hand tools. captive. identified and registered knives and blades must be used No snap blade knives must be used Knives and blades must only be used for the task for which they were designed Equipment must be accounted for and the condition checked and recorded (minimum start and end of production) In the event of breakage or loss. The use of wood within the site production and storage areas where possible must be eliminated (e. g. bolts etc. Cardboard boxes are opened correctly to prevent ripping.13 14. secured clean storage.g. packing or storage areas (other than in locked and managed display cabinets). The use of Tesco trays or punnet trays (e. All pens used within production. rulers. 14. plastic trays. calculators. must not be permitted. The number of miscellaneous items must be kept to a minimum. Storage and packing areas are regularly swept to remove card shards from packing boxes.2 Page 38 of 72 . Shadow boards. Staples used where no alternative is viable by exception and prior Tesco TM approval.g. magnetic holder.e. no lid) factory issue pens with no clear plastic parts in production and storage. All damaged product containers and trays (including bulk wooden boxes) must be removed from the system and corrective action implemented to prevent reoccurrence. Metal detectable pens. Staples and drawing pins must not be permitted in production.12 Equipment Foreign Body Control Foreign Body Control Miscellaneous Items Knives and blades must not be stored in personal lockers. 14. one piece and of a contrasting colour. (These may be of the impregnated plastic type or of metal construction) Alternatives to staples and drawing pins are available should be used wherever possible. foil trays etc) to store other materials e.15 Cardboard Control The use of cardboard in production areas must be managed / controlled. Tesco Produce Packhouse Standard Version 1. in sites where metal detectors are used.14 One piece (i. nuts.11 14. Required miscellaneous items must be of a contrasting colour and managed e. storage and packing areas must be site issued.14. Equipment must be upgraded to improve detection sensitivity where advances in detection are developed. A detailed procedure must be in place to handle incidents when metal is found in material. A full investigation must take place to ensure the source of contamination is identified and the risk of other materials being contaminated must be assessed. The operation and sensitivity of the detector in use must be well understood by relevant site personnel. 15. The checks must be recorded. colour sorter or magnets) must be specified as appropriate for the products that are being examined. Each batch of metal detectable plasters must be checked to ensure they are detected by the lowest sensitivity metal detector. Foreign body detection equipment (metal detector. Corrective actions must be put in place to prevent a recurrence. 15.2 Equipment 15. Record details of the investigation.5 15.6 Training Tesco Produce Packhouse Standard Version 1. either by the equipment manufacturer or trained contractors (minimum annually). The foreign body detection system must be serviced at regular intervals.1 Foreign Body Detection Item Tesco COP Detail Where metal detection is used All sites must comply with the requirements as detailed in Tesco Code Of Practice 375 .3 Equipment 15. In the event of any detector test failing (whether due to failure to detect a test piece or failure to reject product) all material that has been checked since the previous satisfactory test must be isolated and retested through a unit that has been confirmed to be working correctly. All staff involved with foreign body detection must be trained not only in the technical and operational aspects but also the principles of metal What Good Looks Like Where risk assessment or Tesco TM deems foreign body detection is required the equipment should be properly specified as appropriate for the product being examined. x-ray.Metal Detection.4 Plasters / Wound Dressing/ BandAids Detector Failure 15.2 Page 39 of 72 .Section 15 Section No. and foreign body detection to ensure full understanding of the purpose.7 Foreign Bodies Procedures must be in place for actions when foreign bodies are found. Details of the investigation must be recorded. A full investigation must take place to ensure the source of contamination is identified.2 Page 40 of 72 . 15. Tesco Produce Packhouse Standard Version 1. do not need laboratory accreditation.2 Laboratories For UK/ROI – Laboratories must have a current accreditation (UKAS. Action and investigation must be evident where results fail to meet specified limits. What Good Looks Like 16. The scope of accreditation must cover all tests undertaken.2 Page 41 of 72 . organoleptic and other specific requirements. All tests performed by the laboratory must be accredited by their in country national accreditation body. CLAS or LABCRED) and if applicable be registered on the Tesco Approved Laboratory Scheme.3 16. Testing must be conducted in accredited laboratories. to ensure requirements are met. Laboratories must participate in proficiency / correlation testing. The manufacturer must be able to demonstrate that the methods used for their product testing are included in the scope of the laboratory approval.1 Inspection and Analysis Item Product Testing Detail Finished product testing must be completed to ensure compliance with Tesco Product Specifications for microbiological. Procedures must be in place to cover reporting of routine results and out of specification results. 16. Ongoing trend monitoring system must be in place. quality sampling etc.5 Reporting Action/ Investigation Trend Analysis Tesco Produce Packhouse Standard Version 1. A sampling plan must be in place and followed. Routine QC checks which are completed in a laboratory environment such as measuring dimensions of the product. 16.Section 16 Section No. physical. chemical. Accreditation must be by an internationally recognised country body.4 16. 6 Water Supply .Section 17 Section No.Ice All ice whether produced on site or purchased will be microbiologically tested against a set schedule. the water must be tested at the start of each season until the season is completed. the potability must be demonstrated on a continuing basis. certificates of potability from the provider are acceptable.g.2 Water Supply Where product misting systems are in use they must use potable water. chemical and physical parameters.4 Water Supply Water Supply Public Water Potability testing must be completed by accredited laboratories covering microbiological. 17. impact on environment and waste management. storage. 17.5 Water Supply Private Water 17. handling. Tesco Produce Packhouse Standard Version 1. treatment. Additional testing may be required based on risk assessment.2 Page 42 of 72 . Where risk assessment deems potable water is acceptable for process operations (e. (Guidance should be sought from Tesco TM especially in locations where water may not be of potable quality). Where water is from a private source. The composition of water delivered to the site must be known and the standard required for use in production as an ingredient (whether as water. pre-washing of produce) this must be agreed and signed off by the Tesco TM.g. If non potable water is used on site it must be segregated and controlled e. for toilet flushing. for cleaning or other uses must be defined. Potability must meet local requirements as a minimum. 17. Water used in processing food. The assessment scope must include source. ice or steam). Ice manufactured on site must be tested for microbiological levels as per other water testing (at a minimum of twice annually). as an ingredient or for cleaning must be potable. If certain water sources are only used seasonally. What Good Looks Like Assessment includes the consideration of Legionella and Cryptosporidium.1 Water and Waste Water Management Item Risk Assessment Detail A risk assessment must be completed on water safety/quality. Certificates of potability must be provided minimum 6 monthly.3 17. 17. Water may be sourced from a Public (mains) supply or from a private source. Where water is from a Public supply. Dead ends on potable water lines must be eliminated.9 Water Treatment Water Plan Automated controls and an alarm mechanism should be in place to notify management if levels fall outside set limits. ASPIRATION There must be a schematic plan of all water circuits within the site which is reviewed annually.10 Water Storage 17. Where water treatments are in place they must be monitored to ensure they remain effective through monitoring of critical parameters. 17. Sewage disposal must not compromise food safety or employee health. Tanks must be inspected and cleaned at frequencies determined by risk assessment.11 17. There must be a backflow prevention device fitted to main water lines. free and total chlorine. contact time and pH during use. Waste water and sewer drains must not be vented inside the facility.2 Page 43 of 72 . A site using chlorination as a treatment has a system in place to monitor and record dosing levels. 17.17. Potable and non-potable water lines must be identified throughout the site. Bulk water storage facilities must be constructed from approved materials.7 Water Treatment Purchased ice must have an annual certificate of potability. of a size that prevents stagnation and designed to exclude light and pest entry.12 Water System Waste Tesco Produce Packhouse Standard Version 1.8 17. Labels used for special promotions must be highlighted on the coding schedule with start and end date of labelling clearly stated.4 Control of Coding 18. 18. midnight or start of shift). Records with actual copies of the label must be authorised and retained.g. hourly intervals.2 18. Printed labels must be kept from the start and end of the print run. the area must be clear of all packaging (including promotional packaging). These labels must be authorised. An ‘Issue’ log must be kept. barcode 18.1 Product Labelling and Coding Item Packaging Supplied To Production Detail Packaging supplied to the production must be controlled and checked to ensure it is correct and for the right product. All unused coded packaging must be accounted for and disposed of. Product labelling and coding checks must be completed and documented at start up. Changes in month and year must be highlighted on the coding schedule. Also encompass all necessary detail i.g. The time of any code changes must be agreed with Tesco and documented (e. An ‘Issue’ log must be kept.Section 18 Section No.5 Control of Off Line Printed Packaging If codes change before midnight. Coding schedules and promotional information must be cross-checked by an authorised person prior to issue. end of run.6 18. Country of origin. At start up and changeovers. The material must be stored in a restricted access area until issued to production.2 Page 44 of 72 .3 Packaging Changeover Control of Coding Coding information on the schedule is written in the same format as that on packaging. The correct document controlled coding schedule must be available on line with the date information.e. The authorised person has been trained and assessed as competent. 18. what time does the code move to the next day e. date code. All off line printing must be controlled and checked.7 Control of Coded Packaging Product Labelling In the case of printed boxes/bags it is acceptable to cut out and retain the coding information only for the Tesco Produce Packhouse Standard Version 1. agreement in writing from the Tesco TM must be available. Changes in bold or in a contrasting colour. All coding information applied to a product must be correct and reflect the requirements as per the specification. in between and after What Good Looks Like 18. The material must be stored in a restricted access area until issued to the production line. This should be supported by shelf life data. g. 18. (see section 19) labelling and coding checks must also include: • Price per unit (e. fire.2 Page 45 of 72 . Where product catch weight systems are place. breaks).8 Product Labelling 18. 18.9 Control of Barcodes Barcodes are verified using scanners or in store for validation and the till receipt should be checked and retained.line disruption (e. A labelling and coding procedure must be in place and include action to be taken in the event of an error. purpose of traceability.g. All personnel carrying out labelling and coding checks must be trained against the procedure. Coding checks must be completed for all runs (including ‘top up’ runs) and records including physical labels / sleeves retained to support each check.10 Control of Coding Tesco Produce Packhouse Standard Version 1.alarm. per Kg) • Manual price confirmation • Barcode confirmation • Packaging tare Barcodes on all packaging must be checked against Tesco issued information before the packaging is used. On line printed bar codes must be checked and recorded at regular intervals. breakdown. Volume. over their entire shelf life.2 Page 46 of 72 . volume and tare verification checks should be completed hourly (or more frequently with smaller batch sizes). Procedures must detail the actions to be taken if the results fail to meet specification. Where statistical methods are used to manage weight or volume.4 Weight/Volume Control Weight. allowance may need to be made for weight loss during transport and display. must be documented. In the case of desiccating products. equipment and training must be in place. 19. For products that comply to EU average weight/volume legislation (agreed as part of the Tesco product specification): • • Records must show the individual average and upper/lower results for each check Procedures must detail the actions to be taken if the mean average or upper/lower results for the batch results fail to meet specification What Good Looks Like 19. volume and count for each product manufactured that conforms to legal requirements in the country of manufacture and the intended country of sale. Results should be signed off by a competent individual at the end of each batch.2 19.Section 19 Section No. In countries where applicable. if no allowance for desiccation is made. appropriate procedures. For products manufactured outside of the EU and not destined for sale Tesco Produce Packhouse Standard Version 1. the extent of desiccation in those products. All sites must comply with the requirements in Tesco Code Of Practice 378 . the product must conform to Tesco specifications.1 Weight.3 Procedure Weight Control 19.Contents Control. Where the quantity is not governed by legislation. Size and Count Checks Item Procedure Detail Sites must have a clear documented policy and procedure for the management of weight. Line speeds (and batch sizes) must be taken into account when determining frequency of weight and volume checks. Records must show the individual finished pack results for each batch. All automated content control equipment must have adequate security devices. top labels are not applied and dedicated personnel remove these packs from the line. Procedures must be in place to ensure that the correct numbers of items are present in the pack when a number has been declared. A system should be in place to verify the pack rejection mechanism is effective. Similar systems may be utilised for catch weight product where defined weight bands are required. weight checking equipment must be approved by the relevant Government Inspection or Enforcement officer.6 Automated Weight Control Automated Weight Control in the EU. 19. 19.19. standard deviation and control limits where the legislation is applicable (e.2 Page 47 of 72 . The weights used to verify this must be calibrated or checked against calibrated weights on a predetermined frequency.10 Equipment Settings / Security Tesco Produce Packhouse Standard Version 1.g. All scales and equipment used for finished product weight control must have documented verification checks at a minimum frequency of the start and end of production day as part of the calibration process.g. volume and count must conform to legal requirements in the country of manufacture and the intended country of sale e. T1 & T2 EU average weight)] for samples and whole batches. Where automatic reject systems are not in place methods of identifying and segregating non conforming products must be in place e.g. rejected products must be rejected into a locked bin. Where ‘In-line’ check-weigh systems are used and an automatic reject system is in place. Products packed to either minimum or average pack weight (where applicable) should utilise automated check weigh systems ASPIRATION Where ‘In-line’ check-weigh systems are used they must be capable of recording minimum or average weight data (where the legislation is applicable) and providing a printed record of weights [mean average. the procedures for weight.8 Verification of Weight Control 19.9 Count Control Dedicated personnel are in place to count the items on the line. Documented checks of product count must be in place. Where required. Records should be signed off at the end of each batch. Maximum Allowable Variance in the US.5 19.7 Weight Control 19. so only authorised personnel have access to alter settings. use of a translator) A documented induction training programme must be given to all new starters. pictorial training aids. (Copies of certificates may form part of these records e. wrong answers should be closed-out to demonstrate full understanding. 20. Documented and agreed job descriptions (or working instructions) must be available for all personnel.2 20. pesticide application records). The competency of employees must be reviewed at defined intervals and re-training undertaken where necessary. 20. irrespective of their national origins. The level of language understanding must be known for all personnel (including agency or temporary personnel).2 Page 48 of 72 .6 Job Descriptions All personnel must have a clear understanding of what is expected of them in their job roles. Training must be delivered by competent and capable trainer/s (may be in company or external).g. A training matrix should be available showing which employees are trained in which activities. including agency and temporary personnel before they start work.8 Training Records Review 20.Section 20 Section No. (This may be translated documents. Records must be signed and dated by the trainer and trainee. All personnel must have a basic understanding of food safety before they start work. instruction.1 Training Item Training Detail The site must ensure that all personnel are adequately trained. trained and able to train others).7 Specific Training/records 20. ‘Train the trainer’ qualified trainers or based on company size technical managers that can demonstrate competence Where tests are used. specialist or job specific training must be available. (Matrix should also demonstrate those untrained. training and supervision in an understandable format for all workers. Induction training records must be available for all personnel. in training. Safe use of chemicals.9 Tesco Produce Packhouse Standard Version 1.5 Induction / Food Handler Training The induction includes: • • • • • Food safety Personnel hygiene procedures and rules Glass breakage procedure Health and safety Quality policy 20. instructed and supervised commensurate with their activity and are demonstrably competent to carry out their activity. first language or literacy.3 Literacy Training 20. What Good Looks Like This may be in the form of a literacy test.4 Training 20. Records of further hygiene. 20. The site must provide information. The policy must be authorised by senior management. There should be a documented action plan in place to address anomalies identified.3 21.7 Organisational Structure Deputising Cover Document Retention Record Completion For produce traceability records should be kept for a minimum 24 months 21.Section 21 Section No. Details of deputising cover for personnel with responsibility for legal and safety issues must be documented.5 21.1 Quality Management System Item Quality Management System Detail The site must have a Quality Management System (QMS).2 Page 49 of 72 .2 Quality Policy A Quality Policy Statement must be in place stating the company's intentions to produce safe. All employees must be aware of the policy by displaying it in employee areas. An organisational structure chart must be in place showing management authority.8 Tesco Produce Packhouse Standard Version 1. The QMS must contain procedures/records as required by the Tesco Produce packhouse standard. What Good Looks Like The site will conduct a gap analysis against the current site QMS systems and the Tesco Produce packhouse standard. legal and quality products. All documents must be adequately controlled. All records must be accurate and fully complete. which is maintained and regularly reviewed. A quality manual must be in place and available to key employees outlining company policies and procedures. All documentation and records must be retained for a defined period and available for review within 4 hours from the request. 21. authorised and be of the correct version. Alterations to records must be appropriately authorised. Where QMS extend to field/orchard based operation SOP may be in place.6 21.4 Quality Manual Document Control 21. 21. 21. count.1 Product Development Item Product Claims Detail Where product claims are made.g. country of origin. weight.Section 22 Section No. size. What Good Looks Like Evidence available to demonstrate claims (e. Nurture. organic etc) Tesco Produce Packhouse Standard Version 1.2 Page 50 of 72 . 22. documentary evidence must be available on site to substantiate these claims. variety. Section 23 Section No. flood and other natural disasters Sabotage and malicious contamination Vandalism and terrorism Food safety. A communication plan must be in place to manage potential incidents.2 Contacts The likelihood of the occurrence of the above issues must be risk assessed. Key contact information must be maintained including: • Internal contacts (in and out of hours) • Customers (in and out of hours) • Suppliers (raw materials and services) • Government/Enforcement bodies Each site must have a recall plan in the event that food safety. legality and quality.3 Recall Plan Any communication with bodies such as the UK Food Standards Agency (regarding Tesco branded products) will be co-ordinated by Tesco. 23. water and energy supplies.2 Page 51 of 72 . labour and communications Fire. The procedure must include in detail: • • • How to report an incident to Tesco The full process of traceability identifying key points in production and distribution How product will be withdrawn or recalled from distribution and sale 23. Including: • • • • • Disruptions to distribution. legality and quality issues What Good Looks Like 23. All affected products must be located within 4 hours of the withdrawal/recall being started. The withdrawal/recall of Tesco brand products from Tesco stores will be Tesco Produce Packhouse Standard Version 1. Reconciliation of product must be verified against production records. legality is in doubt.1 Product Recall/Incident Management Item Incident Management Detail Procedures must be in place to manage all incidents and potential emerging issues which could affect food safety. and the Incident Management Teams understand of.4 23.2 Page 52 of 72 . The results of the test must be investigated and where corrective action is required this must be implemented. 23. There must be contactable cover at all times. the Recall Plan and Incident Management Procedures (minimum annually).managed by Tesco. A mock recall (or mock incident) must be undertaken to test the effectiveness of. Tesco Produce Packhouse Standard Version 1.5 Training Mock Recall/ Incident There must be a trained incident management/recall team with named deputies. The completion of corrective actions within agreed timescales must be verified.7 Tesco Produce Packhouse Standard Version 1.Section 24 Section No.2 Internal Audits 24. All elements must be audited at a defined frequency. Audit reports must detail non-conformances and recommendations. legality and quality are maintained.1 Internal Audits Item Quality Management System Audits Detail Internal Audits of the Quality System must verify whether activities comply with the documented procedures. 24.4 Auditors 24. Audits must be conducted by trained auditors with experience in the area being assessed. As a minimum internal audits must include: • The HACCP Plan and CCPs • All aspects of the Prerequisite Programme • Good Manufacturing Practices (where not included as prerequisites) • Allergen Controls (where applicable) • Process Controls • Cleaning (to include an inspection during the main cleaning operation)Site fabrication • Traceability • Employment Agency • Recall Plan / Incident Management Controls • Off site storage of raw materials /packaging /finished product Audits must be scheduled throughout the production year and the scope and frequency of each one established.6 Corrective Actions Third Party / Tesco Audits 24.2 Page 53 of 72 . Audits must also evaluate the effectiveness of the procedures.5 Audit Records External auditors are acceptable. Audits must be completed to schedule.3 Audit Schedule 24. These must be brought to the attention of the person responsible for the activity audited. minimum annually. Records of audits results must be available. Additionally where the company is very small demonstration of competence by the technical manager is acceptable Records may be held on computer and printed off when needed 24. Agreed corrective actions arising from audits conducted by third parties/ Tesco must be implemented in agreed timescales and verified. policies and work instructions to ensure food safety. Timescales and corrective actions must be agreed by both parties. What Good Looks Like 24. 2 25. 25. Complaints from all sources must be covered in the procedure e. . If a withdrawal/recall is required Tesco must be notified using the incident management procedures. operational departments) • Output from quality assurance processes e. product or production line will trigger a review. taste panels Complaints from all methods of reporting (e.6 Trend Analysis Product Withdrawal Tesco Produce Packhouse Standard Version 1.Section 25 Section No.g.g. alleged illness and trends need to be investigated. telephone.: • Customer representatives • Stores • Central buying departments • Retailer customer complaints departments • Law enforcement bodies • Internal departments (e.1 Customer Complaints Item Complaints Procedure Complaints Procedure Detail A complaints policy and procedure to handle complaints must be in place. Full records must be kept and the outcome of the investigation promptly reported to relevant personnel and departments. 25. production teams and Tesco TM. What Good Looks Like A certain number of complaints linked by complaint type. Each complaint must have a unique reference number. 25. Isolated incidences where a customer doesn’t like the taste or there is a quality perception issue may not require a full investigation.5 25. This must be part of or linked to the site Incident Management Procedures where necessary. Corrective actions must be effective to prevent a re-occurrence.4 Complaint Handling All complaints must be investigated in detail by trained personnel. post.g. Information from trend analysis of complaints must be communicated to the site management.3 Complaint Handling 25. Complaint log includes: • Nature of complaint • Product information • Durability • Whether product sample has been requested etc All instances of foreign body contamination. and email) must be captured on a logging system. The investigation must determine whether the complaint is product specific or an issue which may affect more than one product.g.2 Page 54 of 72 . Where requested the full corrective actions must be reported to Tesco. whole site and any off site storage • Pest control programme must be reviewed annually. flying insects.Section 26 Section No. A current documented pest control programme must be available. products produced. crawling insects. These employees must ensure that the visit schedule is maintained and that the PCP is contacted where deviation from the arranged schedule occurs. type of materials handled and pest control methods to be employed. If the site is vulnerable to nocturnal pests e.2 Page 55 of 72 . The risk assessment must consider the location. 26. Company employees engaged as PCPs must have proof of appropriate training and licence as required by state or local regulations. cockroaches. The Pest Control Provider (PCP) may be a specialist company or a trained employee. 26.g.3 Pest Control Programme e.2 Pest Control Programme Mobile packing units/rigs should be secure and not allow for the entry/harbourage or contamination by or from pests. The pest control programme must be based on risk assessment. within dead spaces. Copies of the PCPs valid training certificates and licence must be available. 26. Same day service dependant on risk.g. the company is a member of a recognised trade association (applicable in the country that they are operating in).4 Training 26. Training of company employees can be by the PCP or other qualified • • • • • What Good Looks Like 26. Where the PCP is a specialist company. Tesco must be informed of continual/persistent pest activity at a site. stored product insects. night inspections should be included.g. 8-12 service inspections (evenly spaced throughout the year) and 4 in depth inspections from a field biologist (UK) or named senior pest controller per annum. The programme must stipulate the following as a minimum: The pest control provider The procedures used for pest control The pests covered within scope (dependant on country) A minimum number of visits must be specified Material Safety Data Sheets must be included for all chemicals used • Emergency call out details • Details of the site area included in the programme e. A trained company employee and nominated deputy must be accountable for managing the pest control programme. birds etc.5 Management & Supervision Tesco Produce Packhouse Standard Version 1. This includes high / low levels. rodents.1 Pest Control Item Pest Control Detail All sites must have an effective pest control programme covering the whole site and product must not be at risk from pest activity. 26. the password is known by more than one individual). Toxic baits must not be used routinely in open product and storage areas. Where an infestation is evident. canopies e. must be kept in the pest control file. a concession (to use toxic baits) is required from the relevant TTM before toxic baits are used. netting etc) must comply with in country legislation and not put product at risk of contamination. In country risk assessment make depict varying heights for EFK based on target insects. Where sites have bird activity. A full and detailed plan indicating positions and type (i.g. use of bird scarers. Bulbs in EFK units must be protected (shatterproof tubes) and changed according to manufacturer recommended or (minimum annually) with records available. actual sightings of rodents or recent droppings).8 Birds Tesco Produce Packhouse Standard Version 1. The position of Electric flying insect killers (EFK) must be determined by risk assessment. All points must be appropriately sited. Where electronic / paperless systems are in operation.7 Flying Insects Located at all entrances to the production and storage areas.2 Page 56 of 72 . the designated individual and their nominated deputy must have access to the system (e. over product lines or positioned to be blown out by air movement). must be sufficiently proofed / netted to prevent nesting birds. 26.g. Risk assessment must determine the sighting of Pheromone traps where deemed necessary. at loading bays etc. Pheromone must be replaced on predetermined frequency to ensure effectiveness. Activities to control birds (e.g. shooting. The position of EFK units must not pose a contamination risk to product (e. Baits must be secured to walls or floors to prevent removal. Bait boxes must be robust and tamper proof (to prevent removal of bait other than by PCP or pest activity).experts. 26. toxic/non-toxic) of all baits and monitoring equipment (internal and external).g.6 Pest Plan Toxic baits are only used where there is clear evidence of a problem (e.g.e. The PCP must report any proofing requirements identified.Lay new Insect Monitors . Where serious infestations are identified. Tesco Produce Packhouse Standard Version 1. There must be a full programme of follow up visits to ensure complete eradication of the issue e.10 Service Record / Visit Report 26.2 Page 57 of 72 . All pests and or evidence of pests must be reported. 26. any hygiene/ housekeeping conditions likely to effect pest prevention and any access difficulties/‘lost’ baits. Reports must be signed off by personnel responsible for pest control on site (or a designated deputy).Clear up every dropping every visit SPI (Stored products insects) . work completed. . During each visit activity/action reports must be completed by the PCP. observations of activity and recommendations. where there is infestation externally and additional baiting is in place then follow up visits should also be considered (this may not be alternate days. However. During routine visits all traps. including documentation of chemicals used. bait stations. and other monitoring equipment must be opened and inspected.9 Schedule PCPs visits must be conducted to the agreed schedule.11 Visit Follow Up Rodents -Alternate days until no evidence on 3 consecutive visits e g: Wed/Fri/Sun.In depth inspection of affected area plus all adjoining areas (including above and below) .g.26. if noted during the inspection (even if the pest type is not specified in the programme).Weekly Follow-up inspections Cockroaches -Treatment weekly for six weeks Alternate day follow ups are specifically for internal areas. the PCP must ensure the site representative understands the extent of the infestation and potential for product contamination.After deep cleaning and insecticide application where deemed essential . Follow up and verification of all corrective actions must be documented. Where used. sticky boards. live catch systems must be inspected daily or more frequently where required by in country legislation.2 Page 58 of 72 . monthly night-time inspections for 6 months.g. where activity is measurable. 26. are inspected every 12 hrs. where used. acceptable limits should be established with action evident when levels fall outside specified limits. 26. Sticky traps are banned from use in some countries.13 Pest Control UK requirements are that live catch systems such as. fly and moth counts.12 Trend Analysis Trend analysis of pest control data must be evident e. Records need to be in place to demonstrate compliance. Tesco Produce Packhouse Standard Version 1.-Thereafter. 27.1 Maintenance Item Equipment and Facilities Detail The structure and fabric of the buildings and equipment must be maintained in good condition with repairs completed. drilling. What Good Looks Like Mobile units/rigs should be numbered to help facilitate maintenance 27.5 27. legality and quality. Engineering activities must be controlled: • Welding. Procedures must be in place to manage work not completed within agreed timescales. flaking paint. The material used must be suitable e. riveting and soldering etc.4 27. approved contractors or the equipment manufacturer. legality and quality. damaged surfaces. A system must be in place to prioritise repairs that may impact on food safety. Work must be completed in the agreed timescales.6 Foreign Body Risks Equipment Engineering • • Risk assessments must be completed prior to work commencing to ensure product and packaging is not put at risk. must not take place on equipment while it is being used for production or on any equipment immediately adjacent. no sticky tape. unless suitable hygienic screening is in place Temporary repairs must be controlled to ensure product is not put at risk. A system must be in place to identify and correct potential sources of foreign bodies or hygiene hazards e. All repairs must be completed in agreed timescales. There must be a planned preventative maintenance (PPM) program that covers all equipment critical to safety. Repairs to or servicing of equipment must be completed by trained engineers.g.2 Page 59 of 72 .2 Preventative Maintenance Records 27.3 27. well maintained and replaced when necessary. Permanent repairs must be made promptly Tools must be kept clean.g. which is fully implemented.Section 27 Section No. A system must be in place to record all maintenance work requested and PPM work completed. Tesco Produce Packhouse Standard Version 1. 10 Engineering Tesco Produce Packhouse Standard Version 1. Engineers and Contractors must comply with necessary Health and Safety requirements of the site. including wearing of protective clothing. 27. Where cleaning is required following maintenance.8 Engineers/ Contractors 27. a system must be in place to assess cleaning requirements prior to use in production. Production product containers/ Tesco trays must not be used as general storage containers in these areas.27. Only food grade lubricants may be used on food handling/contact equipment.9 Engineering 27. Information must be available to demonstrate food grade suitability for materials used. this must be undertaken before production commences and must be recorded. The areas must be within the scope of the site Pest Control Programme. hygiene and housekeeping.7 Engineering Engineering workshops and associated areas must have good standards of fabrication. Equipment must be checked and signed back to production by the engineer and production/QA (depending on sites procedures) following work and any necessary cleaning. A list of approved contractors who have been briefed on site controls must be in place. After engineering work has been completed.2 Page 60 of 72 . Calibration certificates and records of verification must be available and up to date. Alternatively. All equipment is verified on a defined basis which may be daily e. check weighers. legality and quality must be checked for accuracy at pre-determined frequencies.4 Master List 28. deterioration and misuse. Measuring and monitoring equipment must be protected from unauthorised adjustment. damage. based on risk assessment. A contingency or back-up device should be available in the event of CCP / legal measuring equipment being out of service or away for repair.g. a reference probe is externally calibrated to National Standards annually and factory temperature probes are calibrated against the probe at a defined frequency. A master list / calibration matrix of all measuring and monitoring equipment requiring calibration must be maintained.2 Page 61 of 72 . scales.Section 28 Section No. Temperature probes are externally calibrated to National Standards annually and then verified internally throughout the year. 28. What Good Looks Like 28.1 Calibration Item Calibration Detail Measuring and monitoring equipment critical to product safety. temperature probes. dosing apparatus. The master list / calibration matrix may include: • Serial numbers and / or ID numbers of equipment • Frequency of calibration • Date of last calibration • Date next calibration is due • Frequency of internal verification • Acceptable equipment tolerances 28.2 Calibration All measuring and monitoring equipment must be calibrated to National Standards where possible or have documented calibration records traceable to National Standards.5 Procedures Measuring and monitoring equipment must be calibrated/verified for accuracy against written procedures detailing: • Frequency of calibration/verification • Method of calibration/verification • Acceptable equipment tolerances • Corrective action to be taken if outside tolerance Tesco Produce Packhouse Standard Version 1. Verification checks across the normal operating range must be conducted on calibrated equipment that is critical to food safety and legality.3 Verification 28. replaced or sent for repair.2 Page 62 of 72 . Documented evidence of training such as a SOP (Training record to state when and against which items person has been trained) Tesco Produce Packhouse Standard Version 1. Product should be traceable back to the last monitored and verified correct measure or acceptable limit.8 28. All calibration / verification must be carried out by trained personnel only. Equipment e. must be calibrated at a frequency recommended by the equipment manufacturer.28.10 Temperature probes Weights Equipment Training Temperature probes must be calibrated / verified at the temperature range at which they are used. metal detectors. counting devices. Where equipment is out of service or away for repair a back up device is available for use.9 28.6 Equipment Equipment that is operating outside of specified limits must be taken out of service. Standard weights that are used for verification must be of the same weight range as the products being produced. etc. Where inaccurate equipment was identified Product must be re-checked /inspected using accurate equipment once rectified prior to supply.7 28. 28.g. Documented corrective action must be evident where inaccurate measuring or monitoring equipment has been used. Sufficient manpower and production downtime must be provided to ensure the cleaning schedule can be completed in full. Cleaning schedules must be in place for all areas. personal hygiene. Checklists must be completed to demonstrate what cleaning has been completed and by whom.8 Cleaning Procedure Tesco Produce Packhouse Standard Version 1.5 Cleaning Chemicals 29. ASPIRATION The site must have a documented procedure for handling blocked drains in the production areas.Section 29 Section No. daily. maintenance. production storage.7 Swabbing 29. The site must have documented cleaning procedures for equipment.1 29. dilution rates.2 Page 63 of 72 .g. all related sections such as training. cleaning equipment. Safety data sheets must be available for all chemicals used on the site. Visual hygiene standards must be checked prior to start-up Hygiene standards can be verified by equipment swabbing according to a risk assessed plan. protective clothing. Suitable equipment should be colour coded What Good Looks Like 29. personnel. chemicals. It must be the responsibility of the management to verify cleaning is completed to specified schedules and standards.4 Cleaning Resource 29. their suitability for the method and food product type. weekly.3 Cleaning Programme Item Hygiene Management Cleaning Procedures Cleaning Schedules Detail Where cleaning contractors are utilised. medical screening etc are still applicable. The necessary resources to complete the cleaning operation in an effective manner must be provided e.e. Schedules must be determined by risk assessment. between shifts. employee facilities and external areas. 29.2 29.6 Cleaning Records 29. Cleaning personnel must be trained in the safe use and handling of chemicals. monthly etc. The factory must be able to demonstrate how chemicals were selected i. The risk assessment must be used to determine the different types and levels of cleaning required on specific equipment between batches. Swabs must be tested by the laboratory a maximum of 24 hours after sampling. Chilled materials must be loaded and unloaded in temperature controlled bays. some good practice must have been considered and documented.1 Transport Item Transport Detail All vehicles used for transportation must be well maintained and in good hygienic condition and must ensure the food safety.7 Breakdown Tesco Produce Packhouse Standard Version 1. Where temperature controlled transport is required.6 Security Temperature Control 30. site moving towards covered bays.4 Contamination Loading Should be included within transport contracts or site procedures if own transport Where loading and unloading is undertaken in non chilled areas.3 30.2 Page 64 of 72 . Where materials are susceptible to weather damage.5 30.g. 30. Procedures must be in place to minimise the risk of cross contamination (including taint) during transportation. Transport must be capable of maintaining product temperature within specification. raw materials. All incidences of refrigeration equipment breakdown must be recorded and corrective actions documented.Section 30 Section No. under maximum load.e. i. Procedures must be in place to ensure product is held under secure conditions during transport. Procedures must be in place in case of breakdown of vehicle refrigeration. work in progress and finished goods. or ways of working must be such that temperature is not compromised. packaging. vehicles must be unloaded/loaded in covered bays or materials suitably covered to protect the materials. chilled transport from the field 30.2 Third Parties 30. What Good Looks Like Also includes vacuum chillers. legality and quality of materials e. If a third party haulage contractor is used. lorries left with chiller unit on while unloading 30. This should include storage facilities where used as part of the contract. all the requirements must be defined within a contract and effectively managed. documented procedures must be in place to ensure the temperature requirements are met. Questionnaires must be checked and signed by a suitably trained representative. medical or fire personnel). Procedures must be in place for managing any bodily fluid spillages e. visitors and contractors must complete a medical questionnaire.g. (E. What Good Looks Like The requirement should be applied to persons working as food handlers in fields. 31.4 Reporting Illness 31. A decision must be made as to whether the employee can continue to work in the existing or another job. People who have suffered from diarrhoea must not enter the production / storage areas until they are symptom free (minimum 48 hours).g.7 Procedures Emergency Entry Procedure for how the area would be cleaned prior to production recommencing. 31. Tesco Produce Packhouse Standard Version 1. within the production and storage areas. Employees must report any illness to their line manager as soon as it occurs.2 Page 65 of 72 . A procedure for return to work after illness must be in place. steps must be taken to minimise any risk to food safety e. an operative has been diagnosed with food poisoning. 31.3 Reporting Illness The areas where the individual has been working should be assessed to enable the potential risk to product to be established.g.g. A structured questionnaire must form the basis for assessment.5 Return To Work “Return to work” forms are assessed by a trained manager. Where the site is aware of a person who has entered the site was suffering from a condition which could have compromised food safety. bleeding etc. Procedures must be in place for people that require entry to food handling areas in emergency situations (e. Employees suffering diarrhoea or vomiting must be excluded from any work on site.Section 31 Section No.2 Visitors / Contractors 31. tunnels and growing houses etc. vomiting. A risk assessment must be completed prior to employees commencing work. which is signed and dated by the applicant. employee may be restricted to low risk areas until medical confirmation received).6 31.1 Medical Screening Item Pre-Employment Medical Screening Detail All personnel must be assessed for health risks before entering the food production / storage area for the first time. 31. Before being allowed into food production/storage areas. 1 32.3 32. A contract between agency and site must be documented and signed by both parties. Audits include a review of payslips and tax and National Insurance payments 32. The contract must be reviewed regularly and include reference to expectations on minimum wage and working hours etc. so that they are informed immediately if the agency’s license is revoked. Once approved. 32. Auditors have a good understanding of employment law and experience auditing personnel records. and food and drink processing and packaging Site is registered on the Government Gateway website for the Active Checks service. the site must pay at least the GLA minimum charge rate.2 Employment Agencies Item Employment Agency Employment Agency (Tesco UK only) Detail The agency policies. GLA licenses are required for all agencies providing workers involved in agriculture.gov.uk (under “Information for Labour Providers”) The Agency must have been approved by a competent auditor from or on behalf of the site prior to commencing supply of personnel to site.5 Employment Agency (Tesco UK only) Employment Agency Agency Contract 32.2 Page 66 of 72 . as listed on www. The completion of corrective actions within agreed timescales must be verified. However the site may be required to conduct questioning of personnel in addition to the licensing process. further audits must be completed to ensure compliance. The agency must conduct face to face interviews with potential employees. The site must have procedures in place to demonstrate that they manage employment agencies. In the UK. Timescales and corrective actions must be agreed by both parties.7 Interviews Tesco Produce Packhouse Standard Version 1. procedures and activities must meet the legal requirements in the operating country. both at the agency site and through questioning of personnel (twice per year minimum). horticulture. In the UK agencies supplying workers for agricultural and food production and processing jobs must have a GLA (Gangmaster Licensing Authority) license. This must include: • Employment history (previous assignments) What Good Looks Like 32.4 32.Section 32 Section No.gla.6 Audits In the UK the GLA licensing process can count as an audit. The licence number must be provided. 10 Employment Agency 32. Agency personnel must be physically shown procedures relating to basic food safety by a trained site based individual (e. agency personnel must be given appropriate instructions and guidance at the site as soon as they arrive e. the disclosure of this information is prohibited by privacy legislation. changing procedures.• • • • Literacy Ability to understand the local language and communicate Confirming legality to work at the site Confirmation of any disability 32. product safety. disciplinary procedures.9 Employment Agency Records must be kept to confirm this (date and name of interviewer) Agency personnel must complete and sign a medical screening questionnaire and Food Handlers Agreement (requiring personnel to report certain medical conditions they have suffered from while away from site) The site and the agency must be able to identify the individual agency personnel that are on site at any time.g. first aid locations etc.8 Medical Screening 32. hand washing. health and safety (standards and requirements) and health screening procedures. 32. The site and agency must be able to identify what job each agency employee is doing in any one day. fire escape routes. personal hygiene rules.12 Personnel Files In a number of countries. The site must be responsible for fully briefing agencies on the site standards regarding hygiene.11 Employment Agency 32.). Names and numbers of workers on site at any one time should be kept (for fire evacuation purposes) 32. The agency must hold a file for each employee which includes: Evidence of eligibility to work in the country Literacy information Training records A signed contractual agreement between the agency and operative • A completed and signed Food Handlers agreement • A signed medical screening questionnaire • Recent photograph of the worker Agency personnel must be suitably trained for all work activities that they • • • • This should include confirming that hearing and eyesight are good where this is important for their job.13 Supervision Tesco Produce Packhouse Standard Version 1.g. Records must be kept to confirm that they have received and understood it. In addition to any off site briefing. etc.2 Page 67 of 72 . 32.15 Training Training materials may be required in the employees’ first language and the use of interpreters if necessary. 32. The ratio of agency personnel to site based supervisors should be documented.will carry out and supervised to an appropriate level. Agency personnel must not be operating in a job that could be potentially dangerous in the absence of suitable training and supervision e. 32. Records must confirm that the employee has received and understood the training given. CCP job. audited and the effectiveness challenged.2 Page 68 of 72 .g. Records must be retained. ASPIRATION The agency must train their personnel using the same criteria as the site training. Records must be signed off by the trainer and trainee.16 Training Tesco Produce Packhouse Standard Version 1. The site must verify performance themselves and provide appropriate training.14 Supervision The number of agency personnel utilised before a site-based agency employed supervisor is required should be agreed by the site. 33.2 33. minimising overall environmental impact and how this is measured. from neighbours or ground contamination).2 Page 69 of 72 .g. Tesco Produce Packhouse Standard Version 1. What Good Looks Like Where measures have been put in place to protect the site from potential contaminants (e.Section 33 Section No. Where the site has had an independent environmental audit completed.1 Environment Item Policy Detail A site specific Environmental Policy must be in place.conformances raised must be effectively managed. any non. 33.3 Risk Assessment Independent Audits A documented assessment must have been completed to identify any potential environmental risks and how they are being controlled. these must be regularly reviewed to ensure they continue to be effective. detailing responsibility for meeting local legislative requirements. The site must be registered with SEDEX (where required by the relevant Tesco operating country). 1) Employment is freely chosen 2) Freedom of association and the right to collective bargaining are respected 3) Working conditions are safe and hygienic 4) Child labour shall not be used 5) Living wages are paid 6) Working hours are not excessive 7) No discrimination is practised 8) Regular employment is provided 9) No harsh or inhumane treatment is allowed What Good Looks Like The policy makes reference to the ETI Base Code and is signed by the owner or director.2 Page 70 of 72 .2 ETI Base Code Tesco Produce Packhouse Standard Version 1. 34. in site newsletters and displayed on staff notice boards. A written ethical trading policy statement must be in place which must be communicated to the workforce. The self assessment information must be completed and kept up to date. The site must comply with Tesco requirements for ethical trade audits (where deemed necessary). 34.1 Ethical Trading Item Corporate Commitment to Ethical Trading Detail Management must have knowledge of the Ethical Trading Initiative (ETI) Base Code and Tesco ethical trading requirements.Section 34 Section No. The policy is mentioned at induction. The site must comply with the ETI base code. legality and quality of product supplied to Tesco and the GMP standards of the production facility. that this corrective action is effectively implemented. legality and quality issues that are identified with Tesco product.1 Management Control Item Senior Management Notification Senior Management Review Detail The site must have systems in place to ensure that the relevant senior manager is notified of any safety. What Good Looks Like This review may form part of regular scheduled management meetings.2 Page 71 of 72 . The senior management team must ensure that where the need for corrective action is identified. where the Technical / Quality department provide information on site performance e.3 Corrective Action Tesco Produce Packhouse Standard Version 1. Key Performance Indicators (KPIs) 35. Systems must be in place to ensure that the senior management team regularly review and effectively action any non conformance raised regarding the safety. 35.Section 35 Section No.g.2 35. 2 Page 72 of 72 . Key Performance Indicator Formerly “Natures Choice” is a Tesco Agricultural Standard A Tesco UK Packhouse guidance document for QA Best Practice Pest Control Provider Personal Protective Equipment Plant Protection Product List Planned Preventative Maintenance A basic environmental or operating condition that is necessary for the production of safe. and to whom a Tesco purchase order is addressed. Not a requirement. company or other entity to whom a Tesco purchase order is addressed. which is reused to make the same or a similar product A site supplying Tesco that is approved monitored and controlled by a primary site.GLOSSARY OF TERMS Agent Allergen ASPIRATION BRC IOP A Person. processing. firm. firm. Process step at which control is required to prevent or eliminate a food safety hazard or reduce it to an acceptable level Closed Circuit Television Codex Alimentarius Revision 4 (2003) Company contracted/paid by a supplier or primary site to pack the product produced by the supplier or primary site into retail packaging. legal food. The operations carried out to implement HACCP A Person. company or other entity who imports Tesco products. tests and other evaluations in addition to monitoring to determine compliance What Good Looks Like CCP CCTV Codex Contract Packer Critical Limit EFK ETI EU GAP GLA GMP HACCP HACCP Study Importer KPI Nurture One Team PCP PPE PPPL PPM Pre-Requisite Primary Site QMS Re-Work Secondary Site Sedex SOP Supplier T1 T2 TTL/ TTM or TM/ CTM TPPS UKAS Validation Verification WGLL Tesco Produce Packhouse Standard Version 1. The British Retail Consortium and Institute of Packaging Technical Standard and Protocol for Companies Manufacturing and Supplying Food Packaging Materials for Retailer Brand Products. A manufacturing. A Criterion which separates acceptability from unacceptability Electric Fly Killer Ethical Trading Initiative European Union Good Agricultural Practice Gangmaster Licensing Authority Good Manufacturing Practice A system which identifies evaluates and controls hazards which are significant for food safety. A secondary site does not supply product to Tesco directly Supplier Ethical Data Exchange (ethical trading database) Supplier Operating Procedure A Person. company or other entity who acts on behalf of a supplier. assembling or packing site accountable for the product safety and legality. A substance that can cause an allergic reaction in some people. procedures. Quality Management System Material left over from production. An additional element which Tesco believe will help move standards forward within the supply base. Tolerable negative weight value Minimum tolerable negative weight value Tesco Technical Library / Tesco Technical Manager / Tesco Category Technical Manager Tesco Produce Packhouse Standard United Kingdom Accreditation Service A process of obtaining evidence to demonstrate controls are effective The application of methods. Sometimes fatal. firm.