Hygiene and Sanitation Audits

Audit Date 15-Oct-2021

Site Premier Pinetown Bakery

Auditor Douglas Punungwe

Hygiene and Sanitation Audits  

Section Details Percentage Weight

Visual Inspection-Premix Area 90.00% 4.50

Visual Inspection-Make Up Area 90.00% 4.50

Visual Inspection- Moulding and Proving 90.00% 4.50

Visual Inspection-Baking Area 90.00% 4.50

Visual Inspection-Cooling Area 100.00% 5.00

Visual Inspection- Slicing and Bagging Area 90.00% 4.50

Visual Inspection-Cratewash Area 100.00% 5.00

Visual Inspection- DISPATCH 90.00% 4.50

Visual Inspection-Truck wash 90.00% 4.50

Visual Inspection-Abutions 90.00% 4.50

Visual Inspection-Canteen 100.00% 5.00

Organisation, Planning and Management of Cleaning 100.00% 5.00

Prevention of cross contamination 96.67% 4.83

Verification of cleaning activities 100.00% 10.00

State of Cleaning Equipment 90.00% 4.50

Training 100.00% 5.00

Chemical Control 100.00% 5.00

Management of Cleaning Team 100.00% 5.00

Visual Inspection Raw material Stores 100.00% 5.00

Overall Score 95.33%

Audit Summary

The bakery was observed in a clean state however the premix area attention to detailed cleaning needs to improve for floors ,edges and corners were observed dirty . Adrain was also observed not cleaned with dirty build up. Some moulds on shower walls were observed starting to build up . Of concern also are the vendor truckswhich were observed with dirty load bodies. Lastly the despatch floors were also observed with black stains and in need of scrubbing.

Standard Findings Score(%) NCR

Visual Inspection-Premix Area ---- Overal Score : 90.00%

All items of equipment, utensils, floors, walls, drains and all auxillaryitems must be visually clean.

A drain by the diosna mixer side was observed notcleaned and with dirty build up.

90.00 21054Current Status

Visual Inspection-Make Up Area ---- Overal Score : 90.00%

All items of equipment, utensils, floors, walls, drains and all auxillaryitems must be visually clean

Hi level air ductor pipe above make up area wasobserved with dust build up.

90.00 21055

Visual Inspection- Moulding and Proving ---- Overal Score : 90.00%

All items of equipment, utensils, floors, walls, drains and all auxillaryitems must be visually clean

High level air doctor's, louvers and wooden supportstructures were observed with dust build up.

90.00 21056

Visual Inspection-Baking Area ---- Overal Score : 90.00%

All items of equipment, utensils, floors, walls, drains and all auxillaryitems must be visually clean

Some stains were observed on oven outer surfaces. 90.00 21057

Visual Inspection-Cooling Area ---- Overal Score : 100.00%

All items of equipment, utensils, floors, walls, drains and all auxillaryitems must be visually clean

No none conformance was observed during the timeof the audit.

100.00 0

Visual Inspection- Slicing and Bagging Area ---- Overal Score : 90.00%

All items of equipment, utensils, floors, walls, drains and all auxillaryitems must be visually clean

Dust build up was observed on overhead cable racks 90.00 21058

Visual Inspection-Cratewash Area ---- Overal Score : 100.00%

All items of equipment, utensils, floors, walls, drains and all auxillaryitems must be visually clean.

No none conformance was observed during the timeof the audit.

100.00 0Current Status

Visual Inspection- DISPATCH ---- Overal Score : 90.00%

All items of equipment, utensils, floors, walls, drains and all auxillaryitems must be visually clean.

Dirty floors, corners and edges were observed withblack stains and demanding to be scrubbed.

90.00 21059

Visual Inspection-Truck wash ---- Overal Score : 90.00%

All trucks are to be clean with no scuff/ crate marks inside loadbody, inside cabin to be clean and doors corners and edges must beclean

All vendor trucks were observed with dirty load bodies.

90.00 21060

Visual Inspection-Abutions ---- Overal Score : 90.00%

All ablution facilities ladies and gents to be kept in a clean and tidycondition. All shower floors , shower curtains, drains must be clean.Area behind lockers and on top of lockers must be clean and tidy.

All window seals were observed with dust build up. 90.00 21061Current Status

Visual Inspection-Canteen ---- Overal Score : 100.00%

Canteen or eating area to be kept clean and tidy on a clean as yougo basis.

No none conformance was observed during the timeof the audit.

100.00 0

Organisation, Planning and Management of Cleaning ---- Overal Score : 100.00%

1.0- Master Cleaning Schedule- Cleaning and/or sanitizing programsshall specify at a minimum, areas,items of equipment and utensilsto be cleaned and/or sanitized, responsibility for cleaning task,responsibility for inspections.

Master cleaning schedule was observed complete. 100.00 0

1.0.2-Documents must be controlled, i.e. they must be signed byACS representative and approved by client representative. TheMaster Cleaning Schedule must be reviewed at least at an Annualbasis. MCS documentation to carry last review date, next reviewdate and amendment numbers.

Documents approved and current all revision numbersand dates present

100.00 0

1.1.1-Planning for Good Cleaning Efficacy- Site management shallkeep documented evidence of planning to ensure all cleaningactivities as detailed in the Master Cleaning Schedule are allocated tospecific cleaner/(s). Such planning should cater for successionplanning when individuals are off duty or on sick leave.

Activities planned for, cleaners allocated, 100.00 0

1.1.2- Site management shall ensure that agreed minimum reorderlevels for cleaning chemicals are adhered to, to ensure that there arealways adequate stocks of detergents and sanitizers to achieve therequired cleaning efficacy

Stocking levels adequate above reorder level. 100.00 0

1.1.3- Cleaning Consumables and Equipment:- Site managementshall keep adequate cleaning consumables and equipment in goodorder at all times to ensure that all cleaning activities stated in theMCS are achieved.

Adequate cleaning consumables and cleaningequipment on site.

100.00 0

1.1.4- Deep Clean Planning:- Site management shall keepdocumented evidence of deep clean planning; this may be in theform of a detailed Master Sanitation Schedule showing when all deepcleaning is to be done and / or clear communication to Maintenanceand Production on proactive deep clean planning and or records ofoutstanding work.

Detailed master sanitation schedule or communicationto production or maintenance in place

100.00 0

Prevention of cross contamination ---- Overal Score : 96.67%

1.2.1- Preparatory Procedure:- Cleaning and/or sanitizing programsshall include a preparatory procedure which will specify guidelines forprevention of cross contamination during cleaning.

Procedure in place and fully understood by sitemanagement and cleaners.

100.00 0

1.2.2- Potential contamination from Cleaning Activities:- Cleaningactivities shall be performed in a way that does not pose crosscontamination risks. No cleaning shall be done overhead open foodproducts, No use of air pressure or hose during production, Nocleaner shall move food products without production supervision

No cross contamination risks observed. 100.00 0

1.2.3- Equipment Color coding:- Cleaning equipment shall bededicated between high and low risk areas and within those areasbetween Food Contact surfaces and non food contact surfaces.Ablutions and Yard shall not be used inside production facilities.Equipment used for allergen clean up, glass breakage and bloodspillage must be controlled.

Colour code system fully implemented. 100.00 0

1.2.4- Glass breakage Procedure:- Provisions shall be made for theclean up of any glass breakage within the facility. dedicatedequipment for such glass clean up shall be made available and becontrolled. Records for such clean up shall be kept and depending onclient policy samples of the glass may be kept.

Procedure, forms, kit in place and implemented. 100.00 0

1.2.5- Provisions shall be made for the clean up of any blood orbody fluids within the facility. Cleaning cloths and mop heads shallbe made available for such clean up and locked away for use in theevent of any blood or body fluid spillages. Records for blood/bodyfluid spillage clean up shall be kept.

Procedure, forms, equipment in place and systemimplemented.

100.00 0

1.2.6- Cleaning and Disinfection of Cleaning Equipment:- Cleaningequipment shall be part of a regular cleaning and disinfection regime,records of such cleaning and disinfection shall be kept up to date.Cleaning equipment shall be kept up to date. Cleaning equipmentshall be kept clean and tidy during cleaning. Mopping water must bechanged frequently to avoid use of dirty water. Provisions shall bemade for an appropriate washing and drying station for cleaningequipment.

Few dirty equipment observed, records in place. 80.00 21062

Verification of cleaning activities ---- Overal Score : 100.00%

Verification of Cleaning activities shall be in line with the frequenciesdocumented in the Master Cleaning Schedule.

Verification in line with Master cleaning schedule. 100.00 0

1.3.2-Intergrity of Inspection System:- "User Route"-The time spentdoing inspections must reflect that individuals doing inspections arepaying attention to detail. Actual findings in the plant on detailedcleaning must be inline with the self inspection of site management.

Inspection time indicates, detailed inspection. 100.00 0

1.3.3 Corrective Action Loop:-In case of deviations/nonconformances, Corrective Action Request shall be raised;these mustbe acted upon and closed out timeously. Handover sheets must besigned by Client Representative.

Corrective action closed out effectively. 100.00 0

1.3.4-Pest and Foreign objects sighting logs- Cleaners within eacharea must record all pest and foreign object sightings and suchinformation must be effectively handed over to clientrepresentative.

Pest and foreign objects findings recorded and handedover to client rep.

100.00 0

1.3.5:- Area Manager Verification- Site Inspections by Area Managerto verify site level- organising, planning and management of cleaningshall be done at the agreed/stated frequencies. Identified nonconformances must be closed out on site level.

Reports current and follow up actions done. 100.00 0

State of Cleaning Equipment ---- Overal Score : 90.00%

2.1- All equipment used must be food grade:- no use of woodenequipment, only lint free cloth may be used, no use of householdcloths, no use of wire brushes and other such material that maycontaminate products ref Site Quality Manual section 2.1

Food grade equipment in use. 100.00 0

2.2- State of cleaning equipment-Cleaning Equipment must be in agood state of repair. No temporary fittings are allowed on anycleaning equipment. Equipment must be replaced periodically no useof worn out or broken equipment.

All rhino trollies were observed with broken trollies. 70.00 21063

2.3-Cleaning Equipment Storage- Cleaning Equipment shall be storedin a hygienic manner on equipment racks and/or in storeroom aftercleaning. No mixing of dedicated equipment, no equipment must beleft lying around, cleaning hoses must be rolled up and stored neatlyin designated area when not in use.

Equipment stored in hygienic manner 100.00 0

Training ---- Overal Score : 100.00%

3.1-Training program:- A documented training program for thecleaning team shall be in place: detailing training needs, frequency,training document and exit criteria. A training Matrix shall be filledshowing all staff members and the training given to each employee.

Procedure in place and training matrix complete. 100.00 0

3.2-Supervisory Management Training:-Site Managers andSupervisors shall be trained to ensure they are equipped to organise,plan, and manage cleaning activities on site.

All was observed in order. 100.00 0

3.3- Training Records:-All identified training needs must be coveredfor the relevant staff, the training records must be filled inchronological/alphabetical order for easy retrieval. Training must bein line with succession planning.

All was observed in order. 100.00 0

3.4-Colour Code Training:-Cleaners shall demonstrate anunderstanding of equipment colour coding and the risks associatedwith cross contamination.

3/3 aware of equipment colour coding . 100.00 0

3.5- Food Safety Awareness-Cleaners shall demonstrate anunderstanding of Food Safety and an ability to identify potentialhazards in the workplace.

3/3 aware of food safety. 100.00 0

Chemical Control ---- Overal Score : 100.00%

4.1 Chemical Control Procedure:- Site management will keep a list ofapproved chemicals and chemical concentration verificationschedule, deteailing the frequency of chemical dilutionsverifications.

Verification schedule and approval list filed. 100.00 0

4.2-Quality System Certification- All chemical suppliers used shallhave a recognised certification for their Quality Management Systeme.g. ISO 9000

All was observed in order. 100.00 0

4.3- Chemical Dilution Registers- Site management shall keeprecords of all chemical diliutions, these must be updated on anongoing basis.

All dilutions up to date and accurate. 100.00 0

4.4-Chemical Verification:-Site management shall keep records ofchemical concentration verifications in line with chemicalconcentration verification schedule.

Chemical verification up to date and accurate. 100.00 0

4.5-Detergents certification:-All detergents must carry the SABS1828:2000 mark, site management must keep the SABS certificateand the permit detailing which chemicals are registered or certified.

All was observed in order. 100.00 0

4.6-SABS 1853:2001- All sanitizers and detergent-sanitizers mustcarry the SABS 1853:2001 mark. Site management must keep bothcertificate and permit detailing all approved chemcals on site.

All was observed in order. 100.00 0

4.7- Material Safety Data sheets and Technical data sheets to beavailable in chemical store for all chemicals.MSDS and TDS to bedisplayed and must be easily retrievable in case of emergencies

MSDS and TDS available and displayed in chemicalstore for all chemicals.

100.00 0

4.8:-Access to chemicals must be controlled on site only designatedand trained personnel to have access to keys of chemical store oraccudose

Chemicals in storage/accudose locked away. 100.00 0

4.9-Chemical Storage:-All chemicals are to be stored neatly inchemical store off the floor, acidic and alkali chemicals are not to bestored near each other.

Stored off the floor and acids separate from alkalis 100.00 0

Management of Cleaning Team ---- Overal Score : 100.00%

5.1PPE:- All hygiene operators are to have the established uniformsat all times on site. The uniforms must be clean and presentable, allsafety requirements as highlighted on MSDS sheets must be catered

Staff in clean and tidy PPE all requirement met. 100.00 0

for

5.2 Plant Handovers:- Site management shall keep a documentedhandover between shifts and/or with management. Handover todetail work to be completed and obstacles encountered in cleaning

Handover to production and in between shiftsimplemented.

100.00 0

5.3- Staff registers:-Site management shall keep up to dateattendance registers, these shall be completed at the beginning ofshift and individuals who come late must be disciplined

Registers up to date 100.00 0

5.4:- Communication of Trend analysis, non conformances tohygiene operators during start up meetings / invocoms.

Evidence of feedback to cleaners on trends andNCR`s

100.00 0

Visual Inspection Raw material Stores ---- Overal Score : 100.00%

All items of equipment, utensils, floors, walls, drains and all auxillaryitems must be visually clean.

No none conformance was observed during the timeof the audit.

100.00 0

Average Score   95.33%