Task to be done (FSSC 22000 V5 Findings)

Major or Documentation or Status

Details of non-conformity
Minor Requirements physical
Pit for rice feeding on external section, external storage tanks, reprocess feeding area and utilities are 1(a) Lock & key for all potential Document 1(a) Lock & Key Done
not covered in existing TACCP study, areas for storage e.g. silos, 1(b) CCTV Under
underground tanks for Assessment.
Rice, water. R.O reservoir,
saccharification tanks, protein
Minor filling and glucose filling, enzymes
storage in lock & key as well.

1(b) CCTV camera will be

installation after assessment to
be done.

they have defined CCTV cameras are installed but still not installed, CCTV camera will be installed Physical CCTV Under
Minor
after assessment to be done. Assessment.

visitor card is defined as control measure but visitors cards were not issued to auditor and consultants Visitor cards are available at Physical ?
Minor
on audit day facility

Tanks found without lock and key during site visit Lock & key for all potential areas Physical Lock & Key Done
for storage e.g. silos,
underground tanks for
Rice, water. R.O reservoir,
Minor
saccharification tanks, protein
filling and glucose filling, enzymes
storage in lock & key as well.

Seal inspection of vehicle and product packing seal integrity at incoming is not being performed Seal integrity of packaging is Document Done(evidence shared)
Minor
though documented in TACCP study inspected and recorded.

Food fraud risk assessment has not been performed for enzymes and packaging material. Further Food Fraud risk assessment is Document Done Document Shared
Minor existing risk assessment does not cover likelihood of detection. carried out for enzymes and
packaging material

Minor Allergens risk assessment has not been performed considering contamination and there is flour mill in Allergen risk assessment is Document Done Document Shared
 Task to be done (FSSC 22000 V5 Findings)

portion 1. carried out

Risk assessment of frequency for environment monitoring program is not justified through risk Document and physical Document Updated.
assessment, further they have not performed testing to verify. 3RD Party environmental Testing from GEL under
Minor
monitoring to be negotiations
carried out.

Scope does not describe rice protein, packaging for site products and location. Scope is defined with respect to Document Done Document Shared
Minor
rice protein production.

They have not documented risks and opportunities relevant to organization having impact on FSMS Risk and opportunities are Document Done Document Shared
Minor
with their mitigation plans. defined department wise.

Retention time of records and control of electronic documents and records not covered in existing Retention time is mentioned in Document Done(document shared)
procedure. SOP for Document
Minor
MANAGEMENT & IN Document
master list.

Raw, process aids and packaging material descriptions are not documented. Product description is Document Done Document Shared
redeveloped containing raw
Minor
materials, processing aids and
packaging material descriptions.

Existing procedure for traceability talks about cold room, chillers and CIP chemicals and parameters of Updated procedure for Document Done Document Shared
Minor filling machines while these are not being used at size. Further, traceability of rework is not addressed traceability is in place
in procedure. Traceability of reworked product is not being ensured.

Some of the emergencies like public health emergencies, interruption of water and communication Updated procedure for Document Done Document Shared
Minor ways are not documented in existing procedure. Drill for emergencies has neither been planned nor Emergency preparedness &
conducted. responseSea is in place

Ingredients, process aids and rework are not addressed in process flow diagram. Flow diagram is re drawn Document Done Document Shared
Minor including ingredients, process
aids and rework.
 Task to be done (FSSC 22000 V5 Findings)

Some of the potential hazards have not defined in system like aflatoxins, pesticide residues for rice. New HACCP Study is performed Document Done Document Shared
Moisture is defined as physical hazard at drying step of rice protein whereas moisture is quality
parameter however fungus and aflatoxins that may be produced by moisture have not been
considered. Same hazard is defined with different severity like metal is defined with 1 severity at few
steps i.e. rice, rice storage and milling/grinding while same is defined with 2 severity at slurry
preparation. Salmonella is defined with 1 severity for enzymes while with 3 at process water.
Microbial growth is identified with 2 severities at slurry preparation while with 3 at evaporation.
Specific microbes are not identified at these steps. Severity of any hazard cannot be changed.
Conductivity is defined as physical hazard while it is a quality parameter. Some of the steps like
Major
sieving/ sifting, stone catcher and sieving after dryer and stitching of rice protein bags with needle are
not considered as step in existing HACCP study. They have not used decision tree for the
categorization of control measures in an effective way. Existing decision tree does not talk about
OPRPs while they have defined OPRPs in system and no CCP is defined. Scale for likelihood of
occurrence is not defined in a measurable way. Hazard identified with 3 severities (maximum severity)
is further considered as non-significant while it is against food safety principles. They have selected
OPRP for magnet at grinding of rice protein where significant hazard identified is metal while magnet
cannot capture SS and their process equipments are made up of SS. Sieve is not considered as control
measure for rice protein.

Major Validation of control measure was not properly performed. New HACCP Study is performed Document Done Document Shared

Existing procedure does not cover correction and corrective action. Correction and Corrective action Document Done ( Document Shared ).
Major
to be described in procedure.

Verification for OPRP is not covering individual OPRP. PRP verification plan is not documented. No To be carried out by qc as Physical Testing from GEL under
product testing has been performed for aflatoxins, pesticide residues, microbiological analysis and prerequisite negotiations
Minor
heavy metals. Personal hygiene and cleaning process verification through swab testing has also not
been performed.

Magnet gauss strength has not performed. To be carried out by 3rd party Physical Done. Certificate available.
Minor
resource.

Minor No evidence found that all clauses of FSSC version 5 were covered in internal audit. No evidence found Internal audit to be carried out Document Done(document shared)
that internal auditors have competency on additional requirements of FSSC and ISO 22002-1. with checklist covering all clauses
 Task to be done (FSSC 22000 V5 Findings)

of FSSC V5.

Few agenda points like performance of external providers and incidents/recall/withdrawal etc. were MRM inputs should be align as Document Done(document shared)
Minor
not covered in MRM. per FSSC V5.

They have not performed water testing. To be carried out by 3rd party Physical Testing going on with SGS.
Minor
resource

Flying insects observed in liquid glucose filling hall, bird found in process hall and there was opening in Closure of gaps Physical Exhaust fans and meshes
Major process hall that was not screened and would probably be the possible entrance for bird in process over windows are being
hall.
placed (going on).

Uniforms shirts of the staff members working in process hall were having buttons and pockets above Button less and pocket free Physical Under
Minor waist line. shirts/ tee shirts to be provided consideration/quotations
to all personnel as uniform

Few tests have not been covered in health screening of the food handlers contrary to the Medical tests to be carried out as Physical Done. Reports Available
Major
requirements of SFA regulations 2018. per Sindh Food Authority

Raw material inspection is not being performed for enzymes at incoming. Enzymes inspection to be carried Document Done (evidence shared)
Minor
out and recorded.