PRP Manual JCK Agri P

FSMS PLAN DEVELOPMENT MANUAL
PRP Manual
J C K AGRI PRODUCTS
ISSUE NO : 01 REVISION NO : 00 DOC NO:

DATE OF ISSUE: 25.03.2015 DATE OF REVISION : 00 PAGE NO:
Table of Content
Content
Page
01. Construction and Lay-out of Building and Associated Utilities 02
02. Security 03
03. Internal Site Standards 04
04. Site Facilities 05
05. Waste Disposal 06
06. Equipment and Maintenance 07
07. Management of Purchased Materials & Handling of Products 08
08. Prevention of Cross Contamination 09
09. Cleaning & Sanitizing 11
10. Pest Control 12
11. Personnel 14
12. Training 16
Page 1 of 18
Issued By: FS Team Leader Approved By: Director
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01. Construction and Lay-Out of Building and Associated Utilities (External Standards)
The buildings are located near the main roads which are designed earlier for a small plant and
modified to medium scale plant which maintain sound hygienic conditions for virgin coconut oil,
creamed coconut/ coconut butter and coconut flour processing.
The sufficient safeguards are provided to protect from pests, domestic animals, dusts and other
chemical, physical and biological agents of possible contaminants
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02. Security
Access to the site by employees, contractors and visitors are controlled and visitor’s coming is
reported. All employees are aware to encourage identifying unknown persons to the site. Security
people are maintained site security and ensured that only authorized staff has access to
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production and storage areas via designated access points. Restricted area are clearly marked and
controlled.
Transportation is done under strict supervision of the security people. Company drivers are
handled all spice receiving vehicles throughout the premises.
03. Internal Standards
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3.1 Lay-out, Product Flow & Segregation

Internal design & layout of food establishment is designed for appropriate food hygienic
requirements. Segregation of the food establishment is done avoiding any cross contamination
and product flow is design as per the first in – first out hypothesis.
Reference: Factory Lay-out (Annex 01)
3.2 Building Fabric

3.2.1 Walls
All the structures within the buildings are made out of durable and non corrosive materials which
used for hygienic food products with smooth surfaces and easy to clean and maintain. They are
finished and maintained to prevent the accumulation of dust and minimizing mould growth.
3.2.2 Floors
Floors are tiled and kept clean and free from accumulation of water and other contaminant
materials. Proper drainage system is sited and maintained. Temporary measures are allocated for
damage floor with action plan in given time period and they are repaired as quickly as possible.
3.2.3 Ceilings/ Overheads
The ceilings are made of impervious materials and easy to clean. They are also finished and
maintained to prevent the accumulation of dust and minimized mould growth.
3.2.4 Windows
Windows are designed to open where ventilation is needed and they are screened with metal and
plastic meshes to prevent ingress of pest. The frames are totally fixed with windows and broken
& damaged windows are immediately repaired or replaced.
3.2.5 Doors
Doors are made with stainless steel bars and scatter proof glass and painted with non toxic paints
where its necessary. Doors in processing, packing and storage areas are close fitting and
adequately proofed. They are in good condition and easy to clean.
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04. Site Facilities
4.1 Air Quality & Ventilation

Ventilation is provided with natural air circulation with the use of industrial fans in the drying
and milling division. In packing division, the area is fully air conditioned.
4.2 Lighting
Adequate natural and artificial lighting is provided in all processing areas. Light bulbs are
covered with the protective covers. Lights are kept clean, damage ones are replaced or carried out
for maintenance. Both natural and artificial lights are used to inspect the physical characters of
products.
4.3 Supply of Water

Water is used in the wet section for the washing of fresh coconut kernels and also used for
drinking and washing purpose of workers. Tube well is used to supply water for the wet section,
foot bath, hand wash, and for the drinking purpose whereas well water used for washing and
cleaning purpose of employees and the factory as well as for the boiler to generate steam.
Microbiological and chemical parameters of the well water comply with the relevant legal
regulations of the country.
4.4 Supply of Energy

Both electric power and fuel (Wood, Coconut shell, etc) are used as energy sources in which
depend on the equipments and machineries.
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05. Waste Disposal
All collected waste will be removed from the establishment and disposed in such a way to avoid
any environmental impact. Collected solid waste materials especially coconut shells are used as a
fuel where spoiled coconuts, testa, broken and damage coconuts are send for the production of
coconut oil. Liquid waste is sent for the effluent treatment. Rejected or damaged packaging
materials are returned to the supplier immediately or send for the recycling.
Waste collection containers in the production area are clearly identified, easily used and emptied
at appropriate frequency.
Ref: Waste Discharging Rerecords (MDC/FSQMS/PRP/007)
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06. Equipments and Maintenance
Equipments and machineries in the processing area are installed in the way of easy to access and
cleaning. Those are at least 50 cm away from the walls. Machineries standard on the floor are on
a sound foundation with cleanable and non-absorbent materials. Food grade paints are applied on
the food contact surfaces of machineries and equipments. Certain traditional materials which are
essential such as wooden shovels are used in processing. Electric cables cover with electric
resistant materials. If there any risk point, they are clearly labeled with handling instructions.
Maintenance and repair activities will do under strict supervision of the nominated person.
Ref: Equipment & Machinery Maintenance Record (MDC/FSQMS/PRP/008)
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07. Management of Purchased Materials, Handling of Products

7.1 Storage
Fresh kernels/ fresh coconut meat and finish products are stored in separate areas to prevent cross
contaminations. Areas are not physically separated and demarcated using painted lines on the
floor. All materials kept on pallets at least 20 cm away from the walls to access of cleaning
purpose, pest control and to supply product ventilation. Packing materials store in separate
building and they will carry into the processing area at the time of packing.
Reference: Purchasing Procedure (PM/07/PU)
Food Grade Certificates (DC/PU/FG)
Packing Material Quality Control Procedure (MDC/FSMS/03/12)
Raw Material Quality Control Procedure (ADX/FSMS/03/11)
Non- food chemicals such as cleaning agents and chemicals for laboratory testing are clearly
labeled and store away from finished products and packing materials. Usually these types of
materials are stored in the laboratory separately. Chemicals which are harmful (Sulphuric acid) to
human, store with handling instructions. If there any non-confirm products, they are stored
separately with specific labels.
Reference: Food Grade Certificates (DC/PU/FG)
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7.2 Transportation
Vehicles used to transport raw materials are internally inspected by supervisors for its cleanliness
and maintenance at every receiving and dispatching. These vehicles should be identified for the
purpose of delivering food items. Cleanliness of vehicles is maintained as per the company
standards.
All vehicles should be clean, free from moisture, foreign matters and pest to prevent
contamination of packed products. Outside vehicle owners are advised to maintain company
requirements. At the time of delivering, vehicles are always closed. Containers are subjected to
inspection which is conducted by independent inspection service.
Reference: Vehicle Inspection and Lab Sample Register Records (RC/PR/VLS)
08. Prevention of Cross Contamination
8.1 Incoming Materials

Every purchasing/ receiving of major & minor raw materials are aligned with to the quality
criteria of the company acceptance level, specially sensory and hygienic requirements.
Purchasing of packing materials, fresh coconuts and utensils are from registered suppliers.
Suppliers are identified for supplying based on quality including food safety parameters, price
and delivery on time.
Reference: Good Receiving Note (RC/PR/GRN)

Despatch Note (RC/PR/DN)
Vehicle Inspection and Lab Sample Register Records (RC/PR/VLS)
8.2 Process Control

Processing of various products such as virgin coconut oil, creamed coconut/coconut butter and
coconut flour are carried out as per the process control plan in the HACCP plan.
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Specifications for raw materials, process steps and finished products are selected as per the Sri
Lankan Food Regulations, Company Standards, Sri Lanka Standard Specifications, Food
regulations under food Act and Codex Standards to produce wholesome, quality and safe
products those conforming to the relevant product standards.
Preparation process is carried out in such conditions to prevent contamination of physical,

chemical and biological objects. Receiving, cleaning, storage, preparation, packing and other
processing are done hygienically prevent any cross contamination.
Separate group of workers are allocated for the different processes and they are not permitted to
handle other activities without the permission of responsible staff member.
Workers are not allowed to wear jewellery, wristwatches, - etc. when entering into the
preparation area. They are checked daily for appropriate wearing of uniforms, masks and head
caps. Workers are checked for clean hair, nails and whether they have wounds, skin lesions,
rashes or any other ailments which can direct contaminate with the product.
Workers are instructed and provided hand washing and drying facilities at the entrance with
effective detergent and disinfectant to prevent contaminations and keep good hygiene.
Reference: Personnel Hygiene Monitoring Records (RC/PR/PHM)

Glass Procedure (PM/07/GL)
Containers or bags from the outside are not allowed to take beyond storage hall and containers of
different sizes and colors are used for different purpose / in different processing area.
A system of color codes is used to differentiation and identification of different stages, levels and
categories of the product and other items.
● Black color tags - used for the items which are waiting for inspection.
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● Green color tags - used for items ready for dispatch or ready for the next step of the
process.
● Red color tags - used for any item that could not suitable for its usage.
09. Cleaning and Sanitizing
Cleaning programme is routinely implemented as per the cleaning schedule. Dry cleaning and
wet cleaning are done in certain areas in different frequencies.
Disinfectant agents are non toxic, food grade and odorless materials. Those are clearly identified
and store in separate area and used in accordance with manufacturer’s instructions.
Cleaning equipments store in separate area with hanging facilities. All brooms and hand brushes
are kept clean without holding dust and other waste materials. Those are labeled to clean specific
area of the production premises. Utensil washing area is away from processing site and washed
utensils are kept for drying purpose with good ventilation conditions to prevent contamination.
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Workers are trained in advance with cleaning & sanitizing procedures. Supervisors are checked
after cleaning to effectiveness of cleaning purpose and swab test is done to verify the cleaning
process.
Ref: Cleaning Records (ADX/PRO/C)
10. Pest Control
10.1 Preventing Access

The building is kept in good repair to prevent access to pests and doors are closing during non
working hours. Holes, drains and other places where pest are likely to access are kept sealed.
Wire mesh screens for open windows are used to reduce the pest entry. The building is modified
to eliminate breeding sites of insect and vertebrate and other pests. The surrounding area is kept
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clean to prevent harborage and breeding of pests. Windows are tightly closed to prevent entering
of birds and they cover with mesh also. External doors are close fitting and no gaps.
Good house keeping practices i.e. eliminating accumulation of food and packing materials,
palletizing of goods, removing rejected products as soon as possible are maintained by workers.
Incoming materials are carefully inspected to minimize pest infection from any damaged packing
materials or damage products. Domestic animals are not allowed to enter the factory
environment. Staff members and employees are advised not feed to animals both inside and
outside or not encouraged to stay animals inside the factory premises and to keep the premises
clean.
10.2 Harborage and Infestation

The surrounding area is kept clean to prevent harborage and breeding of insect, vertebrates and
other pests. Windows are tightly closed to prevent entering of birds and they cover with mesh
also. External doors are close fitting and no gaps.
10.3 Monitoring & Detection

Extermination of pest in different areas of the premises is done as per the pest control schedule.
The company has contract basis services of an approved pest control organization to control the
pest in outside of factory. They agree to make twelve inspections and treatments per annum at
regular intervals. Supervisors regularly monitor and document the effectiveness of fumigation
process.
10.4 Eradication
Non- toxic baits are used to control the pest in inside the factory, especially food handling area.
Usually rodents glue traps are used. Internal bait/ trap stations sited by food safety team with
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instructions from pest control officers. Designed site map is showing where stations are located
and they are labeled to easy identification of inspections.
Reference: Pest Control Monitoring Plan (PL/PR/PC)

Pest Control Monitoring Record (RC/PR/PC)
Pest Control Service Monitoring Record (RC/PR/PCS)
Bait Map (PRP/07/BM-AX/02)
Where stored product present insects (ex: Coconut flour), fumigation treatments are applied to
those products either room fumigation or tarpaulin fumigation using phosphene gas. Recognized
Fumigation Company has authority to do this process.
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11. Personnel
11.1 Personnel Behavior

Strict supervision is implemented to maintain personal cleanliness of food handlers. Protective
clothing, gloves, masks and head caps are provided to them. Those are stored on specific
locations. Protective cloths are not having any buttons and top pockets. Pockets are at hip level.
They are checked daily for appropriate wearing of uniforms. Head caps remain all hairs and head
grips and clips are covered with cap. Workers are not allowed to wear any hanging jewellery,
pins and wristwatches when entering into the production area.
All workers are entered to processing site from specific entrance. Movements between different
areas are minimized. Supervisors are directed them to relevant job and employees are not move
to another area without having permission from authorized officer. Smoking, spitting, chewing
and eating are prohibited in the production premises.
11.2 Personnel Hygiene

Personal are advised to wash their hands and foots before starting operations and after use of
toilets using provided disinfectants and detergents. Hand washing facilities are provided at the
entrance of processing area and near the toilets.
Detergent and disinfectant are provided in the one solution with dispensers at every washing
facility, towels also supplied with holders for proper drying of hands of all. Each dispenser fill
with cleaning solution, when the level becomes ¼ of the volume of the dispenser; monitoring of
this practice is responsibility of the production supervisors
Necessary work instructions are displayed in the processing establishment. Smoking, spitting,
chewing, eating is strictly prohibited in the processing area. Personnel are not allowed to take
their meals inside the factory.
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Reference: Personnel Hygiene Monitoring Records (RC/PR/PHM)
11.3 Health Status & Medical Screening

Company maintains a health screening programme for employees involved in the production. At
the recruitment, all employees are subjected to a medical declaration for their suitability in
handling of food items; records of such examinations are kept. Annually they are subjected to
medical examination by a medical officer.
Employees are instructed to inform to the Production Manager under the following conditions;
● Jaundice
● Diarrhea
● Vomiting
● Fever
● Sore Throat
● Skin lesion
● Any discharge from ear, eye or nose
In such situations medical examinations are done and records of such situations are maintained.
First aid equipments are kept separately and issue only by authorized office member.
Reference: Medical Records (RC/PR/ME)
Medical Declaration Records (RC/PR/MD)
Personnel Hygiene Records (RC/PR/PH)
11.4 Visitors
There is adequate screening of all visitors when entering into the preparation area. They have to
report their arrival to store manager and to be fulfilled company requirements (purpose of
visiting, free from any diseases, arrival & departure time, etc,).
Reference: Visitors Declaration Form (FO/PR/VD)
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12. Training
Company identifies that food hygiene and sensory assessment of virgin coconut oil, coconut flour
and creamed coconut/coconut butter are as important as the employee training areas. The
personal is trained to gain the knowledge in personal hygiene, sensory check of product to get the
product with good / fresh criteria, quality management, food preparations and HACCP system at
our establishment.
Team has identified skill environments of all employees and arranged relevant training program
for that requirements. Effectiveness of the training given will be periodically evaluated.
Ref: Training Plan (ADX/FSMS/07)
Training Records & Evaluation Records (ADX/FSMS/08)
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FSMS PLAN DEVELOPMENT MANUAL

ISSUE NO : 01 REVISION NO : 00 DOC NO:

03. Internal Site Standards 04

04. Site Facilities 05

05. Waste Disposal 06

06. Equipment and Maintenance 07

07. Management of Purchased Materials & Handling of Products 08

08. Prevention of Cross Contamination 09

09. Cleaning & Sanitizing 11

10. Pest Control 12

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

03. Internal Standards

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

3.1 Lay-out, Product Flow & Segregation

3.2 Building Fabric

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

04. Site Facilities

4.1 Air Quality & Ventilation

4.3 Supply of Water

4.4 Supply of Energy

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

05. Waste Disposal

Ref: Waste Discharging Rerecords (MDC/FSQMS/PRP/007)

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

06. Equipments and Maintenance

Ref: Equipment & Machinery Maintenance Record (MDC/FSQMS/PRP/008)

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

07. Management of Purchased Materials, Handling of Products

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

08. Prevention of Cross Contamination

8.1 Incoming Materials

Reference: Good Receiving Note (RC/PR/GRN)

8.2 Process Control

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

Preparation process is carried out in such conditions to prevent contamination of physical,

Reference: Personnel Hygiene Monitoring Records (RC/PR/PHM)

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

09. Cleaning and Sanitizing

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

10. Pest Control

10.1 Preventing Access

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

10.2 Harborage and Infestation

10.3 Monitoring & Detection

Issued By: FS Team Leader Approved By: Director

ISSUE NO : 01 REVISION NO : 00 DOC NO:

Reference: Pest Control Monitoring Plan (PL/PR/PC)