How to Write a Food Safety Plan

Introduction
Americans are concerned about food safety. It is true that our food supply is safer than any time in history but the repeated media information on recalls and some of those rare yet disastrous bacteria like E coli 0157:H7 have people scared. he food industry is very competitive but !hen it comes to food safety" companies" universities and producers all !ork to#ether to improve safety. $ompanies have found that !hen one company is mentioned in the ne!s !ith a safety issue" all companies that produce similar products also #et hurt in the marketplace. %or e&ample" !hen spinach !as mentioned several years a#o !ith E coli 0157'H7" all spinach sales declined. his is the reason that !hen it comes to food safety" producers all !ork to#ether to be a non(competitive topic in a competitive industry. In order to reduce the incidence of recalls" la!suits and media attention" many retailers in Europe and the )nited *tates and various #overnment a#encies be#an to discuss the causes and preventive measures needed to #ive consumers confidence in their food supply. hey eventually came up !ith a list of +,ood A#ricultural -ractices+ .,A-/ !hich can be thou#ht of as +best practices+ in other industries. If producers !ere to observe these practices" the incidences of recalls" la!suits and media attention !ould drastically diminish. he ra! fruit and ve#etable industry is the most critical in that many fruits and ve#etables do not have a +kill step+ .heat via cookin#/ in processin# !hich !ould normally kill patho#enic bacteria. %or that reason" !e continually hear about recalls involvin# tomatoes" leafy #reens" spinach" melons and berries. he main patho#ens of concern are *almonella and E. coli. 0any of these are from fecal contamination from humans or animals that #et into fields via irri#ation !ater" inade1uate hand(!ashin# by harvest cre!s" se!a#e contamination via draina#e and manure amon# several other contamination routes. ,A- is all about controllin# these contamination routes. At the present time" these ,A- pro#rams are voluntary but in the near future" it !ill likely become a re1uirement. Every producer should kno! that if someone #ets sick from eatin# your product" you are al!ays liable. A food safety plan !ill not #uard a#ainst a la!suit but it does minimi2e the probability of it happenin# plus a 3ury is more sympathetic if you can prove by a food safety plan that you did everythin# you could to make your product as safe as possible.

4ou may !ant to !rite a food safety plan because the store or market they !ant to sell to is re1uirin# a food safety audit. here are several types or brands of audit pro#rams but they are some!hat similar. he most basic one and the one !e are usin# for a starter pro#ram is the )*5A ,A- -ro#ram. *everal ma3or companies no! have pro#rams that many stores and supermarkets are re1uirin# referred to as third party ,%*I .,lobal %ood *afety Initiative/ audits. hese include -rimus6abs" *7% and ,lobal,A- !hich are similar in content to )*5A ,A-. 8e !ill address these other pro#rams else!here. 9efore you ever be#in !ritin# a %ood *afety -lan" you should find out !hat the buyer is actually re1uirin#. 5oes the buyer !ant )*5A ,A-:,H- audit or a commercial ,A- audit; If the buyer does !ant a )*5A ,A-:,H- audit" ask !hich parts or scopes they !ant to include .-arts ," 1"<" =" -art 7;/ he material in this notebook is presented to assist fruit and ve#etable #ro!ers in passin# a food safety audit. his !orkbook focuses on the )*5A ,A- audit. *ince farms" crops" auditors and other factors are all so variable from farm to farm" !e cannot #uarantee one !ill pass the audit but by usin# the su##estions in this notebook" the probability of passin# an audit is improved. If one is 3ust be#innin# to start a ,A- audit for the first time" the amount and depth of information and procedures !ill be frustratin# and over!helmin#. 8e su##est one 3ust focus on understandin# !hat auditors !ill be lookin# for and !ritin# an actual food safety plan. >nce one sees !hat a food safety plan looks like" one !ill reali2e it !as not as bad as the an&iety that preceded it. here are a fe! !ords to define and keep separate. A food safety program is !hat one is actually developin#. his includes trainin# the people and understandin# !hat auditors !ill be lookin# for. A food safety plan is a !ritten document that describes your pro#ram from the standpoint of policies" procedures and documentation. 0ost of the information contained here is about !ritin# an actual food safety plan. 8hen one is be#innin# to plan for an audit" understand that the !ritten plan is only part of the audit. here are other thin#s one must do that are not in the plan. In addition" 3ust because one says somethin# in their plan" doesn?t mean the auditor !ill take your !ord for it. Auditors !ill visit !ith employees askin# about your food safety plan. %or e&ample" if you say employees !ill be trained monthly" the auditor may ask an employee !hen they had their last trainin# session and ho! often they occur. Above all" be honest !ith the auditor and !hat you put in your plan. 5o not try to overly impress auditors !ith your plan. 8hatever you put in your plan" you !ill be audited on. 0ost audits are #oin# to cost you about @1000 !hen you fi#ure in the cost for the audit itself and travel e&penses for the auditor. herefore" you !ant to do everythin# you can to prepare in advance. In most instances" you !ill have to pay for an audit even if you fail to pass it. In addition" since most auditors char#e by the hour" you !ant all you documentation and plans up to date and in a lo#ical order. At @A5:hour" you do not !ant to be lookin# about for documents and receipts !hile the auditor !aits for you.

Writing a Food Safety Plan.

he first step in !ritin# a food safety plan is to look over the audit )*5A ,A- audit forms found in $hapter 5 in this notebook. his is the order of !hat an audit !ill #o in and the items the auditor !ill be lookin# for. Boticed the audit form is broken do!n into sections. ,eneral 7uestions -art 1( %arm Cevie! -art <' %ield Harvestin# and %ield -ackin# activities -art =' House -ackin# %acility -art D' *tora#e and transportation -art E' 8holesale 5istribution $enter : erminal 0arkets -art 7' -reventative %ood 5efense -rocedure If you are strictly a #ro!er and do not have a packin# house" you have to comply !ith ,eneral 7uestions and -arts 1 and <. If you have a packin# house" you must do -art =. he other parts are for stora#e units" distribution centers and terminal markets. -art 7 is currently not bein# audited at the present time unless the re1uestin# or#ani2ation is re1uestin# it. *o read over the parts that you !ill have to comply !ith. Botice that some of these are thin#s that an auditor !ill 3ust observe !hile others re1uire some !ritten pro#ram. Botice in the far left column of )*5A ,A- Audit form in column marked +5oc+. A +5+ indicates that a document is re1uired to sho! conformance to the 1uestion. A document may be a combination of a *tandard >peration -rocedure .*>-/ outlinin# a company policy as !ell as a record indicatin# that a particular action !as taken. An +C+ indicates that a record is re1uired to be kept sho!in# an action !as taken. hese may be referred to as lo#s or lo# forms. A +-+ indicates that a policy must be documented in a food safety plan in order to sho! conformance to the 1uestion. The Order of a Food Safety Plan 8hen you be#in to !rite your food safety plan" I su##est you put items in the follo!in# order. 1. Information *heet ( his not actually part of the food safety plan but it provides the auditor some necessary information that is not in your food safety plan. he information includes a farm description" land use : soil" !ater 1uality" pre(harvest assessment" manure usa#e" etc ( *ee the blank form in $hapter =.9 <. $over pa#e: -erson desi#nated to oversee the food safety pro#ram. he cover pa#e is the name and address of your operation. It also tells the auditor the person desi#nated to oversee the food
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safety pro#ram at your operation. his may be you or someone you dele#ate to conduct trainin# and all the other details of the plan. *ee form in $hapter =.$ =. able of $ontents ( his is stron#ly su##ested so the auditor can find various documents and policies easily. *ee e&ample in $hapter =.$ D. 0ission *tatement ( he mission statement says you are a professional interested in the safety of your product and your concern for the consumer. *ee e&ample in $hapter =.$ 5. 0aps ( If a picture is !orth a thousand !ords" maps are !orth even more. Include maps of your entire farm" ad3acent land" sho!in# creeks" slope of land" location" ho! your traceback code system !orks" locations of toilets" rodent traps" packin# houses" etc. 4ou can use hand(dra!n maps or even some online resources like ,oo#le Earth. *ee e&amples in $hapter =.$ E. *tandard >peratin# -lan .*>-/ ( A !ritten *tandard >peratin# -rocedure .*>-/ e&plains ho! your farm or production company complies !ith each audit section. $reate your *tandard >peratin# -rocedure .*>-/ by lookin# throu#h the sample food safety plan and editin# it to conform to your operation once you understand !hat is re1uired in the )*5A ,A- audit checklist. *ee a sample *>- in $hapter =.$ 7. *>- Appendi& he *>- Appendi& contains policies and procedures that re1uire documentation but provided in #reater detail compared to the basic *>-. If policies are short !ith little detail re1uired" most policies can #o in the *>- section but policies and procedures re1uirin# lon#er" more detailed !rite(ups may need to be included in this section. I have numerous policies and procedures in $hapter =.$ for your use if you so desire. F. 5ocumentation: hese are sometimes referred to as +lo# books+. hey can appear inter( dispersed throu#hout the *>- as in our e&ample or as a separate section in the %ood *afety -lan. he enclosed !orksheets in $hapter D are intended to serve as templates to cover most of the documentation and record keepin# that !ill occur as part of a typical food safety pro#ram. %eel free to modify these records to fit your particular situation. 4ou may !ish to include your farm name and lo#o in the top of each sheet but you may !ish to 3ust remove the te&t bo&es. Bot every si2e and type of operation !ill need to use every sheet but use the ones that are needed to tell your food safety story. It is e&pected these sheets !ill serve as a foundation and inspiration for further customi2ation. A. *elf(Audits ( Accordin# to the )*5A ,A- audit 1uestion -art <" item G1 +A documented pre(harvest assessment is made on crop production areas+. 4ou !ill need to do!nload some audit forms and do a self( assessment of operation before bein# audited. his is usually a pre(harvest assessment. *ee $hapter =$ for sample self(audit forms.

>vervie! of the ,A- -rocedures

In #eneral" ,A- focuses on preventin# food risks from microbiolo#ical" chemical and physical ha2ards. 0icrobiolo#ical ha2ards are bacteria like E coli" *almonella" $lostridium perfrin#ens" etc. $hemical ha2ards are thin#s like pesticide and herbicide residues" #as:oil spills" etc. -hysical ha2ards are thin#s like rocks" #lass and other forei#n ob3ects. 9y follo!in# ,A- procedures" !e minimi2e the risk from these various ha2ards. he most common ha2ard is microbiolo#ical. In fact" I !ould estimate that over A0H of produce recalls you hear are about bacteria. As you revie! the )*5A ,A- audit 1uestions" you !ill notice that they focus on areas that control primarily bacterial ha2ards. 6isted belo! are those areas that must be controlled in order to control bacteria. I I I I I I I I 8ater 7uality 0anure and 0unicipal 9iosolids 8orker Health" Hy#iene and *anitary -ractices oilet and Hand(8ashin# %acilities Ad3acent and -revious 6and )se Harvestin#" field packin# and ransportation -ractices Employee rainin# raceability

1/ 8ater 7uality ( 8ater is used for drinkin#" irri#ation and !ashin#. 0any bacteria are transferred from dirty !ater to plants. %or this reason" it is important to have irri#ation !ater checked for coliforms: E coli. 0ost E coli are harmless bacteria but they serve as an indicator of fecal contamination. 5rinkin# !ater must be +potable+ meanin# it is for drinkin# and is 1uite clean. Irri#ation !ater can come from a municipal source" a !ell or surface !ater. 8hen dealin# !ith crops like berries" and fruit eaten ra! .that do not #et a heat treatment/" it is best to use !ell !ater that is tested at least annually. In addition" drip irri#ation systems are preferred over overhead sprinkler system because the !ater is deposited on the roots rather than on the edible portion of the crop. he E-A limit for non(drinkin# !ater .non( potable/ uses is <.< fecal coliforms:100 mls. Irri#ation !ater should be treated if fecal coliforms e&ceed that number. -ond !ater or !ater pumped from a stream or river should #enerally be e&cluded from use as irri#ation !ater.

</ 0anure and 0unicipal 9iosolids ( %eces contains many bacteria that cause food(borne illness. 8hether you use animal manure or processed human biosolids" it is important that it is heated or treated so as to remove or kill harmful patho#ens. =/ 8orker Health" Hy#iene and *anitary -ractices ( Humans are the carriers of many diseases and their hy#iene can cause many problems. 9y only usin# healthy !orkers and makin# sure they understand and practice proper hy#iene and safety practices can !e assure our produce is safe to eat

D/

oilet and Hand(8ashin# %acilities ( his topic may be considered human hy#iene but it is so important to health and is often i#nored" it is considered a topic unto itself. 4ou may have noticed in restrooms there is usually a si#n posted that states +Employees must !ash their hands before returnin# to !ork+. he lack of !ashin# hands is the leadin# cause of spreadin# bacteria and viruses especially those viruses causin# the flu.

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Ad3acent and -revious 6and )se ( 4ou may be runnin# a real safe operation but ho! !as the land used prior to your operation. If it !as used as a dump or a place used to store cattle or chicken manure it could have some very ne#ative conse1uences for your operation. Also" you must be co#ni2ant of ad3acent land use. If the nei#hborin# farm is a dairy operation" it may be hard to keep your produce free of fecal contamination. E/ Harvestin#" %ield -ackin# and ransportation -ractices ( he procedures one uses to harvest" pack and transport produce can have a bi# impact on the ultimate safety of the food product. 9y follo!in# certain procedures as eluded to in the ,A- audit checklist" !e can vastly minimi2e the transfer of patho#ens from e1uipment to produce. 7/ Employee rainin# ( 0ost employees of produce operations !ant to do the +ri#ht thin#+ !hen !orkin# but because of their cultural back#round may not understand the importance of certain procedures re1uested of them. %or this reason" !e need to continually train employees and train them in a !ay that they are most comfortable !ith. Althou#h you may learn best by readin#" many produce harvest people may learn best !ith a video in their native lan#ua#e. F/ raceability ( his term has to do !ith our ability to kno! !here our product #oes and can it be recalled if necessary. -roduce #ro!ers need to be able to code their produce in some !ay to trace it for!ard in the marketplace. %ood manufacturers are also re1uired to be able to track food both +one step for!ard+ .!here they sent it/ and +one step back!ards+ .!here it came from/. Also in this area" !e must perform mock recalls at least annually to prove !e can recall our produce if a problem !ere to arise.

The GAP Manual

he follo!in# is a step by step reasonin# and detailed e&planation of the items in a %ood *afety -lan. It !as adapted from information by 8esley Jline of the Cut#ers E&tension *ervice on the !ritin# of a ,A- %ood *afety -lan. It #oes throu#h the )*5 A ,A- audit procedure !ith su##estions on !ritin# your food safety plan. he )*5A ,A- audit is arran#ed accordin# to the specific sections of the audit on !hich your farm or operation may be assessed. hey include +,eneral 7uestions+ as !ell as these four specific areas: I I I I %arm Cevie! %ield Harvest and %ield -ackin# Activities House -ackin# %acility *tora#e and ransportation

he farm or production operation can be certified in any one or all four audit areas noted above' ho!ever" the General uestions section must be completed before other areas are audited. 5urin# a ,A- audit" you !ill be asked to e&plain and demonstrate ho! your farm or production company complies !ith each of these areas. 5ocumentation !ill be re1uired in some instances" as indicated by the letter +5+ in the same section of the audit 1uestions. A document may be a combination of standard operatin# procedures .*>-/ that e&plains the company policy and the lo# that sho!s the actions taken. An +C+ re1uires a lo# sho!in# the action and a +-+ re1uires a policy:standard operatin# procedure must be documented in the plan. E&amples of the re1uired documents: policies and lo#s are included in $hapter =. hese documents and policies can be modified to fit individual operations. 8e have also included a %ood *afety -lan !hich you may alter to fit your product and operation. Any 1uestion in the audit !here B:A is shaded out must be ans!ered either yes or no. Any shaded bo& in the +B>+ column must be ans!ered +4E*+. If the 1uestion cannot be ans!ered +4E*+" the audit !ill be reported as an +automatic unsatisfactory+ and the audit !ill be stopped. !o areas !hich must be completed before re1uestin# an audit are: a/ 5evelopin# a %ood *afety -lan to e&plain your food safety pro#ram ( the plan should contain everythin# that is included in the farm?s food safety pro#ram" but do not include anythin# !hich cannot be accomplished. b/ 5esi#natin# a lead person in your or#ani2ation ( one individual in the or#ani2ation must be desi#nated by name to implement and oversee the food safety pro#ram. 5urin# an audit" the follo!in# conditions !ill result in an automatic +unsatisfactory+ assessment and the audit !ill be stopped: a/ +An immediate food safety risk is present !here produce is #ro!n" processed" packed or held under conditions that promote or cause the produce to become contaminated.+ E&amples of this !ould be the use of non(potable !ater in the product !ashin# process or a leaky se!er pipe in the production or stora#e area. b/ + he presence or evidence of rodents" or an e&cessive amount of insects or other pests in the production area durin# packin#" processin# or stora#e.+ his can be evidence on the floors" outside buildin#s or other places in the production or stora#e areas !hen the pest may come in contact !ith the produce. c/ +>bservation of employee practices .personal or hy#ienic/ that 3eopardi2e or may 3eopardi2e the safety of the produce.+ E&amples include puttin# used toilet tissue on the floor or in a container in the lavatory' observin# that employees do not !ash their hands after toilet use' eatin# on the #radin# line" etc. a/ +%alsification of records+
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b/ +A documented .!ritten/ food safety pro#ram is not in place+ c/ + he operation has not desi#nated someone to implement and oversee the food safety pro#ram.+ ,ettin# *tarted A documented food safety pro#ram that incorporates !hat the farm does to implement the pro#ram is the first step to complete before considerin# an audit. his %ood *afety -lan tells the auditors !hat you have been doin#" outlines procedures and has e&amples of all forms used to verify ,A-s. *o belo! is a list of items in chronolo#ical order that need to be addressed. -lease note" statements in bold are e&amples of !ordin# that may be used in a food safety plan.

First! collect information that the auditor !ill need. 0ost audits !ill cost about @1"000. Audits char#e for travel and also by the hour. 4ou !ant the auditor to #et in" do the audit and be #one a#ain as fast as possible. herefore" have the information he:she needs available and easy to find. I su##est you fill out the form in $hapter =.9 called ,A- Audit $hecklist. Second! develop a cover pa#e and desi#nate a person to oversee the food safety pro#ram. his person should be a responsible person !ho heads up trainin# and food safety policy for the operation. hey !ill also be the person accompanyin# the auditor. An e&ample of the cover sheet and form re1uired for the desi#nated food safety person is found in $hapter =.$ called $over pa#e: 5esi#nated %ood *afety -erson. Third! create a able of $ontents that corresponds to the specific sections of the audit. ,eneral 7uestions" %arm Cevie!" %ield Harvestin# and %ield -ackin# Activities" House packin# %acility" *tora#e and 5istribution etc. Cemember" you only have to have included in your food safety plan those items that you en#a#e in. A sample table of contents is found in $hapter =.$ Fourth! develop a 0ission or Kision *tatement. 8rite it do!n and place it at the be#innin# of your plan. his statement should address briefly and #enerally your company?s commitment to food safety" food 1uality" food sanitation and !orker hy#iene. *ee $hapter =$ for a sample mission statement. "#ample$ Management and employees of Fruit and %egeta&le 'ncorporated are committed to producing and mar(eting a safe product through good agricultural and handling practices that focus on principles of food safety and )uality.

Fifth! for each section .-art/ in the able of $ontents for !hich you !ill be audited" e&plain in !ritin# as clearly as possible ho! your farm complies !ith that section. 0ake sure standard operatin# procedures are used and e&amples of the correspondin# document forms are included in each section. E&amples of *>-s and documents can be found in $hapters =$.
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Si#th! if you have policies and procedures that are too lon# for the *>-" you may !ish to include a *>Appendi&. *ee $hapter = $ for e&amples of numerous policies and procedures. Se*enth! accordin# to the )*5 A ,A- audit 1uestion -art <" item G1 +A documented pre(harvest assessment is made on crop production areas?L. 4ou !ill need to do!nload some audit forms and do a self(assessment of operation before bein# audited. his is usually a pre(harvest assessment. *ee $hapter =.$ for sample audit forms

Going Through the Audit +hec(list

6et?s no! #o throu#h the )*5A ,A- audit checklist !ith an e&planation of !hat items auditors are lookin# for. his is basically a len#thy narrative of !hat the %ood *afety -lan should contain. Bote: statements in parenthesis and in italics refer to a lo#" si#n or additional information found else!here in this manual. General uestions 'mplementation of a Food Safety Program his section consists of a revie! of the %ood *afety -ro#ram and the %ood *afety -lan that has been desi#ned for your operation. Management must indicate who has &een designated to implement and o*ersee the program and also who is named as the &ac(up in case this person is not a*aila&le. he )*5A ,A- Auditor may be asked for the %ood *afety -lan to revie! before the day of the audit. his !ill speed up the process and reduce time for everyone on the day the actual audit is held. Tracea&ility raceback is the ability to track food items" includin# fresh produce" back to their ori#inal source. his cannot prevent an initial food borne outbreak" but it may help speed up the process to pinpoint the source of the contamination. he faster the source is located" the faster the rest of the produce industry can #et back to normal. . A !ritten procedure must be included in the %ood *afety -lan on ho! the farm !ill track individual containers one step for!ard and one step back. 0aintain as many detailed records as possible includin# the harvestin# dates" specific field and product location !ithin the field or orchard" number of packa#es !ithin a lot" packin# and shippin# date and harvestin# cre!. Each container must also have a +5ate of -ick+ .or the actual date the produce !as picked/. Each container must contain some type of identification to maintain its inte#rity throu#hout the harvestin# and marketin# process. he label on the bo& #enerally is sufficient to trace the product to the farm or packin# house" but each !holesale bo& must have a harvest:packin# date stamp or code !ith the date incorporated on the bo&. -lacin# a label on the !rapped pallet !ill not meet this standard. If packin# in more than one shed or packin# under someone
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else?s label" additional identification is needed to trace the product back to the packin#house. A hand( labelin# #un can be used to code each bo& !here a series of numbers can identify the container. An e&ample of a code datin# system is 1E55EA1E7" !here the first three di#its represent the pickin# date .Mulian calendar date for Mune 1D is 1E5. he fourth di#it is the #ro!er I5 number .5/. he si&th di#it is the field number .E/" the seventh di#it is the picker number .A/ and the last three di#its may be the harvest date .Mulian for Mune 1E may be 1E7/. he other numbers can be used for more information or be 2eros. At the end of each packin# day record the be#innin# and endin# numbers in a book or computer. he code for these numbers needs to be recorded once and filed. he code is to assist the #ro!er if there is a 1uestion about !here product !as sent.. Cecall procedures must be included in the %ood *afety -lan. As a minimum" effective recalls should be able to track produce one step for!ard and one step back. 0ock recalls should be scheduled at least every si& months to ensure the system !orks properly. A mock recall is a practice e&ercise to determine if you kno! !here the product !as shipped and if it can be recall. he farm must document the customers contacted" the amount of product remainin# from the ori#inal shipment and the disposition of product !hich could not effectively be recalled. his may include sales to customers or reshipment to other customers !ho could be contacted if necessary. Auditors !ill revie! the traceback procedures and reports from the mock recall. ,ote$ this does not mean you ta(e control of the product. The auditors want to see if you ha*e the a&ility to ta(e control if a recall is re)uestedWor(er Health N Hygiene his section re1uires mana#ement to describe ho! !orkers are trained and instructed to practice proper hy#iene. "#ample$ Pota&le water is a*aila&le to all employees in the pac(ing shed and through porta&le water stations located in the har*est fields. he company must document that the !ater !as tested at least once a year and indicate it is potable or !hat corrective measures !ere taken to make it potable .*ee Water source testing log). If municipal !ater is provided a copy of the test can be obtained from the municipality. *i#ns should be posted at !ash stations to inform employees that they must !ash their hands before #oin# to !ork" after breaks" or anytime they leave their !ork station and return .*ee Please wash your hands often!). he location of the hand !ashin# station must be visible to the employer or supervisor. Must havin# a sink in the rest room is not acceptable. *i#ns should be posted to inform visitors that they are re1uired to follo! #ood hy#iene:sanitation practices .*ee Visitor sign in sheet and Health & safety notice). If the auditor observes an employee not !ashin# their hands before be#innin# !ork or returnin# to !ork" the audit !ill be an +automatic unsatisfactory+ and the audit !ill be stopped.

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All employees must receive documented trainin# on proper sanitation and hy#iene practices .*ee Employee food safety education and training log). his can be throu#h formal presentations" videos" one(on(one instruction or demonstrations. -eriodic refresher or additional sessions may be needed as ne! employees are hired. he trainin# should include" at minimum" methods of hand !ashin#" method of scrubbin# fin#ernails and proper use of toilet facilities. he portable toilets:restrooms should be cleaned on a re#ular basis and properly stocked !ith toilet paper" sin#le use paper to!els" potable !ater for hand(!ashin# and soap. he use of hand saniti2ers is not a substitute for soap. hey do not do a very #ood 3ob in a#ricultural situations. Also" hands must be !ashed prior to puttin# #loves on hands. A supervisor should keep a record of !hen the facility !as cleaned and by !hom. If a commercial service is used to maintain the toilet facilities make sure they record visits and do proper maintenanceO In some instances" the #ro!er !ill need to desi#nate an employee to service the facilities bet!een the commercial operators? visits. .*ee Use Toilets Properly Please put used toilet paper in the toilet and !estroom and toilet facility maintenance log). *mokin# and eatin# areas must be separate from production or packin# areas. In the field" eatin# and smokin# should be confined to road!ays or ed#es of the field. In packin# house" it should be in desi#nated areas a!ay from the receivin#:loadin# or packin# lines. he area should be separated by painted lines or partitions. *i#na#e in packin# and stora#e areas desi#natin# either no smokin# or smokin# areas is encoura#ed. 8orkers !ith diarrhea disease or symptoms of other infectious diseases should not !ork !ith fresh produce. hey should be #iven the opportunity to !ork in other areas if physically capable. ,ro!ers should encoura#e employees to report any illness at the be#innin# of the !ork day. A policy must be included in the %ood *afety -lan on procedures if someone is sick. "#amples from Good Manufacturing Practices for food processing esta&lishments under ./ +F0! //1./1 state 23a4 5isease control. Any person who! &y medical e#amination or super*isory o&ser*ation! is shown to ha*e! or appears to ha*e! an illness! open lesion! including &oils! sores! or infected wounds! or any other a&normal source of micro&ial contamination &y which there is a reasona&le possi&ility of food! food6contact surfaces! or food6pac(aging materials &ecoming contaminated! shall &e e#cluded from any operations which may &e e#pected to result in such contamination until the condition is corrected. Personnel shall &e instructed to report such health conditions to their super*isors.2 %ollo!in# are some symptoms.

Pathogens Often Transmitted &y Food +ontaminated &y 'nfected Wor(ers. -atho#en *ymptoms
11

Hepatitis A virus *almonella species *hi#ella species E. coli0157:H7 *taphylococcus aureus *treptococcus pyo#enes

%ever" 3aundice" vomitin# Bausea" vomitin#" diarrhea" fever 5iarrhea" fever" cramps *evere abdominal pain" !atery diarrhea" vomitin# 5iarrhea" nausea" vomitin# %ever" *ore throat !ith fever

he %ood *afety -lan must contain a !ritten procedure that describes !hat action is taken should blood or other bodily fluid come in contact !ith the product" ho! the product !ill be destroyed" or removed from the packin# line and ho! food contact surfaces !ill be cleaned and saniti2ed. A statement similar to the follo!in# should be included in the plan: 7lood and 7odily Fluid Procedures When &lood or &odily fluid comes in contact with produce! the product will &e immediately remo*ed from the area in sealed plastic &ags and destroyed. All surfaces that came in contact with the contaminated produce will &e cleaned and saniti8ed &efore using those surfaces for produce. Employees must be instructed verbally or throu#h si#ns posted at various locations throu#hout the facility that they should seek proper first aid treatment if they receive cuts or abrasions. he responsible person should then determine !hether the employee could return to their !ork area or be assi#ned to another task !hich does not brin# them in direct or indirect contact !ith produce. his policy should be documented in the %ood *afety -lan. For e#ample 6 employees are instructed to contact their super*isor for first aid treatment All cuts are treated and the super*isor determines the employee9s a&ility to continue with their wor(. Employees should be sho!n throu#h practical application or videos the proper use of pre(harvest and:or post(harvest application materials. Any individual applyin# materials should have a pesticide license or be under the supervision of someone !ho has the license. >nce the General uestion part has been audited" the auditor !ill calculate the score. he passin# score for this part is 1F0 points .each part !ill have different points/. he auditor !ill first subtract any points that !ere not applicable .B:A/ then calculate the percent score. F0H is a passin# score for each part. his part must be passed before any other section can be audited. Part / : Farm 0e*iew

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All 1uestions covered in the General uestions *ection are applicable to this section. If the farmin# operation does not pass the General uestions *ection then the farm does not meet the minimum re1uirements for a Farm 0e*iew or any other part of the audit and cannot pass it. Water ;sage his section describes the sources of !ater used for irri#ation" applications of pesticides and fertili2ers" coolin# and frost protection and ho! each source is applied. he method of application and the type of crop can have an effect on the potential for microbial contamination and the spread of individual patho#ens. 6ist all the sources of !ater and methods used in the different operations. 8ater used for drinkin#" hand(!ashin# and the final rinse of produce must be +potable+ meanin# safe for human consumption. his means the test for #eneric E coli is 2ero . In some test methods the result may read PabsentQ or PR1Q. *everal patho#ens can be transported in !ater includin# E. coli "almonella species" "higella species" #iardia $yclospora etc. Any of these can cause serious food borne illness if the produce becomes contaminated. In addition" once the produce is contaminated it is difficult" if not impossible" to completely remove the patho#en. 5escribe all irri#ation sources. If municipal !ater is used" an annual report from the locality that identifies the presence and levels of or#anisms should be obtained. %arm !ell !ater should be annually. hese !ater tests can #enerally be obtained from your local county sanitation office. If the !ater source is from surface !ater such as a pond or stream" tests should be carried out three times durin# the #ro!in# season ( at plantin#" at peak use and near harvest. In #eneral" surface !ater should B> be used in berries" fruit and produce that are eaten ra! .i.e. !ithout a heat treatment/. If one does choose to use surface !ater" it is best to use the drip irri#ation method/. 0ost county sanitation offices !ill not test surface !ater so you may have to re1uest samplin# from a certified pro#ram. A list of $ertified 6aboratories can be found at' http:::!!!.ade1.state.ar.us:techsvs:labcert.aspG5isplav 4ou may !ish to call a laboratory first and see if they are !illin# run a pond or stream !ater sample test. *urface !ater tests must include = samples at each testin# period. All tests of irri#ation !ater must include at least fecal coliform and should include #enetic E. coli !ith a count of the number of E. coli or fecal coliform units not 3ust a presence or absence. he report from the testin# laboratory is sufficient for documentation. he laboratory must use an Environmental -rotection A#ency .E-A/ accepted method for the analyses" e#. E-A 1E0= for E. coli. Bote spray !ater must be from a #ood !ater source that does not contain patho#ens above an acceptable level. Acceptable levels for #eneric E. coli present is less than 1<E colony formin# unit or most probable number .cfu or mpn/:100 ml of !ater for one sample or an avera#e of less than 1<E for a 5 sample avera#e. Bo sample can be over
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<=5 cfu:100 ml that comes in direct contact !ith folia#e or 57E cfu:100 ml that does not come in direct contact. he food safety plan should include a statement of your acceptable limit for E. coli. $orrective procedures to be employed !hen re1uired should also be outlined in the %ood *afety -lan .*ee Water source testing log). 8ater for irri#ation should be tested annually or more often for fecal coliforms. .<.< fecal coliforms per 100 mls is the E-A limit for non(drinkin# .non(potable/ uses/. >verhead irri#ation !ater should be treated if fecal coliforms e&ceed this limit. Bo matter !hat the source of !ater" it must be protected from contamination by !ildlife" livestock" manure sources etc. Sewage Treatment Indicate !hat type of se!a#e system the farm uses. If a septic tank is used" identify the location of the tank and drain field and !hether there is a se!a#e treatment facility ad3acent to the farm. Ad3acent means appro&imately %& mile or closer. Includin# a map of the system !ill speed up the audit process. he auditor may ask to be sho!n the draina#e field. Animals:8ildlife:6ivestock It is not possible to e&clude all !ildlife from production fields" but every effort should be made to reduce or e&clude the population !hen possible. his can include fencin#" mechanical scarin#" chasin#" huntin#" etc. 5omestic animals should be e&cluded from production fields durin# the #ro!in# season. his includes pet do#s and catsO 5omestic animal !aste from ad3acent fields or stora#e areas must be e&cluded. his has been the source of several food borne illness outbreaks. If a croppin# area is closer than 1 mile from an animal production area and no natural barrier e&ists" the auditor may say it is too close and those points !ill be lost. Indicate !hether the crops are located near dairy or poultry operations that could pose a contamination risk. 6a#oons located near or ad3acent to fields could leak or overflo! and cause runoff into the fields. Any stored manure should be contained to prevent crop contamination. 0easures should be taken to assure that livestock do not have access to ponds or streams used for irri#ation. he animals should stay appro&imately <00 feet from the !ater source. here is no documentation needed for these 1uestions" but the auditor !ill observe if efforts are bein# taken in this area. $rop areas should be monitored for the presence or si#ns of !ild or domestic animals in the field. his does not need to be done daily" but on a re#ular schedule determined by the #ro!er. his is especially important 3ust prior to harvest. 8alk throu#h the fields at least the day prior to harvest and the mornin# of harvest and note si#ns of animals that have passed throu#h or fed in fields '"ee &nimal monitoring log). Manure and Municipal 7iosolids
14

If no manure or municipal biosolids are applied" indicate that fact in the food safety plan. 0anures can represent a si#nificant source of human patho#ens if not handled properly. 0unicipal biosolids are not recommended for use on small fruit" ve#etable crops or bearin# fruit trees. his is especially important if the crop is #ro!n close to the soil. Indicate !hether the operation uses manure or municipal biosolids. If ra! manure .uncomposted/ is used" apply and incorporate it in the fall preferably !hen the soil is !arm on a cover crop. Ca! manure must be applied at least t!o !eeks prior to plantin# and at a minimum of 1<0 days prior to harvest. If the 1<0(day !aitin# period is not feasible" apply only properly composted manure. Application of manure or biosolids must be documented in the %ood *afety -lan. Cecord the rate" dates and location of applications. '"ee (anure application log) -roperly composted manure lo!ers the level of patho#ens. 5escribe ho! the manure is composed in detail. his includes the type of compostin# .passive or active/" compostin# time" temperature of pile .if active/" ho! many times the pile !as turned and microbial testin# reports for active treatment. If storin# compost prior to application" #ro!ers must use some type of containment to reduce the chance of runoff" leachin#" !ind spread or recontamination. If composted manure or treated biosolids are purchased" documentation of analysis reports must be maintained for each shipment and made available for revie!. hese reports must include the amount of fecal coliform and E. coli present.

Soils Include a short narrative history of the farm or farms in the %ood *afety -lan and describe !hat the land !as used for previously. If the land history indicates a recent possible source of contaminants from dairy" feedlots" other !aste or floodin#" the soil should be tested for microbial contaminants. he results must be available for revie! and any corrective action taken to prevent product contamination must be documented. %loodin# should be addressed in the food safety plan. If floodin# occurs alon# stream beds" s!amps" etc. the soil !ould need to be tested for harmful patho#ens. %loodin# does not include standin# !ater after heavy rains. Tracea&ility 5evelop a map sho!in# all farm fields" #reenhouses and tunnels" then identify them by number or symbol. his can be used if a recall occurs to pin point production areas. Part . : Field Har*est and Field Pac(ing Acti*ities

15

his part relates to harvestin# commodities and packin# them in the field. he emphasis is on !orker sanitation and harvestin# activities. Harvestin# e1uipment should be cleaned re#ularly. -ackin# e1uipment that comes into contact !ith the product should be as clean as possible. A pre(harvest assessment must be carried out prior to harvest. his assessment helps the #ro!er evaluate the field to be harvested and materials needed for harvest .*ee Pre)Har*est &ssessment +og) Wor(er Sanitation and Hygiene 0ana#ement must ensure that employees in the field take the necessary precautions to avoid microbial contamination of the produce. ,ro!ers should make sure that all state and %ederal >ccupational *afety and Health Administration .>*HA/ and %ederal 8orker -rotection *tandards .8-*/ re1uirements are revie!ed !ith supervisors to ensure that the proper number of toilet facilities and potable !ater are available in the field. A porta3ohn must be !ithin 1:D mile or 5 minute !alkin# time. Even if field sanitations units are not re1uired" a toilet facility must be available for all !orkers at a reasonable distanceO 8orker sanitation and hy#iene is one of the main potential sources of produce contamination. his must be stressed to !orkers on a re#ular basis throu#h trainin# and observation. he use of #loves does not take the place of hand(!ashin#O If #loves are used" hands should be !ashed prior to !earin# #loves. *i#ns should be posted in the appropriate lan#ua#e for employees informin# them to !ash their hands after use of the toilet .*ee Please wash your hands often!). he hand !ashin# stations must be placed outside the toilets so !orkers can be observed usin# them. -ortable toilets must be supplied and maintained on a re#ular maintenance schedule and documentation is re1uired for this activity .*ee !estroom & toilet facility maintenance log). Include a !ritten procedure in the %ood *afety -lan about ho! to contain spills should one occur. "#ample$ The ser*ice company is immediately called and a dirt &arrier is constructed around the spill. All field hand(!ashin# facilities must include potable !ater for hand(!ashin#" soap and sin#le(use paper to!els. he field toilets should not be located in the field that is bein# harvested or near product already harvested or packed. 8orkers must be encoura#ed to use field toilets and to use them properly. )sed toilet paper tissue cannot be placed in a bo& or other receptacle in the facility it must be put in the holdin# tank of the toilet. ;sed toilet tissue that is disposed of on the floor or in a &o# will cause an unsanitary condition and will cause the audit to fail. *i#ns should be placed outside and inside the toilet facility to encoura#e proper use" .*ee Please use toilets pro*ided in the field and Please put used toilet paper in the toilet).

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Field Har*esting and Transportation his section relates to the use of harvest trays" tables" baskets" totes" bulk haulin# vehicles or other harvestin# containers used durin# the process of harvestin#. Ceusable harvest trays" totes" bins" etc. should be cleaned and:or saniti2ed appropriately" in a timely manner" and documented in the %ood *afety -lan .*ee Har*esting container saniti,ation). If the containers are stored outside" they should be saniti2ed before reuse. -ackin# containers that are dama#ed or soiled and no lon#er repairable or cleanable should be discarded in an effort to reduce microbial contamination. 8hen harvestin#" !orkers should not stand inside bins or carry personal food items or other non(produce items in the harvestin# containers. Include a statement in the food safety plan that !orkers are prohibited from usin# harvestin# containers for carryin# or storin# non( produce items durin# the harvest season and enforce the rule. All fields packin# re1uires the use of ne! or saniti2ed containers .*ee Har*esting container saniti,ation) that have been stored properly. Each container must have an identifiable label or !ritin# to enable traceability. his can be accomplished !ith a label #un or !ritin# on the container. %ield e1uipment should be cleaned as needed. his includes hand(harvestin# e1uipment .knives" pruners" machetes" etc./ !hich must be cleaned and saniti2ed .*ee -nife $leaning +og and .ield har*esting e/uipment and transportation saniti,ation) on a scheduled basis. hat schedule for the e1uipment" includin# hand(harvestin# e1uipment" must be included in the food safety plan. For e#ample 6 Field (ni*es are cleaned and disinfected at the end of each day &y washing then placing in a container of &leach for at least .1 minutes. 8ater that is applied to !ash and clean e1uipment must be potable .*ee Water source testing log). $are must be taken to remove e&cess dirt or protect field packed produce from contamination because of possible e&posure to manure and animal fecal material in the soil. -lacin# another container under the harvest container or stackin# on pallets !ill help reduce contamination. *ome #ro!ers may !ant to consider usin# harvest aids to keep produce off the #round. 8hen usin# harvestin# e1uipment" the li#hts and any #lass surfaces must be protected so produce does not become contaminated in case of breaka#e. If somethin# does become contaminated the harvest cre! should have instructions on ho! to proceed. For e#ample 6 'f there is glass<plastic &rea(age in the field! the contaminated area will not &e har*ested within fi*e feet and any produce that had &een har*ested from the area will &e placed in plastic &ags and remo*ed from the field. his statement needs to be in your food safety plan. A similar procedure and statement is needed in case of contamination by chemicals" petroleum products" pesticides. %or mechanically harvested crops" devise methods to input and remove forei#n ob3ects such as #lass" metal" rocks" etc. If !ater is used !hen harvestin# in the field" it must be microbial safe" !hich means a !ater test is necessary.

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8a#ons or trailers used to transport produce from the field must be inspected for cleanliness" odors" dirt or debris before be#innin# the loadin# process. -roduce should be loaded in a manner to minimi2e dama#e to the product .*ee .ield har*est & field pac0ing inspecting). Any e1uipment used to haul #arba#e" manure" or other debris should not be used to haul fresh produce or contact containers or pallets that are used to haul fresh produce !ithout first bein# carefully cleaned and saniti2ed. -roducts packed in the field should be protected .covered/ !hen bein# moved to the stora#e or processin# area. arpin# or usin# enclosed trailers !ill reduce the chance of contamination from birds and dust. 8hen the product is unloaded at the stora#e area it should be done under a roof or tarp cover .not mesh cover/. Include in the food safety plan a statement about coverin# produce durin# transport if a coverin# system is used. Each load movin# from the field should have a +trip ticket+ that lists at a minimum: harvest date" field number and number of containers" i.e.: baskets" bins" bo&es" etc. his ticket is passed to the receiver of the product upon delivery. Part = : House Pac(ing Facility his is a critical area for food safety. 8hatever !as done to keep the produce safe durin# harvestin# and transportation to the packin# house can be undone in the packin# house. ,ood handlin# practices that include !ater testin#" disinfection of !ork areas" !orker hy#iene" etc. must be addressed to sell a safe product. 0ecei*ing Harvested product should be properly stored after delivery to the packin# house. -roduct should not be stored in the shade under trees .this is a primary source for contamination from roostin# birds/ or 3ust covered !ith a mesh material. -roduct that !ill be packed several hours or days later should be properly stored under refri#eration or other controlled stora#e appropriate to the commodity. his prolon#s product shelf life and protects it from contamination. Washing<Pac(ing >ine *ource !ater used in the packin# of fresh fruits and ve#etables" either for !ashin# or as a !ay to disinfect or apply !a&es" must be potable. 0unicipal !ater is re#ulated and must be tested for potability on a re#ular basis. If usin# municipal !ater" obtain a copy of their test results at least once a year. %arm !ells should be tested at least t!ice a year to determine if potable .*ee Water source testing log). est results must be available for revie! by the auditors. *urface .ponds" lakes" streams" etc./ !ater is not considered potable for a packin#house and cannot be used unless the !ater source has a treatment system and the !ater is tested on a re#ular basis.

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If usin# !ater" the temperature should be monitored on a re#ular basis in dump tanks" flumes" etc. It can be checked automatically or !ith a standard thermometer at the same time as the disinfectant concentration. his should be done hourly. emperature is critical because if the !ater temperature is cooler than the produce" !ater can be dra!n into the produce. his is of special concern for tomatoes" peppers" apples and potatoes" cantaloupe and peppers .*ee Produce disinfection lo#/. he !ater should be !ithin 10S% of the product pulp temperature. 8hen !ater is taken in" it is possible for microor#anisms to be taken in at the same time. Ceusin# !ash !ater may result in the build(up of microbial loads" includin# undesirable patho#ens from the crop. $onsider practices that !ill ensure and maintain !ater 1uality. here are several practices !hich !ill help reduce cross(contamination and maintain !ater 1uality. hese include: I I I I I I -erform periodic !ater samplin# and microbial testin#. $han#e !ater as re1uired to maintain sanitary conditions. 5evelop standard operatin# procedures for !ater 1uality. $lean and saniti2e !ater contact surfaces includin# dump tanks" flumes" !ash tanks and hydro coolers on a re#ular schedule. Install backflo! devices and air #aps to prevent contamination of clean !ater. Coutinely inspect and maintain e1uipment desi#ned to assist in maintainin# !ater 1uality.

At the end of each day" packin# areas should be cleaned. Also" the !ashin#" #radin#" sortin# and packin# lines should be cleaned and:or saniti2ed to reduce the potential for microbial contamination .*ee Pac0ing house and storage cleaning recommendations Pac0ing house and storage facility) daily inspection log Pac0ing house and storage facility)monthly inspection log and Pac0ing house and storage facility)/uarterly log). -rocedures for carryin# out these practices must be documented in the %ood *afety -lan. 0ake sure to include a copy of all lo#s used to address cleanin# and sanitation in the packin# house. he best !ay to reduce patho#ens is to keep them off the produce in the first place. >nce a product is contaminated" it is very easy for this contamination to be transferred to other produce durin# the packin# process. his makes it critical that the !ater used to !ash" move or disinfect produce is monitored closely. here are several antimicrobial chemicals labeled to treat !ater in the packin# operation. he effectiveness of these a#ents depends on the chemical" physical state" treatment conditions .!ater temperature" pH and contact time/" resistance of the patho#en and nature of the fruit or ve#etable surface. *ome of the products used are chlorine" o2one" ultraviolet radiation and hydro#en dio&ide. here are other products under investi#ation !hich !ill be available in the future. *elect the product !hich !ill fit best for the packin# house operation and follo! all manufacturers? recommendations.

19

If usin# chlorine to disinfect produce" make sure the concentration of free chlorine is correct Ti.e. 100( 150 parts per million .ppm/ for lettuce" cabba#e and leafy #reens" apples and melons' <00(=50 ppm for tomatoes" potatoes and peppersU at pH E.0(7.0 and contact time of 1(< minutes. Bo matter !hich method is used to disinfect produce" the system must be monitored. ,ro!ers !ho have an automated system think there is no need to check it on a re#ular basis. his is not true. 5evelop a manual monitorin# system" even if the system is automated. %or e&ample" chlorine levels" pH and contact time should be checked manually each hour if the system if not automated .*ee Produce disinfection log). he procedure used to disinfect the !ater alon# !ith lo#s should be included in the %ood *afety -lan. If an outside firm is employed to handle the disinfection system their lo#s should be available for revie!. Areas of possible contamination also include open mesh steel cat!alks" motors !ithout shields" overhead drippin#" leakin# pipes" and ceilin#s drippin# from condensation and bo& conveyors to second floor stora#es. -roduct in flo! 2ones runnin# under these mentioned areas could be sub3ect to contamination from dirty shoes" drippin# lubricants and !ater" cob!ebs or dust han#in# from ceilin#s or li#ht fi&tures. *hield the flo! 2one to keep the area contaminant free. Ice or cold !ater .hydro coolin#/ is often used to reduce the temperature of a product. 8ater used for this must be potable in order to reduce the risk of food contamination. If ice is purchased" a !ater report should be obtained from the source to ensure the !ater is potable. If usin# farm !ell !ater" the !ell should be tested t!ice a year for fecal coliform and E. coli .*ee Water source testing log). Ice makin# facilities must be saniti2ed on a re#ular schedule. his includes the production and stora#e area and any conveyors" au#urs or bins used to transport the ice. If ice is purchased" obtain the schedule from the seller. he schedule should be documented in the %ood *afety -lan. Ice must be transported in covered containers. If bins are used" either transport in a closed truck or cover the bins !ith plastic. At no time should ice be placed in !ood bo&es:bins or moved over !ood surfaces. here is a chance !ood !ill #et into the ice then be introduced into the produce. 9ins used to transport ice should be saniti2ed before fillin#. Pac(ing House Wor(er Health and Hygiene %acilities used by employees to take breaks" prepare for !ork and:or eat meals must be clean and separate from the packin# areas. his area may be !ithin the buildin# a!ay from the packin# area or be an outside(desi#nated area. All places must be kept clean to the e&tent that the nature of the !ork allo!s. 8orkers cannot eat or take breaks !ithin the packin# area. 8ater can be allo!ed on a packin# line" but the container must be plastic and located belo! the packin# line. If the packin# house has a !ritten policy related to hairnets" beard nets and any restrictions relatin# to 3e!elry" it must be !ritten do!n. -ersonal hair follicles and 3e!elry such as !atches" earrin#s and rin#s
20

can harbor microor#anisms. he same policy must be enforced for employees and visitors .*ee Please note hairnet 1eard net and 2ewelry policy). 0ake sure to post the policies !here everyone can see them. Pac(inghouse General House(eeping %ood(#rade approved lubricants must be used on all packin# e1uipment. 6ubricants such as 85(D0" 6i1uid 8rench" etc. used in other parts of the packin# area are not acceptable in areas that come in contact !ith the product. %ood(#rade and non(food(#rade lubricants:chemicals must be stored separately either in separate rooms or se#re#ated !ithin the same room. he intent is that the t!o are sufficiently separated and prominently marked in order to prevent cross contamination or mistaken use of non(food(#rade for food #rade. Include a !ritten policy in the %ood *afety -lan related to !here food(#rade lubricants are used and stored. ,rounds surroundin# the packin#house should be kept clear of !aste and litter to discoura#e breedin# of pests and rodents. ,arba#e receptacles:dumpsters need to be maintained re#ularly and located a reasonable distance from the packin# house entrance. his includes emptyin# on a re#ular schedule and closin# the lids !hen not in use. If the dumpster is located ad3acent to the packin# house" it must have a lid. Areas surroundin# the #round around the dumpster should be reasonably free of debris. All #arba#e containers in the packin# facility must be covered. Areas around the packin# house should be #raded to allo! !ater to drain a!ay. If obvious lon#standin# !ater is observed the auditor cannot a!ard these points. -ackin#houses that cannot be enclosed durin# non(!orkin# hours !ill not be considered an enclosed facility. 8hen operatin#" it is normal and acceptable to have some doors open. All #lass materials i.e. li#htin# e1uipment must be covered in case of breaka#e. Any overhead li#htin# re#ardless of hei#ht above the product must be protected or have shatter proof bulbs. he packin# house interior must be clean and maintained. 5urin# packin# operations some evidence of dirt and debris !ill be visible" but there should be no evidence that it has accumulated over time and been i#nored. 5rains for !ash !ater must be clear to prevent !ater from runnin# onto the packin#house floor. All !aste!ater from toilets and hand !ashin# must drain a!ay from the packin# area in case of a spill. A !ritten policy must be included in the %ood *afety -lan on !hat !ill happen to open finished product that is spilled or comes in contact !ith the floor. A statement like the follo!in# could be included in the manual. All product that is spilled! will &e collected and disposed of in the dumpster. Another

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e&ample ( When water is used to disinfect produce the spilled product will &e e#amined for damage. 'f not damaged! it will &e run through the disinfection system prior to repac(ing. >nly ne! or saniti2ed containers are to be used for packin#. If containers are saniti2ed" maintain a lo# and describe ho! the containers are saniti2ed in the food safety plan .*ee $ontainer saniti,ation log). All containers must be stored to protect from birds" rodents and other pests. Pest +ontrol Inside the packin# house" an established pest control pro#ram must be maintained and documented !ith service reports available for revie! by the auditors .*ee 3ait station control log). All traps and bait stations should be numbered" fla##ed and marked on a map for easy identification. 9ait stations containin# poison must be located outside the packin# house. raps and non(poison means can be used inside. 5ocument the pest control pro#ram in the %ood *afety -lan. 8alls" floors" ceilin#s" doors" etc. should be checked for holes and repaired !here pests may enter. In addition" there should be no loose insulation materials protrudin# from !alls or ceilin# !here pests may hide. $onsider usin# screens" !ind curtains" bird deterrent tape" traps" etc. to discoura#e pests. -et do#s" cats or other animals should not be allo!ed to run free in the facility. Tracea&ility he food safety plan must contain a system for tracin# all incomin# and out#oin# product. his can be accomplished !ith stickers" ink stamps or !ritin# on each container. Cecords must be maintained in case of a recall. his can be done !ith a lo# or electronically. *ee the introduction section for an e&ample of a traceability system. Part ? : Storage and Transportation +ontainer and Pallets he stora#e interior must be clean and maintained. 5urin# operations some evidence of dirt and debris !ill be visible" but there should be no evidence that it has accumulated over time and been i#nored. 5rains must be clear to prevent !ater from floodin# the stora#e floor. All !aste!ater from toilets and hand !ashin# stations must drain a!ay from the stora#e area in case of a spill. he stora#e facility should be cleaned on a re#ular schedule or as re1uired to minimi2e free( floatin# dust and other airborne contaminants .*ee Pac0ing house & storage cleaning recommendations Pac0ing house and storage facilities)daily)inspection Pac0ing house and storage facilities)monthly)inspection and Pac0ing house and storage facilities)/uarterly) inspection). All visible debris and unnecessary items should be removed in a timely manner.
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If the products are stored in bulk .i.e. potatoes and onions/ a lo# should be used to inspect the stora#e prior to loadin# .*ee Pac0ing house & storage cleaning recommendations Pac0ing house and storage facilities)daily)inspection Pac0inghouse and storage facilities)monthly)inspection and Pac0inghouse and storage facilities)/uarterly)inspection). Any product stored outside must be covered and protected from contamination. ,rounds surroundin# the stora#e buildin# should be kept clear of !aste and litter to discoura#e breedin# of pests and rodents. his includes emptyin# #arba#e containers on a re#ular schedule and closin# the lids !hen not in use. If the dumpster is located ad3acent to the packin# house" it must have a lid. Areas surroundin# the #round around the dumpster should be reasonably free of debris. All #arba#e containers in the stora#e facility must be covered. A !ritten policy must be included in the %ood *afety -lan on !hat !ill happen to open finished product that is spilled or comes in contact !ith the floor. A statement like the follo!in# could be included in the manual. All product that is spilled! will &e collected and disposed of in the dumpster. Another e&ample ( When water is used to disinfect produce the spilled product will &e e#amined for damage. 'f not damaged! it will &e run through the disinfection system prior to repac(ing. $ontainers not bein# used are stored and protected from contamination by pests" bird droppin#s" dirt and !ater. 8herever containers are stored" inside or outside" they must be covered for protection. he auditor !ill !ant to see the stora#e area. he containers must be protected from e&posure to soil and other forei#n material. A system to repair" clean and:or disinfect containers and pallets should be in place. Pest +ontrol Establish proactive procedures to e&clude pests and animals. *creens" !ind curtains" bird deterrent tape and traps should be utili2ed to reduce problems !ith pests. 5o#s and cats should not be allo!ed to roam the stora#e area. A pest control lo# should be maintained indicatin# dates of inspections" inspection reports and steps taken to eliminate any problems .*ee 3ait station control log). Each trap should be numbered" fla##ed and marked on a map indicatin# bait station location. All bait traps containin# poison must be located outside the stora#e area. >nly non(poison methods can be used in the stora#e areas. he pest control pro#ram should be !ritten do!n and included alon# !ith a copy of the lo# in the %ood *afety -lan. he auditor !ill look over the stora#e areas to see if they are !ell maintained. his includes !hether there are ma3or cracks and crevices in the !alls" doors" ceilin# and floors !here pests may hide. All areas !here pests may enter should be sealed to the e&tent possible. Insulation in the ceilin# and !alls should not be loose. his is an ideal location for birds and other pests to hide. The presence or e*idence of rodents! &irds! other mammal type pests! pets! e#cessi*e amounts of insects or feces in the storage area will result in an immediate failure of the audit.

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'ce and 0efrigeration 8ater used to produce ice should be potable in order to reduce the risk of food contamination. If purchasin# ice obtain a copy of the !ater test from that location or if from a farm !ell have it tested at least t!ice a year .*ee Water source testing log). Ice makin# facilities must be saniti2ed on a re#ular schedule. his includes the production and stora#e area and any conveyors" bins or au#urs used to transport the ice. .*ee 4ce "anitation .acility +og) >btain a copy of the saniti2ation lo# from the icemaker. he schedule should be documented in the %ood *afety -lan. All ice hauled to a separate location must be transported in a closed truck or the bins covered. Bo ice should be transported in !ood containers since the !ood cannot be saniti2ed or ice may #et into the produce. Cefri#eration systems must be maintained re#ularly and kept in #ood operatin# condition. *tora#e temperature lo#s !ill help auditors verify the rooms are maintainin# proper temperatures 5"ee "torage temperature log). It is su##ested that the temperature be checked before startin# !ork for the day. his !ill #ive the most accurate readin# in the stora#e. hermometers should be checked on a re#ular schedule for accuracy and those checks should be documented .*ee Thermometer log). hermometers only need to be checked for accuracy monthly. he easiest method is to place an ad3ustable thermometer in a 3ar !ith crusted ice and !ater. Even if an automated system is in place" thermometers should be manually checked monthly.

A ,ote on cali&ration of your thermometer$ his information on thermometer calibration is brou#ht from +%ood *tore *anitation+" 1AFF" *i&th Edition" ,ravani" Cobert 9." Cishoi" 5on $" $ornell )niversity %ood Industry 0ana#ement 5istance Education -ro#ram" 6ebhar(%riedman 9ooks" $hain *tore -ublishin# $orp. Melting Point of 'ce +ali&ration Method 1. -lace ice in a container and let it melt. <. *tir to make sure that the temperature in the ice:!ater mi&ture is uniform throu#hout the container. =. 8hen the ice is partially melted and the container is filled !ith a 50:50 ice and !ater solution" insert the thermometer and !ait until the needle indicator stabili2es. he thermometer should be =<S% .0S$/. D. If the thermometer is not readin# =<S% .0S$/" it should be ad3usted by holdin# the head of the thermometer firmly and usin# a small !rench to turn the calibration .he&/ nut under the head until the indicator read =<S% .0S$/.

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An important item to remember as you are calibratin# your thermometer usin# the meltin# point of ice method is to never add tap !ater to ice because this !ill not be =<S% .0S$/ but !ill be at a hi#her temperature. he calibration !ill be much more accurate if you use meltin# ice. he refri#eration units should not come in contact !ith produce and the condensers" fans" etc. must be cleaned on a scheduled basis. he best time to clean the units is 3ust prior to the stora#e season. If the rooms are al!ays used a schedule should be established to clean them at least once a year. Cecord !hen the units are cleaned. If stora#e racks are used in the stora#e" make sure ice product does not drip on the produce belo!. Ice product should be stored on pallets at floor level. Transportation Employees should make every effort to ensure that trucks and trailers are clean" free of odors that could taint food taste and #enerally are in #ood condition. Cefri#eration units should be calibrated on a re#ular schedule and produce items should be shipped only !ith produce items. $anvas shoots on refri#eration units should be in #ood shape !ith no rips or holes and securely fastened to the unit and trailer. A lo# must be maintained to sho! that trucks !ere checked prior to loadin# .*ee $arrier monitoring log). -roduce temperature re1uirements durin# shipment should be recorded on the manifest. he trailer should be at the proper temperature prior to loadin#. he refri#eration units are not desi#ned to lo!er temperatures" but to maintain temperatures. If shippin# strai#ht loads of produce" consider placin# a temperature recorder in the trailer to document air temperatures. A company policy must be included in the %ood *afety -lan e&plainin# ho! trucks are loaded to minimi2e produce dama#e. %ollo!in# is an e&ample: Procedure to minimi8e produce damage Produce is palleti8ed with glue strips on the top of each carton! hand stac(ed and wrapped with plastic to secure cartons to the pallet. Pallets are secured with load &races after loading the truc(. Tracea&ility he food safety plan must contain a system for tracin# all incomin# and out#oin# product. his can be accomplished !ith stickers" ink stamps or !ritin# on each container. Cecords must be maintained in case of a recall. his can be done !ith a lo# or electronically. *ee Introduction section for an e&planation of a raceback system.

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Part @ : Pre*entati*e Food 5efense Procedures At the current time" this section is only bein# audited if re1uested by the or#ani2ation re1uestin# an audit. It is rarely bein# audited at the present time.

Further 'nformation
he t!o references belo! #o into #reater detail on the above items for those !antin# more information. $ornell ,A- ( Kery complete. his is very informative !ith documents etc. http:::!!!.#aps.cornell.edu:Educationalmaterials:%Apdfs:$ompleteAssessment.pdf -enn *tate )niversity( 9ack#rounders to )*5A ,A- Audit 7uestions. -rovides an e&planation of the various items in the audit itself" http:::e&tension.psu.edu:food(safetv:farm:ho!(do(i(!rite(a(food( safetv(plan:usda(audit

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