DEPARTMENT OF FOOD TECHNOLOGY

DGMMES COLLEGE MAMPAD

PROJECT REPORT

2018-2019

SONAS EAT A TREAT

AJMAN, UAE

DONE BY

RINSHA PT
 INPLANT TRAINING REPORT

Submitted to department of food technology of DGMMES COLLEGE

OF MAMPAD in partial fulfillment of requirement for the award of BSC in food
technology 2016-2019.
 CERTIFICATE

This is certify that Mrs.RINSHA PT worked under the supervision during

the seasons of 2016-2019 on the project entitled inpalnt training at SONA
ROASTERY ,AJAMAN ,U.A.E. This project report being submitted dept of food
technology

PLACE: MAMPAD HOD

DATE
 ACKNOWLEDGMENT

The project work at the SONA ROASTERY was started under the
sincere guidance of MRS.CIBIA GEROGE head of food technology dept: MES
MAMPAD COLLEGE.

I am also thankful to our principal Mr.P.K.BABU Sir for making all

necessary facilities available for me also great thanks to Mr.JAWAHAR SIR,
Mr.ASKAR for motivating me to do this project.

I am also grateful to GM.Mr.JABAR, Production Manager Mr.SHERIF

of SONA ROASTERY for giving a chance to undergo training of the company.

Also very thanks to Mr.RAJMAL the quality controller of the company

and to Mr.ALIKUTTY who store in charge of the company.

Great thanks to our family, friends for encouraging us throughout.

SL.NO CONTENT PAGE.NO
1 Introduction
2 Dry roasting
3 Frying
4 Product description and verification
1.roasted nuts
2.non roasted nuts
3.fried snacks
5 Manufacturing ,distribution of roasted nuts
and snacks (flow chart 1)
6 Manufacturing ,distribution exporting of
 roasted nuts and snacks (flow chart 1b)
7 Importing ,storage, repacking and
distribution of non roasted nuts ,pulses and
spices
8 Peanut candy production
9 Prerequisite program
10 Design and construction
11 Microbial threatening
12 Eradication test
13 Sanitary facilities
14 Sanitation standard operating procedure
15 GMP programme
16 Maintance related to food safety
17 Programme
18 Delivery
CHAPTER I

INTRODUCTION

SONA ROASTERY uses the freshest ingredients ever since its inception
back in 1992.it is far by the most popular bran for all varieties of nuts as the proven
to be of great value for money. With the goal procedure and sell the best and
freshest through the quality accredited factory in the emirates of AJMAN .U.A.E.
SONA brings a healthy range of nuts, snacks, species etc.

To its consumers it continues to diversify its range of products whilst keeping top
notch standards and creating innovative packaging and marketing value.

Address
Sona Roastery
Muwaihat Roundsbout
Near Ajman Medical Centre
Industrial Aera-1
Ajman,U.A.E.

COFFEE BEANS BEING ROASTED

DRY ROASTING

Dry roasting is a process by which heat is applied to dry foodstuffs without

the use of oil or water as a carrier. Unlike other dry heat methods, dry roasting is
used with foods such as nuts and seeds, in addition to some eaten insects as house
crickets.dry roasted foods are stirred as they are roasted to ensure even heating

Dry roasting can be done in a frying pan or wok (a common way to prepare
spices in some cuisines, or in a specialized roaster as is used for coffee beans or
peanuts .dry roasting changes the chemistry of proteins in the food changing their
flavor, and enhances scent and taste of some spices .roasted spices are commonly
prepared by adding various herbs. Spices and sugars in the frying pan and roasting
until brown

Common dry roasted foods include peanuts butter ,which is made from
peanuts that have been dry roasted ,tea, which is made from tea leaves that have
been dry roasted (either immediately after picking off after fermentation and coffee
and chocolate which are made from roasted coffee beans and roasted cocoa beans
respectively

FRYING

Frying the cooking of food in hot fats or oils, usually done with a shallow
oil bath in a pan over a fir of as so called deep fat frying, in which the food is
completely immersed in deeper vessels of hot oil. Because the food is heated
through a greasy medium, some authorities consider frying to be technically a dry
–heat cooking process.

PRODUCT DESCRIPTION AND VERIFICATION

1. ROASTED NUTS
Major Products Almond roasted & salted
Sun flower seed roasted
Pistachio roasted & salted
White seed roasted
Pranuts roasted & salted

Intended Use Ready to eat

General public
Method Of Distribution %Storage Delivery vans
Ambient temperature

Material Used For Packing Plastic covers,card board box

Labeling Instruction As per u.a.w. law
Shelf Life 6 months -12 months
Distribution Local and international markets
PRODUCT DESCRIPTION AND VERIFICATION
1. NON ROASTED NUTS

Major products Cashew nut chilly

Peanuts chilly
Mixed nuts
Peanuts white plain
Peanuts candy,etc
Intended use Ready to eat
General public
Method of distribution %storage Delivery vans
Ambient temperature

Material used for packing Plastic covers,card board box

Labeling instruction As per u.a.w. law
Shelf life 6 months -12 months
Distribution Local and international markets
SONA ROASTERY Doc.no:01
Revision no: 00
Issue date:15.03.2011
PRODUCT DESCRIPTION AND VERIFICATION
3. FRIED SNACKS

Major products Super banana chips

Green peas roasted
Ring murukku
Tapioca chips etc.
Intended use Ready to eat
General public
Method of distribution %storage Delivery vans
Ambient temperature

Material used for packing Plastic covers, card board box

Labeling instruction As per U.A.W. law
Shelf life 6 months -12 months
Distribution Local and international markets
MANUFACTURING, DISTRIBUTION OF ROASTED NUTS AND SNACKS
(FLOW CHART 1)

PROCESS FLOW CHART 1

Receiving of raw Receiving of Receiving of

material packaging material returned products

Inspection
Packaging material Storage
store

Reject Accept

Inspection

Dry storage
Discard

Frying ccp1 Roasting

Addition of
oil

Removal of Removal
waste of waste
 Cooling

Removal of waste
packing material Packing

Metal desertion ccp1

Finish products
storage

MANUFACTURING,Dispatch
DISTRIBUTION EXPORTING OF ROASTED NUTS
AND SNACKS (FLOW CHART 1B)

PROCESS FLOW CHART 1

Receiving of raw Receiving of Receiving of

material packaging material returned products

Unacceptable Inspection
Accepta Packaging material Storage
ble store

Reject

Inspection

Dry storage
Discard

Frying ccp1 Roasting

Addition of
oil

Flavor mixing
Removal of Removal
waste of waste
 Cooling

Removal of waste
packing material Packing

Metal desertion ccp1

Finish products
storage

Dispatch

IMPORTING, STORAGE, REPACKING AND DISTRIBUTION OF NON

ROASTED NUTS, PULSES AND SPICES

Process flow chart 1

Receiving of raw Receiving of Receiving of

material packaging material returned products

Inspection
Packaging material Storage
store

Reject Accept

Inspection

Dry storage
Discard
 Removal of waste
packing material Repacking

Metal desertion CCP1

Finish products
storage

Dispatch

PEANUT CANDY PRODUCTION

PROCESS FLOW CHART 1

Receiving of raw Receiving of Receiving of

peanuts packaging material returned products

Unacceptable Inspection
Accepta Packaging material Storage
ble store

Reject Dry storage

Inspection
 Preparation Acceptable

Destoning unacceptable
Removal of storage
waste reject
Storage for destined
peanuts area preparation

Roasting
heating

Cooling
Cooling

Removal of splitting
waste
Storage peanuts

Mixing Cooling

Metal desertion ccp1 Packaging

Removal of waste
packing material

Dispatch

PRE REQUISITE PROGRAMS

PREMISES GENERAL

The building and surrounding of SONA ROASTERY are designed,

constructed and maintained in a manner to prevent conditions which may result in
contamination of food products .adherence to the requirement is verified through
the establishment .There is sufficient space in the premises of the building to be
easily accessible by any vehicle for receiving and dispatch of the products finished
.the products supplies of SONA ROASTERY are According to the satisfaction and
requirement of customers.

BUILDING
The building and facilities are designed to readily permit cleaning and
prevent entrance and harboring of pest and entry of environmental contaminants.
Building are sound construction and are maintained in good repair and do not
present any chemical, microbiological or physical hazards to the products. The
building is designed in such a way that it permits adequate cleaning and sanitation,
minimizes contamination by extraneous material, prevents access by pests.

DESIGN AND CONSTRUCTION

Air curtain is installed at the entrance of the warehouse so as to
minimize contamination from dust Floor, walls, ceiling are constructed of material
that is durable, smooth and cleanable
A. LIGHTING AND GLASS POLICY
Adequate lighting is provided in the ceiling with in all area of store to
facilitate maximum visibility. All lighting is covered with plastic casing so as to
prevent contamination of products with glass, dust; any such breakage of the glass
is recorded.

Ref /: glass breakage record

B.CROSS CONTAMINATION
 Traffic pattern of the staff in the storage area is designed to prevent any sort
of cross contamination to the food products proper segregation of products is done
in the storage aera.the flow of work is unidirectional &the workers thoroughly
clean &sanitize their hand after each absence from their station .employees stay in
an different place and it is totally separated from the ware house.
AFLATOXIN
Aflatoxin is a type of mold that is considered a human Carcinogen. It’s
found in certain commonly eaten foods including peanuts,peanuts,butter and corn
,and is most harmful in part of the world where people consumes large amount of
these foods, such as Asia and Africa.
The species of molds that combine to form aflatoxin grow in soils when
conditions are just right Including even decaying food, plants, hay and grains are
piled together to decompose in areas with high moisture and high temperature
There are actually at least 13 different types of naturally occurring aflatoxin
toxic molds that researchers have been able to identify ,of the 13 species the type
called aflatoxin b1 is considered the most toxic ,capable of causing health
problems such as liver disease or cancer. Autoimmune responses, digestive issues
and in rare cases even death.
Research has shown that consuming aflaxtoxin through the food supply is
one of the major issues of liver disease specifically the type called hepatocellular
carcinoma in certain countries such as china and Africa
Rapid test for afltoxin from neogen can screen a wide variety of grain, grain
products and nut samples for total aflatoxins(i.e. B1,B2,G1,G2) at 20ppb ,or
Provide fully quantitative results in the range of 1 to 150ppb.
Neogens agri screen natural toxin kits are screening tests that compare up to
five samples at a time against a known level of toxin. The tests provided visible
results that clearly show whether a sample contains more or less of a toxin than the
control provided.
Neogens,neocolumn for aflatoxin are immunoaffinity columns that
efficiently clean and concerted the toxins prior to analysis by HPLC or neogens
vertex test kits. The aflatoxin DR column also can be read with a fluorometric
reader.
Neogens reveal for aflatoxin screening kit is extremely easy to use and
interpret test strips that screen samples against set thresholds.
Neogens reveal Q+ (QUANTITATIVE) screening kit for aflatoxin is
extremely easy to use and interpret test strips that screen samples against set
thresholds.

2.0 SANITARY FACILITIES

This part of the clause details on the general sanitizing facilities such as wash
rooms ,lunch room and change room, hand washing and sanitizing facilities.

2.1 HAND WASHING AND SANITIZING FACILITIES

Hand washing and sanitizing facilities are made available. Hand washing facilities
are provided near the toilets to wash their hands after visiting the toilets.

Signboards are kept directing personnel to wash their hands with antimicrobial
soap and use of hand sanitizer after using the lavatory.

2.2 EQUIPMENT CLEANING FACILITIES

Equipment cleaning program is designed, implemented and a cleaning program

chart is available for checking
2.3 WATER SUPPLY

Ajman municipality potable water is used .the tank cleaning is done once in 3
months

3.0 TRANSPORTATION AND STORAGE

All incoming material are from approved suppliers and shifted from the containers
of packages or from vehicle to the temperature controlled store rooms

Effective measures are taken to prevent contamination of good by direct or indirect

contact with contaminating material

3.1 TEMPERATURE CONTROL

All goods stored at the warehouse is segregated according to the type and stored
under suitable conditions. Good not affected by atmospheric conditions are stored
at normal room temperature. Whereas good liable to deterioration are stored in
suitable environmental conditions and proper room temperature as specified by the
suppliers /manufactures is maintained.

4.0 STORAGE

This section covers incoming material and non –food chemical products. The
storage capacity at

Total storage capacity is 5500sq.ft

4.1 INCOMING MATERIAL

All the products are properly segregated and stored in order to avoid the
contamination and spoilage. The products are properly segregated and labeled .fifo,
which is first in first out policy, is followed.

Ref: raw material receiving records

FINISHED PRODUCTS STORAGE

Finished goods is stored and handled under conditions to prevent deterioration,

finished products are stored in a way to prevent contamination and deterioration

5.0 EQUIPMENT

All the measuring equipment like weighing balance etc.are properly calibrated .all
the external calibration are carried out by approved agency which establish
traceability national/international standards

5.1 GENERAL EQUIPMENT DESIGN

Equipment and plastics crates are constructed of corrosion resistant material and
moreover there are designed and maintained in the manner that prevents
contamination of food products. Products contact surfaces are non-absorbent, non-
toxic, smooth, free from pitting, unaffected by products and withstand repeated
cleaning and sanitization

5.2 EQUIPMENT INSTALLATION

The equipment is installed in an manner that prevent contamination of product is

adequate space is provide within and around equipment .it is accessible for
cleaning, sanitizing, maintenance and inspection
The equipment is maintained in an clean and hygienic condition in accordance
with the sanitation program

5.3 EQUIPMENT CALIBRATION

Thermometer is fixed in the stores and the calibration record is available. The
digital weighing machine is duly calibrated

5.4 PREVENTIVE MAINTENANCE

Preventive maintenance record is to be maintained and monitored according to the

instructions provided by equipment installer

Ref: preventive maintenance record

6.0 PERSONNEL

Personnel program such as necessary training to personnel and also the

effectiveness of the training program is implemented and available for checking

6.1 MANUFACTURING CONTROL

No manufacturing activity is being carried out

6.2 HYGIENIC PRACTICES

Ongoing training in personal hygiene and hygienic handing of product is provided

to every products handler and training in personal hygiene and hygienic handling
of products is provided to all person entering products handing areas.

6.3 COMMUNICABLE DISEASES

The company does not permit any person, while known to be suffering from or
known to be a carrier of a disease likely to be transmitted through products are
while afflicted with infected wounds, skin infection, sores or with diarrhea, is
Permitted to work in any product handling & storage area in any capacity in which
there is any likelihood of such a person contaminating food with pathogenic micro
–organisms. This aspect is well taken care. Medical card for all workers is
provided.

6.4 INJURIES

The company does not permit any person having open cuts or wounds to handle
products or product contact surfaces. This aspects is well taken care by the
company

6.5 WASHING OF HANDS

It is ensured that all the employee who is entering the storage area, wash their
hands thoroughly with disinfectant soap under warm running, potable water. Hands
are washed after handling any contaminated products and using toilets facilities
.this aspects is well taking care in the company.
6.6 PERSONAL CLEANLINESS AND CONTACT

It is ensured that employees working in products handing &storage area maintain

personal cleanliness while they are on duty. Protective clothing, hair, covering,
functional to the operation the employee is engaged in, are worn and maintained in
a sanitary manner. Gloves are used only in sorting area where it is essential.
Employee in receiving, sorting and storage areas should not wear falling objects
like jewelry. Tobacco, gum, and food are not permitted in products handling Areas.
Personal effects and street clothing are not kept in products handling areas and are
stored in a manner to prevent the contamination of products

6.7 CONTROLLED ACCESS

Outside access of personal and visitors in controlled to prevent contamination .all
necessary precautions are taken to prevent contamination .no person without prior
permission is allowed to enter in products storage area.

Personal program such as necessary training to production personnel’s and also

verify the effectiveness of the training program is implemented available for
checking.

7.0 SANITATION AND PEST CONTROL

The organization has adequate sanitation program and shall be used as per the
customer request
7.1 SANITATION PROGRAM
Written sanitation program is made available to outline the parameter
needing to be controlled in the establishment to ensure safety of the food product.
This also takes care of equipments sanitation program such as floors, walls, ceiling,
drain, lighting devices, refrigeration unit, and anything else affecting the safety
product.
For each area and each piece of equipment and utensil, the written cleaning
and sanitation program specifies the chemical and frequency of the product.
The chemical used are in accordance with the manufactures instruction .the
sanitation program is carried out in a manner that does not contaminate food
product during of subsequent cleaning and sanitizing.
Effectiveness of the sanitation program is monitored and verified by visual
inspection microbiological testing is done as per the decided frequency .record of
monitoring; corrective action and verification results are available.
7.2 PEST CONTROL PROGRAM
Pest control program is available with aims approved by Ajman municipality
pest control section the record for the same are made available the pest control
program includes, the name of a control person for pest control, the name of the
extermination company where applicable or the name of the person responsible for
the program, the list of chemical and method used, a map of bait location, the
frequency of inspection and pest survey and control report are made available
Effectiveness of the pest control program is verified by onsite inspection of areas
for the presence of insect and rodent activity
REF: PEST CONTROL RECORD
STORAGE PRACTICES
All product are neatly stocked on clean pallets with proper labeling and
segregation .the pallets are placed away from wall and product are rotated
On monthly basis to prevent creation of harborage areas for pest. Adequate care is
being given to the storage area for control of dust.
8.0 SAMPLING AND LABORATORY ANALYSIS
Samples of food product shall be once in three month to ajman municipality
approved food testing laborites for microbial analysis as per the approved standard
.the sample shall involve
 Food samples
 Swab counts of equipment
 Swab counts of personal
 Water count once in a year
REF: LAB ANALYSIS REPORT
The following codex alimentarus decision tree was used to identify critical control
points (ccps)
 SANITATION STANDARD OPERATING PROCEDURE

1.0PEST CONTROL PROGRAM

Purpose

To control food hazards and other agents likely to contaminate food

Scope

 This procedure applies to all processing and storage areas, outside

grounds, and office responsibility
 pest control co, and HACCP team leader

OBJECTIVES

To outline the requirement of the pest control program including

 The responsible party for pest control and the frequency of visits, company
license, insurance and certification of PCOS id and signatures of PCOS
 List of approved chemical and method of application of the chemicals
 schematic map identifying the location of all pest control devices numbering
on map matches the numbering system of all devices the use of balt
sections, glue boards, mechanical traps and electric fly killers,
 Content of service report by the contractor, how all traps, glue boards and
EFKS area audited and tracked
 Quarterly pest activity trending in graphical formals including rodents,
crawling insects and flying insects
RESPONSIBLE PARTY AND DOCUMENTATION

The responsible party of the pest control with the facility is pest control and
cleaning service. The contract is contained in the pest file along with company
licenses, insurance and certification of all PCOS. The names of the PCOS in the
file are matched with those on service reports and monitoring traps

MASTER LIST OF APPROVED PESTICIDES

A master list of approved chemicals and their made of application government

approval, MSDS and label for all pesticides are contained in the file .if the
contractor intends to use a chemical not include on the list of approved chemicals,
he must notify us prior to its use and issue a new list of approved chemicals, mode
of application, MSDS and sample labels.

Master list of approved pesticides used on site is contained in the file.

LABELING

 Traps, bait stations, glue board and insectocutor are labeled, moniterd
tracked and record are maintained

CHEMICALS, MSDS AND LABELS

 Each chemical must be approved by the government department for each

approved chemical, a copy of MSDS and label must be includes in the file.
 The concentration of pesticides used /quantity use d must be included on in
case of new suppliers for the supply of finished goods, packaging material
which affect the quality and safety of the products the following procedure is
adopted.
 The concerned outlets the recruitment of the material to be purchased
  The samples obtained are subjected to the analysis for specification
 Based on test results the recommendations are made and intimate to the
purchase department
 Subsequently the sample /material received are kept under test trials prior to
include the party in approved list of suppliers
 If test result are consistent the suppliers name is included in the approved list

Approval: General Manager (s)-is responsible for the recommendation

E. CONTROL OF RECORDS

This document details the procedure to be followed by impact for the control of all
the records viz.quality records, related to HACCP while are maintained to
demonstrate the achievement of the required quality and the effective operation of
the HACCP system

2.0 SCOPE AND RESPONSIBILITIES

This procedure applies to all the records generated by impact trading

3.0 DEFINITIONS

3.1 QUALITY RECORD

A document that furnishes objective evidence of the activities performed of result

achieved

3.2 ADMINISTRATIVE RECORDS

All the records related to administrative activities which include training records

3.3 TECHNICAL RECORD

This includes work sheet, reports, certificate etc.

4.0 PROCEDURES

QUALITY SYSTEM RECORD

 Each staff member of impact is responsible for ensuring that quality records
generated within their work area are indentified in accordance with this
procedure
 Record will be filed, stored and maintained in a good and safe way so that
they are readily retrievable and loss of deteriratation is minimized
 It is the responsibility of the person generating a document to ensure that
they are legible, accurate, complete and identifiable and that they are stored
and maintained
 No unauthorized personnel are allowed access to quality records .internal
and external auditors shall be given full access to review these records. The
request for such access shall be agreed /approved by the concerned
authorized person of impact
 External customers will not have any accesses to these records unless and
otherwise authorized by the general manager

STORAGE FILE

Service report along with the method of application which must match the mode
of application in the master pest control file

2.0 GMP PROGRAMME

PURPOSE

To prevent cross contamination of the product

SCOPE
This program applies to employee, visitors and contractor entering the factory

RESPONSIBILITY

HACCP team leader

OBJECTIVE

 An effective GMPs program for food handlers, maintained department

visitor and contractors
 Posting of GMPS for all employees, contractors and victors
 Employee are trained on GMPS on an ongoing basis
 An established and effective self audit program

PROCEDURE

GMP PROGRAMME FOR FOOD HANDLERS

 Food should be manufactured under clean contiditon

 All people working should be prohibited from wearing insecure jewelry
including ring. Stones, pendants, ear ring, poppy pins etc. a measure to
protect the product from forging material adulteration
 Eating .smoking or drinking, chewing gums and storage of personnel effects
in production area should be prohibited
 All poisons and dangerous cleaning compound, sanitizing agent and
lubricant should be applied and stored in such a manner so as to prevent any
contamination of food product or packing material
 Pluming ,sewage disposal and toilet facilities should be controlled way to
prevent food contamination
  Food processing equipment should be so designed and constructed to
preclude any adulteration of food with lubricant ,fuel, metal fragments and
other contaminates
 All reasonable precautions should be taken to ensure that production
procedure do not contaminate food with fifth, harmful chemical undesirable
microorganism or any objectionable material
 Proper attention should be given to personal appearance and attitude of the
staff
 Eating, smoking or drinking ,chewing gums and storage of personnel effects
in production area should be prohibited
 All poisons and dangerous cleaning compound ,sanitizing agent and
lubricant should be applied and stored in such a manner so as to prevent any
contamination of food product or packing material
 Proper attention should be given to personal appearance and attitude of the
staff
a) A clean, neat and tidy appearance
b) An absence of skin infections
c) Good dental hygiene
d) Clean hands with short fingernails with no evidence of nail biting and short
hairs
e) Clean, polished shoes

Careful and conscientious control is required in the following practices

a) Staff should not wet finger to open bags or to pick sheets of wrapping papers
b) Staff should not pick the nose
c) Whenever testing of food is necessary it should be tone with the disposable
spoons
 d) Coughing and sneezing on to hands should not be allowed
e) Sinks should not be used for hand washing
f) While wearing hand gloves, no other object should be touched e.g trolleys,
trays, door etc.
g) in case it becomes necessary then the gloves should be changed
h) All the workers should wear protective clothing with hairnets and beard
masks wherever applicable
i) No food items crates or bags should be kept on the floor directly
j) All dustbins should always be covered
k) All drainage holes should always be covered
l) Racks should be loaded from top to down and unloaded from bottom up
avoid foreign material to fall on the product
m) Checking of machine prior to use is important to ensure previous days
cleaning

B) GMP PROGRAMME FOR MAINTENANCE STAFF

1. Before entering into processing area, all maintenance staff should wear
protective clothing with hairnets and beard mask wherever applicable

2. Proper attention should be given to personal appearance and attitude of the staff

a) A clean, neat and tidy appearance

b) An absence of skin infections
c) Good dental hygiene
d) Clean hands with short fingernails with no evidence of nail biting and short
hairs
e) Clean, polished shoes
 f) A belief in the need of hygiene

3. All maintenance people entering in the process should not wearing insecure
jewelry including ring. Stones, pendants, ear ring, poppy pins etc. in order to
protect the product from forging material adulteration

4. Eating, smoking or drinking, chewing gums should be prohibited

5. All poisons and dangerous cleaning compound, sanitizing agent and lubricant
should be applied and stored in such a manner so as to prevent any contamination
of food or food product packing material

6. Checking of machine prior to use is important to ensure previous days cleaning

7. Lubricants for the machines should be applied in such a manner as not to

contaminate the food product by spilling

8. Maintentance staff should be very careful about reconciling of parts or tool for
machinery

9.All the machinery should cleaned and covered with plastic cover after working
,if machine is not use put on that one label not in use and if the machine is out of
order write down out of order

10. In case of breakdown, the maintenance workers should properly clean and
sanitize the machinery after maintenance is over before releasing it into production

11.Person showing illness ,open lesions including boils,sores,common cold fever

or any other aliment by which there is a possibility of product their being
contaminated will be excluded from operation until the condition is corrected and
the production in charge should be intimated by disease notification form.

C) GMP PROGRAM FOR CONTRACTOR AND VISITORS

  They must use hair restraint that covers all hair
 The must use beard restraints
 All visitors /contractor shall wear protective clothing when entering the
production to cover any body hair that poses a contamination risk to product
or raw material
 No gum chewing, eating or use of tobacco products in any areas of
production
 no false eye lashes ,false nails, strong perfumes ,body glitter jewels or
exposed nail polish worn in the facility

POSTING OF GMPS

GMPS are posted at all relevant location for employees, contractor and visitors

GMP TRAINING PROGRAMME

Employee are trained on GMPS on an ongoing basis after six months and record
for group of individuals trained are maintained

SELF –AUDIT PROGRAM

Self audit record are established and maintained to check the implementation of
self audit program

PURPOSE

To control food hazards and other agents likely to contaminate food

SCOPE
This procedure applies to all processing and storage aeras, outside ground and
offices

RESPONSIBILITY

Cleaner on duty

PROCEDURE: WASTE DISPOSAL

 Waste disposal is one of the most important practices, proper disposal of

waste is necessary for maintain clean, neat environment and to prevent
contamination
 Solid waste is collected is covered bins and is disposed through the waste
disposal trolley in the municipality trash pins. For the disposal of liquid no
hazardous waste, mainly this wash water is done mainly through the
municipal sewage system.
 All the waste bins are placed in designed areas with proper labeling and all
waste bins are foot operated to avoid cross contamination

4.0 MAINTENANCE RELATED FOOD SAFETY PROGRAM

PURPOSE

To avoid cross contamination

SCOPE

This procedure applies to all equipment requiring maintenance activities which

tool and spare parts are used

RESPONSIBILITY

External maintenance co
PROCEDURE

Whenever there will be machinery breakdown, maintenance Staff will follow the
following procedure

A. ISOLATING AREA

It is the responsibility of the maintenance staff to isolate area by signage/tape or

cordon off area to include that maintenance is underway

B. NOTIFYING RESPONSIBLE PARTIES

Following any maintenance it is the responsibility of the maintenance staff to

notify the concerted personnel so that equipment can be cleaned and sanitized as
per the documented cleaning and sanitizing procedure. Notification is recorded on
the maintenance activity report

C.RECONCILING PARTS AND TOOLS

o The maintentence staff will note the details of the tool and parts
brought inside the production area on the maintenance related food
safety reconciliation checklist
o Following maintenance all parts and tool must be reconciled
accounting and signing on records. Following maintenance all parts
and tool must be reconciled by accounting and signing on records
o if any tools or parts are missing ,it should be informed to the person in
charge

5.0 CLEANLINESS OF STORE SURROUNDING

PURPOSE
To avoid any contamination and maintain cleanliness

RESPONSIBILITY

Store in charge

PROCEDURE

 Removed of dust ,cobwebs on the wall and canopy shall be done every
month
 The floor shall be swept on daily basis
 Plant pots kept inside and outside are clipped ,disinfected cleaned and
maintained by external company
 Rodent traps kept outside are cleaned on daily basis

6.0 DELIVERY VAN

PURPOSE

Protect food from potential source of contamination

SCOPE

Transportation &delivery of finished products to customers

RESPONSIBILITY

Delivery man