FOOD SAFETY INSPECTION REPORT
#SYS-B-209SYS-B-209
City Produce-FreshPoint
4651 Greatland
San Antonio, TX 78249City Produce-FreshPoint
4651 Greatland
San Antonio, TX 78249
INSPECTION DATE
January 27, 2009January 27, 2009
AIB International Inc.
1213 Bakers Way • PO Box 3999 • Manhattan, KS 66505-3999
(785-537-4750) • (800-633-5137) • Fax (785-537-1493)
http://www.aibonline.org/
RATING
A Prerequisite and Food Safety inspection was conducted at this facility on January 27, 2009. The writer was accompanied throughout the inspection by Mr. Hank Weinstein, General Manager, and Mr. Will Compton, Operation Manager.
The writer received excellent cooperation and, on some occasions, the items were immediately corrected.
At the conclusion of the inspection, a meeting was held to discuss the observations, recommendations, and rating.
Based on the observations made, the information obtained, and the criteria set forth in the AIB International Inc. Consolidated Standards for Inspection of Food Distribution Centers, the overall food safety level of this facility was considered to be:
TRAINING
SYSCO HACCP VERIFICATION
(135)
The “Serious” or “Unsatisfactory” items are shaded, boxed, and bolded in the text of the report. Refer to the definitions in the AIB International Inc. Consolidated Standards for Inspection.
The “Improvement Needed” items are designated in bold type and require prompt attention.
AIB International Inc. states that the report as given herein is to be construed as its findings and recommendations as of the date of this report. AIB International Inc. does not accept or assume responsibility for the Prerequisite and Food Safety Programs in effect with (customer). AIB International Inc. is only reporting the food safety conditions of (customer) as of the date of this report and assumes no responsibility or liability as to whether (customer) does or does not carry out the recommendations as contained in this report.
RATING ANALYSIS
DATE OF INSPECTION: January 27, 2009
TYPE OF INSPECTION: Announced to Corporate Personnel OnlyAnnounced to Corporate Personnel Only
OVERALL RATING: TRAINING
RATED ITEMS
UNSATISFACTORY ITEMS:
Item #1.23
Item #4.12
SERIOUS ITEMS:
Item #1.26
Item #5.6
Item #5.9
Item #5.17
IMPROVEMENT NEEDED ITEMS:
Item #1.4
Item #1.22
Item #1.27
Item #2.17
Item #4.1
Item #4.4
Item #4.5
Item #4.6
Item #4.7
Item #4.9
Item #4.10
Item #4.11
Item #5.1
Item #5.5
Item #5.7
Item #5.11
Item #5.12
Item #5.13
Item #5.25
FACTUAL OBSERVATIONS AND SPECIFIC RECOMMENDATIONS
OPERATIONAL METHODS AND PERSONNEL PRACTICES
1.1 All transports/containers and ingredients were inspected upon receipt for cleanliness, pest activity, structural defects, or other issues that could jeopardize product integrity. Inspection documentation, including rejected shipments, was maintained. Minimum temperature requirements were defined for perishable materials, and documented when received on the receiver bill. Documentation of received material temperatures indicated compliance to requirements.
1.2 Food products were stored and removed from storage to prevent product contamination. Materials were stored off the floor and 18 inches (45 cm) away from the wall to facilitate cleaning, inspection and pest management operations. Space was provided between rows of product to allow access for cleaning and inspection. Receiving dates on labels placed by this company during receiving were visible on materials to facilitate stock rotation.
1.3 Storage areas were clean, well-ventilated and dry. Materials in storage were adequately protected against contamination. Packaging materials, toxic chemicals, non-product materials, and research and development materials were segregated. Infrequently used materials, and packaging supplies were inspected on a defined frequency for evidence of infestation. It was understood that frozen foods were not staged for longer than 30 minutes on refrigerated docks or longer than 15 minutes on unrefrigerated docks. An 18 inch (50 cm) painted inspection line was along floor wall junctions around the interior perimeter.
1.4 Ingredients, packaging supplies, and other materials were rotated on a “First-In, First-Out" basis or other verifiable method to ensure stock rotation. No formal procedure was in place to monitor and repalletize insect-susceptible materials such as the two bags of Japanese Bread Crumb bakery item received in November 2008, that were stored for more than four weeks. It was recommended that where products are susceptible to stored product pest activity, such as grain based materials, that they be inspected and documented on the pallet, on a monthly basis for potential pest activity. (IMPROVEMENT NEEDED)
1.5 Pallets were clean, dry, and in good repair. Slipsheets were not provided to protect ingredients and product from damage. Two bags of Japanese Bread Crumbs were stored directly on a pallet in the ambient storage room. It was suggested that the pallet have a slip sheet installed under these bags to prevent potential foreign material from wood or nails that may enter the bag.
1.6 A designated rework area was provided to segregate rework and salvage materials. Rework was processed on a minimum of a weekly basis to prevent excessive inventory. Rework materials were identified for traceability.
1.7 Release procedures were defined for the food products at this facility. Release records indicated that procedures were followed and that materials were only released by authorized personnel.
1.10 N/A – No samples are taken.
1.16 Trash or inedible waste was stored in properly identified and covered containers and handled in a way that did not provide a source of contamination. Trash disposal met regulatory requirements or was disposed of by a licensed contractor.
1.20 Single-service containers were generally not reused and were crushed, punctured or otherwise disposed of to prevent product contamination. A 5 gallon pickle container was used on the exterior of the building as a cigarette container. It was suggested that single service containers not be reused as a sanitary control.
1.22 Materials, work-in-progress, and finished products capable of supporting the rapid growth of pathogenic microorganisms were properly stored. Temperature sensitive materials were stored at 40⁰F (4⁰C) or below or 140 F (60⁰C) or above as defined by country requirement. Continuous recording thermometers were placed in all rooms or areas where frozen foods were stored or handled. Thermometers were understood to be calibrated and maintained according to the ice water calibration procedure observed during this survey, but no record of this calibration was available. Freezers and coolers were provided with vinyl strip doors or other effective methods to maintain temperatures. It recommended that a record of the calibrations be maintained to verify the accuracy of these thermometer units. (IMPROVEMENT NEEDED)
1.23 Incompatible materials were stored under conditions that prevent cross contamination. This includes segregation of raw and cooked materials and hazardous ingredients, such as allergens. Systems were in place to reduce any potential physical, chemical or microbiological contamination risks. An allergen Control program was in place and identified all allergens with the exception of fish; however, Almonds were stored on the center racking over a non allergen, and there did not appear to this writer to be a functioning allergen segregation program. Where needed, measures were in place to prevent material contamination that could cause consumer complaints. It was recommended that all allergens be identified, and stored only like
over like. Protective measures were provided in most areas, by storing iced products on the floor near the floor drain grate, where iced down product was stored over like or dissimilar items, except in one case a ice packed Oceano packaged Savoy Salad was stored over a similar salad material from a different packer, and melting ice was noted between the two products. It was strongly recommended that iced products be stored only over the same field lots, or otherwise protected with a drip pan or other suitable method to prevent potential cross contamination. (UNSATISFACTORY)
1.24 Containers and utensils were constructed, handled, and maintained to prevent contamination. Misuse of containers or utensils was not observed.
1.26 All shipping vehicles were inspected prior to loading for cleanliness and structural defects that could jeopardize product integrity. Inspection documentation was maintained and included lot code designation, amounts, and the point of distribution to ensure traceability and recall. For perishable loads, documentation included the temperature of the precooled vehicle and however no perishable and frozen material temperatures were taken and recorded at shipping. Transportation breakdown procedures were documented to ensure the integrity of materials during transport. Security seals were provided on and documented for all outbound vehicles. In bound Transport refrigeration units are properly fitted with temperature recording devices and procedures are in place to maintain temperatures and allow air circulation. The delivery trucks were one compartment only and did not have the capability of freezer sections. No dry ice of other method was used to store frozen items, such as frozen smoked salmon under frozen conditions during delivery that may be as long as 3 to 4 hours. Although, no frozen loads were being loaded during this survey, it was recommended that frozen items be shipped under frozen conditions to maintain food safety and HACCP requirements. (SERIOUS)
1.27 Adequate hand washing and sanitizing stations were located at appropriate locations and were stocked with single use towels or hand dryers and sanitizers, as appropriate. Hand sanitizer concentrations were monitored. “Wash hands” signs were displayed in restrooms, lunchrooms, smoking areas, and in most cases, by sinks and entries to work areas. The sink in the cool dock near the repack table was labeled as a hand wash sink. It was recommended that the sink be labeled according to the intended use, and that a hand wash sign be displayed nearby to prompt employees to wash hands. (IMPROVEMENT NEEDED)
1.28 Washrooms, showers, and locker rooms were maintained in an acceptable sanitary condition. Lockers were inspected as a sanitary control and no open food or drink was allowed in them.
1.29 Trained supervisors were in place to monitor compliance to Personnel Practices. Personnel were observed washing hands appropriately and good personal hygiene practices were observed. It was suggested that hand washing procedures were monitored periodically for effectiveness.
1.32 Personnel were not observed eating, drinking, or smoking in unauthorized areas, however the GMP program did not specifically define the areas where eating and drinking may occur. It was stated that it was not allowed in receiving and storage areas. All personal property was stored in appropriate locations defined by company programs. The facility did not define any exceptions to personnel practices programs. It was suggested that the policy be defined where personnel may eat, drink, etc.
1.33 Effective procedures were in place to ensure that personnel with boils, sores, infected wounds, infections or other communicable diseases were not permitted to come in contact with food, as required by law.
1.34 All non-facility personnel, including visitors and contractors, followed the facility personnel practices requirements.
MAINTENANCE FOR FOOD SAFETY
2.1 Facility boundaries were defined and controlled. Measures were in place to prevent contamination from local activities or neighboring properties that could impact the facility.
2.2 Outside grounds were maintained in a way that prevents product contamination. Measures included, but were not limited to, managing drainage, litter, weeds, and dust and maintaining waste and equipment graveyards to eliminate pest attraction to the facility.
2.3 Some measures were taken to maintain facility security. Security strategies included: fencing, controlled gate access, controlled parking, locked doors, limited access to sensitive areas, surveillance cameras, truck seals, employee screening, awareness and training programs, etc.
2.4 Adequate space was observed between equipment and structures to facilitate access for cleaning and maintenance activities.
2.5 Floors, walls, and ceilings throughout the facility were well constructed and maintained. The auditor considered this facility to be very well designed and maintained. Drainage was designed and maintained to allow access for cleaning and to prevent product contamination. There was no evidence of roof leakage.
2.6 Fixtures, ducts, and pipes were properly installed and maintained to prevent contamination from leaks, condensation, or insulating material. There was no evidence of flaking rust, paint or other loose materials, such as insulation, on or in a product zone.
2.7 All fluorescent light tubes, essential glass, brittle plastics, and ceramics in the facility are of the safety type or otherwise protected from accidental breakage, or were accounted for in the Glass, Brittle Plastics, and Ceramics Program.
2.8. Adequate ventilation was provided in the facility. Filters were in place in air makeup units to remove particles of 50 microns or larger. Fans, filters, and blowers were maintained on the Preventive Maintenance schedule, were accessible for cleaning, and were operated in a way to avoid product contamination. Ventilation systems adequately minimized odors, fumes, and dust as appropriate to the process. Insect screens were provided on windows or doors used for ventilation to prevent pest entry.
2.9 Adequate barriers were in place to prevent rodents, insects, and birds from entering the facility. Cracks, crevices, and other pest harborages were eliminated and doors were pest proofed to less than ¼-in (6mm) to prevent pest entry.
2.10 There was no evidence of leaks or excessive lubrication in product zones where contamination was likely.
2.12 Operations were separated to prevent product contamination. The process flow was arranged based on personnel, airflow, materials, and equipment. Toilet rooms did not open directly into material storage areas. Where appropriate, wash bays or areas for cleaning activities were located away from work or storage activities.
2.15 The facility followed a written temporary repair program that defined food grade materials appropriate for use with temporary repair materials. Repairs were dated and replaced with permanent repairs as soon as possible. Work orders and repair requests were maintained and demonstrated that temporary repairs were identified and addressed in a timely manner. No temporary repairs were identified during this survey.
2.16 Food contact surfaces were smooth, corrosion-free, constructed of non-toxic material, and there was no evidence of spot or tack welds.
2.17 Temperature measuring devices were monitored frequently and attached to mechanical failure alarms that activate when temperatures exceed set limits. A calibration program that is traceable to a national standard was understood to be conducted by the contracted refrigeration company but no calibration records were maintained, in place for all food-safety related regulating and recording controls. It was recommended that the records of these monthly calibrations be maintained for the cooler and freezer zones. (IMPROVEMENT NEEDED)