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PRODUCTION & PROCESS CONTROLS

Version 4.0

Click to view all PRODUCTION & PROCESS CONTROLS

Key – Those standards which have greater significance (all other standards are normal)

Recommendation – Those which do not affect certification

New – A completely new standard which the member must now adhere to

Revised – A standard that has changed and requires the member to take some different or additional action to before

Upgraded – The standard has been upgraded to a Key standard or from a Recommendation to a full standard

Appendix – Referenced in ‘How you will be measured’. Indicates that additional information is provided in the Appendices, which are available at the end of each section.

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Where to find help – at the end of each section we have indicated where you can get extra guidance if you need it.

Aim:

PRODUCTION & PROCESS CONTROLS

MP.PC.1

Standards

The flow of the process from intake to dispatch must be controlled in order to prevent cross contamination between production areas, by people, equipment or waste

How you will be measured

MP.PC.1.a

Restrictions are in place to minimise movement of people between dirty and clean areas

MP.PC.1.b

Where movement between dirty and clean areas occurs, risk assessed controls such as designated protective clothing and clean protective footwear are in place

MP.PC.2

Standards

Systems must be in place to thaw frozen products in a controlled manner

How you will be measured

MP.PC.2.a

Thawing is undertaken in accordance with documented procedures that outline the temperature and time requirements

MP.PC.2.b

During thawing the surface temperature does not exceed: - 7 degrees celsius for beef, lamb and pork - 4 degrees celsius for poultry

Thawing protocol

MP.PC.3

Standards

Equipment settings must only be completed by trained and authorised staff (New)

How you will be measured

MP.PC.3.a

Controls are password protected or restricted, where applicable

MP.PC.4

Standards

Where online check weighers are used, a procedure must be documented to cover operation and testing (New)

How you will be measured

MP.PC.4.a

As a minimum, procedure includes: – regard to any legal requirements – Identified competent staff responsible for testing – Method and frequency of testing – Operating effectiveness

MP.PC.5

Standards

Packaging must be purchased from approved sources (Revised)

How you will be measured

MP.PC.5.a

The approval system manages any risks to the site

MP.PC.5.b

Warranties are received for packaging that is described as food safe

MP.PC.5.c

Only the correct version of packaging (where labels or printed packaging has changed) is accepted on site and released into production i.e. no obsolete packaging is accepted on site

Packaging approval

MP.PC.6

Standards

Packaging must be suitable for its intended use, as confirmed by up to date specifications (Revised)

How you will be measured

MP.PC.6.a

Up to date and formally agreed specifications available for all packaging

MP.PC.6.b

The specifications detail the suitability and legality of the packaging for its intended use

MP.PC.6.c

Packaging that is in direct contact with food is food safe

MP.PC.6.d

As a minimum, specifications are reviewed every 3 years or sooner if changes occur

Packing specification
Specifications review

MP.PC.7

Standards

A documented procedure for the receipt of packaging must be in place detailing checks that must be carried out

How you will be measured

MP.PC.7.a

Procedure sets out: - visual checks that must be carried out - certification checks that must be carried out

Documented procedures

MP.PC.8

Standards

Packaging must be stored in a suitable, clean, pest-free area

How you will be measured

MP.PC.8.a

Packaging stored separately to raw materials, chemicals and waste

MP.PC.8.b

No evidence of pest contamination or damage

MP.PC.9

Standards

Packaging must be able to be moved to the point of use, without the risk of contamination

MP.PC.10

Standards

Systems must be in place to prevent the use of obsolete packaging, including labels (New)

How you will be measured

MP.PC.10.a

A documented procedure details the control and disposal of obsolete packaging including the disposal of obsolete printed materials e.g. rendering trademarked materials unusable

Documented procedures

MP.PC.11

Standards

Systems must be in place to ensure that products are packed and labelled with the correct packaging/ labelling (Revised)

How you will be measured

MP.PC.11.a

A documented procedure details the system and checks that are made - positive release of packaging/ labels to the packing line - artwork approval from Red Tractor confirming the correct Red Tractor logo use for the product if applicable

MP.PC.11.b

System includes: - before, during, when changing batches of packaging material and at the end of a packing run, checks are made that the correct packaging and labelling is or was in use - checks made of any printing carried out at the packing stage inclding as appropriate, date coding, batch coding, quantity indication, price information, bar coding, country of origin, allergen information - following product changes, checks are made that the correct packaging and labelling is in use - positive release of packaging/ labels to the line - after the packing or labelling run, left over packaging is removed

MP.PC.11.c

The system is managed by responsible, competent and trained persons

MP.PC.11.d

Where offline coding or printing of packaging material occurs, any changes to printing parameters are completed by an authorised member of staff

MP.PC.11.e

For online verification equipment e.g. bar code scanners, the equipment is tested to ensure it is working correctly and can reject product when packaging information is out of specification - testing frequency based on the site’s ability to identify, hold and prevent the release of any affected materials should the equipment fail

Documented procedure, Red Tractor artwork approval

MP.PC.12

Standards

Cooking instructions on packaging must be validated (New)

How you will be measured

MP.PC.12.a

Product cooked according to instructions produces a consistently safe and ready-to-eat product

MP.PC.13

Standards

Systems must be in place to minimise the risk of contamination of product by metal (Revised)

How you will be measured

MP.PC.13.a

Finished retail packs and product for direct sale to consumers (including vacuum and modified atmosphere packs) are: - metal detected or X-rayed in accordance with a documented procedure, or - the risk of contamination is reduced through the use of alternative methods of protection in accordance with a documented procedure, the reliance on which is supported by a risk assessment - - -

MP.PC.13.b

Documented procedure includes the type, location and sensitivity of the detection and/or removal method

MP.PC.13.c

The risk assessment considers: - the risks relevant to the method chosen and, where appropriate, consideration is given to: - supplier approval audit findings - supplier previous performance - customer complaints - product source - risks associated with the production process - the nature of the product - possible end use

MP.PC.13.d

Any evidence that risks have not been adequately controlled results in a complete review of the risk assessment and the protection method chosen. - The decision to not metal detect is fully reviewed by senior management. - The reviews are documented

MP.PC.13.e

Where metal detectors or X-ray equipment are used, they identify contaminated product i.e. contaminated product is either automatically rejected and diverted from the line or the line stops, with an alarm

Metal risk assessment and procedures

MP.PC.14

Standards

Documented procedures must be implemented when the metal detector or X-ray equipment detects contaminated product (Revised)

How you will be measured

MP.PC.14.a

Procedure outlines the actions to be taken when contaminated products are detected, including: - re-testing requirements - investigating to identify the contamination - when products must be destroyed

Metal detection procedure

MP.PC.15

Standards

Where a product is found to be contaminated with metal, the source of contamination must be investigated and action taken to prevent a reoccurrence

MP.PC.16

Standards

Metal detectors or X-ray equipment must be tested regularly for correct functioning, in accordance with a documented procedure (Revised)

How you will be measured

MP.PC.16.a

Documented procedures detail the frequency, methods and recording of test results

MP.PC.16.b

Where metal detectors are used, the documented procedures include: - type of test material i.e. separate pieces of ferrous metal, stainless steel and non-ferrous material (or if a foil container is used, ferrous only) - size of test material for the different product types - placement of the test material to check accurate detection (i.e. placing at the point of lowest sensitivity, passing through the centre of the detector)

Metal detecting test procedures

MP.PC.17

Standards

Where a test on a metal detector or X-ray equipment fails, corrective actions must be implemented

How you will be measured

MP.PC.17.a

Actions include: - stopping use of the affected machine (where necessary stopping the production line) - retesting all available products that have passed through the detector since the last successful test - recording and reporting of the issue and corrective action to senior management

Corrective action

MP.PC.18

Standards

Where a site is handling known allergens, risk assessed procedures must be in place to minimise the risk of allergen contamination of products (Revised)

How you will be measured

MP.PC.18.a

Risk assessment is used to identify the potential allergens on site and the risks that need controlling

MP.PC.18.b

Procedures are in place to control the risks and prevent cross contamination (cross-contact) of any product not containing the allergen.

Risk assessed procedures

MP.PC.19

Standards

A risk assessed schedule of finished product testing must be in place (Revised)

How you will be measured

MP.PC.19.a

A risk assessment determines the frequency of testing

MP.PC.19.b

Testing schedule is documented, along with testing methods and specified limits

MP.PC.19.c

Test results are reviewed regularly to identify trends

MP.PC.19.d

Test results are kept for 3 years

Testing schedule and results

MP.PC.20

Standards

Where testing identifies non-conforming products, corrective action must be implemented (Revised)

How you will be measured

MP.PC.20.a

Where non-conformities and/or unsatisfactory trends are identified, the root cause is determined and corrective and preventative action is implemented where applicable

MP.PC.20.b

All relevant details are recorded and reported to senior management

Corrective action

MP.PC.21

Standards

Any testing carried out that is critical to product safety and legality, is to internationally recognised methods in appropriately accredited laboratories

How you will be measured

MP.PC.21.a

Laboratories are accredited to ISO 17025, CLAS, Lab Cred or equivalent, demonstrated by a current certificate

Lab certificate

MP.PC.22

Standards

Non-conforming products must be dealt with appropriately, in accordance with the site’s documented procedure

How you will be measured

MP.PC.22.a

The procedure details the action to be taken which may include re work; quarantining or rejection; destruction

MP.PC.22.b

Destruction or waste disposal is carried out in accordance with legislation

MP.PC.22.c

Non-conforming products must be clearly labelled/ identified as such

MP.PC.22.d

Where a non-conformity is in relation to safety of the product, a root cause is undertaken and all relevant details recorded

Non-conformity root cause

MP.PC.23

Standards

Systems must be in place to check the fitness of livestock for human consumption (Revised)

How you will be measured

MP.PC.23.a

Food Chain Information is received and reviewed for all incoming livestock to verify livestock

MP.PC.23.b

Food Chain Information is used to verify that incoming liestock are: - not within withdrawal period - not showing signs of abnormality - within a Salmonella Control Plan (pigs & poultry)

MP.PC.23.c

All incoming livestock are visually assessed for signs of disease or conditions

MP.PC.23.d

Livestock considered unfit for human consumption are rejected, handled/ disposed of accordingly and do not enter the food chain

MP.PC.24

Standards

Systems must be in place to ensure that livestock are of suitable cleanliness at slaughter

How you will be measured

MP.PC.24.a

A documented Clean Livestock Policy is in place that sets out the site’s livestock cleanliness standards

MP.PC.24.b

The requirements of the policy are communicated to suppliers and all incoming livestock checked against it

MP.PC.24.c

Where the requirements of the clean livestock policy are not met at intake, corrective action is implemented

Clean livestock policy

MP.PC.25

Standards

Where the monitoring identifies suppliers failing to meet the sites requirements, corrective action must be implemented (Revised)

How you will be measured

MP.PC.25.a

Corrective action includes reporting a persistent and recurring issue to the appropriate farm assurance scheme

MP.PC.25.b

If a supplier is a Red Tractor Assured farm or transport member, the recurring issue is reported to Red Tractor

Corrective actions

MP.PC.26

Standards

Systems must be in place to prevent cross contamination between species on the slaughter line in multi species abattoirs

How you will be measured

MP.PC.26.a

Slaughter of different species separated by time and cleaning or space (e.g. separate slaughter lines and separation in storage)

MP.PC.27

Standards

Risk assessed systems that minimise contamination of the carcase must be implemented

How you will be measured

MP.PC.27.a

Systems in place to avoid contaminating the carcase during the bleeding and dressing (evisceration, skinning) process by: - use of clean, regularly sterilised knives - carrying out evisceration in a manner to avoid spillage of the digestive tract - dealing with gut bursts/ removing abscesses during the evisceration process

MP.PC.27.b

Systems in place to avoid contamination of the carcase by wastes produced on the production line

MP.PC.27.c

Systems in place to remove, test and dispose of Specified Risk Material (in accordance with legal requirements and a documented procedure)

MP.PC.27.d

The production line is designed to reduce the likelihood of carcases touching one another

MP.PC.27.e

The design of the production line prevents carcases touching surfaces (walls etc.) within the site

MP.PC.28

Standards

Systems must be in place to identify, isolate and deal with diseased, dirty or otherwise contaminated carcases

How you will be measured

MP.PC.28.a

Carcases are regularly checked along the production line for signs of contamination

MP.PC.28.b

Carcases dealt with in accordance with a documented procedure

MP.PC.28.c

Carcases: - trimmed where the contamination is minor, or - partially or fully rejected for human consumption where the contamination is major or the nature of the contamination is that the carcase cannot be made food safe

MP.PC.28.d

Where the carcase is rejected, the root cause is investigated and appropriate corrective action implemented

MP.PC.29

Standards

Risk assessed systems that minimise contamination of the carcase must be implemented (Revised)

How you will be measured

MP.PC.29.a

Staff in contact with carcases wash hands regularly to avoid spreading contamination

MP.PC.29.b

The evisceration process design minimises contamination of the carcase, including venting undertaken in a way that avoids the rupture of the intestinal tract

MP.PC.29.c

At appropriate points along the production line carcases are washed, inside and out, with clean potable water

MP.PC.29.d

The design of the line prevents carcases touching surfaces (walls etc.) within the site

MP.PC.29.e

Birds are inspected post plucking to ensure feather removal has effectively taken place

MP.PC.30

Standards

Systems must be in place to identify, isolate and deal with diseased, dirty or otherwise contaminated carcases

How you will be measured

MP.PC.30.a

Salmonella positive flocks are processed in line with HACCP principles which ensures measures are in place so that positive carcass are kept separate from other carcases

MP.PC.30.b

Carcases dealt with in accordance with a documented procedure including regular checks along the production line for signs of contamination and disposed of into category 2 waste stream

MP.PC.30.c

Where the contamination is minor the carcase may be portioned condemned

MP.PC.30.d

Where the contamination is major and the carcase cannot be made food safe, it is disposed of into category 2 waste stream

MP.PC.30.e

Where condemned carcases exceed expected levels the root cause is investigated and appropriate corrective action implemented

MP.PC.30.f

Carcases are clean and free from contamination prior to deboning

MP.PC.31

Standards

Systems must be in place to minimise the risk of staff handling raw poultry meat coming into contact with packagings