Document printed for Helen Nicholl of Princes on 20/06/2006 Uncontrolled copy if printed INTRODUCTION Low acid sterilised foods are defined as products, any component of which has a pH > 4.2 at the end of a process and which can support the growth of Clostridium botulinum. Chapter printed for Helen Nicholl of Princes on 20/06/2006 1. ROLE OF SENIOR MANAGEMENT 1.1 Senior management and especially the Principal of the Company and his Production Executive shall understand, approve and support these safety standards. They shall ensure that persons given delegated responsibility for day to day implementation are fully aware of and competent to perform critical duties. 1.2 A suitably qualified Technologist with experience of cannery operations and heat process evaluation shall be employed by the Company. An individual satellite production unit shall have a resident technologist or technician who has a direct line to the Company Technologist. Chapter printed for Helen Nicholl of Princes on 20/06/2006 2. LABORATORY Each production site should have suitably equipped laboratory(microbiological and chemical) that has been approved by Marks and Spencer plc and/or accredited by a suitable authority e.g. Campden Food R.A. Alternatively a contract should be in operation with an outside accredited laboratory. Chapter printed for Helen Nicholl of Princes on 20/06/2006 3. RAW MATERIAL CONTROL 3.1 All raw materials shall be bought to an agreed specification from known suppliers. 3.2 Where appropriate key ingredients should have a relevant microbiological standard included in the raw material specifications. There should be facilities for the monitoring of incoming consignments. Chapter printed for Helen Nicholl of Princes on 20/06/2006 4. CAN MANUFACTURING 4.1 All cans for St Michael product must be from an approved source agreed upon by Marks & Spencer and the manufacturer. Cans are to be bought to an agreed specification, confirming the critical control points outlined in Appendix 1. 4.2 Can making plants must exhibit hygiene standards commensurate with those required for good food manufacturing practices. 4.3 It is the responsibility of the Food Manufacturers Technical team to ensure that the agreed standards are achieved and maintained. 4.4 There shall be an ongoing documented system of auditing the can maker (minimum 2 times per year). Page 1 of 33 Untitled Document 6/20/2006 file://P:\Buyer%20Requirements\Marks%20&%20Spencers\Low%20Acid%20COP%20Ju...
Transcript
Document printed for Helen Nicholl of Princes on 20/06/2006
Uncontrolled copy if printed INTRODUCTIONLow acid sterilised foods are defined as products, any component of which has a pH > 4.2 at the end of a process and which can support the growth of Clostridium botulinum.Chapter printed for Helen Nicholl of Princes on 20/06/2006
1. ROLE OF SENIOR MANAGEMENT1.1 Senior management and especially the Principal of the Company and his Production Executive shall understand, approve and support these safety standards. They shall ensure that persons given delegated responsibility for day to day implementation are fully aware of and competent to perform critical duties.
1.2 A suitably qualified Technologist with experience of cannery operations and heat process evaluation shall be employed by the Company. An individual satellite production unit shall have a resident technologist or technician who has a direct line to the Company Technologist. Chapter printed for Helen Nicholl of Princes on 20/06/2006
2. LABORATORYEach production site should have suitably equipped laboratory(microbiological and chemical) that
has been approved by Marks and Spencer plc and/or accredited by a suitable authority e.g. Campden Food R.A. Alternatively a contract should be in operation with an outside accredited laboratory. Chapter printed for Helen Nicholl of Princes on 20/06/2006
3. RAW MATERIAL CONTROL3.1 All raw materials shall be bought to an agreed specification from known suppliers.
3.2 Where appropriate key ingredients should have a relevant microbiological standard included in the raw material specifications. There should be facilities for the monitoring of incoming consignments.Chapter printed for Helen Nicholl of Princes on 20/06/2006
4. CAN MANUFACTURING
4.1 All cans for St Michael product must be from an approved source agreed upon by Marks & Spencer and the manufacturer. Cans are to be bought to an agreed specification, confirming the critical control points outlined in Appendix 1.
4.2 Can making plants must exhibit hygiene standards commensurate with those required for good food manufacturing practices.
4.3 It is the responsibility of the Food Manufacturers Technical team to ensure that the agreed standards are achieved and maintained.
4.4 There shall be an ongoing documented system of auditing the can maker (minimum 2 times per year).
4.5 If there is any deviation from the specification or normal can quality, the can maker must be notified immediately. Can lots with defect cans must be quarantined until a full and thorough investigation has been implemented by both the can maker and manufacturer.
Any critical or major defects must be notified to Marks & Spencer. Failure to do so may result in product withdrawal.
4.6 Finished pallets of Cans/ends shall be fully labelled (appendix 2) Chapter printed for Helen Nicholl of Princes on 20/06/2006
5.0 PACK INTEGRITYA strict system for the reception and checking of containers is to be specified and documented (appendix 3). Chapter printed for Helen Nicholl of Princes on 20/06/2006
5.1 CAN SEAMING STANDARDS
5.1 CAN SEAMING STANDARDS
5.1.2 Sufficient seamer mechanics and seam checkers shall be on site throughout production. Mechanics and checkers must have attended a theoretical and practical course of instruction.
5.1.2 Seam analysis shall be carried out with the tear down technique as the primary standard. Section and visual display and/or pressure testing may be used as supplementary aids.
5.1.3 A can shall be taken from each seaming head and the canners end checked:
- before start of production.
- at 2 hourly intervals.
- after any adjustments to seaming heads, and
- at each change of can size.
Records shall be kept of these checks.
5.1.4 All staff employed on and around the seaming operation shall be taught to recognise can seam defects - including skidders, cut overs, knocked down flanges, false seam, split droops and other irregularities.
Ref:- Campden Food Research Association "Visual Can Defects" document for training purposes.
Visual checks of the can makers double seam, side seam and canners end seam shall be made by staff on a continual basis. Records of their findings must be kept.
5.1.5 The Technologist shall co-ordinate seam checking operations and the assessment of results.
5.1.6 Double seams should be produced to the following critical parameters.
Actual overlap : 1.02mm (0.04 inch) minimum
% Body Book Butting : 70% minimum
Tightness rating : 70% wrinkle free seam minimum
Measurements should be taken from at least three points on each can including all corners on irregular shaped cans. A System shall operate for the adjustment of the seamer when critical measurements approach the can makers tolerances.
Cans produced with double seams outside the critical parameters shall be quarantined with a Marks and Spencer technologist informed.
Any modification to these standards can only be authorised if it is agreed in writing with a Marks and Spencer Technologist and included in the Product File.Chapter printed for Helen Nicholl of Princes on 20/06/2006
See relevant Codes of Practice for standards to be adopted (Appendix 4).
5.2.1 The container manufacturer's specification should be carefully followed. In particular barrier thickness, sealing and process conditions must be agreed and carefully monitored.
5.2.2 Visual examinations of heat seals should be continuous.
5.2.3 Detailed examination of the seal area should be carried out frequently during production and evaluated by agreed methods
e.g. (a) pressure/vacuum techniques
(b) dye testing
(c) gas detection equipment
(d) electric current
5.2.4 Establishment of the process schedules must be carefully considered particularly with regard to the position of the cold spot in geometrically irregular containers.
5.2.5 Processing schedules will be confirmed by 100% incubation of all new St Michael products.
5.2.6 Processed products must not be wet handled.
5.2.7 Refer to C.O.P. for plastic containers, Appendix 4, No. 4.
Chapter printed for Helen Nicholl of Princes on 20/06/2006
6..0 PROCESS CONTROLThe Technologist shall be responsible for specifying all aspects of process control. A HACCP shall be put together for each process in line with appendix 6. The following points must be covered.Chapter printed for Helen Nicholl of Princes on 20/06/2006
6.1 CONTAINER FILLINGFor each product there shall be written clearly defined parameters critical to safe heat processing. These parameters may include:
- Uniformity of product mix.
- Addition of thickener.
- Multishot fill accuracy.
- Headspace.
- Temperature prior to retorting.
- Use of chilled/frozen raw materials.
- Vacuum.
Chapter printed for Helen Nicholl of Princes on 20/06/2006
6.2 RETORT OPERATORSAll retort operators shall be considered as key personnel and have received theoretical and practical training. Chapter printed for Helen Nicholl of Princes on 20/06/2006
6.3 RETORT OPERATION
Each retort shall be equipped with the following instrumentation:-
6.3.1 THERMOMETERS
A mercury in glass bulb thermometer or platinum resistance thermometer (P.R.T) shall be regarded as the primary temperature measuring instrument. Other temperature measurement instruments can only be considered as a guide to the temperature. The thermometer or thermocouple shall be connected into free steam with a 2mm bleed in a steam retort or immersed in process water in a water retort.
The thermometer should have a scale of not less than 150mm (6 ins) for a range of 500C (1220F) and should be graduated in divisions of not more than 10C or 20F. The scale must be cross referenced to the glass by a datum line.
The retort thermometer shall be calibrated quarterly at the process temperature and in the appropriate medium (i.e. steam or water) against an internationally approved standard thermometer (e.g. National Physical Laboratory). The thermometer shall be numbered and marked with the date of last calibration. The approved standard thermometer shall be checked every 3 years.
One accurate clock or two or more synchronised clocks shall be sited within the retort area in an easily seen position. This must be used as the sole means of recording time measurements.
6.3.3 TIME/TEMPERATURE RECORDERS
Shall be fitted to all retorts. Charts must be of adequate size to easily identify 10C and 1 minute divergences.
When processing, the retort operator shall synchronise the chart with the clock and mark the appropriate product code on the related temperature curve of the chart. The charts shall then be forwarded to the technologist for examination each day.
6.3.4 PRESSURE GAUGES
A pressure gauge shall be fitted to the main steam line serving the retort area. The gauge shall be clearly marked with the minimum pressure required to achieve adequate venting of all retorts simultaneously.
In addition, each retort shall be fitted with a pressure gauge.
6.3.5 HEAT PROCESSING LOG
There should be a written log to record the critical parameters of heat processing. An example of a suitable log is given in appendix 5. The information recorded shall be identifiable to each retort batch and should be forwarded to the technologist for examination each day.
Retorts with automatic controls and read-outs must be supported by manually written logs.
6.3.6 RETORT OPERATION MANUAL
A manual should be available to the retort operator covering the following areas.
A description of the operation of the retort Venting procedures, cooking times/temperatures and cooking procedures for each product. An outline of how to complete the processing log. Retort basket control systems. Written systems to cover foreseeable process deviations such as filler breakdowns, pressure loss, low initial product temperature and experimental work.
All continuous cookers must have a physical carrier bar or revolution counter to enable full separation of standard products from isolated non-standard products e.g. during the run-out of product which have been subjected to a cooker stoppage.
Where appropriate, additional controls may be required, for example:
Hydrostatic cookers shall incorporate the following:-
At least two mercury in glass thermometers, one at the bottom and one at the top of the steam chamber.
A permanently open 6mm bleed situated in the steam chamber, just above the operating water level and visible to the operator.
A system for measuring and recording chain speeds to ensure the sterilising time is controlled within ± 1 minute.
Rotary basket retorts shall incorporate a system to record the rate of rotation of the baskets. The accuracy of rotation shall be controlled to within ± 0.5 r. p. m.
Water circulation retorts shall incorporate a visible and audible alarm to indicate the failure of the re-circulating pump.
Water retorts shall incorporate a water sight glass.
Fan/Circulation Systems (e.g. air/steam retorts) should be fitted with a sensor (e.g. proximity detector) connected to an audible alarm system.
Showered water retorts should have similar alarm systems to monitor water circulation pumps. The state of holes in shower heads must be checked weekly.
Heat exchangers should be cleaned on both sides with inhibited acid to maintain the highest rates of heat transfer. Where heating and cooling of the process water is direct only water of the correct microbiological quality may be used.
Reel and Spiral sterilisers require careful consideration with regard to:-
- Filling controls of solid/liquid ratio
- Condensate removal
- Rotational speed of the retort which should be specified in the scheduled process
- Can revolution
- A cooker speed recorder should be linked to the main drive gear.
- Permanently opened steam bleed units must be fitted at a maximum of 2 metre intervals along the top of each cooking shell.
6.3.8 RETORT BASKET CONTROL
The layout of the retort area must be designed to prevent unprocessed cans by-passing the retorting operation. There must be clear physical and personnel separation between the unprocessed and processed cans.
Heat sensitive tape or tags which change colour at a pre-determined temperature shall be attached to a sample of cans in each retort batch. The tape or tags must not be fixed to the basket.
The following information should either be written on the heat sensitive tape or attached to each retort basket.
Date
Product Code
Retort number
Position of basket within the retort
Retort cook number
There must be a written document to record critical process and retorting details relating to each retort basket from filling to packing. Details to be recorded should include product code, basket number, batch identification, retort number, date of packing/labelling.
There must be a system at the end of the operation for collecting the heat sensitive tape/tags when the product is being labelled. This information should be forwarded to the technologist and be fully identifiable with incubation samples and finished product code.
There should be a daily reconciliation of baskets filled against baskets processed and process records should be signed off by a qualified person.
The retort operator should be responsible for checking the condition of the retort basket and confirmation of the correct stacking systems within the basket.
There should be a quarantine area or system to isolate cans that may have received an incorrect heat process.
6.3.9 EXPERIMENTAL WORK
Experimental work which includes any change in processing, no matter how slight, shall be isolated from normal production, clearly identified and only released for normal consumption if tests show with certainty that the product is correctly processed.
A heat distribution examination of each retort must be carried out every two years and the records retained.
At least six temperature probes should be sited between the product throughout different areas of the retort. One probe should be sited next to the mercury bulb thermometer and the retort chamber filled with cans.
The temperature variation in the retort once the sterilisation temperature has been reached should
be no greater than +10C or - 0.50C (+20F or - 10F) of the mercury bulb thermometer and achieved within one minute of the hold period starting.
THE HEAT DISTRIBUTION EXAMINATION MUST BE REPEATED AFTER ANY ALTERATIONS TO STEAM FLOW, CHAMBER DESIGN, BASKET LOADING SYSTEM, LAYER PAD MODIFICATIONS AND ANY OTHER MATERIAL CHANGE IN RETORT OPERATION.
6.3.11 VENTING
The information obtained from the heat distribution should be used to arrive at a venting schedule for each retort. There should only be one venting schedule for each retort based on the most adverse conditions established during heat distribution.
The venting schedule should be incorporated into the Retort Operation Manual and should take the form "vent for __________minutes and then continue venting until a temperature of _________is reached".
6.3.12 ESTABLISHMENT OF A HEAT PROCESS
The Fo value of each process must be determined, discussed and agreed with the Marks and Spencer technologist. IN ALL CASES THE F0 VALUE SHOULD BE DETERMINED BY HEAT PENETRATION.
The temperature measuring system monitoring the rate of heat penetration to the slowest heating point of the can must be routinely calibrated to give an accuracy of within
+ 0.20C.
A minimum of three separate heat penetration runs should be carried out with a minimum of three replicated cans in each run. Nine results should be attained before a scheduled heat process based on the lowest value obtained is set for the manufacture of production batches.
The location of the probe in the can must be appropriate to the product. With multishot fill and other complex products, such as conduction/convection packs, it will be necessary to identify the slowest heating point in the can by experiment.
Particular attention must be taken of the most adverse production circumstances that may be encountered, for example:-
Low initial temperature
Double starch
Double garnish weight
Low fill temperatures
Solids to sauce ratio
Low moisture contents
Maximum particle size
A record should be kept of all abuse tests and details recorded in the Product File.
ONCE A SCHEDULED HEAT PROCESS HAS BEEN ESTABLISHED IT MUST NOT BE CHANGED WITHOUT WRITTEN AGREEMENT FROM A MARKS AND SPENCER TECHNOLOGIST. Heat penetration data shall be supplied to Marks and Spencer.
Fo VALUES MUST BE RECALCULATED FOLLOWING ANY CHANGE OF RECIPE, FILL TEMPERATURE, CONTAINER SIZE OR OTHER CRITICAL FACTORS.
There should be an annual re-appraisal of the Fo values of each product with the Marks and Spencer Technologist.
The minimum Fo value is to be obtained in the heating phase only. No account is to be taken of the cooling phase.
Minimum heat processes will normally be Fo=6 for simple conduction or convection packs and Fo=8 for complex multi-component products or when H.T.S.T. processes are used.
100% incubation may be required on novel products or processes, followed by subsequent visual examination of every container prior to final packing. The precise details of time and temperature of incubation will be agreed with the Marks and Spencer Technologist. Chapter printed for Helen Nicholl of Princes on 20/06/2006
7.0 WATER SUPPLIES
An up-to-date plan of the water system, including the product cooling system, must be available.
Tests should be carried out on a weekly basis on water supplied to the plant, on the following parameters.
CHEMICAL : pH, hardness, free residual chlorine, suspended
solids.
Any changes from the normal should be investigated.
In addition, microbiological tests shall be carried out weekly and the results should fall within the following standards.
Total colony count 370C/48hrs/<10 colonies/ml
220C/72hrs/<100 colonies/ml
Coliforms 0 in 100ml (MPN broth method or membrane filtration method, 370C).
The water treatment, storage and distribution system of the factory must be designed and constructed to prevent contamination and allow periodic cleaning.Chapter printed for Helen Nicholl of Princes on 20/06/2006
8.0 COOLING WATER
8.1 Water used for product cooling must be chlorinated. Alternative systems must be agreed with the Marks & Spencer Technologist before use.
8.2 After chlorination, the water shall be stored in a covered and baffled tank with a capacity sufficient to cope with maximum operational requirements without reducing the chlorine contact period below 20 minutes. After construction of the cooling system and any modification such as the installation of new retorts, the 20 minute contact time must be re-established.
8.3 The chlorination plant shall be capable of achieving a residual chlorine level measured as free available chlorine of at least 4 ppm at the end of the contact period.
8.4 Water in the tank and distribution pipework shall be run through at the start of each days production to ensure the presence of free chlorine at the retort before the cooling cycle commences. The system for running through the water shall be incorporated into the retort operators manual. Records of chlorine checks shall be kept.
8.5 Re-circulating cooling water systems shall be designed to minimise the risk of contamination and to allow regular cleaning. Particular attention should be given to cooling towers, sumps, collection channels and storage tanks. To maintain hygiene of re-circulated cooling systems, water immediately prior to re-chlorination should contain residual levels of free available chlorine.
8.6 Samples of cooling water shall be taken before the start of production and thereafter at 2 hourly intervals to ensure the presence of free available chlorine after cooling and records kept.
8.7 Records of these tests must be retained and kept with other daily process documentation. Failure to register the presence of free chlorine must bring about
emergency dosing and the quarantine of cans cooked since the last satisfactory test.
8.8 There shall be a written instruction displayed for the emergency dosing of chlorine to cooling water in the case of breakdown of automatic equipment.
8.9 Microbiological samples of cooling water shall be taken post can cooling each day, ensuring that free available chlorine is neutralised with a sterile solution of sodium thiosulphate at the time of taking the sample.
8.10 Microbiological analyses must include total colony counts (220C for 72 hours and 370C for 48 hours) and coliforms, with standards:-
Coliforms 0/100ml MPN Broth Method or Membrane Filtration Method 370C
Any results outside these limits must result in quarantine of the days production and a Marks and Spencer Technologist being informed.Chapter printed for Helen Nicholl of Princes on 20/06/2006
9.0 POST PROCESS CONTROL
9.1 The systems and equipment used for the transfer of containers (pre and post retorting) shall be designed to avoid excessive seam contact or potential damage.
9.2 Containers must not be touched by hand or labelled before they are completely dry and cool. There shall be no handling of wet processed containers.
9.3 There must be an efficient container drying system after retorting, in particular:-
9.3.1 Containers shall be removed from retorts at a target product temperature of 400C so the growth of thermophilic organisms is prevented and natural drying of water on the can surfaces is facilitated.
9.3.2 Immediately on removal from static retorts the full crates shall be rested on a 450angled tipping device for 30 seconds minimum to remove excess water from the cans. A well drained area is required for this operation to avoid stagnant water accumulation.
9.3.3 There must be no re-wetting of the cans after processing by washing, or storage in areas where water from roof leaks, condensation or washing operations could cause re-wetting.
9.3.4 In the case of continuous sterilisers, measures should be taken to accelerate can drying (e.g. can dryers) and to avoid wet handling during labelling.
9.4 Essential personnel such as retort operators or quality controllers who may need to handle selected cans should use sterilised tongs. These staff shall be regularly medically examined and be free from skin, bronchial or gastro-intestinal disorders. Adequate hand washing and sterilising facilities should be provided in the retort crate unloading area.
9.5 Where post process transfer systems mechanically handle wet and warm cans, all post process can conveying surfaces likely to become wet shall be cleaned/sanitized sufficiently to achieve a microbiological standard of less than 500 TVC per 25 square centimetres swabbed. (3 days @ 22 - 250c incubation).
There must be a daily thorough cleaning after production with a detergent followed by sanitizing with a 300 ppm chlorine solution, rinsing off after 15 minutes. In addition can contact surfaces shall be sprayed two hourly throughout production with a 3300 ppm Quaternary Ammonium solution.
The effectiveness of the cleaning/sanitation techniques should be monitored daily by microbiological swabbing. Chapter printed for Helen Nicholl of Princes on 20/06/2006
10.0 FACTORY LAYOUTFactory layout shall be such that physical separation is provided to prevent cross-contamination or contact between:-
Processed cans and unprocessed containers.
Processed cans and raw materials, including spices.
Processed cans and any other source of contamination e.g. poorly designed or drained floors, leakage, condensation.
Staff handling raw materials shall not be allowed to pass into processed can areas. Similarly staff from processed can areas shall not pass into raw material or unprocessed can areas.
Access to retort areas must be limited to essential personnel.Chapter printed for Helen Nicholl of Princes on 20/06/2006
11.0 INCUBATION & QUARANTINE11.1 At least 2 containers from each retort load or 2 cans per hour from continuous sterilisers to be taken and incubated one at 370C for 14 days and one at 550C for 10 days.
11.2 Containers shall be placed in the incubator as soon as possible after cooling. Incubator temperature should be confirmed by mercury thermometer at weekly intervals.
11.3 Containers from the 370C and the 550C incubation shall be visually checked for swells and the contents examined for:
(i) pH
(ii) Nitrite level (if appropriate)
(iii) Smell and visual appearance
(iv) Culture as necessary
11.4 Results of incubation test must be cross referenced to the results of seam checks, retort logs, basket records, temperature charts, cooling water microbiological and chlorine tests. These tests shall be examined in total by the technologist and approved by him.
11.5 ANY SUSPICIOUS OR UNSATISFACTORY RESULTS SHALL BE NOTIFIED TO A MARKS AND SPENCER TECHNOLOGIST. ALL SAMPLES MUST BE
11.6 All finished goods must be quarantined and labelled "HOLD" until there is a positive release given by the technologist.
Under NO circumstances shall the goods be released if any of the test results are below standard. Product must not be released before 14 days, unless there is written agreement from the Marks & Spencer Technologist.Chapter printed for Helen Nicholl of Princes on 20/06/2006
12.0 ASEPTIC PROCESSINGCareful consideration must be given to the plant design and installation for both the processing and cleaning (C.I.P.) schedules.
12.1 Equipment must be constructed in accordance with sound aseptic practice with all contact surfaces non-porous to prevent ingress of micro-organisms.
12.2 Dead ends, crevices and traps must be avoided. The holding time for the process may be varied by inserting or removing additional pipe work to the holding section. The scheduled process must be confirmed prior to start.
12.3 All pumps (back pressure, booster, C.I.P.) should be designed to maintain adequate flow rates through the systems.
12.4 The process temperature must be measured (P.R.T.) at the inlet and outlet of the holding tube. The come up time and cooking are ignored in the process calculation.
12.5 Critical process parameters (time, flow rate and temperature) should be connected to an automatic cut out system with audible alarms.
12.6 The evaluation of the heat process must allow for the minimum residence time of a fluid element or particle in the holding section with the lowest temperature reached in the food. Careful consideration must be given to the rheological properties of the food.
12.7 Calculation of the Fo value should be agreed with the Marks and Spencer technologist and/or confirmed by an independent body e.g. Campden R.A.
12.8 It is useful to have the process capabilities of the designed equipment proven by spore reduction techniques prior to installation and commissioning with the machine manufacturers.
12.9 The electrical properties of foods must be considered with processors using electrical resistance heating e.g. Ohmic.
12.10 Pre-sterilization programme must be agreed with the Marks and Spencer technologist.
12.11 Aseptic filling and sealing procedures must also be agreed.
12.12 An adequate incubation procedure must be in place to prove the commercial sterility of all production. All new lines should be subject to 100% incubation and
iv) Beaded - Double reduced tinplate should be used.
Can testing to include parallelity of slit blanks, lacquer, free spaces, dye tests, ball tests, rip & twist test, pre weld overlap from a cold weld, air test, copper sulphate test of side stripe, inside diameter, parallelity, cylinder height, flange lengths, finished can height.
Records of all tests are to be fully documented and held for a minimum of 3 years.
3. END MAKING
- Outer diameter
- Hook curl height
- Lacquer
- Embossing
- Countersink depth or unit depth
- Compression ring design
- Compound specification and weight distribution
- Ring pull ends:
- depth/uniforming of profile
- protection of score internally & externally
- protection/customer safety feature
4. DOUBLE SEAMING
i) Seam analysis shall be carried out with standard teardown techniques. Section and visual display and/or pressure testing may be used as supplementary aids.
ii) A can shall be taken from each seaming head and the end checked:-
iii) Double seams should be produced to the following critical parameters.
Actual overlap : 1.02mm (0.04 inch) minimum
Body Hook Butting : 70% minimum
Tightness rating : 70% wrinkle free seam minimum
5. FINAL PACK TESTING
Where possible 100% pressure testing of cans should be implemented to reject to pinholes greater than 3 thousandths of an inch.
6. PALLETISATION/PACKING
Cans to be - (i) layered on clean layer pads between layers and the complete pallet protected with a plastic or board shroud; (ii) in plastic liners in cardboard boxes.
7. IDENTIFICATION
i) CANS
Where possible cans should be inkjet coded on the body with the date, time and line number.
- Outer case/Pallets - sequential pallet/carton coding is essential.
- Every pallet/carton to have a minimum of 2 production labels attached recording can size/no of cans/date, line and shift of manufacture/lot no./ pallet sequence no. (order of manufacture)/can specification code. This label should have a space for cannery use only to aid in reconciliation, covering plant, line, date. time of use, operator inspection
(See Appendix 2).
ii) ENDS
Pallet/carton label as for cans, but with number of ends/end press number/end specification code/end diameter. (See Appendix 2).
- Warehousing to be clean and dry with an efficient system of locating and rotating
- Product to be outloaded sequentially in line with individual pallet numbers.
- Records to be kept of pallet numbers shipped, together with the name of the purchasing manufacturer. These records to be kept for 2 years.
9. DISTRIBUTION
- To be in clean dry vehicles and accompanied by a delivery sheet confirming pallet/carton numbers/specification of cans/quantity of cans.
10. RECALL PROCEDURE
The can maker must keep records of despatch and final destination for each lot or partial lot. Chapter printed for Helen Nicholl of Princes on 20/06/2006
APPENDIX 2 - RECOMMENDED OUTER CASE/PALLET LABEL FOR CANS/ENDSCAN/END ............
PRODUCT CODE
FOR CANNERY USE ONLY
PLANT
LINE AND PRODUCT
DATE
TIME
OPERATORNO. OF CANS/ENDS
LOT NO.
DATE OF MANUFACTURE
LINE OF MANUFACTURE
PALLET SEQUENCE NO.
Chapter printed for Helen Nicholl of Princes on 20/06/2006
APPENDIX 3 - RECEIPT OF EMPTY CANS/ENDS AT FOOD CANNERSRECEIPT OF EMPTY CANS/ENDS AT FOOD CANNERS
1. Warehouse staff to oversee off-loading and ensure that contents of vehicle agree with delivery sheet with respect to:-
2. Can/Ends to be located in the warehouse to ensure sequential use, by pallet number, in production (first in first out).
3. There should be a random check of cans/ends arising from each can making day. These are to include evaluation of:-
- Side Weld
- Double Seam - Side Weld
- Flanges
- Cleanliness and internal appearance of the cans
These records must be documented.
4. A full visual inspection of the cans must be carried out at deboxing/ depalletisation. Trained staff must be able to recognise and remove any defect cans. All defects should be recorded as to their source and frequency.
NO ATTEMPT SHALL BE MADE TO RESHAPE OR USE DAMAGED CANS
ANY CRITICAL DEFECT OR UNUSUAL OCCURRENCE MUST BE IMMEDIATELY NOTIFIED TO THE TECHNICAL MANAGER.
Regular review of problems should be held with the can makers (minimum 2 x per year).
5. Each pallet/carton should be recorded as to the date/time of use/line andfinished product. (Use of pallet/carton label shown in Appendix 2 would be efficient andenable reconciliation with all product records).
6. All cans are to be washed/air blown before filling. This system must be checkedhourly to confirm that it is operating, and records are to be documented.
Chapter printed for Helen Nicholl of Princes on 20/06/2006
APPENDIX 4 - CODES OF PRACTICE AND GUIDELINESReaders are strongly recommended to consult the following documents:-
1. "Code of Practice No 10" ex. MAFF/HMSO (being revised 1994).
2. "Post Process Sanitation in Canneries" (Technical Manual No. 1)
ex. Campden Food R.A.
3. "Canning Retorts and their Operation" (Technical Manual No. 2)
ex Campden Food R.A.
4. "The Shelf-Stable Packaging of Thermally Processed Foods in Semi-rigid Plastic Barrier Containers".
All water regardless of source is to comply with the Marks and Spencer Code of Practice for Quality of Water Supplies.
CONTAINERS
S.P.2.
All containers must be bought to an agreed specification.
S.P.3.
Containers must be inspected on reception at an agreed frequency to ensure that they meet the specification.
S.P.4.
Containers must be stored in conditions which will not cause damage or deterioration.
S.P.5.
All container deliveries must be identified and recorded, and their use documented throughout the manufacturing process to allow full traceability.
RAW MATERIALS
S.P.6.
Raw materials must be bought to a specification agreed with a Marks and Spencer Technologist.
S.P.7.
A random and representative system of Quality Control Inspection must be in place to ensure that all raw materials meet the specification.
S.P.8.
Raw materials must be stored under conditions which will not cause damage or deterioration. Any special storage conditions stipulated in the specification must be observed.
Raw materials must be used within a time stipulated in the specification. If the material is not used within this time, they must be resubmitted for repeat Quality Control checks before use.
MANUFACTURING
S.P.10.
Factory Hygiene is to conform with M&S C.O.P. Guide to the Principles of Food Factory Cleaning.
S.P.11.
Metal Detection in the factory is to conform to the M&S C.O.P. For the Prevention of Complaints.
Factory pest control standards must comply with the M&S C.O.P. for Preventative Pest Control.
S.P.13.
Manufacturing controls must be in place to ensure that the physical parameters critical to the heat process (e.g. particle size, starch content) never exceed the abuse conditions agreed in the establishment of the scheduled heat process. See section 4.H of this Code of Practice.
S.P.14.
Where heat processes of less than Fo 6 are used, e.g. shelf stable cured meats, manufacturing controls must be in place to ensure that the chemical parameters critical to that heat process
i) Salt
ii) Nitrite
iii) pH
iv) Water Activity
are maintained with the stated limits.
FILLING
S.P.15.
Initial filling temperatures must be stated and monitored.
S.P.16.
Adequate limits must be agreed for filling weights and volumes, and controls be in place to ensure that these are met.
S.P.17.
Where relevant, solid to liquid ratio's must be stated and limits set.
N.B.
The calculation of any scheduled heat process must taken into account any factor which may affect the rate of heat penetration into the container e.g. headspace, solid to liquid ratio, starch content, particle size. See section 4.H. of this code of practice.
Food containers must be hermetically sealed with specific dimensions reproducible within defined tolerances to achieve product safety.
S.P.19.
Systems must be in place to ensure that the stated closure dimensions or characteristics are maintained within the defined tolerances.
Visual examination of all closures must be a continuous on line exercise, this must be reinforced by a frequent physical examination of closure dimensions or characteristics, e.g. tear down of can seams, pressure burst tests for heat formed seals, see section 4.A and 4.B of this code of practice.
Systems must be in place to identify and differentiate between unprocessed and processed goods. Any unidentified goods must be destroyed.
S.P.21.
There must be physical separation of unprocessed and processed goods.
S.P.22.
Systems must be in place to ensure that no delay occurs between closing a container and processing that container, which may allow the contents to become unfit e.g. through bacterial spoilage.
S.P.23.
Where a heat process has been calculated allowing for a minimum initial filling temperature, systems must be in place to ensure that no container below that temperature is processed.
PROCESSING
S.P.24.
Before production of any St Michael Low Acid Sterilised food occurs, the scheduled heat process must be calculated by experiment. See section 4.H. of this code of practice.
S.P.25.
A Heat Distribution Test must be carried out on any vessel which is used to heat process St Michael Low Acid Sterilised Foods. Where this Heat Distribution Test indicates an area of slowest heating or fastest cooling, any Heat Penetration experiments carried out to calculate the scheduled heat process should take place at this point.
S.P.26.
Heat processing plant must have the controls and recording equipment to adminster and provide details of the scheduled heat process.
S.P.27.
All containers must be identified to enable traceability back to the heat process it received.
S.P.28.
The water used to cool processed containers must be treated to prevent the growth of potential leaker spoilage organisms. This water treatment may be chemical e.g. chlorination, or physical e.g. the use of the heat process water through a heat exchanger. See section 6 of this code of practice.
At the end of a production run, all documentation relating to the scheduled heat process must be collected together and reconciled by a suitably qualified person.
POST PROCESS HANDLING
S.P.30.
After processing, containers must be dried either by residual heat or by air/hot bed driers.
Post process conveying systems for containers must be cleaned/sanitised to meet the standards laid down in section 7.E. of this code of practice.
INCUBATION
S.P.33.
All Low Acid Sterilised Foods must be held until samples have been incubated at 37�C and 55�C and checked for the parameters laid down in section 11.C. of this code of practice.
S.P.34.
For new products in flexible packaging, these goods may be subjected to 100% incubation and inspection.
S.P.35.
No product is to be released for sale until the incubation results are confirmed as acceptable.
STORAGE
S.P.36.
Processed containers must be stored in a manner which prevents mechanical or chemical damage, and in conditions laid down in the M&S Code of Practice for hygiene. Chapter printed for Helen Nicholl of Princes on 20/06/2006
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