Production and Process Controls :
All production processes are conducted under strict sanitation principles. production process is carried out in one shift under the control of production In charge, who is a qualified and experienced person. The details of the operating procedures and process controls adopted in the manufacturing of finished products are described under the section: Standard Operating Products
Equipment of the factory is created such that it facilitates then smooth flow of production process. All the equipment are designed to facilitate easy cleaning and avoid contamination by lubricants, fuels or metal fragments etc.
Equipment that do not come n contract with food products is also designed for easy cleaning. Utensils, which are used in processing, and packing are made of stainless stel, plastic or other non-corrosive substances that facilitates easy cleaning nd prevents accumulation of dirt or slime.
Material Handling and Storage : Seperate storing facilities are provided for
- Raw materials
- Finished Products
- Sanitising agents
- Toxic Compounds
- Packaging materials
- Consumables and Additives
Raw material : Non-confirming materials are marked as reject/rework as the case maybe and segregated and stored separately.
Finished Products : Finished products are stored in controlled temperature or at ambient Temp. The dies and floor of the storage are provided with non-corroding and non-contaminating material and good air circulation is maintained. The floor of the storage area is cemented and easy to clean and disinfect.
Sanitizing agents , Toxic compounds and Fuels All cleaning compounds are clearly identified using labels and are stored separately in Chemical room.
Packaging materials are stored in two different rooms- one for corrugated cartons and the other for flexible Laminate materials. The walls and floor are kept clean and proper pest control measure is maintained.
The packaging material is stacked on pallets, away from the wall and direct contact from floor. Storage of Consumables Separate storage facility is provided for consumables and additives. They are stored on pallets and issued as per requisition.
Product Inspection :
Production Inspection is done to ensure that the process carried out are as per laid out standards and specifications.
Product inspection carried out in there stages
Incoming Raw materials Inspection
Finished product inspection
In coming raw materials :
The raw material is receive in cares / cartons and bags in proper conditions. The materials are inspected for the narcoleptic factors and product temperature at the time of receipt. Company purchases on specifications only from reputed suppliers. Personnel are trained to find out the variations and other abnormalities in the raw Material
In process Inspection :
The on-line supervisor does in-process inspection at each and every stage of production. The supervisor also checks for any non-conformity in process materials. In-process samples are drawn from different stages of production and inspected for organoleptic factors; observations are recorded in In-process QC Report.
In-process samples from different stages of production are drawn minimum analyzed for bacteriological factors and the results are recorded in the in-process Product Analysis Report cleanliness of the processing areas, utensils, tablets etc minimum once in 30 days and analyzed for the relevant microbiological analysis and the results are entered in the Sanitary Sample Analysis regular
Finished Product Inspection
Finished product inspection os done to ensure that all finished products meet the specification of the company and the buyer. Samples are drawn from finished product for organoleptic and bacteriological inspections(if need) by supervisor. Results are recorded in Finished Products QC Report.. samples are also drawn and tested for the specific requirements of the buyer or importing country by supervisor when ever required. external approved laboratories on special request from the buyer may also carry out inspections . The results are filled in the buyer inspections file.
When the results of the inspection are inconclusive , re-sampling is done to reconfirm the accuracy of the results-increasing the sampling scale to double. The result is recorded in the considered register
Process Control :
Standard operating procedure compiles the procedures of manufacturing and process control. Every individual step is monitored and processed under strict hygine and sanitation care. Continous monoitorising of the process is practiced and any deviation in the critical issues and process steps is immediately rectified and corrective actions are taken.
The objective of these guidelines is to describe the special measures considered appropriate for the wood policy keeping in view the safety while processing, handling or packaging of the food product and prevent food any risk of physical hazards. The use of wood in the wood must be avoided. Avoid any type of use of wood inside the process area. No any woody things for personal use are allowed inside the process areas
Wooden chairs, tables or stools should be allowed within the processing hall
Glass Policy :
The objective of these guidelines is to describe the special measures considered appropriate for the glass policy keeping in view the safety while processing. handling or packaging of the food product and to prevent food from any risk of physical hazards.
The use of Glass porcelain and enamelware in the food must be avoided. fluorescent tube should be protected with non-breakable sleeves. Avoid any type of use of glass inside the process area. No any glassware for personal use is allowed inside the process areas. Brushes should be used for the sweeping unbroken glass. all filling hoppers, elevators and belts conveying open food should be protected again overhead contamination. Guards must be easy to remove to facilitate cleaning. Hoppers, silos and tanks containing food must be checked and cleaned before use and protected from contamination with close fitting lids or covers which always be used correctly
- There should be proper light shielding within all the processing areas
- Light source near the cooking and packaging areas must be critically checked to be avoid any chance of physical hazards
- Use of insect cutters away from the processing lines as they must be properly covered to assure the protection and safety of process or product.
- Light source inside the equipment/ machines like cooling tunnels must be checked with regular frequency.
- Gauges that are made of glass -front must be properly covered by plastic film.
- Use of any glass container like flask, beaker are strictly prohibited in the processing areas.
- Use of glass thermometer must also be prohibited inside the processing area. It may replace with probe thermometer.
- Drinking of water by glass container is also strictly banned inside the processing areas.
- Window screens must be properly checked from breakage point of view to avoid any physical hazard of glass.
Prepared food /food product must be away from the wall windows/screens and covered properly to avoid any chance of glass breakage either from window screen or light shield covering to risk of contamination.
Worker must be trained regarding the glass status, and their precautionary techniques. At Khatt Sweet Water LLC plant all the requisite measures are being considered to avoid any type of contamination by the glass.
Stock Rotation Policy
We observe following policies for the storage of different products.
Appropriate conditions are provided to prevent the harmful deterioration and to protect them from contamination.
All the raw materials are inspected at the time of receiving for date of production and expiry along with other acceptable criteria
According to date order, we follow First In First Out (FIFO) and First Expire First Out (FEFO) in the raw material storage area. The same policy is followed in the end product storage.
Minor ingrediants are received in batches only and are consumed in the same way, like colour , flavour and preservatives
All items are identified by date of expiry and production date to ensure the issuance as per defined stock rotation policy.
The supervisor is already instructed to rotate the stop on monthly basis of easy and efficiet handling of all products.
Production incharge makes it sure that the stocks are rotated according to FEFO & FIFO and verify the same at every month, not only in raw materials store but also in end product storage area
Issuance is made to production department by following FIFO&FEFO so that all products are being consumed as per date order or used by date