Glass Policy

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Glass Policy
This requirement is intended to ensure that potential brittle breakage materials typically within food production areas e.g. glass bulbs / clear Perspex used for guarding machinery / equipment and machinery dials, are minimised and routinely checked for integrity. There should also be procedures and records in place for effective management of breakages. Higher risk areas are production areas where the product is exposed and not covered / packaged and where the potential breakage item is more likely to break due to its vulnerability or location.
In order to show compliance with this requirement, Safwan’s curry paradise should produce a list of all site glass and hard plastic breakage items by area and check them routinely. Include detail on the list so it is clear what staff are checking. Include a column to record any issues with the items and ensure that issues are dealt with appropriately. Routinely carry out a check of all items and record this check. For key areas use a pre start-up & production finish check with a list of items. Document a procedure stating how breakages are managed. Train staff in the procedures and in how to use the check sheet and record this in staff training files.
Changes to consider:
Ensure all lighting is covered with shatterproof tubes
Ensure new equipment and utensils are ‘food grade’ and are undamaged before use
Glass & breakage clearance procedure
The following action must be taken if a glass / breakage occurs:
Quarantine the area and staff and stop all production movement
Inform manager / supervisor immediately
Manage to assess the likelihood of contamination
In consultation, a plan is to be formed and unaffected materials released
The affected area and materials are to be examined carefully and stock in the proximity of the spillage is to be isolated and examined.
Affected product and / or open product within the vicinity must be disposed of correctly.
The area is to be completely cleared and thoroughly cleaned of all glass fragments by sweeping carefully. Any glass / brittle fragments found are to be filed with this document
The area must be cleaned effectively with detergent to remove all residues
The area must be finally checked by a manager before work commences
Cleaning equipment used for cleaning up a glass spillage must be disposed of. Staff involved in clean-up operation must change protective clothing and check shoes before work commences
A full investigation must be carried out and recommendations made to prevent recurrence. The report should detail the time, product involved, down-time and action taken etc.
Renew bulb / tube where appropriate
Date:
Time:
Area:
Reported to:
Follow above procedure:
Details of incident:
Product name / code:
Recommendations:
Area signed off fit to use:
The following is an example procedure and breakage form:
Allergen control
Allergens are defined as a protein that triggers a human immune response and physical health response. Other substances, such as monosodium glutamate (MSG) and sulfites may also trigger an allergenic response but are not proteins.
For production in the EU, the allergens are listed in Regulation No. 1169/2011 on the provision of food information to consumers (see appendix 1) and controls must be put in place to prevent their unintentional presence in foods from cross-contamination.
Prerequisite programs can be used to control allergens based on two approaches:
by keeping allergens out of the premises through good supplier control, or
by implementing strict measures to minimise the potential for cross-contamination.
Good Manufacturing Practices (GMP) form the basis for minimising allergen risks. However, there are a number of ways of separating the production of allergen-containing products from those that do not contain the allergen or contain a different allergen, these include:
Allergen Risk considerations
Proposed procedure
Recipe Verification
The first requirement to avoid allergen risks is to ensure the correct materials are used in the recipe. Systems therefore need to be designed to avoid recipe mistakes. An example would be a system which checks barcodes in the recipe against those of the raw materials or ingredients when these are weighed out for a pre-mix and prevents the operator from continuing if they do not match.
Internal Labelling for Handling and Production
There must be control procedures to ensure proper labelling of raw materials, semi-finished goods and products (for instance, Colour‐label allergenic raw materials and keep them in designated areas.) When finished packing materials are of the same or similar appearance, (e.g. for different flavour variants), it is especially important to ensure that the correct packaging is used. In this context, a checklist to be signed by the person responsible is recommended.
Equipment and Layout Design
Avoid the crossover of open production lines (e.g. conveyor belts) to prevent cross contamination through spillage. Allow adequate space between production lines and around equipment to permit effective cleaning and inspection thus helping to minimise the risk of allergen cross-contact. Scheduling production runs, i.e. where possible, production runs should be scheduled such that products with allergenic materials are produced last (before a full wet cleaning).
Dedicated Lines, Areas and Equipment
Where practically possible, areas and equipment should be dedicated to a specific allergen profile within a production facility. This includes weighing equipment, scoops and utensils, containers, etc. These tools and aids should be colour-coded or appropriately labelled, or a validated cleaning programme should be in place.
Movement Control
Limit movement between physically separated areas or dedicated equipment, to avoid allergen cross-contact between these and other operations. Manage the movement of equipment, personnel, vehicles and maintenance tools.
Packaging and Post-Production Controls
Incorrect packaging and/or labelling is a major cause of allergen-related product recalls. Procedures for checking that the correct labels are applied to products should be implemented and audited regularly, so that accurate information is provided to allergic consumers. Checks should be in place between processing and packing to ensure the correct packaging is used, for example, with the use of automated label verification systems. If packaging materials are stored (even for short periods) in processing areas, there is the potential for cross contact with allergenic material. Production planning should include the order in which different products are manufactured and packaged. Special attention must be paid when the production of bulk volumes takes place at one location and the packaging of the finished product at another. In such cases, the order of packaging must be designed to reduce the risk of cross-contact by allergens and must include effective cleaning routines.
Cleaning
Where there is a significant risk of cross-contact from shared equipment then the equipment must be capable of being cleaned effectively. Appropriate protocols must be in place to verify and validate the cleaning regime. (refer to cleaning section)
Air
Implications of potential airborne contamination should be assessed. Dedicated air handling units with controlled pressure between areas or dust extraction systems might be required for very dusty production areas. Accumulations of settled allergenic material on flat surfaces (e.g. machine guards, window sills, shelves) should be cleaned up.
Non-food material
Implications of the use in processing areas of other sources of allergenic materials and foods causing intolerances should be risk-assessed. Some examples include peanut oil in lubricants, wheat flour in cardboard packaging release agents.
training
Allergen education may be easily incorporated into good manufacturing training periods. As always, after education sessions documentation of the employee by signature, date, trainer and materials covered should be available for review. Allergen education should be conducted on a company-wide basis.
Verification of the Allergen Control program is by documentation that the procedures are being followed and product labelling is correct. Validation of the Allergen Control Program is by specific allergen testing swabs on equipment prior to start of the operation.

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