Preventive Controls
When your metal detector kicks out 2 wands but not the third what do you do?
Stop running product.
Put product on hold from the last good check (you can find that in infinity)
Fix the metal detector issue.
Leave a comment in infinity on the failed metal detector check.
An operator asks you 'what should my product weigh' what do you say to them and where do you find these specifications?
Between LSL and Target.
Formula weights and spec limits on the weight checks on infinity.
We are running Strawberry fruit bars on the vitalines and we need to go to a different flavor like Pomegranate or Grape... what do you do?
1. Check the changeover matrix and see if this is allowed. (K/team/changeover matrix)
2. It is not allowed on changeover matrix- because this is a seed issue. This isn't an allergen issue. Technically we can change over if needed.
3. Follow the proper flush out procedures and continue to changeover.
Your material loss is above 3% on the milk side. What can you do to help move this down to less than 1% at the filling step?
1. Speed up the filler
2. Raise the filler bowl
3. Lower the height of the product inside the filler bowl.
4. Monitor your control chart on infinity
You find a container of Kroger Carmel Praline in the soap cage and it has gaskets stored in it. Explain how you would react and the rules around this.
1. Throw this away
2. Coach associates on shift
3. Rules: cannot use product containers other than for its intended purpose i.e caramel praline.
Let's analyze the pasteurizing process... where in this process are the Food Safety Preventive controls?
Time
Temperature
If an operator asks where can I find what condiments or variegates go into my product where do you find that?
K;/Team/Formula Weights
We have another plants milk and it is past code to sell to stores. What is the past code threshold to stores? And what can we do with this product?
1. Threshold: 12 days
2. As long as the day you rework is sooner than the expiration date on the bottle you can put this milk into ice cream rinse tanks.
There is a peanut found in the fruit feeder on the inline after a full days run it was found at night. What do you do?
1. Get finished product from that run and give it to the lab to test for peanut allergen using a Neogen test kit.
You find an operator flushing out their bowl and going to the next product in the clean room. The bottles they are using to flush out the bowl have cap rings and have been filled with milk prior. What do you do?
1. Coach associate on the rules- cannot run bottles under the filler that have been filled with milk or juice or other dairy items. The bottles need to be clean and have not been filled prior with any fluid.
We have a listeria swab come back positive- what do we do to address it?
Fill out the form Dominick emails.
Follow each step in the process on the form to eliminate the listeria.
Clean the area in question for three days in a row.
Give it to the lab.
If the flavor vat area or pasteurizing has the wrong formula or there are weird numbers getting generated what do you do?
Reference the correct formula in K/team/formulas
Determine the times that the wrong formula was batched and inform lab.
Put on hold if necessary.
The pasteurizer has mix x10 CC Vanilla that is left over from a run and they want to put it into another mix. What mixes can they put this in? If you don't know where do you find this information?
1. x13, x19, x29 ,x 24,x20 , x43, x65, x64, x75 and x80
2. K/team/changeover matrix/ mix to mix matrix
If you pick up something off the floor and you are wearing gloves. What shall you do next? Why?
wash and sanitize your hands
Put on new gloves.
Why? Hygiene Policy
Ants were spotted in the hot room. What do you do? Why?
Put this in the bug book.
Why? Ecolab tech evaluates what is written once a week.
Metal detection
Vision system Validation
Label Verification
ATP Swabs
Environmental Swabs
If we receive texture comments on our ice cream where can that root cause come from?
Homogenization Pressure
Mix dwell time
Freezer barrel blade angles
Overrun settings
Formula (too much or too little powders/sugars)
Remelt tanks (using too much 30% or more mix on rework)
Filling up the lanco too much on start up
Why can't we rework x10 CC Vanilla into x34 Novelty Vanilla?
CC Vanilla (560005). 560005 is an artificial sweetener (High fructose corn syrup 42%) and you cannot put that sweetener into mix that doesn't already have that in it's formula.
Since X34 Novelty Vanilla doesn't have 560005 it cannot have CC vanilla in it.
You notice a person walking around the plant not wearing a plant uniform, not following any GMP practices, and you don't recognize them what do you do? Why?
1. Ask who they are and get a smock, boot covers and hair nets.
2. This is a food defense measure. We need to account for everyone in the plant that they are here to not hurt or contaminate our product.
We have dirty forktrucks that go in and out of basic hygiene areas (warehouse) to the controlled hygiene areas (by flavor vats and sandwiches) what do we do to control the cross contamination of bacteria?
We have to have powder down between the warehouse doorway, batching area and cone room.
When writing a HARPC plan what are the three risk categories and give examples
Biological- biology
Physical- foreign object
Chemical- allergens/pesticides
What do you do if the operator runs bottles that don't have caps on them?
Technically we cannot re-cap milk products once they have left the filler.
An operator has a mustache. Do you tell them to cover it or not? What policy are you referencing? Where do you find this policy?
Yes tell them to cover it.
Referencing the Hygiene policy.
You find this on the wiki page under QA/Policies
A raw material is having quality issues. i.e. White Chocolate is yellow in color and not white. What do you do? Why?
1. Fill out the Blue Form located in the warehouse.
2. Drop off the blue form to the Planning ASP office or mailbox.
3. Contact the lab tech and/or lead and get approval to run. The lab will taste it and evaluate how it looks on the physical product. This is a food quality issue so no customer will get sick if this ships out.
** Lab approved to run this product because the red chips on it covered the yellowish color and it was undetectable in this scenario and it tasted just fine.
You are walking around with an auditor and that auditor notices: Milk trailer doors are being left open and the trailers are dirty … The auditor asks … 1. what is your policy for cleaning the trailers 2. what is your policy for making sure trailer doors are getting closed. 3. Why are these a big deal to auditors?
1. Every trailer shall be cleaned
2. Every trailer door shall be closed on the lot after it leaves case dock.
3. Pest control and cross contamination