Management System Report for

Organisation Name:
National Foods Limited

Standard:

FSSC Food Manufacturing Version 3.1

Type of audit: FSSC 22000 SV 1, and CB transfer

This report is confidential and distribution is limited to the audit team, the organisation and the
Bureau Veritas Certification Office.
Bureau Veritas Certification UK Limited, Registered in England & Wales, Company Number: 2244967
Registered Office: Brandon House, 180 Borough High Street, London, SE1 1LB, United Kingdom
 Organisation Information
Organisation Name National Foods Limited
Address A 13-14, NORTH WEST INDUSTRIAL AREA, KARACHI, PAKISTAN
Contact Name Mr. Jawwad Qureshi
Telephone 0332-2937977
Email Address Jawwad.qureshi@nfoods.com

Audit Information
Audit Standard(s) FSSC Food Manufacturing Version 3.1
No. of Employees AS per contract
No. of Shifts 01
Audit Type FSSC 22000 SV 1, and CB transfer
Audit Start Date 21.08.2017
Audit End Date 22.08.2017
Audit Duration 32 hours (Total)

Auditor Information
Team Leader Syed Umair AIi
Team Member(s)

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1 Audit Findings

Summary of Audit Findings

Number of Non Conformities against ISO 22000:2005 Major Nil Minor Nil

Number of Non Conformities against ISO/TS 22002-1: 2009 Major Nil Minor 03

Number of Non Conformities against FSSC additional requirements Major Nil Minor Nil

Type of follow up audit

Is a follow up audit required? N Desktop / On-site
required:

Team Leader Recommendation

Standard Recommendation
ISO 22000: 2005 NA
FSSC Food Manufacturing
• Recommended for continuation of certification
Version 3.1

Scope

“Manufacturer and packaging of spices, récipe blends, dehydrated vegetables, pickles

and chutneys, Desserts and instant drinks”

Accreditation UKAS
No. of Certs required 1
Languages English
Reason for Issue of
Initial audit (recommended for certification after closure of non-conformance.
Certificate

Further Instructions (additional certificate instruction or information for the office)

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2 Audit summary

2.1 Audit objectives

The objectives of this audit are:

1. To confirm the management system conforms with all the requirements of the audit
standard
2. To confirm that the organisation has effectively implemented its planned arrangements
3. To confirm that the management system is capable of achieving the organisations policies
objectives

2.2 Details of existing certificates

Standard Accreditation body Certification Body Validity date

Nil

2.3 Previous audit results

Verified and proper corrective actions have been taken.

2.4 Audit methodology

The audit team conducted a process-based audit. The audit methods used were interviews,
observations of activities and review of documentation and records.

The audit of the Management System within the organisation was under taken and included the
items:

1. Management system documentation

2. Effective implementation
3. Improvement
4. Key performance objectives and the monitoring of these towards achievement
5. Internal audit programme
6. Management review
7. Corrective and preventive action

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2.5 Nonconformities
The Team Leader concludes that the organisation has established and maintained its management
system in line with the requirements of the audited standard and demonstrated the ability of the
system to achieve requirements within the scope.
The following 03 minor non-conformance was raised in re certification audit.

1. Training on Pest Management of internal pest management team by the third party
contractor that is C-Shine was not conducted as per the requirement of the signed
contract.
2. Rusted screws, nuts were found on sachet filling machines, where product expose
openly.
3. Specification of the compressed air was not available, that is coming in direct contact
with product during sorting of the red spice in new grinding plant (In Hosokawa unit).

2.6 Opportunities for improvement

No

2.7 Good practices

The audit team identified the following good practices:
• Implementation of Pre-requisite programs was very strong.
• Strong traceability system
• Competency of key personnel performing task at CCP & OPRP found up to the mark.
• Management commitment.
• Awareness of food safety and hygiene throughout the chain.
• Openness during the audit

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3 Detailed audit report

List of key personnel present at audit

Name &Job Title Present at Audit (a)

Opening Site Tour Document Closing

Meeting Review Meeting
Mr. Jawwad Qureshi (DM QA) a a a a
Mr. Azhar Ali (GM Factories) a a a a

a a
Mr. Muneer Hussain( Quality
Manager)
Mr. Inaam Zafar(Sr officer QA) a a a
Mr. Owais Ilyas(SDM QC) a a a
Mr. Adeel Sarwar a a a
Mr. Salman Ghafoor (BUM Snacks) a a a
Mr. Muzammil Mustafa( Sr. a a
Manager Ops)
Adeel Noor(Sr. Dy. Manager) a a
Ms. Alia (AM QC) a a
Ms. Maria Sahar( HSE Officer) a a
Mr. M Rizwan(Manager Export) a a
Mr. Azam( Admin Manager) a a

Company profile & other relevant information

National Foods began its journey in 1970 as a Spice company with a revolutionary
product that popularized the concept of having clean, healthy food. National foods’
initiatives since then is to make hygienic food, reduce time spent in the kitchens, foster
health and contribute towards a positive and a more rewarding lifestyle. Winning the
hearts of millions of consumers worldwide, National Foods strives to deliver excellence
in food taste and quality. The company has successfully expanded its global footprint
across 40 countries in 5 continents. National Foods continues to spread happiness by

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offering authentic flavors, thereby re-uniting individuals with their longstanding Pakistani
heritage.

Food safety hazards and control measures

They defined food safety hazards and their control measures regarding Biological hazards
(bacteria, mould, pests & insects), Chemical hazard (detergent, Pesticide residues, chlorine
residues), Aflatoxins and physical hazards (dirt, dust, wood twigs etc.) have been identified as
significant hazards in hazard assessment. Different control measures in different areas have been
devised for these hazards.
For Biological hazards: Cleaning and sanitation plan, Aflatoxin testing
For Chemicals: Approved chemicals are been used only and allowable concentration is been
added in the process step by the highly trained personnel only under supervision of food safety
team members.
For Physical: RO plant is installed and minor ingredients are purchased from only approved
vendors

Prosecution and enforcement activities from relevant authorities

Pakistan Pure food Law
Weights and Measuring Standard
Consumer Act 2005
Guideline on nutrition labelling PS:2099-2017
Overview of relevant changes to documentation, requirements, processes and
products since last audit

NA

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 Audit report summary specific to FSSC additional requirements

Reference Complies Remarks

FSSC part 1 Appendix 1A Yes No
Specifications for services
1
The organization shall ensure that all services (including utilities, transport and
maintenance) which are provided and may have an impact on food safety.
1.1 Shall have specified requirements X Well established
Shall be described in documents to the
1.2 extent needed to conduct hazard X Well described
analysis
Shall be managed in conformance with
Implementation is found
1.3 the requirements of technical X
satisfactory.
specification for sector PRPs.
Summary:
Water analysis report for heavy metals, chemical & Microbiological analysis from PCSIR Dated
29-11-16, report # WQL/KH/143/12/16 was found during the audit and found satisfactory. In-house
weekly water testing was also carried out for TVC, yeast and moulds, coliform and TDS. Water is
being tested from outsource lab that is PCSIR in order to have compliance for WHO requirements.
Records of testing for chemical, microbiological and heavy metals were verified and found within
specification against WHO guidelines The organization has also well-established lab for water
testing and records of inhouse testing were also verified and found within standard values. The
company is using Boiler chemicals that were placed in lock & key at specified place. The company
has established canteen, maintenance activities etc. and being managed through outsourced
parties via contract. Contracts like C Shine for Pest, Lucky Enterprise for janitorial services and M
Khameed for canteen were reviewed properly mentioned. Vehicle Inspection checklist was also
available. Inbound and outbound vehicle inspection is carried out to avoid cross contamination of
the product / materials. Maintenance program of the FBO is very comprehensive and maintained.
Preventive, corrective & reactive maintenance techniques are followed but major focus is on
preventive maintenance. The FBO has preventive maintenance plan (ENG-F-01) and records
were verified for margarine pasteurizer and found satisfactory. Water supply is maintained through
water treatment. Water is being monitored by the onsite lab for physical and microbiological
requirements

The food manufacturing organization shall ensure that all services (including fumigation, utilities,
transport and maintenance) which are provided and may have an impact on food safety:
Compressed air is being used in processing line for drying.
Lighting level was observed sufficient in different areas during the site tour. Intensity of lights is
being measured in processing area.
Maintenance program of the FBO is very comprehensive and maintained. Preventive, predictive,
corrective & reactive maintenance techniques are followed but major focus is on preventive
maintenance. Maintenance record of dated 29.05.2017 and dated 18.12.2016 were verified and
performed as per preventive maintenance plan.
- shall have specified requirements
- shall be described in documents to the extend needed to conduct hazard analysis
- shall be managed in conformance with the requirements of ISO/TS 22002-1:2009,

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2 Supervision of personnel in application food safety principles.
The organization shall ensure the
effective supervision of the personnel in Supervision of
the correct application of the food safety personnel is properly
2.1 X
principles and practices commensurate done as verified through
with their activity (ref. ISO 22000, record.
clause 6.2.2).
Summary:
Production plants are managed by production supervisor who report to Production Manager. Job
description of the section heads are clearly mentioned guiding, coaching and monitoring of staff
regarding food safety and quality. Weekly personal hygiene checklist is not found.
Section heads monitor the performance of his staff regarding food safety and quality, and then he
provides information to HR for TNA (training need analysis) development of his staff followed by
training provision and evaluation of effectiveness. FBO has developed training plan for the year
2017. Training records for Hygiene, Hand washing, CCP monitoring and internal auditing in food
safety in 2nd week of May and 3rd week of May and June 2017 was verified where attendance
sheets found. Records of Mr. Jawwad Qureshi designation Deputy Manager QA were verified.
Evaluation was done through exam for food safety process and product monitoring with skill
calibration test performed and finally assigned independent job.
3 Specific regulatory requirements
Organizations seeking certification shall
assure that specifications for Organization is complying
ingredients and materials take account the regulatory
3.1 X
of any applicable regulatory requirements as per local
requirements [e.g. control of prohibited & International laws.
substances].
Pakistan Pure food Law
Weights and Measuring Standard
Consumer Act 2005
Guideline on nutrition labelling PS:2099-2017
PS:3944 code of practices general principles of Food Hygiene.

4 Management of inputs
The organization shall implement a
system to assure that analysis of inputs
Tests are being performed
critical to the confirmation of product
from ISO 17025
4.1 safety is undertaken. The analyses X
accredited lab. PCSIR
shall be performed to standards
Karachi
equivalent to those described in ISO
17025.
Summary:
The FBO is conducting chemical analysis from well-established chemical laboratories and also
being verified from outsourced accredited laboratory that are critical to product conformity.
Management has provided all resources to conduct all analysis critical to product conformity by
outsourced lab, records of analysis for aflatoxins were verified for microbiological analysis dated
24-02-17 for seasoning also found within specified limits.

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 Audit report summary specific to ISO 22000:2005

Reference ISO 22000 Complies Remarks

Yes No
4 Food Safety Management System
Summary:
FBO has developed and maintained a well-managed food safety management system. The
company has established food safety manual. All the mandatory SOPs, work instructions,
forms & checklists have been established in the system. FBO has established and maintained
the food safety management system in line with FSSC 22000 requirements. All the measures
regarding management of building, equipment’s, materials, peoples and work environment
have been taken to ensure the food safety. Food safety policy is documented in document
QMS/ QFP and is available in English and urdu (native language of workers). Policy was
displayed in the facility at several location i.e. spice, near main entrance to facility, QA/QC
lab etc. Compliance of policy was checked from workers in pickle section and found
satisfactory. Food safety objectives were found within the system and were in line with the
policy of the organization. Detailed action plan / road map to achieve objective and milestones
against each objectives were defined.
The protocol for the control of documentation and proper record keeping in the organization
is defined in the SOP of Document and Record Control MR/3/001and updated master list of
documents and record is also maintained issue 01. Updated master list was verified during
the audit and found satisfactory.
Access control system (supported by colored cards) at security gates is established to avoid
the un-authorized entry at plant and ensure restricted entry in high hygiene areas.
4.1 General requirements X Found well managed and
satisfactory during site tour and
document review.
4.2 Documentation requirements X Found well managed and
satisfactory during site tour and
document review.
5 Management responsibility
Management was observed committed in development and implementation of food safety
Management system. Top management of the FBO has established Food Safety Policy
(MR/POL/1-01), which is signed by the CEO and well communicated within the system. The
policy is bi-lingual (English & urdu) and communicated at different locations as display boards.
Awareness of the policy in staff was verified during the audit and found satisfactory. Food
Safety Objectives are established by the management which are communicated in the system
and monitored against the targets. The objectives were reviewed in last management review
meeting dated 12 Aug 17. Top management has appointed Mr. Jawaad as Food Safety Team
Leader. He is M. Sc in Food Science and Technology with more than 15years industrial
experience. Company has established job descriptions of all the concerned persons. Job
description of FSTL was verified and found satisfactory. Emergency team is established as
per the procedure. Management review was conducted as per the procedure MR/3/002 on
12 as per defined frequency given in management review SOP (MR/3/002). Minutes of
meeting verified where proper decision is taken and targets dated with responsibility are
defined and follow-up activities are recorded.
5.1 Management commitment X Found compliant touring site
tour
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5.2 Food safety policy X Established as per requirement

5.3 Food safety management system X Established as per requirement

planning
5.4 Responsibility and authority X Defined and found as per
requirements
5.5 Food safety team leader X Nominated Mr. Jawwad Qureshi
and have enough competency
on FSSC
5.6 Communication X Established as per requirement
5.7 Emergency preparedness and response X Established & implemented as
per requirement
5.8 Management review X Established as per requirement
6 Resource Management
Summary:

Management was observed committed in development and implementation of food safety

management system. Top management of the FBO has established Food Safety Policy,
which is signed by the Director and well communicated within the system. The policy is bi-
lingual (English & urdu) and communicated at different locations as display boards.
Awareness of the policy in staff was verified during the audit and found satisfactory. Food
Safety Objectives are established by the management which are communicated in the system
and monitored against the targets. The objectives were reviewed in last management review
meeting.
Top management has appointed Mr. Jawwad Qureshi as Food Safety Team Leader. He is
M. Sc Food Science with more than 15 years industrial experience. Company has established
job descriptions of all the concerned persons. Job description of FSTL was verified and found
satisfactory. Emergency team is established as per the procedure. The company has
provided all necessary resources for safety and legality of products. HR department is well
established and fulfilling the recruitment, training and development of staff as per standard
requirement.QA/ QC department is responsible for proper handling of safety and quality
related documents. Change room, wash room and canteen were observed in well order. Hand
washing facilities are established at entrance as well inside plant for to maintain high level of
personal hygiene.
Plant Manager is responsible for staff health status, security, building maintenance and Pest
control. The procedure has been defined for the staff screening against Hepatitis, cholera,
Typhoid at time of employment every employee is asked to go for medical checkup. The staff
is only taken in the process area when they are cleared through these reports. If any person
is ill and goes on leave he cannot go inside the process until doctor not recommended him.
Last Management review was conducted on 12-08-17. Minutes of meeting was reviewed and
all the agenda points have been covered as per the requirement of the standard.

6.1 Provision of resources X Found as per requirements

6.2 Human resources X Procedure is established with all
relevant requirements are
addressed.
6.3 Infrastructure X Found hygienically designed
and maintained.
6.4 Work environment X Found as per requirements.
7 Planning and realization of safe products
Summary:
The team has developed detailed HACCP plans (NFL/HACCP/003/02) each product category
that is spices and pickle after conducting hazard analysis (NFL/HACCP/PIC/3/002) and their
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 risk assessment. HACCP. Detailed hazard analysis was also documented by using of all
process was conducted by food safety team was documented. Procedure for hazards
Analysis MR/SOP-08 is maintained for conducting Hazard Analysis and risk assessment.
An SOP for establishing for pre-requisite program has been documented and established. A
detailed pre-requisite plan is also documented and established with details of the activities
performed by and verified by compliance concern in document no MR/Pl-16. The current
issue of the PRP plan was 01. Food safety team has identified Pre-requisite which are
documented in its SOP-31 few of them are Infrastructure and layout, Personnel Hygiene and
employee Hygiene, Equipment’s and their suitability, Ware Housing, Store management,
Allergen management and prevention of cross contamination.
OPRP Plan for Pickle/ Chutney (NFL/HACCP/PIC/3/002)
OPRP Plan for Spices (NFL/HACCP/SPI/3/002) were reviewed and found satisfactory.
Records were verified for the month of August 2017.
Procedure for implementation and execution PRP are also maintained such Employee
Hygiene and workers health is covered in the procedure of Procedure for Employee Health
and Personal Hygiene, cross contamination prevention is covered in its particular MR/SOP-
25 ‘prevention for cross contamination, allergen managements is covered in procedure for
handling allergens, glass and brittle plastic material are covered by the procedure for handling
glass and brittle plastics.
Implementation of PRP were witnessed during the site tour and found satisfactory further
more records of daily Compliance monitoring reports were also verified for, 23/02/2017,
11/05/2017, and 09/06/2017.
Process flow diagrams for each process (NFL/HACCP/PIC/3/001) and
(NFL/HACCP/SPI/3/001) is been documented and approved by FSTL. The process flow
diagrams are verified by the food safety team on yearly basis and last year food safety team
verified the process flow diagrams which was led by the FSTL. Records were maintained in
form of minutes and verified flow diagrams were signed by the FSTL.
Labelling on product is conducted as per customer and PSQCA requirements. These PSQCA
requirements are cited below in respective section. Detailed product descriptions are also
available as per standards requirements. CCP monitoring protocol is defined in the procedure
for the hazard analysis. CCPs are being monitored by plant operators and verified by QA QC
inspectors deputed in that section. Records of CCP monitoring were verified for the Qorma
product which was produced on 11/06/2017.

PRPS:
PRPs are properly established as per requirements. The company established Prerequisite
program (MSFI/MR/PL-16). OPRP plans for all product categories were also documented
with proper control measures. OPRP plan for spice MR/Pl-13, OPRP PLAN for Kheer is
documented in MR/PL-11, OPRP plan for rice is documented in MR/PL-15 and for recipe
spice is MR/PL-14.

CCP Pickles/ Chutney:

CCP1 : Vegetables storage in Brine Tanks (Should be Minimum 24o Baume during Storage)
TPC = < 5000 cfu/g, Mold & Yeast Count = <100 cfu/g
CCP 2: Equilibrium pH of Matured Pickle(Shuold be ≤ 4.6) (Microbial contamination may
occur due to lower quantity of Acids than specified.) TPC = <5000 cfu/g, Mold & Yeast Count
= <100 cfu/g

CCP3: Metal Contamination (Physical contamination may occur due to larger metal particles
presence higher than specified.) Fe = NMT 2mm, Non-Fe = NMT 3mm ,S.S = NMT 3mm

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 CCP Spices:
CCP1: Fumigation of Spices (Improper fumigation: Insects or their eggs may survive in
spices if they are not exposed to fumigant for recommended dose and time.) Minimum 200
ppm phosphine gas during fumigation period i-e 120 hrs. OR Dose 2Tablets/cubic meter
and fumigation periode 120hrs.

CCP2: Cold Storage Temperature (Spoilage and infestation may occur if temperature is not
controlled) Plums =1 to 5°C

CCP3: Product Moisture (Spoilage and infestation may occur if product moisture is high)
Should be 100% free from insects / TPC = <1 x 10 6 Cfu/g, M/Y = 1 x 10 5 cfu/g, T.Coli = 1
x 10 5 cfu/g

CCP4: Metal Contamination (Physical contamination may occur due to larger metal particles
presence higher than specified.) Fe = NMT 2mm, Non-Fe = NMT 3mm ,S.S = NMT 3mm.
The monitoring and measuring devices associated OPRPs and CCPs are calibrated at an
appropriate frequency. Equipments associated with monitoring & measuring of product &
process safety & quality were found calibrated against the master equipment which was
traceable to certified standards. Calibrated equipments (weighing balances, pH meter etc)
had tags which were traced and verified during record review
Internal Audits are being conducted periodically (SOP MR/3/004) depending upon the
criticality of the system to conform the adequacy of Food Safety Management System.
Monitoring records of All CCPs were reviewed dated 06-05-17, 16-6-17 and 14-07-17 and
found within the limits.
Internal audit was held on 25 Jan 2017 to 05 Feb 2017 whereas its notification made on 15-
01-17 as per procedure. 08 NCRs were raised. It was seen that the NCRs & observations
arising in result of this Internal audit are properly addressed and closed. Internal Audits are
being imparted by adequately trained Internal auditors.

7.1 General X
7.2 Prerequisite programmes (PRP’s) X PRPs are properly established
as per requirements. However
Records of personal hygiene
was not found
7.3 Preliminary steps to enable hazard X All steps are well defined prior
analysis to hazard analysis as per
requirements.
7.4 Hazard analysis X Hazard assessment of
operational pre-requisite
program (OPRPs) and CCP is
properly conducted.
7.5 Establishing the operational PRP’s X OPRPs are properly
established and being
monitored.
7.6 Establishing the HACCP Plan X HACCP plan is properly
established and being
monitored.
7.7 Updating of preliminary information and X Well established and
documents specifying the PRP’s and implemented.
the HACCP plan.

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7.8 Verification planning X Verification plan (MBL- QA-SP-
10) is well established and
implemented.
7.9 Traceability system X Well established &
implemented. PRD/03/011
7.10 Control of nonconformity X Well established and
implemented.
8 Validation, verification and improvement of the FSMS
Summary:
Company has established validation team to validate the CCPs & OPRPs. Validation was
conducted by the validation team and records were maintained. Validation study verified for
all the CCPs and found satisfactory. The validation is reviewed every yearly through
performing validation study. The monitoring and measuring devices associated OPRPs and
CCPs are calibrated at an appropriate frequency by the quality department. Equipments
associated with monitoring & measuring of product & process safety & quality were found
calibrated against the master equipment which was traceable to certified standards.
Calibrated equipments (weighing balances, pH meter etc) had tags which were traced and
verified during record review Calibration is outsourced from Delta and Scale Services. Internal
Audits are being conducted periodically depending upon the criticality of the system to
conform the adequacy of Food Safety Management System.
The last audit was conducted as per the schedule: Internal audit was held on 15-01-17 to 05-
02-17 whereas its notification made on 15-01-17 as per procedure. 08 NCRs were raised. It
was seen that the NCRs & observations arising in result of this Internal audit are properly
addressed and closed. Internal Audits are being imparted by adequately trained Internal
auditors. Company has established validation team to validate the CCPs & OPRPs. Validation
activity was executed by the team in view of scientific and technical data. The record was
verified and found satisfactory. There is comprehensive log available for customer
complaints/feedback and their trend analysis for continual improvement to measure
effectiveness of food safety management system. Records for Customer feedback through
consumer survey results were verified and found satisfactory.
8.1 General X
8.2 Validation of control measure X Validation is properly done as
combination per requirements
8.3 Control of monitoring and measuring X Controls are properly
established and monitored.
8.4 Food safety management system X There is verification system
verification established as per
requirements.
8.5 Improvement X There is comprehensive log
available for customer
complaints/feedback and their
trend analysis for continual
improvement to measure
effectiveness of food safety
management system.
Use of certification mark & logo X

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 Audit report summary specific to PRP’s - ISO/TS 22002-1:2009

4. Construction and layout of buildings

Result: Identification of
Indicate: specific requirement
OK which is not fulfilled Details of Major or minor Non-
Major NC = (e.g. text in clause in conformity
Requirements Major ISO/TS 22002- OR:
Minor NC = 1:2009 / legislation / Justification / explanation for
minor sector code / requirement being NA
NA = not customer
applicable requirement).
4.1 General requirements OK Well maintained

4.2 Environment OK Well Maintained

4.3 Locations of OK Well maintained
establishments
Summary:
Company has established well designed site layout. All the establishments like offices, change room,
wash rooms, canteen, processing halls, material store, finished goods store, workshop etc are designed
in such a way to minimizing risk to food safety. Traffic pattern was available.

5. Layout of premises and workspace

Result Req. not fulfilled Details of Major or minor / NA

5.1 General requirements OK Documented

5.2 Internal design, layout OK Well maintained
and traffic patterns
5.3 Internal structures and OK Well maintained
fittings
5.4 Location of equipment OK Well maintained
5.5 Laboratory facilities OK Well maintained. Raw material,
Inprocess and Finished
products checked by the labs
5.6 Temporary or mobile N/A
premises and vending
machines
5.7 Storage of food, OK Well maintained
packaging materials,
ingredients and non
Food chemicals
Summary:
The company has well maintained buildings (interior and exterior). Structures and ceiling were
observed well maintained and finished. Dedicated storage facilities are maintained for raw materials,
packaging materials and food chemicals. All the laboratories (laboratories, reception lab, micro lab,
chemical lab etc) were also observed in good repair and maintenance. Walk ways are marked with
yellow colours. Speed limits are also mentioned for movement of vehicles. There is separate workshop
and parking area.

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6. Utilities – air, water, energy
Result Req. not fulfilled Details of Major or minor / NA
6.1 General requirements OK
6.2 Water supply Ok From City line

6.3 Boiler chemicals Ok NA Food Grade status of boiler

chemicals was evident during
the audit.
6.4 Air quality and Not OK The organization Specification of the
ventilation shall establish compressed air was not
requirements for available, that is coming in
filtration, humidity direct contact with product
(RH%) and during sorting of the red spice
microbiology of air in new grinding plant (In
used as an Hosokawa unit).
ingredient or for
direct product
contact.
6.5 Compressed air and OK NA Oil free compressor
other gases
6.6 Lighting OK Well maintained
Summary:
Water supply is maintained through water treatment which is well maintained.
Water analysis report for heavy metals, chemical & Microbiological analysis was found during the audit
and found satisfactory. Lighting level was observed sufficient in different areas during the site tour.
Food grade status of boiler chemicals was not available and raised as minor non-conformance.
Water supply is maintained through water treatment system which is well maintained. Water is being
tested from outsource lab that is PCSIR in order to have compliance for WHO requirements. Records
of testing for chemical, microbiological and heavy metals were verified and found within specification
against WHO guidelines. The organization has also well -established lab for water testing and records
of weekly in-house testing were also verified and found within standard values. The FBO is conducting
chemical and microbiological analysis from well-established in-house laboratory and also being verified
from outsourced accredited laboratory that are critical to product. The company is using Boiler
chemicals that were placed in lock & key at specified place. The company has established canteen,
laundry, maintenance activities etc. and being managed through outsourced parties via contract.
Contracts like canteen with M/S M Khameed, was verified where all terms related to food safety is
addressed. All relevant activities onsite verified and found satisfactory.. Compressed air is being used
in processing line. However Specification of the compressed air was not available, that is coming in
direct contact with product during sorting of the red spice in new grinding plant (In Hosokawa unit).
Lighting level was observed sufficient in different areas during the site tour. Intensity of lights is being
measured in different sections of product preparation and display area.

7. Waste disposal
Result Req. not fulfilled Details of Major or minor / NA
7.1 General requirements OK
7.2 Containers for waste OK Properly identified, segregated
and inedible or hazardous and at designated position.
substances

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7.3 Waste management OK Timely, according to the
and removal schedule
7.4 Drains and drainage OK All drains are covered
Summary:
FBO has implemented well maintained waste management system (NFL/HACCP/GMP/03/019). The
FBO lifts general waste and scrap with a frequency of a week from waste collection area away. Waste
bins are marked for different types of wastes. Waste collection area is marked and found in acceptable
condition. Drains are of covered type and included in cleaning program.

8. Equipment suitability, cleaning and maintenance

Result Req. not fulfilled Details of Major or minor / NA
8.1 General requirements Not OK Food contact Rusted screws, nuts were
equipment shall be found on sachet filling
designed and machines, where product
constructed to expose openly.
facilitate cleaning,
disinfection and
maintenance.
Contact surfaces
shall not affect, or be
affected by, the
intended product or
cleaning system.
8.2 Hygienic design OK Found satisfactory
NFL/HACCP/GMP/03/016
8.3 Product contact OK Found satisfactory and cleaned
surfaces
8.4 Temperature control OK Records verified and found
and monitoring equipment satisfactory.
8.5 Cleaning plant, utensils OK Records verified and found
and equipment satisfactory.

8.6 Preventive and OK Records verified and found

corrective maintenance satisfactory.
Summary:
Post maintenance line clearance activity is recorded. Hygiene rules are defined for entrance protocol
and maintenance activities in different areas. All monitoring devices associated with CCPs and
OPRPs are calibrated by maintenance department. Calibration for weighing balance, temperature
gauges, and autoclave were verified and found satisfactory. In the cleaning plan (PRP-10-10 A)
Work instruction for Cleaning and sanitation Program (NFL/HACCP/GMP/03/011).
Rusted screws, nuts were found on sachet filling machines, where product expose openly.(minor NC)
All monitoring devices associated with CCPs and OPRPs are calibrated by maintenance department
were verified and found satisfactory. Records for Temperature monitoring of process & product for
dated 30.03.2017 were verified and found satisfactory. Master sanitation plan is properly established
where records of cleaning & sanitation dated 03.04.2017 were verified and found satisfactory.
Maintenance program of the FBO is very comprehensive and maintained. Preventive, corrective &
reactive maintenance techniques are followed but major focus is on preventive maintenance.
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Maintenance record of filling machines dated 17.05.2017 and dated 21.02.2017 were verified and
performed as per preventive maintenance plan.

9. Management of purchased materials

Result Req. not fulfilled Detail of Major or minor / NA
9.1 General requirements OK
9.2 Selection and OK Supplier management is found
management of suppliers satisfactory. Approved list
9.3 Incoming material OK Records verified and found
Requirements (raw/ satisfactory.
ingredients/ packaging)
Summary:
FBO has established an effective supplier control program. Suppliers’ performance is evaluated for
quality and safety of materials by supplier visits and audits. Approved supplier list is maintained and it
lies with procurement and QA department. Frequency of supplier evaluation is min once / year which
are conducted by QC or any nominated QA official. Supplier evaluation checklist is established and
records of evaluation for verified for Boxes and found as per standard requirements. Incoming material
inspection records were verified like incoming good inspection for Shujaabad oil, Saima Packages, M
& F etc was verified and found as per the procedure.

10. Measures for prevention of cross-contamination

Result Req. not fulfilled Details of Major or minor / NA
10.1 General requirements OK
10.2 Microbiological cross- OK Well managed
contamination
10.3 Allergen management OK No Allergen in the process
10.4 Physical contamination OK Well managed and defined.
Summary:
FBO has maintained the facility in such a manner to avoid cross contamination among materials; semi-
finished goods and finished goods. Allergen management is covered in the HACCP study. Changeover
was not done because there are no different products lines. Allergens list was properly updated.
Following Allergens were identified.
Mustered seed, Turmeric, Nuts, Peanuts, Soya Lecithin, Wheat Flour, Potassium Metabisulfite.
Plants sections are managed by cleaning and sanitation to avoid cross contamination. Dedicated
storage areas are established and found as per standard requirements. There is glass policy
(NFL/HACCP/GMP/03/0017) is properly established and no breakage occur in the last one year.

11. Cleaning and sanitizing

Result Req. not fulfilled Details of Major or minor / NA
11.1 General requirements OK
11.2 Cleaning and OK Well maintained
sanitizing agents and tools
11.3 Cleaning and OK Wet & dry cleaning program is
sanitizing programmes properly established. House
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 Keeping
NFL/HACCP/GMP/3/009
11.4 Cleaning in place N/A
(CIP) systems
11.5 Monitoring sanitation OK Properly measured through
effectiveness swab test.
Summary:
FBO has established cleaning and sanitation checklist. Monitoring records dated 02-08-17 &
23.06.2017 were found available during audit and found satisfactory. Effectiveness of cleaning &
sanitation checklist is measured with monthly GMP audit checklist by the QA department and analyzed
by lab. Analysis. Swab testing for workers hand, machine(filling machine, drying,) and packing material
is being done internally and record verified from and found within specified limits. Disinfectant is used
for Hands.

12. Pest control

12.1 General requirements
Result Req. not fulfilled Details of Major or minor / NA
Not OK Hygiene, cleaning, competency and training of
incoming materials nominated pest controller
inspection and was found. However Training
monitoring procedures on Pest Management of internal
shall be implemented to pest management team by the
avoid creating an third party contractor that is C-
environment conducive Shine was not conducted as per
to pest activity. the requirement of the signed
contract.

12.2 Pest control OK Program is properly

programmes established and implemented
12.3 Preventing access OK Program is properly established
and implemented

12.4 Harbourage and OK No such incidence found

infestations during site tour
12.5 Monitoring and OK Records verified and found
detection satisfactory
12.6 Eradication OK Well recorded.
Summary:
FBO has established pest control procedure managed by third party that is C-Shine. PCO was Mr.
Aijaz. Different tools and techniques like 128 mechanical traps, 34 bait stations, and 83 insect-o-cuttors
and fumigation (from Delta pest Management Services) activities are in practice. Training on Pest
Management of internal pest management team by the third party contractor that is C-Shine was not
conducted as per the requirement of the signed contract (Minor Non-conformance).
Numbering and placement of equipment was verified and found as per plan (map). Pest control logs
and fumigation record verified for 2nd week of April 2017 and found as per plan and found satisfactory.
Fumigation report dated 14.06.2017 also verified where delta methrin approved by WHO usage
application is also verified and found as per instruction. Trend analysis for the Month of December,
2016 was verified and system found effective with continual improvement is observed. Target pests
have identified and their control measures were documented and monitored as per defined SOP.
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13. Personnel hygiene and employee facilities
Result Req. not fulfilled Details of Major or minor / NA
13.1 General requirements OK
13.2 Personnel hygiene OK Well maintained
facilities and toilets
13.3 Staff canteens and OK It was properly maintained
designated eating areas in good hygiene
13.4 Workwear and OK Well managed
protective clothing
13.5 Health status OK Records found satisfactory
13.6 Illness and injuries OK Records found satisfactory
13.7 Personal cleanliness OK Monitoring records of
Personal hygiene was found
adequate.

13.8 Personal behaviour OK Found compliant

Summary:
FBO has established Hygiene program (NFL/HACCP/GMP/03/001). Awareness regarding hygiene was
verified during site tour (NFL/HACCP/GMP/03/004).
Record for personal hygiene and food safety training conducted on 10-02-2017 by Food Safety Team
Leader to factory staff was verified and the effectiveness monitored by section heads was verified as
per plan. Staff hygiene is also being monitored by swab test conducted by QC department and record
verified and found satisfactory. Health screening record of Mr. Naveed and Mr Idress were verified as
conducted and found Satisfactory Canteen was cleaned, Lights were canteen processing area were
not covered. Work instructions of canteen operations were available.

14. Rework
Result Req. Not fulfilled Details of Major or minor / NA
14.1 General requirements OK NA ----
14.2 Storage. Identification OK NA Work instructions for
and traceability traceability PRD/03/011
-- OK NA
Summary:
No Rework is being used in process.

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15. Product recall procedures
Result Req. Not fulfilled Details of Major or minor / NA
15.1 General requirements OK Mock recall 05 Aug 2017

Chicken Biryani
15.2 Product recall OK Procedure for product recall
requirements (NFL/HACCP/GMP/2/008)
Summary:
FBO has established recall procedure. No recall has been occur so for. . Mock recall was initiated by
FSTL dated 03-04-17 on the product of Spice Chicken Biryani; and completed in 2.2 hrs. Record was
verified and found satisfactory.

16. Warehousing
Result Req. not fulfilled Details of Major or minor / NA
16.1 General requirements OK Well maintained
16.2 Warehousing OK Proper Storage. Cleaning was
requirements good
16.3 Vehicles, conveyances OK
and containers
Summary:
FBO has maintained warehousing conditions in an appropriate manner. Raw Spices, mangoes etc are
received in bags. All the activities are managed by FBO. Proper layout and demarcation of layout was
observed during the audit. All the vehicles are dedicated for the company products. Good cleaning and
hygienic conditions were observed during the audit. Containers found in good cleaning and hygienic
conditions which were verified and found satisfactory. Incoming vehicle inspection record for March 2017
was verified and found satisfactory.

17. Product information and consumer awareness

Result Req. not fulfilled Details of Major or minor / NA
17.1 Product information& OK
consumer awareness
Summary:
All the products were found in compliance with labelling requirements. Product ingredient and storage
conditions are clearly marked on each product. No labelling complaint has been received so far.
Ingredients list was present on all primary unit.

18. Food defence, biovigilance and bioterrorism

Result Req. not fulfilled Details of Major or minor / NA
18.1 General requirements OK
18.2 Access controls OK

Summary:
FBO has established visitor control procedure and food defense program with risk assessment is
conducted for areas critical with respect to food security. Every visitor reports at the gate and shows
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his / her identity (NIC). Visitor record dated 04.05.2017 verified and found satisfactory. Security calls to
concerned attendee, who acknowledges and receives the person. The company card is issued to
visitor. They are different colors of cards which are specific to access in different areas.
The company has assessed the hazard to products posed by potential acts of sabotage, vandalism or
terrorism and in place proportional protective measures like water source is controlled etc.

Result Req. not fulfilled Details of Major or minor / NA

Other items required by OK
applicable legislation,
recognized sector codes
and customer
requirements.

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Nonconformity summary sheet FSSC22000Major
Date &
Standard &
No Details of non- Correction / Corrective action Evidence Acceptance by
clause Root cause analysis
. conformity taken provided Team Leader
number
(Y/N)

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 Minor
Date &
Standard &
No Acceptance by
clause Details of non-conformity Root cause analysis Correction / Corrective action taken
. Team Leader
number
(Y/N)
01

1 Clause#: Training on Pest

12.1 of ISO Management of internal pest
TS 22002 management team by the
third party contractor that is
C-Shine was not conducted
as per the requirement of the
signed contract.

2 Clause#: Rusted screws, nuts were

8.1 of ISO found on sachet filling
TS 22002 machines, where product
expose openly.

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3 Clause#: Specification of the
6.4 of ISO compressed air was not
TS 22002 available, that is coming in
direct contact with product
during sorting of the red
spice in new grinding plant
(In Hosokawa unit).

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