Audit Report Korangi Factory 16 Aug 2021

UNITED KING FOODS (PVT) LTD
Internal Audit / Inspection Findings against SFA Checklist

Date of Audit: Korangi Factory
16th August 2021
Root Cause
S. No # Area (To Be Filled by Finding Recommendation (Corrective Actions) Finding Severity
Auditee)
1. Stagnant dirty water observed next to A prompt cleaning with proper surveillance to be Improvement Needed
diesel storage in Raw Material receiving carried out to avoid such circumstances.
corridor.
2. Dish washing containers storage area Deep dive approach with respect to cleaning Improvement Needed
found heavily accumulated with dirt, protocols to be adopted with strict follow ups on
dust, debris and some miscellaneous frequent basis.
items.
3. Raw material receiving corridor gate Fixed all gaps on immediate basis ensure that no Improvement Needed
upside screen fixture has the prominent opening or gap of 5mm or more remain to be
gate of more than 5mm. closed out since this much gap is sufficient
enough for pest entrance and harborage
4. Stagnant Dirty water observed under A prompt cleaning with proper surveillance to be Serious
Raw Material vegetables washing area. carried out to avoid such circumstances.
5. Receiving Corridor Alive cat found hiding near backside of A comprehensive IPM system needs to be Major
cold store area. introduced in the facility to eliminate pest related
issues.
6. Empty Pesticide spray bottle found A comprehensive chemical control program Improvement Needed
under washing area of raw material should be in place to avoid any chemical
receiving corridor without any contamination issue.
controlled mechanism.
7. Multiple Alive American cockroaches A comprehensive IPM system needs to be Major
found inside of underground water introduced in the facility to eliminate pest related
storage tank of factory. issues.
8. Inadequate drain mechanism associated Deep dive approach with respect to cleaning Serious
to “Raw Meat & Vegetable washing protocols to be adopted with strict follow ups on
Sink” cause drain blockage that has frequent basis.
created a mini pool / bank of dirty water
with high potential for pest growth such
as drain flies and mosquitoes.

16th August 2021
Root Cause
Auditee)
9. A live lizard found on the back side of A comprehensive IPM system needs to be Major
insect-o-cutter installed in raw material introduced in the facility to eliminate pest related
receiving corridor. issues.
10. Raw Material Different food commodities like Potato A prompt cleaning with proper surveillance to be Serious
Receiving Corridor & Onion found under the pallet since carried out to avoid such circumstances.
they have high potential to attract pest.
11. Alive Norway Rat found under the pallet A comprehensive IPM system needs to be Major
containing Potato & Onion sacs. introduced in the facility to eliminate pest related
issues.
1. Eating evidences such as “Supari Eating practices should be only allowed in Severe Serious
Wrapper” found on a rack in finish good designated areas only such as canteen area.
raw material room.
2. Ingredient product “Mangoes” found All product , raw material, packaging material, Improvement Needed
uncovered in a plastic basket in finish semi-finished, product contact surface
goods raw material room. equipment are supposed to be kept covered
properly to avoid cross contamination as Package
integrity should considered on a top priority
Finish Goods Raw since any dis integrity may lead to product cross
Material Room contamination issues and may have adverse
effect on product shelf life.
All products package integrity should be
evaluated on frequent basis to avoid such
observations.
3. Sugar found suspended and scattered All product , raw material, packaging material, Serious
on the rack in finish good raw material semi-finished, product contact surface
room. equipment are supposed to be kept covered
since any dis integrity may lead to product cross

16th August 2021
Root Cause
Auditee)
contamination issues and may have adverse

A prompt cleaning with proper surveillance to be

carried out to avoid such circumstances.
4. A damaged polyethylene pouch All product , raw material, packaging material, Serious
containing “Raisins” without any date of semi-finished, product contact surface
expiry found kept on a rack in finish equipment are supposed to be kept covered
good raw material room. properly to avoid cross contamination as Package
Finish Goods Raw All products package integrity should be
Material Room evaluated on frequent basis to avoid such
observations.
All kinds of unidentified commodity weather
product, ingredient, or its container, or any
utensils and / or equipment should be identified
with its dedicated purpose only to avoid any
occurrence of cross contamination furthermore
Proper MRD including information such as date
of receiving, date of production and expiry date /
limit should be in place on all commodities to
make assure operational functions such
FIFO/FEFO & traceability norms are carried out
adequately
5. Under rack area of finish good raw A prompt cleaning with proper surveillance to be Improvement Needed
material room found heavily carried out to avoid such circumstances.
accumulated with dirt, dust & debris.

16th August 2021
Root Cause
Auditee)
6. No date of receiving observed on Proper MRD including information such as date Improvement Needed
multiple raw materials such as “Ovaltine of receiving, date of production and expiry date /
pouches, Mitchell tomato puree & limit should be in place on all commodities to
Bakels chocolate container.” make assure operational functions such
adequately
7. Number of unidentified sacks containing All kinds of unidentified commodity weather Serious
“Almonds” with incomplete MRD (only product, ingredient, or its container, or any
date of receiving was mentioned) found utensils and / or equipment should be identified
in finish good raw material room. with its dedicated purpose only to avoid any
Finish Goods Raw of receiving, date of production and expiry date /
Material Room limit should be in place on all commodities to
adequately
8. An unidentified sack containing All product , raw material, packaging material, Serious
“Almonds” found in damaged condition. semi-finished, product contact surface
equipment are supposed to be kept covered
All kinds of unidentified commodity weather
product, ingredient, or its container, or any

16th August 2021
Root Cause
Auditee)

adequately
9. Finish product “Ferrero Rocher” box Prompt GMP protocols to be followed up to Improvement Needed
found under the pallet in finish good raw avoid such incidents.
material room.
10. Under pallet area found heavily Deep dive approach with respect to cleaning Serious
accumulated with dirt, dust & debris in protocols to be adopted with strict follow ups on
Finish Goods Raw finish good raw material room. frequent basis.
11. Material Room Food commodities like “Almond chunks” Prompt GMP protocols to be followed up to Improvement Needed
found under pallet in finish good raw avoid such incidents.
material room.
12. No date of receiving found on Olper’s Proper MRD including information such as date Improvement Needed
cartons in finish good raw material of receiving, date of production and expiry date /
room. limit should be in place on all commodities to
adequately
13. A damaged bag of ingredient product All product , raw material, packaging material, Serious
“Bakels Red Velvet” found in finish good semi-finished, product contact surface
raw material room. equipment are supposed to be kept covered

16th August 2021
Root Cause
Auditee)

observations.
14. Personal belonging such as helmet Adequate number of lockers need to be provided Improvement Needed
found kept on a rack in finish good raw for employees so that they can keep their
material room. personal belongings there and this sort of mis
happen will not occur again.
15. Three pairs of Domestic slippers found Adequate number of lockers need to be provided Improvement Needed
kept under rack in finish good raw for employees so that they can keep their
material room. personal belongings there and this sort of mis
Finish Goods Raw happen will not occur again.
16. Material Room Number of pairs of domestic clothes Adequate number of lockers need to be provided Improvement Needed
found hanged on wall, kept on rack in for employees so that they can keep their
finish good raw material room. personal belongings there and this sort of mis
happen will not occur again.
17. Expired product approx. 143 packets of FIFO follow-ups to be made on realistic approach Major
“White chocolate chips” with date of to avoid any traceability failures that may lead to
production 10/05/19 and date of expiry product expiry.
10/05/21 found in finish good raw
material room.
18. An unidentified sack containing “Pista” All kinds of unidentified commodity weather Major
without any MRD found in finish good product, ingredient, or its container, or any
raw material room. utensils and / or equipment should be identified

16th August 2021
Root Cause
Auditee)

Finish Goods Raw make assure operational functions such
Material Room FIFO/FEFO & traceability norms are carried out
adequately
1. Some unidentified sacks containing All kinds of unidentified commodity weather Major
“Whole wheat Flour” & “All Purpose product, ingredient, or its container, or any
Flour” found without any MRD in Main utensils and / or equipment should be identified
Store. with its dedicated purpose only to avoid any
adequately
2. Main Store Number of domestic flies ( 22 in count ) A comprehensive IPM system needs to be Serious
found in Main Store. introduced in the facility to eliminate pest related
issues.
3. No PVC curtain / Air curtain is installed A prompt selection of decision to be made to Improvement Needed
at entrance to Main Store since there installed either PVC curtain and / or Air curtain at
were massive evidence of house flies main entrance to avoid pest entrance to the
observed. facility / outlet.
4. A local polyethylene bag containing All kinds of unidentified commodity weather Major
“White Chickpeas (Safaid Chana)” product, ingredient, or its container, or any
without any identification and MRD utensils and / or equipment should be identified
found kept on a rack in Main Store. with its dedicated purpose only to avoid any

16th August 2021
Root Cause
Auditee)

adequately
5. A local polyethylene bag containing “Dal All kinds of unidentified commodity weather Major
Chana” without any identification & product, ingredient, or its container, or any
MRD found kept on a rack in Main store. utensils and / or equipment should be identified
Main Store adequately
6. SPI (Store product insect) found in A comprehensive IPM system needs to be Major
“Khaskhas” packet with date of introduced in the facility to eliminate pest related
production 02-Jul-21 and date of expiry issues.
instruction use with in 06-Months.
7. Critical packaging defect observed as All product , raw material, packaging material, Severe Serious
damaged packing of “Kalonji” with date semi-finished, product contact surface
of production 08-Aug-21 and use within equipment are supposed to be kept covered
06 Months instructions found kept on properly to avoid cross contamination as Package
rack in Main store. integrity should considered on a top priority
observations.

16th August 2021
Root Cause
Auditee)
damaged packing of “Ejwain” with date semi-finished, product contact surface
of production 28-Jun-21 and use within equipment are supposed to be kept covered
06 Months instructions found kept on properly to avoid cross contamination as Package
rack in Main store. integrity should considered on a top priority
observations.
Main Store damaged packing of “White Sesame semi-finished, product contact surface
Seeds” with date expiry 31-Dec-21 equipment are supposed to be kept covered
found kept on rack in Main store. properly to avoid cross contamination as Package
observations.
10. Rodent droppings of Norway Rat found A comprehensive IPM system needs to be Major
under pallet area in Main store. introduced in the facility to eliminate pest related
issues.
11. Rodent evidences such as gnaw marks A comprehensive IPM system needs to be Major
observed on carton of seasoning with introduced in the facility to eliminate pest related
date of receiving 30-Apr-2021. issues.

16th August 2021
Root Cause
Auditee)
12. Number of unidentified pouches All kinds of unidentified commodity weather Major
containing “Bread Crumbs” without any product, ingredient, or its container, or any
MRD found in Main store. utensils and / or equipment should be identified
adequately
damaged packing of “Karara Zeera semi-finished, product contact surface
Main Store Powder” pouch found in main store equipment are supposed to be kept covered
room. properly to avoid cross contamination as Package
observations.
14. An unidentified plastic container All kinds of unidentified commodity weather Major
(claimed to be containing honey) product, ingredient, or its container, or any
without any identification and with utensils and / or equipment should be identified
incomplete MRD (as only date of with its dedicated purpose only to avoid any
receiving was mentioned) found in Main occurrence of cross contamination furthermore
store. Proper MRD including information such as date

16th August 2021
Root Cause
Auditee)

adequately
15. Different seasoning packets of different Training on lean management tool such as on a” Improvement Needed
products such as some pouches of BCT- 5S “needs to be provided
550 with MFG 29-03-21 & EXP 28-03-22
whereas some pouches of PCT-220 with
MFG 11-04-21 & EXP 10-04-22 found
kept in a same basket without any
segregation in Main store.
products such as some pouches of VP- 5S “needs to be provided
Masala with MFG 15-03-21 & EXP 14-03-
Main Store 22 whereas some pouches of CCT-365-B
with MFG 28-07-21 & EXP 27-07-22
found kept in a same basket without any
damaged packing of “Red Chili Crushed” semi-finished, product contact surface
pouch found in main store room. equipment are supposed to be kept covered
observations.
products such as some pouches of VR- 5S “needs to be provided

16th August 2021
Root Cause
Auditee)
491 with MFG 15-03-21 & EXP 14-03-22

whereas some pouches of CST-001 with
MFG 28-07-21 & EXP 27-07-22 found
damaged packing of “PSA-310” pouch semi-finished, product contact surface
with MFG 08-08-21 & 07-08-22 found in equipment are supposed to be kept covered
main store room. properly to avoid cross contamination as Package
Main Store All products package integrity should be
observations.
damaged packing of “BSA-28” pouch semi-finished, product contact surface
with MFG 03-08-21 & 02-08-22 found in equipment are supposed to be kept covered
main store room. properly to avoid cross contamination as Package
observations.
products such as some pouches of CCT- 5S “needs to be provided
365-A with MFG 01-JUN-21 & EXP 31-

16th August 2021
Root Cause
Auditee)
DEC-21 whereas some pouches of CCT-

365-B with MFG 28-07-21 & EXP 27-07-
22 and some pouches of CSA 105B with
MFG 20.04.20 & EXP 19.12.21 found
22. Under rack area found heavily A prompt cleaning with proper surveillance to be Serious
accumulated with dirt, dust & debris in carried out to avoid such circumstances.
Main store.
23. A sack containing “Desiccated Coconut” All kinds of unidentified commodity weather Major
found without any MRD in Main store. product, ingredient, or its container, or any
Main Store occurrence of cross contamination furthermore
adequately
24. Damage Flour packet observed with All products package integrity should be Severe Serious
almost 40 % content exposed to evaluated on frequent basis to avoid such
environment in Masala Store. observations.
25. Leakage cum spillage evidence observed All products package integrity should be Severe Serious
in Glucose carton and on surrounding evaluated on frequent basis to avoid such
floor in Masala Store. observations.
damaged packing of “Garam Masalah” semi-finished, product contact surface
with MFG 21-May-21 & use within 01 equipment are supposed to be kept covered

16th August 2021
Root Cause
Auditee)
year instructions found in main store integrity should considered on a top priority
room. since any dis integrity may lead to product cross
observations.
27. Number of unidentified polyethylene All kinds of unidentified commodity weather Major
bags & sacks (which was claimed to be product, ingredient, or its container, or any
containing Cornflour, Fine flour, Sugar & utensils and / or equipment should be identified
Icing Sugar) without any MRD & with its dedicated purpose only to avoid any
identification tag found in Main store. occurrence of cross contamination furthermore
Main Store Proper MRD including information such as date
adequately
28. An unidentified sack containing “Zeera” All kinds of unidentified commodity weather Major
without any MRD found in Main store. product, ingredient, or its container, or any
adequately

16th August 2021
Root Cause
Auditee)
29. An unidentified sack containing “Dal All kinds of unidentified commodity weather Major
Chana” without any identification & product, ingredient, or its container, or any
MRD found in Main store. utensils and / or equipment should be identified
Main Store make assure operational functions such
adequately
30. Rodent droppings Norway rat found A comprehensive IPM system needs to be Major
under pallets containing raw material introduced in the facility to eliminate pest related
sacks in Main store. issues.
31. Under pallet area containing raw Deep dive approach with respect to cleaning Serious
material sacks found accumulated with protocols to be adopted with strict follow ups on
dirt & dust in Main store. frequent basis.
32. Cobwebs found on corner of racks in A prompt cleaning with proper surveillance to be Improvement Needed
Main store. carried out to avoid such circumstances.
1. 05 domestic flies observed in biscuit A comprehensive IPM system needs to be Improvement Needed
store. introduced in the facility to eliminate pest related
issues.
2. Finish product “Sugar stick” covering All product , raw material, packaging material, Improvement Needed
Biscuit Store found damaged in biscuit store. semi-finished, product contact surface

16th August 2021
Root Cause
Auditee)

observations.
3. Rodent droppings Norway rat found on A comprehensive IPM system needs to be Major
Biscuit Store the corner side of the rack containing introduced in the facility to eliminate pest related
finish product trays in biscuit store. issues.
4. Dust looms observed on the wall fixture A prompt cleaning with proper surveillance to be Improvement Needed
fan of biscuit store. carried out to avoid such circumstances.
5. Eating evidence such as “Supari Eating practices should be only allowed in Serious
Wrapper” found in biscuit store. designated areas only such as canteen area.
1. Uncovered product trays containing All product , raw material, packaging material, Severe Serious
“Rolls“except only first tray found in semi-finished, product contact surface
Freezer # 02 with trays found to be dirty equipment are supposed to be kept covered
from down side that comes in contact properly to avoid cross contamination as Package
with product while staking and may integrity should considered on a top priority
cause dirt / foreign matter cross since any dis integrity may lead to product cross
contamination to the product in Blast contamination issues and may have adverse
freezer room. effect on product shelf life.
2. Blast Freezer Room A plastic bottle used for drinking water All unidentified and suspected items to be Minor
purpose without any identification tag surveillance on a periodic interval to avoid such
found kept with semifinished product circumstances.
trays in Freezer # 01 in blast freezer
room.
3. Uncovered product trays containing All product, raw material, packaging material, Severe Serious
“Chatpata Samosa“ except only first tray semi-finished, product contact surface
found in Freezer # 01 with trays found equipment are supposed to be kept covered
to be dirty from down side that comes properly to avoid cross contamination as Package
in contact with product while staking integrity should considered on a top priority
and may cause dirt / foreign matter since any dis integrity may lead to product cross

16th August 2021
Root Cause
Auditee)
cross contamination to the product in contamination issues and may have adverse
Blast freezer room. effect on product shelf life.
observations.
4. Rodent droppings “Norway rat” found A comprehensive IPM system needs to be Major
on corner side of Freezer # 01 & 02 in introduced in the facility to eliminate pest related
blast freezer room. issues.
5. Blast Freezer Room Flaking paint evidence observed on roof All flaking and sprouting paints issues need to be Improvement Needed
ceiling & wall side structure in Blast fixed on priority to avoid any physical and / or
freezer room. chemical contamination chances
6. Roof ceiling found extremely dirty in A prompt cleaning with proper surveillance to be Improvement Needed
Blast Freezer room. carried out to avoid such circumstances.
7. A person found with long & dirty nails in GMP protocols to be strictly follow to avoid any Improvement Needed
blast freezer room. mishappening related to food safety and product
quality.
8. Non foot operated waste bin found in All dust bins need to be kept covered to avoid any Serious
Blast freezer room. cross contamination.
1. SS trays containing semifinished product All product , raw material, packaging material, Major
“Chatpata Samosa” found uncovered semi-finished, product contact surface
with evidence of dropping condensate equipment are supposed to be kept covered
Fast Food Cold water from cold store inside surface in properly to avoid cross contamination as Package
Storage fast food cold storage. integrity should considered on a top priority
observations.

16th August 2021
Root Cause
Auditee)
2. SS trays containing “Boiled Chicken” All product , raw material, packaging material, Major
found uncovered with evidence of semi-finished, product contact surface
dropping condensate water from cold equipment are supposed to be kept covered
store inside surface in fast food cold properly to avoid cross contamination as Package
storage. integrity should considered on a top priority
observations.
3. SS trays containing “Aloo Samosa” found All product , raw material, packaging material, Major
uncovered with evidence of dropping semi-finished, product contact surface
Fast Food Cold condensate water from cold store inside equipment are supposed to be kept covered
Storage surface in fast food cold storage. properly to avoid cross contamination as Package
observations.
4. SS trays containing “Chillos Sauce” All product , raw material, packaging material, Major
found uncovered with evidence of semi-finished, product contact surface
dropping condensate water from cold equipment are supposed to be kept covered
store inside surface in fast food cold properly to avoid cross contamination as Package
storage. integrity should considered on a top priority

16th August 2021
Root Cause
Auditee)

observations.
1. Under pallet area of fast food cold Deep dive approach with respect to cleaning Serious
storage found accumulated with dirt, protocols to be adopted with strict follow ups on
dust, debris, wrappers of different frequent basis.
products & some miscellaneous items.
2. Product Ingredient “ Cheddar Cheese” FIFO follow-ups to be made on realistic approach Major
found expired with date of to avoid any traceability failures that may lead to
Manufacturing “ 12-02-2021 “ and date product expiry.
of Expiry “ 11-08-2021 “in a freezer “
Dedicated for R & D “ with identification
Freezer Corridor # 03 observed in Freezer Corridor.
3. Freezer # 03 “Dedicated for R&D Temporary maintenance works need to be super Improvement Needed
samples“ found with an out of order finished on immediate basis.
temperature monitoring device in
freezer corridor.
4. Semi Finished Chicken Samosa trays All product , raw material, packaging material, Major
found uncovered kept in freezer # 02 semi finished, product contact surface
furthermore it was observed that water equipment are supposed to be kept covered
droplets are dropping on product due to properly to avoid cross contamination as Package
temperature difference on every time a integrity should considered on a top priority
freezer is opened. since any dis integrity may lead to product cross
observations.

16th August 2021
Root Cause
Auditee)
5. Trays found dirty from inside and A prompt cleaning with proper surveillance to be Improvement Needed
outside surfaces containing semi carried out to avoid such circumstances.
Freezer Corridor finished Chicken samosa inside.
6. Dust, Dirt and debris accumulation Deep dive approach with respect to cleaning Improvement Needed
observed under freezer # 02 and # 04. protocols to be adopted with strict follow ups on
frequent basis.
1. Water spillage along with dirt and debris A prompt cleaning with proper surveillance to be Improvement Needed
accumulation observed on floor very carried out to avoid such circumstances.
next to a PVC drum containing product
ingredient “Sorbitol“ that was kept
directly on floor near cold store room.
2. A local polyethylene bag containing All kinds of unidentified commodity weather Severe Serious
“Dark Chocolate Chips” found without product, ingredient, or its container, or any
any MRD in cold store. utensils and / or equipment should be identified
Cold Store occurrence of cross contamination furthermore
adequately
3. Cold store internal base / floor found Wooden based equipment, tools, Infrastructure, Improvement Needed
made of wooden material. Framework and utensils are not recommended in
food operation facilities since they are prone
enough to be avoided due to their porous nature
to allow deposition of dust , dirt and debris inside
their body structure as well as they sometimes in
presence of moisture may provide harborage for
different pests.

16th August 2021
Root Cause
Auditee)
4. Manda tray found uncovered kept in All product , raw material, packaging material, Major
Cold store since it has high potential for semi-finished, product contact surface
water droplets to be dropped on equipment are supposed to be kept covered
product due to temperature difference properly to avoid cross contamination as Package
as many times in a day cold store is integrity should considered on a top priority
operated ( Loaded and unloaded). since any dis integrity may lead to product cross
observations.
5. Cold Store Green chilli packaging found damaged All product , raw material, packaging material, Improvement Needed
with potential for water droplets to be semi-finished, product contact surface
dropped on product due to temperature equipment are supposed to be kept covered
difference as many times in a day cold properly to avoid cross contamination as Package
store is operated ( Loaded and integrity should considered on a top priority
unloaded). Since it has potential for since any dis integrity may lead to product cross
product to product cross contamination contamination issues and may have adverse
that may lead to product sensory effect on product shelf life.
characteristics failure. All products package integrity should be
observations.
6. Lemon packaging found damaged with All product , raw material, packaging material, Improvement Needed
potential for water droplets to be semi-finished, product contact surface
dropped on product due to temperature equipment are supposed to be kept covered
difference as many times in a day cold properly to avoid cross contamination as Package
store is operated ( Loaded and integrity should considered on a top priority
unloaded). Since it has potential for since any dis integrity may lead to product cross
product to product cross contamination

16th August 2021
Root Cause
Auditee)
that may lead to product sensory contamination issues and may have adverse
characteristics failure. effect on product shelf life.
observations.
7. Alive German Cockroach found in main A comprehensive IPM system needs to be Major
cold store. introduced in the facility to eliminate pest related
issues.
8. Semi Finished Spring rolls found partially All product , raw material, packaging material, Major
uncovered along with a spring roll being semi-finished, product contact surface
used as a “ Paper Weight Support” for equipment are supposed to be kept covered
wrapping sheets to avoid its unstable properly to avoid cross contamination as Package
Cold Store movement and to keep it rigid against integrity should considered on a top priority
chiller air circulation in main cold store. since any dis integrity may lead to product cross
Furthermore tiny water droplets contamination issues and may have adverse
evidence observed on the roof top of effect on product shelf life.
cold store ceiling with extreme potential All products package integrity should be
to be dropped on any product due to evaluated on frequent basis to avoid such
temperature fluctuation inside cold observations.
store.
9. Semi Finished “ Boiled Chicken “ stuff All product , raw material, packaging material, Major
found partially uncovered kept in SS semi-finished, product contact surface
trays in cold store. Furthermore tiny equipment are supposed to be kept covered
water droplets evidence observed on properly to avoid cross contamination as Package
the roof top of cold store ceiling with integrity should considered on a top priority
extreme potential to be dropped on any since any dis integrity may lead to product cross
product due to temperature fluctuation contamination issues and may have adverse
inside cold store. effect on product shelf life.

16th August 2021
Root Cause
Auditee)

observations.
10. Semi Finished “ Beef Cutlets “found All product , raw material, packaging material, Major
partially uncovered kept in SS trays in semi-finished, product contact surface
cold store. Furthermore tiny water equipment are supposed to be kept covered
droplets evidence observed on the roof properly to avoid cross contamination as Package
top of cold store ceiling with extreme integrity should considered on a top priority
potential to be dropped on any product since any dis integrity may lead to product cross
due to temperature fluctuation inside contamination issues and may have adverse
cold store. effect on product shelf life.
Cold Store observations.
11. Semi Finished “ Crispy Pockets Stuff“ All product , raw material, packaging material, Major
found uncovered kept in SS trays in cold semi-finished, product contact surface
store. Furthermore tiny water droplets equipment are supposed to be kept covered
evidence observed on the roof top of properly to avoid cross contamination as Package
cold store ceiling with extreme potential integrity should considered on a top priority
to be dropped on any product due to since any dis integrity may lead to product cross
temperature fluctuation inside cold contamination issues and may have adverse
store. effect on product shelf life.
observations.
12. Semi Finished “ Beef Shami Kabab All product , raw material, packaging material, Major
“found uncovered kept in plastic tray in semi-finished, product contact surface
cold store. Furthermore tiny water equipment are supposed to be kept covered
droplets evidence observed on the roof properly to avoid cross contamination as Package
top of cold store ceiling with extreme integrity should considered on a top priority

16th August 2021
Root Cause
Auditee)
potential to be dropped on any product since any dis integrity may lead to product cross
due to temperature fluctuation inside contamination issues and may have adverse
cold store. effect on product shelf life.
observations.
13. Product Ingredient “ Khoya “ found in a All product , raw material, packaging material, Major
damage packaging with a date of best semi-finished, product contact surface
before instruction use within 60 days in equipment are supposed to be kept covered
cold store since there is very high chance properly to avoid cross contamination as Package
of cross contamination observed as integrity should considered on a top priority
khoya is kept partially uncovered in the since any dis integrity may lead to product cross
same cold store where meat based contamination issues and may have adverse
Cold Store products such as Raw Chicken,beef effect on product shelf life.
cutlets, boiled chicken and crispy pocket All products package integrity should be
stuffs are kept in similar situation that is evaluated on frequent basis to avoid such
not properly covered creating an observations.
extreme likelihood for a product to
product cross contamination in cold
store.Furthermore tiny water droplets
evidence observed on the roof top of
cold store ceiling with extreme potential
to be dropped on any product due to
temperature fluctuation inside cold
store.
14. Raw Chicken found kept partially All product , raw material, packaging material, Major
covered in cold store Furthermore tiny semi-finished, product contact surface
water droplets evidence observed on equipment are supposed to be kept covered
the roof top of cold store ceiling with properly to avoid cross contamination as Package
extreme potential to be dropped on any integrity should considered on a top priority

16th August 2021
Root Cause
Auditee)
product due to temperature fluctuation since any dis integrity may lead to product cross
inside cold store. contamination issues and may have adverse
Cold Store effect on product shelf life.
observations.
1. Primary packaging cake cards found All product , raw material, packaging material, Serious
kept without any covering in multiple semi-finished, product contact surface
racks in packaging store room. equipment are supposed to be kept covered
Packaging Material observations.
2. Store Under Rack areas found dust, dirt and Prompt cleaning practices to be adopted on Improvement Needed
debris accumulated in packaging store immediate basis to avoid such happenings
room.
3. Rodent droppings “ Norway Rats “ A comprehensive IPM system needs to be Severe Serious
observed under rack area in packaging introduced in the facility to eliminate pest related
material store. issues.
4. Eating evidence as biscuit left over Eating practices should be only allowed in Improvement Needed
traces along with a “ Packaging designated areas only such as canteen area.
container used for products Cup in a
Cake found used for tea with traces of
tea dried content inside observed on a
shelf in packaging store that may have
high potential for any pest harborage

16th August 2021
Root Cause
Auditee)
specially for crawling insects such as

German Cockroaches and rodents.
5. Eating evidence as food item ( Some Eating practices should be only allowed in Improvement Needed
Bakery Product ) left over traces designated areas only such as canteen area.
observed on a primary packaging
material cake card on a shelf in
packaging store that may have high
potential for any pest harborage
Packaging Material specially for crawling insects such as
Store German Cockroaches and rodents
6. Primary packaging material use for Salad All product , raw material, packaging material, Serious
/ Rasmalai found without any covering semi-finished, product contact surface
in main packaging store. equipment are supposed to be kept covered
observations.
1. Broken tile fixture observed on floor in Adequate civil maintenance work needs to be Improvement Needed
tray washing area. carried out to keep building infrastructure up to
mark.
2. Plastic Trays Alive German Cockroach observed in A comprehensive IPM system needs to be Severe Serious
Washing Area dish washing area. introduced in the facility to eliminate pest related
issues.
3. A significant opening / gap observed of Fixed all gaps on immediate basis ensure that no Improvement Needed
more than 15 mm that was partially opening or gap of 5mm or more remain to be

16th August 2021
Root Cause
Auditee)
covered with a polythene shopper in closed out since this much gap is sufficient
tray washing area has very possible enough for pest entrance and harborage
potential for pest entrance and
harborage in this section.
4. Waste and garbage area found Fixed all gaps on immediate basis ensure that no Improvement Needed
associated very next to tray washing opening or gap of 5mm or more remain to be
area with a weak control as there were closed out since this much gap is sufficient
found a number of prominent gaps enough for pest entrance and harborage
fixture of more than 5 mm that has high
potential for pest entrance and
Plastic Trays harborage .
5. Washing Area Uncovered waste bin found in tray All dust bins need to be kept covered to avoid any Improvement Needed
washing area. cross contamination.
6. Walls , roof ceiling and floor found dirty A prompt cleaning with proper surveillance to be Improvement Needed
in tray washing area. carried out to avoid such circumstances.
7. Ceiling fan fixture found extremely dirty A prompt cleaning with proper surveillance to be Improvement Needed
in tray washing area. As per a service chit carried out to avoid such circumstances.
by Maintenance dept it is claimed to be
cleaned last on “ 06th October 2020”. (A
prolong period of 11 Months since it was
last cleaned).
1. Only one date of receiving chit observed Proper MRD including information such as date Serious
on a crate “ 12 -08-2021” with no best of receiving, date of production and expiry date /
Egg Breaking before instruction on it, furthermore it is limit should be in place on all commodities to
Department facility best practice to consume “ Eggs “ make assure operational functions such
within a period of 03 days maximum, FIFO/FEFO & traceability norms are carried out
since 05 days old chit was observed on a adequately.
crate furthermore purchase slip was
asked to be provided for scenario

16th August 2021
Root Cause
Auditee)
justification but facility failed to provide

evidence.
2. Eggs washing sink found chocked as A prompt cleaning with proper surveillance to be Serious
resulting a pool of dirty water with a carried out to avoid such circumstances.
very unpleasant smell observed in egg
breaking room.
3. Exhaust fixture found extremely dirty in A prompt cleaning with proper surveillance to be Improvement Needed
egg breaking dept. carried out to avoid such circumstances.
4. Egg Breaking Hand Sanitizer unit found significantly Administrative &Temporary maintenance works Improvement Needed
Department broken indicating an evidence of bad need to be super finished on immediate basis
practice that food handlers found
engaged in their routine operation are
not habitual of sanitizing / or washing
their hands.
5. Long and dirty nails evidence observed GMP protocols to be strictly follow to avoid any Improvement Needed
on a food handling employee in egg mishappening related to food safety and product
breaking dept quality.
6. Floor found extremely dirty in egg A prompt cleaning with proper surveillance to be Improvement Needed
breaking area. carried out to avoid such circumstances.
1. No Hand Sanitizer unit is available at the Hand sanitizer station need to be fixed in a Improvement Needed
entrance section of employees. suitable area
2. Staff entrance area found block with a Training on lean management tool such as on a” Improvement Needed
1st Floor Corridor pile of trays kept directly on floor. 5S “needs to be provided
3. Area Insect cutter found in 1st floor corridor A comprehensive IPM system needs to be Improvement Needed
area entrance has a massive number of introduced in the facility to eliminate pest related
dead flies inside its tray since it has to be issues.
cleaned on frequent intervals. As per
maintenance cleaning chit it was last
cleaned on 29-07-2021 (18 days ago It
was last cleaned).

16th August 2021
Root Cause
Auditee)
1. Most of the food handling employees GMP protocols to be strictly follow to avoid any Serious
found in fast food section without mishappening related to food safety and product
wearing face mask properly as their quality.
noses and mouths were exposed as they
have fixed their masks on their chins.
2. An uncovered tray found containing All product , raw material, packaging material, Serious
“Crispy Pocket stuff “kept under side of semi-finished, product contact surface
make table in fast food section. equipment are supposed to be kept covered
Fast Food Section observations.
3. Calibration tag was missing on weighing All critical tools that variation may have an Improvement Needed
scale along with its identification tag in impact on food quality and safety such as
fast food section. weighing scale, thermometers etc. need to be
calibrated and identified in all operational areas.
4. Wooden handled broom is being used in Wooden based equipment, tools, Infrastructure, Improvement Needed
fast food section. Framework and utensils are not recommended in
different pests.
5. Eating evidence as a small SS jug found Eating practices should be only allowed in Serious
containing tea content inside kept designated areas only such as canteen area.

16th August 2021
Root Cause
Auditee)
directly on floor very next to waste bin Wooden based equipment, tools, Infrastructure,
and Wooden handled broom next to Framework and utensils are not recommended in
freezer # 02 in fast food section. food operation facilities since they are prone
different pests.
6. Freezer # 02 gasket found extremely Deep dive approach with respect to cleaning Improvement Needed
dirty from inside. protocols to be adopted with strict follow ups on
frequent basis.
7. Shredded cheese found in a bowl that Since Meat and Poultry based products can not Major
was kept directly on Semi finished be kept together with dairy based products as it
Fast Food Section product “Chicken Lollipops in a same may have potential for a synergic / dual hazard (
freezer # 02. Chemical and biological hazard together) as
some times when we observe a temperature
disorder failure there are very high chances for
microbial contamination even products or any of
a product from both categories are packed they
may pose a cross microbial contamination as well
as they have potential for a chemical reaction /
Allergen reaction if not covered, hence therefore
not recommended to be kept together even if
they are properly packed in one portion of a
refrigerator or freezer to avoid cross
contamination.
8. Punjabi Samosa filling Stuff found All product , raw material, packaging material, Severe Serious
partially uncovered in freezer # 02 in fast semi-finished, product contact surface
food section. equipment are supposed to be kept covered

16th August 2021
Root Cause
Auditee)

observations.
9. Hand washing station found extremely Deep dive approach with respect to cleaning Serious
dirty with evidence of an unpleasant protocols to be adopted with strict follow ups on
smell from drain observed that has high frequent basis.
potency to cross contaminate and alter
finished product sensory profile or may
deteriorate product intrinsic attributes
10. Fast Food Section Alive German cockroach observed near A comprehensive IPM system needs to be Major
hand washing station in fast food introduced in the facility to eliminate pest related
section. issues.
11. Partially uncovered tray observed All product , raw material, packaging material, Severe Serious
containing “Boiled Chicken stuff “inside semi-finished, product contact surface
freezer # 03 in fast food section. equipment are supposed to be kept covered
observations.
12. Lemon Juice container found an MRD For homemade lemon juice, you should use it Serious
claiming a best before instruction use within 2 to 3 days. The store-bought one should
within 30 days whereas in previous stay safe for a bit longer, like 4 to 5 days. Ideally,

16th August 2021
Root Cause
Auditee)
audits shelf life for same commodity you always use all of the fresh juice right away,
found to be of 10 days and 15 days but that's not always feasible.
respectively, since no shelf life
assessment data is in place to assure
that commodity has a justified /
authentic / validated shelf life claiming.
13. Rough welding, tack welding evidences Sometimes Welding process might introduce Serious
observed on the surface of cleaver used stress cracks and microfractures that
in fast food section. compromises the integrity of weld and its
corrosion resistance that has an adverse impact
on food safety as these stress cracks and
microfractures may provide space for dust and
dirt deposition that can creat a possible cross
Fast Food Section contamination source that effect the product
shelf life and enhance food safety related risk to
the food consumers.
14. Alive cockroach observed at the A comprehensive IPM system needs to be Major
backside area of freezer # 02 in fast food introduced in the facility to eliminate pest related
section. issues.
15. Hand soap dispenser found empty in All hand soap and sanitizer dispensers need to be Improvement Needed
hand washing station in fast food surveillance on a frequent period to assess that
section. all stations are filled adequately with soap and
sanitizers respectively on all critical stations.
16. Open / uncovered dustbin found Adequate number of foot operated waste bins Serious
without foot operated mechanism in should be installed in all food operational and
fast food section near hand washing associate areas with proper / intended working
station. mechanism.
17. No date of opening is mentioned on Date of opening should be mentioned on packet Serious
pouch containing Ketchup inside as it with a revised (reduced shelf life since no vacuum
was kept in a normal room temperature

16th August 2021
Root Cause
Auditee)
environment and it was claimed to be application is carried out to counter off / rule out
used within 3 days without any written moisture from environment.
validation of shelf life operational Raw materials technical shelf life limit may need
protocol. to be revised for commodities that are critically
sensitive to storage conditions challenges
18. No date of opening is mentioned on Date of opening should be mentioned on packet Serious
pouch containing Mayonnaise inside as with a revised (reduced shelf life since no vacuum
it was kept in a normal room application is carried out to counter off / rule out
temperature environment and it was moisture from environment.
claimed to be used within 3 days Raw materials technical shelf life limit may need
without any written validation of shelf to be revised for commodities that are critically
life operational protocol. sensitive to storage conditions challenges
19. A food handler found wearing ring in his Prompt GMP protocols to be followed up to Major
Fast Food Section ring finger observed working in fast food avoid such incidents.
section with bare hands.
20. A locker found locked from outside and Alternate deputy mechanism need to be in place Improvement Needed
its keys custodian was not present at the for all employees as if they are not available at
time inspection was carried out. facility so any operational activity may not be
ceased due to their absence.
21. ChaatPapdi perforation dye / mould Since thread looms are considered to be a Major
found covered in a cloth piece that has physical source of contamination that may result
potential loosing threads and may in risks to consumers health if not observed while
contaminate not only the tool but also consuming may impact possible food reactions
food product such as raw dough of that may results in serious illness to end
chaatpaapdi. consumer such as Food Poisoning, throat
chocking, Gut Chocking etc
22. Expired product “ Beef Sample Qeema “ FIFO follow-ups to be made on realistic approach Major
found with date of processing 13thjuly to avoid any traceability failures that may lead to
2021 with an instruction to be used product expiry.
within 30 days ( technically this was

16th August 2021
Root Cause
Auditee)
expired 03 days ago) in freezer # 01 in

fast food section.
23. German Cockroach found inside a A comprehensive IPM system needs to be Major
cabinet / locker dedicated for keeping introduced in the facility to eliminate pest related
production tools inside. issues.
24. Cabinet walls found to be extremely A prompt cleaning with proper surveillance to be Serious
dirty from inside having a possible carried out to avoid such circumstances.
potential for pest harborage inside
cabinet.
25. Damage packaging of condiment spice A prompt cleaning with proper surveillance to be Major
observed with a date of production 14- carried out to avoid such circumstances.
08-2021 with instruction use within 15 A comprehensive IPM system needs to be
Fast Food Section days observed in a cabinet where introduced in the facility to eliminate pest related
cockroaches have significant harborage issues.
along with dirt and debris evidence. All product , raw material, packaging material,
semi-finished, product contact surface
observations.
26. An ingredient commodity “White Since all powder based product should be kept in Serious
Masalah “ with date of production 03 any air tight container to avoid any moisture
August 2021 with instruction to be use accumulation chances that may lead to fungus
with in 01 year without any authentic / growth ( Food Safety Issue ) / lumps formation (
validation shelf life declaration data Quality Issue ) that may alter product quality and

16th August 2021
Root Cause
Auditee)
since product was tied manually in a technical shelf life. Furthermore date of opening
common polythene shopper. should be mentioned on container with a revised
(reduced shelf life since no vacuum application is
carried out to counter off / rule out moisture
from environment.
Raw materials technical shelf life limit may need
to be revised for commodities that are critically
27. Condiment spice “ Mace “ found without All kinds of unidentified commodity weather Major
any MRD in fast food section. product, ingredient, or its container, or any
Fast Food Section occurrence of cross contamination furthermore
adequately
28. MRD expiry notes / chits are being used All kinds of unidentified commodity weather Improvement Needed
for fixing corrugated carton flips. Since product, ingredient, or its container, or any
most of MRDs were found to be out of utensils and / or equipment should be identified
date (Expired ) . with its dedicated purpose only to avoid any
adequately furthermore FIFO follow-ups to be

16th August 2021
Root Cause
Auditee)
made on realistic approach to avoid any

traceability failures that may lead to product
expiry.
29. Inside Corrugated box a dead domestic A prompt cleaning with proper surveillance to be Serious
fly corpse found adhered to a PVC carried out to avoid such circumstances.
container that was empty from inside. A comprehensive IPM system needs to be
introduced in the facility to eliminate pest related
issues.
30. Inside Corrugated box a dead German A comprehensive IPM system needs to be Major
cockroach corpse found with a pouch introduced in the facility to eliminate pest related
that was opened / uncovered containing issues.
product ingredient SHAN LAAL MIRCH
Fast Food Section powder inside.
31. Some unidentified Masalah powder All kinds of unidentified commodity weather Major
found without any MRD in corrugated product, ingredient, or its container, or any
carton kept inside a cabinet in fast food utensils and / or equipment should be identified
section. with its dedicated purpose only to avoid any
adequately
32. Product ingredient “ Zeera “ found All kinds of unidentified commodity weather Major
without any MRD in a manually tied product, ingredient, or its container, or any
polythene shopper that also contain a utensils and / or equipment should be identified
dead German coackroach corpse inside with its dedicated purpose only to avoid any
it in fast food section. occurrence of cross contamination furthermore

16th August 2021
Root Cause
Auditee)

adequately
33. Fast Food Section Product ingredient “ KuttiMirch“ found All kinds of unidentified commodity weather Major
without any MRD in a manually tied product, ingredient, or its container, or any
polythene shopper that also contain a utensils and / or equipment should be identified
dead German cockroach corpse inside it with its dedicated purpose only to avoid any
in fast food section. occurrence of cross contamination furthermore
adequately
1. Corner fixture found damaged at the All product , raw material, packaging material, Improvement Needed
entrance of main kitchen. semi-finished, product contact surface
Main Kitchen integrity should considered on a top priority
observations.

16th August 2021
Root Cause
Auditee)
2. Some False ceiling fixtures found Immediate maintenance to be carried out to Improvement Needed
damage at the entrance of main kitchen make manufacturing operations smooth.
section
3. Open drain found at the washing area of Fixed all drains on immediate basis ensure that Serious
main kitchen. no opening or gap of 5mm or more remain to be
closed out since this much gap is sufficient
enough for pest entrance and harborage
furthermore all drains need to kept clean all the
time and hose pipes need to be intact all the time
4. Broken tile fixture observed in washing Adequate civil maintenance work needs to be Improvement Needed
area of main kitchen. carried out to keep building infrastructure up to
Main Kitchen mark
5. Food handling employees found in Main comprehensive GMP protocols need to be Serious
Kitchen section without wearing face practiced to avoid unhygienic issues.
mask properly as their noses and
mouths were exposed as they have fixed
their masks on their chins.
6. Exhaust fan louver screening found Fixed all gaps on immediate basis ensure that no Improvement Needed
missing in main kitchen area. opening or gap of 5mm or more remain to be
closed out since this much gap is sufficient
enough for pest entrance and harborage.
7. Raw onion along with dirt dust and A prompt cleaning with proper surveillance to be Improvement Needed
debris evidences observed under make carried out to avoid such circumstances.
table in main kitchen.
1. Insect cutter tray found heavily A comprehensive IPM system needs to be Improvement Needed
accumulated with domestic dead flies introduced in the facility to eliminate pest related
Cake Section next to corridor passing through cake issues.
department
2. Foot operated waste bins found out of All dust bins need to be kept covered to avoid any Improvement Needed
mechanism / order in cake section. cross contamination.

16th August 2021
Root Cause
Auditee)
3. Cake section main entrance gate found A comprehensive IPM system needs to be Improvement Needed
failed to be closed properly having introduced in the facility to eliminate pest related
potential for domestic flies entrance to issues.
the dept since no PVC Curtains are
installed on entrance.
4. SS Container found failed to be closed All product , raw material, packaging material, Serious
properly since it contains uncovered semi-finished, product contact surface
product ingredient White syrup inside. equipment are supposed to be kept covered
Cake Section effect on product shelf life.All products package
integrity should be evaluated on frequent basis
to avoid such observations.
5. Unidentified product found inside a All kinds of unidentified commodity weather Major
manually tied polythene shopper product, ingredient, or its container, or any
without any MRD with an ambiguity in utensils and / or equipment should be identified
aspect of product recognition as some of with its dedicated purpose only to avoid any
food handler was saying its an icing occurrence of cross contamination furthermore
sugar, where as other was saying it is “ Proper MRD including information such as date
All Purpose Flour “ etc. of receiving, date of production and expiry date /
adequately
6. No date of opening is mentioned on Date of opening should be mentioned on packet Improvement Needed
tetra pack containing Olper’s Milk inside with a revised (reduced shelf life since no vacuum
as it was kept in a visicooler it was

16th August 2021
Root Cause
Auditee)
claimed to be used within 3 days application is carried out to counter off / rule out
without any written validation of shelf moisture from environment.
life operational protocol. Raw materials technical shelf life limit may need
7. No date of opening is mentioned on Date of opening should be mentioned on packet Improvement Needed
Bottle containing PUK Cream inside as it with a revised (reduced shelf life since no vacuum
was kept inside a visicoooler and it was application is carried out to counter off / rule out
claimed to be used within 3 days moisture from environment.
without any written validation of shelf Raw materials technical shelf life limit may need
life operational protocol. to be revised for commodities that are critically
8. Cake Section Dirty stagnant water found on the A prompt cleaning with proper surveillance to be Serious
corner of hand washing station in cake carried out to avoid such circumstances.
dept.
9. Hand Washing station sink found chock A prompt cleaning with proper surveillance to be Serious
with a very unpleasant smell that may carried out to avoid such circumstances.
have potential for altering product
sensory profile in cake dept.
10. Hand washing soap dispenser found Adequate Number of Hand Sanitizer stations Improvement Needed
empty in cake dept. should be in place to avoid any risk related to
personal hygiene.
All hand soap and sanitizer dispensers need to be
surveillance on a frequent period to assess that
all stations are filled adequately with soap and
11. Hand washing station found dirty in cake A prompt cleaning with proper surveillance to be Improvement Needed
section. carried out to avoid such circumstances.

16th August 2021
Root Cause
Auditee)
12. Broken tile fixture found on floor in cake Adequate civil maintenance work needs to be Improvement Needed
dept carried out to keep building infrastructure up to
mark
13. Uncovered finished cakes found in All product , raw material, packaging material, Major
freezer # 02 in Cake section Since it was semi-finished, product contact surface
observed that water droplets are equipment are supposed to be kept covered
dropping on product due to properly to avoid cross contamination as Package
temperature difference on every time a integrity should considered on a top priority
freezer is opened. Furthermore ice tiny since any dis integrity may lead to product cross
crystals evidences observed on finished contamination issues and may have adverse
cakes. effect on product shelf life.
Cake Section observations.
14. Calibration tag found missing on a All critical tools that variation may have an Improvement Needed
weighing scale in cake section. impact on food quality and safety such as
weighing scale, thermometers etc. need to be
calibrated and identified in all operational areas.
15. Dark Chocolate Bars / Bricks found kept All product , raw material, packaging material, Major
opened without any adequate covering semi-finished, product contact surface
inside production table rack since make equipment are supposed to be kept covered
table front edge area has potential properly to avoid cross contamination as Package
flaking paint evidence that may get integrity should considered on a top priority
dropped and mixed in to the product since any dis integrity may lead to product cross
and cause chemical to product cross contamination issues and may have adverse
contamination issue furthermore cake effect on product shelf life.
production was not being executed at All products package integrity should be
the time when inspection was carried evaluated on frequent basis to avoid such
out. observations.

16th August 2021
Root Cause
Auditee)
All flaking and sprouting paints issues need to be

fixed on priority to avoid any physical and / or
chemical contamination chances
16. Primary packaging “cake cards “ found All product , raw material, packaging material, Serious
kept without any liners or covering in semi-finished, product contact surface
cake section. equipment are supposed to be kept covered
Cake Section since any dis integrity may lead to product cross
observations.
17. Cake Finished carton found containing A comprehensive IPM system needs to be Major
Flying Insect “ Peppered Moth “ on a introduced in the facility to eliminate pest related
Cake product “ Cake Heaven “ in issues.
Premium Cake Dept.
1. Fan Fixture in Cake Chiller section found Deep dive approach with respect to cleaning Serious
extremely dirty has potential to cross protocols to be adopted with strict follow ups on
Cake Chiller contaminate finished uncovered cake frequent basis.
products such as Cup Cakes”.
2. Dirty Trays are being used for keeping Deep dive approach with respect to cleaning Improvement Needed
finished cakes on them. protocols to be adopted with strict follow ups on
frequent basis.
1. Exhaust fan fixture has a massive gap Fixed all gaps on immediate basis ensure that no Improvement Needed
Metal Tray Washing fixture of more than 50 mm with a very opening or gap of 5mm or more remain to be
Area high potential for any pest entrance or closed out since this much gap is sufficient
harborage. enough for pest entrance and harborage.

16th August 2021
Root Cause
Auditee)
2. Non foot operated dustbin found in All waste bins / dustbins need to be covered to Improvement Needed
metal tray washing area. eliminate risk of cross contamination and pest
harborage.
Foot Operated Waste bins are recommended to
avoid hand to surface cross contamination.
3. Metal Tray Washing Flaking paint evidences observed on wall All color jobs need to be carried out on a Improvement Needed
Area side and roof ceiling in metal tray tentative schedule.
washing area. All flaking and sprouting paints issues need to be
fixed on priority to avoid any physical and / or
chemical contamination chances
1. Hand sanitizer dispenser found missing Adequate Number of Hand Sanitizer stations Improvement Needed
at the entrance of ovens area. should be in place to avoid any risk related to
personal hygiene.
2. Exhaust fan louver screening has the A prompt cleaning with proper surveillance to be Improvement Needed
Ovens Area prominent gaps of more than 5mm in carried out to avoid such circumstances.
ovens area.
3. Personal belongings “Domestic clothes” Adequate number of lockers in locker room Improvement Needed
found hanged on wall at the backside of should be in place to avoid such scenarios further
ovens in ovens area. more locker room should be away from
production premises.
4. Ventilation space screening found A prompt cleaning with proper surveillance to be Improvement Needed
heavily accumulated with dust particles. carried out to avoid such circumstances.
5. Non foot operated dustbin found in All dust bins need to be kept covered to avoid any Serious
ovens area. cross contamination.

16th August 2021
Root Cause
Auditee)
6. Wooden handled knives observed in Wooden based equipment, tools, Infrastructure, Improvement Needed
ovens area. Framework and utensils are not recommended in
Ovens Area enough to be avoided due to their porous nature
different pests.
1. Hand sanitizer dispenser found empty in All hand soap and sanitizer dispensers need to be Improvement Needed
biscuit &petties dept. surveillance on a frequent period to assess that
2. Insect o cutter light found out of order in A comprehensive IPM system needs to be Improvement Needed
biscuit & petties dept. introduced in the facility to eliminate pest related
issues.
Temporary / Preventive maintenance works
Biscuit & Petties need to be super finished on immediate basis.
Department Furthermore a Job Order should be in place for
all Equipment’s that are “ Out of Order/ Under
Maintenance “.
3. Eating Evidence such as some some Eating practices should be only allowed in Serious
biscuits found with intention for eating designated areas only such as canteen area.
in Biscuit & Patties dept.
4. Eating evidence / personal belonging Eating practices should be only allowed in Improvement Needed
material such as spoons and rice dish designated areas only such as canteen area.
out spatula found in a cabinet in
production hall with tagging for
intended use in biscuits and patties
dept.

16th August 2021
Root Cause
Auditee)
5. An unidentified pouch found claimed to All kinds of unidentified commodity weather Major
be containing egg inside without any product, ingredient, or its container, or any
MRD in biscuit and patties dept. utensils and / or equipment should be identified
adequately
6. A beverage bottle found being used for Furthermore, all unidentified and suspected Improvement Needed
drinking water purpose without items to be surveillance on a periodic interval to
Biscuit & Petties identification of intended use. avoid such circumstances
7. Department A freezer without any identification All product , raw material, packaging material, Serious
observed in biscuit and patties dept semi-finished, product contact surface
with evidence of broken / damaged/ equipment are supposed to be kept covered
detached gasket along with dirt properly to avoid cross contamination as Package
accumulation on freezer internal hinges. integrity should considered on a top priority
observations.
8. Unidentified dairy item “ Butter” found All kinds of unidentified commodity weather Major
without any MRD in freezer in biscuit product, ingredient, or its container, or any
and patties dept. utensils and / or equipment should be identified

16th August 2021
Root Cause
Auditee)

adequately
9. Damaged packaging with partial All product , raw material, packaging material, Major
exposure of product “butter” observed semi-finished, product contact surface
in a freezer with a high probability to be equipment are supposed to be kept covered
cross contaminated with condensate properly to avoid cross contamination as Package
droplets that may occur while opening integrity should considered on a top priority
of freezer in biscuit and patties section. since any dis integrity may lead to product cross
Biscuit & Petties All products package integrity should be
Department evaluated on frequent basis to avoid such
observations.
10. Date of opening found missing on “ Date of opening should be mentioned on packet Improvement Needed
Chocolate chips “ packet that was kept with a revised (reduced shelf life since no vacuum
open in a freezer in biscuit and patties application is carried out to counter off / rule out
kept. moisture from environment.
Raw materials technical shelf life limit may need
11. Alive German cockroach found crawling A comprehensive IPM system needs to be Major
on floor in biscuit and patties dept. introduced in the facility to eliminate pest related
issues.
12. Damaged empty cartons found kept in All product , raw material, packaging material, Improvement Needed
an unidentified verbally claiming to be semi-finished, product contact surface
discard area. equipment are supposed to be kept covered

16th August 2021
Root Cause
Auditee)

observations.
13. Hand washing station drain found All product , raw material, packaging material, Serious
uncovered in biscuit and patties dept. semi-finished, product contact surface
Biscuit & Petties since any dis integrity may lead to product cross
Department contamination issues and may have adverse
observations.
14. Another Alive German cockroach was A comprehensive IPM system needs to be Major
seen near production table on the wall introduced in the facility to eliminate pest related
side support fixture in biscuit and patties issues.
dept.
15. Foot operated waste bin found out of All dust bins need to be kept covered to avoid any Serious
mechanism in biscuit and patties dept. cross contamination.
1. Freezers Room An apron found hanging on a door Adequate number of lockers in locker room Improvement Needed
fixture in freezers dept. should be in place to avoid such scenarios further

16th August 2021
Root Cause
Auditee)
more locker room should be away from

production premises.
2. Product MRD chit found pasted in such All kinds of unidentified commodity weather Improvement Needed
a manner inside a tray that it was product, ingredient, or its container, or any
coming in direct contact to the semi utensils and / or equipment should be identified
finished product “Mava Butter French with its dedicated purpose only to avoid any
Heart “. occurrence of cross contamination furthermore
Freezers Room adequately
3. Dirt and debris accumulation in space Adequate deep cleaning in hard to excess areas Improvement Needed
between two freezers with on planned intervals to avoid such happenings
identification # 08 &# 09 respectively in further more comprehensive GMP protocols
freezer room. need to be practiced to avoid unhygienic issues.
4. Eating evidence “ Supari “ wrapper Eating practices should be only allowed in Serious
observed near freezer # 08 in freezer designated areas only such as canteen area.
room.
5. Open “Cheddar Cheese “found without All kinds of unidentified commodity weather Major
proper covering and MRD in freezer # 07 product, ingredient, or its container, or any
in freezer room. utensils and / or equipment should be identified

16th August 2021
Root Cause
Auditee)

adequately
6. Chocolate Phool “ Semi finished” dough All kinds of unidentified commodity weather Severe Serious
found with a manual MRD in freezer # 06 product, ingredient, or its container, or any
in freezer room. utensils and / or equipment should be identified
adequately
7. Unidentified dough without any All kinds of unidentified commodity weather Major
Freezers Room covering and MRD found pasted on the product, ingredient, or its container, or any
lid of an SS Container in freezer # 05 in utensils and / or equipment should be identified
freezer room. with its dedicated purpose only to avoid any
adequately
8. Unidentified dough found in manual All kinds of unidentified commodity weather Major
polythene covering without any MRD in product, ingredient, or its container, or any
freezer # 05 in freezer room. utensils and / or equipment should be identified

16th August 2021
Root Cause
Auditee)

adequately
9. Damaged packaging observed in All product , raw material, packaging material, Major
ingredient Product “ Mava Naan Khatai “ semi-finished, product contact surface
in Freezer # 04 in freezer room. Since equipment are supposed to be kept covered
visible physical traces of some dirt properly to avoid cross contamination as Package
particle observed on surface of dough integrity should considered on a top priority
material as it was kept under a plastic since any dis integrity may lead to product cross
tray which bottom side was found to be contamination issues and may have adverse
dirt accumulation hence it is a physical effect on product shelf life.
cross contamination to the product in All products package integrity should be
Freezers Room freezer # 05 in freezer room. evaluated on frequent basis to avoid such
observations.
10. Wooden plank structure stock found at Wooden based equipment, tools, Infrastructure, Improvement Needed
backside of freezer # 04 in freezer room. Framework and utensils are not recommended in
different pests.
11. Eating evidence as “ Domestic utensils “ Eating practices should be only allowed in Serious
found being used for cooking of non designated areas only such as canteen area.
commercial food for personal feast in a
small room that is adjacent to freezer
room.

16th August 2021
Root Cause
Auditee)
1. Waste bin found uncovered in export All dust bins need to be kept covered to avoid any Serious
store room. cross contamination.
avoid hand to surface cross contamination
2. Dirty buckets / trays are used for All product , raw material, packaging material, Improvement Needed
keeping finished products “ Doughnut “ semi-finished, product contact surface
without covering in Export storage equipment are supposed to be kept covered
room. properly to avoid cross contamination as Package
Export Storage All products package integrity should be
Room evaluated on frequent basis to avoid such
observations.
3. A personal found with long & dirty nails GMP protocols to be strictly follow to avoid any Improvement Needed
in Export storage room. mishappening related to food safety and product
quality.
4. Under rack area found heavily A prompt cleaning with proper surveillance to be Serious
accumulated with dirt, dust & debris in carried out to avoid such circumstances
Export storage room.
5. Eating evidence “Naswar ball” found Eating practices should be only allowed in Major
under rack in Export storage room. designated areas only such as canteen area.
6. Roof fan found dirty with accumulation A prompt cleaning with proper surveillance to be Serious
of dust looms in export storage room. carried out to avoid such circumstances
1. Hand sanitizer dispenser found empty in All hand soap and sanitizer dispensers need to be Improvement Needed
Dry cakes Dry cakes dept. surveillance on a frequent period to assess that
department all stations are filled adequately with soap and

16th August 2021
Root Cause
Auditee)
2. Primary packaging material “Cake cards” All product , raw material, packaging material, Serious
found kept uncovered under production semi-finished, product contact surface
table in Dry cakes dept. equipment are supposed to be kept covered
observations.
3. A plastic bottle being used for drinking All kinds of unidentified commodity weather Minor
water purpose found without any product, ingredient, or its container, or any
Dry cakes identification tag in Dry cakes dept. utensils and / or equipment should be identified
department with its dedicated purpose only to avoid any
adequately
4. Chocolate slab bars found partially All product , raw material, packaging material, Serious
uncovered kept in exposed environment semi-finished, product contact surface
in Dry Cakes Dept. equipment are supposed to be kept covered

16th August 2021
Root Cause
Auditee)

observations.
5. No shelf life determination evidence An adequate Shelf Life protocol with respect to Serious
observed as some semi finished product individual commodity to be carried out to avoid
ingredients / compound ingredients external challenges.
found with a same date of retention Self-declaration is acceptable when there is a
Dry cakes (Best Before) for commodities such as “ concrete shelf life study data is in place if not
department Chocolate Butter Cream,”. “Almonds avoid false claiming.
Chips etc. in dry cake dept. A precise data related to each ingredient should
be in place to assure that technical shelf life
declarations and claims are true and acceptable
as per given / current environmental
circumstances.
E.G : Product shelf life and storage condition and
temperature relations in Pantry, Fridge and
Freezers etc.
1. Hand Dryer found missing near hand Adequate number of hand dryers should be Improvement Needed
washing station in “ Baklava Dept “ available in food facility with effective
performance as per intended use.
2. Underside area of sink found dirty in Deep dive approach with respect to cleaning Improvement Needed
Baklava dept. protocols to be adopted with strict follow ups on
Baklava Dept frequent basis.
3. A locker observed to be locked with Improvement Needed
availability of keys as custodian was not
available in morning shift in baklava
dept.
4. Dirt and debris found under production Deep dive approach with respect to cleaning Improvement Needed
table area in “ Baklava “ dept. protocols to be adopted with strict follow ups on
frequent basis.

16th August 2021
Root Cause
Auditee)
1. Hand sanitizer dispenser found missing Adequate Number of Hand Sanitizer stations Improvement Needed
in territory of doughnut dept. should be in place to avoid any risk related to
personal hygiene.
2. Eating evidence such as a pouch found Eating practices should be only allowed in Serious
containing “ Tea “ inside in Doughnut designated areas only such as canteen area.
dept
3. Doughnut Dept Dirt and debris found under production Deep dive approach with respect to cleaning Serious
table area in “ Doughnut “ dept. protocols to be adopted with strict follow ups on
frequent basis.
4. Exhaust fan found extremely dirty in Deep dive approach with respect to cleaning Improvement Needed
doughnut frying area. protocols to be adopted with strict follow ups on
frequent basis.
5. Expired Product “ Bread Bran Mix “ with FIFO follow-ups to be made on realistic approach Major
best before instruction “ 16 August 2021 to avoid any traceability failures that may lead to
“ and time “ 00 :44 am hence it was just product expiry.
expired some hours ago in “ Doughnut
Fry “ area.
1. False ceiling fan fixture found extremely Deep dive approach with respect to cleaning Improvement Needed
dirty with a cleaning chit evidence “ protocols to be adopted with strict follow ups on
Export Packing Area Cleaned by Najam on 12th May 2021, frequent basis.
since today is 16th August and it has not
been cleaned in a period of 03 months
and 04 days “.
1. Some medical screening records found Medical screening is a mandatory requirement Serious
Documentation to be insufficient as due to some by state and regulatory of any countries province
anomalities related to disease as it helps to screen out all contingent diseases

16th August 2021
Root Cause
Auditee)
requirements need to be ruled out for that may be chronic as well as very easy to spread
following employees such as while performing routine tasks.
1. Daniel Nazeer Gill Since Janitorial staff are at very high risk of
(Housekeeping Dept). attaining germs to themselves with a super
2. Shahazad Aashiq ( immunity systems and associated environment
Housekeeping Dept ). therefore all janitorial work should be done by a
3. Nasir Khan (House Keeping dedicated team for intended work and they
Dept). should not be deputed for any work related to
4. Nasir Habib ( Bread & food operations due to their actual intended job
Doughnut Dept ). that has extreme severity to spread contiguous
diseases.
2. Housekeeping checklist is not being Housekeeping checklist format need to be Serious
Documentation filled at facility. revised to include all necessary elements to make
evidence with a “prone” approach.
3. COA/ Purchase slip for raw materials COAs availability should be mandatory for each Serious
such as Eggs and vegetables found lot prior to material receiving and this action
unavailable at the time of auditing, should be considered as a “ Must Have
Obligation” for all suppliers during routine
evaluation of supplier.
4. Water filtration record is not available at All chemicals that come in contact to food Serious
facility. product or with ingredient must have at least
MSDS as well as food grade certificate to avoid
any occurrence of cross contamination
5. 3rd Party water analysis for Heavy Metals External testing of all critical ingredients Serious
and Microbial testing are not available including potable water should be carried out at
at Facility. least annually to make food safety & Quality
culture alive to meet global challenges related to
food operations.
6. Discard Oil and Ghee record found Since Documents were not shown at the time of Serious
unavailable at the time of auditing. auditing as no custodian was available at facility

16th August 2021
Root Cause
Auditee)
furthermore no documents were share later on

email even a prolong leverage bracket for
documents evidence submission was given but
no response resulted even a after a weak gap
from the day of auditing, hence it’s a serious
concern to provide document evidence on time
to avoid any allegation related to lack of
professionalism.
7. Cleaning Chemical such as “ Evans “ All chemicals that come in contact to food Serious
MSDS was not available at the time of product or with ingredient must have at least
Auditing. MSDS as well as food grade certificate to avoid
any occurrence of cross contamination
8. Documentation IPM records were not available at the A comprehensive IPM system needs to be Serious
facility during audit. introduced in the facility to eliminate pest related
issues.
9. Packaging material food grade All packaging material that come in contact to Serious
certificate for “ Cake Cards, Liners and food product or with ingredient must have a food
Butter paper “found missing at facility grade certificate to avoid any occurrence of cross
during audit. contamination.
10. Customer Complaint Records were not Since Documents were not shown at the time of Serious
available at facility during Audit. auditing as no custodian was available at facility
professionalism.

16th August 2021
Root Cause
Auditee)
11. Rodents Cage Map found unavailable at A comprehensive IPM system needs to be Serious
facility during auditing. introduced in the facility to eliminate pest related
issues.
12. Water tank cleaning certificate found Since Documents were not shown at the time of Serious
unavailable at facility during audit. auditing as no custodian was available at facility
Documentation from the day of auditing, hence it’s a serious
professionalism.
13. Calibration Master Documents found Since Documents were not shown at the time of Serious
missing for weighing gauges and auditing as no custodian was available at facility
temperature devices in facility during furthermore no documents were share later on
audit. email even a prolong leverage bracket for
professionalism.

16th August 2021
Root Cause
Auditee)
Korangi Factory
Audit Status of 16th August 2021
Finding Severity No. Of Findings Severity %
Major 64 25.91
Severe Serious 19 7.69
Serious 66 26.72
Improvement Needed 96 38.87
Minor 2 0.81
Total 247

Audit Report Korangi Factory 16 Aug 2021

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UNITED KING FOODS (PVT) LTD

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

contamination issues and may have adverse

A prompt cleaning with proper surveillance to be

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Proper MRD including information such as date

Internal Audit / Inspection Findings against SFA Checklist

since any dis integrity may lead to product cross

Internal Audit / Inspection Findings against SFA Checklist

limit should be in place on all commodities to

Internal Audit / Inspection Findings against SFA Checklist

make assure operational functions such

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

make assure operational functions such

Internal Audit / Inspection Findings against SFA Checklist

491 with MFG 15-03-21 & EXP 14-03-22

Internal Audit / Inspection Findings against SFA Checklist

DEC-21 whereas some pouches of CCT-

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

All products package integrity should be

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

All products package integrity should be

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

All products package integrity should be

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

specially for crawling insects such as

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

justification but facility failed to provide

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

integrity should considered on a top priority

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

expired 03 days ago) in freezer # 01 in

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

made on realistic approach to avoid any

Internal Audit / Inspection Findings against SFA Checklist

Proper MRD including information such as date

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

Internal Audit / Inspection Findings against SFA Checklist

All flaking and sprouting paints issues need to be

Internal Audit / Inspection Findings against SFA Checklist