Audit Report Korangi Factory (12th June 2021) Announced

Internal Audit / Inspection Findings against SFA Checklist
Korangi Factory
Auditing Date : 12th June 2021
S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

(To be Filled By Status
Auditee )
01 Broken tiles observed in dispatch area. Immediate fixture of broken Tile / floor
need to be paved / fixed on priority to keep Minor
food manufacturing operations smooth with
rational food safety approach
02 Massive number of flies observed in dock A comprehensive IPM system needs to be Improvement Needed
receiving and dispatch area. introduced in the facility to eliminate pest
related issues
Cracks observed on walls fixture near factory Fixed all gaps on immediate basis ensure Minor
03 Dock Area main gate. that no opening or gap of 5mm or more
(Receiving & Dispatch Area ) remain to be closed out since this much gap
is sufficient enough for pest entrance and
harborage.
Acetic acid cans found in receiving area without All commodities being considered as food Minor
04 any pallets and its external surface found product and /or ingredient should be kept
extremely dirty with receiving date 25-05-2021 off the floor to avoid cleaning issues and
obstacles with respect to hard to access
area.
Coconut broom found in receiving area. Since wooden material is not recommended Improvement Needed
in food operations as it creates opportunity
05 with respect to pest harborage and other
critical food safety concerns that may lead
Korangi Factory

Auditee )
to severe cross contamination.
Phenyl bottle found next to hand washing and

dish washing chemicals cans in receiving area Improvement needed
06 with no chemical controls. A comprehensive chemical control program
should be in place to avoid any chemical
contamination issue.
Unidentified can observed next to hand washing All kinds of unidentified commodity weather Improvement Needed
07 and dish washing liquid containers in product product, ingredient, or its container, or any
receiving area, its label shows that “ this product utensils and / or equipment should be
Dock Area is intentionally use in textile industries. MSDS is identified with its dedicated purpose only to
(Receiving & Dispatch Area ) required for the product. avoid any occurrence of cross
contamination
All product , raw material, packaging

material, semi finished, product contact Improvement Needed
“Potatoes” received as raw material found in surface equipment are supposed to be kept
08 damaged / open sacs. covered properly to avoid cross
contamination as Package integrity should
considered on a top priority since any dis
integrity may lead to product cross
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.
Drinking water dispenser bottle found extremely A prompt cleaning with proper surveillance Improvement Needed
Korangi Factory

Auditee )
09 dirty kept directly on floor in raw material to be carried out to avoid such
receiving area. circumstances.
Raw material washing station Adequate deep cleaning in hard to excess

(Vegetables & meat ) found extremely dirty from areas on planned intervals to avoid such Improvement Needed
10 underside area in raw material receiving corridor. happenings further more comprehensive
GMP protocols need to be practiced to
avoid unhygienic issues.
Fixed all gaps on immediate basis ensure

Wall cracks observed next to underground tank that no opening or gap of 5mm or more Improvement Needed
11 opening platform. remain to be closed out since this much gap
Dock Area is sufficient enough for pest entrance and
(Receiving & Dispatch Area ) harborage.
Alive cats observed in two different locations in A comprehensive IPM system needs to be Major
raw material receiving area one found near main introduced in the facility to eliminate pest
12 electric panel and the other one found mounted related issues
on cable tray channel passing over raw material
washing station.
Alive American cockroaches found inside fixture A comprehensive IPM system needs to be Major
13 of underground water tank. introduced in the facility to eliminate pest
related issues
Under pallets area containing onion and chili sacs Adequate deep cleaning in hard to excess Serious
14 found dirty. areas on planned intervals to avoid such
Korangi Factory

Auditee )
happenings further more comprehensive

Dock Area New coconut brooms receiving observed kept in Since wooden material is not recommended Improvement Needed
15 (Receiving & Dispatch Area ) material receiving area and it was kept next to in food operations as it creates opportunity
pallets containing onions sacs. with respect to pest harborage and other
No PVC curtains installation observed at entrance A comprehensive IPM system needs to be Improvement Needed
01 to main store room. introduced in the facility to eliminate pest
related issues
02 Flies observed in main store room. A comprehensive IPM system needs to be Improvement Needed
introduced in the facility to eliminate pest
Main Store Room related issues
03 No hand sanitizer station found in main store Hand sanitizer station need to be installed Improvement Needed
room. in all food and associated operational areas
to avoid any unhygienic condition.
FIFO failure observed in potato samosa seasoning FIFO follow-ups to be made on realistic Improvement Needed
04 “ PSA 310 “ as some pouches found with date of approach to avoid any traceability failures
production 10-04-2021 and date of expiry 09-04- that may lead to product expiry.
2022 whereas some pouches of same product
found with date of production 15-03-2021 and
Korangi Factory

Auditee )
date of expiry 14-03-2022 found kept at the back

side of the trays.
A pouch found without any MRD and All kinds of unidentified commodity weather Major
identification that on investigation found to be product, ingredient, or its container, or any
beef cutlets seasoning ( BCT 550 ) in main store. utensils and / or equipment should be
identified with its dedicated purpose only to
05 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
Main Store Room
FIFO failure observed in Beef Samosa seasoning “ FIFO follow-ups to be made on realistic Improvement Needed
BSA 285 “ as some pouches found with date of approach to avoid any traceability failures
06 production 06-04-2021 and date of expiry 05-04- that may lead to product expiry.
side of the trays.
Dual shelf life observed for commodity “ beef Proper MRD ( Without Duplication ) Major
07 samosa seasoning BSA 285 “ as some pouches including information such as date of
indicates shelf life of 12 months whereas other receiving, date of production and expiry
pouches indicates shelf life of 20 months. date / limit should be in place on all
Korangi Factory

Auditee )
Internally damaged aluminum pouches All product , raw material, packaging Major
containing “ Chana Tarkari “ seasonings with date material, semi finished, product contact
of production 07-03-2021 and date of expiry 06- surface equipment are supposed to be kept
03-2022 observed in main store room. covered properly to avoid cross
08 contamination as Package integrity should
observations.
Technically Illogical shelf life claiming observed in Shelf life disclaimer should be logical
Main Store Room roasted chicken packets with date of production enough that it may not pose any irregular Improvement Needed
09 23-01-2021 with expiry instruction best before calculation other than normal international
27-10-2021 which on calculation found to be of practices. Raw materials technical shelf life
09 months and 04 days. limit may need to be revised for
commodities that are critically sensitive to
storage conditions challenges
Flaking paint evidence observed on MS shelves / All flaking and sprouting paints issues need Improvement Needed
10 racks fixtures in main store room containing to be fixed on priority to avoid any physical
seasoning trays on it. and / or chemical contamination chances
F
Korangi Factory

Auditee )
11 FIFO failure observed in Vegetable Roll seasoning IFO follow-ups to be made on realistic Improvement Needed
“ VR 491 “ as some pouches found with date of approach to avoid any traceability failures
production 15-03-2021 and date of expiry 14-03- that may lead to product expiry.
side of the trays.
FIFO failure observed in seasoning “ MBR 220 “ as FIFO follow-ups to be made on realistic Improvement Needed
12 some pouches found with date of production 10- approach to avoid any traceability failures
04-2021 and date of expiry 09-04-2022 whereas that may lead to product expiry.
some pouches of same product found with date
of production 08-03-2021 and date of expiry 09-
03-2022 found kept at the back side of the trays.
Main Store Room Critical packaging defect observed as damaged All product , raw material, packaging Major
seal in spice pouches of Shan Foods such as “ material, semi finished, product contact
TEEKHI KAALI MIRCH POWDER” &“ surface equipment are supposed to be kept
13 KHUSHBOODAR LEHSUN “ covered properly to avoid cross
observations.
Critical packaging defect observed as damaged All product , raw material, packaging Major
seal in Vegetable roll seasoning VR 491 pouches “ material, semi-finished, product contact
Korangi Factory

Auditee )
14 in main store room. surface equipment are supposed to be kept

covered properly to avoid cross
observations.
Adequate number of Stool or SS monkey ladder Adequate number of stools ( Non Wooden ) Improvement Needed
15 required in main store room to avoid over staked should be in place to make food operational
and high to reach areas for handlers to perform activities smooth.
their jobs adequately in main store room.
A manually packed (in Polyethylene Bags ) “ Since all powder based product should be Improvement Needed
Main Store Room CHAAT MASALA “ with date of production 02-06- kept in any air tight container to avoid any
2021 with an expiry claiming to be used with in moisture accumulation chances that may
01 year, since it is manually packed and there are lead to fungus growth that may alter
16 no sufficient control for moisture and humidity product quality and technical shelf life.
at the storage area so it is hard to keep it safe for Furthermore date of opening should be
longer period as it has potential to attain fungus mentioned on container with a revised
growth that may lead to afla toxin presence in (reduced shelf life since no vacuum
commodity. 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 sensitive to storage conditions
challenges
Korangi Factory

Auditee )

Critical packaging defect observed as damaged material, semi-finished, product contact Major
17 packing in “ SAABUT LAAL MIRCH “ pouches “ surface equipment are supposed to be kept
with date of production 24-05-2021 with expiry covered properly to avoid cross
instruction use within 03 months found in main contamination as Package integrity should
store room. considered on a top priority since any dis
observations.
Technically Illogical shelf life claiming observed in Self-declaration is acceptable when there is Improvement Needed
18 “Beef Flavor” packets with date of production 23- a concrete shelf life study data is in place if
01-2021 with expiry instruction best before 27- not avoid false claiming.
10-2021 which on calculation found to be of 09 Raw materials technical shelf life limit may
months and 04 days. need to be revised for commodities that are
Main Store Room challenges
19 Under pallet area containing sugar and flour bags Adequate deep cleaning in hard to excess Major
found extremely dirty since it was claimed to be areas on planned intervals to avoid such
cleaned 04 days ago but due to congested area it happenings further more comprehensive
has accumulated dust and debris inside the GMP protocols need to be practiced to
pallets. avoid unhygienic issues.
20 Norway Rodents dropping observed inside racks A comprehensive IPM system needs to be Major
containing seasoning trays in main store room. introduced in the facility to eliminate pest
Korangi Factory

Auditee )
related issues
21 Underside area for racks containing seasoning Adequate deep cleaning in hard to excess Improvement Needed
found accumulated with dirt and debris inside in areas on planned intervals to avoid such
main store room. happenings further more comprehensive
22 FIFO failure observed in “ Vegetable roll VR 491 FIFO follow-ups to be made on realistic Improvement Needed
“seasoning cartons that are received from “ Main approach to avoid any traceability failures
Warehouse Supply “ with different date of that may lead to product expiry.
production such as 25-02-2021,15-03-2021 with
expiry 24-02-2022 & 14-03-2022 respectively.
Main Store Room

23 FIFO failure observed in “ Chicken Samosa CSA FIFO follow-ups to be made on realistic Improvement Needed
105 A “seasoning cartons that are received from “ approach to avoid any traceability failures
Main Warehouse Supply “ with different date of that may lead to product expiry.
production such as 03-02-2021,10-04-2021 with
expiry 02-02-2022 & 09-04-2022 respectively.
24 Weighing scale found without identification and All critical tools that variation may have an Improvement Needed
calibration tag in main store room. impact on food quality and safety such as
weighing scale, thermometers etc need to
be calibrated and identified in all
operational areas.
25 Alive American Cockroach Nymph found under A comprehensive IPM system needs to be Major
Korangi Factory

Auditee )
rack area along with debris evidence in main introduced in the facility to eliminate pest
store room. related issues
01 Under pallet area of walk in cold store containing Adequate deep cleaning in hard to excess Major
“ Bakels “ products such as “ Chocolate emulsion areas on planned intervals to avoid such
found accumulated with dirt, debris, oil & happenings further more comprehensive
chemical spillage. GMP protocols need to be practiced to
02 Under pallet area of walk in cold store containing Adequate deep cleaning in hard to excess Major
“ Bakels “ products such as “ Chocolate areas on planned intervals to avoid such
compound” anf “ Lautier Flavors “ found happenings further more comprehensive
containing rodents droppings and Almonds GMP protocols need to be practiced to
seeds. avoid unhygienic issues.
Raw Material
03 ( Walk-in Cold Store ) Open hole of approx 55 mm observed near AC Fixed all gaps on immediate basis ensure Improvement Needed
unit fixture in walk-in cold store that no opening or gap of 5mm or more
room. remain to be closed out since this much gap
harborage.
04 walk-in cold store A prompt cleaning with proper surveillance Minor

room walls fixture found dirty. to be carried out to avoid such
circumstances.
05
Product ingredient “ Bakels “ compound Proper MRD including information such as Improvement Needed
Korangi Factory

Auditee )
chocolate observed with no date of receiving date of receiving, date of production and
whereas its date of production is 28-01-2021 with expiry date / limit should be in place on all
date of expiry 27-07-2022 found in walk-in cold commodities to make assure operational
store. functions such FIFO/FEFO & traceability
6
06 No temperature monitoring device is found All critical tools that variation may have an Improvement Needed
installed in walk-in cold store whereas a product impact on food quality and safety such as
ingredient “ Bakels Compound Chocolate “found weighing scale, thermometers etc need to
with storage condition recommended be calibrated and identified in all
temperature range between 15°c to 20°c. Though operational areas.
feel like temperature was observed to be around
22°c to 25°c.
07 Material receiving evidence found on only one Proper MRD including information such as Serious
container of “ Bakels Chocolate Emulsion date of receiving, date of production and
Raw Material “whereas there were 05 more containers of same expiry date / limit should be in place on all
( Walk-in Cold Store ) ingredient product found with no date of commodities to make assure operational
receiving since it raises concerns with a situation functions such FIFO/FEFO & traceability
if that container with date of receiving is taken norms are carried out adequately
out for production so it may be considered to be
a matter of mal functioned FIFO practice since
there will be no evidence left to identify that
when theses containers were received?
08 No date of receiving observed for Ingredient Proper MRD including information such as Improvement Needed
product “ Bakels bags Moist plain cake “ in date of receiving, date of production and
Walk-in cold store. expiry date / limit should be in place on all
Korangi Factory

Auditee )
09 Material receiving evidence found on only one Proper MRD including information such as Serious
carton of “Crave Dark Chocolate “whereas there date of receiving, date of production and
were more cartons of same ingredient product expiry date / limit should be in place on all
found with no date of receiving since it raises commodities to make assure operational
concerns with a situation if that container with functions such FIFO/FEFO & traceability
date of receiving is taken out for production so it norms are carried out adequately
may be considered to be a matter of mal
functioned FIFO practice since there will be no
evidence left to identify that when theses
containers were received?
10 Almond sacs found with receiving date only and Proper MRD including information such as Serious
no MRD was available to mention date of expiry date of receiving, date of production and
in Walk-in cold store. expiry date / limit should be in place on all
Raw Material commodities to make assure operational
( Walk-in Cold Store ) functions such FIFO/FEFO & traceability
11 Ingredient product “ Lautier Jalapeno Flavor “ Proper MRD including information such as Improvement Needed
found with actual date of production “19-09- date of receiving, date of production and
2020” with expiry limit use within one year has expiry date / limit should be in place on all
another date of production note with date 21-09- commodities to make assure operational
2020 on investigation it is found to be date of functions such FIFO/FEFO & traceability
receiving that was incorrectly written as date of norms are carried out adequately
production.
No Date of receiving and MRD is available for Proper MRD including information such as
Korangi Factory

Auditee )
12 “Sugar Vermicelli “in Walk-in cold store. date of receiving, date of production and Serious
expiry date / limit should be in place on all
Ingredient product “ Horlicks “ found to be Since all powder based product should be
13 repacked / filled in local polyethylene pouch with kept in any air tight container to avoid any Improvement Needed
manual tie with date of production 10-06-2021 moisture accumulation chances that may
with a claiming expiry / shelf life of one year, lead to fungus growth ( Food Safety Issue ) /
since this product is not manufactured in lumps formation ( Quality Issue ) that may
Pakistan it was claimed to be produced on 10 alter product quality and technical shelf life.
June 2021 it seems confusing that a product to be Furthermore date of opening should be
imported from other country is received, mentioned on container with a revised
quarantined, released from custom, transferred (reduced shelf life since no vacuum
to distributor and then received at United King application is carried out to counter off /
Warehouse Supply System and then received at rule out moisture from environment.
Raw Material korangi factory in just 2 days ? Raw materials technical shelf life limit may
( Walk-in Cold Store ) need to be revised for commodities that are
challenges
Ingredient product “ Horlicks “ found to be Since all powder based product should be
14 repacked / filled in local polyethylene pouch with kept in any air tight container to avoid any
manual tie with date of production 10-06-2021 moisture accumulation chances that may Serious
with a claiming expiry / shelf life of one year, lead to fungus growth ( Food Safety Issue ) /
since its original packing is not used neither the lumps formation ( Quality Issue ) that may
filling technology so it is quite difficult to claim alter product quality and technical shelf life.
the same shelf life that is mentioned on actual Furthermore date of opening should be
ingredient product bag . mentioned on container with a revised
(reduced shelf life since no vacuum
Korangi Factory

Auditee )
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
challenges
15 Medical First aid component “Sunny Plast “found All first aid / medical aid need to be
in Walk-in cold store next to peanut butter practiced at facility time office instead of Improvement Needed
carton. store and other food associated operational
Raw Material area to avoid cross contamination.
( Walk-in Cold Store )
16 All product , raw material, packaging

material, semi finished, product contact
Retort packing pouches found without any surface equipment are supposed to be kept
covering in a room claiming to be “Uniform Room covered properly to avoid cross
“. contamination as Package integrity should Improvement Needed
observations.
01 Mango wooden crates found in uniform room. Since wooden material is not recommended
Uniform Room in food operations as it creates opportunity Improvement Needed
with respect to pest harborage and other
Korangi Factory

Auditee )
Furthermore mangoes should be stored in a

way that its strong smell may not alter other
products sensory profile.
02
No date of production and expiry observed on Proper MRD including information such as
Uniform Room ingredient product “ Raisin Dry Fruit “ brand date of receiving, date of production and Serious
name “ Watan “ found in Uniform Room. expiry date / limit should be in place on all
03 A proper stool / Monkey Ladder ( Non Wooden ) To achieve a prompt GMP associated
is required to make food handling job adequate resources should be provided to make and Improvement Needed
and convenient for operational practices in keep the work environment healthy in
uniform room and walk in cold store area. aspect of achievements.
04 A dead “ Pharoah Ant “ found in store room A comprehensive IPM system needs to be Improvement Needed
underside rack area. introduced in the facility to eliminate pest
related issues
01 Flaking paint observed in MS racks containing Serious

sugar pouches in premix section.
Premix Room
Korangi Factory

Auditee )

Sugar bags found open and in local polyethylene material, semi finished, product contact
02 bags claiming one year shelf life since filling surface equipment are supposed to be kept Improvement Needed
protocols are totally different at united king and covered properly to avoid cross
at sugar manufacturing facility. contamination as Package integrity should
observations.
Ingredient product “ Bakels Doughnut Since all powder based product should be
Concentrate “ with date of production “ April kept in any air tight container to avoid any
2021” & date of expiry “ Nov 2022 “ claiming a 20 moisture accumulation chances that may
03 months shelf life While recommended lead to fungus growth ( Food Safety Issue ) /
Premix Room temperature range is 16°c to 20°c since product lumps formation ( Quality Issue ) that may
bag found opened without any adequate alter product quality and technical shelf life. Serious
resealing as well as no any date of opening Furthermore date of opening should be
mentioned on it though claiming shelf life found mentioned on container with a revised
to be prolong and challenging in aspect to (reduced shelf life since no vacuum
provided storage conditions since there is no application is carried out to counter off /
temperature monitoring device installed in rule out moisture from environment.
premix section. Raw materials technical shelf life limit may
need to be revised for commodities that are
challenges
Korangi Factory

Auditee )
Cob webs found under pallets in premix section A prompt cleaning with proper surveillance
04 containing flour and sugar premix bags. to be carried out to avoid such Improvement Needed
circumstances.

Damaged bag of wheat flour found in premix surface equipment are supposed to be kept
05 room. covered properly to avoid cross Serious
observations.
Flaking paint evidence found in roof ceiling in All flaking and sprouting paints issues need
06 premix section. to be fixed on priority to avoid any physical Improvement Needed
Premix Room and / or chemical contamination chances
Waste bin found in premix section was not Adequate number of foot operated waste Improvement Needed
07 sufficient as per intended use as its foot bins should be installed in all food
operating clutch bar found partially non operational and associate areas.
operative.
08 No product identification & MRD tag found on Proper MRD including information such as Serious
containers containing “ Acacia Honey “ with any date of receiving, date of production and
Korangi Factory

Auditee )
date of production and expiry mentioned on it. expiry date / limit should be in place on all
09 Wooden chair with damage structure .A non-wooden chair is recommended.

(Foam deterioration evidences) found kept in Since wooden material is not recommended
Premix Section in food operations as it creates opportunity Improvement Needed
Premix Room critical food safety concerns that may lead
10 Norway Rodent dropping evidence observed in A comprehensive IPM system needs to be

underside area of racks in premix area. introduced in the facility to eliminate pest Major
related issues
01 All eating activities need to be restricted to

Pan Spitting evidence observed on wall structure canteen area only.
at back side of freezer F # 03 in store corridor A comprehensive surveillance protocol Serious
area. needs to be in place at facility entrance to
hinder all food handlers to allow to keep
and carry food stuff during food operation
hours.
Store Corridor
02 Freezer being used for “R & D Sampling “found to Since assessing any product shelf life for Serious
be rusty and in tempered conditioned” which commercial launching needs some rigid
Korangi Factory

Auditee )
seems to be not recommended for any shelf life protocols for that a prompt system with
study as it may alter the desired results for précised controls need to be in place to
samples kept under observation inside freezer. drive a true shelf life study for validation
and further improvement to develop a
product profile with all intrinsic and
extrinsic protocols. Since being
compromised is not a solution in this case
so to avoid such situation a validated and
suitable set of devices and equipment
should in place to make situation successful
all the time.
03 Flaked paint evidences observed on wall All flaking and sprouting paints issues need Improvement Needed
structure behind freezer # 03 in store corridor to be fixed on priority to avoid any physical
area. and / or chemical contamination chances
04 An unidentified drum found in store corridor on All kinds of unidentified commodity weather
investigation it is said to be containing “Pickle” product, ingredient, or its container, or any Serious
with no MRD available on it. utensils and / or equipment should be
avoid any occurrence of cross
contamination
Store Corridor
05 Uncovered product such as “ Shaami Kabab “ All product , raw material, packaging
found in Freezer # F02 with trays found to be material, semi finished, product contact Serious
dirty from down side that comes in contact with surface equipment are supposed to be kept
product while staking and may cause dirt / covered properly to avoid cross
foreign matter cross contamination to the contamination as Package integrity should
product. considered on a top priority since any dis
Korangi Factory

Auditee )

observations.
06
A freezer was found with calibration tag and Temperature operational storge range need
temperature device monitoring device as well to be mentioned on freezers since freezer Improvement Needed
though temperature range found differ from temperatures being consider universally are
universally recommended temp range i.e. -18°c -18°c and below.
or below.
07 Store Corridor
A comprehensive IPM system needs to be
Flies found in store corridor. introduced in the facility to eliminate pest Improvement Needed
related issues

Uncovered trays found containing product material, semi finished, product contact
01 ( Chillos ) in Cold Store next to “ Biscuit Store surface equipment are supposed to be kept
“with trays found to be dirty from down side that covered properly to avoid cross
comes in contact with product while staking and contamination as Package integrity should Serious
may cause dirt / foreign matter cross considered on a top priority since any dis
contamination to the product. integrity may lead to product cross
Cold Store effect on product shelf life.
( Next to Biscuit Store ) All products package integrity should be
observations.
Korangi Factory

Auditee )
02
Uncovered trays found containing product material, semi finished, product contact
BBQ rolls in Cold Store next to “ Biscuit Store surface equipment are supposed to be kept
“with trays found to be dirty from down side that covered properly to avoid cross Serious
comes in contact with product while staking and contamination as Package integrity should
may cause dirt / foreign matter cross considered on a top priority since any dis
contamination to the product. integrity may lead to product cross
observations.
03
Cold Store Dirty trays found in cold store containing “ PURI “ surface equipment are supposed to be kept
( Next to Biscuit Store ) some of them was without liner with high covered properly to avoid cross Serious
potential to be cross contaminated with foreign contamination as Package integrity should
matter attached with dirty trays bottom. considered on a top priority since any dis
observations.
01
Flaking paint observed on side walls in “Biscuit All flaking and sprouting paints issues need
Room “. to be fixed on priority to avoid any physical Improvement Needed
and / or chemical contamination chances
Korangi Factory

Auditee )
02
Proper MRD including information such as
Biscuit Store No Identification and “ MRD” was mentioned on date of receiving, date of production and
cartons that were told to be “ For Export” since expiry date / limit should be in place on all Improvement Needed
they do not have access / authority to get them commodities to make assure operational
opened. functions such FIFO/FEFO & traceability
03
Pan spitting evidences observed on wall structure Eating practices should be only allowed in Serious
in biscuit store. designated areas only such as canteen area.
04
Flaking paint evidence observed on MS shelves / All flaking and sprouting paints issues need Improvement Needed
Biscuit Store racks for storing biscuit trays in biscuit store. to be fixed on priority to avoid any physical
01
Dead cockroach ( American Nymph ) found in A comprehensive IPM system needs to be
underside area of freezer kept in frozen packing introduced in the facility to eliminate pest Serious
dept. related issues
02
Rodents dropping ( Roof rats and Norway rats ) A comprehensive IPM system needs to be
found inside underside area of freezer kept in introduced in the facility to eliminate pest Serious
frozen packing room. related issues
03
Frozen Packing Dept. Underside area of freezer found containing Adequate deep cleaning in hard to excess
heavily accumulated with dirt and debris in areas on planned intervals to avoid such Improvement Needed
frozen packing dept. happenings further more comprehensive
Korangi Factory

Auditee )
Foot operated dustbin are required in frozen Adequate number of foot operated waste
packing area since there was a waste bin bins should be installed in all food Improvement Needed
04 observed that can be used manually any may operational and associate areas.
cause hand use possibility while being
operational.
Open wiring observed along with adhesive taping Temporary maintenance works need to be Improvement Needed
05 in freezer wire in frozen packing dept. super finished on immediate basis
A comprehensive IPM system needs to be Improvement Needed

06 Flies observed in frozen packing dept. introduced in the facility to eliminate pest
Frozen Packing Dept. related issues
01 Partially uncovered chicken found kept in trays in All product , raw material, packaging Severe Serious
main cold store room that may have potential to material, semi finished, product contact
cross contaminate with other product surface equipment are supposed to be kept
ingredients. covered properly to avoid cross
Main Cold Store ( -18°c) observations.
02
Broken pallets are being used in cold store room. Adequate number of pallets with good Minor
condition to support material top load
Korangi Factory

Auditee )
should be in place to make food operational

activities smooth.
03

“Frozen PURI “found without adequate covering / material, semi finished, product contact
Liner / separator and no MRD was observed in surface equipment are supposed to be kept
main cold store. covered properly to avoid cross Major
observations.
04
Main Cold Store ( -18°c) “ CHOOZIT” cheese culture found without any Proper MRD including information such as Serious
MRD in main cold store. date of receiving, date of production and
expiry date / limit should be in place on all
05
Cold store underside area from base found Adequate deep cleaning in hard to excess
heavily accumulated with dirt, dust and debris, areas on planned intervals to avoid such
along with vegetable residue such as “Garlic bulb happenings further more comprehensive Improvement Needed
and Norway rodent dropping”. GMP protocols need to be practiced to
Korangi Factory

Auditee )
01
Since wooden material is not recommended
Wooden based floor observed in “ Walk-in Cold in food operations as it creates opportunity
Store “ with respect to pest harborage and other Improvement Needed
“ Walk-in Cold Store “ to severe cross contamination.
(01°c to 10°c )
02
Since wooden material is not recommended
Oil spillage observed on wooden floor in “ Walk- in food operations as it creates opportunity Improvement Needed
in Cold Store “ with respect to pest harborage and other
03
Flaked paint observed on wall side fixture of cold All flaking and sprouting paints issues need Improvement Needed
store container. to be fixed on priority to avoid any physical
04
Adequate deep cleaning in hard to excess Improvement Needed
“ Walk-in Cold Store “ Rack structure upper side found to extremely areas on planned intervals to avoid such
(01°c to 10°c ) dirty containing miscellaneous debris inside in“ happenings further more comprehensive
Walk-in Cold Store “ GMP protocols need to be practiced to
05 Wall support fixture has gaps of more than 5 mm Fixed all gaps on immediate basis ensure
from outer side of “ Walk-in Cold Store “ that no opening or gap of 5mm or more Improvement Needed
remain to be closed out since this much gap
Korangi Factory

Auditee )
harborage.

Primary packaging material “ Cake Card “ found material, semi finished, product contact
un wrapped in packaging store. surface equipment are supposed to be kept Serious
01 Packaging Store covered properly to avoid cross
observations.
02
Poisonous bait is being used in rodent cages in A comprehensive IPM system needs to be Major
Packaging Store packaging store. introduced in the facility to eliminate pest
related issues
03
Rodents dropping found in under racks in A comprehensive IPM system needs to be Serious
packaging store. introduced in the facility to eliminate pest
related issues
01
Egg Dept. Exhaust fan found extremely dirty in egg dept. A prompt cleaning with proper surveillance Improvement Needed
to be carried out to avoid such
circumstances.
02
Korangi Factory

Auditee )
Tray washing area ventilation louver has Fixed all gaps on immediate basis ensure Improvement Needed
Plastic Tray Washing Area prominent gap for pest entrance in plastic tray that no opening or gap of 5mm or more
washing room. remain to be closed out since this much gap
harborage.
01
Alive cockroach observed in fast food dept A comprehensive IPM system needs to be
underside area of freezer. introduced in the facility to eliminate pest Major
related issues
Fast Food Dept.
02
All critical tools that variation may have an
Temperature monitoring devices for freezer impact on food quality and safety such as Improvement Needed
were not working in Fast food dept. weighing scale, thermometers etc need to
operational areas.
03
All dirty racks and trays need to be
Rust evidence observed on MS trolley racks in sufficiently washed and cleaned on a
fast food dept. frequent basis furthermore all trollies need Serious
to be at least painted adequately with lead
free paint / food grade paint ( Epoxy ) or be
replaced with SS material with product
contact surface made of ( SS 316 L ) and ( SS
Fast Food Dept. 304 ) For lower body portion.
04
Open wiring observed in fast food dept. Temporary maintenance works need to be Improvement Needed
super finished on immediate basis
Korangi Factory

Auditee )
05
Broken tiles observed in fast food dept. Immediate fixture of broken Tile / floor
need to be paved / fixed on priority to keep Improvement Needed
food manufacturing operations smooth with
06
All kinds of unidentified commodity weather
Unidentified can found being used for drinking product, ingredient, or its container, or any Improvement Needed
water purpose in fast food dept. utensils and / or equipment should be
contamination
07
Since Cutting boards rough surface have
Cutting board found with rough surface in fast potential for debris accumulation leading to
food dept. cross contamination to avoid this cutting Improvement Needed
boards need to be evaluated on frequent
interval and should be replace accordingly
with a suitable one to avoid any cross
contamination occurrence.
08
Ingredient product “ Qalmi Shoora “ / Hunter Proper MRD including information such as Improvement Needed
Beef White Masala found “ Soon to expire” with date of receiving, date of production and
respect to consumption calculation as date of expiry date / limit should be in place on all
production is 29-07-2020 with expiry limit use in commodities to make assure operational
Fast Food Dept. one year found in fast food dept. functions such FIFO/FEFO & traceability
Korangi Factory

Auditee )
09 Some cupboards/ cabinets/ lockers found locked Alternate deputy mechanism need to be in
since authorized personal was not available so place for all employees as if they are not
could not see what is inside the lockers? available at facility so any operational Improvement Needed
activity may not be ceased due to their
absence.
10
Ingredient product “ Qalmi Shoora “ / Hunter Proper MRD including information such as
Beef White Masala found without any date of receiving, date of production and
identification & MRD in fast food dept. expiry date / limit should be in place on all Serious
11
material, semi finished, product contact Serious
surface equipment are supposed to be kept
Damage packaging observed in “ Shami Masala “ covered properly to avoid cross
claiming 1 year shelf life found in fast food dept. contamination as Package integrity should
observations.
Fast Food Dept.
12
Hand dryers found out of order in fast food dept. Adequate number of hand dryers should be
available in food facility with effective Improvement Needed
performance as per intended use.
Korangi Factory

Auditee )
13
Dustbin found kept very near to freezer and Waste bins need to be kept in a suitable Improvement Needed
production table in fast food section. area to avoid any cross contamination
occurrence that may lead to any food safety
failure.
14
Uncovered intermediate product ( Filling stuff ) material, semi finished, product contact
found in freezer in fast food dept. surface equipment are supposed to be kept
covered properly to avoid cross Serious
observations.
01
A comprehensive IPM system needs to be
Alive cockroach found crawling on freezer in cake introduced in the facility to eliminate pest Major
dept. related issues
02
Water spillage observed in cake dept next to A prompt cleaning with proper surveillance
freezer. to be carried out to avoid such Improvement Needed
circumstances.
Cake Dept.
03
Hand dryer sensor found weak in cake dept. Adequate number of hand dryers should be Improvement Needed
Korangi Factory

Auditee )
available in food facility with effective

performance as per intended use.
04
A dough mixing machine found with a tag that Temporary maintenance works need to be
shows “ Out of Order” super finished on immediate basis further Improvement Needed
with no evidence of job order # ? job cards need be place at the idle
machinery to assure that it is being
surveillance to attain maintenance job done
on priority.
05
Visicooler fans found dirty in cake dept. Adequate deep cleaning in hard to excess Improvement Needed
areas on planned intervals to avoid such
06
Visicooler internal structure found dirty in cake Adequate deep cleaning in hard to excess
dept. areas on planned intervals to avoid such Improvement Needed
07
Damaged waste bin found in cake dept. Damaged waste bin need to be replaced Improvement Needed
with an adequate one.
08
Drain flies found on production table in cake A comprehensive IPM system needs to be Serious
dept. introduced in the facility to eliminate pest
Korangi Factory

Auditee )
related issues
09 Cake Dept. Product direct contact utensils / tools found in A prompt cleaning with proper surveillance
dirty condition on floor directly in cake dept. to be carried out to avoid such Serious
circumstances.
10
Premium cake dept. found locked having no key Alternate deputy mechanism need to be in
as well as no authorized person since factory place for all employees as if they are not
manager was chairing the visit at that time. available at facility so any operational Improvement Needed
activity may not be ceased due to their
absence.
11
Immediate fixture of broken Tile / floor
Broken tiles fixture observed at the entrance of need to be paved / fixed on priority to keep Improvement Needed
cake dept. food manufacturing operations smooth with
01
A prompt cleaning with proper surveillance
Main kitchen exhaust fan found dirty. to be carried out to avoid such Improvement Needed
circumstances.
02
All critical tools that variation may have an
Weighing scales found without any identification impact on food quality and safety such as Improvement Needed
and calibration tag in main kitchen weighing scale, thermometers etc need to
operational areas.
Korangi Factory

Auditee )
03 Main Kitchen No chair is available at main kitchen since carton Adequate number of chairs ( Non Wooden ) Improvement Needed
stuffed boxes are being used for sitting in main to make work environment convenient for
kitchen. food related operations.
04
Wooden brush along with wooden churner found Since wooden material is not recommended Improvement Needed
in main kitchen. in food operations as it creates opportunity
05 Low light lugs observed in main kitchen. More than 500 light lugs are recommended Improvement Needed
to achieve and attain adequate food
operations.
06 All product , raw material, packaging

Raw Meat found uncovered with flies roaming surface equipment are supposed to be kept
around observed in main kitchen. covered properly to avoid cross
contamination as Package integrity should Serious
Main Kitchen All products package integrity should be
observations.
07 All kinds of unidentified commodity weather

Korangi Factory

Auditee )
Unidentified sanitary utensils are found being product, ingredient, or its container, or any Improvement Needed
used in main kitchen. utensils and / or equipment should be
contamination

Audit Report Korangi Factory (12th June 2021) Announced

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Audit Report Korangi Factory (12th June 2021) Announced

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Internal Audit / Inspection Findings against SFA Checklist

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

to severe cross contamination.

Phenyl bottle found next to hand washing and

All product , raw material, packaging

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

Raw material washing station Adequate deep cleaning in hard to excess

Fixed all gaps on immediate basis ensure

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

happenings further more comprehensive

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

date of expiry 14-03-2022 found kept at the back

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

norms are carried out adequately

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

14 in main store room. surface equipment are supposed to be kept

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

All product , raw material, packaging

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

Main Store Room

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

04 walk-in cold store A prompt cleaning with proper surveillance Minor

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

norms are carried out adequately

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

application is carried out to counter off /

16 All product , raw material, packaging

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

Furthermore mangoes should be stored in a

01 Flaking paint observed in MS racks containing Serious

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

All product , raw material, packaging

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

All product , raw material, packaging

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up

09 Wooden chair with damage structure .A non-wooden chair is recommended.

10 Norway Rodent dropping evidence observed in A comprehensive IPM system needs to be

01 All eating activities need to be restricted to

Auditing Date : 12th June 2021

S.No # Area Root Cause Finding Recommendation Finding Severity Follow up