Nestle Foreign Body PD Best Practices For Our Suppliers 2019 Final

Foreign Body Prevention & Detection
BEST PRACTICES FOR

Nestlé RAW MATERIAL & PACKAGING SUPPLIERS
3rd Edition
©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

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ACKNOWLEDGEMENTS
We acknowledge the contributors, both Nestlé and our Suppliers, who collaborate
throughout the year to develop the Foreign Body Prevention & Detection Best Practices.
It is through your dedication, perseverance and teamwork that we develop this essential
educational tool, always with the safety of our consumer in mind.
The Nestlé Foreign Body Guiding Team, 2019

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PREAMBLE:
A foreign body is any kind of material such as metal, glass,

plastic, stones, materials of animal origin (insects, bones, hairs), materials
of plant origin (wood, stalks) or by-products (burnt particles, scorched
particles, etc.) the consumer does not want or expect to find in the
products they purchase.
Our consumers deserve safe and wholesome products at their table and it
is our responsibility as food manufacturers to provide this at every
occasion. To protect the integrity of the Nestlé brand and the well-being of
our consumers, we need to ensure that raw materials and packaging are
produced with the highest quality standards. This means our suppliers are
prepared to prevent and detect foreign bodies entering their supply chain.
Foreign Body Prevention & Detection, Best Practices for Nestlé Raw
Material & Packaging Suppliers is developed in collaboration with our
suppliers. It is an educational tool that explains the types of foreign bodies
in the supply chain, potential points of entry and how to mitigate their
occurance. Here we present the 3rd edition, introducing new guidance
on foreign body mitigation in Cocoa, Meat, Flour, Flexible Film and
Bulk/Big Bags (FIBC). We’ve also included a section on current
equipment technologies for prevention and detection of foreign
bodies and guidance on the use of wooden pallets.
Foreign body prevention and detection is a critical element at Nestlé and it

is through awareness, development and implementation of best practices
that we continually achieve success in keeping our consumers safe.

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TABLE OF CONTENTS
Introduction: Three Lines of Defense..................................................................6
Raw Material Foreign Body Prevention Guidance
Ingredients:
Baked Goods....................................................................................................................... 7
Cereal - Grains and Flour.................................................................................................. 9
Cocoa Beans and Powder.................................................................................................. 11
Dairy Ingredients - Powder............................................................................................... 15
Fruit................................................................................................................................... 17
Meat................................................................................................................................. 20
Nuts.................................................................................................................................. 22
Oils and Fats.................................................................................................................... 26
Poultry.............................................................................................................................. 28
Sugar................................................................................................................................. 30
Vegetables:
Fruit Vegetables.................................................................................................... 36
Herbs..................................................................................................................... 38
Leafy Vegetables................................................................................................... 40
Underground Bulbs and Root Crops....................................................................42
Vegetable Stalks.................................................................................................... 45
Packaging Foreign Body Prevention Guidance:
Bulk Bags/Big Bags/Super Sacks/FIBC...............................................................47
Glass..................................................................................................................... 49
Flexible Film......................................................................................................... 51
Paper................................................................................................................... 54
Plastic.................................................................................................................. 56
Prevention of Hair Contamination........................................................................... 60
Equipment Technology for Prevention and Detection...................................63
Wooden Pallets..................................................................................................71
Annex I: Glossary...............................................................................................72

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INTRODUCTION: THREE LINES OF DEFENSE
Foreign body management is an integrated approach encompassing a set of
complementary control measures. It covers the whole value chain and be organized
along the three lines of defense that include:
First Line of Defense:
- Suppliers delivering raw or packaging materials that are free from foreign
bodies.
- Properly equipping our suppliers and Nestlé tipping lines to prevent, separate
and/or detect any residual risks.
Second Line of Defense:
- Processing equipment.
- Practices during manufacture up to packaging.
- Measures for prevention, detection and removal during processing.
Third Line of Defense:
- Environment in processing areas and maintenance shops.
- Downstream steps such as warehousing and distribution.

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Baked Goods
Main Foreign Body Risks: Production process:
Metal, plastic, hair, insects, fat residues
Area of Vulnerability Potential Issues Mitigation actions

 Sieves and magnets on all separate incoming ingredient
 Wheat flour: metal, grains, insects lines. Always consider design which needs to be adapted to
 Sugar: metal, plastic the product/process (fit for purpose: design, gauss, air gap)
Ingredients  Fat: metal, stones  Metal detectors on sugar line
 Milk powder: metal, plastic  Experience and knowledge on how to properly open bags,
 Water: metal and stone residues big bags, trailers
 Destruction of insect eggs (entoleter) at mill
 Line inspection and release
 Plastic fibres from manual tools
Cleaning operation  GMP of cleaning tools
 Metal from automatic pumps and
 Preventive maintenance
brushes
 Sieves in return circuits of cleaning fluids
 Poor dispersion, dough balls  Fine sieves (1 mm)
Wet mixing
 Metal shavings  Equipment maintenance and repair
 Hair in manual operations  Zoning and uniform policy
 Closing equipment
 Foreign objects from the environment
Doughing  Covering trolleys
 Metal shavings
 Zoning and uniform policy
 Hair in manual operations
 Metal detector before laminator
 Pieces of moulds: metal and plastics  Moulds and conveyors preventive maintenance and daily
Laminating / Moulding  Parts of conveyors: plastics routine inspection
 Foreign objects from the environment  Rework procedure
 Hard parts from rework  Line coverage and cover cleaning policy
 Metal pieces from the oven or conveyor  Oven and conveyors preventive maintenance and daily
belt routine inspection
 Burnt particles stuck into the belt  Operating temperature and speed
 Plastic coating from the conveyor belt  Presence / correct orientation of metal brushes located
Baking below the oven
 Running time of the oven empty to clean the belt
 Color sorter at the exit of the oven
 Metal detector at the exit of the oven
 Accumulation of product residues on  Complete coverage of the conveyors
edges and corners, which randomly stick  Box and conveyors preventive maintenance and daily
to the biscuits routine inspection
Conveying / storage  Plastics & tissues from the conveyor  Metal detector before the filler with < 2-mm capacity for
belts and transport/storage boxes all metal types
 Dust and other foreign object from the
environment
 Metal to metal contacts  Preventive maintenance and daily routine inspection
 Plastics from pouch material, easy-to-  Operator intervention protocol
open strings or easy-to-reseal zip  Center lining of sealing jaws
Filling
 Dust and other foreign object from the  Sharpness of foil/zip cutting tools
environment  Coverage of the filler & laminate rolls
 Accumulation of product residues
 X-ray inspection to reduce metal, glass & stone risks
 Sharp parts damaging the laminates  Preventive maintenance and daily routine inspection
Casing  Cleaning schedule
 Dust from cardboards
 Glue and tape materials

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Baked Goods
Typical Defects:
DEFECT DESCRIPTION EXPLANATION
Carbon Residue Defects Caused by carbon residues of biscuit on the net of
Light/dark/greyish deposits or black marks on the surface, bottom or the oven, baked again and taken up by raw
inside the item biscuits at the entrance of the oven
Carbon residues due to ineffective cleaning of

some belts (oven or transport/packaging lines)
Indigenous foreign body Example of fat accumulation:

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Cereal – Grains and Flour
Barley, Corn, Oat, Wheat, Rye, Rice
For crop calendar (harvest/production):
Main Foreign Body Risks: http://www.usda.gov/oce/weather/CropCalendars/in
Metal, plastic, insects, fiber and string dex.htm
Area of Potential Issues Mitigation actions

Vulnerability
 Stones & Crop remains: straw, stubble, roots
 Ploughing to bury old plant materials.
etc. Check for traces in the field
 In the absence of ploughing, no-tilling1 practice, ensure
 Insect events or contamination: Check
proper cultivation.
payment records to identify rebate due to low
 Avoid growing areas with lots of stones
quality
 Visit farm mechanical area & workshop to understand metal
 General foreign body: Farmer interview and
Field Selection & risks, level of care / organization
assessment
Preparation  Select best in class farmers & support the training programs
 Rubbish dumps: Short distance from roads,
 Walk the fields to assess risk and then remove foreign
industry etc. Examples: highways, car parks,
objects https://www.youtube.com/watch?v=bYGNI7dNCJU
etc.
 Select appropriate herbicide where necessary or mechanical
 Weed: records, previous use of herbicides
 Plastic / metal: pieces of drip tape irrigation weed control (chemical free)
 Foreign seeds: review seeds and their  Use only certified seeds. If using own seed, proper cleaning
certificates is needed.
 Repair conditions of machinery  Cleaning, servicing and maintenance of all machinery before
 Weed development: Inspect field at early use, i.e. for sowing, fertilizers application and crop
stage of growth. protection application
 Weed development and history: Check  Record weed development. Select appropriate herbicide
previous use of herbicides where necessary or mechanical weed control (reduced
Sow, plant and grow  Weed development: direct sawing, no tilling chemical control methods)
crop  General foreign bodies: Inspect the fertilizers  Use only certified artificial fertilizers
 Insects: Study spray records to assess history  If using organic / recycled, ensure there is a foreign body
 Metal & Plastics: Inspection of irrigation prevention program (magnets, sieves …) in the production
equipment process – (ensure fit for purpose: design, gauss, air gap)
 Plastics: Inspection of water source  When necessary, select appropriate insecticides and
application timing
 Grids to remove large foreign bodies in water
 Conditions of machinery: inspect  Service & cleaning of harvest equipment, sieves
 Remains of previous crops & Rubbish: Define  Remove foreign objects
risk areas and walk the fields  In case of severe weed infestation, record, remove, segregate
 General foreign body: Inspect containers / part of the crop from the rest of the field
trailers  Cleaning instructions for personnel.
 Cross-contamination: Check harvested grain  Destruction of damaged containers.
Harvest at start and during harvesting process  Avoid use of wooden containers.
 Cover containers when transporting/waiting/empty
 Ensure cleaning between different crops
 Calibration of equipment at start and where necessary
during the harvesting process
 Control the height of the harvester
 Clean, Maintain & repair trailers / conveyors & storage
 General hygiene: Inspect trailers / conveyors facilities.
and storage facilities  Cleaning, dusting & drying steps should be efficient, well
 No segregation between crops, tools, spare maintained and not a source of FB
equipment  Where necessary fumigate to control for insects (non-
Transport & Storage  Insects: Monitor activity during the whole chemicals exists such as CO2 …).
storage period.  Service the facility ensuring no leaks, no access to birds,
 Insects: Check temperature and moisture rodents,
gauges/ equipment  Efficient Magnets and Metal Detectors (ensure fit for
purpose: design, gauss, air gap)

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Cereal – Grains and Flour: Milling Facilities
 Metal & rubbish: Inspect the unloading  Maintain & Clean the equipment and areas
bay, conveyors & storage.  Training of personnel.
 Insects: Monitor insect activity during the  Review of written recommendations (responsibilities,
whole storage period. cleaning, sampling, release, specification limits)
 Insects: Check temperature and moisture  Where necessary fumigate to control for insects (non-
Reception & storage gauges/ equipment chemicals exists such as CO2).
 Service the facility ensuring no leaks, no access to birds,
rodents, …
 Efficient Magnets and Metal Detectors (ensure fit for
purpose: design, gauss, air gap)
 Absence of detection and removal
 Repair, maintain and clean
equipment:
 Calibration, validation, learn from the rejects
 Effectiveness of detection and removal
 Aspiration, destoners, densimetric tables
equipment: Assess calibration, validation,
 Optical sorting
Pre-milling verification, monitoring, rejects.
 Sieving before milling
 Hygiene: Area cleanness.
 Training of personnel / uniform
 Insects: Building/door tightness and
sealing  Heat treat / Fumigate where necessary (non-chemicals
 Hair: Operator uniforms, practice exists such as CO2)
 Metal: Equipment conditions.  Maintain and clean
Milling/Flour  Plastics & insects: Area cleanness.  Destruction of insect eggs (entoleter)
Production  Plastics: Written recommendations for  Sieving during milling
operators  Calibration
 Insect: History of activity  Training of personnel / uniform
 Metal and loss of parts from the line.  Efficient Magnets and Metal Detectors (ensure fit for
 Insects and rubbish: Ability to clean, purpose: design, gauss, air gap)
cleaning effectiveness.  Repair and maintenance
 Plastic and strings: Bag specifications  Line separation
 Insects and rubbish: Storage conditions of  Cleaning validation, routines, documentation
bags
 Training of personnel
 Plastic, strings & paper: Inspection of bags
 No use of recycled bags
Packing at reception
 Review of packaging specifications
 Insects: Consider use of liners inside and
 Inspection / Cleaning of bags before usage
outside
 Proper closure of bags
 Insects and rubbish: Pallet conditions
 Pallet specifications
 Insects: Pallet1 and Wrapping standards1
 Undamaged pallets
1  Wrapping tightness of bags and pallets
Nestlé Internally accessible links only
Specific guidance: Rice

Areaof Vulnerability Potential Issues Mitigation actions
 Cortex remains after de-hulling  Sieves after de-hulling step
De-hulling (removal of
 Metal from line  Repair and maintenance
outer cortex) incl. oats
 Rubber parts from line  Cleaning
 Black grains  Optical sorting (color)
Polishing  Damaged grains  Equipment calibration, validation, monitoring
 Cortex remains  Repair, maintenance and cleaning
 Repair and maintenance
 Metal parts from autoclave / cooker / trays  Cleaning
Parboiling  Metal detectors / Magnets (ensure fit for purpose: design,
 Calcium carbonate agglomerates
gauss, air gap)

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Cocoa Beans and Powder
Cocoa Powder Processing Product Information:

Federation of Cocoa Commerce (FCC)
Main Foreign Body Risks: requirements
Metal, plastic, hair, stones, plants, insects, pests, fibre, ISO 2451 – International Cocoa Standard
string, wood Used to grade standards and classify cocoa
beans, both include foreign body expecations.
Area of Vulnerability Potential Issues Mitigation Actions
Supplier / Trader /  Plants / other crops  Planting and cultivation equipment is well maintained
Farmer and fit for purpose, posing no additional foreign body
 Insects / Pests ingress risks
 Controlled cultivation covered through approval
process.
 Wood, string, metal, plastic from the
 Integrated Crop and Pest Management (ICPM)
environment
implemented and maintained
 Removal of rubbish through field walks and regular
 Personal effects from employees inspections
 Protection against animals, e.g. bird scarers
 Animals or animal remains  Appropriate machinery cleaning before and during
cultivation
 Debris from surrounding areas, e.g. glass,  Loud noises to scare away animals
rubber, waste  Adequate training of operators involved
 During the processing stages of fermentation and
drying, ensure all contact surfaces are free from lose
foreign material
Transport and Storage  Remains of previous load  Vehicles are approved for use and inspected prior to
loading
 Metal, plastic, plaint from machinery,  Basic safety training in place and standards adhered to
equipment or transport  Suitable and clean storage conditions with appropriate
cover and protection
 Pest prevention programme
 Pest from inadequate pest control in the
 Good hygiene practices
storage facility
 Adequate training of operators involved
 Sieves / grids at this stage can significantly help remove
 Personal effects from employees some of the larger foreign bodies and reduce the cost of
transporting non-bean matter
Raw Material Intake  Stones, wood, metal, personal effects, pest  Documented incoming material inspections
remains or plastic from the cultivation stage  Foreign body library collated and feedback provided
to the supplier and transport
 Metal from transit vehicles  Sorting equipment on intake to remove the larger
foreign bodies, for example a heavy duty grate with
 Personal effects from employees large openings to help remove any large vegetable and
organic material
 Pest ingress at intake point, during unloading  Magnets: Heavy duty grate magnet, cleaned twice per
shoft. Magnets should have a strength of at least 8,000
gauss, although 10,000 is preferred
 Metal, plastic or fibres from conveyor and
sorting equipment
 No wooden pallets is preferred, although if essential,
they should be inspected for integrity and kept a
suitable distance away from any entry / sample points
 Pest prevetion programmes in place
 Preventative maintenance of unloading and sorting
equipment
 Hygiene zoning in place
 Sorting equipment inspected regularly to prevent
issues and detect findings
 No plastic liners
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 Preventative maintenance programmes in place
 Belt fibre / string from damaged conveyors  Regular inspections / listening to the line
 Correct calibration of machinary
 Metal from damaged bearings / screws /  Adequate training for operators and clear defined
pumps standards followed
 Suitable work wear provided and cleaned correctly
 Good manufacturing practice
 Metal from plant failure causing metal on
 Knife mill after the nibs have been roasted (<2 micron,
metal contact
roating at 3000rpm)
 Metal or plastic from plant failure due to

Numerous sieves of various sizes throughout the process to
foreign bodies found in the raw materials,
remove material which may damage equipment.
damaging the equipment
 Ensuring that the sieves / mills have the optimum
size / detection capability
 Poor conditions of cleaning equipment  >200 micron sieve recommended for the coarse
liquor
 Poor fabrication / inadequate cleaning Lehmann Stone Mill or Ball Mill
 Ensure that each sieve / mill has a further
 Inadequate pest proofing detection step in the event of any failure. For
example, more than 2 sets of ball mills will ensure
that if a failure occurs there is no risk to the
 Contamination from water sources /
product
environment
 Regular cleaning, at least twice per shift and
checks of the equipment to ensure it is
 New equipment as a source of foreign functioning correctly, e.g. removal of debris from
bodies the magnets
 If unusual findings occur on the magnet, then
 Magnet is saturated with too much metal inspections should be completed hourly until
normal conditions are resumed.
 Use of damaged plastic or wooden pallets  Magnets ensure fit for purpose: design, gauss, air
gap- redundant magnets are also recommended
In Process  Clean, potable water source for potential risk of foreign
 Foreign body contamination through the
bodies
water source
 Pest prevention programme in place
 No wooden pallets is preferred, although if essential, they
should be inspected for integrity and kept a suitable
distance away from any entry / sample points
 Nuts should pass through a metal detector before passing
onto the grinder
 The grinder presents a risk of metal contamination,
therefore a magnetic liquid trap is be followed by a metal
detector
 New equipment should be assessed for suitability, foreign
body risks, recesses allowing for build up of dirt or foreign
matter and for detectability in the event of a failre or wear
and tear
 Cleaning equipment should be regularly inspected for
integrity and replaced as necessary. It is good practice to
have pictures of the required condition of equipment and
when to replace, next to the shadow boards
 Regular GMP / hygiene audits to ensure general
cleanliness and fabrication is not posing any avoidable
risks

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Contaminantion from the vehicles  Inspect vehicles on arrival before loading
 Correct work wear and appropriate GMP training
Contamination from the operators provided to the operators
 Pallets are inspected before entry and damaged pallets
Wood or plastic from damaged pallets are removed
 Pest prevention programme maintained throughout
Infestation / contamination from within the packing and shipping, with clear responsibilities defined
pallets for the transport / shipping process
Packing and  Correct storage processes in place with no part pallets /
transport/ shipping Pest ingress part filled containers left open or unsecure
 Final detection equipment, e.g. metal detection and final
sieves (4mm mesh) are checked as per the HACCP
defined frequency and suitable verification activities are
documented
 Metal detection validation is completed by an expert and
documented

Examples of equipment used to remove / reduce foreign bodies
during the Cocoa making process
Sorting stairs used to grade the beans

and remove variations in sizes of Bean cleaning stage Further bean cleaning with inspection
material passing through point grid and cover to protect entry of
any further foreign bodies

PAGE 13
Examples of foreign bodies found during the Cocoa making process
Example of the findings found on one The collection bucket of foreign bodies
magnet removed at the cleaning stage

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Dairy Powder
Dairy powder processing Product Information:

Federation of Cocoa Commerce (FCC)
Main Foreign Body Risks: requirements
Metal, plastic, hair, fibre, string ISO 2451 – International Cocoa Standard
Used to grade standards and classify cocoa
beans, both include foreign body expecations.
Area of vulnerability Potential issues Mitigation actions

Preparation of the line  Cleaning with damaged cleaning tools  Selection of materials adapted to the purpose should be
(brushes, scrapers, vacuum cleaner, etc.) established.
 No tools management available  Do not use sponges or similar materials which could be
 Tools are placed in unexpected places (on a source of Foreign bodies
cables, on electric cabinet, etc.)  Inspection plan and interval for change of tools should
 Improper repaired cleaning tools (tapes, be defined
spare bolts, nuts, grinding dust left on the  Regular visual check of the condition by operators
line after maintenance work, etc.) before use should be done. Visual standard is a good
practice. Sufficient utensils quantities should be
available in case of need.
 Dedicated places according to the tools use should be
defined.
 Repair should be forbidden for equipment in contact
with food and minimized for non-contact places
Raw material  No Foreign body assessment included in  Have a supplier approval system in place including
management RM supplier assessment Foreign body prevention and detection
 Packaging specification not designed to  Recommended is the use of strippable packaging (e.g.
prevent Foreign body creation paper bags, bags in an outer box)
 No protection of the RM packaging  Plastic big bags should not be a source of plastic and
 Use of RM with damaged packaging fiber strings
 No Foreign body prevention at the tipping  RM packaging should be protected during the transport
station or liquid milk reception and/or and in the warehouses
downstream  Damaged packaging should be put aside and not used
 No management of RM opening tools  Grids and/or sieves should be present at the tipping
(knives, cutter, etc.) stations and/or strainers and filters at the milk reception
 No operator awareness during discharge and downstream for liquid semi-finished products.
operations  Rules should be clearly defined (e.g.no breakable tools,
 No zoning, no stripping area for wet or dry visual checking, attached tools, sharp…)
mix ingredients  Concerned operators should be trained to the foreign
bodies prevention and detection
 Zoning rules should be established. A stripping area
should defined for all types of ingredients
Equipment state in  Use of damaged plastic pallets  Plastic pallets should be regularly checked. Damaged
the environment  Cable arrangement and binders not ones should be put apart and not re-used in production
managed area.
 Cable and arrangement setup should not create a
potential source of foreign bodies

PAGE 15
Dairy Products: Powder
Condition of  The product is exposed to the  Closed line (but easy to inspect) is preferred. Use
equipment in contact environment during the process. flexible part to have a fool proof installation at the level
with the product  Air filters as a potential sources of fibers of the measurement instruments.
 Improper repairing done in equipment  Specifications need to be aligned with usage and need to
in contact with food (cable binder, tape) be checked at reception.
 Use of cotton-type sleeves  Operators need to be trained in installing the filters.
 Gaskets as a source of foreign bodies.  Properly sized frames and housing should be in place.
 Sight glass as source of foreign bodies  Improper home-made repairing should be forbidden for
 Plastic sieve as source of foreign bodies equipment in contact with the product.
 Broken Lexan©,  A proper procedure on managing damaged equipment
 Glass from gauges in contact with product need to be in place.
Use plastic flexible connections as they are less
susceptible to wear and tear compare to cotton material.
Preventive change plan should be in place.
 Location of all gaskets in contact with food is known.
Do not use materials with evidence of deterioration /
damage.
 Damaged gaskets should be replaced and cross
contamination risk in products quickly assessed.
 A preventive maintenance plan should be in place.
 Only original spares should be used or validated by
equipment suppliers during the change management
 In case of gasket damage, can it be detected downstream
i.e. on sieve, by metal detector or X-ray?
 Hard plastic in contact with food and in a close
environment should be mapped. Preference should be
to eliminate them. If not possible, a check frequency
should be defined according to the risk (e.g. in a Hard
plastic check-list)
 A procedure should be defined in case of hard plastic
breakage.
 Plastic sieves model are not recommended.
 In case of use, an adapted visual check needs to be done
before product release
Operator personal  Ear plugs, glasses, gloves.  Clear rules about PPE items should be in place
protective equipment (awareness in case of lost parts…)
(PPE)  Only detectable items should be used in production area.
Clothes, fibrous  Clothes, Hairnet, Pens, Personal items  Clothes and hairnets should not be a source of strings
material and other (security badges, etc.) and fibers
material used on line  Office materials (paper clips, staples,  Clear rules about personal items should be in place
mobile phone, etc.)  Office material should not be used on production line
excepted clear validated detectable items by your metal
detector and/or X-ray.
Finished Packaging  Paper bags with internal plastic layer,  Use of strippable paper bags and/or bag–in-box
material plastic bags and big bags as sources of specifications is highly recommended for dry mix
foreign bodies ingredients.
 No properly protection of the big bags  Plastic big bags should not be a source of plastic and
and/or bags during the transport fiber strings
 Pallets should be protected from the top until the
pallets by adapted covers and plastic stretch film.
Engineering practices  Plastic pieces coming from perforation  Hygienic rules to be defined for technical intervention.
and other technical operations in Technicians have to be trained concerning the rules
production area they have to respect.
 A procedure for line release after maintenance and
before production should be in place (cleaning, visual
checking, recording…)

PAGE 16
Fruit: Tree Fruit
Pome and Stone Fruit
Apple, pear, peach, plum and cherry
Main Foreign Body Risks Crop calendar (harvest/production)
-Animal and animal parts/excrement; soil, glass; whole/visibly intact insects, Crop Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
metal, hard plastic, hard/sharp wood, bone, stones; Allergens. Northern Hemisphere
-Soft, brittle, round: plastic fibers, string, thread, paper, soil, sand, paint or Apple
varnish chips rubber, soft wood, hair; small insects/ insect parts, feathers, Pear
fur.
Peach
-Extraneous vegetable matter: apple carpel, seed/seed fragments, pits/pit
fragment, peel/skin (black spots), stems, blossom ends, leaves and plant Plum
fibers. Cherry
Southern Hemisphere
Apple: wood, glass, apple carpel, seed, and seed fragments Apple
Pear: loose seeds, peel, stems (internal and external), core material, dark Pear
spots
Peach
Peach: pit fragments, peel, dark spots; mushy, tough rubbery or hard flesh
Cherry: pits, black spots Plum
Cherry

 Lack of GAPs with FOB control, worker  There is a documented and verified Good Agricultural
training Practice (GAP) standard and foreign body control
 Animal remains, hair, feathers visible  Farm worker training on GAP - prevention of worker
 Field perimeters close to roads and urban introduction of foreign material, sanitation.
areas.  A copy of the GAP guidelines and check list is
 Used packaging, plastics, string, rubber, glass, available upon request
metal, rubbish (e.g. from nearby dump)  Internal and external audits are performed with
Farm/Field:  Metal & plastics from equipment e.g. documented corrective actions for FOB; mock recall
Selection and PRUNING tools and containers) for foreign objects
preparation  Poorly maintained farm machinery and  Inspect insect control records: Monitor infestation
equipment; lack of repair schedule levels and react appropriately if threshold level is
 Neighboring trees with allergens exceeded
 Service records of farm equipment, i.e. machinery,
tools containers with replacement of worn, damaged
equipment
 Allergen plants present  Inspect field at early stage of growth

 Insect infestation  Selective use of relevant insecticides based on risk
 Animal inhabitants of fields/Birds frequenting assessments and forecasting & biological control
fields  Ensure minimum insect infestation at or around the
 Worn, damaged bins time of harvest. Take into account pesticide
Pre-harvest: recommended harvest interval
Sowing and growing  Periodical inspection of fields
season  All boxes /bins should be checked for damage,
cleaned and maintained before each harvest season
 Replace damaged bins

PAGE 17
Fruit: Tree Fruit
Harvest:  Harvest and transport machinery with foreign  Avoid use of wooden containers and / or damaged
Apples, pears, peaches bodies (e.g. plants, stones, hairs, plastic, containers
and plums are hand- metal, rubbish)  Clean and maintain equipment before/during harvest
picked.  Animals habitant in orchard (snakes, birds) (hauling bins)
 Insects habitant in orchards (pollinating,  Recommended to cover the containers when
Cherry trees use biological control) transporting.
harvesting equipment  Visible debris – plastics, rubbers, tubes, glass,  Inspection and removal of debris before harvest
that shakes the tree and metal, gloves, tools  Prevent extraneous getting into bins during harvesting
collects berries on tarp  Insufficient GAP of personnel in contact with (leaves, etc)
that dumps cherries on harvested crop (poor sanitation, lack of  Proper GAP personel training/adequate hygiene for
conveyor that dumps into training) personel and facilities
a water tank where debris  Damaged/worn harvest bins  Ensure glass containers are not used near fruit bins
are removed.
 Crop/container contact with ground  Clean on-farm storage facilities

 Condition of on farm storage/staging areas  Adequate sanitation/cleaning and inspection
 Broken/wood/plastic containers, discarded schedule/records for all containers, trucks before use
gloves, tools  Cleaning and removal of foreign materials at loading /
 Poor hygiene of transportation trucks unloading
(inspection/cleaning frequency and records)  Recommend to cover open trucks during transport and
 Open trucks/containers (exposure to parking
elements, debris)  Minimal hold time in the transport phase
 Infestation of containers, trucks, crop  Avoid use of wooden boxes/bins
 Time crop held in field  GAPs training for personnel
Post Harvest:  At risk transportation routes (back-hauling,  Ensure that no glass bottles or contaniners are stored
(Containers/bins and weather extremes, delays) near fruit storage bins.
transportation)  Off load area (exposure to elements, debris)
 Personnel in contact with harvested crop
 Lack of hygiene/training of personnel in
contact with harvested crop
 Visable field dirt and FOB in storage
containers/bins
 Manual sorting, cleaning and trimming
 Processing line (broken pieces)
 General hygiene of storage facilities  Clean storage area

 Damaged and rotten crop material  Inspect the unloading bay and storage for debris,
 Transportation routes rubbish
 Off load area (exposed to all elements)  Use appropriate storage conditions based on short
 Visible metal & rubbish term or long term storage and maturity needs.
 Infestation (Temperature and/or controlled atmosphere storage
 Building/door tightness and sealing may be necessary)
Storage:  Lack of controlled atmosphere storage  Visual inspection/sorting of apples when removed
(Farm and/or supplier  Uncovered lights pose potential glass FOB if from storage
storage) broken  Service the facility ensuring no leaks, no access to
birds, rodents
 Monitor storage period (humidity, temperature,
infestation, mold, senescence)
 Make sure all lights properly covered
 Rodent traps in place around storage area

PAGE 18
Fruit: Tree Fruit
Specific Guidance: Diced Apple Particulates

 Damaged fruit prone to mould/rot.  Avoid bruising and damage during harvesting,
 Wood, glass, metal, stone, plastic. transportation and storage
 Allergens (e.g. tree nuts)  Remove severely bruised apples during pre-sorting
 Visual sorting can be effective, if the level of bruising
is not too high.
Harvest,  Clean storage containers before using
Transportation and  Prevent foreign material/allergens from falling into
Storage storage containers during harvesting and
transportation
 Size peelers/corers/slicers appropriately and
maintain equipment to avoid metal shavings from
peeling or cutting
 Apple carpel pieces, core and peel material.  Need crisp apples to effectively core and cleanly cut.
Optimize time and conditions for controlled
Significant defect in apple dices - described as
atmosphere (CA) storage and mellowing prior to
fingernails, plastic, insect fragments by some sorting
consumers.  Optimize the variety of apple for qualities essential
to coring: size, apple symmetry, shape of carpel.
Good coring varieties include Crispin and Rome.
 Apples are too soft, bruised, dark spots. Poor coring varieties include Golden Delicious and
 Apple are too small, too large and/or Fuji, which both have odd shaped carpel that
asymmetrically shaped/cross-cores protrudes into the flesh
Peeling, coring,  Metal from cutting tools  Pre-sort to optimum size of apples for the type of
dicing/cutting peeler/slicer/corer. Remove apples that are too small
 Plastics from conveyor belts
and with cross-core. Remove larger apples that can
damage the peelers/corers
 Separate the apples into large and med/small
streams - one bank peeler/corer/slicers optimized
for each
 Use 1" corer rather than standard 3/4"
 Slow the speed of the line to allow adequate control
- especially at hand sorting
 Metal from oven, grids, roller dryers, fillers and  Equip the line with magnets, sieves, metal detector
conveyors and visual sorting (ensure fit for purpose: design,
 Plastics from conveyor belts and sealing gauss, air gap).
gaskets  The number and locations of magnets, sieves and
 Insects & pest metals detectors makes sense
 The latest magnet technology have 10000+ Gauss
and can attract stainless steel shavings & welding
materials
Drying and filling  Sieve size and design is state of the art
 The inspection rate is frequent
 The catch/reject are recorded and used for
continuous improvement
 All pieces of equipment are validated.
 A maintenance and verification plan is in place for
all pieces of equipment
 Employees in all areas should contribute to Pest
management
 Insect control and treatment shows effectiveness
through insect absence
 Zoning should be fit for purpose

PAGE 19
Meat:
Ground Red Meat Products (Beef, Pork) Product Information:
Feeder plants debone and separate raw material items that
Main Foreign Body Risks: supply further processing plants. The processing plants
Bone, metal, flexible plastic, hair formulate raw and may perform cooking to finished
products.

Feeder/Supplier Plant  Bone, metal, flexible plastic, hair  Documented finished material inspections with
established control limits for defects
 Plant is approved with performance targets in
place for foreign body reduction
 Combo storage with caps to prevent
contamination during transit and storage
Raw Material Controls  Bone, metal, flexible plastic, hair  Documented incoming material inspections
 Documentation for each foreign material found
with rapid communication back to the supplier
on each incident
 Rating suppliers on foreign objects per million
pounds
 Regular performance discussions with ranking
against competitors
 Purchase changes based on ranking
 Supplier hair control program in place
 Different color plastics from Feeder Suppliers to
differentiate in case of contamination
 Bone, metal, flexible plastic, hard  No wooden pallets are used in dumping stations
plastic, hair, wood – plastic only
 Incoming raw meat/trim x-rayed utilizing metal
and ceramic standards before grinding to
prevent large foreign bodies being converted
into multiple smaller pieces
 All incoming raw meat/trim pass through a
metal detector with 2 heads oriented 45o to the
line
 Inspection belt with a waterfall in the line to flip
the meat with adequate visual inspection
 Blade/plate checks completed on a routine,
frequent basis by trained, qualified operators
In Process  Meat x-rayed after initial grind to 2 mm
sensitivity
 X-ray post final grind, with x-ray validated and
verified on a regular basis for effectiveness
 Stuffed Products: All raw meat blends x-rayed
at stuffing process for log/stick products
 Stuffed Products: All logs/sticks of cooked
meat x-rayed prior to slicing.
 Finished cooked meat pieces: slices x-rayed
and passed through a metal detector with 2
heads oriented 45o to the line.
 Run limits established for metal findings and
other routinely found foreign bodies with

PAGE 20
 Bone, metal, flexible plastic, hard corrective and preventative measures
plastic, hair, wood implemented when thresholds are exceeded
 Belt inspection programs in place and completed
during pre-op and operational periods
 Hair control programs with lint rollers and
checks for efficiencyPlastic liners minimum 7 mil
 Retractable bottom combo dumpers used
 No wooden pallets in exposed product zones
 Conversion of any plastic in facility to colored,
and metal detectable (i.e. pens, gaskets, zip ties,
In Process etc.)
 Small part and tool accountability program
 Proactive process in place to routinely evaluate
line or area for foreign material potential. (line
mapping exercise)
 Employee engagement / awareness / incentive
program for findings
 Wood, plastic liners, debris from  Mandatory pallet caps
Supply Chain stacked storage. Stones, glass, other  Pallet inspection program before use
debris from pallets
Examples of Foreign Bodies in Meat

Commodities: Metal shot Bone Pieces
Flexible Plastic Wood

PAGE 21
Nuts: Ground Nuts (example Peanuts)
Main Foreign Body Risk: For crop calendar (harvest/production):
Stones,plastic,rubber,wood,insects, http://www.usda.gov/oce/weather/CropCalendars/index.htm
glass, hair, metal, other plants

Field  Stones, rocks, sand, plant material, wood  Selection of field/farmer/growing area
Choice & Preparation  Used packaging, plastics, string, rubber,  Soil preparation incorporating previous crop
glass, metal remains and other plant material.
 Rubbish from nearby dump  Removal of rubbish (field walks)
 Stubble/plant material from previous  Protection against animals, birds (fence, bird
crop Weeds including previous crop and scarers)
grasses  Service of machinery replacement of old parts
 Animal remains, hair, feathers
 Metal & Plastics from cultivation
machinery
Sowing to Pre-Harvest  Foreign crop seeds & weeds in seed at  Use only certified seed. Clean sowing equipment to
sowing remove any foreign crop seeds from other crops
 Metal & Plastics from sowing equipment  Service and repair sowing equipment before use
 Weeds & foreign plants  Selective use of herbicides and or mechanical weed
 Insect infestation control. Use pre and post emergence herbicides
 Animal habitants of fields where appropriate
 Birds frequenting fields  Selective use of relevant insecticides based on risk
assessments and forecasting
 Fenced and periodical inspection of fields
 Removal of bolting, flowering, plants
Harvest  Harvest and Transport Machinery with  Machinery cleaning before and during harvest.
foreign bodies (plants, plastic, metal,  Loud machinery to scare way animals
rubbish)  Machinery height adjustments
 Animals habitant in fields (rabbits,  Inspection and removal of debris before harvest
squirrels, snakes) (field walks)
 Insects habitant in fields (pollinating,  Use of harvesting machinery that removes stones &
biological control) similar foreign bodies. Ensure correct calibration of
 Debris – plastics, rubbers, tubes, glass, machinery.
metal  Ensure correct dry time of peanut vines for peanut
 Personnel in contact with harvested crop separation from plant
 Stones
Shelling/Production  Transportation trucks and Open trucks  Cleaning of trucks & covering open trucks
 Transportation routes  Minimal hold time in the transport phase and
 Storage silos storage silos
 Off load area (exposed to all elements)  Cleaning and removal of foreign bodys at loading /
 Processing line (metal, rubber, plastic) unloading
 Personnel in contact with harvested crop  Good manufacturing practices
 Shells  Blowers ventilators
 Field trash (metal, stones, glass, plastic,  Hand sorting
rubber)  Good manufacturing practices for personnel
 Rodents, snakes, insects  Sorters on line (optic & manual), gravity separators
 De-stoners

PAGE 22
Nuts: Ground Nuts (example peanuts)
Storage (pre-processing  Various debris  Clean storage and transport bands
(field/Farmer  Rodent/pest infestation  Apply first in first out principle
storage/Supplier storage  Use controlled atmosphere storage
 Sorting of crop when removing from
storage
 Pest control program
 Special attention – Rocks, stones,
foreign dried plants, plastics,
metal, shells  Special attention – Optic and manual
sorting, screeners, gravity separation for
rocks/stones. Removal of stones with
appropriate harvest machinery
Examples of Foreign Bodies in Nuts at Nestlé Factory:

PAGE 23
Nuts: Tree Nuts (example almonds)
Pecans ( Halves and Pieces), Almonds, Hazelnuts, etc. Crop Calendar (harvest/production)
http://www.usda.gov/oce/weather/CropCalendars/index.
Main Foreign Body Risks: htm
Shells, Sticks, Crop Related FM, Rocks, Glass, Hair, Metal, Leaves,
Wood, Plastic
 Stones, Rocks, Dirt/Sand, Sticks, Wood,  Proper maintenance and preparation of ground under
Field preparation &
Leaves, Glass, Grass, etc. from the ground tree prior to shaking and harvest
Harvest
during sweeping/harvest  Removal of debris from orchard floor prior to harvest.
 Metals and Plastics from Harvesting and  Service and repair of harvesting equipment and
Transport Machinery transport vehicles
 Proper cleaning/clean out of transport bin or vessels
 Animals, reptiles, insects, etc. habitant in
prior to filling with pecans during harvest.
orchards at the time of harvest
 Use of proper pesticide applications during growing
season (e.g herbicides to guarantee weed-free band
down the trees)
 Not allowing any animals to graze or held in orchards.
 Proper maintenance, preparation, and inspection of
ground under tree prior to harvest
 Integrated Pest Management to avoid pest issues (e.g.
pecan nut case-bearer)
 Stones, Rocks, Dirt/Sand, Sticks, Wood,  Proper aspiration/blower systems along with proper
In-shell Cleaning,
Leaves, Glass, Grass, etc. from the ground cleaning reels to remove debris from in-shell pecans as
Grading, Sizing during sweeping/harvest they are graded
 Loose pecan shells and fragments
 Stones, Rocks, Glass, Metal from the  Destoner/water bath used to remove foreign materials
Cracking & Shelling
harvesting and grading processes that will sink, including alcohol flotation process
Production
 Metal from Processing or Harvest  Rare Earth Magnets, Metal Detection (ensure fit for
 Plastic from Processing or Harvest purpose: design, gauss, air gap)
 Production Employees (Hair, etc.)  Aspiration equipment, Electronic color Sorting
 Pecan Shells, Stems, Sticks, Crop FM Machines, Hand Picking
 Pest, insects  Good Manufacturing Practices (hair nets, lint rollers,
use of smocks/coats/uniforms)
 Integrated Pest Control Program, Proper plant design
and sanitation

PAGE
24
Nuts: Tree Nuts (example almonds)
Examples of Foreign Body Removal Systems:

PAGE 25
Oils and Fats
Oilmix, Polyunsaturated Fatty Acids (PUFA), Corn, Peanut, Refer to Peanut Best Practice for mitigation of foreign bodies
Rapeseed, Sunflower, Coconut, Palm. originating at the fields.
Main Foreign Body risk: Metal, hair, pest, plastic

Engineering practices  Metal pieces coming from weldering,  Hygienic rules to be defined for technical intervention
cutting, perforation and other technical in production area
operations in production area  Production line to be protected during operations in
the environment
 Technicians have to be trained concerning the rules
they have to respect.
 A procedure for line release after maintenance and
before production should be in place (cleaning, visual
checking, recording…)
 Soldering should be replaced by weldering
Filling area  Cross contamination coming from process  The equipment should be closed during production. A
equipment fine filtration should be done
 Insects presence in the filling area  before the storage tank for bulk and filling line (at
 Foreign bodys present inside the least 1mm)
containers  Sieve integrity should be checked before release of the
production
 Strong implementation of the pest management
should be present
 A procedure should be defined to minimize Foreign
bodys contamination originating with the packaging
container (covered conveyors, inverter, rinsing, regular
inspection)
Operator hygienic rules  Contamination with hair during  See for details the general guidance document specific
intervention by operators which need to to prevention of hair contamination
open the equipment (cleaning,
maintenance)
Finished Packaging  Foreign bodys coming from metallic  Packaging should not be a source of metal
material design and barrels  Use colored blue plastic liner
transport  Plastic liner stuck in the solid grease not  Pallets of small containers should be fully protected
visible during transportation by covers and stretch film.
 Foreign bodys from environment during
the transport
Loading of the tanker  Introduction of Foreign bodys during the  Dedicated food grade tanker with cleaning certificate
loading (tanker equipment, manhole (for tanker and equipment) with recording of validated
opening) cleaning operations to be checked for acceptance
before loading
 Covered premise for loading operation is preferred
 Strong implementation of the pest management
should be present
 Loading hoses and connection parts protected from
environment (e.g.: covers)
 Opening of the manhole should be managed to avoid
introduction of Foreign bodys from environment
 Proper garment for operators and drivers (hairnet,
long sleeve, beard protection…) are in place
 A sieving of 1mm is recommended before loading

PAGE
26
Oils and Fats
Plastic liners stick to solid fat blocks. Using clear liners makes it very difficult to visually detect torn plastic
pieces in the block. Using colored plastic helps operators visually identify the presence of plastic pieces.

PAGE 27
Poultry
Production Information:
Trim, formed, tenders, whole breast Feeder plants debone and separate raw material items
which supply the further processing plants which
Main Foreign Body Risk:
formulate and cook to finished products.
Bone, fat/gristle/cartilage, hair, plastic, metal, glove, wood
De-bone process and  Bone, Fat/Gristle/Cartilage  Manual de-bone only. Auto de-bone not authorized as
Feederplant it creates a higher amount of defects
performance  Use of X-ray to detect and remove bone
 Fishbone RCA completed. De-bone process and
control plan has established defect rate, SPC & control
limits, sampling & frequency, type and numbers of
bone recorded, and CA related to adjust line speed
 Bone Detection and Removal Control Plan has
established defect rate and x-ray validation procedur.
 Control limits established at these locations in the
process: after mechanical de-bone, after manual trim,
pre and post x-ray
 Vertical integration. Purchase of trim or tender from
open Market (not vertically sourced) is approved by
Nestlé
 Feeder plant performance data is shared weekly and a
robust chargeback and rejection program is in place.
Eliminate underperformers and use raw material from
best performers
 Calibration of deboner daily and validate Fat, Grisle,
Cartlidge complies with specifications
Feeder plant  Hair, Plastic, Metal, Wood, Glove  Hair removal program to include Lint rollers and floor
audits to quantify hair found on employees and facility
(platforms, steps, bridges)
 Robust belt inspection program and use of metal belts
or metal detectable. Plastic liners 7 mil.
 Tool issuance program
 Blade and grinder weight collection and checks.
 Plastic pallets. Tote dipping process that prevents
debris on pallets from contaminating product
Further Processing plant  Hair, Plastic, Metal, Wood, Glove  All above
 X-ray and Metal Detection. Locked reject bins.
 Foreign Body Control Plan (Capability of devices x-ray
and MD)
Supply Chain  Warehouse (stacked storage) and  Mandatory Pallet cap/cover
Transportation conditions (trailer  Remove debris on top of pallet cover prior to use
cleanliness). Debris falling into cases or
totes. Pallet debris (wood, stone, glass).

PAGE
28
Poultry

Trim  Bone, Fat/Gristle/Cartilage  Dual pipeline x-ray units with 180 degree turn into
second unit
 Reject mechanism for each unit
 Minimum two persons to inspect material rejected
from pipeline x-ray units
 DSI calibrated daily to adhere to spec
Tender  Bone, Fat/Gristle/Cartilage  Specification for tender not to exceed 1/4 inch but
is inspected and clipped to 1/8”
 Dual x-ray passes with re-work loop
All  Bone  COA requirement that all material to passed
through an x-ray system to detect and eliminate
bone
 X-ray detection & rejection capable of detecting at
99% effectiveness to 1/8" and outgoing defect level
1
bone per 10,000 lbs. of material
X-ray  Bone  Validation procedure using double pass method of
minimum 1,000 lbs. to be conducted once per
quarter
 Defect rate is recorded for pass 1 and pass 2. Pass 1
cannot exceed 20 bones per 10,000 lbs. Pass 2
cannot exceed 1 bone per 10,000 lbs.
 1/8 inch pulley bone used for daily calibration and
conducted once per hour
 X-ray infeed reject rate cannot exceed 95%

PAGE
29
Sugar (Dry)
Liquid and Powder

For crop calendar (harvest/production):
Main Foreign Body Risks: http://www.usda.gov/oce/weather/CropCalendars
Metal, Stone, Wood, Plastic, Insect/Pest, Paper, /index.htm
Fibre/string, Burnt Particles.
For all Mitigations in Italics, see Common Risks section below:

Dry Sugar Production (Process steps common to Beet only)
Delivery of beet to Sugar  Remains of previous crop / other plants /  Washing at reception into factory with a rotating arm
Manufacturer weeds / soil / stones / rubbish over a large grid to remove foreign objects
Unloading and Storage  Pest activity  Pest prevention program is in place
 Supplier Quality Assurance (SQA) program in place
 Metal, plastic, paint from machinery/  Filters / sieve / magnets / metal detector downstream
farming equipment, transport (ensure fit for purpose: design, gauss, air gap)
 Random sampling of raw materials at delivery
Slicing of beet and  Metal from blades / rollers / shredders  Preventive maintenance program.
Diffusion  Visual inspection of sliced material
 Filters / sieve / magnets / metal detector downstream.
 Debris/burnt particles from the diffusion (ensure fit for purpose: design, gauss, air gap)
tank which can be percieved as foreign  Tank is on a cleaning schedule
objects  Crystallisation step to achieve 99% purity.
 Visual inspection of each batch before despatch
Filtration of juice  Filter failure e.g. foreign bodies passing  Filter in place (Range 50-75um)
through or filter mesh contamination  Preventive maintenance program
 Filter failure detection / inspection system in place
 Filter integrity is checked for integrity and findings on
a regular defined frequency determined by HACCP
study
Dry Sugar Production (Process steps common to Cane only)
Delivery of cane to Sugar  Remains of previous crop / other plants /  Magnet present to protect crushing equipment
Manufacturer, Unloading weeds / soil / stones / rubbish (ensure fit for purpose: design, gauss, air gap)
and Storage  Crystallisation and purification steps downstream to
 Metal, plastic, paint from machinery/ remove foreign bodies
farming equipment, transport  Filters / sieve / magnets / metal detector downstream.
(ensure fit for purpose: design, gauss, air gap)
 Supplier Quality Assurance is in place
 Pest prevention program is in place
 Pest activity
Slicing/crushing of cane  Metal from blades and rollers  Preventive maintenance program
Juice extraction  Filters / sieve / magnets / metal detector downstream
Delivery of raw sugar to  Pest activity  Pest prevention program
refinery  Foreign objects introduced during  Random sampling of raw materials at delivery
shipping  Goods-in checks are completed on arrival
 Metal, plastic, paint from machinery/  Supplier Quality Assurance is in place
equipment, transport and environment /  Filters / sieves / magnets / metal detector downstream
previous loads

PAGE 30
Sugar (Dry)
Dry Sugar Production (Process steps common to both Beet & Cane production)
Clarification /  Calcification, lime particles.  The purpose of purification is to remove soluble and
Purification insoluble impurities
 Contamination from purification tank. (i.e.  Cystalisation step to acheieve 99% purity
material flaking off from sides of tank,  Time and temperature controlled
burnt sugar).  Preventive maintenance program
 Visual inspection of each batch. Burnt sugar is
monitored to ensure it is within specification (limits
defined locally)
 Restricted volume of milk of lime
 Juice passes through filters to remove calcium
carbonate
 Visual inspection of each batch before despatch.
 Tank is part of a cleaning schedule. Appropriate food
safe material used to coat the internal sides of the
tank
Evaporation  Burnt sugar particles  Time and temperature controlled
 Pan scale / rust  Cells are part of a cleaning schedule
 Evaporation is carried out under vacuum to prevent
caramelisation
 Crystallisation step to achieve 99% purity
 Product Intervention / Maintenance
 Permit required for any intervention / maintenance
and sign off required
 Sieve present downstream
Crystallisation  Burnt sugar particles  Time and temperature controlled
 Pieces of pan scale / rust  Crystallisation takes place in vacuum pans to prevent
burnt sugar
 Pans are part of a cleaning schedule
 Sieve present downstream
Centrifugation & Crystal  Metal from plough, cylindrical basket,  Preventive maintenance program
Washing spindle, wire cloth, metal sheets and other  Sieve / magnets / metal detector downstream (ensure
moving parts from the centrifuge fit for purpose: design, gauss, air gap)
 Contamination from water supply /
environment / water circuit  Water is on a testing schedule
Drying & Cooling  Contamination from air supply.  Filtered air is used
 Contamination from environment /  Additional clean Personal Protective Equipment (PPE)
operator post crystalisation for food safety purpose, including hairnets and clean
laundered lab coats
 Permit required for any intervention / maintenance
and sign off required
 Dryer is time and temperature controlled and is part of
 Burnt sugar particles a cleaning schedule
 Visual inspections on each batch prior to dispatch.
 Preventive maintenance program
 Metal from Stainless Steel Claws used in  Sieve / magnets / metal detector downstream (ensure
the granulator / dryer fit for purpose: design, gauss, air gap)
Intermediate Storage  Pest ingress  Pest prevention program and enclosed route to silo
(Silo)  Contamination from silo walls  Silo is part of a planned cleaning schedule
 Contamination from human intervention  Product Intervention Permit required for any
i.e cleaning / maintenance intervention
Food safety PPE is worn. Employees receive food safety
 Contamination through air supply due to and Good Manufacturing Practice (GMP) training
filter failure  Air filters are checked as part of a preventive
maintenance program

PAGE 31
Sugar (Dry)

Dry Sugar Production (Process steps common to both Beet & Cane production)
Packing into bags  Metal or plastic from bagging machines.  Preventive maintenance program
 Contamination from  Foreign body detection equipment present (type
equipment/environment upstream. determined in HACCP study according to
 Failure to clean magnet leading to risk/line type i.e
blinding Sieve / Grading / Locker / Scalping Screen (Max
 Screen mesh wire / ball from locker screen aperture 2mm)
as a source of foreign body (metal). Magnets (ensure fit for purpose: design, gauss, air gap)
 Sealing equipment (i.e Needle, string) Metal Detector (Minimum 2mm FE, NFE, SS)
 Operator physical contamination (i.e hair,  Verification frequency is determined based on
belongings) the risk and history as determined in HACCP
 Pieces of packaging contaminating study
product  Operators are trained to ensure magnet checks
 Contamination from the environment are performed correctly
 Pest ingress  Visual change in particle size to indicate sieve
 Conveyor material (fibre, string) failure. Sieves are inspected for integrity
 Process alarms / operator inspection / automatic
line safety stop following failure
 Food safety PPE is worn. Hygiene zoning is in
place.
 Supplier Quality Assurance program in place
 Operators over-seeing the filling process
 No wooden pallets is preferred, although if
essential, they should be inspected for integrity
and kept a suitable distance away from any entry
/ sample points
 Pre requisites are in place, such as tool control,
cleaning and Pest prevention program
 Preventive maintenance program and conveyor
alarms
Transportation bulk  Contamination from  Foreign body detection equipment present (type
(Tanker / Ship) equipment/environment upstream determined in HACCP study according to risk/line
type i.e
Sieve / Grading / Locker Screen (Max aperture 2mm)
Magnets (ensure fit for purpose: design, gauss, air gap)
Metal Detector (Minimum 2mm FE, NFE, SS).
 Verification frequency is determined based on the risk
and history as determined in HACCP study.Visual
 Screen mesh wire / ball from locker screen change in particle size to indicate sieve failure. Sieves
as a source of foreign body (metal) are inspected for integrity.
 Contamination from the wagon ship  Wagon / Ship is only used for transportation of food, is
container (i.e. previous product, pieces of fully inspected, and is compliant with the permitted
pallet or environment) prior loads list
 !Cleaning schedule and certificate is present for all
tankers inspection for presence and integrity of seals.
 Approved Distribution Company
 Pest prevention program
 Pest ingress  End caps fitted to hoses when not in use
 Food safety PPE and GMP operator training
 Contamination from operator (hair,  Samples taken and tested for each load before release
clothing)
 Contamination from upstream process /
burnt sugar

PAGE 32
Sugar (Liquid)
Liquid Sugar Manufacture
Re-melt / Dissolver  Contamination from dissolvers (burnt  Preventive maintenance program
sugar particles, material from sides of the  Filters downstream.
pan, product build up)  Equipment is part of a cleaning schedule
 Contamination from water supply  Water is on a testing schedule
Filtration  Filter failure e.g. foreign bodies passing  Recommended filter size at this step: 8um
through or filter mesh contamination  Preventive maintenance program
 Filter failure detection / inspection system in place
 Filter integrity is checked for integrity and findings on
a regular defined frequency as determined in the
HACCP study
 Further filters / magnets are present downstream
Heat exchange  Metal from equipment  Preventive maintenance program
 Product build up, risk of burnt sugar  Filters present downstream
 Heat exchange system is part of a cleaning schedule
Sterilisation & filtration  Metal from sterilisation columns and  Preventive maintenance program
steps pumps  Recommended filter size at this step: 50um
 Metal from filter mesh  Mesh integrity is checked on a regular defined
frequency and corrective action taken in case of failure
 Filters present downstream
 UV Sterilisation lamp failure – Glass  Audited glass and hard plastic register to be in place
 High temperature shrouded shatter proof glass
 Glass breakage procedure in place
Production Plant &  Pest ingress  Pest prevention program and enclosed route to silo
Storage Tanks  Contamination from silo walls  Storage tanks are part of a cleaning schedule
Transportation - Bulk  Contamination from  Foreign body detection equipment present (type
equipment/environment upstream determined in HACCP study according to risk/line
type i.e
filters (recommended 50um).
 Verification frequency is determined based on the risk
and history as determined in the HACCP study
 Wagon is only used for transportation of food is fully
 Contamination from the wagon (i.e inspected and complies with permitted prior loads list
previous product, pieces of pallet)  Cleaning plan and certificate is present for all tankers.
 Inspection for presence and integrity of seals
 Approved distribution company
 Pest prevention program
 Correct storage and end caps fitted to hoses when not
 Pest ingress
in use
 Correct PPE and operators are given GMP training
 Contamination from operator (hair,  Samples taken and tested for each load before release
clothing)
 Any remain foreign bodies / burnt sugar
!Note on Bulk Tanker Deliveries: Tanker checks include history of deliveries, seal integrity, seal numbers, cleanliness of
the tank, loading valve and hose. Hauliers provide seal numbers in advance of the tanker arriving and are validated and
recorded at delivery. A valid cleaning certificate is provided and checked for each tanker prior to loading and cleaning is
validated and verified to demonstrate no residual material, allergens or chemicals. The contract held with the haulier
defines expectations and previous delivery allowances, cleaning method and suitable validation.

PAGE 33
Sugar (all)
Risks common to multiple process steps in sugar manufacture
Water  Contamination from water source /  The quality and safety of water at point of use is
environment / water circuits ensured through pre-requisite programs i.e preventive
maintenance, cleaning, security, circuit mapping. The
source and origin of water is taken into consideration
in the HACCP study and an appropriate monitoring
and verification program is in place
Environment  Building is not pest proof  A Pest prevention program is in place and corrective
actions are taken
 Poor fabrication / inadequate cleaning  Buildings must provide reliable barriers to pest access
from the external areas
 High level cleaning plan in place. Good Manufacturing
Practice (GMP) audits are carried out
 Contamination from the environment  Air filters are routinely inspected and replaced as part
through air transmission of preventive maintenance program.
 Plant is enclosed where possible
Machinery parts / all  Belt fibre / string from damaged conveyors  Suitable material is used for product type. Conveyors
conveying / material are inspected for integrity and corrective actions taken
moving steps i.e. pumps /  Belt tracking / alarm system is recommended.
valves  Metal from damaged bearings / screws /  All equipment including bearings / pumps / screws
pumps are part of a maintenance schedule
  Audio and visual inspections are carried out routinely.
 Metal from plant failure causing metal on  Process shut down in the event of a failure and
metal contact adequate investigation / correction
 Preventive maintenance program is defined with
frequency determined according to risk
 Operators are trained to recognise unusual sounds /
conditions which could indicate plant failure
 Appropriate metal detection device(s) present as
determined by HACCP study
Equipment / tools  Poor condition of tools / cleaning  Presence and integrity of tools should be checked
equipment (plastic) regularly
 Wooden or sponge material should not be used.
 Replacements are available in the event of damage.
 Shadow boards and visual standards are
recommended
 Operator GMP training
 Cables are away from product, and are metal
 Contamination from equipment (metal, detectable
plastic, cable ties, signage material)  All equipment is part of a Preventive Maintenance
Program which is risk assessed. Improper 'home-
made' repairing i.e using cardboard or tape should be
forbidden. A procedure on managing damaged
equipment should be in place
 A HACCP study is in place for all process steps.
 A sign off procedure after maintenance is in place
 Use materials less susceptible to wear and tear
inspected regularly
 Magnets are validated and cleaned frequently. Critical
limits are defined. Operators are trained to perform
 Magnet is blinded (metal). magnet checks (ensure fit for purpose: design, gauss,
air gap)
 Appropriate material is used and is risk assessed to
 Use of sleeves/gaskets (plastic, gortex). include inspection frequency
 New equipment as a source of foreign  Change management system is in place
bodies.
 Use of damaged plastic / wooden pallets

PAGE
34
Sugar (all)

Risks common to multiple process steps in sugar manufacture
 Uncovered equipment / conveyors / silos  Wooden pallets should be avoided or segregated.
 Equipment/transportation is not kept Damaged pallets should quarantined for
clean resulting in contamination to the return/disposal.
product.  Closed line (but easy to inspect) is preferred.
 A cleaning schedule is in place and signed off. Dry
cleaning if possible. Wet cleaning should be
controlled and all areas are dried down and inspected
for water residue after the clean is complete.
 Hygiene zones are defined.
Human Intervention  Sampling / inspection intervention  All personel receive frequent and role specific food
 Failure to report foreign body incidents. safety training including foreign body control, Critical
 Incorrect method used for checks / Control Points (CCP), Operational Pre-Requisitites
operating the machine. and all relevant SOP's, including:
 Management of rejected products to ensure that
rejected product is handled correctly and not
accidentally reintroduced into the good product
stream.
 Inspection of rejected product during production.
 Root cause investigation methodologies.
 Non conforming product procedure is in place.
 Physical contamination (i.e hair,  Appropriate food safety protective clothing procedure
belongings, clothing etc). is in place i.e laundering, hygienic design, personal
hygiene practices, belongings, metal detectable
stationary.
Examples of Foreign Bodies in Sugar at Nestlé Factories i.e Stones, wood, string, burnt
particles.

PAGE 35
Vegetables: Fruit Vegetables
Tomatoes, Peppers, Eggplant For crop calendar (harvest/production):
http://www.usda.gov/oce/weather/CropCalendars/index.htm
Stones, plastic, rubber, wood, insects,
glass, hair, other plants

Field  Stones, rocks, sand, glass  Selection of most optimal field/farmer/growing area
Choice & Preparation  Used packaging, plastics, string, rubber,  Removal of rubbish (field walks)
glass, metal, rubbish (e.g. from nearby  Soil preparation by incorporating previous crop
dump) remains and other plant material
 Stubble/plant material from previous crop  Protection against animals, birds (scarers)
 Weeds including previous crop and grass  Service of machinery - Replacement of old parts
machinery
 Insect infestation control. Use pre- and post emergence herbicides
 Animal habitants of fields/Birds where appropriate
frequenting fields  Selective use of relevant insecticides based on risk
assessments and forecasting & biological control
 Periodical inspection of fields, bird scarers
Irrigation  Metal, rubber and plastics coming from  Maintain and repair irrigation equipment
irrigation equipment  Ensure complete removal of all parts when removing
sprinkler and drip irrigation pipes from field
 Check water source for potential risk for foreign
bodies
Harvest  Harvest and transport machinery with  Machinery cleaning before/during harvest.
foreign bodies (plants, hairs, plastic,  Metal detectors on machinery where possible
metal, rubbish)  Blowers on machinery to remove hairs, insects
 Animals habitant in fields (rabbits,  Loud machinery to scare away animals
squirrels)  Machinery height adjustments
 Insects habitant in fields (pollinating,  Inspection and removal of debris before harvest
biological control) (field walks)
 Debris – plastics, rubbers, tubes, glass,  Manual sorting of debris after harvest of freshly
metal picked produce.
 Personnel in contact with harvested crop  Use of harvesting machinery that removes stones &
 Stones similar foreign bodies. Ensure correct calibration of
machinery
 Proper training and providing adequate personal
hygiene facilities
 correct calibration of machinery

PAGE 36
Vegetables: Fruit Vegetables
Post-Harvest  Transportation trucks & Open trucks  Cleaning of trucks & covering open trucks at all
 Time crop held in the field times during transport and parking
 Transportation routes  Minimal hold time in the transport phase
 Off load area (exposed to all elements)  Cleaning and removal of foreign bodies at loading
 Processing line (broken pieces) / unloading
 Personnel in contact with harvested crop  Blowers ventilators
 Hand sorting
 Good manufacturing practices for personnel,
sorters on line (optic & manual), gravity separators
Storage (pre-  Various debris  Clean storage and transport bands
processing  Damaged and rotten crop material  Apply FIFO principle
(field/Farmer  Use controlled atmosphere storage
storage/Supplier  Sorting of crop when removing from storage
storage
Specific Raw Material Guidance
Crop Potential issues Mitigation actions

Special attention – Rocks, stones, glass, foreign Special attention – Optic and manual sorting,
dried plants, plastics, tubes, dried stalks screeners, gravity separation for rocks/stones

PAGE 37
Vegetables: Herbs
Parsley, Coriander, Bay leaf, Oregano For crop calendar (harvest/production):
Stones, Metal, Plastic, Rubber, Wood,
Insects, Glass, Hair, other plants.

Field Choice &  Stones, rocks, sand, glass  Selection of most optimal field/farmer/growing area
Preparation  Used packaging, plastics, string, rubber,  Removal of rubbish (field walks)
glass, metal, rubbish (e.g. from nearby  Soil preparation by incorporating previous crop
 Stubble/plant material from previous  Protection against animals, birds (scarers)
crop  Service of machinery - Replacement of old parts
 Weeds including previous crop and grass
machinery
bodies

PAGE 38
Vegetables: Herbs
Harvest  Harvest and transport machinery with  Machinery cleaning before and during harvest.
foreign bodies (plants, hairs, plastic,  Metal detectors on machinery where possible
 Personnel in contact with harvested crop  Use of harvesting machinery that removes stones &
 Stones similar foreign bodies. Ensure correct calibration
of machinery
hygiene facilities
 Off load area (exposed to all elements)  Cleaning and removal of foreign bodies at loading
 Processing line (broken pieces) / unloading
 Hand sorting
sorters on line (optic & manual), gravity separators
storage

 All of the above apply  All of the above apply
 Special attention – Rocks, stones,  Special attention – Optic and manual sorting,
foreign dried plants, plastics, tubes, screeners, air blowing for light particles such as
glass. insects, stalks
 Insects, foreign leaves, stalks, weeds,
plastic, dried leaves of other plants

PAGE 39
Vegetables: Leafy Greens
Raw material concerned: For crop calendar (harvest/production):
Spinach, Kale, Cabbage, http://www.usda.gov/oce/weather/CropCalendars/index.htm
Broccoli

Stones, plastic, rubber, wood,
insects, glass, hair, other plants

Field  Stones, rocks, sand  Selection of most optimal field/farmer/growing area
Choice &  Used packaging, plastics, string,  Removal of rubbish (field walks)
Preparation rubber, glass, metal, rubbish (e.g. from  Soil preparation by incorporating previous crop
nearby dump) remains and other plant material
 Stubble/plant material from previous  Protection against animals, birds (scarers)
crop  Service of machinery - Replacement of old parts
 Weeds including previous crop and
grass
machinery
Sowing to Pre-  Foreign crop seeds & weeds in seed at  Use only certified seed. Clean sowing equipment to
Harvest sowing remove any foreign crop seeds from other crops
 Metal & Plastics from sowing  Service and repair sowing equipment before use
equipment  Leave a buffer area between the side of the field and
 Weeds & foreign plants the sown area
 Insect infestation  Selective use of herbicides and or mechanical weed
 Animal habitants of fields/Birds control. Use pre- and post emergence herbicides where
frequenting fields appropriate
 Selective use of relevant insecticides based on risk
 Check water source for potential risk for foreign bodies
foreign bodies (plants, hairs, plastic,  Metal detectors on machinery where possible.
 Insects habitant in fields (pollinating,  Inspection and removal of debris before harvest (field
biological control) walks)
 Debris – plastics, rubbers, tubes, glass,  Manual sorting of debris after harvest of freshly picked
metal produce.
 Personnel in contact with harvested  Use of harvesting machinery that removes stones &
crop similar foreign bodies. Ensure correct calibration of
 Stones machinery
hygiene facilities

PAGE
40
Vegetables: Leafy Greens

Post-Harvest  Transportation trucks & Open trucks  Cleaning of trucks & covering open trucks at all times
 Time crop held in the field during transport and parking
 Off load area (exposed to all elements)  Cleaning and removal of foreign bodiess at loading /
 Processing line (broken pieces) unloading
 Personnel in contact with harvested  Blowers ventilators
crop  Hand sorting
 Good manufacturing practices for personnel, sorters on
line (optic & manual), gravity separators
storage

Special attention – Rocks, stones, foreign Special attention – Optic and manual sorting, screeners,
dried plants, plastics, tubes, insects, gravity separation of heavy materials, calibration of harvest
regrowth of other plants, dried leaves, machinery.
extraneous dirty

PAGE 41
Vegetables: Underground Bulbs and Root Crops
Raw materials concerned: For crop calendar (harvest/production):
Beetroot, Carrots, Celeriac roots, http://www.usda.gov/oce/weather/CropCalendars/index.htm
Onions, Potatoes, incl. Garlic

Stones, metal, plastic, rubber,
wood, insects, glass, hair, other
plants.

Field Choice &  Stones, rocks, sand/Plant material, wood  Selection of most optimal field/farmer/growing
Preparation  Used packaging, plastics, string, rubber, area
glass, metal, rubbish (e.g. from nearby  Removal of rubbish (field walks)
dump)  Soil preparation by incorporating previous crop
 Stubble/plant material from previous crop remains and other plant material
 Weeds including previous crop and grass  Protection against animals, birds (scarers)
 Animal remains, hair, feathers  Service of machinery - Replacement of old parts
machinery
 Crop type (carrots & parsnips bolting) assessments and forecasting & biological control
 Removal of bolting, flowering, plants
irrigation equipment  Ensure complete removal of all parts when
removing sprinkler and drip irrigation pipes from
field
bodies

PAGE 42
Vegetables: Underground Bulbs and Root Crops
foreign bodies (plants, hairs, plastic. Metal,  Metal detectors on machinery where possible
rubbish)  Blowers on machinery to remove hairs, insects
 Personnel in contact with harvested crop  Use of harvesting machinery that removes stones
 Stones & similar foreign bodies. Ensure correct
calibration of machinery
hygiene facilities
 Use of harvesting machinery that removes stones
& similar foreign bodies. Ensure correct
calibration of machinery
 Off load area (exposed to all elements)  Cleaning and removal of foreign bodiess at
 Processing line (broken pieces) loading / unloading
 Hand sorting
sorters on line (optic & manual), gravity
separators
Storage  Various debris  Clean storage area and transport conveyors
(pre-processing,  Damaged and rotten crop material  Apply FIFO principle
field/farmer  Use controlled atmosphere storage
storage/supplier  Sorting of crop when removing from storage
storage)

PAGE 43
Carrots  Bolting plants to be removed manually on a regular
 Special attention – Rocks, stones, plastics, basis in the fields.
tubes, bolting plants, woody carrots/parsnips  Use varieties with reduced bolting risk
 Avoid sowing during cold period
Potatoes and sweet potatoes  Variety selection
 Necrosis or simply inefficient peeling can  Selection of growing region / climate
cause dark specs, which are causing  Agreement on quality grade (A, B ...)
significant consumer dissatisfaction.  Sufficient sorting processes
 Sufficient peeling depth

PAGE
44
Vegetables: Stalks
Leek, Chives, Asparagus For crop calendar (harvest/production):

Stones, plastic, rubber, wood, insects,
glass, hair, other plants

Field  Stones, rocks, sand  Selection of most optimal field/farmer/growing area
Choice &  Used packaging, plastics, string, rubber,  Removal of rubbish (field walks)
Preparation glass, metal, rubbish (e.g. from nearby  Soil preparation by incorporating previous crop
 Stubble/plant material from previous crop  Protection against animals, birds (scarers)
 Weeds including previous crop and grass  Service of machinery - Replacement of old parts
 Metal & Plastics from cultivation machinery
Sowing to Pre-  Foreign crop seeds & weeds in seed at  Use only certified seed. Clean sowing equipment to
Harvest sowing remove any foreign crop seeds from other crops
 Animal habitants of fields/Birds frequenting where appropriate
fields  Selective use of relevant insecticides based on risk
irrigation equipment  Ensure complete removal of all parts when
removing sprinkler and drip irrigation pipes from
field
bodies
foreign bodies (plants, hairs, plastic, metal,  Metal detectors on machinery where possible
rubbish)  Blowers on machinery to remove hairs, insects
 Animals habitant in fields (rabbits, squirrels)  Loud machinery to scare away animals
 Insects habitant in fields (pollinating,  Machinery height adjustments
biological control)  Inspection and removal of debris before harvest
 Debris – plastics, rubbers, tubes, glass, metal (field walks)
 Personnel in contact with harvested crop  Manual sorting of debris after harvest of freshly
 Stones picked produce.
 Use of harvesting machinery that removes stones &
similar foreign bodies. Ensure correct calibration of
machinery
hygiene facilities

PAGE 45
Vegetables: Stalks
 Off load area (exposed to all elements)  Cleaning and removal of foreign bodiess at loading /
 Processing line (broken pieces) unloading
 Hand sorting
 Good manufacturing practices for personnel, sorters
on line (optical & manual), gravity separators
storage

All of the above apply All of the above apply
Special attention – Rocks, stones, foreign dried Special attention – Optic and manual sorting,
plants, plastics, tubes, dried stalks screeners, gravity separation for rocks/stones, blowers
for light materials

PAGE
46
Packaging: Bulk Bags/Big Bags/Super Sacks/FIBC
Bulk Bags/Big Bags/Super Sacks/FIBC – assumes new, virgin material Guidance on measures to ensure the quality and safety of
(not used) supersacks can be obtained from the FIBC Association:
https://fibca.com/wp-
Main Foreign Body risks: content/uploads/2015/10/FIBC_Food_Safety_Guide.pdf
Fibres, plastic other extraneous material through cross
contamination such as metal, plastic and wood. Additonally, these
materials can tagle with process equipment especially if strings are
excessively long.

Raw Material  Must not have a loose liner and should be a form-fit PE
liner adhered by food grade adhesive or sewn to heavy duty
tabs at corners such as from approved supplier TransPac
USA
 Liner should be of contrasting color to product and can
include EVOH layer if moisture barrier properties are
needed.
 The EFIBCA (European Flexible Intermediate Bulk
Container Association) standard is required:

 Must not be loosely woven, but rather tightly knit with
precise weaving machines
 Should include goose necking inner liner and appropriate
closure (knotted, tie wraps, colored metal detectable zip
tie)
 Must not have frayed or loose fibers, but rather the seam
Processing :Weaving  Hair edges rolled, sewn, and ultrasonic cut.
 Dust  Cutting of threads should be made with a hot knife or
 Fibres ultrasonic cut to ensure the edges are sealed
 String  Tying rope for the emptying and filling of spouts should be
 Plastic a good quality PP tape.
 Wood  Multi use sacks may be dry (vacuum) or wet cleaned before
 Metal filling and thoroughly examined for damage to stitching,
 Insects and/or Rodents gluing, welding and for surface abrasion, cuts, tears and any
other damage to the sack
 Before filling, all super sacks need to undergo a thorough
Filling quality inspection. This may include but not limited to
(where applicable) running the sacks through metal detectors. All threads and
loose materials need to be removed and checked for defects
and damages..
 Pallets also need to undergo a quality inspection. The use of

a cardboard pad (e.g. slip sheet) between the pallet and the
sack is needed
 Must fit on standard 40”x48” pallet with no overhang to
prevent damage during transport. It is preferable that the
dimensions of the pallet are about 100mm larger than the
length and width of the Big Bag.
Palletizing  Should be stretch wrapped to mitigate product settling over
time and causing bag to overhang
 Should have a 3-ply min. solid fiber pad between pallet and
supersack with appropriate gauge
 Plastic is preferable to wood for pallet material

PAGE 47
Packaging: Bulk Bags/Big Bags/Super Sacks/FIBC
 Must have the correct certification and safe working load
 Assurance of load safety and stability (SWL) with safety of 5:1 for single use and 6:1 for multi-use
 Disintegration due to UV light  Must meet all regulatory requirements for use with food
 Dust products
Shipping/Storage  Hair  Bags should be stored protected from sunlight, pests, dust,
 Insects and/or Rodents etc. and should be segretated according to robust GMP
policies.

PAGE
48
Pass/Fail Criteria of FIBC:
& Metal Detectable

PAGE
49
Packaging Material: Glass
Generic Glass Containers Generic production process:
Batching – Furnace – Forehearth and Feeder – Forming –
Annealing (surface coating) – Cold End Inspection – Packing
Main Foreign Body risks:
– Warehouse/Distribution
Glass fragments, extraneous foreign matter

Forehearth or Forming  Internal tear: glass surface rupture on inside  Follow Forehearth temperature and mechanical control and
of container, can vary in length and width monitoring procedures; machine timing, alignment;
and is open. mold/blank cooling procedures; gob forming and delivery
 Blister soft Inside: blister next to internal temperature controls in forming
surface already burst or capable of  Investigate furnace interior, review batch and cullet
burst/broken materials to conform to spec. Check flame.
 Blister Sealing Surface: soft blister on the  Also forehearth temperature controls; monitor of gob shape
sealing surface that can breakin normal use and weight
 Blister Soft Outside: blister next to outside  Control furnace and forehearth temps., control gob weight,
surface already burst or capable of burst control gob shape, control guide ring.
 Sugary top/crizzled sealing surface/crushed
sleeve (defect related to thermal conditions
and/or mechanical conditions)
 Non Glass Inclusions; metallic/non-
metallic FB in the glass that can contribute
to breakage
 Overpress/wire edge finish: Fin of glass on
inside of finish protruding upwards above
top. Wire press same except does not
protrude above
Forming step  Mold fins: raised fin of glass on moulded  Mold equipment alignment, requalification procedures,
joint forming equipment controls
 Over-pressed bottom: sharp edge that  Follow forming housekeeping procedures, folow jam
could break off and add to tramp glass procedures, follow machine alignment procedures
 Ultra thin bottom: thickness out of spec.  Control forehearth temp., control gob weight, maintain
machine settings for timing, blank cooling, final blow
 Bird swing: General defect description:
filament connecting two "sides" of container.  Control forehearth temperature, control gob temp., review
 Internal stuck/fused glass: fragment machine settings: timing, blank cooling, final blow, invert
adhering to inside of container settings
 Plunger pull/hot plunger: internal  Follow housekeeping procedures, follow machine jam
projection, sharp, base or neck area procedures, follow requalification procedures, maintain
 Stuck plug: similar to plunger pull covers over take outs
projecting inside bore  Control forehearth temperature, control gob temp., review
 Choked bore machine settings.
 Sugary bore/top (aka crushed sealing  Control forehearth temperature, control gob temp., review
surface, crushed sleeve, surgary top, crizzled machine settings.
sealing surface)  Control forehearth temperature, control gob temp./shape,
 Ring Finish Damage: small fragment on adhere to machine settings for timing, blank, cooling, final
Forming sealing surface blow
 Flange Finish: horizontal fin extending  Control forehearth temperature, control gob temp., adhere
from external ring to machine settings for timing, blank, cooling
 Internal Tear: open, internal rupture; can  Foaming machinhe alignment and timing, follow forming
insert fingernail housekeeping procedures, manage reject controls
 Loose glass fragment  Mold equipment alignment, forming controls
 Cracks/fractures

PAGE 50
Packaging Material: Glass
 Control forehearth temperature, control gob temp. Adjust
plunger temperture
 Forming housekeeping procedures, maitain covers over
machines/conveyors
Forming  Control glass temp., follow forming, annealing, conveying
and handling procedures
Not as common:
 Glass membrane: complete or partial  Control forehearth tem., gob temp., machine settings of
membrane of glass obstructing mouth or timing, blank cooling, final blow, invert settings nd
located just above base mechanical alignment
Forming
 Uneven Glass distribution: can lead to  Reduce glass temperature/stabilize glass temp; decrease
tramp glass gob shape; adjust gob positioning; adjust hardness of
parison
Physical/internal contamination Follow housekeeping procedures hot end to palletizing,

Full protection of stacked containers during shipment;
Inversion on slip sheets w/full stretch film application;
Packing, distribution
Finished containers inverted in cases with interim sheet on
or any point in process
top and bottom between glass and case; Use of clean/new
or distribution
pallets; pallet inspection to cull damaged pallets.
Specific Guidance:
Practice Process location
Line Spacers Annealing and cold end
InGaAs* SWIR* Camera/3D
scanners/other optical scanning
equipment
Hot/Cold End defect inspection
Manual/visual container
inspection
Thermal Inspection Hot End
Visual monitoring of plunger
Hot End
temp
Manual End of Lehr inspection Annealing *InGaAs: Indium gallium arsenide
Cross breaking resistance Cold End
*SWIR cameras can image through glass, allowing operators to
Bore gauge Cold End inspect both the interior and exterior walls of the bottle, as well
dielectric inspection Cold End as monitor the temperature uniformity and cooling rate of the
Automated finish inspection: material.
Cold End
chipped finish, crizzled finish
Non-contact & covered conveyors Cold End to palletizing
Container inversion Before palletizing

PAGE 51
Packaging Material: Flexible Packaging Film, Laminates, Bags
Flexible Packaging Film, Laminates, Bags, etc.
Raw material
receiving (film, Finishing Packing &
Main Foreign Body risks: solvent , ink,
adhesives & resin)
(Slitting / /Bagging) palletization
Dust, particles, hair, insect, plastic/ film residues, sticker,

undeclared splice joints.
Lamination
Transportation Storage &delivery
(Extrusion / Dry)
Storage Printing
Production process
Raw material  Foreign material introduced to the material  Define raw material specification and seek declaration
receiving (such as during the supplier's manufacturing process from suppliers (COC, COA).
film, solvent, ink, such as insect, dust, unannounced tape,  Supplier audit program with supplier evaluation
adhesives, resin, hardened foreign material. (ex.GFSI)
paper core and etc)   Ensure IPM program is robustly managed and all
 Use of damaged plastic pallets points of entry are sealed. Install air curtains and auto
doors
 Wooden pieces and dust from the tear film  Plastic pallets should be regularly checked. Damaged
or not well wrapped. ones should be eliminated.
 Protect material during in-plant transportation by
covers and stretch film.
 Walls in areas of heavy traffic are protected by
stainless coverings
 Dirt, dust particles : packaging damage  Strong implementation of the GMP and pest
during transportation management
 Mouldy pallet  Inspection the container at reception at per defined
Transportation  Foreign materials introduced due to checks
unhygienic conditions of transport used  Supplier to follow 'Transport hygiene policy'
 Vehicle inspection check before goods unloaded
 Foreign objects from the environment such

as dust, dirt, insect and etc.  Dedicated storage area for different type of materials
 Bird nesting (droppings, feathers, etc.)  Warehouse cleaning program
Storage  Enclosed warehouse with netting installed.
 Pest control program including monthly inspection

PAGE
52
 Dirt, Dust,  Pallet inspection program
 Wood chips ( from pallet)  Pallet top is covered with slip sheet ( corrugated
 Glass and hard plastic board/ single facer)
 Broken blade  Glass and hard plastic management program (
 Insect identification , monitoring and systematic incident
 Hair management)
 Ink residues  Cutter Blade daily inspection and management
 Tapes.splice tape program (identification, monitoring and systematic
 Sticker incident management)
Printing
 Pest control program.
 Personal hygiene policy including jewellery policy,
hair net and etc.
 Ink supply system which include ink filtering process
at two stages- initial ink preparation and during
process

PAGE
53
 Printing and laminator machines are equipped with on
 Dirt, Dust,
line camera detection system
 Wood chips ( from pallet)
 Glass and hard plastic  On line web scanner that capable of detecting foreign
 Broken blade object such as splice tape and insects
 Insect  Each printed roll shall go through an edit process which
 Hair foreign material such as sticker/ insect can be filtered
Printing out. Rolls wrapping procedure. Every single roll process
 Ink residues
 Tapes.splice tape before and after should be wrapped
 Sticker  Poly E melted peices: resin filters and magnetic metal
hopper grates to contain foreign bodies.
 Splice joint tape from supplier's film  On line web inspection scanner to detect
 Printing and laminator machines are equipped with on
line camera detection system
 Insects  Pest management program including monthly inspection
 Insect proofing facilities such as 'double door', curtain
strip, netting and etc.
 Personal hygiene program including jewellery policy,
hairnet policy and etc.
 Hair  On line web inspection scanner is capable to detect and
tag any of the FB detected. NCR issued ( with defect
image
provided) and follow by NCR close out at finishing process
 Rolls wrapping procedure. Every single roll process before
 Dust, dirt
and after should be wrapped
 Pallet management program
 Wood chips ( from pallet)  Pallet top should cover with slip sheet ( corrugated
board/ single facer)
 Glass and hard plastic management program (
 Glass and hard plastic identification , monitoring and systematic incident
management)
 Blade management program (identification, monitoring

 Broken blade and systematic incident management)
 Foreign body ( such as wax, dust and  Resin hopper with filter to filter out any dust or foreign
etc.) from resin used particles in the resin
 Adhesive supply c/w adhesive filtering process
 Hardened adhesive residues
 Weekly cleaning program
Lamination  Film residues stick on splicing knife (  Preventive maintenance program
(Extrusion/ Adhesive) Unwinder/Rewinder)  Weekly machine cleaning
 Periodical die cleaning program
 PE lump, carbon deposit  On line web inspection scanner is capable to detect and
tag each of the FB detected. NCR issued ( with defect
image
provided) and follow by NCR close out at finishing process
 Web width to include suitable provision for side trim
allowance
 Every roll identified with unsmooth side trimming
 Side trim
process (side trim embedded) shall be tagged; NCR
reported and sent for another special rewinding process.
Follow by NCR
close out at finishing process
 Food grade powder
 Over dose set off powder
 Equipment periodical maintenance
 On line web inspection scanner is capable to detect and
tag each of the FB detected. NCR issued ( with defect
 “Corrugated board”, tape, sticker image provided) and follow by NCR close out at finishing
process

PAGE
54
 “ Internal corrective action request’ system triggered for
corrective action

PAGE 55

 Dirt, dust  Rolls wrapping procedure. Every single roll
process before and after should be WRAPPED
 Every roll send for finishing process must go
through a special designed 'air shower room' or
decontamination steps
 Finishing area is identified as critical hygiene
area with additional personal hygiene program
(such as dedicated shoes), quarterly air
monitoring program and etc
 Hair  Personal hygiene program such as hair net
 Operator to go thru a 'air shower' room before
entering to the finishing process
 Wood chips ( from pallet)  Pallet management program – dedicated pallet
use for finishing process area only
 Pallet top should cover with slip sheet
(corrugated board/ single facer). The slip sheet
is free from any foot prints and wear & tear
 Broken blade  Blade management program (identification,
monitoring and systematic incident
Finishing ( Slitting, management)
Rework & Bagging  In line sensors to detect tape splices
processes )
 Glass and hard plastics  Glass and hard plastic management program (
identification , monitoring and systematic incident
management)
 Insects
 Pest management program including monthly
inspection
 Insect proofing facilities (such as air shower
room, auto shuttle door and etc.)
 Side trim ( for slitting process)
 Proper side trim design and travelling path
 Web width to include suitable provision for
side trim allowance
 Bags' side trim
 Static removal device
 Cleaning program
 Foreign material due to warehouse  Rolls wrapping procedure. Every single roll
environment such as bird dropping, insects, process before and after should be wrapped
dusts and etc.  Enclosed warehouse with pest proofing
infrastructure such as netting, curtain strip,
double door,
 Pest control management program.
Packing& palletisation  Personal hygiene procedure
 Packing materials or tools drop on the  All packing materials/ tools are kept on a specify
products / pallet packed such as tapes, glue containers
bottle, label and etc.
 Glass and hard plastic management program (
 Glass and hard plastic identification , monitoring and systematic
incident management)
 Rolls wrapping procedure. Every single roll

 Dirt/ dust particles.
process before and after should be wrapped
 IPM and rigorous master cleaning program
Storage & Delivery
 Transportation specific hygiene policy.
 Possibility of unhygienic  Vehicles inspection
transport / container used conditions of  For export containers- third party surveyor
program

PAGE
56
Packaging Material: Paper
Paper Production process:
Paper, Cup, Solid Board, Micro Flute Board
Paper for packaging for confectionery or ice cream
with direct food contact!
Main Foreign Body Risks:
Pieces of paper (fiber), hair, wood, metal (Aluminum foil)

 Metal from grinding & transport  Inspection at reception.
Ingredients:  Colorants & additives are manually dosed:  Incoming control should include control of FB and
metal, wood, foreign paper evaluate in Hazard analysis.
 Parts of packing film  Note: Most foreign bodies introduced at this point will
Metal, wood, foreign
paper, film be welded into the parts
 Remove external packing in basic hygiene areas
Keeping & internal  Foreign paper  Mold preventive maintenance and clean-up
transportation:  Metal from transport frequencies (flakes and angel hairs)
 Insects, hair  GWP and GMP in place
Paper, wood  Wood from broken pallets  Pest control management on high level
 Hair and dust attracted by static electricity  Full coverage of unwinding/cutting process (top and
Unwinding/Cutting:
 Hard plastic from broken equipment sides, no gaps)
 Remains of paper after cutting operation  GMP of unwinding/cutting
Hair  Parts of knife  Using only knife with integral blade
 Broken or deformed hard parts of equipment  Right maintenance
Printing:
 Metal parts of equipment  GMP at dosing point
 Foreign objects from the environment  Ensure operator hygiene and GMP rules
Hard plastics, hair  Handling dosing of colorant & additives  Dosing station SOP and set up
 Shaving of metal against metal moving parts
 Part to sharp metal contacts  Preventive maintenance and daily routine inspection
 Excessive conveyor pressure  Operator intervention protocol
 Part break due to hit or mis-assembly  Center lining of moving parts, esp. star wheels
 Dust and other foreign object from the  Full coverage of the carving process
Stamping: environment and compressed air.  In case of risks for hard plastic due to breaking parts,
 Part of foil after stamping apply a glass and hard plastic break procedure (see
Metal, plastic  Plastic covered due to improper design prevention and control of glass breakage)
Remains of paper after carving operation  Right filters on compressors
 Visual inspection of after foil stamping
Moulding/Gluing &  Plastics, paper & tape from transport/storage  Ensure operator hygiene and GMP rules
packing: boxes  Box handling practices
(where applicable)  Dust and other foreign object from the  Tape usage
Hair, paper, fiber operator pockets or the environment  Using of OPL standards for packing of FG
confetti
 Sharp parts damaging the liner  Pallet integrity simulation tests
 Broken or deformed hard parts due to case  Transport test involving full truck load
handling, sticker application or shrink  Careful operation when in manufacturer control
Palletizing: wrapping  “Fragile” stickers, if applicable
 Transport conditions (temperature, humidity  Use only special knife with solid blade
Hair, paper, wood or shocks)  Liner integrity, liner color ≠ part color
 Parts of blade  Tape usage
 Cardboard headspace and thickness

PAGE 57
Packaging Material: Paper

HACCP study  No assessment of foreign bodies risk  Identification of all sources of foreign bodies at each
step of the process (metal-to-metal contact, fibers /
Pieces of paper, hair, strings, rubber, pest, glass...)
wood, metal (Al foil)  Implementation of pre-requisite programs and control
measures to mitigate the risk

PAGE
58
Packaging Material: Plastic
Plastic Products: Caps, PET Preforms and Containers / Bottles

Production Process Injection or Compression molded PE, PP Caps & Injected PET Preforms
& Bottle / Container Blowing
Main Foreign Body Risks Hard Plastics, Metal Pieces, Dirt / Dust Particles, Angel Hair
Production process (General Flow Diagram):

PE, PP or Reception Resin Silo / Resin / Ingredient Drying / Injection or Compression –
PET Resin Transportation and Storage Hopper Feeding Heating molding & mold opening
Optical Bulk Storage and Preform Preform Elevator

Conveying Sorting Packing Palletization Transportation tipping hopper belt Unscrambler
In-feed Optical Container Bulk Storage and

rail Sorting Transfer Conveying Packing Palletization Transportation
* Note: The actual flow may have less or additional steps so please adapt to the actual conditions. And keep
focus on the requirements mentioned in the pre-requisites.
General Guidance
Pre-requisites  All items coming into contact with resins, preforms, caps or containers / bottles should be easily
Processing Equipment accessible for inspection and cleaning. Protections and carters shall be rigid and transparent
& Parts Design wherever possible, easily removable by hand (with appropriate safety guarding) and hinged from
one side.
 All items coming into contact with resins, preforms, caps or containers / bottles should not have
sharp edges, nuts, bolts (or similar) on their surfaces which can create hindress along material
movement. In case of resin momenvement, it can generate foreign bodies; in case of caps,
preforms and bottles, it will generate foreign bodies, sharp edges and cause altration of the final
finish.
 Parts in movement having direct contact with the resins, preforms, caps or containers / bottles, or
that could have indirectly contact with the product should not be greased. Hygienic mechanical
sealing solutions should be provided.
 Greasing of parts in movement having direct contact with the resins, preforms, caps or containers
/ bottles, or that could have indirectly contact with the resins, preforms, caps or containers /
bottles is protected by double sealing and visible leakage chamber.
 On equipment, drip trays under lubricated parts must prevent from any leakage on the packaging
and on the floor. In fact, the machine is protected at any place where grease or lubricants could
migrate towards resins, preforms, caps or containers / bottles
 Manual cleaning of any parts of the equipment in contact with the resins, preforms, caps or
containers / bottles is possible
 Good welding practices must avoid any leakages, any retention areas and cracks that are difficult
to clean, and any corrosion of welding joints, which could create cracks and generate foreign
bodies.

PAGE 59

PE, PP or PET Resin  Metal, Foreign Plastics for the  Define your raw material specifications and agree with
Metal, Foreign manufacturing process, packing and your suppliers
Plastics storage at manufacturer.
Transportation  Dirt / Dust Particles; Packaging damage  Define and agree transportation conditions
Dirt / Dust Particles during transportation
Reception and Storage  Plastic pellets: metal from grinding &  Inspect the container at reception as per pre-defined
Metal, Wood, Foreign transport checks
plastics, Dirt / Dust  Colorants & additives are manually dosed:  Inspect the packages in the received lot as per pre-defined
particles metal, wood, foreign hard plastics checks
 Dirt / Dust Particles; Packaging damage

during transportation
Resin Silo / Hopper  Nuts / bolts from top cover or associated  Tipping design must ensure that no wood particles or dirt
Metal, Wood, Foreign assembly from the pallet can be transferred into the hopper with
plastics, Dirt / Dust  Plastic pieces from breakage of top cover or the resin
particles associated assembly  Properly covered and hinged
 Dirt/Dust Particles accumulated on the  Preferably do not joined with nuts and bolts on the top
outer packaging which could fall into preforms
 Regularly inspected for breakage
Resin / Ingredient  Colorants & additives are manually dosed:  Controlled operation
Feeding metal, wood, foreign hard plastics
Foreign plastics
Drying / Heating  Particles detached from ducts/pipes, etc.  All ducts, pipes for PET resin and regeneration air have to
Foreign plastics,  The circulating air carrying dust particles. be food contact grade
Dust Particles  The circulating air is properly filtered
Injection or  Hard plastics from start-up operation and  Inclined plane or speed slow down device to prevent part
Compression – from fall on conveyors break and loose hard plastic
molding & mold  Angel hairs from cooling/de-molding  Mold preventive maintenance and clean-up frequencies
opening process (flakes and angel hairs)
Plastic Particles  Plastic flakes from mold mis-adjustment  Line start-up inspection and release (hard plastics)
 Soft plastics from guiding curtains and  GMP guide curtains (soft plastics)
conveyors  Mold coverage and roof repair
 Metal and paint flakes if the machine is not
covered
Conveying  Hair and dust attracted by static electricity  The conveyor must comply with food contact grade
Plastic Particles,  Hard plastic from broken conveyors material and is covered.
Hair, Dust  Top cover made of rigid transparent plastic, all along the
conveyors path
Optical Sorting  Broken or deformed hard parts  The optical sorter is equipped with camera(s) and reject
Plastic Particles,  Parts of conveyors: plastics system to remove any defective part
Hair, Dust  Foreign objects from the environment  The pieces are best controlled if they have the same
orientation and spacing at the entrance into the
equipment
 The sorter is calibrated, validated and monitored
Bulk Packing  Broken or deformed hard parts  Liner integrity, liner color ≠ part color
Plastic Particles, Foil  Plastic from the conveyor belt  Tape usage
 Plastic foil from the packaging liner  Cardboard headspace
 Cardboard thickness
 Box handling practices
Palletization  Sharp parts damaging the liner
Plastic Particles  Broken or deformed hard parts due to case  Pallet integrity simulation tests
handling, sticker application or shrink  Transport test involving full truck load
wrapping  Careful operation when in manufacturer control
 Transport conditions (temperature,  “Fragile” stickers, if applicable
humidity or shocks)

PAGE
60
Storage and  Dirt / Dust Particles;  Define and agree storage and transportation conditions
Transportation  During storage in warehouse
Metal, Wood, Foreign  Packaging damage during transportation
plastics, Dirt / Dust
particles
Preform tipping  Nuts / bolts from feeding / tipping  Tipping design must ensure that no wood particles or
Metal, Wood, Foreign equipment dirt from the pallet can be transferred into the hopper
plastics, Dirt / Dust  Plastic or metal pieces from breakage of with the preforms
particles feeding / tipping equipment
 Dirt/Dust Particles accumulated on the
outer packaging
Preform hopper  Nuts / bolts from top cover or associated  Properly covered and hinged
Metal, Foreign assembly  Preferably do not joined with nuts and bolts on the top
plastics  Plastic pieces from breakage of top cover or which could fall into preforms
associated assembly  Regularly inspected for breakage
Elevator belt  Nuts / bolts from elevator belt  The preform path is smooth and free of obstructions
Metal, Foreign  Metal shaving, plastic pieces from conveyer such as bolt heads, nuts or rivets that are likely to
plastics belt damage the preform, or that could accidentally fall into
 Foreign objects from the environment a perform and generate foreign bodies in the product.
 Elevators and belts are designed in a way that wearing
parts are not generating particles to avoid foreign body
contamination.
 The elevator belt is covered.
Unscrambler  Foreign objects from the environment  Design in such a way as to prevent preforms from
Dust Particles remaining inside the equipment without being sorted.
 During normal operation unscrambler is covered
In-feed rail  Nuts / bolts from in-feed rail  Screws and bolts maintaining the sensor is positioned in
Metal, Foreign  Foreign objects from the environment a way that they cannot accidentally fall inside the
plastics, Dust preforms.
Particles  Infeed rail top covered. Side access is guaranteed.
Optical Sorting  Broken or deformed hard parts  The optical sorter is equipped with camera(s) and reject
Metal, Foreign  Parts of conveyors: plastics system to remove any defective part
plastics, Dust  Foreign objects from the environment  The pieces are best controlled if they have the same
Particles orientation and spacing at the entrance into the
equipment
 The sorter is calibrated, validated and monitored
Container / Bottle  Hair and dust attracted by static electricity  The bottle transfer shall not affect the integrity or the
Transfer  Hard plastic from broken conveyors quality of the package: it shall not scuff, scratch, crease
Plastic pieces  Foreign objects from the environment or otherwise damage bottles during normal operation
Foreign plastics,  Top cover made of rigid transparent plastic, all along the
Hair, Dust Particles conveyors path
Conveying Dust  Dust Particles  Neck Conveyers:
Particles  The neck conveyers are regularly cleaned and inspected
- both from inside and outside
 Air (meant for transferring) is properly filtered
 Filters are regularly inspected and maintained
 Bottle / container neck guide is realized in plastic
material and run without any lubrication

PAGE 61

Bulk Packing  Broken or deformed hard parts  Liner integrity, liner color ≠ part color
Plastic Particles, Foil  Plastic from the conveyor belt  Tape usage
 Plastic foil from the packaging liner  Cardboard headspace
 Cardboard thickness
 Box handling practices
Palletization  Sharp parts damaging the liner
Plastic Particles  Broken or deformed hard parts due to case  Pallet integrity simulation tests
handling, sticker application or shrink  Transport test involving full truck load
wrapping  Careful operation when in manufacturer control
 Transport conditions (temperature,  “Fragile” stickers, if applicable
humidity or shocks)
Storage and  Dirt / Dust Particles;  Define and agree storage and transportation conditions
Transportation  During storage in warehouse
Metal, Wood, Foreign  Packaging damage during transportation
plastics, Dirt / Dust
particles

PAGE 62
Prevention of Hair Contamination
Main Origins: Known Origin of Hair contamination:
Animals
Origin Field Slaughtering Cleaning /washing Transforming Packaging Environment
Human Meat & poultry X X X X
Packaging
Ingredients X X X
Employees X X X X X
Packaging X X

 Incoming animals: hair and feather remains
 Have a clear & agreed specification addressing
 Other ingredients with hair on pack, inside
absence of hair and feather
Animal fur and  Lack of standard / specification
 Have it trained internally and externally
feather  Specification not mutually agreed
 Have this as visual reminders for operators
 Lack of internal & external awareness for the
 All ingredient processing lines have a hair removal
specification
step (see below)
 Absence of hair prevention policy  Traffic takes place away from open products
 Non respect of the hair policy (zone, frequency)  Zoning and uniform policies are clear and
 Hair nets not covering all hairs, incl. beard, communicated broadly
sideburns  The uniform includes long sleeves and pants with
 Improper hair net quality tight ends
Human hair  Conflicting interpretation of the hair policy  Mirrors are available to verify the uniform
 People traffic close to open products  In open product areas, the hair net covers head, neck,
 Forklifts traffic close to open products shoulders and sideburns
 Hair nets should be worn prior to the uniform
 The tissue density of the hair net should be ≥ 20
gram per square meter (med. surgery grade)
 Lack of prevention program against fiber  Work with the supplier of the packaging material
generation  Define the optimal packaging specifications
 Opening of ingredient packaging  Define the optimal sealing conditions
 Sealing of packaging materials  Define the optimal machine settings
Hair-like fiber
 Sealing control is not a release parameter  Define the best manner to open bags without fiber
from plastics
generation
 Train your clients on how to safely open ingredient
bags
 The open parts of the line past the dust aspirators

and last sifting steps
Handling dry  Hair, wood or dust visible on the floor Zoning:
ingredients  Outer surface of the bags  Define the areas with open products as high risk
 Lack of specific area to strip the bags  Restrict traffic to the minimum in those areas and
make visible on floors / walls
Handling wet  Collect hair on the floor & plastic surfaces
ingredients  The open part of the line past the last washing  Communicate / Train employees
and rinsing steps  Revise cleaning frequencies based on findings
 Packaging or pipes with electrostatic surfaces  Review wall & door tightness
 Hair, wood or dust visible on the floor
 Lack of specific area to strip the pallets

PAGE 63
Prevention of Hair Contamination
Manufacturing Practice Basics Best Practice (on top of basics)
People  In medium and high care areas:
 Hair net covers all hair with no exposed
 Caps completely cover hair and ear-lobes hair on head, neck, shoulders and
with no exposed parts, single use sideburns
 Beard masks completely cover beard and  The tissue density of the hair net is ≥ 20
moustache gram per square meter (med. surgery
 Long sleeve uniform in locations where grade)
products or materials are exposed  Detailed descriptions in place
 Shirts always underneath pants establishing sequence of wearing
 Mirror at each hairnet delivery station uniforms, correct use during production
 Hairs sticking out of hairnet with low and intervals
tissue density:  Lint sticky rollers at all entries with
visual training
Methods  Prevention training included in the site  Training includes all facility staff.
induction plan and yearly repetition  Visual reminders on the shop floor
 Training includes at least production, connected with the training given
quality, maintenance, engineering staff, (picture)
and contractors.  Training methods actively adapted based
 Behavior monitoring organized on the on findings on the floor and claims from
shop floor, including correct use of caps clients
and uniforms as part of the routine GMP  Training effectiveness verified on the
hygiene verifications floor by testing for the presence of hairs
on uniforms and surfaces
 Compressed air is not in use in areas with  Air pressure control, tight doors &
The Environment open products windows, filtration of recirculated air.
 Ventilation is not directed towards open Air showers.
products  Collect and record dust & hair on floor
 Open food and primary packaging are and surfaces
covered  Optimum frequency for environmental
 Restricted traffic in open product areas cleaning
 Trend analysis communicated to all
employees
 Check if air circulation is not a source for
hair contamination (are there filters?)
Materials  In basic areas:
 Vacuum or antistatic systems for bags,
 External liner always covering bags and big
big bags and their protection
bags
 Procedure to inspect bags and big bags
 Flexible package and auxiliary material
for dust, fiber and hair before use
always protected in the warehouse
Management of Complaints  Each client information and claim triggers  Client information and claim shown to
a specific root cause analysis, followed by all employees and reviewed by
corrective actions management
 A specific reply to the client is made  Yearly objectives set for client
within 2 weeks information and claims
 All programs for managing of foreign  Yearly objectives set for internal findings
bodies are incorporated into the  Yearly technical improvement visits
management system of the factory organized with selected clients
 Outcome of activities and trends are
PAGE
64
input to management reviews

PAGE
65
Hair Risk Zones

PAGE
66
Equipment Technology for Prevention and Detection
Type of Foreign Bodies: Stones, Plastic, Rubber, Wood, Glass, Metal, Bone
Topic X-Ray Optical Sorting

Metal Detection
Varies by light source and sensor
technology options (can be combined for
specific applications):
 Laser
 Pulsed LED
 Hyper & Multispectral imagining
 Interactance spectroscopy
 Shortwave Infrared
Contaminants are high-  Camera
Contaminants are density or have a a high
magnetizeable or atomic mass number Characteristics that can be profiled:
electrically conductive relative to the product  Color
Principle of Detection
 Blemishes
 Bio-Luminescence
 Structure
 Water / Oil Concenration
 Toxins
Shape / Size / Geometry
Coil lifespan 10+ years. Unit X-ray tube for high voltage Minimum of 10+ years
is replace when coil fails. 4-6 years
X-ray tube for low voltage
8-10 years
Average Lifespan Tube are replaced without
whole unit replacement
Inline Application Inline Application Bulk Inspection Application
Approx 1 meter/3.28 feet Approx 1.7 meter/5.57 feet Approx 1.8 meter to 4.2 meters
Line foot print (not
including rejection device) or less or less
1.8 meters to 6 meters - including infeed
conyenance
Bulk flow, gravity fed, Vertical beam, bulk flow Free-fall (chute)
descrete package machine, pipeline,
inspection, pipeline horizontal beam (side On-Belt
Unit Types
shooter)
Off-Belt
Detection of all metal Detection of dense Broad range detection – Food Safety and
contaminants, including contaminants like ferrous, Quality attribute detection (Grading and
ferrous, non-ferrous non ferrous and stainless extraneous matter)
FB Type Detection and
(including aluminum) and steel, as well as other
Approximate size
magnetic and non magnetic contaminants like glass, Free flowing or attached defects
stainless steels stone, bone, high density
plastics, and some rubbers. Excluding embedded/concealed defects

PAGE
67
Equipment Technology for Prevention and Detection
Type of Foreign Bodies: Stones, Plastic, Rubber, Wood, Glass, Metal, Bone
Topic X-Ray Optical Sorting

Metal Detection
0.05% for a stable metal 0.05% when correctly adjusted. User controlled and balanced
detector should be able to Might take periodic adjustments based on capabilities of the
consistently function without if product composition changes technology and varying quality
false reejcts, and minimal slightly. of inputs and the targeted end
periodic adjustments. specification.
FRR Rate
Location of implementation in
supply chain (harvest, mid-
process, finished material)
Speed-400m/min Speed-120m/min Speed-180m/min (.5-2m
inspection width)
Throughput
300-36,000 lb/hr (dehydrated –
IQF application)
Packaged, conveyed products, Packaged, conveyed products, Bulk - wet, dry, frozen, roasted,
loose, bulk products, free- loose, bulk products, pumped raw, fresh, blanched, shelled
falling and vertifcally- liquids, pastes and slurries, and un-shelled
packages products (including continous web products
Product Format powder and granular
products), pumped liquids,
pastes and slurries, continous
web products
Type of metal, shape and Contaminant density, diode size, Presentation of the material in
orientation of metal, aperture product density and depth, a mono-layer: Ensuring defect
size/metal position in chemical compostion (atomic is visible or exposed to sensors
aperture, environmental mass number) product texture or
conditions (electrical uniformity (ie air bubble in Cleanliness of equipment
interferences near unit, plant pipeline), contaminat position,
Factors influencing vibration, and temperature environmental vibration,
reliable detection fluctuations), inspection cleanliness of equipment
speeds product characteristic
and operating frequency,
product uniformity (ie air
bubles in pipeline)
Air, push arm, drop, divert, Air, push arm, drop, divert Small pitch air rejection valves
reverse, end flap, belt/process
Types of rejection stop Intelligent finger (paddle)
rejection
Increased rejection quantity Increased rejection quanity for The nature of the defects
for bulk flow products, pipeline x-ray rejected and the type of
including pipeline metal process control will determine
detectors Should not be re-run through the ability to or suitability for
and reintroduced into prime re-inspection of rejected
Should not be re-run through product due to position of materials or re-purposing of
and reintroduced into prime contaminants over diodes. rejected materials into
Handling of rejected alternate product streams.
materials product due to oritentation
effect
Should not be re-run through
and reintroduced into prime
product due position of
contaminants over diodes.

PAGE
68
Examples of Foreign Material detected from Metal Detection, X-ray, or Optical Sorter:
X-ray: Stones from cereal / grains X-ray: Stones from cereal / grains
X-Ray: Stones from cereal / grains X-ray: Bones from Poultry
X-Ray: Beef Bones and Metal Fragments Metal Detector: Metal Fragments
X-ray: Grease / Carbon Char X-ray: Rubber
PAGE
69
X-ray: Glass / Ceramic X-ray: Glass / Ceramic
Optical Sorter : Blue Rubber Optical Sorter: Wood
Optical Sorter : Rubber Gasket Optical Sorter : Plastic

PAGE 70
Additional Foreign Bodies detected from Optical Sorting

PAGE 71
Examples of Foreign Body Detection / Rejection Devices:
Descrete Package Metal Detector Gravity Fed Bulk Metal Detector
Bulk Metal Detector Horizontal Beam X-Ray
Dual Beam Horizontal X-Ray Bulk Flow X-Ray
©2019, Nestec Ltd., Vevey (Switzerland) May 1,

PAGE 72
Descrete Package X-Ray Bulk Optical Sorting – Chute
Bulk Optical Sorting – Belt
Bulk Optical Sorting – Grading

PAGE 73
Contaminant detection-X-ray
Contaminant Detection-Metal Detection

PAGE 74
Wooden Pallets:
The use of wooden pallets in the supply chain is necessary to transport food products in a safe
way. Unfortunately, wooden pallets are often a source of contamination – microbiolgical and
foreign bodies. Therefore, it is necessary to use clean plastic pallets where exposed food
product is found especially in hygiene-sensitive applications. For these areas, clean, well
maintained plastic pallets are used because of their non-porous, non-odour absorption, and
cleanable surface.
Where wooden pallets are permitted, they should be inspected for integrity and kept a suitable
distance away from any entry / sample points.
All wooden pallets (rented or purchased) and the material they are made from should have the
following characteristics:
 A known food-grade material and a traceable supply chain
 Be clean, dry and in good repair
 Are free of mold, dirt, dust, rodent droppings, insects
 Are not broken or cracked (boards or bearers) which could weaken the
structure or create a dangerous condition
 Have a maximum moisture content of no more than 28%. For ocean freight, pallets
must have a maximum moisture content of no more than 22%.
 Have no protruding screws, nails, splinters or odors from wood treatment
 Are removed from inventory and not used when damaged or contaminated
 Are protected during storage from contamination (including pests)
 Are not placed or stored outside
Examples of pallets that must not be used:
Examples of pallets in good condition:

PAGE 75
Annex I:
Glossary of terms:
COA: Certificate of Analysis
COC: Certificate of Compliance
FIBC: Flexible Intermediate Bulk Container
FB: Foreign Body (same as FOB – Foreign Object)
FOB: Foreign Object
FIFO: First In/First Out
GMP: Good Manufacturing Practice
GWP: Good Working Practice
HACCP: Hazard Analysis Critical Control Point
IPM: Integrated Pest Management
NCR: Non-conformance Report
OPL: One Point Lesson
PPE: Personal Protective Equipment (example: safety glasses)
QRC: Quick Reference Card
RCA: Root Cause Analysis
SOP: Standard Operating Procedure/Practice
SPC: Standard Plate Count

PAGE
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Foreign Body Prevention & Detection

BEST PRACTICES FOR

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

The Nestlé Foreign Body Guiding Team, 2019

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

A foreign body is any kind of material such as metal, glass,

Foreign body prevention and detection is a critical element at Nestlé and it

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Equipment Technology for Prevention and Detection...................................63

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

First Line of Defense:

Second Line of Defense:

- Practices during manufacture up to packaging.

- Measures for prevention, detection and removal during processing.

Third Line of Defense:

- Environment in processing areas and maintenance shops.

- Downstream steps such as warehousing and distribution.

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Area of Vulnerability Potential Issues Mitigation actions

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Carbon residues due to ineffective cleaning of

Indigenous foreign body Example of fat accumulation:

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Area of Potential Issues Mitigation actions

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Specific guidance: Rice

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Cocoa Powder Processing Product Information:

 Metal or plastic from plant failure due to

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Cocoa Beans and Powder

Sorting stairs used to grade the beans

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Examples of foreign bodies found during the Cocoa making process

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Dairy powder processing Product Information:

Area of vulnerability Potential issues Mitigation actions

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Main Foreign Body Risks Crop calendar (harvest/production)

Area of Vulnerability Potential Issues Mitigation actions

 Allergen plants present  Inspect field at early stage of growth

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

 Crop/container contact with ground  Clean on-farm storage facilities

 General hygiene of storage facilities  Clean storage area

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Area of Vulnerability Potential Issues Mitigation actions

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Area of Vulnerability Potential Issues Mitigation Actions

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Examples of Foreign Bodies in Meat

Flexible Plastic Wood

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Area of vulnerability Potential issues Mitigation actions

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Examples of Foreign Bodies in Nuts at Nestlé Factory:

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Area of Vulnerability Potential Issues Mitigation actions

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

©2019, Nestec Ltd., Vevey (Switzerland) May 1, 2019

Main Foreign Body risk: Metal, hair, pest, plastic