Gap Audit – Nyagatare Maize Processing Factory

ISO/TS 22002:2009 Pre-requisite Programmes on Food Safety Part 1: Manufacturing

Gap Audit Checklist

Food safety management systems — Requirements for any organization in the food chain

No. Requirements Observations In Compliance

Clause 4: Construction and layout of buildings

4.1 General requirements Yes
1 establishment designed, constructed No
and maintained
in a manner that:
- facilitates processing operations
- Controls food safety hazards
- Prevent contamination from
surrounding
4.2: Environment Yes
2 How has your facility evaluated No
the environment for potential
sources of contaminants?
Do you have a method for
checking the effectiveness of
prevention measures that you
take to address these potential
sources?
4.3 Location Yes
Check the site boundary, is it No
3 clearly identified?
How is access to your site
controlled?
Is the site maintained? Check
for:
Standing water
Excess vegetation
Leaks in roof or building
Building construction
Clause 5: Layout of premises and work space
5.1: General requirements Yes
1 Internal layouts shall be designed, No
constructed and maintained to
facilitate good hygiene and
manufacturing
 Gap Audit – Nyagatare Maize Processing Factory

ISO/TS 22002:2009 Pre-requisite Programmes on Food Safety Part 1: Manufacturing

Gap Audit Checklist

practices
5.2 Internal design, layout Yes
2 & traffic patterns No
Does the facility have:
Adequate space
Logical flow
Separation of raw and processed
areas?
5.3 Internal structures and Yes
3 fittings No
Are walls and floors washable?
Are the materials resistant to
the cleaning materials used?
Are the junctions between
walls and floors easily
cleaned? (rounded in process
areas)
Are the floors sealed and
drained in wet process areas?
Are the drains trapped and
sealed?
Does design of overhead
fixtures minimize build up of
dirt and condensation?
Are external windows, roof
vents and fans insect
screened?
Are external doors closed
when not in use?
5.4 Location of equipment Yes
4 Has equipment been located in No
a way that facilitates hygiene
practices and monitoring?
Is there good access for:
Operation
Cleaning
Maintenance
5.5 Laboratory facilities Yes
5 How is risk of product No
Contamination controlled at inline and
 Gap Audit – Nyagatare Maize Processing Factory

ISO/TS 22002:2009 Pre-requisite Programmes on Food Safety Part 1: Manufacturing

Gap Audit Checklist

online test facilities?
Are microbiology labs located
away from production areas?
(Without opening directly to
production areas)
Does the location and
operation of the microbiology
lab minimize the risk of
contamination of people, the
plant and products?
5.6 Temporary or mobile premises Yes
6 and vending machines No
Do you have any temporary
structures such as:
Mobile premises
Vending machines
If so, how are they designed to
prevent pest harborage or
contamination of products?
Has your organization
assessed the hazards that the
structures might create?
5.7 Storage Yes
7 Evaluate the storage facilities No
for food, ingredients and non
food chemicals.
Do the facilities provide
protection from:
Dust
Condensation
Drains
Waste
Other contamination
Are the storage areas:
Dry
Well maintained
Well ventilated
Is temperature and humidity
monitoring required, if so, has
it been carried out and
 Gap Audit – Nyagatare Maize Processing Factory

ISO/TS 22002:2009 Pre-requisite Programmes on Food Safety Part 1: Manufacturing

Gap Audit Checklist

documented?
Are all materials off the floor?
Is the space from the floor and
walls sufficient for inspection
and pest control?
Are any exceptions for bulk or
crop materials documented?
Does the design of the area
allow for:
Maintenance
Cleaning
Does the design prevent
contamination and minimize
deterioration?
Is there a separate storage
area for cleaning materials and
chemicals? Is it:
Locked or access
controlled?
Clause 6:

1 Does the organization have product Yes

name or similar identifications? No
2 Is the composition of the product clearly Yes
documented? No
3 Are biological, chemical, and physical Yes
characteristics relevant for food safety No
well defined?
4 Is the intended shelf life and storage Yes
conditions of the product documented? No
5 Is the packaging methodology Yes
described? No
6 Does the organization describe Yes
labelling relating to food safety and/or No
instructions for handling, preparation,
intended use, distribution, and delivery
of the product?
Clause 8.5.1.4: Intended use
 Gap Audit – Nyagatare Maize Processing Factory

ISO/TS 22002:2009 Pre-requisite Programmes on Food Safety Part 1: Manufacturing

Gap Audit Checklist

The intended use, including reasonably expected handling of the end product and any unintended use but reasonably
expected mishandling and misuse of the end product, shall be considered and shall be maintained as documented
information to the extent needed to conduct the hazard analysis
1 Did the organization defined the Yes
intended use for every product? No
Clause 8.5.1.5: Flow diagrams and descriptions of processes

Clause 8.5.1.5.1: Preparation of the flow diagrams

Flow diagrams shall be clear, accurate and sufficiently detailed to the extent needed to conduct the hazard analysis.

Are documented flow diagrams in Yes

1 place? No
2 Is the sequence and interaction of the Yes
steps in the operation clearly indicated? No
3 Are outsourced processes indicated? Yes
No
4 Is the entrance of raw materials, Yes
ingredients, processing aids, packaging No
materials, utilities and intermediate
products clearly indicated?
5 Where reworking and recycling take Yes
place? No
6 Where end products, intermediate Yes
products, by-products and waste are No
released or removed?
Clause 8.5.1.5.2 On-site confirmation of flow diagrams
The food safety team shall confirm on-site the accuracy of the flow diagrams, update the flow diagrams where
appropriate and retain as documented information.
1 Was the flow diagram confirmed? Yes
No
Clause 8.5.1.5.3: Description of processes and process environment
a) Was the layout of premises, including Yes
food and non-food handling areas No
described?
b) Were processing equipment and Yes
contact materials, processing aids and No
 Gap Audit – Nyagatare Maize Processing Factory

ISO/TS 22002:2009 Pre-requisite Programmes on Food Safety Part 1: Manufacturing

Gap Audit Checklist

flow of materials described?
c) Were existing PRPs, process Yes
parameters, control measures (if any) No
and/or the strictness with which they
are applied, or procedures that can
influence food safety;
d) Were external requirements (e.g., from Yes
statutory and regulatory authorities or No
customers) that can impact the choice
and the strictness of the control
measures described?
e) Does the HACCP team verify the flow Yes
diagrams annually and whenever there No
are any significant changes to the
product or process?
Principle-1: Hazard analysis
a) Has hazard analysis been conducted Yes
and documented at each step of the No
process?
b) Has a hazard analysis been conducted Yes
for each raw material input? No
c) Have all potential food safety hazards Yes
been identified and assessed to No
determine what needs to be prevented,
eliminated, or reduced to acceptable
levels?
d) Have all potential allergenic hazards Yes
been considered, identified, and No
documented?
e) For any hazard deemed significant, has Yes
at least one control measure been No
determined to prevent it from occurring
or reduce it to an acceptable level?
Principle-2: Determining Critical Control Points (CCP)
a) If the hazard analysis indicates any Yes
significant hazards not minimized or No
eliminated by Good Manufacturing
Practices (GMPs) that are present
within the food manufacturing process,
 Gap Audit – Nyagatare Maize Processing Factory

ISO/TS 22002:2009 Pre-requisite Programmes on Food Safety Part 1: Manufacturing

Gap Audit Checklist

are they identified as Critical Control
Points (CCPs)?
Principle-3: Establish Critical Limits
a) Are Critical Limits established for each Yes
CCP? No
Principle-4: CCP Monitoring
a) Has the organization documented how Yes
each CCP is monitored to ensure it is No
within set critical limits?
b) Is the assigned person(s) to undertake Yes
the monitoring trained in correct No
methods?

c) Are records signed by the person Yes

responsible for monitoring? No
Principle-5: Corrective Actions

a) Have CCP corrective actions been Yes

developed, documented, and No
implemented that define the action(s) to
be taken when monitoring reveals that
the critical limit has not been met?
Principle-6: Verification Activities
a) Are verification procedures Yes
established? No
b) Are verification procedures effectively Yes
implemented? No
Principle-7: Record-keeping and documentation
a) Is record keeping and documentation Yes
for HACCP procedures established? No
b) Are all HACCP-related record-keeping Yes
and documentation procedures No
effectively implemented?