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Document No

MOHA SOFT DRINKS INDUSTRY S.C AWASSA MILLENNIUM PLANT

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1. Introduction An internal Food Safety inspection was conducted at this facility on July 26 and 27, 2012 as per the audit plan annexed xxx. It was started with opening meeting conducted with all division managers and HACCP Team members (see annexed the attendance of the audit). The audit findings were presented during closing meeting by Audit Team leader. 2. Obictive of the audit To verify that the established HACCP plan, PRPs, SOPs, overall facility design and food safety management, control measures and records are well communicated and effective to control possible hazards in the system. 3. Scope of the audit Applies to management commitments, objectives, procedures, plant facilities, processing products from raw materials through production lines to finished products, all HACCP systems, PRPs, SOPs and records established in the system 4. Audit Team leader and Members S.No 1 2 3 4 5 6 7 Name Tinsae Belay Getaw G/Kidan Haile Tekle Habtamu Gebre Melkamu Tomas Solomon Demissie Alemnew Gessesse Responsibility Signature Audit Program Manager Audit Team Leader auditor auditor auditor auditor auditor Remark

5. Summary of the Audit findings The audit was started with conducting an opening meeting explaining the scope and objective of the assessment, clearly introducing the methods of auditing and initiating questions from the Adiuttee provided that common ideas were shared and all of the participants were understood the objective stated in the plan. During Gap assessment different auditing techniques were used like interview, document review and observation

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MOHA SOFT DRINKS INDUSTRY S.C AWASSA MILLENNIUM PLANT

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of the system to verify the effectiveness of the established HACCP based food safety system in the plant. All findings addressing the whole plant were presented on the closing meeting to brief the Adittee about the hidden secrets behind the discovered points. The Agenda incorporated list of findings, review of the findings, conclusions and recommendation including good improvements. Gaps were compared against AIBI consolidated standards for beverage industries, PI standards and HACCP plan executed in the company. 6. Good practices Besides the identified audit findings which can be easily corrected and prevented from reoccurrence in the system, the followings are noted as Good practices in the facility The overall understanding of the management commitment is clearly identified HACCP based food safety is implemented and reaches validation steps Policies(food safety) and procedures were clearly established and identified Budgets and resources were available Team work sprit was developed, programs, documents etc were organized PRPs were established, the HACCP plan was designed and implemented, flow charts, corrective measures were established and one CCP was identified at the UV (microbiological). All procedures and programs were well prepared and documented in the QC&FS division

7. Identified gaps Documentation

o

No clear management review with respect to food safety based on HACCP scheduling & No clearly stated review number in the meeting agenda & the

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MOHA SOFT DRINKS INDUSTRY S.C AWASSA MILLENNIUM PLANT

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FOOD SAFETY AUDIT REPORT FORM

pending issues.(management teams not briefed about the HACCP based food safety plan)

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o No diffusion of documents to the respective divisions (all PRPs, SOPs & Formats etc; the use of old obsolete CIP format was observed.(other divisions do not know well about documents, clinic format used as calculation on its back) o Some products were received without the approval of Quality personnel.(eg crown cork)
o

Formats for certain control measures were not provided(eg preventive maintenance)

Food safety policy was not completely addressing all employees of the plant(broachers were not distributed)

o o

Food safety training was not given to all employees Emergency procedure was established, however no drill was conducted and the procedure was not put in to practical.

No certificate of analysis provided for chemicals used in bottle washer, lubrication etc

Locker inspection record format needs to be revised. Locker inspection frequency is wide and not efficient in addressing all lockers regularly (lockers are randomly selected in a week).Recording ethics not followed (asterisks used in log books) and off duty dates are not stated.

Controlled document format was not posted on toilet and bathroom cleaning and solid waste disposal record log books.

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MOHA SOFT DRINKS INDUSTRY S.C AWASSA MILLENNIUM PLANT

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Employee certificate were not available for fire extinguisher operational training. Fire extinguisher instrument inspection not recorded

o Regular safety materials distribution not started yet. o Employee medical diagnosis data not recorded on the provided format. Supplies/Storage o Storage practices were seen good however there were no enough storage areas that supports FIFO rule and encourage pest harborage in the sugar store.
o o

Labeling was not effectively used ( push cart not labeled) Light trap in the crown cork satellite store was found mis- positioned that may lead in effective pest monitoring.

GMP rules not followed & well understood by the sugar treatment personnel (no safety materials used )

Some concentrates were stored without label (labels were removed but in others there were copied labels labeled on these removed during shipment).

o Poor storage of concentrates(hiding label and improper stacking)

o

Uncovered sugar were noted(external cover with plastic sheet) Water treatment plant

o Cleaning issue in the bore holes cob webs were found under the motor covers o mispostioning of light trap in the gate of chemical satellite store

o Empty bags were stored together with the chemical (NaCl). Syrup room

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MOHA SOFT DRINKS INDUSTRY S.C AWASSA MILLENNIUM PLANT

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o GMP rule not followed by the piece rate workers in the sugar treatment process o condensate in the sugar dissolving ceiling (Room ventilation problem) o Elbows were not soaked during in the idle time. Bottling line& warehouse
o

Glove not worn by filler operators, Hair not covered and uniform not worn in full bottle store

Plastic curtain was noted wear off followed insect activity in the perimeter areas

o EBI caustic check not active o EBI belt (dust was observed on conveyer.)
o

Bottle washer pH meter not effectively working during the audit.(ph; 11.11) but immediately corrected at the time of the audit.

Forklift smoke fumed in full bottle store.(plan was designed to replace by electrical but no evidence)

o Full bottle store over head lights not cleaned. o Cob web found on the wall of full bottle buffer store. o Wall base/ not cleaned effectively in package washing room. o Anti-microbial soap and alcohol not present in hand washing station around package washing area.(one hand wash not functional) o Wall crack observed in full bottle store. o Maintenance of floor in full bottle store undergone during production and label not placed.(no sign for people indicating at working)

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MOHA SOFT DRINKS INDUSTRY S.C AWASSA MILLENNIUM PLANT

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o Ant observed in bottle washer in feed and in alcohol dispenser. Exterior groundings o o o o o o The outside ground inspection perimeter was covered with tall grass weeds. Bottle breakage dumping construction was not completed (near waste water treatment) The broken glasses were not managed effectively in breakage area Damaged drainage cement concrete cover were noted in front of canteen road way. Leakage from the hand washes line noted in toilet room (guard office). Food item fresh tomato around five kilogram weight was observed in the time keeper office. o Shovel/ spade & oil plastic Jeri can were found in the cleaning material cage.(ww) o A barrel containing Potassium permanganate (ppm) was opened & not

Covered, (to be protected from rain fall) o The inside washing sink steel filter was found too much rust build up, hand dryer not fixed (medical laboratory) and the wall of the clinic found dirty. o Waste towel (mop up), eye goggle, & bolt were noted inside electrical breaker box and Personal T-shirts was found on the cover of electric motor (car wash stations). o Tyre repair room was found not cleaned and live Cockroach was noted on the floor o Inspection perimeter behind the locker wall was not kept in the men locker room o All door self closing were not properly functional. (Men & women toilet)

o Labeling was not efficient in side lockers: sanitation materials and other tools were found stored in the same rack. o All hand washes for men and women toilets were not properly functional and Leakage was observed on the water line of hand wash

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MOHA SOFT DRINKS INDUSTRY S.C AWASSA MILLENNIUM PLANT

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o Containers were stored on the floor directly in front of the full bottle warehouse(a few meters from the external door) which were suitable for pest harborage and used as a store for uncontrolled products(salvages) Compressor o Ammonia leakage test do not follow standard procedure, test material is absent. o Drainage hole to the outside is not covered with mesh. o Mechanical trap was not active. Boiler o Floor cleaning was not effective: oil stain was observed. o Dust bin do not have cover. o Boiler panel board inside part was found full of dust. Carbon dioxide Plant o MSDS of chemicals used in the plant were not posted in satellite store. Electrical workshop o Mechanical trap was not active. o MSDS of date coder chemicals not posted. o Empty bottle was found in electrical Formans office. Mechanical workshop o Hair was not covered by one employee. o Floor crack was observed in the room. o Non-food grade chemicals are not labeled. List of Non-conformity
o

No clear management review with respect to food safety based on HACCP scheduling & No clearly stated review number in the meeting agenda & the pending issues.(management teams not briefed about the HACCP based food safety plan)

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MOHA SOFT DRINKS INDUSTRY S.C AWASSA MILLENNIUM PLANT

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FOOD SAFETY AUDIT REPORT FORM

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o No diffusion of documents to the respective divisions (all PRPs, SOPs & Formats etc; the use of old obsolete CIP format was observed.(other divisions do not know well about documents) o Food safety policy was not completely addressing all employees of the plant(broachers were not distributed) o Food safety training was not given to all employees
o

Employee medical diagnosis data not recorded on the provided format.

o Storage practices were seen good however there were no enough storage areas that supports FIFO rule and encourage pest harborage in the sugar store.
o Condensate was noted in the sugar dissolving ceiling (Room

ventilation problem) o Plastic curtain was noted wear off followed insect activity in the perimeter areas
o

EBI disabled for caustic carry over check

o Containers were stored on the floor directly in front of the full bottle warehouse(a few meters from the external door) which were suitable for pest harborage and used as a store for uncontrolled products(salvages)

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MOHA SOFT DRINKS INDUSTRY S.C AWASSA MILLENNIUM PLANT

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o No pad lock for trucks used for carrying finished products

8. Conclusion and recommendation Even though a lot of good works were done, due to the nature of the system and the understanding level of employees, gaps were noted that do not meet the HACCP based food safety requirements. However those all gaps only need attention and a day to day follow up and can be fixed without requiring huge investment. Therefore it is recommended that the gaps should be fixed by identifying their root causes and taking corrective action measures to avoid re occurrences. 9. Attachments o Schedule for the gap analysis o Attendance of opening and closing meeting o Non conformity report