Common Unsatisfactory Findings During Inspections in Australia and New Zealand and How to Prevent Them

Using AIB International’s worldwide database, we identified the most common types of unsatisfactory findings during our inspections. And according to our Consolidated Standards for Inspection classification, these findings fall under the

There are three essential plant programs that are used to properly maintain the site for food safety when it comes to maintenance. They are

Pre-Operational Inspections

First, you need to identify that there is a problem and allocate the resources needed to correct it. Let’s start with the pre-operational inspection. These are typically conducted after sanitation has concluded and prior to resuming production operations. The person(s) assigned this responsibility need to be familiar with the equipment and know where to look for any conditions that might negatively affect food safety; for example, hard-to-clean areas of the equipment. This means checking for over-lubrication, metal-to-metal wear, proper reassembly of parts that may have been removed for sanitation, the condition of equipment surfaces for both food contact and non-food contact areas, damage to brittle plastic and glass items, and a check of the condition of overheads, particularly those overheads that are directly above exposed product and packaging (in the product zone).

Don’t forget to include inspection for the condition of ingredient bins, scoops, interim storage vessels, and other food contact utensils. This preliminary inspection should confirm that all components, utensils, and tools have been removed following the completion of maintenance and sanitation procedures. Prior to startup, any issues that are considered non-compliant with defined standards and a hazard to the final product that will be produced using the equipment must be corrected and verified.

Self-Inspections

The second line of defense is the self-inspection carried out by a multidisciplinary food safety team. This team takes a broader look at the entire operation, but it must still focus on the details of equipment conditions. Conducting some inspections during periods of downtime can allow the disassembly of equipment that could otherwise have issues that would remain undiscovered. Examples include pumps, pipes, mixers, tanks, fillers, etc. Damaged impellers, gaskets, spray balls, and metal-to-metal wear might go unidentified and lead to foreign materials entering the product stream. This team must be trained to thoroughly inspect, identify, and correct any equipment and structural issues. Prompt corrective action must be taken and prioritized according to a risk assessment. Where issues are found, a root cause analysis should always be done to allow for effective preventive actions to prevent the recurrence of the condition.

Preventive Maintenance

Finally, the Preventive Maintenance Program is essential to prevent equipment wear and tear conditions from becoming food safety issues. Additionally, preventive maintenance on the facility’s structures, including the overheads, floors, and drains, must be scheduled. All scheduled activities are very important and should be completed as planned to ensure the manufacturing environment is maintained in a hygienic condition. The frequency of these activities should be based on risk and historical records and adjusted as needed to maintain equipment and the facility in-line with standards.

You cannot overlook the responsibility of all line workers and supervisors to ensure that the equipment and structures are suitable for operations. This means that everyone working in the production and packaging areas must be aware of anything that is not up to the expected and documented standard. Employees must feel empowered to speak up when they identify an equipment or structural condition that may negatively impact the quality and food safety of the product being produced. All employees in the facility must understand that food safety comes first.

Review your last third-party inspection and recent self-inspections. If you are seeing the same types of items repeating, it means that you have not successfully identified and corrected the root cause of the problems. Assemble a team knowledgeable about your plant processes to get to the real reason the conditions exist so you can correct them for the long term. Make sure everyone in your organization understands that ensuring food safety is a daily responsibility.

The success of your business depends on managing and controlling all the details, including those related to maintenance.