Storage


Storage

Good manufacturing practices must be adhered to at all times for items in storage: raw materials, work in progress, finished product, packaging, chemicals, staff hygiene items, etc.  Storage of items is managed to prevent contamination or cross contamination of allergens, chemical, microbiological or physical matter.

 

HACCP Status

  • Normally a CP | Control Point for ambient items
  • Normally a CCP | Critical Control Point for high risk items such as chilled or frozen items

 

Purpose
To ensure all materials are stored in a way:

  • To prevent any potential microbiological, chemical, or physical contamination, or;
  • To prevent cross contamination through allergen mismanagement, or;
  • To ensure quality of product is retained throughout storage
  • To ensure chilled and frozen items are stored and maintained within their temperature critical limits

 

Please note: cross contamination should also be considered for other certification if practiced at your site.  Examples:

  • Halal product vs non-Halal product
  • Kosher product vs non-Kosher product
  • Organic product vs non-organic product
  • And so on

 

All Raw Materials

  • Packaging is suitably labelled and dated
  • Packaging is not damaged
  • Food types are separated, particularly raw materials with allergens or religious status (if religious certified)
  • Food is stored away from chemicals
  • No food product or packaging is stored directly on the floor; is stored on shelving or pallets
  • Stock is to be rotated by the FIFO “first in – first out” principle
  • All goods are stored in a clean, dry and well ventilated location
  • No evidence of pest infestation

 

Ambient, Chilled and Frozen Raw Materials

  • Refrigerated food must be stored at 5ºC or below
  • Frozen food must be stored at –18ºC.  Frozen goods which are to be used immediately are stored in cool room.  Once thawed, raw materials are not to be refrozen
  • Food must be stored so that cross contamination is avoided
  • All cooked foods should be covered
  • Finished product should be stored separately and away from raw ingredients
  • All allergens clearly labelled and segregated
  • Stock must be rotated using the FIFO “first in – first out” principle
  • Stock must be dated unless it is used within a short period
  • Food must not be used if the shelf life date has expired
  • Excess food must be stored separately and dated
  • Minimise opening and shutting cool room and freezer doors
  • No evidence of pest infestation
  • Chilled and freezer temperatures are recorded on the temperature record sheet

 

Opened Dry, Chilled and Frozen Raw Materials

  • All opened raw materials but be placed in food-grade and air-tight containers and completely sealed
  • All opened raw materials MUST have the following information:
    • Product name, batch number/expiration date
    • If applicable: date opened, person’s name, date product must be used by

 

Work in Progress and Rework

  • Only use temperature-controlled environments that permit work in progress or rework
  • Items must be correctly stored and away from raw materials or finished product
  • Allergen control must be adhered to at all times: do not store near non-allergen items
  • All work in progress or rework MUST have the following information:
    • Product name, batch number/expiration date
    • Date made, person’s name, date product must be used by

 

Packaging

  • Packaging material is part of the Approved Suppler Program and suitable for the food industry
  • Packaging material is inspected upon delivery to ensure product is clean, appropriately sealed and undamaged
  • All packaging material must be labelled correctly with amount of contents
  • All packaging material is stored off the floor and on shelving or pallets
  • Storage for packaging is in a designated area away from raw materials and finished product
  • All cartons are closed when not in use to ensure no foreign objects accidentally fall into the packaging materials
  • No evidence of pest infestation

 

Chemical Products and Equipment

  • All hazardous chemicals are stored in a designated area (outside of manufacturing areas) away from food, storage of food products and packaging
  • All chemicals are received in good condition and packaging that is completely intact
  • All chemicals are labelled according to their content
  • Safety Data Sheets (SDS) supports all chemicals including pest control chemicals
  • No evidence of pest infestation
  • Empty chemical containers are stored within chemical storage, ready for the supplier

 

Equipment and Utensils

  • All equipment and utensils must be clean whilst remaining in storage
  • Where appropriate, ensure equipment and utensils are covered
  • Never pack equipment or utensils away wet
  • If stored for a long time; ensure appropriately covered to prevent pest infestation and debris
  • Where applicable, all equipment and utensils is stored off the floor and on shelving or pallets
  • No evidence of pest infestation

 

Finished Product

  • Ensure all products have passed safety and quality checks
  • Store away from raw materials, work in progress, and chemicals
  • No food product or packaging is stored directly on the floor; is stored on shelving or pallets
  • Stock is to be rotated by FIFO “first in – first out” principle (not recorded)
  • All goods are stored in a clean, dry and well ventilated location

 

Critical Limits

  • Chilled items must be at 5°C or colder
  • Frozen items must be at -15°C or colder or be hard frozen to the touch

 

Corrective Action | General

  • Discard all unlabelled product (raw materials, WIP, finished product)
  • Discard broken containers or lids or if packaging is damaged
  • Dispose food outside its shelf life paremeters
  • Food Safety Supervisor to update staff skill set and knowledge
  • Immediately clean up any spillages to prevent pest or microbiological contamination; this includes shelving, walls, and floors
  • Reorganise layout of storage
  • Ensure FIFO stock rotation

 

Corrective Action | Temperature-Controlled Equipment

  • Adjust temperature of storage unit or arrange for equipment repairs if necessary
  • If storage temperature is above 5°C for chilled potentially hazardous foods or above -15°C for frozen foods, check temperature every 30 minutes to ensure temperature returns within critical limits within 2 hours
  • If foods are above 5°C for 2-4 hours, use the food immediately
  • If foods are above 5°C for 4 hours, discard foods
  • If applicable transfer product to another temperature-controlled equipment
    Always check for product integrity; do not refreeze thawing product
  • Report any damaged or spoiled product or equipment to management

 

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