factory inspection (kosong)

[ENVIRONMENTAL HEALTH & SAFETY] FACTORY INSPECTION

Introduction

Factory inspection is a procedure to make sure that the owner of the factory is following

the standard to operate their factory. Usually, this inspection is done There are a few criteria

that considered during the inspection such as cleanliness of surrounding preparation area,

certificate of typhoid injection for all food handlers and method of keeping and handling of raw

materials. Here we are doing Hazard Analysis Critical Control Point (HACCP) in order to

determine the factory is following the standard to operate or not.

HACCP is used to described steps in food processing operation where rapid

microbiological, chemical or physical can be used with good assurance and in a reasonable time

to assess and control the potential for pathogenic or other microbial growth as well as prevent

environment contamination of the food with unsafe substance which would render the product

unfit to eat, harmful and possibly illegal. The concept of control describes those methods such

as monitoring pH, time/temperature recording and others that could be used in place of after

the fact microbial or chemical analysis, to control the process on-line so that the product is

always made safely. According to the National Advisory Committee on Microbiological Criteria

for Foods (NACMCF), HACCP is the responsibility of the food and implement HACCP plans and

for regulatory agencies to facilitate this process. Here we will adapt HACCP in making sweet

potato scratch (Kuih Cakar Ayam).

Administrative Data

Date : 2014

Time : 10.00 am – 12.00 pm

Location : Kampung Lubuk Katak

Activity : Food factory inspection at Tapah

Person Incharge : Miss Faezah, Food Technology Officer

Staff Involved : Driver and UiTM students

General Objectives

1


To ensure that the factory is operate according to certain standard that have been stated in

the Food Act 1983 (Act 281) and Food Regulation 1985.

Specific Objectives

To expose the student the correct procedure in carrying out the food factory inspection and

procedure in enforcing law under Section 11, Food Act 1983.

To ensure the sanitary of the factory is always in good condition.

To evaluate the hygiene of food processing by carrying out HACCP evaluation.

To examine the aspects of food premises facilities and structure of building such as roof,

floor, wall and ceiling.

Equipment Used

1. KKM-PPKM-2/09 form

2. Sampling bag

3. Calculator

4. Clipboard

5. Permanent Marker

6. Camera

7. Film

8. Official seal

9. Stamp pad

10. Torchlight

11. Ball Pen

12. Probe Thermometer

13. Closure notice form

14. Facemask

15. Stapler

16. Sterile glove

17. Authority card

Procedure

2


1. The equipment for inspection was prepared and checked.

2. Once arrived, the owner of the factory was found and had introduced ourselves and also

purpose of visit was explained.

3. Then, all details were collected such as owner IC number, address and license number was

recorded in the KKM-PPKM-2/09 form.

4. The owner of the factory was asked to follow along the inspection.

5. Before doing the inspection, authority card was shown and permission was asked from the

owner.

6. Each part of processing section was observed carefully for HACCP and any mistakes that

happened had been took the picture.

7. KKM-PPKM-2/09 form was filled and rating was given based on the observation.

8. Then, the owner of factory was advised to improve their hygiene level.

9. The rating mark was key in into the computer once reached at the office.

10. Filing was made and the file was tagged according to demerits.

Food Factory Details

Name of factory owner : Amin Bin Hamid

Name of company : Amin Hamid Enterprise

Address : 131C, Kg Lubuk Katak, 35000 Tapah,

Perak Darul Ridzuan

Phone number : 012-5954644

Company registration number : IPO142114-D

Number of workers : 3

Operation time : 8.00am – 5.00 pm

Type of business : Making sweet potato scratch

Worker information :

No Name Gender IC No Working section Nationality

1

2

3


3

4

5

Factory location plan :

4


Floor plan of factory

Keys :

Door

Factory site condition :

Based on my observation, the factory was build close to the river about a few meters

from the back of the factory. Furthermore, around the building also have too much hole that

contain stagnant water. This will lead to breeding of mosquito especially Aedes mosquito.

Drainage system of the premise also is not in proper condition. Drain water was built to flow to

the nearest river.

Type, structure and building sanitary :

No Structure Type Condition Cleanliness Comment

1 Floor

2 Wall

3 Roof

5


4 Ceiling

Natural lighting and ventilation :

In certain building structure lighting and ventilation is the most important thing that was

considered when wants to build certain building. As a result, Uniform Building By-Law or UBBL

was create to make sure when the certain building wants to build, it have enough lighting and

ventilation. In UBBL 1984, Section 39(1) state that “every room designed, adapted or used for

business or other purpose except hospitals and schools shall be provided with natural lighting

and natural ventilation by means of one or more windows having a total area not less than 10%

of clear floor area of such room and shall have openings capable of allowing a free passage of air

not less than 5% of such floor area.”

Windows area

X 100 =

Floor area

Must not less than 10% of clear floor area as stated

in UBBL 1984, Section 39(1)

Open spaces

X 100 =

Floor area

Must not less than 5% of such floor area as stated

in UBBL 1984, Section 39(1)

No Space Floor

area

Lighting and ventillation

Comment

Free open window

area (m2)

Permenant open

space area (m2)

Already

have

Should

have

Already

have

Should

have

6


(m2) (m2) (m2) (m2) (m2)

1 Processing

area

≥4.5m2

(≤5%)

2 Storage

room

≥1.05m2

(≤5%)

Mechanical ventilation :

No. Space Type Amount Condition Sanitary Comment

1. Processing area

2. Storage room

Mechanical lighting :

No. Space Type Amount Conditions Sanitary Comment

1. Processing

area

2. Storage room

Principles of HACCP

1. Conduct hazards analysis

Determining the potential hazards and asses the severity and risks. The hazard

can be physical, chemical and biological hazard.

7


2. Identify or Determine Critical Control Points (CCPs)

After hazards have been identified with severity and risk had been assessed

through step-by-step preparation of a food, CCP can be determined. A CCP is an

operation which control measures will be implements to eliminate, prevent or

minimize the hazards.

3. Establish critical limits at each CCP

Criteria for controlling hazards must be specified. These come from

recommendations according to investigations of food borne outbreaks, research

data and specified requirements in food safety regulations or code of practices.

4. Establish monitoring procedures

For the HACCP system to function properly, critical control points (critical

operations) must be monitored. Monitoring is done by persons involved with

the operation.

5. Establish Control or Corrective Action Procedures

Whenever the results of monitoring indicate that the criteria are not met or the

process is out of control, immediate action must be taken to correct the

situation. Assessment of hazards and risks dictates appropriate action.

6. Establish verification procedures

HACCP should be verified. No matter who develops a HACCP system, an outside

party should verify that correct CCP have been selected, effective criteria for

control have been specified, control measures are in place and monitoring

procedures are the most effective that are available.

7. Establish documentation procedures, as appropriate

This will include records of hazards and their control methods, the monitoring of

safety requirements and action taken to correct potential problems.

8


Description of Food Manufacturing

Firstly, the potatoes were clean and cut. Then, it will be washed with camphor water.

Then, it will be filter to dry and fry it. Next, the oil will be filter and the potatoes were lift to

other container. In another wok, water and brown sugar was cooked thoroughly. The fried

potatoes were poured into the brown sugar and mix well. Immediately, it was lift and put into

round mould. Then, it will be press to compact it and left cool. Once it has been cooled, it was

packed into plastic packaging. Then the plastic packaging was sealed and pack into box to

distribute to groceries in Tapah area.

Type of Food Manufactured

Raw Material

No Raw material Source Physical

Condition

Comment

1

2

3

4

5

9


Protection and Storage of Raw Materials

No Raw materials Storage

method

Protection method

Rack/refri/container

Comment

1

2

3

4

10


Hazard Analysis for Raw Material

Ingredients Hazard

Potential

Rational Source

of Hazard

Significant of Hazard

Does

manufacturer

will eliminate

the hazard?

Potential of

cross

contamination

to other

product

Preventive

Measure

Sensitivity

of the raw

material

Give

serious

effects

Possibility

to happen

Significant?

High High Yes

High Low Yes

Low High Yes

Low Low No

Potatoes

Biological

Pathogenic

microorganism

Chemical

Pesticide

residue

Physical

Sand

Biological

No Hazard

Chemical

11


Camphor

No harmful

chemical

Physical

No physical

hazard

Brown sugar

Biological

No hazard

Chemical

Other chemical

powder

Physical

Impurities

Cooking oil

Biological

No hazard

Chemical

No hazard

Physical

No hazard

Biological

12


Water

E.coli

Chemical

No hazard

Physical

Suspended solid

Process Flow Chart

Hazard Analysis for Processing Method

Processing

Method

Hazard

Potential

Rational Source of

Hazard

Significant of Hazard

Control Measure CCP

Give serious

effects

Possibility to

happen

Significant?

High High Yes

High Low Yes

Low High Yes

Receiving of raw materials

Filter

Wash with camphor waterWashingStorage

Frying (CCP)Cooling (CCP)Packaging (CCP)

13


Low Low No

Receiving of

Raw

Materials

(Potatoes

and brown

sugar)

Biological

Pathogenic

bacteria

Chemical

No hazard

Physical

Sand

Storage of

potatoes

Biological

Growth of

fungus

Chemical

No hazard

Physical

Insects and

Mouse

Biological

No hazard

Chemical

No hazard

14


Washing Physical

Suspended solid

Frying

Biological

Pathogenic

bacteria

Chemical

No hazard

Physical

No hazard

Cooling

Biological

Microorganism

Chemical

No hazard

Physical

No hazard

Packaging

Biological

Microorganism

Chemical

No hazard

Physical

No hazard

15


Critical Control Point (CCP)

Critical

Operation

Potential Risk CCP Monitoring

Procedure

Frequency of

Monitoring

Procedure

Person

Responsible

for

monitoring

Corrective Actions Records

Frying

Cooling

Packaging Cross-

contamination

From food

handler

Supervisor

should do

inspection

frequently

Every time the

worker wants

to start

working

Supervisor

Clean hands

thoroughly and

wearing gloves

before handling

food

Health of workers

should be

recorded and

updated

16


Final Product

Packaging Technique

After sweet potato scratch had been fully cool, it was packed into a plastic. This packaging was

packed manually by hand.

Storage method

Here, they not store the product because it was made based on order. Once the products pack

into box it was straight distribute to the customer. Storage room are use only to keep raw

materials.

Distribution method

Products were sent to the customer by using van to mini market and groceries around Tapah

and Bidor town.

Utensils and Equipment Facilities

No Equipment Made of Condition Sanitary Cleaning

technique

Caring

technique

Comment

1

Wok

2

Sudip

3

Container

4 Stove

5 Basin

17


6

Plastic

sealing

machine

7 Tray

Worker Health Status and Behavior

Worker health status

No. Name

Health Status

Health problem

Comment

Thyphim

injection

Medical

check -up

1

2

3

4

5

Habit and self-hygiene of workers

No. Name Self Cleanness

and cloth

Bad behavior Comment

1

2

3

4

18


5

Sanitary Facilities

Water source

Source of water for this factory is from PAIP.

Toilet Facilities

No. Gender

Toilet Urinal

Condition Sanitary CommentAlready

have

Must

have

Already

have

Must

have

1 Male 1 - -

2 Female 1 - -

Drainage condition

Drain condition of this factory is in good condition. There is no sign or break and the water

move smoothly. It is made up from concrete and cement.

Waste management facilities

All waste from the production of food product will be throwing into rubbish bin and local

authority will collect the rubbish and dispose it at the landfill.

Hand washed or foot bath facilities

Hand washed

19


Workers Foot bath Condition Sanitary CommentAlready

have

Must

have

3 -

Other facilities

No. Items Yes No

1. Vermin/pest/vector Control

2. Health Poster/Notice

3. Fire Extinguisher Facilities

4. Cleaning Schedule

5. First Aid Kit

Evaluation result

Total point (Demerits) =

Total point (Evaluation) 100% - ___ = ___

(See appendix for food factory form)

Comments

Broken ceiling should be repaired immediately because it is dangerous to the workers.

Furthermore, the ceiling also was dirty and full of dust.

The dirty wok should be replaced when there is too much dirt on it.

The workers are not using proper hat to cover their hair during handling the food.

20


At packaging area, there is worker where did not use face mask during packing the food into

the plastic.

Hand wash facilities are not meet the requirement where it should have 3 at least.

No health poster or notice displayed.

No fire extinguisher.

No cleaning schedule.

Suggestion

Better use concrete ceiling instead of asbestos which is tougher, and safe for environment.

The owner should always inspect the workers either they are following the rules of handling

food or not such as using face mask, apron, hat and gloves.

Fans should be clean regularly and make sure in good condition.

Owner of the factory should display some poster on health such as correct ways of washing

hand and other related information.

Owner also should provide and display cleaning schedule so that workers will know their job.

The most important is factory owner should provide fire extinguisher for safety precaution.

Equipment or utensil that use should be stainless steel so that it will not rusting and must be

in good condition.

Hand wash facilities should be provide more so that easier for the workers to clean

themselves.

Reference

Uniform Building by Law 1984 (UBBL 1984)

Guidelines HACCP 1Malaysia

21


Appendix

Collapse ceiling Rack for storing

Workers packing without using face mask Making jelly

22


23

factory inspection (kosong)

Documents