Food Safety Management System¶

This document details the comprehensive food safety framework at Dinweys French Fries Factory, covering HACCP, Prerequisite Programs (PRPs), FSSC 22000 alignment, food defense, food fraud prevention (VACCP/TACCP), traceability, recall procedures, environmental monitoring, and food safety culture.

Overview: GFSI-Benchmarked Food Safety Architecture¶

Dinweys operates a multi-layered food safety management system built on Codex Alimentarius HACCP principles, integrated with ISO 22000:2018 management systems, and aligned with GFSI (Global Food Safety Initiative) benchmarked standards including BRC and FSSC 22000.

Key Insight: FSSC 22000 v6 is recognized by the GFSI and is widely accepted by European and North American buyers. While BRC is more common in the UK retail sector, FSSC 22000 is the preferred certification for many food manufacturers supplying the EU foodservice and ingredient sectors. Dinweys can provide either certification depending on customer requirements. The FSSC 22000 v6 scheme adds new requirements around food safety culture, sustainability, and food fraud mitigation that go beyond the previous version.

FSSC 22000 v6 — Detailed Requirements¶

Overview of FSSC 22000¶

FSSC 22000 is a GFSI-benchmarked food safety certification scheme that combines ISO 22000:2018, ISO/TS 22002-1:2009 (PRPs for food manufacturing), and additional FSSC scheme requirements. Version 6 was published in 2020 with transition to mandatory compliance by 2023.

ISO 22000:2018 Clause Mapping¶

FSSC 22000 Additional Scheme Requirements (v6)¶

Beyond ISO 22000, FSSC 22000 v6 requires:

HACCP Plan for Frozen French Fries Production¶

Product Description¶

Process Flow Diagram¶

Raw Potato Receiving → Storage → Washing → Inspection → Peeling → 
Cutting (Size-select) → Color Sorting → Blanching → Dewatering →
(Coating Application) → Par-Frying → IQF Freezing → 
Packaging → Metal Detection → Carton Packing → Cold Storage → 
Loading & Transport

↑ CCP designations shown in section below

Identified Hazards¶

Biological Hazards¶

Chemical Hazards¶

Physical Hazards¶

Critical Control Points (CCPs)¶

Dinweys operates 6 CCPs across the production process. Each CCP is validated, monitored, and documented with corrective action procedures.

CCP 1 — Raw Material Receiving (Pesticide Residues, Heavy Metals)¶

Calibration Requirements:

Corrective Action SOP:

1. If COA values exceed critical limit → REJECT the entire lot at supplier's cost
2. If COA values exceed target but are below critical limit → Place on HOLD; request re-test from accredited lab
3. If re-test passes → Release with documentation
4. If re-test fails → Reject lot; document in Supplier Non-Conformance Report
5. If ≥ 2 lots from same supplier rejected in 6 months → Initiate supplier audit or de-listing procedure

Validation Evidence: - Annual third-party pesticide residue testing of raw potatoes (accredited lab) - Supplier audit at least every 12 months for all approved potato suppliers - Historical data review: < 0.5% rejection rate over rolling 12 months

Verification Activities:

CCP 2 — Blanching (Pathogen Reduction)¶

Calibration Requirements:

Corrective Action SOP:

1. Temperature drop below 85°C detected:
2. Immediate: Stop product feed; increase steam pressure; check steam trap function
3. If restored within 2 minutes: Divert product from temp-drop period to re-blanching
4. If > 2 minutes: Divert to hold tank; record as non-conforming material
5. Non-conforming product:
6. Evaluate core temperature of potatoes in hold tank
7. If core > 65°C for ≥ 2 min → Product may be re-blanched and released
8. If core < 65°C for duration → Product rejected for human consumption (redirect to animal feed or disposal)
9. Root cause investigation: Steam supply pressure, boiler function, heat exchanger fouling
10. Documentation: Deviation Report Form FR-CCP2; corrective action within 24 hours

Validation Evidence: - Challenge study: Inoculated potato strips with Salmonella enterica (10⁷ CFU/g) and E. coli O157:H7 (10⁷ CFU/g); blanching at 88°C for 3 minutes achieved >5 log reduction (validated by [accredited lab, study ref DWF-2022-BL-001]) - Literature reference: Codex Alimentarius CAC/RCP 53-2003; 5-log reduction for vegetative pathogens achieved at 80°C for 2 min

CCP 3 — Par-Frying (Pathogen Survival)¶

Calibration Requirements:

Corrective Action SOP:

1. Temperature drops below 160°C:
2. If ≤ 1 min: Adjust burner output; wait for recovery; any product in fryer during drop period placed on hold
3. If > 1 min or recovery not achieved within 2 min: Stop product feed; engage backup heating element
4. Hold product evaluation:
5. Measure core temperature of held product
6. If core temperature > 72°C for ≥ 15 seconds → Product acceptable (pathogen kill achieved)
7. If core temperature < 72°C → Product rejected for human consumption
8. Root cause: Gas pressure, burner nozzle maintenance, oil level, heat exchanger fouling
9. Documentation: Deviation Report FR-CCP3; CAPA initiated

Validation Evidence: - Frying at 160°C for 30 seconds achieves product core temperature ≥ 72°C in 9 mm cut fries (validated by thermocouple insertion study, n=50 samples) - 72°C core temp for 15 seconds is equivalent to 6D reduction for Salmonella (FDA Food Code 2017)

CCP 4 — Metal Detection¶

Calibration Requirements:

Corrective Action SOP:

1. Failed test (detector fails to reject test sphere):
2. Stop production line immediately
3. Isolate all product produced since last successful test
4. Re-inspect isolated product through a functioning metal detector
5. Recalibrate and verify with test spheres; if pass → resume production
6. If cannot recalibrate → Switch to standby detector; repair faulty unit
7. Rejected product from air-blast:
8. Weekly collection and forensic examination of reject bin
9. Record type of metal found, size, source (if identifiable)
10. Trend analysis to identify repeat contamination sources
11. Documentation: Deviation Report FR-CCP4; monthly reject trend report

Validation Evidence: - Detection sensitivity verified on-site annually by manufacturer service engineer - Product effect compensation: Detector auto-tunes to frozen product signal characteristics - Conveyor speed: 30 m/min max for specified detection limits

CCP 5 — Cold Storage & Transport (Temperature Abuse)¶

Calibration Requirements:

Corrective Action SOP:

1. Cold storage temperature deviation:

2. −18°C but ≤ −15°C for < 2 hours → Alert; investigate root cause (door open, defrost cycle, HVAC failure)

3. −18°C for > 2 hours OR any excursion above −15°C → Isolate affected product; mark as HOLD

4. Product evaluation: Check core temperature of representative samples; measure quality parameters
5. If core temp never exceeded −12°C → Product may be released with risk assessment
6. If core temp exceeded −12°C → Reject (texture degradation, microbial growth risk)
7. Transport temperature deviation:
8. Logger indicates excursion above −15°C → Flag shipment for evaluation at destination
9. Customer or Dinweys QC evaluates upon arrival
10. Financial responsibility determined by excursion source (pre-loading vs. en route)
11. Documentation: Temperature Deviation Report FR-CCP5; root cause analysis

Validation Evidence: - Cold storage mapped annually (24-point temperature mapping for each chamber; 3D temperature distribution analysis) - Shelf-life validation study confirming 24-month stability at −18°C - Temperature abuse study: 24 hours at −10°C → measurable texture degradation (fracture force reduced by 18%)

CCP 6 — Foreign Matter Control (Optical Sorter / Color Sorter)¶

Calibration Requirements:

Corrective Action SOP:

1. Ejection efficiency below 99.5%:
2. Stop product feed; run test samples with known defects
3. Verify camera focus, lighting intensity, air pressure (min 6 bar)
4. Clean camera lenses; check compressed air line filters
5. Re-run test; if efficiency restored → resume production
6. If not restored → Switch to backup sorter; call OEM support
7. Manual re-inspection of product produced during any sorter malfunction
8. Documentation: Deviation Report FR-CCP6; maintenance log

Validation Evidence: - Sorter performance validated annually by OEM service engineer - Test samples (calibrated defect colors and sizes) used daily - NIR capability enables detection of clear plastics and stones that visible camera alone would miss

Operational Prerequisite Programs (OPRPs)¶

Pre-Requisite Programs (PRPs) — Detailed Standards¶

Each PRP is documented in a standalone SOP with specific standards, monitoring frequencies, and personnel responsibilities.

PRP 1: Facility & Equipment Hygiene¶

Equipment Construction Standards: - All product-contact surfaces: 304 stainless steel minimum (316 for blanching and fryer areas) - No exposed threads, wood, or absorbent materials in production area - Welds: Ground flush, ≤ 0.8 µm Ra surface finish - Conveyor belts: FDA-approved food-grade polyurethane or stainless steel modular

PRP 2: Pest Control¶

Compliance Reference: AIB International Consolidated Standards for Food Processing Sections 5.0 (Pest Control) and GB/T 31719-2015 (Integrated Pest Management in Food Processing)

PRP 3: Water Quality¶

PRP 4: Waste Management¶

PRP 5: Staff Hygiene & Training¶

PRP 6: Maintenance & Calibration¶

PRP 7: Allergen Management¶

Environmental Monitoring Program (Listeria spp.)¶

Dinweys operates a comprehensive environmental monitoring program focused on Listeria spp. detection in the post-blanch processing environment. The program follows the principles of the International Commission on Microbiological Specifications for Foods (ICMSF) and FSMA Preventive Controls requirements.

Environmental Sampling Zones¶

Sampling Protocol¶

Corrective Action Protocol for Listeria spp. Positives¶

Performance Targets¶

Key Insight: Environmental monitoring data is the single best leading indicator of process hygiene. A Zone 3 positive that migrates to Zone 2 and then Zone 1 over several weeks is the classic precursor pattern to a finished product Listeria positive. Dinweys reviews zone 2 and 3 positives as seriously as zone 1 — they are the early warning system.

Food Safety Culture — Measurable Framework¶

Food safety culture is defined by GFSI as "shared values, beliefs, and norms that affect mindset and behavior toward food safety." Dinweys measures culture through five dimensions:

Culture Dimension Matrix¶

Culture Survey¶

Annual anonymous food safety culture survey (adopted from GFSI food safety culture model):

CAPA (Corrective and Preventive Action) System¶

CAPA Process Flow¶

Issue Identified
    ↓
Problem Description (what, when, where, who, extent)
    ↓
Immediate Containment (stop the bleed — isolate, segregate, rework, reject)
    ↓
Root Cause Analysis (RCA)
    ↓
Corrective Action (fix the root cause)
    ↓
Verification of Effectiveness (did it work?)
    ↓
Preventive Action (how to prevent recurrence across the system)
    ↓
Closure (documentation complete, trend added)

Root Cause Analysis Methodology¶

Dinweys uses three RCA tools, selected based on issue complexity:

CAPA Prioritization¶

CAPA Record Fields¶

Supplier Approval Program¶

Supplier Tiering¶

Supplier Approval Process¶

1. Pre-qualification questionnaire — Food safety capability, certifications, production capacity, food defense
2. Document review — Certificates, COAs, product specifications
3. Initial audit — On-site (Tier 1 & 2) or desk audit (Tier 3 & 4)
4. Sample testing — Three consecutive lots tested to specification
5. Trial approval — If samples pass, one production trial lot
6. Approved Supplier List (ASL) — Formal addition to ASL with score

Supplier Scoring System¶

Scoring bands: - A (85–100): Preferred supplier — no restrictions - B (70–84): Approved — continue with improvement plan - C (60–69): Conditional — increased monitoring; corrective action plan required - D (< 60): Not approved / de-listed

Non-Conforming Supplier Procedure¶

• First non-conforming lot: Notification + request for corrective action (CAPA)
• Second non-conforming lot (within 6 months): On-site or desk audit
• Third non-conforming lot (within 12 months): De-listing with 30-day notice; source from alternative supplier

Internal Audit Program¶

Audit Schedule & Scope¶

Audit Checklist Coverage Areas (Full System)¶

Auditor Qualification Requirements¶

Management Review (ISO 22000:2018 Clause 9.3)¶

Frequency¶

• Full management review: Semi-annual (every 6 months)
• Interim review: Quarterly (if significant issues arise or production exceeds 75% capacity)
• Ad-hoc review: Triggered by critical incident (recall, serious food safety event, major regulatory change)

Required Inputs (per ISO 22000 clause 9.3)¶

Required Outputs¶

Management Review Meeting Format¶

• Chair: Plant Manager / General Manager
• Attendees: QA Manager, Production Manager, Logistics Manager, Purchasing Manager, Maintenance Manager, HR Manager, Food Safety Team Leader
• Duration: 2.5–3 hours (full review); 1 hour (interim)
• Documentation: Agenda circulated 1 week in advance; minutes distributed within 2 weeks; action items tracked in CAPA system

Allergen Risk Assessment¶

Dinweys Allergen Status¶

Cleaning Validation for Allergen Control¶

While Dinweys is a single-product facility (french fries), allergen cross-contact risk is assessed for:

1. Incoming raw materials received on shared delivery vehicles: COA for each lot confirms no allergen contamination
2. Test runs with alternative coatings (e.g., wheat flour coating for customer trials):
3. Dedicated equipment or full line deep clean after trial
4. ATP swab (threshold < 50 RLU) + ELISA swab for specific allergen (e.g., gluten < 5 ppm)
5. Visual inspection of all surfaces
6. First 50 kg of standard product post-trial tested for allergen residue before release

Changeover Procedure (Coated to Uncoated)¶

Traceability System¶

One-Step-Forward, One-Step-Backward¶

Dinweys maintains full traceability in accordance with ISO 22000 clause 8.3 and China Food Safety Law Article 42:

Traceability Test¶

Lot Coding System¶

Format: YYMMDD-PRODUCT-SHIFT-LINE-BATCH

Example: 250728-SS-A-1-003

Recall & Crisis Management Procedure¶

Recall Classification¶

Recall Procedure — Step by Step¶

1. Detection: Quality issue identified via COA, customer complaint, regulatory notification, or routine testing
2. Assessment: Food Safety Team evaluates risk level within 2 hours
3. Form initial recall team: QA Manager (lead), Production Manager, Logistics Manager, Sales Manager
4. Containment:
5. Immediate quarantine of suspect finished product lot(s) in cold storage (designated "HOLD" area, padlocked or keycard-restricted)
6. Check WIP (work-in-process) — if product from same raw material batch still in line or in storage, quarantine that too
7. Notification (within timeframes above):
8. Internal: General Manager + all department heads
9. External: Customer(s) — provide lot code, quantity, nature of issue, proposed disposition
10. Regulatory: Local Market Supervision Bureau (China); destination market authority if export
11. Certification body: CB (certification body) notified within 72 hours if recall affects certified products
12. Recovery:
13. Coordinate return of affected product (Dinweys logistics or customer arrangement)
14. Quarantine returned product at Dinweys cold storage
15. Disposition options: rework (if applicable), redirect to animal feed, incineration, landfill with supervision
16. Root cause investigation: CAPA with 5-Why or Fishbone analysis; completed within 30 days
17. Preventive action: Systemic changes implemented; effectiveness verified
18. Mock recall: Conducted annually — results presented at management review

Mock Recall Performance Targets¶

Document Hierarchy¶

Level 1: Food Safety Policy Manual (FSM-001)
Level 2: HACCP Plan (HACCP-001) + Operational Procedures (SOPs)
Level 3: Work Instructions (WI-XXX) + Product Specifications (SPEC-XXX)
Level 4: Records (COAs, temperature logs, training records, audit reports, E-swab results)

Document Control¶

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