Org Devas
Organic
Consulting Services
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Org Devas Organic
Consulting Services
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Consultation with Manufacturer Organic Handling & Manufacturing Plan; Including Certification Compliance Anon. Food ManufacturerAnytown, MN
Editors Note: This plan has been developed by ODC@ for ANON. FOOD Manufacturer's use only Plant Policies re: OG Certification .......4 Ingredient Receiving & Inspection .. ..5 Manufacturing Procedures & Record keeping ......6 Non-Conformance Issues and Complaints . ..7 Addendums (see Master Document List) Master Document List Map of Plant Intake ChecklistProduct Flow ChartExternal Audit* Supplier Certificates* Organic Ingredients Tracking Record* Pesticide and Sanitation MSDS* The underlined items are connected by Hyperlinks The items with * (asterisks) are attached At the end of the Plan
Anon. Food Manufacturer (ANON. FOOD MANUFACTURER) is a medium sized snack producer located in the heartlands of Northwestern Minnesota. The company was started by Ken Nelson in 1973. One of the main goals of the company was to provide gainful employment in an area that was job deficient. Since then ANON. FOOD MANUFACTURER has spawned several support business in the nearby community and continues to employ a large portion of the community. Times have become extremely competitive in the snack food industry and ANON. FOOD MANUFACTURER has adopted several strategies in preparation of this.
Several years ago ANON. FOOD MANUFACTURER was approached by a small manufacturer/food handler with a plan to manufacture what would be the first North American snack food with Organic ingredient components. Since that time this category has become competitive as well. In some years, ANON. FOOD MANUFACTURER produced Organic product that retailed for well over 12 million dollars. Since these initial and attendant contracts were negotiated, ANON. FOOD MANUFACTURERs organic client has merged and moved its manufacturing to in-house processors. ANON. FOOD MANUFACTURER made a critical decision at this point, rather than abandon what is now a viable marketplace they proposed to create their own brand. Realizing that creation of a new brand would be a costly proposition, they decided to take the risk.
Even though ANON. FOOD MANUFACTURER has been manufacturing organic snacks for 16 years they were not aware of the complexities of the organic marketplace and the specific and rigorous needs of supply. Rather than use non-organic oil or use organic canola, which has potential GMO conflict, they decided to use organic sunflower. They also discovered the difficulty of finding an acceptable coating mixture that would meet organic standards. These factors have caused a repositioning. The company will only sell organic chips. This gives them complete control over the ingredient purchasing and processing.
Specific Documents are incorporated into this manual by reference and/or attachment:
Definitions from NOSB and NOP (proposed) www.ams.usda.gov/nop/
Legal Status
Anon. Food Manufacturer is a privately held Minnesota corporation.
Location
Anon. Food Manufacturer is located at 800 Fourth Street in Anytown Minnesota .
Plant Policies Regarding Certification
All ingredients and all products will be certified by the Organic Growers and Buyers Association (OGBA) or an OGBA acceptable certification body. All ingredients for organic food production will be carefully monitored and tracked on a per usage and overall usage basis (see other related policies and procedures). Management will verify these procedures with a routine and surprise internal audit and an outside (OGBA) audit (inspection). All policies and procedures utilized by ANON. FOOD MANUFACTURER will meet or exceed all Federal and State regulations concerning organic food. All records verifying organic procedures and controls will be available to the appropriate authorities. They are detailed in the Master Document List. Any product not meeting ANON. FOOD MANUFACTURER standards for organic criteria quality will be sold as conventional. All sales of off-grade materials will be documented with organic sales and notated.
PersonnelGeneral Manager: Denny Ixxxxxxx Purchasing Manager: Mike HXxxxxxx Operations Assistant: Peggy Mxxxxxx Production Foreman: Warehouse Manager: Steve Kxxxxxxx Shipping Manager: Steve Bxxxxxx Quality Control
All ingredients for organic products will be track-able with the In-House Tracking Sheet (IHTS) (see enclosure) and the I/O Sheet. Attached to the IHTS will be a copy of: the ingredients purchase order the appropriate Bill Of Lading Organic Ingredient Tracking Record any warehouse records a copy of the appropriate outbound Bill of Lading
The total purchases will also be detailed in the I/O Sheet.
Ingredient Receiving & InspectionIngredients for organic products will be received by Steve Bxxxxand/or Steve Kxxxxx. All grain will be received in 50# bags with the proper paperwork accompanying it and a copy of the inbound paperwork will be attached to the IHTS. A copy of the organic certification will be kept in a specific file for each ingredient. The ingredients will be inspected by Steve Bxxxxx and/or Steve Kxxxxxx for quality and soundness. Any deficiencies will be noted and reported to Denny Ixxxxxx. No load with deficiencies of paperwork will be unloaded without Denny Ixxxxxs authorization and notation of exception.
Manufacturing Procedures & Record keeping
Oil is moved from a designated (organic only) bulk storage tank into the frying tank. Before this occurs the frying tank is drained and cleaned. The corn to be ground is soaked overnight with food grade lime to remove the hulls, making masa. The corn is then stone ground and made into slurry which is placed in rolling vats. These vats are dumped into a sheeter. The masa is sheeted and cut into the appropriate size and thickness. Salt is sprayed on the product, it then goes through a fryer filled with certified organic oil. The product is then baked and cooled and moved into a form/fill and seal packaging line. All equipment is routinely cleaned between runs, and extra care is given to cleaning equipment before a run of organic product. At very step of the process a notation is made on the IHTS and the production sheet is attached after each product run.
All totals of organic ingredients and all sales of organic product will be recorded on an I/O Sheet. This will indicate date of purchase and date of sale. This will be kept up to date and be backed up by the IHTS.
Storage ProceduresAll organic ingredients shall be stored in a separate area (for bagged product) or in a separate bin or tank (for bulk product). The area shall be designated for organic product and the container or pallet shall also have a pallet sheet with the label Organic ***** Lot # xxxxx on each pallet or container. (**** = the product/ingredient name), (xxxxx = the actual lot #). They shall be up-to-date and any partial pallets (or containers) shall maintain lot # identity. Each move in or out of storage shall be noted on the IHTS.
Shipping ProceduresAll finished product shipped out of the plant will be accompanied by a document (e.g. outbound Bill of Lading) showing: amounts, product, lot #, and the words certified organic ****** (Product name) and Lot # xxxxx (the lot number). A copy of this document will be attached to the IHTS. This will be stored in a specific IHTS file. The transaction will also be noted on the I/O Sheet. The I/O Sheets will be kept in a designated file.
Non-Conformance Issues and ComplaintsAll issues of non-conformance of product; whether organic or quality in nature, must be addressed by Denny Ixxxxx. All exceptions must be noted and any questions of organic nature that may violate the agreement between ANON. FOOD MANUFACTURER and its certification body must be noted and approved in writing within a reasonable length of time. Any issues of non-conformance and/or any complaints will be noted on the appropriate non-conformance/complaint form and placed into a file to be shared with the organic inspector at the yearly inspection.
Internal AuditsAn annual internal audit will be done by the Quality Manager (or a contracted entity). This audit will be done in conformance to ISO #####. A presentation will be made to management of the conclusions of this audit. A record will be kept on file for the external auditor (inspector) to review.
External AuditsAn annual external audit of ANON. FOOD MANUFACTURER shall be done by an ISO 65 (National Organic Program NOP) accredited certification body inspector. There may also be occasions where ANON. FOOD MANUFACTURER will receive an unannounced or surprise inspection. At the time of any audit, ANON. FOOD MANUFACTURER will make available all records and documents as listed herein.
This manual is a statement of policies and procedures relating to private company policy for ANON. FOOD MANUFACTURER. It is confidential to ANON. FOOD MANUFACTURER and its creators. This must be honored. No other warrants or guarantees are intended or implied. Should this document fall into your hands by accident, please respect its confidential nature and return it to Anon. Food Manufacturer, attn: Denny Ixxxxx.
Purchases Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s)
Sales: Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s) Item Amount Certification(s)
1) Intake Checklists yes____, No_____
2) Product Flow Chart yes____, No_____
3) In-House Tracking Sheets yes____, No_____
4) Last External Audit yes____, No_____
5) Supplier Certificates yes____, No_____
6) Processing Checklist yes____, No_____
7) Input/Output Sheets yes____, No_____
8) Shipping Checklist yes____, No_____
9) Complaint forms yes____, No_____
1) Bill of Lading: does it say Certified Organic________(Product Name) yes____, No_____ does it have a lot code yes____, No_____ 2) Packaing/Labeling does the lot code match the bags/container yes____, No_____ Are the bags/container labeled Certified Organic yes____, No_____ Is the count/weight correct yes____, No_____ 3) Truck Is the truck clean and free from any contamination factors yes____, No_____ Are the Scale Sheets clear yes____, No_____ Is there a clean truck affidavit yes____, No_____
Notes___________________________________________________________ Notes___________________________________________________________ Notes___________________________________________________________ Notes___________________________________________________________ Notes___________________________________________________________ Notes___________________________________________________________ Attach a copy of all intake documents.
1) Bill of Lading: does it say Certified Organic________(Product Name) yes____, No_____ does it have a lot code yes____, No_____ 2) Packaing/Labeling does the lot code match the bags/boxes yes____, No_____ Are the bags/boxes labeled Certified Organic yes____, No_____ Is the count/weight correct yes____, No_____ 3) Truck Is the truck clean and free from any contamination factors yes____, No_____ Notes___________________________________________________________ Notes___________________________________________________________ Notes___________________________________________________________ Notes___________________________________________________________ Notes___________________________________________________________ Notes___________________________________________________________ Notes___________________________________________________________ Notes___________________________________________________________
Attach a copy of all shipping documents.
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