DRAFT

BEVERAGE FACILITIES INSPECTION REPORT

Beverage 5-Cat UK English Template 20090710

#22916-PI-2
Purebev International Corporation - 6615
Km. 42, Governor's, Drive
Brgy. Hugo Perez
Trece Martirez City, Cavite, 4109
Philippines

TYPE OF AUDIT
Rated Inspection
Announced

INSPECTION DATE
October 28 and 29, 2010

AIB International
P.O. Box 11 • Leatherhead, Surrey • KT22 7YZ • UK
Tel: +44 1372 360553 • Fax: +44 1372 361869
http://www.aibonline.org/
 RATING ANALYSIS

DATE OF INSPECTION: October 28 and 29, 2010

TYPE OF INSPECTION: Announced
OVERALL RATING: UNSATISFACTORY

OPERATIONAL METHODS AND PERSONNEL PRACTICES 155

MAINTENANCE FOR FOOD SAFETY 160

CLEANING PRACTICES 135

INTEGRATED PEST MANAGEMENT 130

ADEQUACY OF PREREQUISITE AND FOOD SAFETY PROGRAMS 130

TOTAL: 710

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 FACTUAL OBSERVATIONS AND SPECIFIC RECOMMENDATIONS

OPERATIONAL METHODS AND PERSONNEL PRACTICES

1. Many evidences of eating, smoking and drinking outside designated areas

were noted during the survey as detailed below:

a) In the generator set area, three empty cups, three cups with coffee
residue were noted.

b) In the same area, five cigarette ends were noted, two used match sticks
and two crumpled cigarette packs.

c) In a room in the same area, two drinking cups, an electric stove and an
empty pot.

d) In the male locker room, cigarette ashes together with four fruit seeds
were noted in an unused locker.

Staff and non-facility personnel should be reminded to adhere to the

GMP policies at all times. “No Eating, Drinking and Smoking” notices
could be posted in strategic locations to constantly remind everyone of
this requirement. Staff practices should be monitored and if required
refresher training should be provided to highlight the company
expectations and further develop a positive culture for continuous
improvement. As there were many flammable chemicals stored in the
generator set area, lighting cigarettes in the area could result to fire.
(SERIOUS)

2. An area was designated for the storage of the non-allergenic ingredients

of Pepsi in the raw material warehouse. As toll processing for PCPPI only
happens once a month, the designated area was also noted being used to
store around 280 bags of milk powder. Storing allergenic substances in
the designated area for Pepsi non-allergenic materials increases the risk
of allergen cross contamination issues. The facility was reminded to store
only non-allergenic materials in the area if it will be used for storing non-
Pepsi ingredients. (SERIOUS)

3. More than 10 food handlers working in the distribution equipment area

(packaging) were noted improperly wearing their hair restraints. Hair
strands at the side and at the back were still noted exposed. A manual
packing activity (internally referred as taping) by the entrance to the
finished goods warehouse, all 17 employees were noted not wearing hair
caps. Employees need to be reminded to wear hair caps during product
handling. When they do, they need to ensure that all scalp hairs are
covered. The daily GMP inspection being conducted should include

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 regular checks on employee uniforms and practices (IMPROVEMENT
NEEDED)

4. On several occasions, employees manually packing were noted stepping

on pallet. An employee was even noted stepping on a box of finished
product (non-Pepsi product). It was explained that pallets are used to take
materials off the floor, if they are stepped on, they will be no different
from the floor. Dirt from shoes could also be transferred onto the external
packaging of finished goods if the products are stepped. Employees
should be reminded not to step on pallets and on product to prevent dirt
contamination issues. (IMPROVEMENT NEEDED)

5. A non-functional hand drier was provided in the hand washing station by

the entrance to the recombination area. Five hand washing stations in the
filling room were not provided with either hand drier or single-use towels.
It was explained that the hand washing procedure could be carried out
properly if a hand drying facility was not provided. The non-functional
hand drier should be repaired and hand driers or single use towels should
be provided in the five hand washing stations in the filling room.
(IMPROVEMENT NEEDED)

MAINTENANCE FOR FOOD SAFETY

6. Moderate amount of scratches were noted on the impeller plate of the

simple syrup transfer pump and on the impeller plate of the final syrup
transfer pump. Impellers should be aligned to prevent metal on metal
contact. (IMPROVEMENT NEEDED)

7. The facility had not documented a temporary repair program. A chair

and two desks in the packaging area were noted with clear tape and
carton as temporary repair materials. The edges of the tape were with
dust accumulation and some portions fraying. The use of string, paper,
tape, plastic, cloth and cartons to make repairs or alterations should not
be encouraged as they are materials that are often difficult to clean or
maintain in a hygienic condition. If temporary repairs need to be made
they should be dated and reported as part of the works orders/job request
system to be replaced as soon as possible. The repairs should be
monitored closely to ensure the temporary repair does not become
permanent. Materials that are used to make temporary repairs should be
constructed of food grade materials. (IMPROVEMENT NEEDED)

8. The secondary steel gate at the water treating room was noted with 2 inch
gaps along the bottom and side frame. A dead grass hopper and several
other garden insects were noted in the room. Rubber or plastic strips
should be installed along the bottom and side frames of the gate to
discourage insect entry. (IMPROVEMENT NEEDED)

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 9. The following issues were noted on hand washing stations:

a) Hot water was again noted not provided in any of the hand washing
stations (11 units). It was recommended that hot water be consistently
provided to aid in removing stubborn dirt and grease and to comply with
one of the requirements of the "Code on Sanitation of the Philippines, PD
856".

b) Five units of hand washing stations in the filling room were noted also
used to wash utensils and tools. Combining the two functions could result
to cross contamination. Separate sinks for utensil washing should be
provided. (IMPROVEMENT NEEDED)

10. The following floor issues were noted:

a) Many tiles in the recombination area were noted missing. The

depressions were noted holding water.

b) Flaking epoxy finish were noted on the floor of the UHT room. A large
flake of epoxy material was noted on a nearby drain.

c) Large pitted flooring was noted in the packaging materials staging

area. The pits were noted containing loose concrete pieces.

Floor upkeep should be managed as part of the preventive maintenance.

The material for the flooring should consider the material and personnel
traffic in the area. It should also consider the weight of the materials
being introduced and the various activities in the area. (IMPROVEMENT
NEEDED)

11. A few rust patches were noted starting to develop on the internal neck
portion of the manhole of the process water tank and the soft water tank.
Rust patches were also noted on the platform of the scissor lifter in the
recombination area. The rust patches should be scraped off and be
continuously monitored before the condition is allowed to worsen. A
material capable of withstanding constant exposure to water and acidic
condition be considered as a replacement material. (IMPROVEMENT
NEEDED)

12. A fraying gasket was noted installed at the bottom portion of the final
syrup strainer. A one inch rubber material was noted sticking out of the
equipment. Gasket upkeep should be managed as part of the preventive
maintenance program. (IMPROVEMENT NEEDED)

13. Around five droplets of oil were noted under the platform of the Tetra
Pak filling machine. Although the oil droplets were not above any product
or material, the leaks in the enclosed machinery should be ascertained
and be repaired. The preventive maintenance program should be
reviewed to determine whether it is sufficient to prevent leaking issues.
(IMPROVEMENT NEEDED)

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 14. The front area of the facility was fenced by six layers barb wires. The gap
between barb wires was noted big enough to still allow unauthorized
entry. The wire fencing could also be easily lifted. Due to a recent
typhoon, an old tree had been uprooted where portions of the fence was
hit and lifted. The gap created was also noted big enough to allow entry of
unauthorized persons. Additional barb wires could be fitted in between
the current layers of the fence. The attachment should be tighter so it
cannot be easily lifted. The uprooted tree should be removed to minimize
the gap. (IMPROVEMENT NEEDED)

CLEANING PRACTICES

15. Color coding or labelling of cleaning tools was not defined. To prevent
cross contamination issues, cleaning tools designated to clean specific
areas, food contact surfaces and non-food contact surfaces should be
labelled or color coded. (IMPROVEMENT NEEDED)

16. There were two units of simple syrup filter bag housing. A significant
amount of slime was again noted on the gaskets of both housing units. It
was understood that it was last used and sanitized a week before the
survey. It was explained that slime was indicative of inadequate cleaning
where the residues were used by microorganisms to grow. As it was in a
product zone, the danger of that the microorganisms will contaminate the
inner surface of the filter housing was very high. The cleaning program
should be reviewed to determine whether the current procedure is
sufficient to meet the high level of hygiene expected. More thorough post
cleaning inspections should also be conducted to verify that the cleaning
procedure was carried out properly. (UNSATISFACTORY)

17. A piece of white plastic was noted inside the spray ball in the sugar
dissolving tank #3. Clogged spray ball could result to insufficient
cleaning. The spray ball should be removed and routine spray ball
dismantling should be done to ensure that spray balls are clog-free.
(IMPROVEMENT NEEDED)

18. The following chemical containers were noted without labels.

a) An alcohol spray bottle in the station laboratory.

b) A liquid detergent container in the station laboratory.

c) An alcohol spray bottle and two squirt water bottles in the main
laboratory.

d) An orange liquid degreaser inside a cabinet in the packaging materials

staging area.

The facility was reminded to consistently label cleaning chemical

containers to prevent confusion and misuse. (IMPROVEMENT
NEEDED)

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 INTEGRATED PEST MANAGEMENT

19. Four rodent droppings were again noted inside an electrical cabinet in the
UHT room. Four rodent droppings were also noted inside an electrical
cabinet in the water treating room. It was apparent that the rodents were
entering processing area via the electrical wiring system of the facility.
The subcontracted pest management company should be consulted to
determine the appropriate approach as inspecting and cleaning the
electrical wiring system inside ceiling is dangerous.
(UNSATISFACTORY)

20. More than 20 active ants were noted on the upper surface of sugar
dissolving tank #2. Most of the ants were crawling very near the manhole
hatch. On the nearby staged sacks of sugar, more than 50 live ants were
crawling. Although a non-Pepsi product was being processed at the time
of the survey, it was understood that the same issue was being
encountered during Pepsi product runs. It was explained that with the
number of ants noted, it was very possible that during sugar dumping,
ants will also be introduced into the tank. It was understood that ants
were crawling from unidentified area from the walls or ceiling near the
processing tanks. A more detailed search should be conducted to prevent
the ant harbourage area. Once determined, the area should be sealed to
prevent future harbourage. (UNSATISFACTORY)

21. PVC pipes were cut in several pieces to become rodent bait stations.
When installed on the ground, they were covered with a metal sheet with
one side screwed to the ground, the other side left unfastened resulting to
easy access. Furthermore, a rodent bait pack was noted left on the outside
of a bait station which was just about 20 feet away from the entrance to
the packaging area. The possibility that the bait pack be kicked and be
introduced inside the packaging area was high. The design of the bait
station should be enhanced to make sure they are secured including the
bait pack inside them. Rodent control should be considered to be included
in the service agreement with the subcontracted pest management
company. (SERIOUS)

22. An annual facility assessment had not been conducted covering the areas
in and out of the facility. To determine the effectiveness of the defined
pest management program, a facility assessment should be conducted
covering the inside and outside grounds of the facility. (IMPROVEMENT
NEEDED)

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 ADEQUACY OF PREREQUISITE AND FOOD SAFETY PROGRAMS

23. In light of the many noted evidences of eating, drinking and smoking
outside designated areas, it was recommended that the training program
be reviewed to determine whether the current content and frequency are
sufficient to meet the high level of hygiene expected. (SERIOUS)

24. In light of the noted recurring signs of rodent activity, it was strongly
recommended that members of the food safety team conduct self
inspections with more detail and thoroughness. The team members
should be trained and be able to understand the requirements of the AIB
standard to make the inspection program an effective tool in highlighting
and addressing food safety issues. Inspections should be done using a
three-dimensional (3-D) approach by changing positions constantly as
issues could be present above or below eye level. (UNSATISFACTORY)

25. In light of the noted recurring slime formation of slime in a product zone,
the cleaning program should be reviewed to determine whether the
current content is sufficient to meet the high level of hygiene expected.
(UNSATISFACTORY)

26. In light of the noted several unlabeled chemical container, the chemical
control program should consider more frequent awareness campaigns
informing employees and even non-facility personnel on the dangers of
chemical contamination stressing the importance of the chemical
container labelling. (IMPROVEMENT NEEDED)

27. The facility had not conducted a Vulnerability Assessment to identify food
defense risks. The facility was reminded that to ensure security measures
were being implemented where it is most needed, a Vulnerability
Assessment should be conducted. The output of the assessment should be
used to define the Food Defense Program to ensure reduction of risks of
intentional harm to the facility, personnel and food products. (SERIOUS)

   Number of missed  0 X 305 =  0   
Minimum Mandates 
(from iBase report) 
   Number of  3 X 305 =  915   
Unsatisfactory items 
from matrix: 

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   Number of Major Items  14 X 40 =  560   
from matrix: 
   Number of Serious Items  24 X 20 =  480   
from matrix: 
   Total Matrix Score (1000  -955
minus points) 

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