SHELL EGG PROGRAM
EGG PRODUCTION
(TEMPLATE)
Business:
Manager:
Address:
Phone:
Mob:
Fax:
Email:
Accreditation No:
PIC No:
Egg Stamp No/Design:
The Biosecurity Tasmania template Shell Egg programs (SEP) are to be used as a guidance document only. The hazards
and control measures identified in these food safety plans are generic across the industry, and are based on existing
published research. Businesses must not assume that this guidance document covers all food safety hazards within
their business. If using this document to develop your SEP then you must adapt this document to fit your business,
products, and market requirements, and to ensure that all potential food safety hazards are identified and controlled.
Note: A copy of the completed document must be forward to the Department for approval
For further information or assistance, please contact:
Food Safety Management Officer
Product Integrity Branch
Phone: (03) 6165 3091
Email:
Owen.Hunt@dpipwe.tas.gov.au
Template FSP Egg Production - V1.7 March 2015
Page 1
Contents
PURPOSE: ............................................................................................................................................................................ 3
SCOPE: ................................................................................................................................................................................ 3
DECLARATION and COMPANY POLICY STATEMENT ........................................................................................................... 6
1.0 GOOD MANUFACTURING PRACTISES ........................................................................................................................... 7
2.0 PERSONNEL AND DUTY STATEMENTS .......................................................................................................................... 8
3.0 TRAINING .................................................................................................................................................................... 10
4.0 INTERNAL REVIEWS AND AMENDMENT PROCEDURES .............................................................................................. 11
5.0 PURCHASE/ACQUISITION POLICY ............................................................................................................................... 12
6.0 BIRD ENVIRONMENT................................................................................................................................................... 13
7.0 BIOSECURITY ............................................................................................................................................................... 16
8.0 DETECTION OR SUSPICION OF AN EXOTIC OR NOTIFIABLE DISEASE .......................................................................... 18
9.0 EGG PRODUCTION ...................................................................................................................................................... 20
10.0 CLEANING PROCEDURES ........................................................................................................................................... 22
11.0 CALIBRATION ............................................................................................................................................................ 23
12.0 PRODUCT IDENTIFICATION AND TRACEABILITY ........................................................................................................ 25
13.0 CORRECTIVE ACTION ................................................................................................................................................ 26
14.0 CUSTOMER COMPLAINTS ......................................................................................................................................... 27
15.0 APPROVED SUPPLIER PROGRAM .............................................................................................................................. 28
16.0 PRODUCT RECALL...................................................................................................................................................... 30
17.0 COOL STORE / TEMPERATURE CONTROLLED ROOM ................................................................................................ 33
18.0 HYGIENE AND SANITATION ....................................................................................................................................... 34
19.0 HYGIENE OF PERSONNEL .......................................................................................................................................... 36
20.0 DISPATCH and TRANSPORTATION ............................................................................................................................ 37
21.0 REFRIGERATION ........................................................................................................................................................ 38
22.0 POTABLE WATER ....................................................................................................................................................... 39
23.0 PEST CONTROL PROGRAM ........................................................................................................................................ 40
24.0 EGG STAMP EQUIPMENT FAILURE............................................................................................................................ 41
Form 1 Pre-operational Check ..................................................................................................................................... 42
Form 2 Amendment Record Sheet .............................................................................................................................. 43
Form 3 Repair and Maintenance Record ..................................................................................................................... 44
Form 4 Corrective Action ............................................................................................................................................. 45
Form 5 Customer Complaint ........................................................................................................................................ 46
Form 6 Internal Review Checklist................................................................................................................................. 48
Form 7 Weekly Egg Collection Form ............................................................................................................................ 49
Form 8 Customer List ................................................................................................................................................... 50
Form 9 Employee Training Matrix................................................................................................................................ 51
Form 10 Receival Checklist .......................................................................................................................................... 53
Form 11 Visitor Log ...................................................................................................................................................... 54
Form 12 Recall Checklist .............................................................................................................................................. 55
Form 13 Notification of Equipment Failure (Egg Stamp) ............................................................................................. 61
Appendix 1 PLAN DIAGRAM OF PREMISES LAYOUT ......................................................................................................... 61
Appendix 2 PRODUCT DESCRIPTION ................................................................................................................................. 64
Appendix 3 EGG PRODUCTION FLOW CHART ................................................................................................................... 65
Appendix 4 EGG PRODUCTION – HAZARD ANALYSIS TABLE ............................................................................................. 66
Appendix 5 HAZARD AUDIT SHEET – EGG PRODUCTION .................................................................................................. 68
Template FSP Egg Production - V1.7 March 2015
Page 2
PURPOSE:
To provide a model for uniform hygienic production of shell eggs in Tasmania that documents how the egg production
business meets the five “relevant criteria” of the Primary Produce Safety Act 2011, Primary Produce Safety (Egg)
Regulations 2014 and ANZFA Standard 4.2.5.
The criteria to be addressed in the program are:





Food Safety;
Animal Welfare;
Biosecurity;
Environmental Impact; and
Labelling Standards
SCOPE:
To apply to all operational processes relating to the production of shell eggs for human consumption.
DISTRIBUTION OF MANUAL:
All employees of the premises will be made aware of the contents and have unrestricted access to this Egg Production
manual.
COPIES OF THIS MANUAL ARE HELD in the following locations:[Egg Producer]
Manual No
1
“
2
Other copies as required
“
REFERENCES
Primary Produce Safety Act 2011, Primary Produce Safety (Egg) Regulations 2014;
Australian Egg Corporation Limited (AECL)
 Code of Practice for Shell Egg, Production, Grading, Packing and Distribution 1998
 National Egg Quality Assurance Program.
Rural Industries Research and Development Corporation (RIRDC):
 Code of Practice for Biosecurity in the Egg Industry
 Food Safety Risk Management in Different Egg Production Systems
Primary Industries Standing Committee:
 Model Code of Practice for the Welfare of Animals: Domestic Poultry,
(SCARM 83)
 Model Code of Practice for the Welfare of Animals: Land Transport of Poultry, 1998.
(SCARM 65)
 A Guide to the Implementation and Auditing of HACCP, (SCARM 60)
4 th
Edition,
1995.
Department of Primary Industries and Parks, Water and Environment
 Environmental Guidelines for Poultry Producers 1990
 Animal Health Act 1995
Template FSP Egg Production - V1.7 March 2015
Page 3
DEFINITIONS
Tasmanian Department of Primary Industries,
Parks, Water and Environment (Biosecurity Tasmania):
The Controlling Authority.
Approved Program:
A program approved by the controlling
authority that addresses the hygienic
production of shell eggs for human
consumption.
Co-owner/Operator/Lessee:
HACCP
Hazard
Point
Analysis
and
Critical
Control
Flow Chart Symbols:
= Inspection
D
= Delay
= Operation
= Transport
= Storage
= Combined Actions

Animal Welfare Practice
Activities and procedures which assist in assuring appropriate conditions are maintained for animals.

Biosecurity
Procedures that will prevent or limit the build-up and spread of harmful microorganisms and pests which impact
adversely on animal health.

Control Point (CP)
A Control Point (CP) is an operation (practice, procedure or process) at which control can be exercised over one or
more factors to eliminate, prevent or minimise a food safety, quality, biosecurity or animal welfare hazard.

Critical Control Point (CCP)
A Critical Control Point (CCP) refers to a stage of the production process where it is essential that control be applied
to eliminate, prevent or minimise the risk associated with food safety, quality, biosecurity or animal welfare.

Eggs
means an egg from any avian (bird) species, except ratites, which are fit for human consumption.

Food Safety
Activities and procedures which assist in minimising risk to the safety of food which is deemed fit for human
consumption.

Food Safety Standards
Standards described in the Food Standards Code issued by the Australian New Zealand Food Authority.

Good Manufacturing Practice
Good Manufacturing Practice (GMP) is the system developed to ensure product and process quality and safety
are safeguarded through standardised practices.

Good Hygiene Practice
Good Hygiene Practice (GHP) is the system developed to ensure safety of food and farm biosecurity through the
Template FSP Egg Production - V1.7 March 2015
Page 4
principles of good hygiene and health of food handlers. This is based on the Australian New Zealand Food Authority
(ANZFA) Food Standards Code.

HACCP
Hazard Analysis Critical Control Point – a means of identifying potential hazards to the quality and safety of a product
or process, identifying measures to prevent those hazards occurring, nominating those hazards which are deemed
critical, monitoring those critical hazards and pre-planning corrective responses to hazards should they occur.

Vermin
Vermin includes rodents and predators.
Abbreviations:
Throughout this Manual and associated HACCP Plan, we use the following abbreviations:

Biosecurity Code – Code of Practice for Biosecurity in the Commercial Egg Industry.

CCP – Critical Control Point.

Food Safety Code – Code of Practice for Shell Egg, Production, Grading, Packing and Distribution.

Welfare Code – Model Code of Practice for the Welfare of Animals (Domestic Poultry).
Definitions of non-conformances:

Minor non-conformance: a low risk situation: a non-conformance with the requirements of the
Standards (including a non-conformance with the management’s documented system and food safety
plan) where the potential impact of the non-conformance is not likely to compromise egg safety.

Major non-conformance: a high potential risk situation: a non-conformance with the requirements of
the Standards (including a non-conformance with the owner’s documented management system and
food safety plan) where the potential impact is likely to compromise egg safety if no remedial action is
taken to correct the non-conformance within a specified period.

Critical non-conformance: a high risk non-conformance with the requirements of the Standards
(including a non-conformance with the owner’s documented management system and food safety plan)
where the potential impact of the non-conformance is of substantial and/or immediate significance to
egg safety warranting immediate corrective action.
Template FSP Egg Production - V1.7 March 2015
Page 5
DECLARATION and COMPANY POLICY STATEMENT
I/we, ?????, the operator/s of ‘THIS EGG FARM’, an egg processing premises, Program Approval Nº.E ??, situated at
???, Tasmania, advise that I/we agree to comply with the rules, procedures, specifications and other undertakings as
outlined in this egg production manual. I/we also undertake to comply with the requirements of the following
legislation and codes of practice, in so far as they may be applicable;
i)
Primary Produce Safety Act 2011;
ii)
Primary Produce Safety (Egg) Regulations 2014;
iii)
Tasmanian Code of Practice for Hygienic Production of Shell Eggs for Human Consumption;
and
iv)
Model Code
4th Edition.
of
Practice
for
the
Welfare
of
Animals
–
Domestic
Poultry,
My/our policy is to process and distribute eggs of quality so that my/our clients receive superior quality and best
service possible.
My/our objective is to ensure that myself/we and any staff are aware of their responsibilities regarding product
quality whilst conforming to Legislation and Industry Codes of Practice. My/our commitment to a wholesome product
which is free from disease is outlined in this Egg Production Manual.
I/we shall ensure that any staff are conversant with my/our company objectives, and ongoing commitments to
improving quality in every facet of the company.
Accordingly, I/we declare that I/we, ???? being the operator/s of an egg processing premises, Program Approval Nº E
??, take responsibility for, and appropriate action as necessary for maintaining, the Approved Program.
Signed ......…………….............................
Witness ........……………...........................
Date .......................................
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1.0 GOOD MANUFACTURING PRACTISES
Good Manufacturing Practises are those things which we do that have an effect on food safety and product quality
that are not necessarily directly related to specific product or processes. These include
Environment (the condition of the premises where food is handled)
Storage and handling of food
Personal hygiene practises
This GMP policy includes the following, which are a set of rules that help control the above areas.
Environment
Walls, ceiling, windows and floors are to be kept clean and free from dust and cobwebs.
All doors will be self-closing to prevent entry of dust or insects.
Smoking will not occur inside any of the farm buildings.
Storage and handling
Make sure that unused product is covered and stored in the correct environment (temperature control)
All waste receptacles will be clearly marked and used for their intended use only.
Hygiene Practises
When handling food products, personnel will always wear protective clothing. This includes
Hair nets
Gloves (if required)
Aprons
Boots
Ear muffs
When working with food personnel will not wear jewellery or rings.
Personnel must wash hands after going to the toilet.
Verification
It is the job of the HACCP Officer to continuously check the staff to see if their work practises conform to
Good Manufacturing Practises.
Once a week he will record if staff has complied with GMP’s or if not record what was not complied with.
This will be recorded on the Complaints and Improvements sheet. The full record must be documented.
This includes corrective action (re-training) and when it will be carried out.
Document
Approved Program Manual
Live Bird Details(Purchases, Receivals, etc)
Bird Mortalities
Temperature Records
Customer List
Template FSP Egg Production - V1.7 March 2015
Location
Farm Office
Record books at each shed
Record books at each shed
Form 1 Pre-operational Check
Form 8 Customer List
Page 7
2.0 PERSONNEL AND DUTY STATEMENTS
?????
Owner and operator
CLEANER
-
-
???
Egg room
Egg washer
Grader
Egg room
FEEDMILL OPERATOR
Mixing
Cleaning
Recording
Hygiene
EGG HANDLER
-
Chicken Sheds
Brooder shed
Grower shed
Layer shed
ORDERER
-
-
Feed mill
Order raw ingredients
Inspect ingredients
Store ingredients
Collect eggs
Wash & Dry eggs
Candling
Grading
Packing
Labelling
Storage
Hygiene
POST MORTEMS
Egg Layers
Order Layer flocks
SHED PREPARER
-
Egg Layers
Prepare Brooder shed
Prepare Grower shed
Prepare Layer shed
HUSBANDRY
-
Egg Layers
Vaccinations
DELIVERER
-
Eggs
-
Invoicing
QUALITY OFFICER
Quality Assurance
Training
Product Inspection
CATCHER
-
Brooders, Growers & Layers
Transport
Placement
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3.0 TRAINING
Purpose:
To identify the training needs and provide the resources to satisfy the training of all personnel performing activities
which may affect food safety, biosecurity or animal welfare.
Requirements include:






The skills and experience or qualifications of an employee to perform a particular function shall be documented
(Forms ? and ?) and readily available to supervisory staff who delegate tasks.
All staff shall be appropriately trained to perform the tasks they are given.
All staff shall be given induction training relevant to the duties they will perform.
Staff who have direct contact with live poultry shall be appropriately trained in relation to biosecurity and animal
welfare procedures.
Copies of certificates for any formal training undertaken by staff during their employment will be retained on file.
Staff who handle eggs for human consumption will be appropriately trained in relation to food handling procedures.
Procedure:
All functions within the Company's operations demand a certain skill and this skill factor has been pre-determined and
documented.
Work Instructions (WI) detail the functions that each person are to perform (responsibilities) and the authority that each
person has in the performance of those functions. Skill levels should therefore relate to these functions that need to be
addressed.
The Employee Training Record (Form 9) shall be maintained to show the relationship between applicable functions
and the employee’s skill level. A tick () shall indicate an employee has commenced trained in that function but is not
yet competent. Two ticks () indicates the respective person is competent in that function to the satisfaction of the
Farm Manager. Three ticks () indicates that a certificate has been issued. A “T” shall indicate an employee’s
requirement for training in a particular function. Where blank, indicates the skill is not pertinent to that employee.
The Employee Training Summary is an ongoing record and will be updated as required.
The Company retains records to show evidence of training undergone by employees. Copies of relevant certificates
for training, etc are to be retained in respective files.
All new employees will be given suitable induction training. All employees shall undertake appropriate training to
ensure their understanding and compliance with the HACCP Plan.
See WI No ? and Appendix ?
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4.0 INTERNAL REVIEWS AND AMENDMENT PROCEDURES
The operations and procedures contained within this Approved Program will be reviewed biannually, or as necessary,
so as to ensure they consistently and accurately describe the operations and procedures carried out at this premises.
The results of these reviews will be recorded on Form 6 Review Checklist and shall be kept at the premises, they will
be made available to an authorised officer upon demand.
Any proposed amendment to the program shall be:
i)
ii)
iii)
Submitted to the controlling authority for approval,
Upon approval, sent to each holder of a manual,
Recorded on the Amendment Record Sheet.
All amendments shall be first approved by the Department of Primary Industries, Parks, Water and Environment.
Please contact:
Food Safety Management Officer
Product Integrity Branch
Phone: (03) 6165 3091
Email:
Owen.Hunt@dpipwe.tas.gov.au
All holders of this manual shall be provided with suitably annotated copies of the amendments, all amendments shall
be dated.
All holders of the Egg Production manual shall be requested to appropriately endorse the amendments record sheet
in the front of the quality assurance manual.
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Page 11
5.0 PURCHASE/ACQUISITION POLICY
Livestock
I/we, ???, are/am responsible for all purchases and/or acquisitions of livestock.
The company policy is that:
i)
ii)
only clean and healthy stock is purchased;
only clean and healthy stock is acquired,
All livestock receivals shall be recorded in the Record Book at each shed
Materials
I/we, ????, are/ am responsible for all purchases.
All packaging material purchased will be approved for use in the egg industry. All receivals shall be inspected on
arrival to ensure it is true to order and shall be recorded on Form 10 Receivals Checklist. As soon as possible after
inspection the packaging material will be stored, off the floor, appropriately in a dust and vermin proof environment.
Routine stock rotation will occur, ensuring older stock is utilised first.
All chemicals and veterinary medicines will be inspected on arrival to ensure they are true to order. As soon as
possible after inspection the chemicals and veterinary medicines will be stored separately, in original containers, in a
dust and vermin proof environment. Routine stock rotation will occur, ensuring older stock is utilised first.
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Page 12
6.0 BIRD ENVIRONMENT
6.1 Purchase and Receival of Birds
1.
Birds are purchased from an Approved Supplier.
2.
On arrival, birds are inspected for signs of stress or sickness and appropriate procedures are followed to help the
birds settle into their new environment.
3.
A mortality level of less than 1 in 1,000 on arrival is a desirable target. Higher mortality levels may mean that
hatchery and transport staff training and/or procedures are inadequate and are queried. If the occurrence is
repeated the supplier is removed from the Approved Supplier list.
4.
Records are kept of the vaccination status of birds on arrival and their donor flocks by the Approved Supplier.
5.
Transport during extremes of weather is avoided unless the birds can be adequately protected from the
weather to safeguard their welfare.
6.
Barns are appropriately prepared for the birds prior to their arrival.
7.
Birds shall be handled with due care when placing in sheds.
8.
A system is in place that allows proper monitoring of the birds, particularly in the first few days of placement.
The Farm Manager is familiar with their requirements. Skilled, trained stock handlers are able to use their
experience and ability to gauge the well-being of the flock by observing behaviour and appearance.
9.
Appropriate feed and water must be available and the delivery equipment functioning and appropriately
adjusted.
10. Stocking densities must comply with relevant Codes of Practice and legislation.
Procedure:
i.
I/We will only purchase birds from an Approved Supplier (Sections 6.1 and 6.2 outline the purchasing
procedures that are to be followed).
ii.
The number of Dead on Arrival can be used as an indicator of good animal handling practice and if Mortality
Rates of >1:1,000 are identified, animal management practices are to be reviewed by the Farm Manager. The
number of birds received and the number of dead birds on arrival is to be recorded in the Farm Diary by the
Manager (see WI ?? for details)
iii.
Birds are to be checked for signs of stress and sickness on arrival and this is recorded on the Shed Setup and Bird
Placement Check List (Form 16).
iv.
Prior to the arrival of a new flock of birds, the Farm Manager is to ensure that the sheds or barns in which the
birds are to be placed have been cleaned and prepared, pest control measures taken and the food and water
delivery system checked. Evidence of this check is to be recorded on the Shed Setup, Bird Placement and
Transport Check List (Form 16). For multi aged sheds, cleaning is to be undertaken annually.
6.2
Bird Placement
i.
Stocking densities are to be in accordance with relevant Codes of Practice and legislation. Optimum stocking
density will depend on management, the quality and type of housing and the capacity to achieve and
maintain acceptable levels of temperature, humidity, air exchange, ventilation and humidity.
ii.
Maximum stocking densities apply only to birds housed under good management with optimal temperature
and ventilation conditions.
Template FSP Egg Production - V1.7 March 2015
Page 13
iii.
Stocking densities are re-evaluated if there is evidence of disease or if behavioural changes such as
cannibalism occur.
iv.
Checking of birds is considered one of the most important daily management tasks. Birds must be checked on
arrival and two hours after arrival to ensure birds are not unduly stressed or recovering appropriately. It is also
essential for the first 48 hours after placement and is critical for the subsequent production and welfare of the
birds. Evidence of this will be maintained in the Shed Setup, Bird Placement and Transport Check List (Form 16)
and the Daily Check List (Form 20).
v.
If medication is required, the Farm Manager is to ensure the appropriate level of medication is provided to the
birds. S4 or Prescription Animal Remedy medications cannot be used without consulting a veterinarian. See
section??????
6.3
Rearing
Shed Management
a)
A plan diagram of all holding facilities, their relationship to the processing facility is provided in Appendix 1 of
this manual.
b)
We/I, ?? or a suitably trained employee nominated by us, will check the bird holding sheds regularly for any
problems that may cause injury or stress to the birds. Any defects found are recorded in the Farm Diary and
action is taken to rectify the problem.
c)
All work involving the handling of birds will be carried out competently and with due regard to animal
welfare.
d)
Manure is removed from the holding sheds annually and is spread on farm pasture. There is a sizeable
distance from the sheds to where the manure is spread to provide an effective buffer.
e)
Bird Spacing will be in compliance with Appendix 2 of the Model Code of Practice for the Welfare of Animals –
Domestic Poultry,4th Edition (SCARM 83).
As soon as practical after unloading and/or housing of live birds, all details such as:




Number of birds in consignment;
Where purchased;
Transporter and;
Number of mortalities (if any);
will be recorded in Form 10 Receival Checklist.
Bird Mortalities
i.
We record bird mortalities and culls so that accurate estimates can be made of flock size. This is documented in
the Farm Diary. Unusual increases in mortality rate will be investigated and acted upon.
ii.
All dead birds are removed daily, prior to collecting eggs, these mortalities are recorded in the Farm Diary. Dead
birds are placed in water proof containers outside sheds for disposal in the on farm pit.
iii.
Although manure removal is programed for removal annually, any excessive build-up of manure is removed
sufficiently regularly to ensure there can be no contamination of eggs or cross contamination of birds.
iv.
The formation of aerosols during litter and manure removal should be minimised and staff are to follow the
directions outlined in Work Instruction ??.
Template FSP Egg Production - V1.7 March 2015
Page 14
v.
Birds will be closely observed during unloading for evidence of injury, sickness or disease.
vi.
Severely injured, moribund birds and those requiring emergency slaughter will be humanely killed without
delay.
vii.
Any bird will be disposed of, without delay, in accordance with Section 7.4 of the Tasmanian Code of Practice
for Hygienic Production of Shell Eggs for Human Consumption .
6.5
Feed mill Program
Receiving Ingredients
Ingredients are only purchased from the suppliers listed in our Approved Supplier program. If any problems arise with
ingredients, Approved Supplier list may need reviewing.
All feed ingredients used in the feed mill are stored in plastic bags or in bulk sealed bird proof silos.
All receivals are to be inspected and recorded on Form 10 Receival Checklist
Inspecting Ingredients
All ingredients must be inspected upon arrival. This needs to be done by a trained person (Feed mill Operator). In
regards to smell, appearance, moisture content, colour etc. ingredients should be consistent with normal product.
Any ingredient that doesn’t meet the standard should be destroyed or returned. This will be recorded on the Incoming
Goods sheet.
Mixing
All ingredients must be added to each mix at the correct weight. This requires trained and competent personnel.
Every batch will be recorded, correctly mixed and placed in the correct silo. This will be recorded in the Farm Diary.
Template FSP Egg Production - V1.7 March 2015
Page 15
7.0 BIOSECURITY
Procedures are in place that will prevent or limit the build-up and spread of harmful microorganisms and pests in the
farm and production areas and the biosecurity programme and the implementation of these procedures are to inhibit
the movement of infectious agents harmful to poultry into, within or out of a facility containing poultry susceptible to
those agents.
Diseases such as;

Avian Influenza, Virulent Newcastle’s Disease and Very Virulent Infectious Bursal Disease; and

Salmonella Enteritidis;
can be introduced to the farm via contaminated fertile eggs and birds purchased for rearing and laying, feed, litter,
equipment, vehicles, wild birds, other animals and people.
7.1
Requirements:
i.
Equipment on the farm is to be properly cleaned and maintained. When equipment is brought onto the farm it
shall be either from a non-contaminated site or cleaned and sanitised before use.
ii.
Equipment that is to be used should either be single use or of such material and construction that will allow proper
cleaning and sanitising.
iii.
All vehicles, including vehicles used for delivering eggs, and those used for the collection of feed, dead birds,
manure and reject eggs, are a potential biosecurity hazard and must not be allowed to contaminate the farm.
iv.
Staff are trained in poultry management, bird and egg handling, biosecurity and hygienic practices relevant to their
tasks.
v.
Work practices are developed so as to minimise hazards (eg. visiting young birds before older).
vi.
Appropriate signs are posted to indicate areas of restricted access or activities (eg non-smoking or non-eating
areas).
vii.
If staff are absent unexpectedly, the remaining staff shall be able to determine which tasks are urgent and which
can be completed as time becomes available.
viii.
The entry of Visitors is controlled and movements on the Farm are monitored. If it is suspected that visitors have
been to contaminated sites that day, access are prohibited or appropriate sanitation procedures used.
ix.
Visitors are questioned at the Shed Boundary.
x.
Visitors and staff shall wear farm dedicated clothing, clean coveralls or disposable clothing. Footwear is to be farm
dedicated, covered, disposable or be able to be sanitised before entry into sheds and ranges.
7.2
a)
Procedure:
Standard cleaning procedures have been developed to ensure that equipment, buildings and storage areas remain
clean. These procedures are documented at (WI 11).
b) The Farm Manager is to ensure that buildings and equipment are well maintained and in good order.
c)
The Farm Manager maintains a Cleaning Schedule (WI 11) that outlines sites, tasks and frequency. Evidence of daily
cleaning is recorded on Form 1 Pre-operational Checklist.
Template FSP Egg Production - V1.7 March 2015
Page 16
d) An Employee Training Summary indicating the skill levels of individual employees is described in the Training section
3. Refer to (Form 9 Training Record) for details.
e)
Good Hygiene Practices (GHP) address the food safety and biosecurity risks associated with egg production. The
greater the chance of microbial spoilage or contamination of product or the introduction of infectious agents of
significance to flock or human health, the higher the risk and therefore the greater the level of hygiene training
required by the employee. (WI 11) details the farm’s cleaning program.
f)
Appropriate standards of care for personal hygiene are impressed on all staff. Particular attention are given to
contamination which can be caused by failing to wash hands or clothing and contact with poultry or other birds.
g)
The Farm Monthly Check List is completed by the Farm Manager.
h) People are a potential means of introducing infection onto farms and packing stations (e.g. by moving from dirty to
clean areas, inappropriate hygiene practices and if they also visit other farms or packing stations, etc).
i)
Visitors are kept to a minimum and are subject to the same degree of hygiene control as staff. Washable or
disposable overalls and boots are provided for visitors and washed or disposed of after use.
j)
Parking facilities are provided away from areas where birds are housed.
k)
People should not be allowed access if it is suspected that they have been to contaminated sites that day.
l)
The Farm Manager should maintain the Visitors, Equipment and Vehicles Log (Form 11 Visitor Log), which records
movements onto the farm of all visitors including subcontractors and transport drivers.
m) Staff should follow internal biosecurity procedures such as conducting work activities in such a manner that they
move from low contamination risk areas to higher contamination risk areas and not the other way.
n) Any staff suffering from a condition or symptom that may expose eggs to a possible contamination (a Food Safety
requirement) or if they may present a risk to birds from a contagious disease (a Biosecurity requirement) are to
report immediately to their Supervisor.
o) Staff shall wash their hands before and after egg collection and after contact with any potentially contaminating
material.
p) All rubbish is placed in bins and emptied regularly.
q) Smoking is prohibited in buildings and only permitted in designated areas.
r)
Food and drink may only be consumed in the designated area.
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8.0 DETECTION OR SUSPICION OF AN EXOTIC OR NOTIFIABLE DISEASE
Procedures have been developed to deal with birds showing symptoms consistent with an Exotic or Notifiable Disease.
DPIPWE are the controlling authority should the need arise to combat the incursion of an Exotic or Notifiable disease.
Discovery and Notification
If any bird handler encounters any suspicious abnormality or any unusual condition with birds, especially if it affects
more than one bird, then officers of Biosecurity Tasmania are to be notified without delay. This initial contact can be
made by telephoning the Exotic Disease Hotline on 1800 675 888.
All instructions given by Biosecurity Tasmania officers shall be complied with. These may
include:
i)
ii)
iii)
iv
v)
vi)
vii)
viii)
ix)
x)
Stoppage of all production operations,
Stoppage of all egg processing on the premises,
Stoppage of all bird movement at the premises,
Stoppage of all unnecessary personnel movement at the premises,
Stoppage of all movement from the premises,
Restricting premises access to authorised persons only,
Close and lock all cool rooms and freezers,
Turn off all taps, to restrict water flow,
Close and lock all access gates to the premises and post guards,
Await the arrival of Biosecurity Tasmania officers.
Isolation
(Biosecurity Tasmania are in charge)
This phase involves the coordinating of several activities.
i)
ii)
iii)
iv)
v)
vi)
vii)
Disinfection
A communication centre will be established,
An official entry/exit point will be established,
DPIW are in charge of all procedures to control persons and vehicles entering or leaving,
All birds at the premises will be examined by Biosecurity Tasmania,
Any dogs at the premises will be kennelled,
All water will be shut off, including effluent pumps to minimise the possible spread of contaminated
waste,
Owner/operator/lessee will supply records detailing origin of birds at premises, destination of all
eggs and egg products that left the premises in the last 24 hours and any other information
Biosecurity Tasmania may request.
(Biosecurity Tasmania are in charge)
The owner/operator/lessee will make available the following:
i)
ii)
iii)
Trace Back
Drainage plan of the premises,
Premises site and floor plan,
List of cleaning chemicals in storage,
(Biosecurity Tasmania are in charge)
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The Controlling Authority will be provided with the following information:
i)
Origin of all birds that have come onto the plant in the last 24 hours,
ii)
How stock was transported and by whom,
iii)
Destination of all egg, egg products, bird carcases, by-products and all other waste that has
left the premises in the last 24 hours,
iv)
The names and where possible the addresses of all persons who
have been at the premises within the last 24 hours.
Responsibility (Biosecurity Tasmania are in charge)
Although Biosecurity Tasmania are in charge the operator will have certain responsibilities, including:
i)
ii)
Providing assistance to Biosecurity Tasmania,
Actioning workforce to respond to Biosecurity Tasmania requests.
Communication and Notification
When there is reasonable grounds to suspect that an Exotic or Notifiable disease is present at the premises
the owner/operator/lessee will make all members of the workforce aware of its presence. Additionally he
shall request their full cooperation with Biosecurity Tasmania.
Persons, other than employees, who regularly visit the premises and their reason for being at the premises,
are:DPIPWE auditor Phone
Deliveries:
 Live Birds
 Feed
 Litter
 Services (State what services)
Vaccinations
Vaccination programs shall be developed and implemented in consultation with the hatchery, which supplies birds.
Any signs of unusual illness or poor health in a flock shall be immediately drawn to the attention of a veterinarian or
the responsible department in the State or Territory in which the farm is based;
When medication has been given to a flock, eggs shall not be sold during the recommended withholding period as
stated on the label. Records of vaccinations must be made available during audits or upon request
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9.0 EGG PRODUCTION
9.1
Feed mill Program
Receiving Ingredients
Ingredients may only be purchased from the suppliers listed in our Approved Supplier program. If any problems arise
with ingredients, Approved Supplier list may need reviewing.
Inspecting Ingredients
All ingredients must be inspected upon arrival. This needs to be done by a trained person (Feed mill Operator). In
regards to smell, appearance, moisture content, colour etc. ingredients should be consistent with normal product.
Any ingredient that doesn’t meet the standard should be destroyed or returned. This will be recorded on the Incoming
Goods sheet.
Mixing
All ingredients must be added to each mix at the correct weight. This requires trained and competent personnel.
Every batch will be recorded, correctly mixed and placed in the correct silo. This will be recorded on the Bird Record
Sheet.
9.2
Bird Growing
Air Quality and Temperature
Every day the air quality and temperature of the bird environment will be checked by a trained person who will record
the findings and any deviations requiring rectification in the Bird Record Sheet (Weekly summary).
Water/Feed
Three times a week the bird environment will be checked by a trained person to ensure that the birds have access to
acceptable quality and levels of feed and water. All findings and any deviations requiring rectification will be recorded
in the Bird Record Sheet (Weekly summary).
9.3
Layer Flocks
See 8.0
Egg Collection
(Describe)
Wash & Dry Eggs (If applicable)
To ensure that the eggs have a reduced risk of contamination from microbiological sources both the temperature of
the washing water and the dryness of the washed egg need to be monitored. A trained person will record on the
Weekly Egg Collection Sheet that this has been done every time the Eggs are washed (or hourly).
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Eggs will be cleaned in accordance with one of the methods described in the Tasmanian Code of Practice for Hygienic
Production of Shell Eggs for Human Consumption – 2004 (Describe)
Candling and Grading
(Describe how you inspect eggs for faults and grade for packing)
Packing and Storage
(Describe your system for the packing and storage of eggs)
Waste Disposal
(Describe your system for waste disposal)
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10.0 CLEANING PROCEDURES
The premises and all equipment used in the production of eggs will be maintained in a clean and orderly condition.
10.1
Packing/Grading Room
-
-
The premises where eggs are handled include the collection area, packing room and the delivery vehicle.
None of these things needs sanitising, but they need sweeping out regularly to keep the environs free
from dust and cobwebs. The floors of these areas should be hosed down at the end of each day to
remove any dropped product.
Equipment that comes into contact with the product includes the Egg weigher and the Egg washer.
These need to be kept clean and the egg washer will be washed out after each use.
10.2 General/Outside/Outbuildings
-
-
Clean out of premises and equipment will be done by trained personnel.
Every time the premises are sanitised before operation or cleaned after operation the trained personnel
will record that it has been done.
The premises’ surrounds will be maintained in a clean and orderly manner. The accumulation of
miscellaneous items and weed growth around the premises’ surrounds and out-buildings will be
minimised to prevent the harbouring of vermin.
If any deviance from the standard is detected or loss of control noted it will be recorded on the
Complaints and Improvement sheet. This also requires the corrective action to be recorded.
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11.0 CALIBRATION
All equipment used on these premises that weighs, measures, inspects or tests product is calibrated to ensure that
they are reading accurately.
Below is a list of all the equipment that requires Calibration at these premises:
Electronic scales.
Hand held thermometer.
Egg Grader
Mix all scales
Egg washer temperature gauge
Cool room temperature gauge and thermostat.
Freezer temperature gauge and thermostat.
Truck temperature gauge and thermostat.
Methods of Calibration
All the above equipment will be checked in accordance to the Tasmania Government Weights and Measures Act 1934.
The methods of calibration are as follows.
The Electronic scales will be tested against a test weight.
The Egg grader will be tested using the supplied egg weights that will be checked on the Electronic scales
after it has been verified accurate.
The mix all scales will be tested against a test weight
The hand held thermometer will be tested annually using ice water slurry.
Every other temperature gauge will be tested against the hand gauge after it has been verified accurate.
Every thermostat will be tested against the gauge supplied with it.
Frequency of Calibration
-
Thermostats and Temperature gauges will be tested annually.
The Electronic scales, the mix all scales and the hand held thermometers will be verified as accurate
annually.
The Egg grader will be checked quarterly.
Storage of Measuring Equipment
-
-
The Electronic scales will be stored in the Egg room. They should be kept clean and dry and free from
dust. They will be sanitised before use and cleaned with hot soapy water after use (be careful when using
water on electronic equipment)
The Hand held thermometer will be stored in its protective box in the implement cupboard.
The egg weights for the Egg weighing machine are to be stored in their protective boxes on the shelves in
the office.
Product Identification
-
All product produced between times of calibration must be identifiable.
Dates of equipment calibration must be clearly marked on Calibration check sheet.
Records
-
All calibrations will be checked and recorded on the Calibration check sheet. This must be dated and
signed
-
If equipment is out of calibration it must be noted and corrective action taken (increase
frequency of calibration or replace equipment).
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CALIBRATION RECORD SHEET
Equipment
Target
Electronic scales
+/- .005 kg @ 1 kg and
3 kg
Egg Grader
+/- .005 kg @ specified
weights
Mix all Scales
+/- .500 kg @ 1 kg and
10 kg
Hand held
thermometer
+/- 1oC
@ 0 oC and 20 oC
Chiller Temperature
gauge & Thermostat
+/- 1oC
@ 0 oC and 20 oC
Freezer
Temperature gauge
& Thermostat
Fridge Temperature
gauge & Thermostat
+/- 1oC
@ 0 oC and –18 oC
Cool room
Temperature gauge
& Thermostat
Truck Temperature
gauge & Thermostat
+/- 1oC
@ 10 oC and 14 oC
Egg Washer
Temperature gauge
+/- 1oC
@ 20 oC and 50 oC
Date
Completed
Result
Signed
+/- 1oC
@ 12 oC and 22 oC
+/- 1oC
@ 0 oC and 5 oC
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12.0 PRODUCT IDENTIFICATION AND TRACEABILITY
Eggs produced at this premises include the following:

Fresh Eggs. – All eggs must be stamped with the producers egg stamp (unique identifier) and packaged in
new egg cartons

The cartons are printed or have adhesive labels attached on which is printed the full name and address of
the producer, the ‘Best-Before’ date, this locates the eggs to a single week when they were packed.
Which every package must be marked with, and a Nutritional Information Panel.

Egg pulp. – recovered from cracked eggs aggregated into clean, leak-proof containers, for pasteurisation.

Egg pulp containers are labelled with name and address of producer, the producer’s egg stamp number
(unique identifier) and date of collection, prior to dispatch for pasteurisation.
(All requirements of the National Standard for Egg Labelling will be met)
The type of egg production system is also printed on the cartons or printed on a self-adhesive labels applied to the
cartons, ie, Free Range, Barn Laid or from Caged birds.
All Eggs produced for sale must be clearly stamped with the approved egg stamp (unique identifier)
Feed mill Products
The products used or produced in the feed mill are the following:
All of the ingredients (see ingredient list in the Feed mill program), bags, any of the finished rations, spilt feed and
general waste, and bait stations.
-
Each ingredient is clearly marked as to type, weight health & safety issues and storage conditions.
Bags if empty are to be stored inside another bag and placed either in the feed mill (to be used for feed) or the
implement shed (to be used for other purposes).
If bags are filled with feed they will be placed in the designated area according to the type of feed in them.
Spilt feed and waste (anything on the floor or surrounds) will be swept up and disposed of.
Bait stations must be placed inside approved containers.
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13.0 CORRECTIVE ACTION
Unsafe product that cannot be made safe is disposed of by ?? Describe.
Eggs, the shells of which have been damaged to the point where the inside is exposed to the air, called a
leaker.
Product out of specification is normally downgraded into either B grade or discarded.
Eggs downgraded as unusable are disposed of an approved refuse disposal area
Note: It is illegal to sell cracked eggs other than in bulk for Pasteurisation.
The Form 4 Corrective Action Form is to be completed whenever there is a possible or actual problem identified. This
can be a food safety or quality issue, OH&S issue, breakdown of equipment or facility maintenance issue.
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14.0 CUSTOMER COMPLAINTS
Customer complaints are to be recorded, it is the Managers responsibility to deal with customer complaints, locate
the cause and introduce corrective action to stop re-occurrences. It is important that everything is filled out in detail
on the Form 5 Customer Complaint Form. This form requires corrective action to be documented and implemented.
The Complaints and Improvement records will be reviewed regularly and any unresolved Complaints or Improvements
will be noted and dealt with.
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15.0 APPROVED SUPPLIER PROGRAM
The list below identifies all the suppliers of product, material, packaging and services (transport) as well as all the
different products and goods that we are supplied.
FEEDMILL
Business
Contact Details
Ingredients
Wheat
Lupins
Soya 48
Lucerne
Limestone
Avizyme 1300
Meat meal
Fish meal
Blood meal
Vegetable Oil
Methionine
Lysine
Cocci – Avatec
- Rumensin
- Maxiban
Avizyme
Bicarbonate Soda
Salt
Biomos
Egg Shell 49
Colour
Vit/Min-Hilay p91s
- Grower p90
- Pullet starter p222
Freight
Freight
Feed & Ingredients
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EGGS
Business
Contact Details
Ingredients
Boxes
Chickens
Beak trimmer
Egg washer
MG Vaccine
Inspection/Pulp
Poultry equipment
Chickens
Poultry equipment
Eggs
Date guns/stickers
Shavings
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16.0 PRODUCT RECALL
A product recall is conducted when unsafe product that has been distributed to other businesses and/or the
consumer, is required to be immediately withdrawn from sale to protect the consumer.
Product may need to be recalled if it:
• is not from an approved source,
•
is contaminated with harmful microorganisms,
•
is contaminated with harmful chemicals,
•
is contaminated with physical matter such as glass or wood, or
•
has been tampered with.
A recall may be required based on a customer complaint. In this instance, a customer complaint form will be
completed. In the event of a product recall, the recall program is controlled by the manager or delegated
employee of the business.
Once the decision to recall a food product has been made, there are three primary objectives:
1. stop the distribution and sale of the product as soon as possible
2. inform the government, the food businesses that have received the recalled food and the public
(consumer level recalls only) of the problem
3. effectively and efficiently remove unsafe product from the market place.
In the event of a product recall, the system as defined in the Food recall protocol prepared by Food
Standards Australia New Zealand (FSANZ) will be used.
Recall procedure
When product is required to be recalled:
1. The business may receive advice from the Department of Health and Human Services regarding
a decision whether a recall is necessary and if further tests should be performed.
2. Management collates and evaluates all information immediately available, and the nature and
extent of the problem. Record all information on Form12 Food Recall Checklist.
3. The recall classification is made based on these findings, and the quantity of affected stock is
established as well as the location of that stock.
4. If the product is onsite or in company delivery vehicles, it is isolated immediately.
5. If the product has been despatched to customers, management will liaise with businesses
regarding a recall from customers. Delivery records can be used for this
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Level of recall
Trade
A trade level recall is conducted when the food is not available for direct purchase by the general public.
The food is only available in wholesalers and catering organisations.
Consumer
A consumer level recall is conducted when the food is available for retail sale
Withdrawal (Only to be used if there is no threat to public health)
Is a removal of the product from the market due to quality issues (Product defect, underweight etc) and is
not a risk to public health
The business must notify FSANZ, Department of Health and Human Services and the Biosecurity Tasmania
on the following numbers if a recall is to be conducted:
Food Standards Australia New Zealand (FSANZ)
Food Recall Coordinator
Ph: 02 6271 2610 (After hours 0412 166 965)
Email: food.recalls@foodstandards.gov.au
www.foodstandards.gov.au
TAS Department of Health
and Human Services (DHHS)
Food Unit
Ph: 03 6222 7705 or 1800 671 738
Email: pophealth.foodincident@dhhs.tas.gov.au
www.dhhs.tas.gov.au
Department of Primary Industry, Parks, Water and Environment (DPIPWE)
Biosecurity Tasmania
Food Safety Branch
Ph: 03 6165 3091 (After Hours 0418 131 214)
Email: owen.hunt@dpipwe.tas.gov.au
http://dpipwe.tas.gov.au/biosecurity-quarantine/product-integrity/food-safety
Details notified include:
• classification of the hazard,
•
description of the product (product type, batch number, ‘best before’ date),
•
quantity of affected product,
•
distribution and sales dates,
•
method for consumer identification, and
•
contact name and telephone number.
The necessity for storage, isolation and disposal of the product is determined by management.
A written record of events and actions are to be kept.
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All staff are trained to enable them to perform their job safely and competently. Training is conducted
internally or by an external organisation.
The FSANZ Food Industry Recall Protocol is available at:
http://www.foodstandards.gov.au/industry/foodrecalls/firp/Pages/default.aspx
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17.0 COOL STORE / TEMPERATURE CONTROLLED ROOM
It is normal practice for cool stores to be cleaned prior to charging with the days product by adopting the following
practices:
i)
ii)
iii)
Dry clean-up of cool store
Floors washed down (If required)
Excess water removed
Scheduled Weekly Cleaning
Each week and in addition to the above routine cleaning practices, cool stores are cleaned using an approved
detergent suitable for the purpose. Ceilings and high walls are inspected and cleaned as necessary.
Scheduled Monthly Cleaning
Each month, (more frequently if required), overhead structures are cleaned, as appropriate.
The cleaning of cool stores is recorded in the cleaning and sanitation record book
Cool Room Loading
It is not normal practice to pre-cool chamber(s) prior to loading as this may lead to excess condensation and drip.
All trays and/or cartons are stored off the floor and are not subject to splash from or wash hoses.
If it is necessary to load cool stores already containing chilled eggs, every care is taken to ensure that:



the cool room temperature does not rise above 20° C,
there is no problem from overhead drip,
cool room sanitation is maintained to an acceptable standard.
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18.0 HYGIENE AND SANITATION
Litter replacement:
Chemical and Dry Goods Storage area:
Dry clean as necessary, chemicals will be removed prior to liquid clean up
Carton and wrappings storage area:
 Dry clean as necessary, cartons and wraps will be removed prior to liquid clean up
Surrounds:
All environs will be assessed on a weekly basis. It is not normal practice to allow the accumulation of materials that
would harbour vermin or detract from the general appearance of the premises.
Repairs and Maintenance/Works in Progress
In addition to the scheduled cleaning and sanitation of the premises, the facility and all equipment is constantly
observed for defects, which due to wear and tear have the potential to compromise the wholesomeness of product or
the welfare of the birds.
All found defects which are unable to be attended to immediately are recorded on Form 3 Repairs and Maintenance
Record.
Cleaning Chemicals
All chemicals are purchased from reputable suppliers. The chemicals fall into four categories: detergents, sanitisers,
hand cleaners and deodorisers. (Deodorisers are not used in packing and storage areas, i.e. used in toilet, amenities
areas.)
All cleaning chemicals are stored in a designated place, away from and with no direct contact with slaughter and/or
processing areas
CHEMICALS USED IN THIS PREMISES ARE:(List all Chemicals used at the premises)
Insecticides:
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Soft detergents:
All detergents/sanitisers used at the premises are hospital food
grade standard.
Hard detergents:
Material Safety Data Sheets must be available onsite for all chemicals used at the facility
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19.0 HYGIENE OF PERSONNEL
Clothing
All persons engaged at the premises commence the working day wearing appropriate clean clothing and footwear. If
clothing becomes excessively soiled during the day it shall be changed.
Visitors
All visitors to the premises shall be appropriately attired prior to admittance to the premises. No person will be
admitted into the production or bird areas after having visited another egg production premises within the previous
??day/s
Personal Hygiene Requirements
All personnel engaged in the, collection, grading, packing, storage of eggs shall:
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
be personally clean at all times
keep hands and fingernails clean at all times
wash hands immediately prior to the commencement of work, after using the toilet, and at all times after
engaging in activity likely to contaminate hands
ensure that clothing is not a source of contamination and is fit for purpose.
immediately and effectively clean their skin, clothing and equipment when it becomes contaminated
where an apron is worn, only use an apron made of readily washable non-absorbent material
where gloves are worn, use only gloves made of readily washable, non-absorbent material, which are kept in
sound, clean and sanitary conditions at all times
remove aprons, if worn, and place them on an approved rack prior to entering toilet area or area not
associated with immediate work area.
Personnel shall not engage in the processing or packing of eggs if suffering from major sores or wounds or
skin conditions or suffering from an infectious or contagious disease
Personnel shall:
a)
conduct themselves in a manner not likely to cause contamination of the product
b)
not smoke or spit in any part of the premises where product is being prepared or stored
c)
not eat food or drink on premises except in rooms or areas provided for that purpose
Staff Illness
The company complies with those provisions of the Tasmanian Public Health Act which make it an offence for staff to
work as food handlers if they are carrying any infectious disease; are a disease carrier; are suffering from any venereal
disease or inflammatory disease.
Staff must report to their supervisor if they have an infectious disease. They will be prevented from working in a
food-contact area.
Injuries
The company has a first aid cabinet with a range of dressings and bandages.
All injuries will be recorded in a nominated "accident book".
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All injuries, other than those which are obviously minor in nature, will be referred to a medical practitioner.
20.0 DISPATCH and TRANSPORTATION
Vehicle Inspections
All vehicles used to convey eggs from the premises will be maintained in good repair and clean condition. The
vehicles will not be used to carry extraneous material which may be deleterious to the conveyance of eggs.
Dispatch Procedures
Only adequately cooled product will be removed from the premises.
Temperature requirements are: not more than 17°C.
Temperature shall be monitored for every consignment and the findings will be recorded in the Dispatch and
Destination Book by ???????? for examination by authorised auditors. If any product is found to be outside of
specification it shall be returned to storage until temperature parameters are achieved.
Transportation
All product dispatched from the premises will be transported in a cartage vehicle that incorporates facilities for the
product to be carted under active refrigeration.
The temperature of all products at load out and the condition of vehicles carting eggs is recorded and retained on file.
The vehicle is equipped with a refrigeration unit to maintain product at required temperatures.
Delivery
Delivery drivers are to visually check a random selection of each consignment with customers to verify egg integrity,
customer to sign the delivery docket upon receival of product if satisfactory. Any defective eggs will be replaced and if
not disposed of at the store, will be marked and returned to the place of origin for disposal in the ?????.
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21.0 REFRIGERATION
Refrigeration Maintenance
All refrigeration maintenance is carried out by qualified personnel.
All cool stores shall be fitted with properly calibrated thermometers so temperature of appliances can be monitored
by the owner or his nominee.
All refrigeration maintenance will be recorded on Form 3 Repairs and Maintenance Record
Monitoring of Refrigeration Performance
Temperatures of all temperature controlled areas shall be monitored at least every 24 hours when operating. These
findings shall be routinely logged and any out of specification findings shall cause corrective action to be instigated
and recorded.
All refrigeration equipment, including thermometers shall be independently maintained and calibrated at least every
six months by a refrigeration contractor. A maintenance report shall be retained on file and made available, upon
request to authorised officers.
Location of Cool Store/s
See Appendix 1 for cool store locations on Plan Diagram of Premises Layout.
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22.0 POTABLE WATER
Water shall be from a supply that is free from pathogenic bacteria or dangerous chemicals. The delivery system,
including any header tanks, shall be enclosed to prevent contamination.
Chlorine can deactivate live virus vaccines and so advice needs to be sought if these vaccines are to be administered
through a chlorinated supply.
Chlorine Testing
Chlorine levels are monitored for each batch of water????????????????? by ??????? and the free residual chlorine
level is recorded Form 1 Pre-operational Check.
The minimum residual chlorine level (At the tap) is to be a minimum of 1ppm
Chlorine testing is to be conducted upon each refill of the tank
UV lamps are to be maintained according to the requirements of the manufacturer
Potable Water Testing
Water used at ?????????? is tested for potability once per year by a NATA accredited laboratory. Test results are
retained on file for audit.
Procedures for dealing with unsatisfactory Water Test.
In the event of an unsatisfactory laboratory result, any action required by the controlling authority shall be followed.
Provision of Hot Water
All hand washing water shall fall into the range 38°- 45°C.
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23.0 PEST CONTROL PROGRAM
Inspection for Rodent Activity
Once a week a trained person will inspect the entire farm premises for any Rodent activity. Areas that require special
care include:
Sheds. Especially in the insulation and the manure, also the container storage areas.
Feed storage areas.
The implement sheds.
The Feed mill.
The Egg room, especially the cool room or container storage area.
The results of the inspection will be recorded on Form 1 Pre-operational Checklist
Baits
Bait will be laid where activity is noted. These bait stations will be recorded on a farm layout map and will be
monitored regularly.
All bait sites will be monitored by a professional pest control agency at least once a month.
Occupational Health and Safety
-
When using baits the trained person will follow all safety instructions on the label of bait containers.
Bait stations will be in an approved container that is inaccessible to any animals other than rodents.
Insects
A trained person will be required to inspect the farm premises for fly populations. If these are deemed to high the
following will be performed;
Fly-poison will be laid in appropriate containers at marked locations around the farm (see the Farm
layout map).
A spray will be applied to certain locations around the farm (see Farm layout map).
A spray will be applied to manure (layer sheds only) to reduce reproduction of flies.
Fly populations will be monitored regularly. Poisoning programs may reduce once the fly population has been brought
back under control.
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24.0 EGG STAMP EQUIPMENT FAILURE
In the event of stamping equipment failure, Biosecurity Tasmania has implemented a program to ensure that
producers can continue to sell eggs without the mandatory egg stamps, for an agreed period of time.
Note: No unstamped eggs are to be sold until an approved corrective action plan is received from DPIPWE.
If the egg stamping equipment fails the following steps must be followed prior to unstamped eggs being released for
sale:

Complete Form 13 (Notification of Equipment Failure) and submit the completed form to Biosecurity
Tasmania within 24 hours of the equipment failure.
Food Safety Management Officer
Product Integrity Branch
Phone: (03) 6165 3091
Email: Owen.Hunt@dpipwe.tas.gov.au
Fax:
62336386
Upon receipt of the notification, the Biosecurity Tasmania will contact you to:
 Confirm the receipt of the notification
 To discuss appropriate to be taken to repair the stamping equipment
 To discuss the systems that are in place to ensure traceability of the eggs sold
 To discuss and agree on a time for the resumption of stamping
Once Biosecurity Tasmania is happy that all necessary action is being taken, a letter will be issued stating that you
have provided sufficient evidence to show that all measures are being taken to repair the equipment. The letter will
provide a grace period from egg stamping until an agreed date, and a copy of the letter must be provided to your
customers.
Following the expiry of the grace period, unstamped eggs will not be permitted to be sold unless an extension is
granted by Biosecurity Tasmania.
Template FSP Egg Production - V1.7 March 2015
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Form 1 Pre-operational Check
Week Commencing:_________________
M
T
W
T
F
S
S
Temperature (°C)
M
T
W
T
F
S
S
Corrective Action
Live bird areas
Grading and storage area
Evidence of pests
(Inspect all areas weekly)
Hand washing facilities
clean and accessible with
soap and paper towels
available
Product contact surfaces
clean
All equipment clean
All packaging material
stored correctly
Coolrooms/Temp control
rooms clean and tidy
Egg transport vehicles
clean and tidy
Area
Corrective action
Initials
Coolroom/Temp Control
Room
Freezer
Bird Mortalities
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Feed
Monday
Wednesday
Thursday
Friday
Saturday
Sunday
Water Check (Test residual chlorine for each batch)
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Tuesday
Template FSP Egg Production - V1.7 March 2015
Page 42
Form 2 Amendment Record Sheet
A/MENT #
DATE
SECTION
Template FSP Egg Production - V1.7 March 2015
SUBJECT
Signature
Page 43
Form 3 Repair and Maintenance Record
Defect
Date
Observed
Template FSP Egg Production - V1.7 March 2015
Risk
H/L
Anticipated
Who
Completion
Completion Responsible
Date
Date
Page 44
Form 4 Corrective Action
The corrective action form is to be completed whenever there is a possible or actual problem identified. This
can be a food safety or quality issue, OH&S issue, breakdown of equipment or facility maintenance issue.
Details of the Problem
Action Recommended
Action taken
Describe what corrective action was taken, and the changes, if any, made as a result.
Employee Name:____________________________________________
Template FSP Egg Production - V1.7 March 2015
Page 45
Signature:_________________________________________________
Date:_____________________________________________________
Form 5 Customer Complaint
Please complete the above details and return as soon as possible
Note: All details provided to us will be treated as confidential and only used to support the accredited supplier
requirements of our food safety program
Customer (complainant) details
Name:
Address:
Suburb:
State/Postcode
Phone:
Mobile:
Email:
Details of the complaint
Product details
Batch Code:
Date Produced:
Quantity
Template FSP Egg Production - V1.7 March 2015
Page 46
Produced:
Distribution
Locations:
Action taken
Describe how the customer complaint was handled, and the changes, if any, made as a result of the complaint.
Employee Name:____________________________________________
Signature:_________________________________________________
Date:_____________________________________________________
Template FSP Egg Production - V1.7 March 2015
Page 47
Form 6 Internal Review Checklist
Complete every 12 months
Satisfactory (S) Unsatisfactory (U) and complete corrective action/comments column
Completed by:_____________________________
Section
Date:____________________
S/U
Corrective Action
1. Management responsibility
Is the policy statement still current?
Is the scope and purpose still current?
Are the members of the HACCP team still
current?
2. HACCP Plan
Are the product specifications still valid?
Is the flow chart still correct?
Is the Risk Analysis still valid?
3. Premises and Equipment
Has the Monthly Maintenance Checklist been
completed?
4. Supplier Approval Program
Is the Supplier Approval List up to date?
5. Egg Handling Procedures
Are they up to date?
Have all monitoring records complete?
6. Testing and Calibration
Have water tests been completed?
Are all results within the Standards specified?
Have any results which exceed the Standards
been reported to the DPIPWE
Have all thermometers and temperature gauges
been calibrated every six months?
7. Cleaning and Sanitation
Has the Pre-Operational Checklist been
completed?
Are the chemicals listed still used?
8. Pest Control
Are procedures still correct?
Are pest control records available?
9. Personal Hygiene
Have all staff been briefed on personal hygiene?
10. Product Identification and Traceability
Is the list of customers up to date?
Are invoices for each sale available?
Template FSP Egg Production - V1.7 March 2015
Page 48
11. Food Recall
Is there a copy of the FSANZ Food Recall
Protocol available?
Are the contact numbers up to date?
12. Staff Training
Are the Staff Training records up to date?
Comments/Corrective Action:
Form 7 Weekly Egg Collection Form
W/C:
AM
PM
Total
AM
PM
Total
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Weekly Total
W/C:
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Template FSP Egg Production - V1.7 March 2015
Page 49
Sunday
Weekly Total
Form 8 Customer List
Business Name
Contact Person
Template FSP Egg Production - V1.7 March 2015
Phone/Email/Fax
Page 50
Form 9 Employee Training Matrix
Date
Name
Training
Comments
Eg. 1/12/13
John Smith
Basic Hygiene
Egg Washing
Template FSP Egg Production - V1.7 March 2015
Sign
Page 51
Template FSP Egg Production - V1.7 March 2015
Page 52
Form 10 Receival Checklist
Date
Supplier &
Transporter
Product/Live
stock No.
Mortalities
Notes
Template FSP Egg Production - V1.7 March 2015
Sign
Page 53
Form 11 Visitor Log
Date
Name
Company
Reason for visit
Template FSP Egg Production - V1.7 March 2015
Time
in
Time
out
Page 54
Form 12 Recall Checklist
Use this Checklist when carrying out a food recall.
TASK
PERSON
RESPONSIBLE
COMPLETION
DATE
Have a copy of procedure related to food recalls.
 Describe the problem;

Determine actions that must be taken.

Review specific directions in the communication(s).
Communicate the food recall notice to all sites
 Document that the recall notice was received at each
site.
Collect health-related information needed for public
communications. The following information must be
collected and documented:
 Determination of where the product was distributed,
to whom, and when; and

Reports of health problems potentially related to the
recalled product (if it has been served), including
physical symptoms of illness and any actions taken.

Identify and record whether any product
was received by customers.

Locate the recalled product by site.

Verify that the product bears identification
code(s) and production date(s) listed in the
recall notice.
Obtain accurate inventory counts of the recalled product from
every customer, including amount in inventory and amount
used.
Account for all recalled product by verifying inventory
counts against records receivals at customer sites.
Confirm that customer sites have segregated and secured the
recalled product.
Template FSP Egg Production - V1.7 March 2015
Page 55
TASK
PERSON
RESPONSIBLE
COMPLETION
DATE
Carry out the following administrative tasks as appropriate:
 Determine if the product is to be returned (to
whom), or destroyed (by whom).

Notify site personnel of procedures, dates, etc. to be
followed for collection or destruction of product.

If the product is to be returned, follow procedures.
The product should be consolidated for collection as
soon as possible, but no later than 30 days after the
date of the recall notification.

If the product is to be destroyed, confirm that written
notification is on file. Follow procedures provided
by State and local agencies.

Consolidate documentation from all sites for
inventory counts.

Document any reimbursable costs.
Complete and maintain all required documentation related to
the recall, such as:
• Recall notice and communications about the product;
• Records of how food product was returned or destroyed;
and
• Reimbursable costs
Maintain copies of all communications received or sent in
relation to the food recall for three (3) years plus the current
year.
Maintain copies of all information provided to public
communication contact person, other media contact(s), and
the public; adverse health reports and actions taken for three
years plus the current year.
Template FSP Egg Production - V1.7 March 2015
Page 56
STOCK RECOVERY CHECKLIST
Co-Ordinator’s Name:
Date:
Product Identification & Description
Product
Package size and shape
Brand (Proof of ownership of product?)
Packed on/use by date/best before code
Shelf life placed on product
Description of problem:
Reported by:
(Attach Corrective Action form if required)
How long has the product been in the
market place?
Would the product have been consumed?
.
Is the product in retail stores?
Is the product only at wholesale level?
Is withdrawal of the product an option?
(Ie Not a public health issue)
How many states or territories will be
effected?
Who/where was product distributed to?
NSW
TAS
What is the quantity of potentially effected
product?
Template FSP Egg Production - V1.7 March 2015
QLD
NT
SA
VIC
WA
Attach details
Attach details
Page 57
STOCK RECOVERY CHECKLIST continued
How many reports/complaints of potential
hazard?
Has the Health department required a
Product Recall yet?
Does medical/engineering evidence(opinion)
support view that the product will or may
cause injury?
Is this opinion supported or in dispute?
Is there an established link between the
product and potential injury?
Is the product to be used directly by the
consumer?
Has the product been tested for
contamination?
If no is the product to be tested and if so
when and where?
If yes have the tests been conducted
correctly? Who by?
Are the results conclusive?
Number:
Yes
No
Attach details
Attach details
Is an independent analysis required?
(if yes – when and where)
Is stock recovery required?
If yes
Trade
-to what level is the
Consumer
stock recovery
Withdrawal
required
If recovery is required
Record name of department official told and time
inform Health Dept,
Council
To be decided in consultation with Health Department, expert advice and FSANZ.
Advice to be documented.
Production
information
Assign employee to prepare the following documentation as indicated on
the next page.
Name of person:
To be done by:
Template FSP Egg Production - V1.7 March 2015
Page 58
Documentation required as result of
stock recovery action
Date:
Person Responsible:
Start Time:
Expected Finish Time
Product
Package size and shape
Brand
Packed on/use by date/
best before code
Production date
Documentation required:
Documentation attached?
All monitoring sheets from that days production.
List of employees on site during the shift
Copies of any Action request form raised during the week prior
to production of the product
Retain and inform supervisor of any effected product still
in the factory with the same production date.
Template FSP Egg Production - V1.7 March 2015
Page 59
STOCK RECOVERY CHECKLIST continued
Recovery Process
Have Distributors been informed?
Have retailers been informed?
Yes
(keep copy of
fax/email)
Yes
(keep copy of
fax/email)
Confirmation from Distributors and
Retailers that all stock has been
removed from the shelves received?
Replacement stock required?
No
(why not)
No
(why not)
Attach details
Delivery of replacement stock
organised?
Have transport requirements for recovery
been organised?
Area / location identified and prepared
for product return?
Final report collated and prepared for
distribution to customers and Health
department?
Corrective Action Form– Fill out CAR Form
Attach details
Attach details
Attach details
Contact Lists/Records - refer to FSANZ Food Recall Protocol
Food Standards Australia New Zealand
Food Recall Coordinator
Ph: 02 6271 2610 (After hours 0412 166 965)
Email: food.recalls@foodstandards.gov.au
www.foodstandards.gov.au
TAS Department of Health
and Human Services
Food Unit
Ph: 03 6222 7705 or 1800 671 738
Email: pophealth.foodincident@dhhs.tas.gov.au
www.dhhs.tas.gov.au
Biosecurity Tasmania
Product Integrity Branch
Ph: 03 6165 3091
Email: Egg.Enquiries@dpipwe.tas.gov.au
www.dpipwe.tas.gov.au/biosecurity/product-integrity/food-safety
Template FSP Egg Production - V1.7 March 2015
Page 60
Form 13 Notification of Equipment Failure – Egg Stamping
Biosecurity Tasmania requires that notification of egg stamping equipment failure must be made in writing
within 24 hours after the holder of the accreditation becomes aware that their egg stamping equipment has
failed.
Email or fax notifications to
BIOSECURITY TASMANIA
Product Integrity Branch
Phone: (03) 6165 3091
Fax:
(03) 6343 2833
Egg.Enquiries@dpipwe.tas.gov.au
Producer information
Accreditation number:
Address:
Name of Accredited Producer:
Egg brands affected:
(If selling eggs under multiple
brands)
Egg Producers affected:
(If stamping for other farmers)
Name of person completing
notification:
Position:
Phone:
Mobile:
Email:
Equipment failure investigation
Investigation summary:
Cause of failure:
Template FSP Egg Production - V1.7 March 2015
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Corrective action taken by accredited producer:
(What actions have been taken to trace eggs without the stamp?)
Estimated egg stamping resumption date:
Actual egg stamping resumption date:
NOTE:

Producer is to maintain a copy of this completed report in their Food Safety
Program for further assessment by a Food Safety Auditor.

A formal letter from Biosecurity Tasmania providing your business with a
grace period from the stamping requirement will not be given until this
notification has been received, and an egg stamping resumption date has
been agreed by both parties.
Office use only:
Date notification received:
Agreed date of resumption of stamping
Approving Officer
Date notified of egg stamping resumption:
Template FSP Egg Production - V1.7 March 2015
Page 62
Appendix 1 PLAN DIAGRAM OF PREMISES LAYOUT
(Not to Scale)
Template FSP Egg Production - V1.7 March 2015
Page 63
Appendix 2 PRODUCT DESCRIPTION
PROCESS:
Production of Shell Eggs.
PRODUCT DESCRIPTION
SCOPE
PRODUCT DESCRIPTION
The HACCP Plan covers the collection, washing,
packing and storage ready for dispatch of whole
shell eggs.
The purpose of this plan is to document the
food safety hazards associated with the
processing of Shell Eggs
Washed? Graded Shell Eggs
COMPOSITION
Whole Shell Eggs
METHODS OF PRESERVATION
Chilled at no greater than 20C
PACKAGING - PRIMARY
Individual section cardboard egg cartons
PACKAGING - SECONDARY
New cardboard cartons
STORAGE CONDITIONS
Held at ?-?C
DISTRIBUTION METHOD
SHELF LIFE
Refrigerated transport at ?C and direct
purchase
? days @ ?oC after packing date
CUSTOMER REQUIREMENTS
Delivery at ?C in clean cartons
SENSATIVE CONSUMER?
No – intended for general consumption
FINAL CUSTOMER PREPARATION
To be cooked before consumption?
PURPOSE
Key
M
C
P
Q
=
=
=
=
Microbiological Hazard
Chemical
“
Physical
“
Quality Related “
Template FSP Egg Production - V1.7 March 2015
Page 64
Appendix 3 EGG PRODUCTION FLOW CHART
Receipt
1
Purchase of Birds, Feed & Litter
2
Water Supply
3
Housing of Birds
4
Feed, Water & Litter
5
Monitor Birds (Health, Feed etc)
6
Collect Eggs
7
Inspect for faults
8
Wash and Dry
9
Grade
10
Candle and Visually Inspect for defects
11
Pack into clean cartons
12
Label and Date
13
Convey to Chiller
14
Store under refrigeration
15
Monitor temperatures
16
Dispatch
Storage (1)
Process
Storage (2)
Template FSP Egg Production - V1.7 March 2015
Page 65
Appendix 4 EGG PRODUCTION – HAZARD ANALYSIS TABLE
STEP
INPUT
HAZARDS
Severity
1 Purchase Birds,
Feed and
Litter
2 Water Supply
Purchasing of birds,
feed and litter
SIGNIFICANCE
Risk
Significant
P – Diseased or injured
birds
H
L
L
Approved Supplier
Certified Health Status
M - Microbial
contaminated of feed and
litter
M – Water contaminated
H
L
L
H
L
L
Approved Supplier
Written assurance that feed and litter pathogen
free
Ensure that water is always potable through
application of recognised water treatment
processes
H
L
L
L
L
L
4 Feed, Water
and Litter
5 Bird Health
6 Collect Eggs
7 Inspect for
Faults
OUTCOME
CCP/CP
CP
Providing potable
water
C - Water contaminated
3 House birds
CONTROL MEASURES
Providing
appropriate
housing and
protection
P – Shed Hygiene,
Predators, Air Quality,
Insects, Rodents and
Extremes of Climate
Adequate provision
of feed, water and
fresh litter
P – Insufficient feed and
water.
L
L
L
Fresh litter not provided
H
H
L
H
L
H
H
Monitor bird health
Manual or
automated
collection of eggs
Visual examination
of eggs for defects
Q – Damaged eggs not
detected
Template FSP Egg Production - V1.7 March 2015
H
L
CP
(Animal Welfare)
CP
(Animal Welfare)
CP
L
Removed replace soiled litter with clean, dry
litter
Trained, experienced bird handler constantly
monitors birds for signs of ill health
Correct technique and procedures
implemented by trained operators
CP
L
L
Machinery operating correctly
Operators trained to identify defects
Retrained if necessary
P – Diseased birds
P – Damaged eggs
Contaminated eggs
Application of sound shed cleaning
methodology
Adequate barriers to prevent the entry of
predators, insects, rodents
Climate controls monitored and maintained
Automatic dispensing equipment in good
operating condition
CCP
CP
(Animal Welfare)
CP
Page 66
STEP
INPUT
HAZARDS
Severity
8 Wash and Dry
9 Grade
10 Candle
11 Pack
12 Label and Date
External
contamination
removed from eggs
by washing
Manual or
automated grading
of eggs
Eggs candled for
visual defects
M – Contamination
remaining on eggs
Eggs packed on
clean trays (flats) or
into clean cartons
M – Trays or cartons not
clean
Apply labels and
packing dates
Q – Labels not applied or
contain incorrect
information
Wrong date
M – Product not
refrigerated
13 Convey to Cool All packages of eggs
Store
placed into
refrigerated
storage
14 Refrigerated
Monitoring and
Storage
recording of
product
temperatures
15 Dispatch &
Eggs assembled
Delivery
and loaded for
dispatch
Deliver eggs to
client
Q – Eggs incorrectly
graded
Q – Cracked shells, fertile
eggs, blood spots not
detected
M – Out of specification
temperatures
Temperature fluctuations
Packages and contents
damaged
Eggs damaged at delivery
Template FSP Egg Production - V1.7 March 2015
H
SIGNIFICANCE
Risk
Significant
H
H
CONTROL MEASURES
Proficiency of operators
Equipment and chemicals adequate for task.
OUTCOME
CCP/CP
Set procedures and
controls in place
CCP
Sanitising facilities in place and functional
Proficiency of operators
CP
Equipment adequate for task.
Proficiency of operators
CP
H
L
L
H
L
L
H
L
L
Packages correctly stored and from approved
suppliers
CP
L
L
L
Proficiency of operators
CP
L
L
L
Proficiency of operators
Equipment adequate for task.
CP
Refrigeration facility maintenance
H
H
H
Records in product temperature logs
L
L
L
Monitoring of product temperature at dispatch
H
L
L
Inspect a % of eggs with client at delivery
CCP
CP
CP
Page 67
Appendix 5 HAZARD AUDIT SHEET – EGG PRODUCTION
Process Step
8 Wash and
Dry
Potential
Hazard
Eggs not clean
CCP
CP
CCP
Control Measures
Critical limits
Proficiency of operators
Equipment and
chemicals adequate for
task.
Eggs clean and
dry as per
manufacturer’s
instructions
Sanitising facilities in
place and functional
14
Refrigerated
Storage/
Temperature
rise.
Damaged eggs
Hazard Audit Table CCP’s
1 CCP
Wash and Dry
CCP
Temperature of
product to be
maintained at < 200C
Monitoring of
temperatures,
recorded in product
temperature logs
2 CCP
Temperature of
product
maintained 200C
No damaged
product
Monitoring and
Records
How; visual checks,
What; eggs
When; each batch
Who; designated
personnel
Where; at egg wash
How; temperature
checks, min – max
temp
What; packaged eggs
When; daily
Who; designated
personnel
Where; daily
production report
Records
Daily
production
report
Daily
productio
n report
Corrective Action
Re wash
Cool all eggs prior to dispatch,
there are no further steps under
the control of ?? Poultry Farm
that will reduce or eliminate the
hazards
Storage/Dispatch
Template FSP Egg Production - V1.7 March 2015
Page 68