Perform internal audit

Case

Cornelis Bartlema Food Group B.V. – Internal Audit
Relationship: Cornelis Bartlema Food Group B.V.
Date/Time:
Present: Remon Hameete (QAssurance)
Purpose: To conduct an internal audit

Internal audit Cornelis Bartlema Food Group B.V.

During the internal audit on 25 March 2019, we looked at the production and quality system at Cornelis Bartlema Food Group B.V. During this audit, Martinus jr. is the one who guided us in this.

The following points for improvement emerged during the audit:

1. Button weighing bunker cleaning and hand gas burner cleaning
2. Do not place raw material products directly on the ground when preparing dough
3. Recipes dough maker file refresh in the manual this has outdated recipes
4. Cover and code products when they are put away
5. Torkrol cleaning dough preparation
6.  Removing cobwebs
7. Cleaning  the tray for auxiliary materials line 1
8. Willet ink cleaner consistently store in the lockable cabinet
9. Solving and closing anticimex action points in a digital environment
10. Still  carry out training according to schedule
11. Supplier assessment still to be carried out
12.  Performing tracing and recall testing
13. Request a new IFS certificate

General

Around the property it looks neat. All the doors are closed and you can’t just walk in. There is a separate entrance for the production staff which is arranged via a drop. Food defense for unwanted visitors is well stopped.

Before we wanted to enter production we had to register as a visitor on RF101 Visitors/mechanics registration. In addition, a visitor’s coat and hairnet had to be put on. I also got another pen that is detectable. I was also asked to take off jewelry. When entering production, hands had to be washed according to procedure.

Central warehouse reception / forwarding

The central warehouse is used for both receipt and storage of raw materials, as well as for finished products. Everything is neatly placed on pallets and all packaging is closed. Also, everything is neatly labeled in the storage space.

Martinus looked at the working method for receiving raw materials. All raw materials that come in are entered into iMIS Tracking. Here the input control is immediately  registered. Spoken with Sjaak who stands at the receipt of goods. He indicates that the entrance check consists of checking the THT, packaging, no pests present, truck clean, no non-food products in the truck and the care of the driver. If something is not right, the office will be contacted to discuss. He indicates that this is fortunately not often the case.

Given the reception of Almond on 19-3-2019 that came in with batch code 19MB122-19110CVI from Zeelandia with a tht of 14-3-2020.

Given the wheat flour 25-3-2019 received with batch code 19MB131-363586

Sjaak stacks all raw materials that are delivered on wooden pallets on plastic pallets because wood is not allowed in production. The only place where wooden pallets are allowed is at the end of the line where the products are palletized.

During our round we saw bait box number 19 from Anticimex and it was neatly attached to the wall. Via the digital system digimex of anticimex we can also immediately see that there has never been a recording at this point.

All packaging materials were neatly sealed. And the rolls of foil are also neatly covered by a plastic bag. Even a broken roll was neatly packed back.

No comments in this space.

Dough preparation

During the audit, various employees, including Jan, prepare dough. Jan is working on the cookie dough (RF013 version 1, 15-03-2018). Another employee is working on the butter dough (RF007 version 3 22-06-2018). A registration form for both types of dough is available in the department. These forms do not correspond to the forms in the handbook but do correspond to the forms in the 32folder structure. However, these registration forms are neatly filled in.

The line comes with a scale to perform weight checks. Based on these weight checks, the dosing machine is adjusted if necessary. The scale on which the checks are carried out was last calibrated on 20-3-2019.

Button of the weighing bunker has caked dough residues. This needs to be cleaned. And that also applies to the hand gas burner. The vercosine was also  directly on the floor which should be off the floor.

During the audit, Jan was consulted about the working method for dough preparation. Jan indicates that the raw materials are combined in a mixing bowl on the basis of the registration form. There are a number of bins of raw materials in the department. These bins indicate which raw material is present in the bin. Each raw material has its own shovel. We looked at the container with the raw material salt, carbon dioxide, egg powder, vanilla powder and beurine.

However, there was a bucket with butter on a pallet that was not covered and also had no identification. Keep an eye on this, so cover and code.

The silo was checked by silowacht on 26-4-2018 Of this, an inspection report is available in which a calibration has taken place.

There is also a torkrol holder whose issue is very fulfilled, which can cause cross-contamination.

Improvement

1. Button weighing bunker cleaning and hand gas burner cleaning
2. Do not place raw material products directly on the ground when preparing dough
3. Recipes dough maker file refresh in the manual this has outdated recipes
4. Cover and code products when they are put away
5. Torkrol cleaning dough preparation

Heating loft

In the heating loft, butter was getting soft. There were several cobwebs on the side which had to be removed.

Improvement

1.  Removing cobwebs

Line2

Line 2 was not produced at the time of the internal audit. However, there were still some raw materials such as some pink cream and also yellow and brown glacé from Zeelandia.

There were also several brushes along line 2 where blue and green are used for the machines and the red for cleaning the floor.

Line 1

During the internal audit, the entire process at line 1 was followed. From the dough preparation to the packaging of the cookies. Filled cakes were made for Aldi at that time.

Along the beginning of the line was a container with auxiliary materials that was very polluted. This needs to be changed or cleaned. The scale that is there is calibrated on 20-3-2019.

There is also a neatly closed greenhouse for various items that can be used along the line. But during the internal audit there is Willet ink cleaner on top of this cabinet which should not be there.

Spoke during the internal audit with Diana van Oort. She explains that she checks the metal detection on the line 5 times a day

During the audit, a weight check and metal detection check was also carried out by Diana. The weight check is carried out 8 times a day and noted on the existing registration form RF 4.9 weighchecker line 1. The metal detection check was performed to show how it works. Checks are carried out 5 times a day (start-up, 9 am, 12 pm, 2:30 pm and end) with the following test sticks:

• 1.8 mm Fe
• 2.0 mm stainless steel
• 2.0 mm Non-Fe

These test sticks correspond to the measurements in the manual and the HACCP study. During the test, the products with test sticks are ejected as they should be. Then the products are detected again without a test stick. They do not contain metal. Everything that is ejected is collected for later testing. The ejected packages are done again by the metal detection. When these are ejected the second time, the product is completely sorted out to check whether metal is actually present in the product.

All registrations on line 1 are kept neatly and correctly. Other dates can also be found at Martinus in the folders where all registration forms are kept.

In addition to the weight and metal control, organoleptic research is also done. This is done 1 year after production. In addition, the product is first assessed visually and then on taste.

Improvement

1. Cleaning  the tray for auxiliary materials line 1
2. Willet ink cleaner consistently store in the lockable cabinet

Boiler room

This space was neatly tidy. There was a container full of yellow hard cream ready for use. There was also the remnant of choco cream neatly covered and coded in this room.

Almond preparation

From line 2 you walk past the Almond preparation where the Almond preparation takes place to the cleaning corner where the barrels and buckets for production are cleaned. Small machines are also cleaned here.

Everything else was in order during the internal audit. It was clean and tidy.

Line 3

The production on line 3 was followed during the audit. Waffles for Joost pastry are produced on the line.

During the audit, it was checked whether metal detection form RF092C was correctly completed on line 3. This is filled in by Piet.

Piet has placed all the test sticks one after the other on three products. All three products have been blown out. After blowing out, the products were again placed on the belt by the employee and went through the metal detection. None of the products actually contained metal. With this test it is clear that the metal detection works and also in a worst case (three products in a row with metal) the products are emitted. The test sticks used on line 3 are:

• 1.5 mm Fe
• 2.5 mm stainless steel
• 2.0 mm Non-Fe

These test sticks correspond to the CCP overview. The checks are neatly registered and carried out. The weight checks are also carried out and are transparent.

The e-weighting is also checked once an hour and registered on RF 4.9. In the event of a deviation in weight, the batch is blocked and the production manager is informed. It decides what will happen to that party.

No comments on this line.

Staff entrance

The staff entrance is very neat. You can see that this section is new construction. We looked at the ladies and gentlemen dressing room. These both look very neat. The shoes are put in bags by the employees and then placed in the designated compartments. We work with ‘impersonal’ lockers because they are unlocked every night. As a result, there is always supervision at the end of the day what remains in the lockers.

Before entering the production area, signs with applicable rules are present.

Canteen

The canteen looks pretty neat. The toilets are also clean.

­External visit

External visitors register and register at the office on form RF1026 Visitors/mechanics registration. This overview has been checked and is neatly maintained.

Office quality service

LCP and CCP analysis

Process step	LCP: Legal Control Point	Comments
Check new labels	Legal requirement (LCP)	To date in 2018/2019, there have been no deviations with .b labels.
All kinds of chocolate and cocoa fantasy	Legal requirement (LCP)	Supplier provides analysis certificates.
All kinds of cocoa fantasy	Legal requirement (LCP)	is affiliated with risk plaza. Website www.riskplaza.nl.
All types of wheat flour	Legal requirement (LCP)	BRC certified
Beurinne	Legal requirement (LCP)	Supplier is affiliated with risk plaza. Website www.riskplaza.nl.
Purchase of food contact materials	Legal requirement (LCP)	No deviations to date in 2018/2019

Process step	CCP: Critical Control Point	Comments
Metal detection testing	CCP	To date in 2018/2019, there have been no metal ejections or incidents related to metal.

Analysis and sampling

Microbiological research is carried out 1x per year on approximately 15 products. By grabbing different products, we try to take as many different raw materials as possible. The microbiological examination is carried out on Listeria monocytogenes, Salmonella and Entros. The results of these studies in 2018 were good. The microbiological studies for 2019 have not yet been carried out.

The water survey was carried out on 12-4-2018. This will also be tested again when carrying out the microbiological examination for 2018.

Cleaning and disinfection

In general, it can be concluded that the cleaning is going very well.

The cleaning takes place by our own staff (mainly machines) and external parties (floor, canteen, etc.). The frequency is fixed on the cleaning control form RF078. This form is completed by Martinus jr. This so that it will be used as a checklist when carrying out the cleaning and not as a checklist afterwards what has not been carried out. In addition, you also prevent the cleaning rounds and the cleaning form from being filled in / checked by the same person. All the necessary papers for the cleaning agents are present.

Complaints from authorities and customers

Only 2 complaints were received in 2018. This number is negligible on the approximately 10 million packages that are sold.

• Once a piece of plastic found in the packaging of the container itself
• And a complaint about taste deviation of consumer that it was no longer brittle.

The complaints have all been dealt with.

Pest control

The pest control is carried out by Anticimex. All necessary data is digitally available via digimex.anticimex.nl. All fly lamps have been replaced by new lamps.

There are 9 routine checks carried out by Anticimex , the last of which dates from 27-11-2018. There are still 2 action points open, the last of which dates from 3-4-2018 and is about checking the blow traps yourself. This is an action point that is still ongoing.

No large numbers of flies were found. This is similar to previous years. The inspection of the lamps and in particular the replacement of the adhesive strips is done every 8 weeks.

Improvement

1. Solving and closing anticimex action points in a digital environment

Registrations

All registrations are kept for a sufficient period of time as prescribed in the handbook and legislation.

Maintenance

All maintenance performed is recorded in an Excel file. This excel file has been seen. We looked at the maintenance carried out in 2018 and 2019.

There have been no calamities. All maintenance has been carried out.

Personnel, education and training

The staff is not yet trained, for CCP metal detection, food defense, allergens and cleaning. The CCP training is only given to employees who work with the metal detection.

In addition, Piet jansen and Herman de Heus followed a course in company emergency response. And Mrs. van Oort also completed a BHV course.

Improvement

1. Training according to schedule also carried out by the CCPs.

Packaging

There were no changes in 2018. The foodgrade statements and migration tests are present at Martinus.

Handbook

The handbook is up-to-date and the available instructions and registration lists are used in production.

The handbook has also been randomly checked with the practice of instructions and registration forms during the internal audit. Based on this, the handbook can be called up-to-date.

Environment

The environment has not had a negative impact on our business operations, the safety of products or personnel. As far as is known, this will not change in the vicinity.

We will of course continue to monitor the planned new construction of the residential area across the street from the company.

Cross-contamination

To date in 2018, there have been no problems with.b regarding cross-contamination. The possibilities for cross-contamination are assessed on the basis of PDA rounds. No problems have emerged from the complaints either.

Assessment of specifications

All necessary specifications are present. Almonds of the Zeemandia with date 14-3-2019. Also seen excellent margarine with date 15-5-2017.

Suppliers

The supplier assessment has not yet been carried out, it still needs to be done. There were no complaints in 2018 towards suppliers.

Improvement

1. Supplier assessment still to be carried out

Traceability and Recall

The tracing test and recall test have not yet been performed. These have yet to be done. For 2018, there was no recall at Cornelis Bartlema Food Group.

Improvement

1.  Performing tracing and recall testing

Internal audits and external audits

On 18-6-2018 the reaudit UTZ was carried out and the RSPO audit was carried out on 16-1-2015. This audit is carried out by IsaCert and is Bert’s responsibility. This audit went well.

There was also an IFS audit on 18 April 2018. This was carried out by Lloyds. During this audit, 5 shortcomings were identified. All shortcomings have been resolved.

Internal complaints

To date, we have had no internal complaints.

Calibration

The scales are calibrated in-house with calibration weights. The scales were last calibrated on 20-3-2019.

The silo is calibrated annually by Silosmacht. This was last done on 4/26/2018.

Corporate security/ food defense

The property is equipped with alarm. The alarm messages run via seQ security. In the first instance, Martinus is called in the event of an alarm.

Martinus assesses the alarm and whether any support is needed from the police or fire brigade.

If Martinus cannot be reached, his son Martinus jr. is called.

During the day the building is closed. One can only enter by ringing the bell or with a batch. This was assessed during the internal audit. It was not possible to enter the building unseen.

There are two cameras at the staff entrance on the outside and one camera on the inside. In addition, staff access and registration are arranged by means of a fingerprint. It has also been decided to use lockers where the codes are automatically removed after 16 hours. As a result, the lockers are not personal and possessions must be removed from the lockers at the end of the day.

Transport

The transport is outsourced to Piet Logistiek. There is a transport declaration available (30-3-2017). Piet Logistiek is also certified for IFS Logistics.

Improvement

1. Request a new IFS certificate

Allergens

We have had no problems with .b allergens in the past year. As a company, we have the following allergens in-house: Gluten-containing grains, milk, egg and soy.

Claims

Cornelis Bartlema Food Group has the claim UTZ, RSPO and fair trade cocoa. Cornelis Bartlema Food Group is certified for all three claims.

HACCP team

The HACCP team consists of the management and an external advisor of QAssurance. Because the two directors themselves work together on the work floor, there is an informal culture within Cornelis Bartlema Food Group. As a result, a lot is discussed informally with the staff and among themselves.

Rework

Cornelis Bartlema Food Group B.V. has three types of rework, namely rework dough, rework cream and rework crumbs. In the handbook, the working method m.b.t.  rework recorded.

The fracture and/or return crumbs to be used intended for reuse may only be used with the following products:

• margarine dough or (50% RB)
• stuffed biscuits
• margarine waffles
• margarine speculaas

Semi-finished coating

Rework coating, consists  of rework coating of 1 day production. Maximum shelf life of 2 months.