Food safety audits allow manufacturers to assess their facility’s cleanliness and effectiveness. These checks can potentially point out issues that may endanger consumers, such as improper handling or poor inspection measures. Learn how to prepare for a food safety audit so you can put out high-quality products and avoid the cost and consequences of a recall.
Why Audit Preparation Matters
What’s the point of a food safety audit? It’s a regulatory check of a manufacturing plant that helps identify possible sanitation and compliance issues. You must prepare for one accordingly to stand the best chance of passing.
A failed audit can have significant consequences, such as:
- Fines
- Legal action
- Disrupted operations
Imagine a manufacturer doesn’t comply with essential safety standards and fails its audit. Governing bodies could enforce a fine or even force the plant to stop all production for public safety. This can cost the company in both the short and long term.
Hefty fines or legal fees can take a toll, while business disruptions may add to the financial losses. However, perhaps the biggest loss for manufacturers is the hit to their reputation. Once-loyal consumers may refuse to purchase products from a manufacturer in the midst of a food safety dispute. Building trust again can be extremely difficult, and many businesses never fully recover.
Understanding Essential Inspection Systems in Food Manufacturing
Your facility should have a Hazard Analysis and Critical Control Point plan to identify possible hazards throughout production. Most manufacturers include the following inspection systems in their HACCP plans:
Metal Detectors
Some products are the subject of massive recalls due to metal shards contaminating the items. Having a high-quality food metal detector at the production facility can help avoid these common and costly issues. If you’re wondering how to prepare for a food safety audit, ensure these systems are up to date.
Metal detectors should be strategically placed throughout the production line, such as at the beginning and end of the packaging process. Document every rejection for quality control purposes and perform regular sensitivity tests.
These machines may need frequent calibration to ensure that they accurately identify contaminants. Running sensitivity tests lets you determine when to calibrate the metal detector.
X-Ray Systems
Modern food x-ray systems, like the ones available through TDI Packsys, are designed to meet the food industry’s unique challenges. X-ray machines can detect a wide range of unwanted materials in products, including:
- Stainless steel
- Animal bones
- Ferrous and non-ferrous metal
- Stones
- Plastic
Food x-ray machines emit very little radiation, so products remain safe for consumption. Integrating them into your packaging process is seamless, thanks to modern advancements. Just ensure you run routine tests to verify the machine’s performance and perform maintenance or repairs as needed.
Checkweighers
Food manufacturers could come under fire if they distribute products that aren’t the right weight. Consumers may complain and demand refunds for products that are grossly underweight. On the other hand, the company may lose money if it distributes products that exceed the standard weight.
That’s why a checkweigher is so valuable. These machines weigh each packaged item and notify the production line of weight discrepancies in real time.
You can ensure consistent fill weights for every package that comes through the line. Logging rejected products also helps with compliance documentation.
Vision Systems
Do you know how to prepare for a food safety audit if you produce bottled, canned, or jarred products? Vision systems are a vital part of avoiding recalls. Cutting-edge technology can inspect the contents inside a container and detect contaminants.
Vision systems are used in & beyond the food & beverage industry to detect leaks/cracks, or discoloration indicating contamination. They can also verify a package’s integrity with label and seal inspections. Automated rejections assist with quality control measures and documentation.
Don’t Forget Compliance Documentation and Record Keeping
How can you pass a food safety audit if you don’t know what experts are looking for? Like a restaurant health inspection, this check involves a thorough sanitation checklist and compliance requirements. Auditors must ensure that your facility meets the safety standards set by the FDA and other regulatory bodies.
Some audits are planned, while others could take manufacturers by surprise. Regularly review all compliance documentation so you know exactly what to expect during your next audit. If your team finds any issues with your facility’s operations, address them promptly to avoid failing your audit.
Your record-keeping practices are just as important as reviewing industry compliance standards. Auditors will likely ask your team members questions about your operations. Having a paper trail to fall back on will help iron out any issues within your facility.
Maintain the following records:
- HACCP plans and updates: Everyone in your facility should be aware of critical control points and any changes in your HACCP plan.
- Standard operating procedures: All employees should have access to your standard operating procedures for quality assurance and consistency.
- Employee training logs and certification: Train every staff member accordingly and document any industry certifications they receive.
- Equipment calibration certificates: These documents help you review your equipment’s maintenance needs.
- Corrective action logs: What steps does your facility take when you identify hazards and need to remove products from the line? Maintain corrective logs for future guidance.
It’s better to be safe than sorry with your record-keeping. Consider using paper and digital systems to ensure you always have access to key information.
Prioritize Team Training and Communication
One of the best ways to prevent poor food safety is thorough training for all plant employees.
If you’re wondering how to prepare for a food safety audit, focus on your team’s training protocols and establish open, clear communication.
Imagine your plant undergoes a surprise audit on a day when one or more staff members are out. Prepare for this scenario by cross-training employees for select positions. Make sure everyone is aware of their responsibilities and designate someone to be a spokesperson for their area of the production line.
Hold mock audit sessions to see how well your food safety training and HACCP education hold up.
Embrace Pre-Audit Preparation Steps
Say you have a set date for an audit in a few months. You can increase your likelihood of passing by conducting internal audits leading up to the official one. An alternative is to hire a third-party professional to perform a mock audit.
During this time, prioritize the following measures:
- Equipment performance testing and calibration
- Documentation review
- Corrective action implementation
- Facility cleaning and organization
If you’re proactive about these measures, you’ll be on the right track for your facility’s inspection.
What Are the Best Practices for Audit Day?
Ask an expert how to prepare for a food safety audit at the last minute, and they’ll tell you it’s much better to take steps in advance. However, there are a few best practices to keep in mind for the day of the check.
Stick to your normal operations instead of making any special changes. Make sure that staff members have access to important documentation, including digital systems and physical records. Once the auditor is on site, it’s important to:
- Interact in a friendly, professional manner.
- Demonstrate your equipment’s capabilities.
- Provide honest responses to all findings.
- Take a collaborative approach to problem solving.
If your plant passes the inspection, it doesn’t mean you can suddenly slack off and change your protocols. You must maintain safe, effective operations that comply with industry standards.
The Benefits of Integrating Technology Into Your Manufacturing Plant
Whether you’re preparing for an upcoming audit or simply want to improve your production line, modern technology can help transform your facility. State-of-the-art inspection systems offer real-time monitoring and automatic rejections. Installing the latest food metal detectors, x-ray machines, or other equipment in your building can help keep contaminated products off store shelves for optimal consumer safety.
Cutting-edge software makes digital documentation and data collection a breeze. Invest in this technology to streamline your production process and continuously track improvements.
Stay up-to-date on the latest advancements in food safety measures. Manufacturers must be willing to adapt to put out high-quality products that consumers love and trust.
Building Audit Readiness for Ongoing Food Safety Checks
A systematic approach to audit preparation can help your facility navigate any challenge. Every employee within your facility should know how to prepare for a food safety audit. Train your team accordingly and make industry compliance a part of your daily operations.
Consider partnering with reliable equipment suppliers like TDI Packsys. Experts can equip your building with state-of-the-art inspection systems and provide support. By using the right equipment and prioritizing food safety compliance, you’ll set your business up for long-term success.
These benefits extend far beyond passing future audits. You can set yourself apart as a trustworthy manufacturer and retain loyal customers. This also reduces the risk of product recalls due to dangerous contaminants, saving you money on legal fees and product waste.
If you’re still wondering how to prepare for a food safety audit or are looking for machines to enhance your facility, contact TDI Packsys. We carry an impressive selection of food metal detectors, x-rays, and more. Contact us online or call 877-834-6750 to learn more.
