- Materials and workmanship
The design of equipment does not allow proper cleaning. Specifically, we observed that the ribbon blender, transition collar, and lower holding tank and screw auger assembly were cleaned on January 25, 2016. The equipment was examined for cleanliness prior to the firm manufacturing a run of Ill River #14 Bread Base. During the examination of the equipment it was determined that a yellowish, tacky residue adhered to the top plate surface of the transition gate between the upper ribbon blender and the lower holding tank. The residue was observed once the gate was moved from the open to the closed position. Employees wiped the residue from the surface with a cloth towel, and then repeated the process of opening and closing the gate and wiping residue from the surface until there appeared to be no additional residue. The firm previously used this same equipment to produce Knead Dough Stick Base on January 21, 2016. Knead Dough Stick base contains the major food allergen of wheat. Ill River #14 Bread Base contains the following major food allergens: wheat, milk, and soy. As noted in previous inspections. The upper ribbon blender unit and lower holding tank assembly cannot be easily disassembled to allow for the transition collar area between the two pieces of equipment to be easily cleaned and examined for cleanliness. Corrected on site. Photographs of the equipment were taken.
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01/26/2016 | Regular |
| No violation noted during this evaluation. | 10/07/2015 | Physical Recheck |
- Adequate lighting
Failure to provide adequate lighting in areas where equipment and utensils are cleaned. Observation #1 - Specifically, we observed that the area where the ribbon blender equipment is installed is illuminated by two overhead mercury vapor ceiling lights. The height of the mixer is nearly equivalent to the height at which the lights are installed, thus much of the lighting that is available for observing cleaning of the ribbon mixer is peripheral light that emits from the lights that are installed in proximity to the north and south ends of the ribbon mixer equipment. The lights are approximately two to three feet from the north and south ends of the ribbon mixer, but are not directly overhead. While cleaning the ribbon mixer, lower holding tank, and screw auger assembly, we observed employees utilize a flashlight and a cell phone camera flash to assist with illuminating equipment surfaces. Observation #2 – Specifically, we observed that the area beneath the lower holding tank was poorly illuminated when employees were attempting to clean the screw auger assembly. The overhead lights, as described in observation #1, did not provide sufficient lighting to allow employees to adequately identify and clean food residue from food contact surfaces. Employees utilized flashlights and cell phone camera flashes to illuminate equipment surfaces to assist with cleaning and post cleaning examinations. 9/11/15 Inspection Update: Observation #1 – No additional lighting has been installed near the top area of the ribbon blender equipment. The permit holder stated that two portable shop lights are being utilized to illuminate low lighted areas beneath the ribbon blender and lower holding tank. These lights can be moved, when needed, to provide additional lighting near the top of the ribbon blender equipment for cleaning or production purposes. An employee performed some additional cleaning of the ribbon blender, lower holding tank, and screw auger assembly during our inspection visit and we observed that the portable shop lights remained attached to lower legs of the metal scaffolding. The lights were not moved during cleaning. Observation #2 – Two portable shop lights were attached to metal scaffolding legs and directed towards the area beneath the lower holding tank area. The addition of the portable shop lights did improve the lighting conditions in this area and assisted with cleaning and post cleaning examinations of equipment and food contact surfaces. Photographs of portable shop lights were taken.
- Cleaning and sanitizing operations
Failure to conduct cleaning and sanitizing operations for utensils and equipment in a manner that protects against contamination of food-contact surfaces and food-packaging materials. Observation #1 - Specifically, we observed at least three pallets of cardboard boxes which were pre-folded, labeled and staged for filling. Each box was covered with a cardboard slip
- Holding in bulk or suitable containers
Failure to hold raw materials in suitable containers so as to protect against contamination. Specifically, we observed that dextrose and shortening ingredients were removed from their original containers and placed into white five gallon plastic buckets in the hand weighing station. The buckets containing dextrose and shortening were not labeled to identify the inner contents. Photographs of these containers were taken. 8/12/15 update - The firm did not communicate any changes or corrections made regarding this deficiency. This item was not verified as being corrected during this inspection. 9/11/15 update – The firm did not communicate any changes or corrections made regarding this deficiency. This item was not verified as being corrected during this re-inspection.
- Labeling
With regards to finished package labeling of Knead Dough Stick Base product - The ingredients statement does not include a full listing of all ingredients contained. Specifically, we observed that the ingredient Datem is comprised of sub-ingredients. These sub-ingredients are not declared on the finished product label. It should be noted that finished product labels were not fully examined for compliance with declaration of ingredients and additional product ingredient declarations may be incorrect. 8/12/15 update – The firm has contacted the FDA Kansas City District Office to coordinate necessary corrections for finished goods product labels. In addition, the firm is working with FDA to recall products that may be misbranded or adulterated due to failure to properly declare major food allergens as well as finished goods that contain a food additive which was determined to be used in excess of regulatory allowances. In summary, labeling issues for finished goods include, but are not limited to, the following: 1) No contact information for the responsible firm as required by 21CFR 101.5 (d)
- Failure to clean - general
Failure to clean food-contact surfaces as frequently as necessary to protect against contamination of food. Observation #1 - Specifically, we observed the interior surfaces of the ribbon mixer to be covered with a powdery, white and yellowish substance. The firm acknowledged that the ribbon mixer was last used on 8/5/2015 to produce a knead dough stick base and had not been cleaned since its last use. In addition, upon examination of the ribbon mixer trough unit we observed the presence of approximately eight beetle-like live insects. These insects were observed along the side walls and in the bottom auger portion of the equipment. The auger canal also was observed to contain remnants of bakery mix from the production run on 8/5/2015. Photographs of the ribbon mixer and ribbon mixer dough trough were taken. 8/12/15 update to observation #1 - We observed the cleaning of the ribbon blender and lower holding tank areas that are used to manufacture and package various bakery base products. The firm's representative stated that this equipment is usually washed on a weekly basis (Friday's). A statement was also made which implied that the lower screw auger assembly, which is attached to the lower holding tank, is dropped and cleaned about one to two times per a week. We asked if the firm has a written cleaning schedule that is followed and were unable to get a definitive answer. No documentation related to cleaning frequencies or actually cleanings were presented during the course of this inspection, nor the inspection on 8/10/2015. Observation #2 - Specifically, we observed that non-food contact surfaces on the exterior of the ribbon blender, lower holding tank, and screw auger assembly, and transition leg between the ribbon blender and lower holding tank are not cleaned effectively and with sufficient frequency to remove build-up of grease and other powder type ingredients. After the exterior surfaces of these pieces of equipment were cleaned via scraping, brushing, using compressed air, and power washing
- Materials and workmanship
The design of equipment does not allow proper cleaning. Observation #1 - Specifically, we observed that the space between the ribbon blender interior side walls and where the ribbon blender shaft ends were difficult to clean. The space between the ribbon blender shaft and the interior side wall measures approximately 1 1/8th inch (widest gap) to ½ inch (narrowest gap). The ribbon blender shaft and blades are not disassembled and removed when the ribbon blender is cleaned. We observed employees cleaning the ribbon blender using plastic dough scrapers, a long handled plastic bristle brush, compressed air, and power washing equipment to clean this area of the ribbon mixer. The primary method used was scraping with the plastic dough scraper, then blowing with compressed air, and finally power washing. The brush was too large to reach into the space described above. After cleaning was complete, we observed a white and yellowish substance adhering to the side wall of the ribbon blender just beneath the ribbon blender shaft. Photographs taken. Observation #2 – Specifically, we observed that the transition opening (manual lever activated slide) at the bottom of the ribbon blender was difficult to access, and also included a slight lip, or ridge, just above the area where the manual slide opens and closes to allow mixed batches to pass from the ribbon blender to the lower holding tank area. The transition opening is located in the bottom, center of the ribbon blender, which measured approximately 41 ½ inches from the top flood rim of the ribbon blender. Employees standing on the metal scaffolding platform cleaning the equipment had to lean over, and into the interior of the ribbon blender, to reach the transition opening. The transition opening was cleaned using a plastic dough scraper, long handled plastic bristle brush, compressed air, and power washing equipment. After cleaning was completed, a small amount of white colored residue was scraped from the lip, or ridge area, that is part of the transition opening. Photographs taken. Observation #3 – Specifically, we observed that the transition leg with connects the bottom of the ribbon blender to the top of the lower holding tank area was never disassembled during the cleaning process. Interior surfaces of this transition piece could not be easily accessed for cleaning or examination to determine the effectiveness of cleaning. After cleaning was completed, we observed white, yellowish, and brownish substances adhering to the exterior surfaces of the transition leg. When the manual lever was fully opened, which allows product to pass from the ribbon blender to the lower holding tank, we observed that a portion of the metal plate (a food contact surface) was still soiled with a brownish colored substance. In addition, when the lever was fully opened then the food contact surfaces of the metal plate were exposed to gross food residue that adhered to, and remained on, exterior surfaces of the transition leg after cleaning was completed. Photographs taken. Observation #4 – Specifically, we observed that the lower holding tank area measured approximately eight feet long, by approximately three feet wide at the top and seven inches wide at the bottom (the tank is tapered), and approximately four feet deep (with screw auger attached). The lower holding tank can only be accessed for cleaning either through the seven inch wide opening on the bottom once the screw auger assembly is disassembled and dropped, or through a side panel on the south end of the tank. The side panel on the south end of the tank measures approximately 2 feet by 2 feet. During cleaning operations, when the screw auger assembly was disconnected from the lower holding tank, we observed that employees were unable to reach the upper portions of the side walls of the tank to scrape the surfaces clean. The employee responsible for applying soapy detergent water was also unable to spray all interior wall surfaces, especially those furthest from the south side access panel and those near the top of the holding tank. In addition, when the equipment was power washed we observed that the pressurized water could not be equally applied to all interior surfaces of the lower holding tank because the screw auger assembly had been reattached to the bottom of the tank and the only access for cleaning was through the side panel on the south end of the tank. There was no access into the lower holding tank from the top since the transition leg would have needed to be disassembled and removed. The transition leg was not removed to disconnect the ribbon blender from the lower holding tank. After cleaning was performed, we observed brownish colored residue remaining on the interior side walls of the lower holding tank. Photographs taken. 9/11/15 update – There were no noticeable changes to equipment design. The permit holder did not indicate any different procedures for equipment disassembly during cleaning. Upon examining the ribbon blender, transition leg, lower holding tank, and screw auger assembly for cleanliness we observed white and yellowish residues on various food and non-food contact surfaces of this equipment. Photographs taken.
- Shown to be effective
The procedure used for sanitizing of utensils has not been shown to provide adequate sanitizing treatment. Specifically, we observed that utensils (buckets) were immersed in chlorine sanitizer solution for a period of less than 10 seconds. The manufacturer's instructions state that equipment and utensils should be immersed for a period of at least two minutes. 8/12/15 Update - The firm had not reported any changes, or corrections implemented, as to how utensils are sanitized. The firm's representative did state that they may consider using a food contact surface sanitizer with a shorter required immersion (contact) time. 9/11/15 Update – No additional changes were discussed regarding sanitizing of smaller pieces of equipment (buckets, scoops, etc). The permit holder had previously discussed the possibility of using a different food contact surface sanitizer
- Running water at suitable temperature
Hand-washing facilities lack running water of a suitable temperature. Specifically, we observed that water temperatures in the men's and women's employee restroom hand washing sinks were of inadequate temperature. The water temperature was observed and measured to be 73 degrees F. Photographs were taken. 8/12/15 update - A 30 gallon on demand water heater has been ordered for the employee restroom area. The water heater was purchased on 8/12/15. A copy of the purchase invoice was provided and is attached with this report. The water heater had not been installed at the time of this inspection. 9/11/15 update – The on demand water heater has not been installed at this time, nor alternative repairs made to the existing hot water heater which furnishes hot water to the men’s and women’s employee restroom hand washing sinks. The water temperatures observed and measured at the hand sinks in these facilities were 75 to 76 degrees Fahrenheit (Photographs taken). The permit holder stated that the existing hot water heater could be repaired by replacing the thermocouple unit. The permit holder had a replacement thermocouple part on hand, but had not replaced the part as of today’s re-check inspection.
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09/11/2015 | Physical Recheck |
- Shown to be effective
The procedure used for cleaning and sanitizing of equipment has not been shown to provide adequate cleaning and sanitizing treatment. Specifically, we observed the cleaning of the ribbon blender, lower storage tank, and screw auger assembly. This equipment was last used on 8/5/2015 to produce a knead dough stick base product. During the cleaning of this equipment we observed employees using plastic/poly dough scrapers, a long handled plastic bristle brush, compressed air, and a power washer to clean interior and exterior surfaces of the ribbon blender, lower storage tank, and screw auger assembly. Photographs of these pieces of equipment were taken. During the process of cleaning food contact surfaces we observed employees scraping gross food residue from interior equipment surfaces using the plastic dough scrapers. Once scraped clean to remove initial gross build-up, the surfaces were then sometimes brushed with the long handled plastic bristle brush, or were sprayed down with compressed air. Following these steps, the equipment was then wetted with a solution of water and dish detergent (Dawn brand dish detergent). The surfaces were permitted to soak for a short period of time (approximately 30 minutes to 1 hour) and were then power washed with a Craftsman (2600 psi, 2.5 GPM, 7.0 hp) gas powered pressure washer. The firm’s representative stated that this was the first time that a detergent had been incorporated into the cleaning process of this equipment. Our observations related to cleaning methods also determined that the equipment used was at times ineffective to clean areas in the ribbon mixer, lower holding tank, and screw auger assembly where small crevasses existed due to equipment design. In addition, we also observed that employees had difficulties reaching certain interior surfaces of the ribbon blender and lower holding tank areas while trying to scrape or power wash these surfaces. We observed that power washing surfaces did not deliver consistent pressurized water coverage on all interior food contact surfaces and a consistent pattern of washing of such surfaces, mostly in the lower holding tank area where access to the area was limited to a single side panel on the south end of the equipment. The furthest portion of the lower holding tank area to be washed was approximately eight feet away, thus resulting in interior surfaces located further away from the access point receiving a different pattern of pressurized water coverage. We observed that no sanitizing solutions were used to sanitize food contact surfaces after cleaning had been completed. Upon completion of cleaning the ribbon blender, lower holding tank, and screw auger assembly, the equipment was examined for cleanliness. There were several areas on the exterior and within the interior of the ribbon blender, lower holding tank area, and screw auger assembly where remnants of white, yellowish, brown, or black food residue was observed adhering to non-food and food contact surfaces. Photographs of these conditions were taken. --The procedure used for sanitizing of utensils has not been shown to provide adequate sanitizing treatment. Specifically, we observed that utensils (buckets) were immersed in chlorine sanitizer solution for a period of less than 10 seconds. The manufacturer's instructions state that equipment and utensils should be immersed for a period of at least two minutes. 8/12/15 Update - The firm had not reported any changes, or corrections implemented, as to how utensils are sanitized. The firm's representative did state that they may consider using a food contact surface sanitizer with a shorter required immersion (contact) time.
- Holding in bulk or suitable containers
Failure to hold raw materials in suitable containers so as to protect against contamination. Specifically, we observed that dextrose and shortening ingredients were removed from their original containers and placed into white five gallon plastic buckets in the hand weighing station. The buckets containing dextrose and shortening were not labeled to identify the inner contents. Photographs of these containers were taken. 8/12/15 update - The firm did not communicate any changes or corrections made regarding this deficiency. This item was not verified as being corrected during this inspection.
- Materials and workmanship
The design of equipment does not allow proper cleaning. Observation #1 - Specifically, we observed that the space between the ribbon blender interior side walls and where the ribbon blender shaft ends were difficult to clean. The space between the ribbon blender shaft and the interior side wall measures approximately 1 1/8th inch (widest gap) to ½ inch (narrowest gap). The ribbon blender shaft and blades are not disassembled and removed when the ribbon blender is cleaned. We observed employees cleaning the ribbon blender using plastic dough scrapers, a long handled plastic bristle brush, compressed air, and power washing equipment to clean this area of the ribbon mixer. The primary method used was scraping with the plastic dough scraper, then blowing with compressed air, and finally power washing. The brush was too large to reach into the space described above. After cleaning was complete, we observed a white and yellowish substance adhering to the side wall of the ribbon blender just beneath the ribbon blender shaft. Photographs taken. Observation #2 – Specifically, we observed that the transition opening (manual lever activated slide) at the bottom of the ribbon blender was difficult to access, and also included a slight lip, or ridge, just above the area where the manual slide opens and closes to allow mixed batches to pass from the ribbon blender to the lower holding tank area. The transition opening is located in the bottom, center of the ribbon blender, which measured approximately 41 ½ inches from the top flood rim of the ribbon blender. Employees standing on the metal scaffolding platform cleaning the equipment had to lean over, and into the interior of the ribbon blender, to reach the transition opening. The transition opening was cleaned using a plastic dough scraper, long handled plastic bristle brush, compressed air, and power washing equipment. After cleaning was completed, a small amount of white colored residue was scraped from the lip, or ridge area, that is part of the transition opening. Photographs taken. Observation #3 – Specifically, we observed that the transition leg with connects the bottom of the ribbon blender to the top of the lower holding tank area was never disassembled during the cleaning process. Interior surfaces of this transition piece could not be easily accessed for cleaning or examination to determine the effectiveness of cleaning. After cleaning was completed, we observed white, yellowish, and brownish substances adhering to the exterior surfaces of the transition leg. When the manual lever was fully opened, which allows product to pass from the ribbon blender to the lower holding tank, we observed that a portion of the metal plate (a food contact surface) was still soiled with a brownish colored substance. In addition, when the lever was fully opened then the food contact surfaces of the metal plate were exposed to gross food residue that adhered to, and remained on, exterior surfaces of the transition leg after cleaning was completed. Photographs taken. Observation #4 – Specifically, we observed that the lower holding tank area measured approximately eight feet long, by approximately three feet wide at the top and seven inches wide at the bottom (the tank is tapered), and approximately four feet deep (with screw auger attached). The lower holding tank can only be accessed for cleaning either through the seven inch wide opening on the bottom once the screw auger assembly is disassembled and dropped, or through a side panel on the south end of the tank. The side panel on the south end of the tank measures approximately 2 feet by 2 feet. During cleaning operations, when the screw auger assembly was disconnected from the lower holding tank, we observed that employees were unable to reach the upper portions of the side walls of the tank to scrape the surfaces clean. The employee responsible for applying soapy detergent water was also unable to spray all interior wall surfaces, especially those furthest from the south side access panel and those near the top of the holding tank. In addition, when the equipment was power washed we observed that the pressurized water could not be equally applied to all interior surfaces of the lower holding tank because the screw auger assembly had been reattached to the bottom of the tank and the only access for cleaning was through the side panel on the south end of the tank. There was no access into the lower holding tank from the top since the transition leg would have needed to be disassembled and removed. The transition leg was not removed to disconnect the ribbon blender from the lower holding tank. After cleaning was performed, we observed brownish colored residue remaining on the interior side walls of the lower holding tank. Photographs taken.
- Cleaning and sanitizing operations
Failure to conduct cleaning and sanitizing operations for utensils and equipment in a manner that protects against contamination of food-contact surfaces and food-packaging materials. Observation #1 - Specifically, we observed at least three pallets of cardboard boxes which were pre-folded, labeled and staged for filling. Each box was covered with a cardboard slip
- Labeling
With regards to finished package labeling of Knead Dough Stick Base product - The ingredients statement does not include a full listing of all ingredients contained. Specifically, we observed that the ingredient Datem is comprised of sub-ingredients. These sub-ingredients are not declared on the finished product label. It should be noted that finished product labels were not fully examined for compliance with declaration of ingredients and additional product ingredient declarations may be incorrect. 8/12/15 update – The firm has contacted the FDA Kansas City District Office to coordinate necessary corrections for finished goods product labels. In addition, the firm is working with FDA to recall products that may be misbranded or adulterated due to failure to properly declare major food allergens as well as finished goods that contain a food additive which was determined to be used in excess of regulatory allowances. In summary, labeling issues for finished goods include, but are not limited to, the following: 1) No contact information for the responsible firm as required by 21CFR 101.5 (d)
- Adequate lighting
Failure to provide adequate lighting in areas where equipment and utensils are cleaned. Observation #1 - Specifically, we observed that the area where the ribbon blender equipment is installed is illuminated by two overhead mercury vapor ceiling lights. The height of the mixer is nearly equivalent to the height at which the lights are installed, thus much of the lighting that is available for observing cleaning of the ribbon mixer is peripheral light that emits from the lights that are installed in proximity to the north and south ends of the ribbon mixer equipment. The lights are approximately two to three feet from the north and south ends of the ribbon mixer, but are not directly overhead. While cleaning the ribbon mixer, lower holding tank, and screw auger assembly, we observed employees utilize a flashlight and a cell phone camera flash to assist with illuminating equipment surfaces. Observation #2 – Specifically, we observed that the area beneath the lower holding tank was poorly illuminated when employees were attempting to clean the screw auger assembly. The overhead lights, as described in observation #1, did not provide sufficient lighting to allow employees to adequately identify and clean food residue from food contact surfaces. Employees utilized flashlights and cell phone camera flashes to illuminate equipment surfaces to assist with cleaning and post cleaning examinations.
- Failure to clean - general
Failure to clean food-contact surfaces as frequently as necessary to protect against contamination of food. Observation #1 - Specifically, we observed the interior surfaces of the ribbon mixer to be covered with a powdery, white and yellowish substance. The firm acknowledged that the ribbon mixer was last used on 8/5/2015 to produce a knead dough stick base and had not been cleaned since its last use. In addition, upon examination of the ribbon mixer trough unit we observed the presence of approximately eight beetle-like live insects. These insects were observed along the side walls and in the bottom auger portion of the equipment. The auger canal also was observed to contain remnants of bakery mix from the production run on 8/5/2015. Photographs of the ribbon mixer and ribbon mixer dough trough were taken. 8/12/15 update to observation #1 - We observed the cleaning of the ribbon blender and lower holding tank areas that are used to manufacture and package various bakery base products. The firm's representative stated that this equipment is usually washed on a weekly basis (Friday's). A statement was also made which implied that the lower screw auger assembly, which is attached to the lower holding tank, is dropped and cleaned about one to two times per a week. We asked if the firm has a written cleaning schedule that is followed and were unable to get a definitive answer. No documentation related to cleaning frequencies or actually cleanings were presented during the course of this inspection, nor the inspection on 8/10/2015. Observation #2 - Specifically, we observed that non-food contact surfaces on the exterior of the ribbon blender, lower holding tank, and screw auger assembly, and transition leg between the ribbon blender and lower holding tank are not cleaned effectively and with sufficient frequency to remove build-up of grease and other powder type ingredients. After the exterior surfaces of these pieces of equipment were cleaned via scraping, brushing, using compressed air, and power washing
- Suitable temp. and pressure
Failure to provide running water at a suitable temperature for cleaning of equipment, utensils and food-packaging materials. Specifically, we observed that the firm’s only source of hot water in the production portion of the plant was a small water heater with a capacity of nineteen gallons. This water heater also provides hot water to the employee hand washing sink and three compartment manual warewashing sinks. While performing clean-out-of place operations with a gas powered pressure washer (attached via a hose to the three compartment faucet) on the ribbon blender equipment, lower holding tank, and screw auger assembly the operator stated about two to three times that washing had to stop in order for the hot water supply to recover. We monitored and observed three separate water temperatures during the pressure washing step and noted that temperatures ranged from 93 -120 degrees F. The water was at its hottest temperature during the initial hook-up and start-up of the pressure washer. We observed on one occasion that the pressure washer was run continuously for approximately four and one-half minutes. During this end of this short run the power washer operator stated that there was insufficient hot water. We monitored the temperature of the water stream from the pressure washer at the end of this continuous run with a calibrated thermocouple and observed the lowest temperature reading of 93 degrees F. Information obtained from the pressure washer equipment indicates that the machine uses 2.5 gallons of water per minute. The pressure washer is not equipped with a water heater booster to further heat water obtained from the source that is feeding it.
- Running water at suitable temperature
Hand-washing facilities lack running water of a suitable temperature. Specifically, Specifically, we observed that water temperatures in the men's and women's employee restroom hand washing sinks were of inadequate temperature. The water temperature was observed and measured to be 73 degrees F. Photographs were taken. 8/12/15 update - A 30 gallon on demand water heater has been ordered for the employee restroom area. The water heater was purchased on 8/12/15. A copy of the purchase invoice was provided and is attached with this report. The water heater had not been installed at the time of this inspection.
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08/12/2015 | Physical Recheck |
- Shown to be effective
The procedure used for sanitizing of utensils has not been shown to provide adequate sanitizing treatment. Specifically, we observed that utensils (buckets) were immersed in chlorine sanitizer solution for a period of less than 10 seconds. The manufacturer's instructions state that equipment and utensils should be immersed for a period of at least two minutes.
- Holding in bulk or suitable containers
Failure to hold raw materials in suitable containers so as to protect against contamination. Specifically, we observed that dextrose and shortening ingredients were removed from their original containers and placed into white five gallon plastic buckets in the hand weighing station. The buckets containing dextrose and shortening were not labeled to identify the inner contents. Photographs of these containers were taken.
- Failure to clean - general
Failure to clean food-contact surfaces as frequently as necessary to protect against contamination of food. Specifically, we observed the interior surfaces of the ribbon mixer to be covered with a powdery, white and yellowish substance. The firm acknowledged that the ribbon mixer was last used on 8/5/2015 to produce a knead dough stick base and had not been cleaned since its last use. In addition, upon examination of the ribbon mixer trough unit we observed the presence of approximately eight beetle-like live insects. These insects were observed along the side walls and in the bottom auger portion of the equipment. The auger canal also was observed to contain remnants of bakery mix from the production run on 8/5/2015. Photographs of the ribbon mixer and ribbon mixer dough trough were taken.
- Labeling
With regards to finished package labeling of Knead Dough Stick Base product - The ingredients statement does not include a full listing of all ingredients contained. Specifically, we observed that the ingredient Datem is comprised of sub-ingredients. These sub-ingredients are not declared on the finished product label. It should be noted that finished product labels were not fully examined for compliance with declaration of ingredients and additional product ingredient declarations may be incorrect.
- Screening
Failure to provide adequate screening or other protection against pests. Specifically, we observed a slight gap beneath the double metal doors, with visible daylight. A gap was also observed between the loading/receiving dock plate and the floor (left side of dock plate). Spider like webbing was also observed on the exterior surfaces of the ribbon mixer. Photographs of these conditions were taken.
- Running water at suitable temperature
Hand-washing facilities lack running water of a suitable temperature. Specifically, we observed that water temperatures in the men's and women's employee restroom hand washing sinks were of inadequate temperature. The water temperature was observed and measured to be 73 degrees F. Photographs were taken.
- Food-contact - corrosion resistant
Lack of corrosion-resistant food contact surfaces. Specifically, we observed stainless steel scoops that are used for hand weighing ingredients to be discolored and were rough to the touch. The scoops surfaces appeared to be pitted.
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08/10/2015 | Regular |
| No violation noted during this evaluation. | 06/30/2014 | Follow Up LOC |
- Labeling
Observation including specific section in violation. Scale used for finished product weight must be calibrated annually
- Storage of cleaned portable equipment (S)
Failure to store cleaned and sanitized portable equipment in a [location] [manner] which protects food-contact surfaces from contamination. Specifically, ***Cleaned food contact equipment (buckets/scoops) shall be stored off the floor and stored open end down on cleanable surface-currently buckets inverted on wood pallet with cardboard liner-owner stated metal racks would be purchased within 30 days
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06/02/2014 | Physical Recheck |
- Floors, walls and ceilings
The plant is not constructed in such a manner as to allow [floors] [walls] [ceilings] to be [adequately cleaned and kept clean] [kept in good repair]. Specifically, ***Walls that are constructed of particle board and drywall must be finished in a manner so that they are easily cleanable, durable non water absorbing and light in color. Wood scaffolding is currently not an easily cleanable surface.
- Cleaning and sanitizing operations
Failure to conduct cleaning and sanitizing operations for utensils and equipment in a manner that protects against contamination of [food] [food-contact surfaces] [food-packaging materials]. Specifically, ***Mixer must be cleaned and sanitized after each use, have written procedure with approved food contact surface sanitizer
- Maintained
Failure to maintain toilet facilities in a sanitary condition. Specifically, ***Clean mens restroom
- Storage of cleaned portable equipment (S)
Failure to store cleaned and sanitized portable equipment in a [location] [manner] which protects food-contact surfaces from contamination. Specifically, ***Cleaned food contact equipment (buckets, scoops) shall be stored off the floor and stored open end down on cleanable surface
- Screening
Failure to provide adequate screening or other protection against pests. Specifically, ***Clean all cobwebs off of walls and ceiling, install weather stripping on exterior door that has light coming in
- Signs
Lack of posted, readily understandable signs directing employees to wash and sanitize hands as appropriate. Specifically, ***Post signs at all handsink reminding employees to wash hands
- Non food-contact equipment in processing area
Non food-contact equipment in [manufacturing] [food handling] areas is not constructed so that it can be kept in a clean condition. Specifically, ***All non food related equipment should be removed or covered / clean manual conveyor (roller track)
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05/08/2014 | Pre Opening |
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