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Dairy Products Safe and True
Part B Standards
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Maintaining and Restarting Non-Operating Dairy Factories and Stores (SUPERCEDED)
- Purpose
- Scope
- Definitions
- References
- Registered dairy factories and stores
- Maintaining a non-operating registered factory
- Restarting a non-operating registered factory
- Maintaining a non-operating registered store
- Restarting a non-operating registered store
- Registration surrended
- Re-registration of premises
- Emergency start-up
- MAF Reg charges
1.1 This standard describes the conditions under which a non-operating registered dairy factory or store may be maintained, and the conditions for recommencing operations.
1.2 This standard satisfies Regulations 8, 9, 15, 16 and 17 of the Dairy Industry Regulations. Factories and stores that conform to this standard will be registered, and their product safety programmes will be approved.
This standard applies where a company ceases to use a registered premises for manufacture or storage of dairy products. The company has these options:
- either maintaining registration of the premises, so as to be able to quickly resume manufacturing or storage operations (see Sections 6-9);
- or surrendering registration (Section 10), and if restarting, following Section 11.
Non-operating means not used for the purposes of manufacturing or storing dairy products. A non-operating store is one that continues to offer storage for dairy products but has not stored any products for the preceding 6 months.
Company means the company responsible for operating the factory or store.
- Dairy Industry Regulations 1990.
5. Registered Dairy Factories and Stores
5.1 A registered dairy factory or store, whether operating or not, must be maintained in a condition suitable for the manufacture or storage of dairy products, and a product safety programme (PSP) must be maintained. These are requirements of the Dairy Industry Regulations.
5.2 All registered premises will be deemed to be operating with their normal approved PSP in full effect until MAF Reg receives written notice of the intention to become non-operational.
6. Maintaining a Non-operating Registered Factory
6.1 To maintain registration of a non-operating factory, the company shall:
- · either maintain the factory in a fully operational state with a current approved and audited PSP,
- · or prepare a specific "non-operational" PSP which includes any special arrangements made for mothballing, and submit it to MAF Reg for approval;
and maintain the approved PSP, and review it annually.
6.2 The PSP of a non-operating registered factory shall include:
- resolving any pathogen tracebacks so that the factory is clear before mothballing;
- a pest control programme (rodents, birds, insects) using traps, baits or fumigation;
- appropriate pathogen surveillance (reduced);
- entry controls and security;
- periodic in-house inspections and corrective actions;
- annual inspection by a MAF Reg-recognised inspection service to ensure that minimum requirements for registration are maintained, with completion of corrective actions;
- details of arrangements for ventilation, drainage sanitation, internal sanitation, plant readiness and maintenance (valves, instruments, motors, etc.), CIP and water treatment;
- keeping records of all the activities above;
- sending exception reports during the month they occur, and in particular any:
- alteration to the pasteuriser or its controls
- alteration to or alternative use of the premises
- alteration to or removal of manufacturing plant and equipment;
- sending status reports to MAF Reg at least every 6 months.
6.3 MAF Reg will approve a non-operational PSP covering the mothballing arrangements and review this PSP annually.
6.4 While it is non-operational, the areas of the factory used for handling dairy products shall not be used for any activities likely to prejudice product safety if the factory were to be recommissioned. This includes storage of non-dairy goods that may pose a risk to product safety and storage of surplus equipment.
7. Restarting a Non-operating Registered Factory
7.1 Before processing dairy products through a recommissioned registered factory, the company shall:
- notify MAF Reg immediately of the intention to restart, the proposed date and the likely duration of use;
- conduct a pre-start inspection using MAF Reg-recognised inspectors and complete corrective actions;
- confirm the pasteuriser has not been altered since the previous validation and, if necessary, revalidate the pasteuriser;
- ensure pathogen monitoring samples for the critical hygiene area are negative immediately before start-up and confirm with MAF Reg, and if necessary resolve any pathogen tracebacks so that the factory is clear before processing commences;
- reactivate the original PSP or an approved alternative before any production commences;
- send MAF Reg immediate reports of these actions.
7.2 MAF Reg will as soon as possible after notification:
- review the original PSP if it has not been reviewed within the preceding 12 months;
- programme a visit to the site where it is intended that it will be in use for more than 1 month.
8. Maintaining a Non-operating Registered Store
8.1 To maintain registration of a non-operating store, the company shall:
- either maintain the store in a fully operational state with a current approved and audited PSP,
- or prepare a specific "non-operational" PSP which includes any special arrangements made for the time that dairy products are not stored, and submit it to MAF Reg for approval;
- maintain the approved PSP, and review it annually;
- notify MAF Reg of the proposed date for recommencing the storage of dairy products, if the store has been closed;
- notify MAF Reg immediately product is received for storage.
8.2 The PSP of a non-operating registered store shall include:
- a pest control programme (rodents, birds, insects) using traps, baits or fumigation;
- periodic in-house inspections and corrective actions;
- annual inspection by a MAF Reg-recognised inspection service to ensure that minimum requirements for registration are maintained and corrective actions are complete;
- resolving any pathogen tracebacks so that the store is clear before mothballing;
- keeping records of all the activities above;
- sending exception reports to MAF Reg as they occur and sending status reports at least every 6 months.
8.3 MAF Reg will approve a non-operational PSP covering the arrangements and review the PSP annually.
8.4 The company shall not use the store for storage of non-food goods with a potential to contaminate future stored dairy products, i.e. chemicals, etc., or conduct any other activity which might prejudice product safety on recommissioning.
9. Restarting a Non-operating Registered Store
Before recommencing storage of dairy products in a non-operating registered store, the company shall:
- notify MAF Reg;
- conduct a pre-start inspection using MAF Reg-recognised inspectors and complete corrective actions.
10.1 Where the company decides not to maintain registration, MAF Reg will cancel the certificate of registration and withdraw approval of the PSP. Certificates are to be returned to MAF Reg, P.O. Box 2526, Wellington.
10.2 The company may not use unregistered premises for the manufacture or storage of dairy products.
11. Re-registration of Premises
11.1 Should the company wish to resume dairy product manufacturing or storage operations at an deregistered premises, it shall:
- apply for registration using the procedure and application form in Dairy Products Safe and True, Section 5.7;
- submit a PSP for approval to MAF Reg;
- gain validation of pathogen, pest and pasteuriser programmes using MAF Reg approved assessors;
- conduct a pre-start inspection using MAF Reg approved inspectors and complete corrective actions;
- confirm the pasteuriser has not been altered since the previous validation or have the pasteuriser revalidated;
- ensure pathogen monitoring samples are negative immediately before start-up and confirm with MAF Reg;
- carry out internal cleaning and sanitation;
- carry out hygiene monitoring checks on the premises and plant and confirm that the results are satisfactory for the production of foods for human consumption.
11.2 MAF Reg will:
- register the premises once all corrective actions have been done (Note: the original registration number may not be available after 2 years);
- visit the premises at start-up to complete the registration requirements, i.e. verification of corrective actions and approval of the PSP;
- approve the PSP after corrective actions are completed.
Companies may require contingency arrangements for emergency start-up, that do not allow time for the requirements of this standard to be completed. In this case the following conditions apply:
12.1 Products manufactured or stored in a recommissioned factory or store which does not meet the requirements of Sections 7, 9 or 11 shall be clearly identified and placed on hold.
12.2 The following minimum testing requirements, intended to provide equivalent assurance of product safety to that normally provided, shall apply:
- Environmental surveillance: Sample environmental sampling sites, both before and after the initial cleaning of the plant.
- Pathogen testing: Sample each pallet and group into at least five composites per day, for at least the first 5 days.
- Other microbiological testing: Sample and test as required by the purchase specification.
- Phosphatase: Test one sample per pallet.
- Foreign matter: Test one sample per pallet.
- Basic compositional tests (fat and moisture): Sample and test as required by the purchase specification, including an assessment of variability.
12.3 The product shall not be released until the proposed disposition has been approved by MAF Reg. The disposition will be approved on the basis of clear evidence of suitability,provided by the company. The product can be accepted for human consumption, and MAF certification can be provided, if all the results from testing in Section 12.2 are satisfactory and there is evidence of effective pasteurisation. Otherwise disposition is subject to negotiation.
13.1 For non-operational premises (Sections 6 and 8), annual fees will cover the cost of an annual review of the PSP and reviewing reports. For dairy factories the annual fees will be $1480 plus GST, and for stores, $180 plus GST, at the current rate of $20 per ¼ hour plus GST. There will be no visit charges.
13.2 For recommissioning non-operational premises, MAF Reg will charge for the review of the original PSP, if it is needed.
13.3 For deregistered premises, MAF Reg charges will cease at the end of the month that the registration and approved PSP certificates have been returned and received by MAF Reg.
13.4 Charges for other services, such as charges in the event of an emergency start-up, will be at the current rate of $20 per ¼ hour plus GST.
Revision status
Rev Date Status By Approved 1 20 April 1995 Issued for use Chief Dairy Officer
Amendment and Control Procedure Amendments to this standard are issued to holders of Dairy Products Safe and True, and to the MAF Reg address list for circulars and newsletters. Suggestions for improvements to this standard will be welcomed. They should be sent to:
The Chief Dairy Officer
MAF Regulatory Authority
P.O. Box 2526
Wellington
New Zealand Food Safety Authority
68-86 Jervois Quay
PO Box 2835
Wellington
NEW ZEALAND
Phone: +64 4 894 2500
Fax: +64 4 894 2501
Contact
NZFSA about this page