GAP ANALYSIS REPORT TO ASSESS THE COMPLIANCE TO IMPLEMENT HACCP STANDARDS AT

Hithadhoo, Seenu Atoll, Rep.of Maldives

RSS PVT. LTD

Report prepared by:

FATHIMATH LEESHA HANEEF Food Safety Chief Consultant & Trainer

Report Prepared for: Addu Training Institute Inspected By: Fathimath Leesha Haneef Inspection Date: 5th October 2011 Report Editor: Pawel Wolski

INTRODUCTION
The main purpose of conducting a GAP analysis on RSS Pvt. Ltd is to examine the current situation of food production and to identify the areas which require

improvement in order to reach the ultimate goal, which is to achieve a HACCP Certification. This report will provide a brief idea of the current standards and facilities available at RSS Pvt.Ltd and recommendations which needs to be implemented in order to achieve a HACCP Certification.

The Benefits and Barriers Certification for RSS Pvt. Ltd

of

Achieving

HACCP

Benefits Increased in consumer and government confidence; Improved product consistency; Decreased business risks; Opportunities to expand to International markets;

Reduction in production costs (Reduced recall/ wastage of food); Improved staff-management commitment to food safety; Reduced legal and insurance costs

Barriers Lack of Human resource constraints; Lack of legal requirements; Lack of expertise and technical support

Recommendation Certification;

Regarding

Achieving

HACCP

Our recommendation to RSS Pvt Ltd is to achieve the Good Hygiene Practices to UK and EU standards and to have these standards implemented at least for 6 months prior to commencing of HACCP Certification. A Haccp Certification is essential for RSS Pvt.Ltd as they would be targeting for an international market. Specially if they want to export to Europe and United Kingdom, they should have a HACCP or any other food safety management system which is internationally recognized. If not EU Nations and UK will have the power to reject their products according to their law EC 852/2004.

OBSERVATION
SECTION A: Purchasing, Delivering and Receiving of food items.
Observation: Not applicable as the land RSS Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: Food items should be purchased from an approved supplier and RSS Pvt Ltd must be aware of where their food items are coming from and the standards they are prepared at. It is very important for RSS to monitor the standards at which the fishing vessels handles the fish. If the fish is deviated by the time they receive it, the chain of HACCP will be broken and it will not be adequate for them to use it.

SECTION B: Dry Storage Facilities

Observation: Not applicable as the land RSS .Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: A proper dry store must be included in the plant design for storage of dry food ingredients. The dry store must be properly ventilated, preferably air conditioned with satin less steel shelving units at least 6 inches above the floor level. The dry store must with adequate lighting and the flooring must be tiled with proper drainage. Dry stores must be designed in a way that the employees could maintain it clean at all times.

SECTION C: Chilled and Frozen Storage

Observation: Not applicable as the land RSS.Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: It is essential for RSS Pvt.Ltd to get walk in freezers and chillers to store their raw fish. Chillers should be segregated for different stages of the production.

SECTION D: Food Preparation Area

Observation: Not applicable as the land RSS.Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: The food preparation area should be designed in a way that only the designated work is done in that particular area. The food preparation area must be designed in a way to eliminate all kinds of hazards and cross contamination. The fish plant should have a proper butchery area, preparation area, packing area and all the areas must be fully separated.

SECTION E: Personal Hygiene

Observation: Not applicable as the land RSS.Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: The food handlers should be provided with clean uniforms for each shift and they should not wear any jewelry inside the food handling area. They should be provided with an adequate hand wash basin with anti bacterial soap, a soap dispenser, a tissue dispenser and tissue, a foot operated waste bin with a foot operated or elbow operated tap to avoid contamination. We also do not recommend the food handlers to use gloves at the preparation stage as it avoids the food handlers from washing their hands as frequent as possible and in between each task. Food handlers working in the butchery area could use protective gloves. Hand wash basins

should be provided at each sub preparation section.

SECTION F: Equipments
Observation: Not applicable as the land RSS .Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: Food handlers should be provided with adequate equipments to prepare safe and risk free food. Equipments should be in a cleanable, sanitazable, durable material which will not cause any chemical poisoning or which will not chip off easily.

SECTION G: Cleaning & Sanitization

Observation: Not applicable as the land RSS.Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: A cleaning schedule with all the relevant information should be provided with a cleaning manual. Proper food graded Chemicals must be used for cleaning and sanitizing and it is the plant must have a separate cleaning closet away from food preparation area for storage of cleaning chemicals and equipments.

SECTION H: Refuse Facilities and Waste Management

Observation: Not applicable as the land RSS .Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: Internal Refuse: Proper foot operated refuse bins with lids should be provided at the food preparation areas. Waste should be segregated discarded. External Refuse: A proper waste management system should be figured out and bins with lids must be provided to store external refuse. External refuse should be stored in a garbage room with air conditioning. The garbage room should be tiled with drainage facility and pest proofed.

SECTION I: Pest Control

Observation: Not applicable as the land RSS .Pvt Ltd has planned to build the fish plant is an empty godown

at the time of the inspection. Recommendation: The premises should be properly pest proofed. An adequate premises is essential for the food preparation and handling areas. Pets should not be allowed inside the food preparation area. Doors should not be left opened. The food preparation areas must have fly killer machines and an integrated pest management system should be implement. Btek should also hire an external pest control contractor for preventive pest infestations and for regular monitoring.

SECTION J: Employee and Management Training

Observation: Not applicable as the land RSS.Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: An ongoing staff training program must be implement. All staff should be trained at least in Foundation Level 1 Food Safety and Foundation Level 1 HACCP. Senior management staff and supervisors should be trained in Foundation Level 2 Food Safety and Foundation Level 2 in HACCP. In order to achieve a HACCP Certification, a HACCP team should be selected and at least the chair person of the HACCP team should be trained at least in Intermediate Level 3 Food Safety and Intermediate Level 3 HACCP.

SECTION K: Food Preparation Premises and Structure

Observation: Not applicable as the land RSS.Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: The structure should be designed in a manner that it is easy to clean and sanitize. The walls must be properly painted to eliminate flaking of paint, ceilings must be properly completed without any gaps, floorings should be completed with safe tiles, adequate drainage should be provided through out the plant and proper ventilation, air conditioning and lighting is essential to the food preparation areas. The structure should be designed in a way that outsiders do not have access into the preparation areas unless with special authorization.

SECTION L: Portable Water Safety

Observation: Not applicable as the land RSS.Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: For a fish processing plant, it is very important to use quality tested water. In order to achive this, an adequate water desalination plant should be installed and maintained. Water should be tested regularly for chlorine and PH levels regularly and water should be tested for legionella at least 3 times an year.

SECTION M: General Health and Safety

Observation: Not applicable as the land RSS.Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: For a fish processing plant should be designed with adequate safety standards. Fire doors and emergency exits should be marked. Btek also should have a Fire Safety Contractor to provide regular fire training. First Aid stations should be provided at the premises with easy access. A team of employees also must be trained in First Aid.

SECTION N: Food Delivery and Despatch Vehicles

Observation: Not applicable as the land RSS.Pvt Ltd has planned to build the fish plant is an empty godown at the time of the inspection. Recommendation: The vehicles which will be used to for despatch of food products and delivery of food products must be with chilled units and it should be maintained at adequate standards.