Lesson 1Preparation and separation of raw and RTE operations: work flow, physical barriers, colour-coding, time limits for exposed RTE foodsHow raw and ready-to-eat areas must separate to stop cross-mixing. Covers work flows, barriers, colour-coding, time limits for open foods, and inspector checks.
Assessing raw-to-RTE product flowsPhysical barriers and zoning controlsColor-coded tools and utensils policyTime limits for exposed RTE productsVerification of changeover proceduresLesson 2Packing room and finished product handling: packaging integrity, foreign-body prevention, packing line guards and metal detectorsControls in packing areas and finished goods handling. Packaging fit, checks, foreign bits prevention, line guards, metal detectors, inspector tests and record reviews.
Cleanliness of packing environmentPackaging material suitability checksLine guarding and physical barriersMetal detector setup and challenge testsPacked product integrity inspectionsLesson 3Labelling, traceability and complaint handling on-site: batch coding review, retained sample practice, consumer complaint log checksInspectors check labels, batch codes, tracking for recalls. Retained samples, complaint logs, site records for quick safety probes.
Mandatory label information checksBatch coding and date marking reviewTraceability one-step up, one-step downRetained sample storage and recordsConsumer complaint log verificationLesson 4Cooking, cooling and hot-holding controls: cooking validation, rapid cooling methods, hot-holding temperatures and monitoringVerify safe cooking, cooling, hot-holding. Limits, validation, core temps, quick cooling, hot temps, monitoring, deviation handling.
Critical limits for cooking temperaturesValidation of cooking and reheating stepsCooling time and temperature controlsHot-holding temperature monitoringHandling undercooked product incidentsLesson 5Pest control, waste management and building fabric: evidences of pests, waste segregation, maintenance of ceilings/doors/lightingPest control, waste, building state. Spot pest signs, contractor reports, waste sorting, upkeep of doors, ceilings, drains, lights for safety.
Evidence of pests and harboragesPest control contracts and recordsWaste segregation and storage areasBuilding integrity and door conditionCeilings, drains and lighting hygieneLesson 6Cleaning procedures and equipment hygiene: cleaning schedules, validation, equipment design for cleanability, residue checksEvaluate cleaning plans and gear cleanliness. Schedules, chemicals, validation, gear design, residue checks with sight, ATP, germ tests.
Review of cleaning schedules and SSOPsDetergent and sanitizer selectionEquipment design for easy cleaningPost-clean visual and ATP checksMicrobiological verification of cleaningLesson 7Chilled storage and cold chain verification: refrigerator/freezer temp checks, load patterns, airflow and defrost impactsAssess chilled stores and cold chain. Fridge/freezer temps, loads, air flow, defrost, alarms, records for steady temps.
Refrigerator and freezer temp recordsProduct loading and stacking patternsAirflow, spacing and blockage risksDefrost cycles and ice buildup reviewTemperature alarms and response logsLesson 8Finished product cold store and dispatch controls: storage rotation (FIFO), temperature monitoring, dispatch checks and transport controlsCheck finished cold stores and dispatch. Stock turn (FIFO), temp watch, loading, transport to keep cold chain and avoid temp abuse.
Assessing FIFO and stock rotationCold room temperature records reviewLoading patterns and door openingVehicle temperature and seal checksPre-dispatch product condition checksLesson 9Personal hygiene facilities and staff behaviour: handwash stations, signage, changing rooms, sick policy adherenceInspect hygiene spots and staff ways. Handwash setup, soap, changing rooms, PPE, sick rules, watch and ask staff in tasks.
Handwash station location and designSoap, sanitizer and drying provisionsChanging rooms and locker controlsObservation of handwashing practiceSickness reporting and exclusion rulesLesson 10Raw material receiving and supplier verification: delivery checks, documentation, temperature on arrival, foreign-body controlsRaw goods intake and supplier checks. Delivery temps, packaging, foreign bits, papers, supplier approval and performance.
Vehicle and load condition on arrivalTemperature checks for chilled and frozenPackaging integrity and contaminationDelivery documentation and COAsSupplier approval and review records
