Doug Trovinger

Rice Cake Packaging Line Icons Prohibited Attention Actions in Emergency Situation Worn Packaging Quality Guide Cleaning and Sanitation Policies Rice Cake Packaging Line Quality Checks and Best Practices Guide Index OPM Quality Overview LRC_LY_QA-PKG-01 2023 2 Key Safety Expectations Daily Sanitation/Good Manufacturing Practice (GMP) Responsibilities Daily Sanitation 3 Container Color Coding 8 Tool Standards 10 Gloves Policy 13 General Cleaning Policies 14 Quality Information 15 Food Safety in the Facility 15 Allergen Information 16 Allergen Procedures Food Product Zones and AIB (American Institute of Baking) Packaging Certification 17 Traceability 18 © 2023 Frito-Lay - All Rights Reserved 5 7 17 17 2 Rice Cake Packaging Line LRC_LY_QTY-PKG-01 – Safety Overview Overview Performance Outcome • A formal and comprehensive Food Safety, Container and Tool policy is an essential part of a sound cGMP/Food safety program in any facility that manufactures or handles food product • Understand that it is your responsibility to make sure we are following all Quality standards set by the plant every day. Every Team Member receives site-specific Quality training. Safety • All employees must wear basic the PPE always required in all production areas: • Hearing protection (moulded plugs, disposable ear plus, or earmuffs) • Safety glasses (must have the ANSI Z-87 Marking; Prescription safety glasses must have the ANSI Z-87 marking and permanent side shields. Tinted lenses are only allowed with prior approval by EHS. • Steel toed slip-resistant shoes with the ASTM-F2413-11 marking (All shoes must be approved by EHS before use). • Hairnets and/or Beard covers • LOTO locks (Green Lock with name engraved) and keys that are readily accessible near workstation • Reflective vests/shirts • Chemical Suits for Wet Changeovers • Other potential PPE needed depending on the work task: • Gloves • Cut resistant for sharps • Heat resistant for hot materials • Nitrile gloves for chemicals/cleaning • Ancillary gloves for general activity • Retractable, rounded-tip safety knife • Aprons • Steel toe rubber boots (during cleanup), etc. • Refer to the Job Hazard Analyses for other PPE that might be needed in the area 2023 © 2023 Frito-Lay - All Rights Reserved 3 Rice Cake Packaging Line LRC_LY_QTY-PKG-01 – Safety Overview Overview References • • • • • • • ISO Standards GMP Standards Current Good Manufacturing Practices Procedure Color Coding Allergen Management SOP's Tool Cleaning Procedure Metal Detection Procedures Tools, Materials, and/or Equipment • • • • • Mops Brooms Dustpans Squeegees Vacuum Accessories (as necessary} Special Notes Consumer satisfaction is the number one focus after Safety in Frito-Lay facilities. We provide our consumers and customers with safe, legal, and highest-quality products that meet or exceed all Customer expectations. No product shall be manufactured or shipped that does not meet these Quality and food safety standards.. 2023 © 2023 Frito-Lay - All Rights Reserved 4 Rice Cake Packaging Line Daily Sanitation/Good Manufacturing Practice (GMP) Responsibilities The purpose of GMP's is to establish practices that ensure a safe, wholesome product for our customers. Failure to follow these practices requires that Resources and Quality Assurance Technicians provide additional training, coaching and/or corrective action. Product produced during a cGMP violation is subject to a HOLD status. Here are some of the cGMP and expectations all employees must adhere to. Head 1. Wear hairnets properly always. a. Barrettes or ties can be worn under Hairnets-No Bobby Pins. b. If you wear a cap, you must wear a hairnet under it. The cap must also be covered by a hairnet 2. If there are visible signs of facial hair, a beard net must be worn over the lip. a. Beards and mustaches must be neatly trimmed so to allow total coverage under a beard net. b. Mustaches trimmed to lip level. 3. No earrings or other facial jewelry (nose ring, tongue rings, etc.). 4. No false eyelashes 5. No excessive make-up 6. No perfume or cologne 7. Ear Protection must be worn on the production floor. (Earplugs must be metal detectable, intact, and accompanied by a strap). Hands 1. Each time you enter the packaging area you must wash your hands in the main sink. a. Use hot water and soap every time. 2. No watches, bracelets, or other hand jewelry. Plain bands, no stones, can be worn on the production floor. 3. No nail polish or false nails. 2023 © 2023 Frito-Lay - All Rights Reserved 5 Rice Cake Packaging Line Uniform 1. Wear a clean uniform at the start of each day. 2. Do not wear anything above the waist that could fall into a product such as pens, pencils, tools, and jewelry. a. No pockets or buttons on shirts. b. No hoodies or shirts with hoods. c. No fleece jackets. d. No frays or holes in pants, shirts, or jackets. e. No bling on clothing. Food and Tobacco 1. No smoking or chewing tobacco anywhere on the production floor or in any area not approved for smoking. a. Candy, gum, tobacco, and cigarettes are not allowed anywhere on the production floor. b. Please consume these in approved designated areas off the production floor. 2. No eating or drinking of beverages anywhere on the production floor. a. Tasting rice cakes and flavorings is permitted for evaluation purposes, quality walls. b. It is NOT acceptable to eat a bag of rice cakes on the production floor. Personal 1. No open cuts or sores a. Use band-aids or dressings from a first aid cabinet and wear gloves when you are out on the floor. b. Band Aids must be metal detectable. 2. Do not cough or sneeze over product zone. a. Cough or sneeze into the arm or sleeve of your uniform. b. Never cough or sneeze directly at someone or any of the production equipment when product is funning. 3. Personal Medications should be stored in your locker and consumed off the production floor. 2023 © 2023 Frito-Lay - All Rights Reserved 6 Rice Cake Packaging Line Daily Sanitation 1. Keep floor swept conducting safety sweeps periodically and/or dust mopped and keep trash barrels empty 2. Wear nitrile gloves when handling products, reworking products, and touching food contact surfaces. a. Replace soiled gloves with a clean pair as necessary and when returning to the workstation or handling nonfood Contact Items. b. Always wear nitrile gloves when handling any product. c. Wear proper protection when cleaning (i.e., gloves, boots, goggles, etc.) 3. Always wear hairnets properly. a. If you wear a cap, you must wear a hairnet under and it. 4. Observe all other Plant Rules and Regulations as they pertain to Sanitation/ GMP within the plant. 5. Spray bottles can be obtained from the chemical cage. a. If you should get one for any reason, it must be clearly marked with a label with the contents and the chemical name. b. If you find a bottle that is not marked and you do not know the contents or know the bottle does NOT contain what the marking states, contact your Resource to dispose. Do not use it. 6. All contaminants are to be kept away from the line and product zones. 7. If maintenance personnel work on a machine near a product zone, ensure the area is 100% free of any contaminant prior to starting or restarting the equipment. Figure 1: Sample of Gloves Used on Production Floor 2023 © 2023 Frito-Lay - All Rights Reserved 7 Rice Cake Packaging Line Container Color Coding To ensure that containers or barrels are used for a single purpose they are color coded. The color of the container tells an employee or visitor whether the contents are to be treated as "edible" and therefore how it should be handled and cared for. Container labels supersede color by QA management permission. Figure 2: White – Inedible Waste Food Byproduct (Right) and White – Product That Can Be Reworked Figure 3: Grey – Trash Cans/Totes 2023 © 2023 Frito-Lay - All Rights Reserved 8 Rice Cake Packaging Line Figure 4: Yellow – Rework Figure 5: Blue - Recycling 2023 © 2023 Frito-Lay - All Rights Reserved 9 Rice Cake Packaging Line Tool Standards 1. Tools that are used at the facility must all be observed for cleanliness and food safety risks prior to use. 2. All tools will go through a process to ensure that the surfaces are clean and free of foreign matter. 3. In the instance tools are going to be stored, these items shall be cleaned prior to storage/use. 4. When items are being prepared to be used, whether they are from storage or being put into production directly upon being retrieved, they will go through a cleaning process prior to being introduced into the production process. 5. The cleaning process used for all (i.e., screwdrivers, etc.) items introduced into the production process will undergo a cleaning process to ensure the integrity of the product is upheld. 6. Once the items have been placed in the production zone, if further work is required, the surfaces must be inspected for cleanliness and re-cleaned if needed. a. This process may require that sanitary towels be used and will require the application of chemicals depending on the situation. b. To ensure that tools are used for a single purpose they are color-coded. 7. Do not store tools or utensils on equipment. Use worktables or carts provided. 8. The color of the tool tells an employee or visitor what the tool is used for and therefore how it should be handled and cared for. 9. Tools should never be used for any purpose other than the one it is color coded for. See Color Coding for procedures. Figure 6: Green – BGMP (Basic Good Manufacturing Practice) Area and Areas That Are Pre-Kill Step 2023 © 2023 Frito-Lay - All Rights Reserved 10 Rice Cake Packaging Line Figure 7: Blue – PPCA (Primary Pathogen Control Area) and Areas That Are Post-Kill Step Figure 8: Orange – HRPA (High Risk Pathogen Area); Areas With Increased Pathogen Activity >> PC Bin Room and ZLF/Waste Compactor Room 2023 © 2023 Frito-Lay - All Rights Reserved 11 Rice Cake Packaging Line Figure 9: White – PCS (Product Contact Surface); Any Area Product (Raw or Finished) Touches. Clean After Each Use Is Standard 10. A knife used in our food manufacturing operations must be capable of being sanitized and must not contain parts that can falloff and contaminate the products we produce. 11. The knife must also be safe for our team members to use given that any device with a sharp edge can produce an injury if improperly used. 12. Knives specified for a specific functional area must be used only in that area. This policy applies to all team members in production, and Maintenance. 13. Razor knives, even if retractable, are never allowed in production, maintenance, or warehouse operations. 14. The knife must be a one-piece design to facilitate proper cleaning and for personnel safety. Scissors do not have to meet these criteria 15. A folding knife has inaccessible recesses that will allow bacteria to grow and foreign matter to collect. 16. A knife with a folding mechanism and spring type retractors, scissors with bolt and screw, etc., could fall apart and contaminate the product stream. 17. An approved knife shall not have a pointed end. All production knives shall have a holder for proper storage. 18. Use only Frito-Lay approved knives that meet the following guidelines. a. A one-piece design b. Can easily be cleaned c. Have no screws or bolts d. Contain no pointed tips e. Each operator must be accountable for the condition of their knife. Any lost or damaged knife must be reported immediately. 2023 © 2023 Frito-Lay - All Rights Reserved 12 Rice Cake Packaging Line General Cleaning Policies 1. Gloves are provided to all employees and free for use in most non-direct food contact situations. 2. Additionally, some specific tasks require the use of specialty gloves for the protection of the employee. 3. Any employee using their hands for direct food contact is required to utilize the Nitrile disposable gloves provided. a. Disposable gloves shall be discarded, and new ones utilized whenever leaving the workstation or when soiled or damaged or handling non-food contact items. b. Replace gloves with a clean pair when returning to the workstation or handling nonfood contact items. c. Black gloves - Square D box and sensor protected cover. 4. All gloves shall be in clean and suitable condition prior to use. a. Gloves shall be discarded when they become soiled, torn, frayed, or otherwise unsuitable for use in a food manufacturing plant or performing tasks that cause them to contact the floor, dustpan, brooms, etc. b. When handling products (finished and raw), use product contact gloves only. Eliminate cross contamination by not using the same glove for different tasks (e.g., Wiping equipment during a seasoning changeover SCO (Supply Chain Optimization). 5. Cloth gloves shall be utilized for Popping (except for changing heater wires), ML (Machine Learning) and Large Line Case Packer, Formost (with exception of paperwork), and (when cleaning jaws); they shall be minimal contact with a product contact surface. (These gloves are not individual use gloves and must be maintained in a sanitary manner. They should be maintained, clean and in good repair and stored properly when not in use.). 6. Sanitation and/or chemical handling gloves shall be worn in all departments during sanitation activities and are not to meet product. These gloves are not individual use gloves must be maintained in a sanitary manner. They should be maintained, clean and in good repair and stored properly when not in use. These gloves should be stored in a clean and sanitary manner. 7. Maintenance gloves are to be used for that purpose only. They are to be maintained, cleaned, and stored properly away from the product. When Maintenance is in food contact areas, they are required to wear the appropriate food contact gloves.(Exception: Maintenance Electrical Gloves, which are stored in the MCC (Main Control Center) Rooms, are leather and are replaced at least every 6 months). 8. Gloves are to be maintained by the employee utilizing them and stored in a sanitary manner within the plant 5S guidelines. a. Popping associates should change cloth gloves as needed and place soiled gloves in the marked container in the Popping room. At the end of shift the associates should dispose of all gloves in marked containers. Gloves in this area should not be left from shift to shift. b. Packaging associates are to store cloth gloves in designated areas. If the gloves become soiled, they should be placed in; the marked container located in the clean room. 2023 © 2023 Frito-Lay - All Rights Reserved 13 Rice Cake Packaging Line c. Cloth gloves should not be dangling from pockets nor should gloves be taken into the restrooms. 9. Nitrile gloves shall not be utilized by more than one employee. Used Nitrile gloves should be discarded. 10. Only company issued gloves are permitted for use in food zones and areas. 11. Nitrile gloves must be always worn where food contact is required. a. It is acceptable to remove products for sampling or testing without gloves, but the product must then be destroyed! Gloves Policy 1. Clean your area before leaving or as needed. 2. Keep trash barrels empty. 3. Spray bottles can be obtained from the chemical cage. a. If you should get one for any reason, it must be clearly and boldly marked with the contents and the chemical name. b. Never use an unmarked bottle that contains a chemical without first knowing exactly which chemical is in the container. After properly identifying the chemical, you must immediately label the bottles contents. If you are unsure of the contents, DO NOT USE and notify your resource immediately! 4. Broom and Dustpan – Can be utilized for any floor area including corners, edge walls, close clearance, around and under machinery etc. a. These tools are in various locations around the department and sanitation storeroom. b. These should NOT be used on any food-contact surface. Keep the floor swept or dust mopped. 5. Foxtail Brush – Normally used for sweeping debris from bags, boxes, drums, counter tops, plant desks etc. a. After using a brush, be sure to clean any debris that was swept to the floor and discard it to a proper trash barrel or cart. b. Foxtail brushes are available from the plant storeroom Brushes are color coded for the job you are performing. Not all brush colors are approved for "food contact" surfaces. 6. Glass Cleaning – Windows, mirrors, counter tops, and Plexiglas require the use of general-purpose cleaner. 7. Sponge Cleaning – Use General Purpose Cleaner for this. a. Obtain the General-Purpose Cleaner from the chemical cage. b. When finished, trash the sponge, rinse your bucket thoroughly and turn it over on racks to dry. Wear protective cleaning gloves (Green gloves) when sponge cleaning. c. Green scratch pads – Single uses only d. Sponges – Single uses only e. Towels – Single uses only f. Micro-fibers towels – Blue is sanitation, and Yellow is production, Red is AM 2023 © 2023 Frito-Lay - All Rights Reserved 14 Rice Cake Packaging Line 8. Bucket Handle Standards a. Green – Shovels, Brooms, and Squeegees >> Tempering b. Blue – Shovels, Brooms, Dust Pans, and Squeegee >> Popping, Flavoring, Ovens, OPM, Formost, and Casepacking c. Orange – Shovels, Brooms, Dustpan, and Squeegees >> Compact Room 9. Wet Mopping - Wet mops and rolling mop buckets are in the Chemical Cage. a. Use a solution of general-purpose cleaner and water proportioned solution. b. Follow mixing directions on the container or posting for the task you are to perform. When you are finished, rinse your mop bucket thoroughly. c. Rinse your mop head clean and hang to dry on the wall hangers in the Chemical Cage. d. Place "Caution - Wet Floor" signs on the perimeters of your area prior to mopping. e. Signs are in each department. There should also be some in the areas were washing down is frequent. Quality Information 1. Improper use or maintenance of containers and containers that lack proper GMP's and Daily sanitation, can pose serious hazards to their contents. a. Such as exposure to food allergens, microbiological contaminates, or foreign material. b. It is important to know, understand, and adhere to the facility's container, tool, and allergen policy. Food Safety in the Facility 1. Food Safety is a program that helps to ensure the safety of the foods we produce for our consumers. 2. Our consumers need to be able to trust that we know what is in our product. 3. Therefore, we manage allergen processes and procedures. 2023 © 2023 Frito-Lay - All Rights Reserved 15 Rice Cake Packaging Line Allergen Information 1. Allergens are substances that can cause severe allergic reactions to some people in the population. 2. Frito-Lay has set up strict procedures to prevent the introduction of allergens into our products unless stated on the label that they contain them. a. A product containing sensitizing proteins in any form is known as an Allergen. b. A changeover from an allergen to a non-allergen requires an extensive cleanup to remove all traces of the allergen. c. There are some consumers that have reactions to allergens that could cause illness and, in some cases, even death. d. When we produce any product that contains an allergen, the ingredient label statement must include all ingredients that are allergens to protect those individuals who are allergic to these products. e. Cross-contamination to the smallest extent could cause sensitive individual harm. 3. Some facilities produce products that contain allergens and specific cleanup and handling procedures for all our allergens. 4. Allergens at the Lynchburg plant are: a. Dairy b. Mustard: Canadian Allergen c. Soy 5. Cross-contamination to the smallest extent could cause sensitive individual's harm. 6. Keep all curtains closed during production and cleanup. 7. Do not use air guns to clean the floors. 8. Only use specified parts for allergenic ingredients. 9. Allergens are monitored by a corporate QA mandate of allergen swabbing for several of the pieces of equipment on the Line. 10. The corporate SOP for swabbing is Allergen Cleaning Validation-. It states: a. An allergen clean-up should be conducted prior to swabbing. b. The protocol for cleaning of the individual line should be conducted, verified, and recleaned, as necessary. c. The line should not be sanitized prior to swabbing. Some sanitizers may interact with the reagents in the test kit. d. The Quality Department will swab area when notified by Production, that area has been cleaned and passed inspection. e. Only production equipment that has been cleaned and qualified to "visibly clean" shall be swabbed. Note: Allergens at a facility can change at any time based on products produced. New products or changes in ingredients or product running can add or remove allergens from this list. 2023 © 2023 Frito-Lay - All Rights Reserved 16 Rice Cake Packaging Line Allergen Procedures 1. The Resource MUST inspect or authorize the line prior to putting it back together for an allergen clean. 2. The Resource MUST sign the changeover document stating that the line has been inspected and the line is at standard. 3. Once the line is approved by the Resource, the line can finish the changeover and put the line back together. Food Product Zones and AIB (American Institute of Baking) 1. The Quality department designates the production area into two product zones: Product Zone and Product Area. Each area has a specific food safety hazard associated with it. 2. Product Zone a. Production area that is in direct contact with food and to barriers top and bottom. Area where products have the most opportunity to become contaminated. 3. Product Area a. Extends 15 feet from all sides of the Product Zone. 4. The American Institute of Baking or (AIB) is the official food safety auditor of Frito-Lay. They are an organization that comes in at least once/year to the site and does a Sanitation and GMP audit in addition to a gluten-free audit. 5. Findings from the audit are scored and findings must be fixed and corrected in a certain timeframe based on AIB standards. a. The food zone encompasses the entire system through case packing. Packaging Certification 1. The Packaging Certification procedures is a protective measure to eliminate product recall due to mixed product or allergens. These procedures also verify packaging attributes to meet PepsiCo standards. 2. The check is completed at startup, changeovers, and shift change. a. The form must be filled out for each line running. b. The PSM audit must be filled out prior to completing the form. c. A separate form must be filled out for each side, east and west. 3. Code Date is document from both sides. 4. Spec and advice numbers are documented for the bags. 5. Bags are inspected for appearance. 6. Best Before and Manufacturer Code Dates are documented from the bag and box. 7. Code dates are checked for the bag and box. See Code Date Section above. 8. Place the completed sticker on the front of the bag you opened for the check. DO NOT cover any label information. 2023 © 2023 Frito-Lay - All Rights Reserved 17 Rice Cake Packaging Line Traceability 1. Corporate Requirements a. Trace Plan/Flow Diagram i. Each point where an ingredient/product is used from material receiving though batching to finished product. b. Data, Time, Lot #, and Quantity 2. Product Trace (Recall) a. Account for >99% of ingredients and packaging material used. b. Account for 99 -102% of finished product shipment to customer, within 24hr. of request for trace (plant 16 hrs./ distribution 8 hrs.). 3. What Do We Trace? a. Ingredients b. Finished product c. Reworked product d. Packaging material that comes in direct contact with the product. e. Trashed ingredients f. Trashed product Figure 10: Packaging Certification 2023 © 2023 Frito-Lay - All Rights Reserved 18