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AIB Rating Information

AIB Rating Information

What is required in the AIB testing?

The list below gives a brief view of some of the items that each facility is graded on. There are five categories to the inspection and a total of 1000 available points to be received.

Adequacy of the Food Safety Program: (total points available 200)

  • A current organizational chart is maintained. That responsibility and authority for ensuring food safety and security, and facility' compliance with federal, state, governmental, and/or other appropriate regulatory laws or guidelines are clearly assigned.
  • A Quality Manual has been developed. This manual includes work instructions and/or job descriptions outlining specific responsibilities of each department. A quality policy, and written policies for all required programs.
  • The plant must have a formal product safety committee that is comprised of at least the Plant Manager, Quality Manager, Quality Supervisor and the Sanitation Supervisor. The committee must meet on a regular basis and all meetings must be documented.
  • The plant must have a self-inspection program with monthly documented inspections of the complete facility performed by members of the product safety committee.
  • A Master Cleaning Schedule (MCS) for periodic cleaning assignments and daily housekeeping schedule must be developed as a formalized, written plan and implemented in the facility. The schedule should include the outside grounds, buildings, drains, and equipment.
  • The facility should maintain the proper and timely acquisition of appropriate tools, material, equipment, monitoring devices, chemicals, and pest control material.
  • Detailed, written cleaning procedures must be developed and on file for all cleaning tasks in the facility. These procedures should include the chemicals, concentrations, tools, and disassembly instructions for equipment at the level needed to facilitate the appropriate sanitation maintenance of the processing and packaging equipment, building areas, and outside grounds.
  • Incoming goods and ingredients received into the facility must be inspected according to established written procedures. A written procedure for segregation of product that might be a food safety issue must be available with the appropriate documentation proving segregation.
  • Bulk deliveries of both dry and liquid material should include visual inspection both before and after unloading and the finding documented
  • Appropriate specifications must be on file for the finished products. The specifications must be detailed to ensure compliance with relevant food safety and legislative requirements. The specifications must be periodically reviewed by relevant parties.
  • Certifications of analysis should be available for the raw materials and packaging materials.
  • The company must have a written employee and Good Manufacturing Practices (GMP’s) policies. Specific written procedures should be on file for food safety training to all personnel, including temporary personnel and contractors. Refresher training documentation should be maintained for all employees.
  • A Hazard Analysis Critical Control Point (HACCP) program must be developed and implemented for all processes and process lines. Including a description of the products manufactures and hazards inherent to them, determined through risk assessment. Identification of critical control points (CCP) and critical limits. Procedures to control the CCPs. Determination of the monitoring frequency for the CCP’s and designation of the person(s) responsible for testing. Established and documented deviation procedures. Written verification program, with proper documentation. Documentation procedures, records of conformance, and corrective actions.
  • A written program for evaluation of customer complaints must be established. Actions appropriate to the seriousness and frequency of the problems identified must be carried out promptly and effectively.
  • A written recall program must be in place and complete product traceability must be accomplished. The recall program must be tested on a scheduled basis and documented.
  • Written procedures must be in place for handling non conformance product, including work in progress, finished product, and returned goods. Corrective actions should equal the seriousness of the risk and records must be kept of the corrective actions and the disposition of the product. Disposition records should account for the total quantity of the nonconforming material produced.
  • The plant should have a written policy on how to handle regulatory and third party inspections. The procedures should include the person(s) delegated to a company, all inspectors and company policies regarding photographs, records, and samples.
  • A Supplier Assessment Program must be in place for product purchased by the company.
  • A written policy for glass and brittle plastics must be in place and a procedure to handle glass breakage in the facility. A complete list of glass items in the facility should accompany this policy.
  • A program for control of bacteria, yeast and mold is required. Records of Laboratory analysis and/or environmental sampling must be maintained and on file.

Pest Control: (total points available 200)

  • A formalized pest control program must be in place at the facility outlining the requirements of the program to reduce the potential for product contamination from pest activity or use of material and/or procedures designed to control pest activity.
  • The facility can be monitored by and outside pest control company or by an in house pest control person. Copies of the current liability insurance and the current applicator’s license must be maintained on file.
  • A service report must be on file from each inspection either by an outside pest control service or by the in house pest control person. These records should include the treatments and tasks carried out, documentation of the checks and findings for the pest monitoring devices, descriptions of the current levels of pest activity and recommendations for actions to correct the conditions allowing a potential for pest activity.
  • Documentation of all pesticides applied on the premises, including rodenticides, included materials applied, target organism, amount applied, specific area where pesticide was applied, method of application, rate of application or dosage, date and time treated, and applicators signature.
  • Material Safety Data Sheets (MSDS) and sample labels must be maintained on file for all pesticides applied on the premises.
  • Traps for monitoring rodent activity inside the building must be properly placed and inspected on a regular basis. All inspection must be documented. Bait stations for rodent control outside the facility must be placed at appropriate intervals. These stations must be tamper resistant, properly positioned, anchored in place, locked, and properly labeled in compliance with regulatory requirements. The service and the results of the checks must be documented on a date tag affixed inside the device.
  • A schematic depicting the locations of the interior and exterior pest control devices must be maintained on file and updated appropriately.
  • Electronic flying insect light traps (ILT’s) and Pheromone lures and traps can be used in the facility to monitor insect activity. These traps should be at least 3 meters from exposed product. The traps should be scheduled for regular cleaning/monitoring with the appropriate documentation for the findings during those checks.

Operation Methods and Personnel Practices: (total points available 200)

  • Eighteen inch perimeters must be maintained in all storage areas to provide cleaning and inspection access. Adequate space should be maintained for cleaning between rows of stored products.
  • Materials in storage should be adequately segregated to prevent contamination. Segregation areas should include areas for allergen containing ingredients packaging materials, research and development items, cleaning and maintenance chemicals, non conformance stock, and non-product related materials, such as parts and equipment.
  • Metal detection equipment must be provided. Metal detectors checked regularly throughout the shift and documented using relevant test pieces for ferrous, nonferrous and stainless steel.
  • Procedures for corrective actions to respond to any failure of the metal detectors must be on file. Including training, isolation, quarantining and re-inspection of all food produced since the last acceptable test of the metal detector.
  • All outside receiving lines must be capped, locked and identified.
  • Adequate hand washing stations must be available and “Wash Hands” signs in place.
  • All containers in the work areas must have appropriate labels for identification.
  • Documentation of the inspection of all shipping vehicles prior to loading must be maintained and kept on file.
  • Employees must be following requirements set in the companies GMP’s.
  • All overhead and personnel service doors should be closed when not in use.
  • All personal property must be shored in appropriate locations defined by the company policy.

Maintenance for Food Safety: (total points available 200)

  • Effective measures must be taken to maintain site security. Site securities at a minimum should include locked doors, limited access to sensitive areas, perimeter lighting, truck seals, employee screening, awareness, training programs, etc.
  • The exterior grounds should be maintained to prevent pest harborage. Waste collection containers should be closed and spillage kept to a minimum.
  • The building should be free of roof leakage, holes or cracks in the walls or roof, and all doors must seal properly to prevent rodents from entering the building.
  • All fixtures, ducts, and pipes must be properly installed and maintained to prevent contamination from leaks, condensation, or insulating materials.
  • A Preventative Maintenance Program should be in place and documented.

Cleaning Practices: (total points available 200)

  • An on going housekeeping program should be in-place throughout the hours of operation so that operational debris is kept to a minimum.
  • Adequate cleaning equipment and tools must be available and stored away from the production areas.
  • The equipment must be cleaned according to the MCS to prevent development of microorganisms, insects, or foreign material.
  • The maintenance cleaning practices must verify that all maintenance debris, tools, and other items generated during maintenance activities are removed from the work area.