Safety and Security
On January 11, 2012, the Nara Factory of Kyoto Grain Systems Co., Ltd. acquired the international food safety system certification standard "FSSC 22000". And, we have established our own food safety policy and hygiene management standards. We strive to provide more secure and safe products our employees work together daily.
About FSSC22000
FSSC 22000 is the food safety standard adopted by the Global Food Safety Initiative (GFSI), an association of international food manufacturers and food distribution companies. It complements the deficiency items of the food safety management system standard "ISO 22000".
For example, ISO 22000 clarifies items of "prerequisite program" which is the basis of food safety. However, with respect to the specific content, it is left to each company.
Therefore, there are differences in how to approach the rules by the company. Due to that rule, there is a problem that the degree of hygiene control varies. To compensate for these problems, FSSC 22000 is available.
Main features of FSSC 22000
- Interactive communication
Food safety is defined as "joint responsibility of all stakeholders involved in the food chain". People involved in the food industry are required to share reliable information.
- System management
Food safety measures will be taken not only at the food production site but also throughout the organization including management. In addition to creating rules and management regulations, it is important to create a mechanism that "how employees operate it".
- HACCP principles
We do not manage the same hazards for all processes in order to manage necessary in a necessary place. We will manage hazards separately, especially on priority and daily.
When important management is required, we will establish management standards according to HACCP 12 procedure.
- Prerequisite programs
It is based on ISO / TS 22002-1 for the rule to be "premise" of food hygiene.
- Food safety measures
Matters concerning food safety such as food defense, raw materials and allergen management are stipulated, and we perform more detailed operation.
Food safety is defined as "joint responsibility of all stakeholders involved in the food chain". People involved in the food industry are required to share reliable information.
Food safety measures will be taken not only at the food production site but also throughout the organization including management. In addition to creating rules and management regulations, it is important to create a mechanism that "how employees operate it".
We do not manage the same hazards for all processes in order to manage necessary in a necessary place. We will manage hazards separately, especially on priority and daily.
When important management is required, we will establish management standards according to HACCP 12 procedure.
It is based on ISO / TS 22002-1 for the rule to be "premise" of food hygiene.
Matters concerning food safety such as food defense, raw materials and allergen management are stipulated, and we perform more detailed operation.
Activities of the project team
We select appropriate people from each department, we are forming a special team and are working on a continuous basis.
Each team conducts meetings once a month, checks the status of initiatives, and strives for improvement.
| Food Safety Team | We are working on matters relating mainly to hygiene management and hazard analysis. Based on our own food safety manual, we check 5S patrols, adaptation status of hygiene standards in the factory, review the rules, and strive to maintain food safety. |
|---|---|
| Health and Safety Committee | We mainly review and revise risk assessment, and we revise and improve work environment. We are aiming for "no occupational accidents" through efforts related to factory tours, employee training, and employee health promotion. |
| Energy Conservation Team | We are grasping and converting the resources used at the factory and are making efforts to reduce the usage (energy conservation). In addition, we are also working to reuse and recycle resources. |
About hygiene management
We have established strict hygiene control standards consisting of 12 original items and follow this standard. We thoroughly manage hygiene in all programs from purchasing to production, shipping and utilities such as raw materials and products, waste and buildings, workplace layout etc.
Prevention of contamination
1
Entry control
At the entrance to the factory, we have a changing room. In that place, we change clothes to work clothes, hand wash and disinfect. Moreover, we keep a record of "name, entry and exit time, carry-in items, physical condition report etc." At entering the factory, adhesive rollers and installed air shower prevent dust and fine foreign substances such as hair from entering. The above behaviors are targeted not only to our employees but also to all visitors including customers.
2
Management of carry-on items
We create a list of items brought into the factory (forbidden items and possible items list). We apply for goods and quantity at entry and report on exit. At our factory, we adopt stationery that is difficult to contaminate products (Example: Knock type marker with no cap). We describe the storage location of the item to be used in the factory and we manage the number.
3
Efforts on hazard analysis
We conduct hazard analysis for each line, set "acceptable level" for each hazard, and operate. The above contents are made visible by documentation. We also check and improve the operation status at the verification activity meeting by the Food Safety Team.
4
Introduction of surveillance camera and alarm system
We installed a chain gate at the entrance to the factory premises, a surveillance camera inside the factory, and introduced an alarm system. We also identify the color of the helmet for each department and visitor so that surrounding workers can easily act.
1
Entry control
At the entrance to the factory, we have a changing room. In that place, we change clothes to work clothes, hand wash and disinfect. Moreover, we keep a record of "name, entry and exit time, carry-in items, physical condition report etc." At entering the factory, adhesive rollers and installed air shower prevent dust and fine foreign substances such as hair from entering. The above behaviors are targeted not only to our employees but also to all visitors including customers.
2
Management of carry-on items
We create a list of items brought into the factory (forbidden items and possible items list). We apply for goods and quantity at entry and report on exit. At our factory, we adopt stationery that is difficult to contaminate products (Example: Knock type marker with no cap). We describe the storage location of the item to be used in the factory and we manage the number.
3
Efforts on hazard analysis
We conduct hazard analysis for each line, set "acceptable level" for each hazard, and operate. The above contents are made visible by documentation. We also check and improve the operation status at the verification activity meeting by the Food Safety Team.
4
Introduction of surveillance camera and alarm system
We installed a chain gate at the entrance to the factory premises, a surveillance camera inside the factory, and introduced an alarm system. We also identify the color of the helmet for each department and visitor so that surrounding workers can easily act.
Control of pests / Allergen countermeasures
1
Measures against insects and rats
We contract with a specialized insecticide dealer, under the guidance of them, regular monitoring, patrols, study sessions etc. are carried out.
（Example: installation of various traps, placement of seat shutters everywhere, blocking of approach path by coking, periodical drug spraying etc.)
2
Allergen management
We have established rules regarding the management of allergens in the factory and we are operating them. For example, on the dedicated soybean line, we have a dedicated entrance and change room. Also, after allergen material is produced, we are checking for allergen residue.
1
Measures against insects and rats
We contract with a specialized insecticide dealer, under the guidance of them, regular monitoring, patrols, study sessions etc. are carried out.
（Example: installation of various traps, placement of seat shutters everywhere, blocking of approach path by coking, periodical drug spraying etc.)
2
Allergen management
We have established rules regarding the management of allergens in the factory and we are operating them. For example, on the dedicated soybean line, we have a dedicated entrance and change room. Also, after allergen material is produced, we are checking for allergen residue.
Traceability system
1
Confirmation when raw materials are accepted
In accordance with our "raw material receiving instruction / questionnaire", the person in charge of charge will check the material to be received. In addition, we collect raw material samples at the time of receipt and perform inspection at Quality Control Division.
2
Retention of records
We manage records so that we can take internal records of all the processes from receipt to manufacture and shipment. The record of each process is double checked by two or more and multiple departments.
3
Information on raw materials, packaging materials, etc.
We are striving to acquire raw material information such as origin, allergen, etc. and safety data sheet (SDS) about materials, packaging materials, chemicals etc. We conduct residual pesticide tests and radioactivity tests for each crop and are striving to supply safe and safe raw materials.
1
Confirmation when raw materials are accepted
In accordance with our "raw material receiving instruction / questionnaire", the person in charge of charge will check the material to be received. In addition, we collect raw material samples at the time of receipt and perform inspection at Quality Control Division.
2
Retention of records
We manage records so that we can take internal records of all the processes from receipt to manufacture and shipment. The record of each process is double checked by two or more and multiple departments.
3
Information on raw materials, packaging materials, etc.
We are striving to acquire raw material information such as origin, allergen, etc. and safety data sheet (SDS) about materials, packaging materials, chemicals etc. We conduct residual pesticide tests and radioactivity tests for each crop and are striving to supply safe and safe raw materials.
Quality management
Product inspection
Based on the standards of each product, inspection is carried out at the manufacturing site and Quality Control Division. We will ship after passing the product inspection.
Analytical instruments / inspection item list
Instruments
Analysis and inspection items
1.Colorimeter
Color tone(L/a/b) [surface/milling/extract]
2.Infrared aquameter
Amount of moisture
3.Near-infrared spectrometer
Rice and wheat protein / water content etc.
4.Digital densitometer
Brix of the extract
5.Water activity measuring instrument
Water activity
6.Magnetostrictive sieve shaker
Particle size distribution of pulverized product
7.Wet type particle size distribution measuring instrument
Particle size distribution of powder
8.A set of microorganism analysis equipment
General bacteria
Thermoduric bacteria
Staphylococcus aureus
E. coli
Fungous
Lactic acid bacteria
Product inspection
Based on the standards of each product, inspection is carried out at the manufacturing site and Quality Control Division. We will ship after passing the product inspection.
Analytical instruments / inspection item list
| Instruments | Analysis and inspection items |
|---|---|
| 1.Colorimeter | Color tone(L/a/b) [surface/milling/extract] |
| 2.Infrared aquameter | Amount of moisture |
| 3.Near-infrared spectrometer | Rice and wheat protein / water content etc. |
| 4.Digital densitometer | Brix of the extract |
| 5.Water activity measuring instrument | Water activity |
| 6.Magnetostrictive sieve shaker | Particle size distribution of pulverized product |
| 7.Wet type particle size distribution measuring instrument | Particle size distribution of powder |
| 8.A set of microorganism analysis equipment | General bacteria Thermoduric bacteria Staphylococcus aureus E. coli Fungous Lactic acid bacteria |