1.1 Managing the risks of plastic contamination

An in-depth look at how to tackle this major contributor to complaints – including risk assessment, controlling and monitoring of plastics, selecting the right types of plastics for different applications as well as best practice for bag opening and knife use.

1.2 Metal prevention and metal detection (including x-ray)

Takes a thorough look at common factory floor metal contamination risks, the management of engineering handovers, use of magnets, how to choose the most appropriate detection equipment, demystifying the principles of the operating and testing of metal and x-ray detectors.

1.3 Practical factory controls

Explores the challenges of making line start-up checks effective, what best practice looks like – and the actions needed to get the maximum protection from your system. We also cover how to control risks like glass, clear hard plastic and hair complaints.

1.4 Handling of raw materials for foreign body prevention

A review of best practice in all aspects of raw material handling, from back door through to production. This includes debox/debag/sieving/filtration as well as tips and ideas to minimise foreign matter risks.

2.1 Basic facts about listeria

This is a basic overview of listeria as a microorganism, the nature of the disease and how this pathogen is ideally suited to food factory environments. We consider it an essential module for those new to food manufacturing or unfamiliar with microbiology.

2.2 Listeria swabbing programmes and investigations

This is a vital module for any factory with listeria concerns. Many factories struggle to track and trace the source of issues, so we cover the principles of swabbing, setting up effective swabbing programmes, follow up process, investigative swabbing methods – with numerous case studies to illustrate.

2.3 Equipment design and building fabric aspects of listeria management

We cover common equipment and fabric design faults that can give listeria a foothold, as well as best practice in equipment installation and top tips on how to achieve good fabric design.

2.4 Cleaning practices, organisation and standards for managing Listeria

This module includes an in-depth look at poor and good cleaning practices, the standard of cleaning that should be aspired to – and how to critically assess those standards thoroughly, with an attitude of zero tolerance to listeria.

3.1 Risk assessment best practice

A step-by-step guide through risk assessment principles, considering both raw materials and the practical factory environment. Delegates will be equipped to conduct a competent and practical allergen risk assessment.

3.2 Practical allergen segregation in factories

A very practical look at the ways in which we can achieve effective segregation of allergens in storage areas during sieving/filtration, decanting and weighing-up, preparation, transfer to production and finished product assembly.

3.3 Allergen testing

We demystify the different types of allergen testing, imparting the skills to set up an effective validation and verification testing programme whilst avoiding common pitfalls.

3.4 Best practice for nuts/sesame handling, gluten free, and dairy free production

This module covers the specific requirements and best practice for segregation, safe handling and manufacturing of each of these categories of allergens.

4.1 Rodents, flying insects & birds

We cover basic pest biology and behaviour to establish a greater understanding of how to control and eliminate them. We also look at the responsible use of rodenticides (internal and external) with rodent infestation factory case studies and practical controls for flying insects and birds.

4.2 SPI & cockroaches

These pests can be extremely difficult to eliminate from food factories, so we discuss the approach required to achieve this alongside numerous photographs and case studies. We also cover the basic biology of these pests in order to understand how they can be prevented from becoming established in the first place.

4.3 Best practice for managing your contractor

Good management of your pest control contractor is vital in running an effective pest prevention system, so this module explores how to select a contractor and get the best out of them.

5. Practical & effective internal auditing – food safety, hygiene and brand integrity (1 module)

This 2-hour course offers a very practical introduction to internal auditing, using the extensive audit experiences of both Liam and Ian. We cover:

•  What an internal audit is and why we do them

• Definitions, outcomes and requirements

• Retailer expectations for self-governance

• The key principles involved in: 

  • role of senior management

  • auditor selection and training

  • auditor competence and monitoring

  • auditors from different disciplines

  • the importance of independence

• How to conduct the audit:

  • audit planning and preparation

  • practical examples discussed (on various subjects)

  • questioning styles

  • collecting evidence (factory and documentation)

  • defining and grading non-conformances

• Tips and techniques for the auditor

• Audit reports and the quality required

• How to follow-up to non-conformances

6. Risk assessment and decision making (1 day module)

Designed for retail technologists, this one day course is built on Liam and Ian’s many years of experience in high-pressure situations. They use real life examples from factories facing urgent issues requiring difficult decisions – including whether to stop production, make a product withdrawal or public recall or to simply work with the manufacturer to form an urgent improvement plan.

The solutions we discuss are not based on taking the easier blanket decision to recall products, but on what is the correct and balanced course of action for all parties.

As part of this training, delegates work in small groups to analyse problem situations and decide on a recommended action plan – Ian and Liam then offer constructive feedback to ensure the integrity of those recommendations.