Internal Plant Quality & Safety Audit Checklist

Food Processing & Packaging Units

Cleaning & Sanitation
Cleaning & sanitation SOPs available and followed
Responsible personnel identified for cleaning duties
Chemicals approved, fit for food use, and stored safely
Storage of cleaning tools in hygienic condition
MSDS available for all cleaning chemicals
Production areas visibly free of dirt/debris
Floors, ceilings, and walls cleaned properly
Segregation of wet/dry waste done as per SOP
Cleaning records updated according to schedule
Plumbing, sinks, and drainage areas cleaned and functional
Critical Controls (OPRPs & Shelf Life)
Roasting temp monitored/displayed, core temperature verified
Raw materials screened with bar magnets
Metal detector verified with test pieces
Proper product labeling (MRP & shelf life) present
Sealing temperature maintained as per standard
Equipment & Utensils
No wet trays/utensils stored inside production
Trays/utensils not stored directly on floor or against wall
All utensils in usable, undamaged, and sanitary condition
Tools & items kept in designated areas (5S system followed)
Machines cleaned, maintained, and functional
Trolleys, crates & SS tables cleaned and maintained
Air curtains present at all entry points and functional
Only food grade lubricants/chemicals used in facility
Factory Hygiene & Packaging
Policies for foreign material prevention (glass, wood, plastic, rubber, etc.) followed
Packaging materials are food grade with specifications available
Packaging and handling protect product from damage/contamination
All packaging items stored safely and clearly labeled
Metal detector checks performed, frequency documented, results valid
Is scalping or sieving applied where required?
Weighing devices checked/calibrated periodically
Additional in-line processes verified during packing
Waste disposal bins available and used properly
Finished Goods Evaluation
Final product weight verified
Leakage test conducted
Sensory evaluation performed
Taste & aroma assessed
Texture & mouthfeel acceptable
Infrastructure & Maintenance
Floor, wall, and ceiling surfaces are intact, washable, and easy to clean
Any cracks, peeling paint, or damages observed on structures?
All electrical wiring secured and not left hanging
Trays, molds & utensils cleaned; wash area sanitary and drains covered
Glass panels, doors, and surrounding areas intact and cleaned
Area beneath machines and tables free from dust and debris
Exhausts are fitted with proper mesh/filters
Sufficient lighting and ventilation provided in workspaces
Emergency sirens/alarms available and functional
No pest activity (flies, cobwebs, ants, rodents) seen
Fire extinguishers available, in-service, and within validity
Tools, materials, and equipment not stored on floor
Tubelights/tubes fitted with protective covers and cleaned
Fly traps/catchers working, glue pads replaced on time
Indoor waste bins covered, functional, and clean
Disposal/dumping area maintained odor-free and hygienic
Calibration procedures implemented and documented
Opening Review
Before starting the audit, confirm whether any scope modifications exist (e.g., staff shifts, product range, new suppliers/equipment, or packaging updates). If applicable, record details.
Personnel Hygiene & Conduct
Employees maintain proper grooming standards (clean uniforms, trimmed nails/hair, no torn clothing)
Confirm absence of jewelry, watches, perfumes or personal ornaments inside production areas
Are hairnets, masks, and gloves worn correctly at all times?
Handwashing facilities have running water available
Handwash liquid/soap & sanitizer provided at designated stations
Do staff follow defined handwashing frequency and technique?
Hand sanitization performed after each wash
Availability of paper towels or air dryers at washing stations
Uniforms and PPE are free from contamination or damage
No personal items (bags, lunchboxes, bottles) in processing zone
Food handlers use gloves when touching unpacked food
Employees show no illness, wounds, or conditions unfit for food handling
First aid kit accessible, updated, and without expired stock
Safety posters / Do’s & Don’ts displayed in visible areas
Visitor movement records maintained properly
Pest Management
Program in place to prevent entry of pests/birds
Electronic insect devices properly positioned & effective
Pest control chemicals approved & stored securely
Timely removal of garbage to prevent pest harborage
Pest control as per schedule and records updated
Layout of pest control devices available
MSDS available for all pest control chemicals
Processing & Production
Production SOPs available at shop floor
All ingredients sourced from approved vendors
Temperature of cocoa butter checked during weighing
Random check of dough temperature post-grinding
At least two product samples verified for weight/taste/appearance
Procurement
Vendor list for all raw & packaging materials available
Specifications documented for RM & PM
COA maintained for all RM received
Rejection/return records maintained
Records & Compliance
Visitor logs updated
FSSAI license valid (if expired, note date)
Medical records of staff maintained
Inspection records for products available
Monthly cleaning records updated
Process logs (roasting, measuring, etc.) maintained
Maintenance logs for equipment available
Personal hygiene verification record maintained
Traceability records for RM & FG updated
Pest control service records filed
Certificates of food-contact materials available
External lab reports for FG & water available
Calibration status shown on equipment (scales, chillers, etc.)
Monthly training records filed
Plant layout plan available
Signature
Storage & Warehousing
GRN recorded for all raw & pre-processed materials
Food vs non-food items segregated; allergen control in place
All materials placed on pallets (not on floor)
COA available for RM & PM
Pallet spacing maintained (1 ft clearance from wall)
FIFO & FEFO stock rotation applied
Rejected/expired items labeled “Do Not Use” & segregated
No broken tools, glass, or waste in store area
Training & Awareness
Staff trained on emergency preparedness & crisis management
Staff able to operate fire extinguishers
Knowledge of SOPs, recipes, shelf life maintained
Awareness on food safety, hygiene & grooming
Staff aware of pest control program
Knowledge of cleaning & sanitation SOPs verified

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