© AusAID 2006 VERSION: 1.0 10 November 2006 Copy Number: 1 © AusAID 2006 VERSION: 1.0 10 November 2006 Copy Number: 1 © COPYRIGHT (2006) AusAID, Australia. All Rights Reserved. No part of this publication may be reproduced, stored in a retrieval system, transmitted, reported, or copied in any form or by any means electronic, mechanical or otherwise without written permission of the copyright owner. Information contained in this publication is confidential and is not to be disclosed in any form to any party without the prior approval in writing of the Chief Executive Officer, AusAID, 62 Northbourne Avenue, GPO Box 887, Canberra ACT 2601, Australia. © AusAID 2006 VERSION: 1.0 10 November 2006 Copy Number: 1 DRAGON FRUIT QUALITY MANUAL Introduction This manual has been developed to support the introduction of Good Agricultural Practices to the Dragon fruit Industry of Vietnam. The manual is based on the requirements of EUREPGAP (Euro-Retailer Produce Working Group Good Agricultural Practice) at the farmer level and BRC (British Retail Consortium – Global Standard: Food) standards as access to these markets is not possible unless complete compliance with these standards is met. The manual has been developed as an outcome of an AUSAID CARD project: Developing GAP systems for Dragon fruit producers and exporters in Binh Thuan and Tien Giang provinces 037/04VIE 2005 to 2007. The manual describes how the Farmers; Packers; and Exporters of the Dragon fruit Industry will comply with the requirements of the EUREPGAP (Version 2.1 – Oct 04), BRC (Issue 4, January 05) and HACCP (Hazard Analysis and Critical Control Point). The manual also includes: Codes of Practice; Protocols; Recommended Systems; Project training material; Compliance documentation samples; The Dragon fruit farm Register; and other relevant project generated material. The Manual is a living document and will be subject to continual improvement. For the purpose of the CARD Project the approach taken has been to develop people and systems at all levels within the Dragon fruit Industry (Research, Extension, Exporter, Packer, Farmer) in the requirements of GAP, Food Safety/Security, and Health and Safety issues. The initiative commenced with a Pilot demonstration and will be systematically expanded. It is expected that, through this development, full compliance with the standards will be met and access to high value markets will be gained by increasing numbers of farmer and packers. ******************************** BRC Global Standards - Food will be applied to packer/exporter: • Accredited certification bodies evaluate companies to confirm conformity of product with the specified requirements laid down within the BRC Technical Standards • Evaluation by the certification bodies will be carried out at a specified frequency to demonstrate the continued conformity of the certified product within the required standard. BRC copyright approval was given provided that the purchase of the BRC Global Standard – Food is made for each packhouse. This Dragon fruit manual is to be used in accordance with the CARD copyright requirements. The layout and format of the BC Global Standard - Food has been used with BRC's approval for the packer section of this manual. This was done to ensure that the "Fundamental" BRC requirement (in red) is clearly identified at the beginning of each packer subsection to indicate the purpose/requirement of the sub section. Within the context of the BRC standard ‘fundamental’ requirements are those where © AusAID 2006 VERSION: 1.0 10 November 2006 Copy Number: 1 certification will not be awarded if companies cannot satisfy these requirements hence the special emphasis on these requirements. The implementation of this manual must be delivered by suitably qualified personnel. Only those certification bodies who have accreditation to ISO/IEC Guide 65 with a scope, which includes meeting the requirements of the standard (or actively seeking accreditation to ISO/IEC Guide 65), shall carry out evaluations against a BRC Standard and issue appropriate certificates. Register of manual copies released: Copy Number Copy Issued to English Vietnamese 1 AusAID 1 1 2 SOFRI 1 1 3 SOFRI 1 1 4 Pilot Project 1 1 5 HortResearch 1 1 6 HortResearch 1 1 7 HortResearch 1 1 ******************************** To gain accreditation under EUREPGAP the farmer will be assessed by an independent and Accredited Certifying Body: EUREPGAP Control Points are split into three categories, ‘Major Must’, ‘Minor Must’ and ‘Recommended”: • MAJOR MUST (47 control points) – Requires 100% compliance to those that are applicable • MINOR MUST (98 control points) – Requires 95% compliance to those that are applicable • RECOMMENDED/SHOULD (65 control points) - Farmers complete this section. Compliance is not compulsory, however auditing is. Web site: www.eurep.org ******************************** The Dragon fruit quality manual will be referred to as “the Manual”. © AusAID 2006 VERSION: 1.0 10 November 2006 Copy Number: 1 CONTENTS Page SECTION A - THE EXPORTER 3 1. Project Scope 3 2. The GAP Project Pilot Programme 3 3. Product compliance with the standards 4 SECTION B - THE PACKER 7 1. HACCP System 7 2. Quality Management System 23 2.1 Quality Management System- General Requirements 23 2.2 Packer Quality Policy Statement 23 2.3 Quality Manual 25 2.4 Organisational Structure, Responsibility and Management Authority 27 2.5 Management Commitment 28 2.6 Customer Focus 29 2.7 Management Review 30 2.8 Resource Management 31 2.9 Internal Audit 32 2.10 Purchasing 34 2.11 General Documentation Requirements 35 2.12 Corrective Action 38 2.13 Traceability 39 2.14 Management of Incidents, Product Withdrawal and Product Recall 40 2.15 Complaint Handling 41 3 Factory Environment Standards 42 3.1 External Environment Standards 42 3.2 Internal Environment Standards 44 3.3 Services 50 3.4 Equipment 51 3.5 Maintenance 52 3.6 Staff Facilities 53 3.7 Physical and Chemical Product Contamination Risk 55 3.8 Housekeeping and Hygiene 56 3.9 Waste/Waste Disposal 57 3.10 Pest Control 58 3.11 Transport 59 4 Product Control 61 4.1 Product Design/Development 61 4.2 Handling Requirements for Specific Materials 62 4.3 Metal Detection/Foreign Body Detection 63 4.4 Product Packaging 65 4.5 Product Inspection and Analysis 66 4.6 Stock Rotation 67 4.7 Product Release 68 4.8 Control of Non conforming Product 69 5 Process Control 70 5.1 Control of Operations 70 © AusAID 2006 VERSION: 1.0 10 November 2006 Copy Number: 1 5.2 Quantity Control 76 5.3 Calibration and Control of Measuring and Monitoring Devices 77 6 Personnel 80 6.1 Training – Raw Material Handling, Preparation, Processing, Packing and Storage Areas 80 6.2 Personal Hygiene – Raw Material Handling, Preparation, Processing, Packing and Storage Areas 83 6.3 Medical Screening 85 6.4 Protective Clothing – Food Handlers and Others Working in or Visiting Food – Handling Areas 86 7. Records 89 8. Grower Register 89 SECTION C - THE FARMER 93 1. Traceability 94 2. Record Keeping 96 2.1 Farmer Records 97 3. Varieties and Rootstocks 99 3.1. Choice of Rootstock 99 3.2 Seed Rootstock Quality 100 3.3 Pest and Disease Resistance 101 3.4 Seed Treatments and Dressings 102 3.5 Propagation Material 103 3.6 Genetically Modified Organisms 104 4. Site History and Management 105 4.1 Site History 105 4.2 Site Management 109 5. Soil and Substrate Management 110 5.1 Soil Mapping 110 5.2 Cultivation 111 5.3 Soil Erosion 112 5.4 Soil Fumigation 113 5.5 Substrates 114 6. Fertiliser Usage 115 6.1 Advice on Quality and Type of Fertiliser 116 6.2 Records of Application 117 6.3 Application Machinery 118 6.4 Fertiliser Storage 119 6.5 Organic Fertiliser 120 6.6 Inorganic Fertiliser 121 7. Irrigation/Fertigation 122 7.1 Predicting Irrigation Requirements 122 7.2 Irrigation/Fertigation Method 123 7.3 Quality of Irrigation Water 124 7.4 Supply of Irrigation/Fertigation Water 125 8. Crop Protection 126 8.1 Basic Elements of Crop Protection 126 8.2 Choice of Chemicals 127 8.3 Records of Application 128 8.4 Pre-Harvest Intervals 130 © AusAID 2006 VERSION: 1.0 10 November 2006 Copy Number: 1 8.5 Application Equipment 131 8.6 Disposal of Surplus Spray Mix 132 8.7 Crop Protection Product Residue Analysis 133 8.8 Crop Protection Product Storage and Handling 134 8.9 Empty Crop Protection Product Containers 136 8.10 Obsolete Crop Protection Products 137 9. Harvesting 138 9.1 Hygiene 138 9.2 Packaging/Harvesting Containers on Farm 139 9.3 Produce packed at point of harvest 140 10. Postharvest Treatments 141 10.1 Hygiene 141 10.2 Postharvest washing 143 10.3 Postharvest Treatments 144 10.4 On-farm Facility for Produce Handling and/or Storage 146 11. Waste and Pollution Management 148 11.1 Identification of Waste and Pollutants 148 11.2 Waste and Pollution Action Plan 149 12. Worker Health and Safety 150 12.1 Risk assessments 150 12.2 Training 151 12.3 Facilities, Equipment and Accident Procedures 152 12.4 Crop Protection Product Handling 153 12.5 Protective Clothing/Equipment 156 12.6 Welfare 157 12.7 Visitors 158 13. Environmental Issues 159 13.1 Impact of Farming on the Environment 159 13.2 Wildlife and Conservation Policy 160 13.3 Unproductive Sites 161 14. Complaint Forms 162 15. Internal Audit 165 REFERENCE PAGES 169 1. Generic Reference Pages 169 1.1 Dragon Fruit Farm Register 169 1.2 Dragon fruit production cycle 170 1.3 References related to Dragon fruit GAP production and packing 171 1.4 Farmer/Packer Supply Contract 176 1.5 Schedule of costs 182 2. Exporter Reference Pages 184 3. Packer Reference Pages 185 3.1 Packhouse basket/crate docket 185 3.2 Process: basket/crate check 186 3.3 Baskets/crates unloaded onto grading conveyor 187 3.4 Packer Purchasing Policy and Supplier Approval 188 3.5 Packer Quality Policy Statement 189 3.6 Quality Management System Policy Statement 190 3.7 Scope of Quality Management System 191 3.8 Packer Harvesting Container Policy 192 © AusAID 2006 VERSION: 1.0 10 November 2006 Copy Number: 1 3.9 Packer Knife & Scissor Policy 193 3.10 New Employee Procedure 194 3.11 Personnel, Visitors and Contractors 195 3.12 Maintenance Policy 197 3.13 Rodent Bait Station Map 198 3.14 Watch Policy 199 3.15 Quality sampling system protocol for Dragon fruit 200 3.16 The Packhouse Management Team Terms of Reference 208 3.17 Position Descriptions List/File 209 3.18 Position Description Template 210 3.19.1 Position Description #1 – Packhouse Manager 211 3.18.2 Position Description #2 – HACCP Manager 215 3.18.3 Position Description #3 – Internal Auditor 218 3.18.4 Position Description #4 – Quality Assurance Manager 221 3.18.5 Position Description #5 – Quality Controller 224 3.18.6 Position Description #6 – Marketing Manager 227 3.18.7 Position Description #7 – Administration Officer 230 3.18.8 Position Description #8 – Administration Assistant 233 3.18.9 Position Description #9 – Fruit Receipts 236 3.18.10 Position Description #10 – Fruit Marshaller 239 3.18.11 Position Description #11 – Fruit Loader 241 3.18.12 Position Description #12 - Grader 244 3.18.13 Position Description #13 – Machine Operator 247 3.18.14 Position Description #14 – Check Grader 249 3.18.15 Position Description #15 – Crate Loader 252 3.18.16 Position Description #16 - Packer 254 3.18.17 Position Description #17 - Stacker 257 3.18.18 Position Description #18 – Transport Supervisor 259 3.18.19 Position Description #19 - Transporter 261 3.18.20 Position Description #20 – Transport Loader 263 3.18.21 Position Description #21 - Cleaner 266 3.18.22 Position Description #22 – Packaging Office 268 3.18.23 Position Description #23 – Packaging Assistant 270 4. Farmer Reference Pages 273 DEFINITIONS 277 ACKNOWLEDGEMENTS We would like to acknowledge the British Retailers Consortium (BRC) for granting us copyright permission to utilise the structure and parts of the standard titled “BRC Global Standard – Food”. We would also like to acknowledge the assistance of Inglis Fruit Packers in the development of this manual. © AusAID 2006 VERSION: 1.0 10 November 2006 Copy Number: 1 1 © AusAID 2006 VERSION: 1.0 8 November 2006 Copy Number: 1 2 © COPYRIGHT (2006) AusAID, Australia. All Rights Reserved. No part of this publication may be reproduced, stored in a retrieval system, transmitted, reported, or copied in any form or by any means electronic, mechanical or otherwise without written permission of the copyright owner. Information contained in this publication is confidential and is not to be disclosed in any form to any party without the prior approval in writing of the Chief Executive Officer, AusAID, 62 Northbourne Avenue, GPO Box 887, Canberra ACT 2601, Australia. [...]... safety, legality and quality are clearly defined and documented 2.4.1 The Packhouse Owner is committed to the production and packing of Dragon fruit that is fully compliant with BRC Technical Standard The scope of this compliance encompasses all the processes involved in: 1 2 3 Receipt of picked Dragon fruit and Inward goods Packing of Dragon fruit Dispatching of packed Dragon fruit Particular attention... other documents describe all operations and systems of the Dragon fruit packhouse Supporting documents include: • Quality system management • Dragon fruit grade standards • Equipment manuals • Protocols for specific functions and processes • Position descriptions for staff • Linkages to external and appropriate web sites 2.3.3 The Quality Manual is made available to all staff Training of packhouse... employees © AusAID 2006 VERSION: 1.0 Copy Number: 1 8 November 2006 25 2.3 Quality Manual The company shall have a Quality Manual which states the company’s commitment to quality and has a scope which addresses the requirements of this standard 2.3.1 The Quality Policy of the Packer is to harvest and pack Dragon fruit at a level of Quality, Traceability, Hygiene, Safety and Welfare that meets or exceeds the... , contamination, tainting, or marking of the fruit skin Harvested fruit storage Input Harvested fruit contaminated with bird dropping in storage Transfer of disease 2 D 12 Grading & quality control processes CP8 Harvested fruit storage Input Harvested fruit contaminated with rodents in storage Transfer of disease 3 C 13 Rodent control CP9 Input Harvested fruit contaminated with glass / metal in storage... development and implementation of this HACCP plan consists of: • The CARD Dragon fruit GAP project team: for the establishment of the quality system in the packhouse • Mr Hiep: Owner of the Dragon fruit packing facility • Mr Dung: HACCP Manager; Owner’s Assistant; Quality Manager; Marketing Manager • Ms Nam: Administration Officer • Mr Dung: Quality Manager of the packhouse • Mr Minh: Packhouse Manager • Mr... sheets CP 8 Harvested fruit contaminated with bird droppings during bin storage Nil tolerance Presence of bird droppings on fruit Visual Continual Graders, Packers, Quality controller CP 9 Harvested fruit is rodent damaged / infested Nil tolerance Presence of rodent chewings or droppings in fruit rodent bait traps Visual Continual for fruit, weekly for bait stations Graders, Packers, Quality controllers,... Harvested fruit is contaminated with glass / metal during bin storage No fruit will be packed that is suspected of glass or metal contamination Presence of glass fragments, staples Visual Continual Fruit Marshaller, Graders CP 11 Fruit contaminated with glass / metal during the container to fruit placement in carton operation All lighting in fruit placement area complies with BRC standard No fruit will... CONTROLS CRITICAL CONTROL POINT Fruit receipts Input Fruit contaminated with foreign matter Poisoning Market access 2 D 12 Segregation & traceability procedures CP12 Fruit receipts Input Container to fruit placement on grader operator with a transferable disease Hepatitis, Salmonella 3 D 17 Health & safety sign off, Segregation & traceability CP13 Fruit Grading Input Fruit contaminated with glass /... part of the packer section of the manual 2 The GAP Project Pilot Programme A pilot scheme has been established by the ‘Project’ which includes Dragon fruit farmers and a packer/exporter The farmers in the pilot range from a group of small holders of between 0.5 and 2 hectares to one farm of almost 70 hectares All farms supplying Dragon fruit for the pilot have installed a quality system that meets the... ‘Developing GAP systems for Dragon fruit producers and exporters in Binh Thuan and Tien Giang provinces 037/04VIE 2005 to 2007’ to address the quality systems employed between the exporter and the customer The Exporter section of the manual will be subsequently expanded as and when material becomes available The packer of the project pilot also exports his packed Dragon fruit Those exporter issues . Number: 1 DRAGON FRUIT QUALITY MANUAL Introduction This manual has been developed to support the introduction of Good Agricultural Practices to the Dragon fruit Industry of Vietnam. The manual. PAGES 169 1. Generic Reference Pages 169 1.1 Dragon Fruit Farm Register 169 1.2 Dragon fruit production cycle 170 1.3 References related to Dragon fruit GAP production and packing 171 1.4 Farmer/Packer. PACKER 7 1. HACCP System 7 2. Quality Management System 23 2.1 Quality Management System- General Requirements 23 2.2 Packer Quality Policy Statement 23 2.3 Quality Manual 25 2.4 Organisational