Sunwest Food Processors Ltd. (Abbotsford, BC)
A Progressive Food Processing Plant
Quality Control Technician – Ready to Eat -Meat Cooking Plant
Sunwest Food Processors Ltd. a Progressive Food Processing Plant is seeking a motivated and experienced QC Technician (FULL TIME POSITION) to join our production team. If you have the following education, training or experience, we want to hear from you:
Responsible for the effective maintenance of the quality parameters of all products of the company in the different stages of processing – from receiving of raw materials, to product formulation, cooking and through to packaging. To support this objective, the position is tasked to be familiar with and monitor the strict implementation of the Hazard Analysis Critical Control Point (HACCP) program, Good Manufacturing Practices (GMP) and Standard Operating Procedures (SOP). Communication is key to success in this position. The QC technician works as a team with Production managers and is to report all observed non conformances to Production managers, Plant manager and QA manager immediately.
Job Functions /Responsibilities
- Monitoring and Control of Production Sanitary Conditions:
Inspect all direct food contact processing equipment and auxiliary tools and equipment (injector, tumbler, totes, lugs, oven, conveyor belts, etc.) are cleaned and/or sanitized prior to a production day (pre-operational check) start and anytime thereafter when there is a product change-over.
Ensure that the processing environment including but not limited to production floors, walls, ceiling and lighting facilities are cleaned and maintained in good condition to prevent harborage of bacteria and other contaminants.
Monitor and ensure that footbaths, boot dips, and hand washing soaps are available, and production personnel understand and follow these basic requirements for food safety. Conduct footbath and boot dips analysis at the start of the every shift and towards the end of the production day.
Check proper housekeeping and GMP practices followed in different process areas during operation.
Conduct microbiological swabbing and air plating at required frequency in key processing areas to verify sanitary conditions.
Analyze sanitation solution from different dispensing stations and recommend corrective action when necessary.
Monitor presence of condensate especially in areas over finished products. Help prevent formation of condensation by enforcing closing of doors between processing rooms.
Participate in the pest control program of the plant by complementing the monthly inspection of a contracted pest management company by conducting weekly inspection of pest stations.
- Monitoring and Control of Processing Materials:
Coordinate closely with the shift receiver and ensure incoming raw meat are in good condition and possess characteristic of fresh safe raw meat. Refer to QA 008a for temperature guideline for raw meat receiving.
Inspect daily all products in the Raw Meat cooler and advise the QA Manager and Production Manager on duty for any raw product that are 5 days old and over for immediate use. Verify that proper stock rotation is followed.
Ensure that any raw product from supplier not eligible to export to the US are properly labelled and kept in a designated area. Follow-up that these products are identified on all records and kept segregated from mainstream products. Familiarize yourself with the Annex W-1, a CFIA publication which lists federally registered companies both eligible and non-eligible to export to the US.
Monitor all dry ingredients and ensure that these are stored and handled in ways and means that prevent cross-contamination or spoilage. Report any mix up of allergenic and non-allergenic ingredients or any ingredient container that is exposed or damaged. Verify the lot numbers of the ingredients used for production. Ensure no expired ingredients are being used.
Ensure that primary packaging materials (food contact packaging, e.g., liners, poly bags, MAP trays) and secondary packaging materials (packaging that may have incidental contact with food, e.g., boxes and plastic tapes) are maintained in sanitary conditions and stored at least one foot from the walls.
Before re-using secondary packaging materials, monitor and ensure surfaces are free from soil, damages, or odour and old labels, if present, are removed prior to use.
Ensure that quality of the oil used in frying is satisfactory and is not contributing to appearance problem in the finished product.
Monitor thawing of frozen raw meat. Temperature of the water may not exceed 21°C; the raw meat temperature may not exceed 4°C.
- Monitoring and Control of Personnel Hygiene
Conduct training overview of plant GMP and food safety practices to new personnel. Review as necessary to production personnel who are in violation of GMP guidelines and food safety protocols.
Monitor and ensure all personnel are washing their hands during the following circumstances:
before commencing work
immediately after using toilet
after handling contaminated item (e.g. dirty utensil, skid, garbage, etc.)
after eating or drinking
after touching nose, mouth, skin or hair
after sneezing, coughing or blowing nose
Observe and report production people who may be suffering from communicable diseases.
Enforce proper handling protocol during MAP day: strict hand washing, wearing of plastic apron and sleeves.
- Monitoring and Control product in process and finished products.
Monitor and record raw product defects such as bones on boneless product, presence of too much fat, feathers, mixed meat portions or presence of foreign objects. Ensure that supplier, product information and kill dates are recorded for traceability.
Oversee product marinating and injection. Verify that the right ingredient is used, amounts of ingredients are calculated and weighed correctly, and lot number or production date of each ingredient is recorded.
Monitor and ensure intermediate product quality parameters are satisfied, i.e., % pick-up, product cook temperature, breading, sauce or glazing application evenly covers the product, and weights requirement.
Verify fryer oil quality with test strips once per shift.
Monitor the finished product quality parameters, i.e., taste, odour and appearance, piece count, thickness, or sizing of the product as the case may be. Verify the accuracy of data recorded by the Lead Hand by doing random finished product tests during the course of production. The QC Technician should checked the finished product specs at production start and randomly during the course of the production run to verify the accuracy of the data reported by the Lead hand.
Verify that correct label is used and properly applied on the boxes, and date codes are legible. Verify allergens in ingredient list are the same as on the production records.
Ensure that product are handled, stacked or stored in a manner that will prevent contamination
Immediately inform the Production Manager, QA Manager and/or Plant Manager if there are observed non-conformances in the product. Hold any non-conforming product for the evaluation or final disposition by the QA Manager and/or Plant Manager.
- Participate in the Productivity and Line Efficiency objectives of the plant.
Evaluate and report excessive production wastages or poor line efficiency that may be caused by machine set-up, deliberate act of some personnel, or the need for more training to new personnel.
Check and verify the product pick-up at the start of the injection or production run and inform Lead hand or Production Manager for corrective action. Pickup tests must be done before production starts so necessary adjustments can be made (15 min before line start)
Advise the Lead hand/Production Manager when the product is being cooked at unnecessarily high temperatures or unreasonably low speed. High cooking temperatures may cause product shrinkage and loss in product moisture content.
Conduct process trend analysis to ensure timely evaluation of production parameters and take corrective actions, if any. Most especially on breaded products like MDM with required piece count, finished product weights play a key factor for piece count compliance and hence profitability.
- Checking, Calibration and/or evaluation of tests and measuring instruments.
Perform accuracy test for digital or hand held thermometers, oven thermometers, and spiral freezer against a certified reference thermometer or with ice or hot water bath at prescribed frequency. The reliability and accuracy of the thermometers of the ovens and the ones for product testing is of utmost importance because the cooking process is a CCP.
Conduct accuracy check of wall thermometers in different refrigerated rooms and knife sanitizers. Keeping the doors close of each room is helpful in maintaining cooling requirements and efficient operations of the roofers.
Perform a weekly accuracy check for weighing scales using standard weights.
Perform efficiency test on the metal detector machine at the start of a production run or every product change-over and randomly at anytime in between.
Conduct an annual check of light intensity and regularly audit the plant for sufficiency of lighting illumination that aids in intercepting foreign elements that maybe present in the product.
- Monitoring and Maintenance of Production Documentation.
Ensure that all operations paperwork provides detailed information about every step in the process chain. All paperwork should be complete and legibly filled-up, signed, monitored at the required frequency and all deviations and corrective actions are documented.
Re-marry paperwork that provides information on the current status of an issue of concern, e.g., original HELD sticker with the release form.
- Support the Production staff training and educational program of the plant.
Observe production personnel for any violation of GMP, HACCP, food safety practices and personal safety protocols and re-train/re-orient personnel when deviations are observed.
- Perform other duties assigned or required by QC Manager.
- Possession of Diploma or University Degree in Food Science.
- Have 1 to 3 years related or previous Quality Control experience.
- Experience in a food processing facility is an asset.
- Flexibility to work different shifts.
- Ability to work in a fast paced environment.
- Be success-driven and have a “can do” attitude.
- Be able to work independently, as well as being a strong team player.
- Strong verbal and written communication skills.
- Have a good attendance and safety record.
- High degree of flexibility and adaptability to take up additional duties and cross-train.
- Occasional overtime may be required.