Environmental Monitoring Program

AP PRINTING & PACKAGING INC. Document No. APPI - EMP - 01 Rev. No. 0 Page 1 of 5

REV. REVISION PAGE

EFFECTIVE DATE CHANGE DESCRIPTION ORIGINATOR
NO. TYPE AFFECTED
Origination of the Food Safety and
0 New Quality Management System, based on All Core Team
the requirements of FSSC version 5.0

Prepared by: Reviewed by: Approved by: DCC USE ONLY

DOCUMENT CONTROL
Monik T. Manuel Lorna S. Duguran Kerwin C. Haw INDICATOR
Name and Signature Name and Signature Name and Signature MASTER COPY

This document is a sole property of AP Printing & Packaging Inc. Any disclosure, unauthorized reproduction or use is strictly prohibited except with permission from AP Printing & Packaging Inc.
Only documents with standard stamps of AP Printing & Packaging Inc. are considered official.
 AP PRINTING & PACKAGING INC. Document No. APPI - EMP - 01

Environmental Monitoring Program Rev. No. 00

1.0 OBJECTIVES
This Environmental Monitoring Program aims to:
1.1 Measure the overall effectiveness of sanitation facility, personnel practices and operational method of AP
Printing and
Packaging Inc.
1.2 Provide information about indicator organisms, spoilage organism, and/ or pathogens of concern in a timely manner,
so that appropriate corrective actions can be initiated to prevent potential microbial outbreaks.
1.3 Identify harborage niches and hot spots in AP Printing and Packaging Inc. production area that may act as a source of
contamination, and
1.4 Validate the Sanitation program and help in determining the frequency required for cleaning and sanitation.

2.0 SCOPE
This Environmental Monitoring Program covers the hygiene zone area from receiving of raw materials up to storing of
finished
good items, and areas with possible source of contamination from outside production area such as handwashing area and
changing room area.

3.0 DEFINITION OF TERMS

3.1 Environmental Monitoring Program is an on-going sampling and testing process that measures the effectiveness of
the contamination control measures in AP Printing and Packaging Inc.
3.2 Adenosine Triphosphate (ATP) is an energy molecules present in every cell, alive or dead.
3.3 Correction is an action to eliminate a detected nonconformity. It includes the handling of potentially unsafe products
and can therefore be made in conjunction with a corrective action.
3.4 Corrective Action is an action to eliminate the cause of a nonconformity and to prevent recurrence.
3.5 Environmental monitoring sampling zone Environmental sampling program use a zone classification to identify the
risk level of areas or sites where product may be exposed to post lethality environmental contamination. Sampling
sites
in AP Printing and Packaging Inc. production facilities are assigned to 3 zones.
3.6 Environmental Pathogen a pathogen of surviving and persisting within the manufacturing, processing, packing, or
holding environment which when that food packaging is contaminated it may result in foodborne illness such as
salmonella, listeria, etc.
3.7 Hygienic Zoning the division of a food packaging manufacturing facility into different areas to avoid food packaging

contamination risks.
3.8 Indicator microorganism is an organism or group of organism which presence reflects the general microbiological
condition of the food packaging or environment (e.g. coliforms, enterobacteriaceae, etc.)
3.9 Spoilage microorganisms a microorganism which result in decreased shelf life, inferior organoleptic properties, and in

This document is a sole property of AP Printing & Packaging Inc. Any disclosure, unauthorized reproduction or use is strictly prohibited except with permission from AP Printing & Packaging Inc.
Only documents with standard stamps of AP Printing & Packaging Inc. are considered official. MASTER COPY
 AP PRINTING & PACKAGING INC. Document No. APPI - EMP - 01

Environmental Monitoring Program Rev. No. 00

some instances, product recalls and withdrawals (e.g. Total Plate count, Yeast and Molds, etc.)
3.10 ATP Swabbing is an additional investigative swabbing conducted from the site of an initial positive direction.
3.11 Zone 1 Direct food contact surfaces.
3.12 Zone 2 Nonfood contact surfaces near food contact surfaces
3.13 Zone 3 Remote non-food contact surfaces that are in or near the processing areas and could lead to potential
contamination of Zone 1 and Zone 2.

4.0 RESPONSIBILITIES
4.1 QC Head reviews the program itself and the trend analysis report and assists during review of
sampling plan.
4.2 QA Analyst conducts swabbing, analyzes the swab samples and conduct trend analysis of the result.
4.3 Production Manager assists during review of sampling plans, management of correction, root cause
analysis and corrective action(s).
4.4 Production Supervisor assists during review of sampling plan and implement control measures.
4.5 Maintenance Head assists during review of sampling plan, management of correction, root cause analysis and
corrective action(s) related to equipment, utilities supply, and other installation.
4.6 HR Head assists during review of sampling plan, management of correction, root cause analysis and corrective
action(s) related to facility control and other cleaning and sanitation practices.

5.0 PROCEDURE DETAILS

5.1 General Guidelines
5.1.1 AP Printing and Packaging Inc. is committed to the implementation of the Environmental Monitoring
Program
in Food Packaging Manufacturing to satisfy the FSSC version 5.1 requirement which state that AP Printing and
Packaging Inc. shall have in placed a risk-based environmental monitoring program with a documented
procedure for the evaluation of the effectiveness of all controls on preventing contamination from the
manufacturing environment and this shall include, at a minimum, the evaluation of microbiological and allergen
control present and data of the monitoring activities including regular trend analysis.
5.1.2 AP Printing and Packaging Inc. shall follow the process step/ procedure to fulfill an effective Environmental
Monitoring Program. EMP Process flow are the following:
5.1.2.1 Identify and develop EMP team per department (refer to 5.1.3)
5.1.2.2 Define scope of Assessment Study by defining product and/ or product categories that will be
covered by the EMP. Studies and analyzes the product contamination.
5.1.2.3 Conduct Hygiene Zone assessment. Segregates the production into hygiene zones based on the
susceptibility or sensitivity of the product to pathogen contamination.
5.1.2.4 Establish parameters and baseline. Identifies the zoning and its equivalent sampling points (refer to
5.1.4). Identified associated pathogen/ Indicator.

This document is a sole property of AP Printing & Packaging Inc. Any disclosure, unauthorized reproduction or use is strictly prohibited except with permission from AP Printing & Packaging Inc.
Only documents with standard stamps of AP Printing & Packaging Inc. are considered official. MASTER COPY
 AP PRINTING & PACKAGING INC. Document No. APPI - EMP - 01

Environmental Monitoring Program Rev. No. 00

5.1.2.5 Collect and analyze the data based on criteria.

5.1.2.6 Identify the Risk Rating by defining the rating of each criterion. Calculate the total risk score for each
item using the EMP Risk matrix.
5.1.2.7 Identifies sampling frequency of each item per zone. Assigns responsible person to monitor EMP.
5.1.2.8 Record the evidence of implementation on the approved EMP. Implement Correction and Corrective
Action in case of deviation.
5.1.2.9 Monitor and verifies the Environmental Management Plan.
5.1.2.10 Schedule awareness for the Environmental Management Plan.

5.1.3 Environmental Monitoring Program Team

EMP Core Team Responsible Person Designation Responsibility
Quality Control Department Lorna S. Duguran QC Head Review the program itself and the trend
analysis report and assists during review of
sampling plan.
Monik T. Manuel QA Analyst Conduct swabs, analyzes the swab samples
and conduct trend analysis of the result
Production Department Dennis F Estonilo Production Manager Assists during review of sampling plans,
management of correction, root cause
analysis and corrective action(s).
Lara Kristina V. Buhayo Production Supervisor Assists during reviews of sampling plans and
implement control measures.
Maintenance Department Gerald Antolin Maintenance Head Assists during reviews of sampling plans,
management of correction, root cause
analysis and corrective action(s) related to
equipment, utilities supply, and other
installation.
HR Department Rosalina B. Agpoon HR Head Assists during reviews of sampling plans,
management of correction, root cause
analysis and corrective action(s) related to
facility control and other cleaning and
sanitation practices.

5.1.4 The Three (3) categories of Environmental Zoning of AP Printing and Packaging Inc.:
5.1.4.1 Zone 1: Direct food contact surfaces.
Press Lamination Die cut Box Forming
Suction Nozzle/ Feeder Suction Nozzle/ Feeder Paper Feeding Suction Nozzle Feeder (front)
Conveyor Belt Conveyor/ Gripper Roller Paper Conveyor Board Delivery/ Conveyor 1

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Only documents with standard stamps of AP Printing & Packaging Inc. are considered official. MASTER COPY
 AP PRINTING & PACKAGING INC. Document No. APPI - EMP - 01

Environmental Monitoring Program Rev. No. 00

Side Guide Adjuster Surface/ Conveyor Belt Paper transferring gripper Gluer/ Conveyor 2
Roller/ Plate Cylinder/ Blanket Round Brush Paper collection board Glue Applicator Sponge
Dampening Laminating Roller Board Frame Belt Feeder
Gripper Heater Roller Stripping Section Mould
Delivery Section Pressure Roller Delivery Section Counter Strip/ Separator
Anti Curl Device Forming Guide
Disc Knife Section 1 Collector Box/ Guide
Disc Knife Section 2
Disc Knife Roller
Delivery Section

5.1.4.2 Zone 2: Nonfood contact

surfaces near food contact surfaces
Press Lamination Die cut Box Forming
Main Switch Feeder Adjuster Paper Feeding Button Feeder Length Adjuster
Switch/ Emergency Button Feeder Switch Paper Conveying Adjustment Cams - Length Adjuster
Handle/ Ink Form/ Impression
Paper Cutter/ Switch/ Adjuster Adjustment Handle Tension Belt Adjuster
Adjuster
Human Machine Operator
Safety Guard Paper Conveying Button Emergency Stop
Interface (HMOI)
Counter button/ Counter
Paper Delivery Adjuster Hand Wheel Gauge Adjustment/ Handle
adjuster
Human Machine Operator
Water/ Air/ Ink Adjuster Shafting Film Manual Adjuster
Interface (HMOI)
Machine CPC Delivery Button Adjustment and usage of
Width Adjuster
front guide stop
Human Machine Operator
Air Hose
Interface (HMOI)
Operating pressure Remote
adjustment
Handle of Frame Board
Die Cutting window handle
Stripping window handle
Adjustment of side jogging
board

This document is a sole property of AP Printing & Packaging Inc. Any disclosure, unauthorized reproduction or use is strictly prohibited except with permission from AP Printing & Packaging Inc.
Only documents with standard stamps of AP Printing & Packaging Inc. are considered official. MASTER COPY
 AP PRINTING & PACKAGING INC. Document No. APPI - EMP - 01

Environmental Monitoring Program Rev. No. 00

Delivery Receiving button

5.1.4.3 Zone 3: Remote non-food contact surfaces that are in or near

the processing areas and could lead to
potential contamination of Zone 1 and Zone 2.
Walls

Ceiling

Production Area Platform

Steel Cabinet

Machine Parts

5.1.5 AP Printing and Packaging Inc. document and implement Environmental Monitoring Program
(EMP) that includes the following:
5.1.5.1 Risk Assessment addressing potential cross contamination
5.1.5.2 Validation of effective implementation
5.2 Risk Assessment
5.2.1 All products/ items per process section shall evaluate the risk of potential microorganism.
5.2.1.1 Pathogens (e.g. Staphylococcus aureus)
5.2.1.2 Spoilage Organism (e.g. yeast and molds)
5.2.1.3 Indicator organism (e.g. Coliforms, E. coli, Aerobic Plate Count)
5.2.2 When the products/ items were determined the risk of potential microorganism, another risk assessment will be
conducted to identify the monitoring technique of the EMP Protocol.
EMP RISK MATRIX
1 2 3 4 5

Negligible Minor Major Critical Multiple Death

A Very Likely Medium High High Unacceptable Unacceptable

B Likely Low Medium High High Unacceptable
C Possible Low Low Medium High High
D Unlikely Very Low Low Low Medium High
E Very Likely Very Low Very Low Low Low Medium

5.2.3 Likelihood of Exposure:

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 AP PRINTING & PACKAGING INC. Document No. APPI - EMP - 01

Environmental Monitoring Program Rev. No. 00

5.2.3.1 Very Likely - Definitely

5.2.3.2 Likely - Frequently
5.2.3.3 Possible - Infrequently
5.2.3.4 Unlikely - Rarely
5.2.3.5 Very Unlikely - Out of Ordinary

5.2.4 Severity of Potential injury/ illness

5.2.4.1 Multiple Deaths - Death due to food safety breach/ Loss of Certification
5.2.4.2 Critical - Single fatality or permanent disability/ increased audit frequency
5.2.4.3 Major - Severe injury or damage to health/ major audit findings
5.2.4.4 Minor - Slight risk of injury or damage to health/ minor audit findings
5.2.4.5 Negligible - No injury or damage to health/ audit observation
5.2.5 Monitoring Techniques
5.2.5.1 Surface ATP Swabbing
5.2.5.1.1 Sampling Tools: Swab stick
5.2.5.1.2 Sampling Location: Food Contact Surface
5.2.5.1.3 Test Method: Rapid surface ATP swabbing
5.2.5.2 Air Analysis
5.2.5.2.1 Sampling Tools: Air plates
5.2.5.2.2 Sampling Location: Production Area
5.2.5.2.3 Test Method: Third Party Laboratory Test
5.2.5.3 Water Analysis
5.2.5.3.1 Sampling Tools: Pour Plate, Multiple Fermentation Tube
5.2.5.3.2 Sampling Location: Maynilad Water Source Meter, Drinking Water
5.2.5.3.3 Test Method: Third Party Laboratory Analysis
5.2.6 Frequency of monitoring technique sampling
5.2.6.1 Weekly
5.2.6.2 Quarterly
5.2.6.3 Annual
5.2.7 Risk Assessment table contain the following:
5.2.7.1 Area
5.2.7.2 Sampling Location/ Site
5.2.7.3 Zone
5.2.7.4 Potential Microorganism
5.2.7.5 Indicator of Hazard
5.2.7.6 Risk Score
5.2.7.7 Risk Level

This document is a sole property of AP Printing & Packaging Inc. Any disclosure, unauthorized reproduction or use is strictly prohibited except with permission from AP Printing & Packaging Inc.
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 AP PRINTING & PACKAGING INC. Document No. APPI - EMP - 01

Environmental Monitoring Program Rev. No. 00

5.2.7.8 Monitoring Techniques

5.2.7.9 Frequency
5.2.7.10 Responsible Person
5.2.7.11Control Measure
5.3 Validation of control measure
5.3.1 All hazards process section shall evaluate the following:
5.3.1.1 Pathogens (e.g. Staphylococcus aureus)
5.3.1.2 Spoilage Organism (e.g. yeast and molds)
5.3.1.3 Indicator organism (e.g. Coliforms, E. coli, Aerobic Plate Count)
5.3.2 Provide the following details needed for validation protocol
5.3.2.1 Food Safety outcome and objective of validation protocol such as target, relevant to intended use,
recognized international standard, approved limit and effectiveness.
5.3.2.2 Control measure to be validated
5.3.2.3 List all materials needed for validation
5.3.2.4 Applicable parameter for validation protocol
5.3.2.5 Decision Criteria for validation protocol
5.3.3 Assemble relevant monitoring information or methodology. Provide duration or frequency of validation and
detailed experimental trials.
5.3.8 Analyze the result such gathered data or statistical data of the validation of control measure
5.3.9 After analysis, define the conclusion of the validation if the control measure is controlling the hazards to specify
the food safety outcome and objective is being implemented or the control measure is not capable in
controlling
the hazard and need to be revalidated.
5.3.10 Document validation protocol of control measure.

6.0 RECORDS/ REFERENCE

6.1 Environmental Monitoring Procedure
APPI - MGT - FSQP - 15
6.2 EMP Risk Assessment APPI - XXXX
6.3 Cleaning and Disinfection Procedure APPI - XXXX
6.4 Machine Daily Sanitation Monitoring APPI - XXXX
6.5 Sanitation Weekly Testing APPI - XXXX
6.6 Validation Protocol APPI - XXXX
6.7 Employment Environmental Program Zone 1 APPI - HCP - 07
6.8 Employment Environmental Program Zone 2 APPI - HCP - 08
6.9 Employment Environmental Program Zone 3 APPI - HCP - 09

This document is a sole property of AP Printing & Packaging Inc. Any disclosure, unauthorized reproduction or use is strictly prohibited except with permission from AP Printing & Packaging Inc.
Only documents with standard stamps of AP Printing & Packaging Inc. are considered official. MASTER COPY