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Awareness Session On BRC - Global Standards for Food Saftey

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BRC - GLOBAL STANDARDS
FOR FOOD SAFETY
ISSUE 6

Published in: Food

Awareness Session On BRC - Global Standards for Food Saftey

  1. 1. BRC - GLOBAL STANDARDS FOR FOOD SAFETY ISSUE 6 1 AWARENESS SESSION ON MMS/7-2-12
  2. 2. HISTORY • BRC – British Retail Consortium • Originally Developed in 1998 • New Name – Global Standard for Food Safety • Based on HACCP Approach • Latest Issue – Issue 6 released on July, 2011 • Sections – IV • Annexures – 10 • Clauses – 112 2MMS/7-2-12
  3. 3. Key Characteristics • This is a process and product certification • More emphasis on Quality, Hygiene and Product Safety • Certification based on grading system • Frequency of surveillance audit based on number of non-conformances • Detailing in allergens and site security • Option of un-announced audits to get A+ rating • GFSI recognized standard 3MMS/7-2-12
  4. 4. Certification Scope • Applicable to the manufactures of the food products, produced and supplied to retailers (Market Shelves). • Scope covers only the particular sites where BRC assessments conducted or the facilities including storage, that are under direct control of the respective site management. 4MMS/7-2-12
  5. 5. Grading • The scoring system based on 5 grades (A+ , A, B, C & D). • The frequency of the surveillance audit depends upon the number of non- conformances (NCs) and their nature accordingly. • The nature of NCs, are: – Minor – Major – Critical – Fundamental • Certification will be granted with the specific grade obtained. • Evidence of the corrective actions is required within 28 calendar days. • Certification Body should justify in the Audit Report if minor NCs are more than 20 or more than 1 major NC. 5MMS/7-2-12
  6. 6. Summary of Grading Criteria, Action Required and Audit Frequency 6 Grade Critical or Manor Non- conformity against the Statement of Intent of a Fundamental Requirement Critical Major Minor Corrective Action Audit Frequency A / A+ 1 to 10 Objective evidence in 28 calendar days 12 months B / B+ 11 to 20 Objective evidence in 28 calendar days 12 months B / B+ 1 1 to 10 Objective evidence in 28 calendar days 12 months C / C+ 21 to 30 Revisit required within 28 calendar days 6 months C / C+ 1 11 to 30 Revisit required within 28 calendar days 6 months C / C+ 2 1 to 20 Revisit required within 28 calendar days 6 months No Grade 1 or more Certification not granted Re-audit is required No Grade 1 or more Certification not granted Re-audit is required No Grade 31 or more Certification not granted Re-audit is required No Grader 2 21 or more Certification not granted Re-audit is required No Grade 3 or more Certification not granted Re-audit is required Note: + grade only apply to un-announced audit scheme MMS/7-2-12
  7. 7. Fundamental Clauses in Standard • Within the standard, certain requirements have been declared as Fundamental Clauses • These requirements relate to systems that are crucial to the establishment and operation of an effective food quality and safety operation. • In all cases where critical or major non-conformity is raised against fundamental clauses, this will lead to further full evaluation to establish demonstrable evidence of continued compliance. • Failure to the fundamental clauses will require a further full audit to establish demonstrable evidence of compliance. 7MMS/7-2-12
  8. 8. Fundamental Clauses in Standard The requirements deemed as being fundamental are:- • Senior Management Commitment and continual Clause 1.1 improvement • The Food Safety Plan - HACCP Clause 2 • Internal Audits Clause 3.4 • Corrective Action Clause 3.7 • Traceability Clause 3.9 • Layout, Product Flow and Segregation Clause 4.3 • Housekeeping and Hygiene Clause 4.11 • Management of Allergens Clause 5.2 • Control of Operations Clause 6.1 • Training Clause 7.1 8MMS/7-2-12
  9. 9. CONTENTS • Section I – Introduction • Section II - Requirements 1. Senior Management Commitment 2. The Food Safety Plan- HACCP 3. Food Safety & Quality Management System 4. Site Standards 5. Product Control 6. Process Control 7. Personnel • Section III – The Audit Protocols • Section IV – Management & Governance of the Scheme • Appendixes 9MMS/7-2-12
  10. 10. Section II - The Requirements 10MMS/7-2-12
  11. 11. 1.Senior Management Commitment 11MMS/7-2-12
  12. 12. FUNDAMENTAL CLAUSE 1.1.1 Documented Policy • Signed by Concerned Overall responsible • Communicated to all 1.1.2 Clear Objectives. These objectives shall be: • Documented and include measures of success • Clearly communicated • Monitored / reviewed the results al least quarterly New format of the objective to be used 1.1.3 Management Review Meeting, annually as a minimum 1.2 Organization Structure, Responsibilities and Management Authority Job Description to be amended for CCP & OPRP responsibilities 12MMS/7-2-12
  13. 13. FUNDAMENTAL CLAUSE 1.2 Organization Structure, Responsibilities and Management Authority Job Description to be amended for CCP & OPRP responsibilities ⁻ Clear structure and defined responsibilities ⁻ Organisation chart in place ⁻ Details of deputy personnel ⁻ System for keeping updated of legal and technology changes 13MMS/7-2-12
  14. 14. 2. The Food Safety Plan - HACCP 14MMS/7-2-12
  15. 15. FUNDAMENTAL CLAUSE 2. The Food Safety Plan – HACCP • Systematic • Comprehensive • Thorough • Fully implemented & maintained • Follows Codex Alimentarius • Reference to legislation • Reference to Company’s own Processes or guidelines 15
  16. 16. 2.1 Codex Alimentarius Steps Step 1 – Assemble the HACCP team Step 2 – Describe the product Step 3 – Identify the intended use Step 4 – Construct a process flow diagram Step 5 – Verify the flow diagram Step 6 – Conduct the hazard analysis Step 7 – Determine the CCPs Step 8 – Establish the critical limits Step 9 – Establish a monitoring system for each CCP Step 10 – Establish a corrective action plan Step 11 – Establish verification procedures Step 12 – Establish documentation Step 13 – Review the HACCP plan 16MMS/7-2-12
  17. 17. 2.1 The HACCP team • Multi-disciplinary • Designated and qualified leader • Records of training Training of HACCP Team in mandatory • Use of consultants If required • Senior management support 17MMS/7-2-12
  18. 18. 2.2 Pre-Requisite Programs (PRPs) • Pre-requisite program includes, but not limited to: ⁻ Cleaning and sanitization Recognized MSDS of cleaning chemicals ⁻ Pest Control Statistical analysis, hazard assessment for frequency and reference of internationally recognised usage of chemicals ⁻ Maintenance Program for equipment and buildings Preventive / corrective maintenance plan for building. SOP to be amended ⁻ Personal hygiene requirements Hygiene cap, mask, gloves, access control, trimming of nails, amendments in instructions. ⁻ Staff training CCP, OPRP, PRPs, Hygiene and food defence 18MMS/7-2-12
  19. 19. 2.2 Pre-Requisite Programs (PRPs) – Continued… • Purchasing ⁻ For all food contact materials and equipment, food grade certificated is required • Transportation arrangements ⁻ Hazard assessment for the selection and inspection • Processes to prevent cross contamination ⁻ Clear identification, segregation and containment • Allergens control ⁻ Known allergens to be mentioned on labels 19MMS/7-2-12
  20. 20. 2.3 Describe the product • Team to describe products and processes • Relevant information collected and maintained • Full description of the product ⁻ It includes by-products, ingredients, packaging and other incoming raw materials used 20MMS/7-2-12
  21. 21. 2.4 Identify intended use • Define Users ⁻ Infants ⁻ Elderly persons ⁻ Allergy sufferers • Define Next Process 21MMS/7-2-12
  22. 22. 2.5 Construct the Flow Diagram • For each product, category or process ⁻ Plan of premises (Plant / Equipment Layout, area wise) ⁻ Raw materials ⁻ Process steps and parameters ⁻ Outsourcing ⁻ Any delays ⁻ Reworking ⁻ Low/high risk segregation ⁻ Identification of CCP / OPRP 2.6 Verify Flow Diagram 22MMS/7-2-12
  23. 23. 2.7 Conduct Hazard Analysis • List all hazards associated with each process step ⁻ Hazard analysis for each incoming Raw Material used • Consider the control measures • Evidence of control of each PRP, OPRP 23MMS/7-2-12 2.8 Determine the CCPs • Logical approach • Risk Assessment criteria & Decision tree • Must eliminate or reduce to safe level • Mandatory to be checked by a Validation Team
  24. 24. 2.9 Establish Critical Limits • Must be measurable • Take into account legal aspects • Refer to Company’s own Procedures • Validate each CCP • Rational for critical limits should be taken from Codex Alimentarius / Internally recognized specifications • Mandatory to be checked by a Validation Team 24MMS/7-2-12
  25. 25. 2.10 Establish Monitoring System • Must be able to detect loss of control • On-line, off-line or continuous measurement • Must include results and date • Periodic verification of results for all OPRPs and CCPs from ISO 17025 Accredited Laboratory. • Signed by person responsible 25MMS/7-2-12
  26. 26. 2.11 Establish Corrective Action Plan • Specify and document • Identify authorised personnel • Procedures for unsafe products • Release procedures • Procedure for correction against immediate issues 26MMS/7-2-12
  27. 27. 2.12 Establish Verification Procedures • Internal Audits • Review of hazards levels • Review of complaints • Review of withdrawals or recalls • Results to be recorded 27MMS/7-2-12 2.13 HACCP Documentation & Record Keeping • Records sufficient
  28. 28. 2.14 Review the HACCP Plan • The review of HACCP Plan will be conducted by Cross Functional Team at least once a year, viewing the following parameters ⁻ Raw Material ⁻ Supplier of Raw materials ⁻ Ingredients / recipe ⁻ Processing conditions ⁻ Processing equipment ⁻ Packaging ⁻ Storage ⁻ Distribution conditions ⁻ Consumer Usage ⁻ New Risk 28MMS/7-2-12
  29. 29. 3. Food Safety & Quality Management System 29MMS/7-2-12
  30. 30. 3.1 Food Safety & Quality Manual • Development and maintenance of a formal documented management system • Fully implemented and reviewed • Outline of working practices • Readily available to key staff 30MMS/7-2-12
  31. 31. 3.2 Document Control • A master list of all controlled documents is required with current revision and issue date 31MMS/7-2-12 3.3 Record Completion and Maintenance • Back-up of the Electronic record is mandatory • Records for product conformity should be maintained for shelf life + 12 months
  32. 32. FUNDAMENTAL CLAUSE 3.4 Internal Audit • Programme of audits critical to safety, quality and legality • Scheduled and frequency by risk assessment • Competent, independent personnel • Documented results of audit positive and negative • In addition to internal audits, following inspections, at least monthly, are mandatory: ⁻ Hygiene inspection for cleaning and housekeeping performance ⁻ Fabrication inspection to identify risks to the product for building and equipment • Corrective and preventive actions verified • Record of audits and actions must be maintained 32MMS/7-2-12
  33. 33. 3.5 Supplier and Raw Material Approval & Performance Monitoring • Control of all purchasing processes based on risk assessment • Risk assessment of each raw material or group of raw materials to identify potential risks to product safety. This shall take the potential for: ⁻ Allergen contamination ⁻ Foreign body risks ⁻ Microbiological contaminations ⁻ Chemical contaminations • Procedures for exemptions if not audited • Clear procedures for on-going assessment • Review within specified “trial” period • Traceability of raw materials to be maintained • Questionnaire based approval shall be re-issued at least every 3 years 33MMS/7-2-12
  34. 34. 3.5.3 Suppliers of Services • A documented procedure for approval and monitoring of suppliers of services is required • Such services includes as appropriate: ⁻ Pest Control ⁻ Laundry Services ⁻ Contracted Cleaning ⁻ Contracted Maintenance ⁻ Transport and Distribution ⁻ Off-site Storage ⁻ Laboratory Testing ⁻ Catering Services ⁻ Waste Management 34MMS/7-2-12
  35. 35. 3.5.4 Management of Out-Sourced Processing • The intermediate process step which is included within the scope of certification • Selection of site on the basis of documented site audit • Maintain product traceability • Maintain procedure of inspection and testing for outsourced product on: ⁻ Release ⁻ Return ⁻ Storage ⁻ Traceability 35MMS/7-2-12
  36. 36. 3.7 General Documentation Requirements • Document Control • Specifications • Record Keeping 36MMS/7-2-12 3.6 Specifications • Adequate and accurate • Manufacturing instructions comply with recipes • Formally agreed • Procedure for amendment and approval • Accessible to relevant staff
  37. 37. FUNDAMENTAL CLAUSE 3.7 Corrective Action • Investigation of cause • Corrective actions completed in a timely manner • Implementation of corrective actions • Review of corrective actions • Verification of actions • Actions must be documented and assign accountability • Identification of the corrective action to address the immediate issues 37MMS/7-2-12
  38. 38. 3.8 Control of Non-Conforming Products • Clear identification of non-conforming products • Secure storage e.g.; isolation of area 38MMS/7-2-12
  39. 39. FUNDAMENTAL CLAUSE 3.9 Traceability • Raw materials to finished product and vice versa • Testing including mass balance • Testing procedures for IP products • Product identifiable at all stages of production • Traceability during rework • Test the Traceability at least annually. • Full traceability should be achievable within 4 hours 39MMS/7-2-12
  40. 40. 3.10 Complaint Handling • Documented system for complaints • Investigation and recording • Implementation of actions by trained staff • Trend analysis to be undertaken to be used continual improvement. 40MMS/7-2-12
  41. 41. 3.11 Management of Incidents, Product Withdrawal and Product Recall • Documented incident reporting procedure • Business continuity plan • Written guidance to staff • Documented recall & withdrawal procedure • Regularly tested at least annually – Results of the test shall include timings of key activity • Results of test to effect improvements • Notification to customer, consumer, CB, Laboratories, logistic handler and regulatory authorities • Certification body to be informed within 3 working days 41MMS/7-2-12
  42. 42. 4. Site Standards MMS/7-2-12 42
  43. 43. 4.1 External Standards • Compliance with local regulations • Location away from “offensive” trades • External areas maintained • Drainage • Suitably surfaced traffic routes • Maintenance of building fabric • Prevention of contamination from OFF-SITE sources MMS/7-2-12 43
  44. 44. 4.2 Security • Prevent access by unauthorised persons • Visitor reporting system in place • Designated access areas • Procedures for secure storage • Registration of the site, if required 44MMS/7-2-12
  45. 45. FUNDAMENTAL CLAUSE 4.3 Layout, Product Flow & Segregation • Designed to control risk of contamination • Process flow suitably arranged • Control of laboratories • Segregated cleaning operations • Lack of congestion • Control of temporary structures • Transfer points to minimise contamination • Segregation for high risk and high care areas • Site Plan shall define: – Access point for personnel and travel routs – Location of staff facilities – Production process flow – Routs for the removal of waste – Routs for the movement of re-work 45MMS/7-2-12
  46. 46. 4.4 Building Fabric 4.4.1 Walls • Suitable for intended purpose • Surface finishes for removal of dirt, mould and bacteria 4.4.2 Floors • Impervious and in good repair • Water/drainage flow away from “high risk” • Clean and well maintained • Should have adequate falls to cope with the flow of any water or effluent towards suitable drainage. 46MMS/7-2-12
  47. 47. 4.4.5 Ceilings/Overheads • Clean and well maintained • Should be appropriate design • Finished surfaces • Prevent dirt, mould, bacteria • Falling items/dirt 4.4.6 Suspended Ceilings • Avoid suspended ceilings in the process areas, especially, laboratories and ingredients / mixing areas 47MMS/7-2-12
  48. 48. 4.4.7 Windows • Glass window be avoided in process areas, warehousing and laboratories. 4.4.9 Doors • Prevention of entry by pests • Good condition • Easy to clean • External doors and dock levellers shall be closed fitting or adequately proofed. 48MMS/7-2-12
  49. 49. 4.4.11 • Glass (bulb, strip lights) to be protected • Electric Fly Killers tubes to be protected 4.4.12 Air Conditioning/Ventilation • Of appropriate design • Adequate ventilation and extraction • Use of filters where appropriate • Positive air pressure where appropriate 49MMS/7-2-12
  50. 50. 4.4 Utilities • Water, ice, steam, air and other gases used directly in contact with or as an ingredient, shall be monitored for possible contamination. • Water for process or cleaning to be potable or pose no risk • Contact materials monitored to prevent risk of contamination • Layouts of water distribution system including: ⁻ Holding tanks ⁻ Water treatments ⁻ Water re-cycling ⁻ Water sampling point should be identified 50MMS/7-2-12
  51. 51. 4.6 Equipment • Suitably designed Properly specified before purchase • Tested and commissioned before use • Positioned for access 51MMS/7-2-12 4.7 Maintenance • Maintenance based on risk assessment • Care during maintenance operations • Regular inspections • Contractors supervised • Post maintenance clearance • Materials to be food grade • Control of temporary repairs • Control of workshops • Work order to be amended for Hygiene Clearance after maintenance.
  52. 52. 4.8 Staff facilities • Designated changing facilities prior to entry • For visitors, contractors and staff entering in processing, storage and packing area • Provision for personal storage • Separation of outdoor clothing • Suitable and sufficient hand-wash facilities • Segregation of toilets • Smoking only in designated areas • Control of catering facilities • Facilities for storage of food • Facilities for visitors • High risk changing procedures 52MMS/7-2-12
  53. 53. 4.9 Chemical & Physical Contamination • Appropriate storage of chemicals • List of Purchased chemicals • Metal Control • Work Instructions • Glass and plastic listed on register • Policy & Work Instructions • Procedures for glass breakages • Incident reports for breakages • Use of wood restricted • In the open product area 53MMS/7-2-12
  54. 54. 4.10 Foreign Body Detection and Removal Equipment • A Documented Hazard Assessment required to identify the potential use of equipment. These maybe; ⁻ Filters ⁻ Sieves ⁻ Metal Detectors ⁻ Magnets • The type, location and sensitivity of the detectors shall be specified and documented • Filters and sieves shall be regularly (frequency) inspected / tested on the basis of a risk assessment • Unless a risk assessment eliminate, metal detection equipment shall be in place • A corrective action system shall be in place in case of unidentified failure of the foreign body detector • For magnets, the type, location and strength shall be inspected and integrity checks to be made. Records of all checks shall be maintained 54MMS/7-2-12 ⁻ Optical Sorting equipment ⁻ X-ray detection equipment ⁻ Gravity separation ⁻ Fluid bed technology
  55. 55. FUNDAMENTAL CLAUSE 4.11 Housekeeping & Hygiene • Cleaning procedure shall be in pace for the building, plant and equipment • A schematic plan of the layout of CIP system • The process parameters of CIP shall be validated • Documented cleaning schedules • Control of CIP systems • Carried out by trained personnel • Documented procedures and records • Strict control of chemicals • Monitoring of effectiveness of cleaning 55MMS/7-2-12
  56. 56. 4.12 Waste / Waste Disposal • Minimise accumulation of waste • Categorisation of waste • Disposal must meet legal requirements • Management of external waste • Secure disposal of trademarked waste 56MMS/7-2-12
  57. 57. 4.13 Pest Control • Maintain preventive control system • Use of contractors or trained personnel • Detailed record & procedures • Hazard Assessment, Pest-wise, to be carried out for the frequency of monitoring • Robust tamper resistant bait stations • Correct siting of fly control devices • Immediate corrective action after infestation • Detailed records of all actions • Trend analysis at least annually 57MMS/7-2-12
  58. 58. 4.14 Storage Facilities • Protection for outside storage • Correct stock rotation • Evidence of Mass Balance check is required • Documented Procedure to maintain product safety and quality during storage • Temperature control procedures 58MMS/7-2-12
  59. 59. 4.15 Dispatch and Transport • Documented maintenance and hygiene procedures for all vehicles including sub-contractors • Contract in place with sub-contractor • Procedures for breakdown • Record of vehicles / container inspection • Traceability shall be ensured during transportation • In case of temperature control vehicles, operation of refrigeration shall be verified and recorded • Contract of vehicles to be amended for ⁻ Restriction of mixed loads ⁻ Security of product during transit ⁻ Clear instructions in case of vehicle breakdown, accident or refrigeration system 59MMS/7-2-12
  60. 60. 5. Product Control MMS/7-2-12 60
  61. 61. 5. PRODUCT CONTROL 5.1 Product Design/Development • New products must under-go production trials – HACCP based • Shelf life to be confirmed • Shelf life trials shall be undertaken using documented protocol. Result shall be recorded • Legal requirements for labelling • Verify the ingredient and allergen labelling is correctly based on the product recipe • Control of product claims • Nutritional claims shall be validated • Process to be documented and effectively communicated 61MMS/7-2-12
  62. 62. FUNDAMENTAL CLAUSE 5.2 Management of Allergens • Risk assessment for specific allergens • List of all allergens on site • Including raw materials, processing aids, intermediate and finished product • Cross contamination during processing • Documented procedure is required • Training for allergen handling • Re-working • Identity preserved materials MMS/7-2-12 62
  63. 63. 5.3 Identification and assurance of origins •Identity preservation of raw materials used, status of each batch shall be verifiable •Traceability of all claims mentioned on the label to be maintained from purchasing, processing, raw materials and final packaging. Records to be maintained •Documented Mass Balance Test shall be conducted at least every 6 months 63MMS/7-2-12
  64. 64. 5.4 Product Packaging • Procedures to confirm specification • Compliance with food safety legislation • Food Grade Certificates for all direct contact packing material • Storage away from food products • Protection of re-usable packaging • Contact liners to be coloured 64MMS/7-2-12
  65. 65. 5.5 Product Inspection & Laboratory Testing • Provision of certificates of validation • Monitoring of incoming, in-process & finished goods • Laboratories accredited or complying with ISO 17025 • Procedures to ensure reliability of test results • Suitably qualified personnel • Test results recorded • Appropriate organoleptic testing and records • On-going shelf-life assessment 5.6 Product Release • Finished product shall not be released unless all agreed procedures have been followed • In case of positive release, procedure shall be in place to ensure all released criteria have been completed and release authorized • Procedures based on risk assessment to ensure safe release • Only by authorised staff 65MMS/7-2-12
  66. 66. 6. Process Control 66MMS/7-2-12
  67. 67. FUNDAMENTAL CLAUSE 6.1 Control of Operations • Validation prior to production and according to “worst case scenario” • On-going validation according to risk assessment • Control of additives, pressure and temperature • On-line quality control including correct code verification • Temperature, pressure monitoring equipment • Re-establish characteristics when changes occur • Procedure for equipment or process failure 67MMS/7-2-12 6. PROCESS CONTROL
  68. 68. 6.2 Quantity Control • Legal requirements of the destination countries or the country where product is going to be sold • Where no legal requirements must conform to customer specification 68MMS/7-2-12
  69. 69. 6.3 Calibration and Control of Measuring and Monitoring Devices • Traceable calibration of all test and measurement equipment • Accuracy within agreed parameters • Records of results maintained • Identification of devices • Prevention from adjustment • Protection from damage or misuse • Corrective action procedures 69MMS/7-2-12
  70. 70. 7. Personnel 70MMS/7-2-12
  71. 71. Copyright © 2008 BRC - Issue 28508 FUNDAMENTAL CLAUSE 7.1 Training • Training to all staff prior to commencing of work • Additional training for CCP(s) handlers, Cross Functional Team and Validation Team • Documented procedures and full training records • Routine review of training procedures • Refresher training to all employees including contractor’s employees • Evidence of periodic review of the competencies of employees 71MMS/7-2-12
  72. 72. 7.2 Personal Hygiene • Work Instructions and on-the-job trainings • Requirements documented and communicated • Risk assessed jewellery policy • No watches and only specified jewellery • Hand cleaning at appropriate frequencies • Hand free taps and disposable towel tissues • Short fingernails, no varnish, no false ones • No excessive perfume or aftershave • Monitoring of hand cleaning • Smoking / eating only in designated areas • Covering of cuts and lesions with company issued and monitored dressings • Testing of first-aid dressings (different from the product colour) if applicable • Control of personal medicines 72MMS/7-2-12
  73. 73. 7.3 Medical Screening • Reporting procedures for infections • Steps to ensure product safety • Visitors/contractors, where appropriate must be medically screened prior to visiting production process areas • Access & Movement of Personnel ⁻ Plan of site ⁻ Designated walkways ⁻ Simple logical routes ⁻ Control of visitors and drivers 73MMS/7-2-12
  74. 74. 7.4 Protective Clothing • Full protective clothing for employees, contractors and visitors working in / entering production / processing areas • Segregation of laundry • A documented procedure is required • Periodic testing for the verification of hygienic condition of protective clothing • No smoking or eating • Hair covered • Control of beards • Suitable footwear • Gloves/aprons adequately controlled 74MMS/7-2-12
  75. 75. THANK YOU MMS/7-2-12 75

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