Tesco Food Manufacturing Standard EN

Food Manufacturing Standard
Author: Terence Wilde ` Applicable to: Product: All Food

Country: Group
Date Issued: 28th Nov 2007 Date Revised: 1st July 2010 Revision Due: 1st July 2012
Legal and Technical Document Matrix No: 347
© Tesco Stores Ltd. All Rights Reserved. This document is supplied by Tesco for use of the immediate recipient
Food Manufacturing Standard

(TFMS)
Version 4.0
Tesco Food Manufacturing Standard Version 4.0 Page 1 of 183

CONTENTS
Introduction to the Tesco Food Manufacturing Standard
Site Audit
Section Page
1 HACCP 8
2 Finished Product Specifications 14
3 Raw Material and Secondary Site Management 17
4 Packaging 25
5 External Areas and Site Security 31
6 Design and Construction of Premises 34
7 Design and Construction of Equipment 41
8 Employee Facilities and Personal Protective Equipment 43
9 Factory Hygiene 53
10 Personal Hygiene 59
11 Process Controls 63
12 Traceability 68
13 Allergen Control 70
14 Foreign Body Controls 74
15 Foreign Body Detection 83
16 Inspection and Analysis 89
17 Water and Waste Water Management 91
18 Product Labelling and Coding 94
19 Weight, Volume and Count Checks 97
20 Training 101
Quality Systems Audit
21 Quality Management System 103

22 Product Development 105
23 Product Recall/Incident Management 107
24 Internal Audits 109
25 Customer Complaints 112
26 Pest Control 115
27 Maintenance 121
28 Calibration 125
29 Cleaning Programme 128
30 Transport 133
31 Medical Screening 135
32 Employment Agencies 138
33 Environment 142
34 Ethical Trading 143
35 Management Controls 146
Appendix 1 – Raw Material Specifications 147

Appendix 2 – Document Review (changes introduced) 149
Glossary of Terms 180
Appendix 3 – Requirements for Traceability Exercise / Document Review 182

Introduction to the Tesco Food Manufacturing Standard (TFMS)
This version of the TFMS (version 4.0) was produced after consultation with Tesco Technical
Managers throughout our international businesses, along with representatives from our food
supplier base. Appendix 2 provides a clear summary of all changes made from the previous
version (version 3.2).
Aim
Tesco is committed to ensuring all Tesco brand products produced by our suppliers are safe,
meet legal requirements and are of the agreed quality. Suppliers must meet Tesco Ethical
requirements (Tesco Ethical Trading Code of Practice – Document No 388).
Objective
The Tesco Food Manufacturing Standard (TFMS) clearly sets out our requirements for
suppliers. In some instances the TFMS will make reference to a Code of Practice which is also
applicable and details our additional requirements on this subject. Under no circumstance does
adherence to the TFMS replace the need for compliance to all relevant legal standards in the
country of manufacture or the intended country of sale. Compliance to the standard is in
addition to the duty held by the supplier to produce safe and legal food.
Scope
The TFMS is applicable to all primary and secondary food suppliers to Tesco. Although
identified as a food manufacturing standard, this document applies equally to sites packing
food.
The Arrangement and Configuration of the TFMS
The Sections and Layout
The food manufacturing industry has many complexities. It encompasses many different
technologies and specific product groups have their own individual risks associated e.g. the
risks associated with short shelf life ready-to-eat chilled foods, will be significantly different to
those associated with uncooked rice grains or canned Tuna fish.
The controls required to ensure food safety will therefore be different for each product type,
depending on a range of factors including personal hygiene, building fabrication, equipment
design etc.
The TFMS details Tesco requirements for all types of food manufacturing (including the
packing of food). It is divided into 35 sections and these are sub-divided into individual clauses
(all uniquely numbered).
To ensure that our requirements for some sectors of the industry e.g. ready-to-eat chilled foods,
are not overly burdensome on other sectors, each clause of the TFMS has been given one of
four classifications i.e. Base, Medium, High & Aspiration. The first 3 classifications relate to
areas of a factory and the controls required. They should not be confused with common food
industry terminology e.g. Base should not be used to describe ‘Low Risk.’ The requirements
detailed for both Base & Medium may well apply in a Low Risk environment (see glossary).

Base
Base factory areas are those where the product is fully enclosed or packaged. These
requirements apply to all manufacturing/ packing sites irrespective of the product or process. If
specific parts of the factory are operated at Medium or High standards, these areas must also
comply with all of the Base requirements.
Example 1: An ingredients warehouse (ambient or temperature controlled) is likely to be a Base

area. The ingredients are sealed from contaminants.
Example 2: A factory that trims and packs fresh produce (e.g. remove the top and tail of root
vegetables) without any further preparation is likely to operate at Base level.
Medium
These requirements specifically apply to areas of the factory where food is OPEN or EXPOSED
to contamination (therefore increasing the risk in these areas). Associated areas or processes e.g.
utensil washing/ storage, de-boxing/ handling food-contact packaging, equipment used for
filling containers etc. will also be considered Medium areas. The clauses classified as Medium
will be applicable in addition to all relevant Base requirements.
Example 1: The area used for cutting and packing of fresh meat is Medium. This will be from
the point of entry to the butchery / packing area, to the point where the chilled products are fully
sealed (packaged) & labelled.
Example 2: The production line for a bakery is likely to be Medium. This is from the point
where ingredients are opened, sieved, mixed, proved and baked, to the point where it is
packaged and labelled.
High
These requirements apply to all areas that are identified as handling or processing high-risk or
high-care products. The clauses classified as high will be applicable, in addition to the relevant
Base and Medium requirements.
The risk in this area is higher than that in the Base / Medium area e.g. the product may be
susceptible to the growth of pathogenic bacteria and may be provided to the consumer as a
ready-to-eat item.
Example 1: The assembly and packaging of a chilled ready-meal is High.
Example 2: The slicing and packing of a chilled cooked meat product is High.
High Care/ High Risk must be physically segregated from Low Risk e.g. by a dividing wall
Aspiration (APSN)
Some sections have additional elements (Aspirations) which Tesco believe will help move
standards forward within the food supply base. These are not prescribed requirements but it
should be noted that ASPN clauses may potentially become requirements in future versions of
the TFMS.

Base, Medium, High – In Combination at a Factory
Base, Medium & High classifications represent the level of control required to effectively
manage the risk at each stage in the process or type of production environment. They therefore
reflect the risk presented to the raw materials, work in progress or finished products from
associated hazards e.g. foreign body contamination or microbiological contamination (possibly
originating from personnel, manufacturing equipment, unprocessed raw materials or the
building fabrication).
Factories that contain Medium or High areas should not be thought of as a ‘Medium’ or ‘High’
factory. It is more appropriate to consider that a factory may have Base, Medium and High
areas and that the product risk / controls required, will be different in each area.
To better understand this concept, it may be useful to consider the layout of a factory that could
contain all of these classifications (Base, Medium and High). If for example a factory is making
chilled ready-to-eat food (clearly hygiene in the production area would be very important), then
the simplified diagram below could represent it.
Example of a factory layout for chilled RTE products
Base Area Medium Area Base Area

High Area
Raw Material & Open / Exposed Despatch
Packaging Food Area Area
High Care
Storage Areas e.g. preparation
Product
area
Assembly
1 2 3 4
1. If, for example, raw materials (food & packaging) are delivered to the factory in sealed
boxes, then the risk of cross contamination in the warehouse is minimal. As this area is still
part of the food factory, basic controls such as protecting the materials from weather damage
or pest activity are clearly important. This area would be considered a base area
2. If, for example, some of these materials are moved into the 1st phase of the production area
and boxes / bags are opened to expose the raw materials (possibly chopping, mixing or other
activities take place in this area), this area would be considered a Medium area as the food
materials are exposed.
3. The next stage maybe the transfer of the materials into a high care / high risk production
area, for assembly into the ready meal, sandwich etc. In this area it is important that the
materials are protected from cross contamination with pathogenic bacteria, as the food will
support bacterial growth and is ready to eat. This area would be classified as High
4. The food product may be packed (sealed) and then transferred from the high care area to
the despatch area. As the food is again protected from contamination, this area would be
considered as Base.
Note: If a factory operates a Low Risk / High Care divide (as above), Low Risk may include
both Base and Medium controls i.e. it is not expected or required that sites use the term
Medium to describe parts of their factory. Medium just describes the level of control required

What Good Looks Like
In many sections examples are given of how a requirement may be met under the heading of
What Good Looks Like (WGLL). This is intended to provide guidance and clarification of what
is required. Due to the variability of the processes and premises at supplying factories,
compliance to ‘WGLL’ may not ensure total compliance to a requirement. The supplier must
determine the most effective method of complying with Tesco requirements and be able to
demonstrate this during a Tesco audit.
PRO (demonstration)
To help identify how the requirements should be met for each clause a P, R, or O will be
indicated under columns headed PRO. These columns indicate whether the requirement is met
through:
P = Procedure. - A documented procedure that has been fully implemented.

R= Record. - Documented and accurately completed records.
O= Observations. - Compliance will be checked through observation.
This avoids the need to qualify each requirement with the comment of “Documented procedures
are required” or “Records must be kept” etc.
Auditing of the Standard
Tesco reserves the right to undertake regular audits against this standard (at factories
manufacturing / packing Tesco brand) and will determine the degree of compliance to each
section. Information on the Tesco audit process can be found on the Tesco Technical Library
(TTL) or from your Tesco Technical Manager. There is a likelihood that some non-
conformances will be raised during the audit and these will be categorized as:
• Critical - Failure to meet a food safety standard or a legal standard; where this failure
puts the customer and or Tesco brand integrity at risk.
• Major – A deficiency which requires prompt attention to prevent a potential food safety
failure or legal issue from arising; where this failure may potentially put customers or
the Tesco brand integrity at risk.
• Minor – A deficiency which requires attention to improve Good Manufacturing Practice

standards, Due Diligence documentation (our ability to defend a legal challenge) or to
achieve compliance with Tesco standards.
Depending on the category of non conformances and numbers identified, sites will receive a
• Blue =
specific rating.
• Green =
Satisfactory
• Amber =
Satisfactory
• Double Amber =
Improvement needed
• Red =
Improvement needed
Not Satisfactory
Note. Double Amber status is used for sites which have consecutive Ambers (and those which
were Red prior to Amber).

New Sites
In instances where a site has not previously worked with Tesco i.e. the audit is undertaken as
part of the initial ‘approval process’, the rating will be either Approved or Not Approved.
Country Specific Requirements
Although this Food Manufacturing Standard is a ‘Group’ document i.e. it applies globally; a
small number of the clauses may apply only to factories supplying products to Tesco stores in
specific countries e.g. to Tesco UK.
Where this is the case, the clause will be in “italics” and slightly shaded (grey). It also will note
the specific country / countries where it is applicable e.g clause 3.10 Controlled Ingredients.
The TFMS also makes reference to additional Tesco Codes of Practice and again these may also
only be applicable to factories supplying products to Tesco stores in specific countries e.g. the
UK (this will be clearly noted)
TFMS Category Guidelines
Due to the nature of certain product types e.g. Fermented meats and Un-pasteurised cheese;
there may be additional guideline documents that need to be read in conjunction with the
TFMS. Suppliers must ensure that they have all the relevant documents and if they are unsure,
any questions should be directed to the relevant Tesco Technical Manager.
Review
Feedback on the standard or any questions should be directed to the relevant TTM or the Tesco
Product Integrity Unit - PIU.services@uk.tesco.com
Training
Speak to your Tesco Technical Manager for information on the availability of TFMS training.
Glossary of Terms
A Glossary of Terms has been provided at the rear of the document (page 180) to aid
understanding of the terminology used in this document.

Section 1 Hazard Analysis & Critical Control Points (HACCP)
X What Good Looks Like

Base
Section Medium
P R O High Item Detail
No.
Aspiration
P R 1.1 Base HACCP Plan An effective, accurate HACCP Plan must be in place. The
HACCP Plan must be developed using Codex
Alimentarius HACCP principles with reference to relevant
legislation, Tesco Codes of Practice and industry guidance.
The HACCP Plan must include a detailed scope

referencing elements of sections 1.1-1.5, 1.10, 1.16, 1.17.
P R 1.2 Base HACCP Team The HACCP system should be developed by a multi- The team should include members
disciplinary team which must have product specific from at least the following
knowledge and expertise. disciplines (not an exhaustive list):
- Technical
If internal expertise is not available, expert advice may be (food science/technology)
obtained from other sources. The operation of the HACCP - Production
system must remain the responsibility of the site. (what happens in factory)
- Engineering
At least one member of the team must have completed a (equipment functionality)
recognised qualification (minimum Intermediate HACCP
or equivalent) and the other members must be suitably With support from Product
trained. Intermediate level training would consist of a 2 Development, Purchasing,
day training course with a mandatory examination at the Distribution etc as appropriate.
end.
A programme of refresher training to ensure up to date

knowledge, should be considered.
P R 1.2.1 ASPN HACCP Team At least one member of the team has completed a
recognised qualification in Advanced HACCP.
P R 1.2.2 ASPN HACCP Team Refresher training of the HACCP team is undertaken
annually, regardless of any change in production processes.

P R 1.3 Base Pre-requisite All environmental and operational controls that are
Programmes necessary to produce of safe and legal food products must
be in place. These cover good manufacturing practices
throughout the site.
• Personal Hygiene
They may include (not an exhaustive list) e.g.:
• Staff Training
• Pest Control
• Cleaning procedures
• Glass/hard plastic control
• Waste control
• Maintenance Procedures
The control measures and monitoring procedures for the

pre-requisite programme must be clearly identified and
documented.
P 1.4 Base Product A full description of the product must be documented This information should be clearly
including relevant safety information e.g.: documented within the scope of the
•
study.
•
Composition
•
Origin of ingredients
Physical or chemical structure
• Treatment and processing

(e.g. water activity, pH etc.)
• Packaging (e.g. modified atmosphere, vacuum)

(e.g. heating, freezing, salting)
• Storage and distribution conditions
• Durability and required shelf-life

(e.g. with specified temperatures)
• Instructions for use

P 1.5 Base Intended Use The intended use of the product must be defined, detailing This information should be clearly
the end user or consumer and suitability for vulnerable documented within the scope of the

groups must be considered e.g. infants, elderly and allergy study.
sufferers.
P R 1.6 Base Flow Diagram A flow diagram covering all steps in the operation Where factories have high care /
including rework, water where used and waste must be high risk facilities, flow diagrams
constructed. This may be generic but it is critical that all should clearly identify where these
process steps are included and identified by product. physical barriers exist in the
process. The CCPs should be listed
The diagram must be verified within the production area. on the flow diagram for reference.
P 1.7 Base Hazards All potential hazards that may be reasonably expected to
occur for each process step and product must be identified.
Hazards identified must be specific to the process step,

generic descriptions such as ‘foreign body’ and ‘micro-
organisms’ are not sufficient.
P R 1.8 Base Hazard The HACCP team must conduct a hazard analysis to Records for this analysis should be
Analysis identify hazards which need to be prevented, eliminated or kept in combination with point
reduced to acceptable levels. 1.10.
• Likely occurrence and severity

The hazard analysis must include:
• Survival or multiplication of micro-organisms

• Presence or production of toxins, chemicals or foreign
• Potential for adulteration/deliberate contamination

bodies and allergens
P R 1.9 Base Control The HACCP team must assess whether an existing pre- .
Measures requisite adequately controls the hazard identified.
The HACCP team must also consider what control

measures (if any exist) for the remaining hazards can be
applied to prevent, eliminate or reduce the risk to
acceptable levels.
If no control measures have been identified the product

/process must be modified so a control measure can be

applied
P R 1.9.1 Base Control The documentation should show links to a specific pre- For example Pest Control or Glass
Measures requisite, rather than generic comment i.e. ‘Pre-requisite’. Control programmes.
P R 1.10 Base Determination The Codex decision tree or equivalent must be used to In combination with point 1.8, there
of CCPs determine if control measures are CCPs (Critical Control should be records of each process
Points). step indicating the hazards and
showing the decision tree answers
that determine whether it is a CCP.
P R 1.11 Base Critical Limits Critical limits must be defined and validated to ensure that
the product is safe. The process must be capable of
operating consistently within the defined limits.
Critical limits must be measurable and justification for

their use must be documented.
P R 1.12 Base Monitoring Monitoring procedures must be established for each CCP
to ensure compliance with the critical limits.
The monitoring system must be able to demonstrate control

and detect loss of control of CCPs.
The precision limits and tolerances of the monitoring

equipment must be considered when defining limits e.g.
tolerance of temperature probes.
Monitoring procedures must contain details on how the

measurements are taken and the frequency.
P R 1.13 Base Monitoring Monitoring records must be signed by the person doing the
Records monitoring and then verified by an authorised person.
P R 1.14 Base Corrective The corrective actions to be taken when a CCP deviates
Actions from critical limits must be detailed and documented by
the HACCP team.
The corrective actions must ensure that the CCP has been

brought under control and any material that may have been
produced whilst the CCP was not in control must be
identified, isolated and a full risk assessment completed.
Product and or materials must be disposed of if the safety

of the product is in doubt.
If the risk assessment deems the product to be safe, it must

not be supplied to Tesco without first discussing the issue
and submitting documented evidence to support product
safety with the relevant Tesco TM. (see also 11.3)
P R 1.14.1 Base Corrective The HACCP must be reviewed at the earliest opportunity
Actions following accepted deviation from the defined critical
limits. (see also 1.18)
P R 1.15 Base Training Personnel in the factory who monitor CCPs must have an Internal workshops to train HACCP
understanding of HACCP and have specific training thinking for all individuals involved
against the latest version of the relevant monitoring in monitoring. These workshops
procedure. would use relevant case studies.
P R 1.15.1 ASPN Training All production personnel should have a basic This would ideally be conducted
understanding of HACCP and how it relates to the area separately to the induction, once
they work in. individuals have become familiar
with the process.
P R 1.16 Base Verification The operation of the HACCP plan must be verified to The verification would demonstrate
confirm that it is effective. a full understanding by firstly
demonstrating conformance i.e. that
• Internal audits
This may include: individuals are actually following
• Review of customer complaints

the stated procedures;
• Review of hazard measurements e.g. microbiological

and secondly that the whole system
including the pre-requisite
results. programme is operating effectively.
P R 1.17 ASPN Verification The HACCP plan is verified by a 3rd party with specialist
knowledge of food microbiology, food chemistry and food
processing technologies if applicable e.g. thermal
processing.

P R 1.18 Base Review The HACCP plan must be reviewed at a pre-determined
frequency (minimum annually) or prior to changes of
product/process which may affect product safety.
• Process steps
This may include changes in (not an exhaustive list):
• Supply or specification of raw materials

• Ingredients/recipe
• Packaging, storage or distribution etc.
• Introduction of new or modification to existing
• Change in factory layout or product flow

equipment

Section 2 Finished Product Specifications & Tesco Technical Library*

Base
Section Medium
No.
Aspiration
R 2.1 Base Agreed Agreed Tesco Specifications must be in place for all For the UK/ROI/US all TTL
Specifications launched products. Specifications must be agreed in specifications should be active on
writing by both parties (electronic signatures are or before the point at which
acceptable). products are on sale.
Copies of the specifications must be accessible on all

production sites.
R 2.2 Base Content Specifications must be fully completed with accurate The content within the specification
information that describes the product, packaging and should be current and contain all
processing details. relevant product information
including full details of rework and
how its used (e.g. percentage to
each batch, used in like for like
product only, life and break in use
of rework), WIP, testing etc
R 2.3 Base Review Specifications must be reviewed and re-agreed with Tesco
when changes to product / process are made and to comply
with the review date on the specification.
P R 2.4 Base Internal Site Where sites transpose information from the Tesco The factory specification including
Specifications Technical Specification to an internal document format (for photographic quality standards will
use in the factory) systems must be in place to ensure be available during each production
accuracy of the information and ensure updates are made run. Photo standards will be of
when applicable (controlled documents). adequate quality and size to be
clearly visible by production staff.
R 2.5 Base Tesco All details of the Supplier and the Site Record must be
Technical complete and accurate, e.g. Address, Telephone, Plant
Library: Approval No, Spec Type, Contact Roles and Details.
Supplier &
Sites Area A system must be in place to review and update the

information.
R 2.6 Base Tesco Tesco Technical Library specifications must be completed
Technical to Gold Standard as defined in the User Guides.
Library:
Specifications The appropriate Gold Standard User Guide must be
Area demonstrably in use.
The person responsible for specification approval must

have attended Tesco Gold Standard Specification training.
Product history must be traceable through the

Specification History section.
Site Details on the front of the specification must reflect the

site where the product is manufactured / packed.
The Specification Status must reflect status of the product,

e.g. where a product is delisted, the specification must be
removed from Active status
R O 2.7 Base Tesco The Alerts system is a key communication tool and all The key email contact for the alerts,
Technical Alerts / Requests from the Tesco Technical Library must be cascades the information to the
Library: responded to within the designated timescale. correct person/department in a
Alerts Area timely manner
O 2.8 Base Tesco Site technical people must be familiar with the access Internal procedures make reference
Technical points for Tesco documentation and the content relevant to these documents, to demonstrate
Library: for their site. they have been reviewed.
Document
Area - Policies, Codes of Practice and Guidelines Area
- Help & Guidance Area
- Labelling Area
- Category Sharepoint
- Home Page – New Policy Documents
It is the responsibility of sites to ensure that where Tesco

COP (relevant to product / process) are in place, that they
are aware of these and comply with the requirements.
O 2.9 Base Tesco Site technical people must be familiar with ‘My
Technical Workspace’ and respond appropriately to the designated
Library: My tasks e.g. out of specification surveillance reports, audits
Workspace and visits etc.
*Currently the requirements specific to the TTL are applicable to sites and suppliers supplying Tesco businesses in the UK, ROI and USA. Where sites
produce products for more than one country, they may also be required to use the TTL and comply with the additional clauses listed. For guidance
speak to your Tesco Technical Manager.

Section 3 Raw Material and Secondary Site Management

Base
Section Medium
No.
Aspiration
RAW MATERIALS
P R 3.1 Base Supplier Risk An effective raw material and supplier control system A risk assessment value would be
Assessment must be in place for all raw materials. generated based on
-Inherent risk of the ingredient
All raw material suppliers must be risk-assessed, based -Number / volume of ingredients
• Inherent risk of the ingredient

on: supplied
• Volume of ingredient supplied

-Number of products the ingredient
• Supplier history
is used in
-Supplier history
Each supplier would be rated and this
value would determine the need for
• Method of supplier approval
Risk assessment must be used to determine:
audit and the audit frequency. This
• Method of supplier monitoring data would form part of the audit
• Type and frequency of raw material sampling and schedule and intake quality checks
testing required.
Raw material supplier risk assessments must be

reviewed annually.
P R 3.2 Base Supplier An approval system must be in place. Approval may If the risk assessment indicates that
Approval include a combination of: the supplier is low risk (e.g. a low
•
risk commodity such as salt) a
Approved site audit report. If no physical audit is supplier self audit may be used.
•
undertaken, this must be justified by risk assessment Provided the response to this is
Valid 3rd party certification to a food standard satisfactory, an audit may be waived.
•
(certificate date still current)
Supplier self audit report which has been reviewed.
Corrective actions have been followed up and

completed.
All raw material suppliers must have a traceability

system in place to trace raw materials back to source.
P R 3.2.1 Base Contingency Where a contingency raw material/supplier is required,
Supply the site must first contact the Tesco TM for acceptance.
Where agreed the site must have the following

information about the product and supplier (as a
minimum):
•
•
A specification for the product
A 3rd Party audit report and certificate
•
•
Test results (micro, chemical), where appropriate
Documentation to demonstrate compliance with
Tesco COPs
Contingency suppliers are those used at very short

notice, generally as a one off due to approved suppliers
being unable to supply.
Raw material must be on a like for like basis (e.g. Not

using coloured cheddar cheese in place of white cheddar
cheese)
R 3.3 Base Third Party If the risk assessment indicates that certification to a The third party audit report will
Audits third party food standard is sufficient, then a valid provide the site with details of non-
certificate, audit report and corrective action summary conformances, which will assist in
must be available on site. The site must be able to the site being able to make a full and
demonstrate that this has been reviewed. proper risk assessment. (e.g. the
report may show a number of failings
in Quality Management systems,
which the site may wish to verify for
themselves)

A certificate does not necessarily
demonstrate closure of non-
conformances. Not all third party
Food Safety schemes issue
certificates on the closure of all non-
conformances. Some verify at next
audit.
Where electronic systems are used by

Certification Bodies for site reports
and certificates, these may be used to
negate the need to print relevant
information. Site however, should be
able to demonstrate they can navigate
the system.
This information may be held on-site

or centrally (e.g. head office).
P R 3.4 Base Audit If risk assessment indicates that a site audit is required,
Requirement the site must be audited before supply commences and
then, according to an audit schedule.
Audits must be completed against a format which

encompasses the principles of the Tesco Food
Manufacturing Standard (i.e. Good Manufacturing
Practices).
If a critical non-compliance is found at a site that is

being audited prior to commencement of supply, then
supply must not commence until the corrective action
has been completed and verified. The same applies if 4
major non conformances found.
If a critical non-compliance is found at a site that is an

existing raw material supplier, which could impact on
Tesco products in the supply chain, Tesco must be
informed immediately. The same applies if 4 major non
conformances found.
A copy of the audit report must be accessible on site

with details of corrective actions. Timescales and
corrective actions must be agreed by both parties.
The completion of corrective actions must be verified
within the agreed timescale.
R 3.5 Base Approved Raw materials must be sourced only from approved
Supplier List suppliers. Details of suppliers and the raw materials
supplied must be kept on an approved supplier list.
P R 3.6 Base Trained Supplier audits must be completed by trained auditors
Auditors with an understanding of processes and the risks
associated with the product area/site being assessed.
P R 3.7 Base Agents & Where raw materials are supplied via an
Importers Agent/Importer:
• It is the raw material site and not the Agent/Importer
•
that must be approved
The Agent may be assessed by the Tesco supplier as
competent to manage approval of the raw material
site
The Agent/Importer must be able to demonstrate that

they have risk assessed the site against Tesco
requirements.
P R O 3.8 Base Raw Material All raw materials must have a specification that includes Both parties have signed and dated
Specifications Tesco criteria where relevant (See Appendix 1: Raw the specification.
Material Specifications)
Raw materials specifications must be agreed by both Electronic signatures are acceptable.
parties.

R 3.9 Base Certificates of The supplier risk assessment must define if a Certificate
Analysis / of Analysis (COA) or Certificate of Conformance
Conformance (COC) is required.
Where a COA / COC is required, raw materials may not

be used until the details on the certificates have been
checked against the raw material specification.
P R O 3.10 Base Controlled Controlled ingredients must be sourced from Valid IT Code of Practice for Controlled Non
Ingredients recognised sources as per relevant Codes of Practices GM Ingredients 216 (Tesco UK
(Tesco UK only) where applicable. only).
If other sources of the same ingredient are used for Code of Practice for Controlled
other customers i.e. non Tesco, which are not Valid IT, a Spice Ingredients 316 (Tesco UK
system to ensure segregation of these materials must be only)
in place.
R O 3.11 Base Tesco Approved All Meat and meat ingredients must be sourced from
Sources Tesco Approved Agricultural Supplier List (203) unless
(Tesco UK only) authorised by the Tesco Technical Manager (Tesco UK
only)
Fresh Produce must be sourced from Tesco Approved

Sources e.g. Nurture Certificated unless authorised by
the Tesco Technical Manager (Tesco UK only).
There may be other in country approved lists. Sites need

to demonstrate compliance where these exist.
P R 3.12 Base Intake Checks All raw materials must be checked by trained staff on Based on risk assessment checks may
receipt according to documented procedures. Intake also include:
•
records must be retained.
•
Product sampling for retention
• Hygiene condition of vehicle

Checks must include: Product testing (microbiological /
• Packaging integrity
chemical / physical /
• Evidence of pest infestation (low levels may be

organoleptic)

•
acceptable in some produce materials)
Date/Lot coding (meets specification and matches
• Temperature (where required)

COA where received)
• Product inspection to demonstrate compliance to

specification (which must be agreed and include
• Pallet condition
quality standards)
P O 3.13 Base Stock Rotation A Stock rotation system must be in place to ensure that
raw materials are used within agreed shelf-life. Oldest
material should be used first.
In some instances e.g. with fresh produce, maturity may

be used to determine the order of use.
O 3.14 Base Date Code All materials available for use must have adequate shelf-
Controls life remaining for the final use of the material.
P O 3.15 Base Part-Used Raw Opened or part used containers of raw materials must be
Materials effectively re-sealed and labelled.
O 3.16 Base Segregation of Sensitive materials e.g. vegetarian, organic and materials
Sensitive and susceptible to other pungent materials (due to potential
Hazardous taint risk), must be suitably segregated to reduce the risk
Materials of cross contamination or taint.
Hazardous materials e.g. citric acid, alcohol, flammable

flavourings/aromas, must be suitably stored and
controlled to reduce the risk of contamination, taint and
injury to persons.
(See sections 11.10 and 13.2)

P O 3.17 Base Non Non Conforming materials must be rejected at intake.
Conforming Where this is not possible the Hold and Release
Materials procedure must be followed see Section 11.4.

P R 3.18 Base Supplier Raw material supplier performance must be reviewed
Monitoring minimum annually.
• Risk assessment
This should include results of:
• Intake inspections
• Testing
• Delivery performance
SECONDARY SITES AND CONTRACT PACKERS

P R 3.19 Base Secondary Sites The supplier and primary site must be able to
and Contract demonstrate that they have controls/systems in place to
Packers effectively manage product safety, legality and quality
when using secondary sites and/or contract packers.
P R 3.20 Base Secondary Sites The supplier and primary site must hold a detailed
and Contract specification for the product produced /packed by
Packers secondary site and/or contract packer.
P R 3.21 Base Secondary Sites The secondary site and/or contract packer must be
and Contract approved and have ongoing audits by the supplier and
Packer Audits primary site.
Audits must be completed against a format which

encompasses the principles of the Tesco Food
Manufacturing Standard.
Suppliers and primary site auditors must be trained
against the Tesco Food Manufacturing Standard before
auditing secondary sites and/or contract packers.

major non conformances are found.

existing supplier, which could impact on Tesco products
in the supply chain, Tesco must be informed
immediately. The same applies if 4 major non
conformances are found.

corrective actions must be agreed by both parties.
The completion of corrective actions must be verified
within the agreed timescale.
P R 3.22 Base Intake Checks All products must be checked by trained staff on receipt Based on risk assessment checks may
For Products according to documented procedures. Intake records also include:
•
From must be retained.
•
Secondary Sites Product sampling for retention

and/or Contract Checks must include: Product testing (microbiological /
• Packaging integrity & pallet condition

Packers chemical / physical /
• Evidence of pest infestation

organoleptic)
• Date coding & Lot / batch coding

• Temperature (where required)
• Product inspection demonstrating compliance to
specification (must be agreed & include quality
standards).

Section 4 Packaging

Base
Section Medium
No.
Aspiration
P 4.1 Base Supplier Risk An effective packaging supplier control system must be
Assessment in place for all packaging.
• Functionality
All packaging suppliers must be risk-assessed, based on:
• Contact with food (see clause 4.3)

• Volume of product supplied
• Supplier history
• Method of supplier approval

Risk assessment must be used to determine:
• Method of supplier monitoring
The packaging supplier risk assessments must be

reviewed on an annual basis.
P R 4.2 Base Supplier A supplier approval system must be in place for all If risk assessment indicates that the
Approval packaging supplier is low risk, a Supplier Self
Audit may be used. Provided the
• Approved site audit report

Approval may include a combination of: response to this is satisfactory, an
• Valid 3rd party certificate e.g. BRC-IOP (certificate

audit may be waived.
• Supplier self audit report which has been reviewed

date still current)
If the risk assessment indicates that
and corrective actions followed up. certification to a third party standard
is sufficient, then a valid certificate
All packaging suppliers must have a traceability system and audit report must be available
in place to trace packaging. on site.

P R 4.2.1 Base Contingency Where a contingency packaging supplier is required, the
Supply site must first contact the Tesco TM for acceptance.
Where agreed the site must have the following

information about the product and supplier (as a
minimum):
•
•
•
•
Documentation to demonstrate compliance with
any Tesco COPs
Contingency suppliers are those used at very short

notice, generally as a one off due to approved suppliers
being unable to supply.
Packaging must be on a like for like basis

P R 4.3 Base Supplier Food contact packaging suppliers must have BRC / IOP The third party audit report will
Approval certification or a similar accreditation, confirming safety provide the site with details of non-
of packaging (and packaging production methods) or conformances, which will assist in
must have been physically audited. the site being able to make a full
and proper risk assessment. (e.g. the
Audit reports must be available on site along with a report may show a number of
corrective action plan. failings in Quality Management
systems, which the site may wish to
verify for themselves)
A certificate does not necessarily

demonstrate closure of non-
conformances. Not all third party
Food Safety schemes issue
certificates on the closure of all non-
conformances. Some verify at next

audit.
Where electronic systems are used

by Certification Bodies for site
reports and certificates, these may
be used to negate the need to print
relevant information. Site however,
should be able to demonstrate they
can navigate the system.
P R 4.3.1 Base Supplier Where sites (or sister companies) manufacture their own
Approval food contact packaging e.g. cans, blown bottles etc.
these operations should be treated as suppliers and
managed as per clause 4.3
P R 4.4 Base Audit If risk assessment indicates that a site audit is required,
Requirement the site must be audited before supply commences, and
then according to an audit schedule.
Audits must be completed against good manufacturing

principles.

major non conformances found.

existing supplier, which could impact on Tesco products
in the supply chain, Tesco must be informed
immediately. The same applies if 4 major non
conformances found.


corrective actions must be agreed by both parties. The
completion of corrective actions must be verified within
the agreed timescale.
R 4.5 Base Approved All suppliers must be approved. Details of suppliers and
Supplier List the packaging supplied must be kept on an approved
supplier list.
P R 4.6 Base Trained Supplier audits must be completed by trained auditors
Auditors with an understanding of processes and the risks
associated with the packaging/site being assessed.
P R 4.7 Base Agent Approval Where packaging is supplied via an Agent/Importer:
• It is the manufacturing site and not the
•
Agent/Importer that must be approved
The Agent may be assessed by the Tesco supplier as
competent to manage approval of the manufacturing
site
The Agent/Importer must be able to demonstrate that

they have assessed the site against Tesco requirements.
P R 4.8 Base Specifications Packaging specifications must be agreed by both parties. Both parties have signed and dated
the specification.
Specifications should include the following information
• Supplier Name and Address

where relevant: Electronic signatures are acceptable.
• Artwork
• Material composition
• Dimensions including thickness and gauge
• Colour
• Suitability for use in different storage / handling
• Confirmation of migration test results (see 4.9

conditions e.g. temperature / humidity
below)

R 4.9 Base Food Contact All food contact materials must comply with legislation Sites should keep themselves up to
Materials for “material and articles intended to come in contact date on the legislation, as amends
with food" Regulations (EC) 1935/2004 or equivalent; as are made on an almost annual basis.
applied in the country of manufacture and intended
country of sale.
A written declaration of compliance must be available. The regulations cover the packaging
A food contact material also includes items other than material, inserts, printing materials
finished product packaging (see clause 7.5.1). (e.g. inks) and adhesives which are
in direct contact with the product.
P R 4.10 Base Intake Checks All packaging must be checked by trained staff on A controlled packaging library is
receipt according to documented procedures. Intake retained.
records must be retained.

Checks must include: Print text is checked against the
• Packaging integrity
packaging library every new print
• Evidence of pest infestation

run.
• Date/Lot coding
• Product inspection to demonstrate compliance to
• Pallet condition
specification
P O 4.11 Base Non Conforming Non Conforming materials must be rejected at intake.
Materials Where this is not possible the Hold and Release
procedure must be followed see section 11.4.
The Hold and Release procedure must be used for

obsolete packaging materials.
P R 4.12 Base Supplier Packaging supplier performance must be reviewed
Monitoring minimum annually.
• Risk assessment
This should include results of:
• Intake inspections

• Delivery performance
P O 4.13 Base Storage Packaging must be stored in a designated area and be For example similar recipes
suitably covered to protect from contamination. (cookies with/without nuts),
different pack sizes (may only have
Similar packaging must be stored separately to prevent different bar codes), promotional
incorrect use. flash labels etc should be segregated
or suitably controlled.
Good segregation may take the form

of product labels separated by
promotional labels, dedicated pallet
spaces in the case of large quantities
or post office style sorting box.
P O 4.14 Base Part-Used Part-used packaging should be returned to storage and
Packaging suitably covered to protect from contamination after use.
Based on risk assessment bulk packaging (e.g. films,

plastic for bases) which is used daily for all products
may be left on line provided it is suitably covered to
protect from contamination and is removed and covered
during cleaning.

Section 5 External Areas and Site Security

Base
Section Medium
No.
Aspiration
P R O 5.1 Base Site Location The site must comply with local regulations regarding
approval or registration of premises and processes.
O 5.2 Base Site Boundaries Site boundaries must be clearly defined and have Entrance to the site via a manned
adequate perimeter fencing. security barrier / check point.
A site plan must be available on site. Where no fencing exists (e.g. the
site is on a business park, isolated
location in countryside etc) the site
should be secure to prevent
unauthorised public access,
domestic animals and unlawful
entry.
O 5.2.1 ASPN Site Boundaries Site should be surrounded by secure fencing and
monitored by closed circuit Television (CCTV).
O 5.3 Base External External areas must be kept tidy and free from No redundant or stored equipment
Maintenance unnecessary items that could provide potential pest stored outside.
harbourage.
O 5.3.1 Base External The yard area should have adequate drainage to prevent
Drainage pooling of water around storage and process areas (e.g.
milk reception) and allow cleaning.
O 5.3.2 ASPN External External drains should be visually identified as factory Painted colour coded arrows on the
Drainage effluent, surface water or sewage and show direction of drain covers, showing direction of
flow. flow and waste type.
O 5.4 Base Grass / Planted When present, vegetation must be kept trimmed and clear
Areas from the production and storage buildings
(approximately1 metre clearance, to prevent pest
harbourage).
Where this is out of the sites control (e.g. site is rented or

neighbouring site is close and they don’t keep vegetation
at bay) there should be evidence of persistent
communications and management of potential issues.
O 5.5 Base External Storage External units (including silos, tanks, chillers & freezers)
Units must be kept locked and have restricted access.
O 5.5.1 ASPN External Units Other external units (e.g. port-a-cabins) which are close Units should be sited on a concrete
to the ground, with large inaccessible voids underneath base and or sealed at base to
should be made inaccessible to rodents. prevent pest ingress.
P O 5.6 Base External Storage Raw materials, packaging and equipment must not be
of Raw stored outside.
Materials,
Packaging, Where unavoidable, items must be in a hygienic
Equipment condition and protected from deterioration,
contamination, pests and must be inspected in detail prior
to transfer to the site. This includes all Tesco reusable
product crates.
P R O 5.7 Base Photographic / The use of photographic/recording equipment must be Visitor / contractor procedures
Recording controlled. include a declaration of any
Equipment intended use of
Only equipment authorised by the site must be permitted photographic/recording equipment.
on site.
P R O 5.8 Base Control of All visitors and contractors must sign in and when Entrance to the site via a manned
Visitors, unannounced, prove their identity. security barrier / check point.
Contractors
All visitors must be accompanied at all times.
A system must be in place to manage contractors and a

manager must be accountable for their movements.
P R O 5.9 Base Control of Access to production and storage areas must be restricted Security guard is on site.
Employees to authorised personnel i.e. employees.
P R O 5.9.1 ASPN Control of A controlled access security system may be in place for
Employees all employees e.g. swipe cards, coded access.
Personnel are encouraged to challenge unknown visitors.

O 5.10 Base Guard Dogs Dogs and other animals should not be present around the
site (see section 26).
Guard dogs (if utilised) must be under the control of

security guards and not free running.

Section 6 Design and Construction of Premises

Base
Section Medium
No.
Aspiration
O 6.1 Base External The structure and fabric of the building must be suitable
Structure & for use, weather proof and pest proof.
Fabric
O 6.2 Base Internal Walls, floors, ceilings, drains and doors must be designed
Structure and maintained to allow effective cleaning. They must be
maintained in a good condition to prevent foreign body
risks.
O 6.2.1 Medium Internal Walls, floors, ceilings, drains and doors must be Swing doors with kick plates.
Structure constructed of impervious materials in open food areas. Floors are anti-slip
Wall/floor junctions must be coved to allow easy

cleaning.
Walls must be protected against damage during normal

use e.g. crash barriers where appropriate.
O 6.2.2 High Internal There must be a floor to ceiling physical barrier between If openings between low risk and
Structure low risk and high care / risk. high care/risk are essential, hatches
should have an interlocking door
Openings between low risk and high care/risk must be arrangement i.e. can not open one
kept to a minimum. Where openings exist (excluding door if the other is open. (also see
main personnel door) they must be risk assessed, clause 11.13.1)
managed and verified.
O 6.2.3 High Internal No roller lifting doors are acceptable in high risk / high
Structure care areas, as they will be in contact with the floor (a
potential Listeria spp present) and when raised may drip
on materials / personnel.

O 6.3 Medium Fabrication Fabrication joints must be sealed and free from mould
Joints and not pose a foreign body risk.
O 6.4 Base Floor Gradients Floors must have adequate slope to drainage and not
form pools water.
The gradient should not be excessive to cause wheel

bases / trolleys to roll to drain.
O 6.5 Base Sinks All sinks in production areas must not be constructed
from porous or breakable material.
Sink waste water must be ducted directly to a drain.
(Specific requirements for hand washing are detailed in

clause 8.15)
O 6.6 Base Drains Drains must be accessible for cleaning and fitted with
screens or traps to prevent pest entry and odours.
R 6.6.1 Medium Drains A drain plan must be in place for the entire site (inside
and outside).
R O 6.6.2 High Drains Drains must flow from high to low risk areas.
A system must be in place to prevent back flow.

O 6.6.3 ASPN Drains A separate drainage system for high risk/high care from
low risk areas.
O 6.7 Medium Walkways Over Walkways and steps over production lines must be fitted
Lines with back plates and enclosed sides to prevent product
contamination.
O 6.8 Base Windows Glass windows and doors in the production and storage
areas must be protected from breakage.
A risk assessment must be completed on surrounding

areas to establish the potential risk of transfer.

O 6.8.1 Base Windows Windows designed to be open, must be suitably proofed
to prevent pest entry (including canteens, toilets and
locker facilities that adjoin the factory).
O 6.9 Base External Doors All external doors must be kept closed when not in use Good door control should be in
and effectively proofed against pests. place (i.e. doors not being left open
for long periods to temperature
If strip curtains are fitted, they must be maintained and controlled areas, or allowing free
kept clean. and effectively proofed against pests. access to birds)
Strip curtains should be full length

and intact. Curtains which part
(slide) on opening of main door are
preferred, as these do not trail over
forklift trucks and products and are
therefore easier to keep clean and
less prone to damage.
P O 6.9.1 Medium External Doors There must be no external doors in open food handling
areas with the exception of identified and controlled fire
exits.
If a close fitting mesh screen is in place, these doors can

be opened to provide ventilation. These doors must not
however be used as personnel routes other than in
emergency situations.
O 6.9.2 High Fire Doors Fire exits from high risk/high care must be alarmed or
tamper evident.
P R O 6.9.2.1 High External Doors Where used, a removable wall section (pod door)
between the high care/ risk and low care wall (to allow
for introduction / removal of large equipment) must be
close fitting and sealed each time after opening.
A full deep clean of the high care/risk environment must

be undertaken if removed, before production
recommences.

O 6.9.3 ASPN External Doors Air curtain or automatic closing doors should be fitted to
external doors.
O 6.10 Base Lighting Lighting in all areas must enable safe working and good
visibility.
Lights must be protected by shatter proof covers and or

sleeves (on the light tubes / bulbs).
Adequate lighting must be in place above product

inspection areas.
O 6.10.1 ASPN Lighting Lighting designed so that bulbs are replaced without
entering production areas.
O 6.11 Base Ventilation and Ventilation and extraction systems must be effective at Risk assessment may need to be
Extraction preventing condensation, excessive dust, pest entry and used in order to determine that
not pose a risk to product (e.g. its location in respect of where condensate is present,
product and processes). samples may need to be sent away
for microbiological and heavy
Similarly if heating is provided. metal screening e.g. chocolate
manufacture.
R O 6.11.1 Medium Ventilation and A documented risk assessment must be conducted to
Extraction determine the requirement for air filtration.
Where air filtration is in place, it must be regularly

inspected and replaced.
R O 6.11.2 High Ventilation and An air filtration system must be in place and be regularly High care - filtration to a minimum
Extraction inspected and replaced. F7* filter grade must be in place.
The filter grades used must be risk assessed to ascertain High risk - filtration to a minimum
the risk from airborne contamination from the local F9-H11* filter grade must be in
environment and the likely occurrence of product place and positive air pressure.
contamination e.g. time product is exposed.
*Under Classification of General
Positive air pressure (>5 Pascals) must be in place in Ventilation Filters EN779:2002

high risk areas and monitored at defined frequencies.
Note: Grades are based on the
An initial assessment / study to measure air pressure efficiency of the filter to trap
must be held by the site. defined particle sizes. F7 grade is
80% efficient and F9-H11 is 98%
efficient.
Generally 5-25 air changes per hour

are sufficient, however in areas
with large doors/hatches that are
frequently opened up to 40 changes
may be required.
O 6.11.3 Base Ventilation and Air socks must be cleaned and maintained at a scheduled
Extraction frequency. Frequency must be adequate to prevent build
up of debris / mould growth.
O 6.11.4 High Ventilation and Air socks must be identified for rotation. High Risk and
Extraction Low Risk air socks should be washed separately.
O 6.12 Base Services All services (pipework for water/gas/steam/compressed
air, electrical cabling/conduit/sockets, ventilation
ducting, compressors/pumps, fire extinguishers/sprinkler
systems etc) should be designed from material suitable
for the purpose and appropriate to the area where used,
intact and allow easy and effective cleaning.
(Health and Safety requirements in the country of

manufacture must be adhered to).
O 6.13 Base Storage Areas Storage areas must be fit for purpose and maintained in a Racking where fitted should be far
clean / hygienic condition. enough away from the wall, to
prevent pallets being pushed up
Materials must not be stored directly against the walls to tight against the wall.
allow inspection.
There should be enough space to
allow walking access between
materials and walls for inspection.

O 6.14 Base Temperature Condensate pipes must flow to drain and not drip on Pipe should end a few centimetres
Controlled product, materials, packaging or production equipment. above the drain and not ducted
Areas directly into the drain.
O 6.14.1 Medium Temperature Condensate pipes must have a trap in the pipe work to Traps are “U” or “S” type which,
Controlled prevent a back flow of air from the drains and condensate contain water, thus preventing air to
Areas must be channelled directly out of the area to a drain in be drawn back.
fully enclosed pipe work.
There should be no break in the
pipe work.
P R O 6.14.2 High Temperature A risk assessment must be carried to determine if Sanitising rings do not negate the
Controlled chemical sanitizing rings are required in condensate drip need to maintain the evaporators
Areas trays. and pipe work properly.
O 6.14.3 ASPN Temperature Doors to temperature controlled areas should be
Controlled automatic closing or alarmed if not closed.
Areas
O 6.14.4 Base Temperature Temperature controlled areas must be capable of
Controlled maintaining the required temperature.
Areas
Freezer areas must be adequately maintained to prevent
excessive build up of ice on walls, floors and ceilings.
O 6.15 Base Production Offices within production / storage areas must be Offices should have basic
Offices managed so that they do not pose a risk to product. equipment (desk, chair, storage,
computer etc) which is of an easy to
Equipment must be kept to a minimum to allow easy clean construction.
cleaning.
They should not be adorned with
Eating and drinking is not permitted in these offices, with personal items (e.g. collectables,
the exception of plain drinking water. cups, bottles etc)
Stationary items should be

consistent with site rules and GMP
(e.g. factory issue pens, no staples,
no drawing pins etc)

P O 6.16 Base Product Sampling of product must only be permitted in areas A separate room containing hand
Assessment clearly designated for this purpose (following a risk washing facilities.
Areas assessment).
After product sampling, hands must be washed.

Additional Food industry guides can be useful tools to aid the Compliance with industry guides
Comment Design & Construction of Premises: such as those listed, may not meet
- Campden BRI “Guidelines for the hygienic design, Tesco requirements in full and are
construction and layout of food processing factories” No listed only as a possible reference
39 (www.campden.co.uk) texts.
- Chilled Foods Association (CFA) - Hygienic Design
Guidelines. (www.chilledfoods.org)
- Campden BRI “Guidelines on air quality standards for
the food industry” No 12 (www.campden.co.uk)

Section 7 Design and Construction of Equipment

Base
Section Medium
No.
Aspiration
O 7.1 Base Design and All equipment must be designed and constructed to Angles, corners and dead spaces are
Construction enable hygienic cleaning and maintenance. eliminated.
It must be maintained in a good condition to prevent

foreign body risks. Equipment should not be located
too close to sinks, waste units,
The layout must not pose a risk of contamination. allergen production, washing etc
R O 7.2 Base Risk Assessment All equipment must be properly specified, commissioned
and risk assessed for food safety prior to use.
O 7.3 Base Construction All surfaces including welds and joints must be smooth Food contact surfaces should have
and impervious. continuous welds, be free of
inaccessible crevices, excessive
scratches and pitting to prevent the
trapping of food debris.
O 7.4 Base Construction Equipment must be constructed from materials that are
not susceptible to damage under normal usage and
cleaning.
O 7.5 Base Construction Parts susceptible to wearing on mechanical equipment
e.g. belts, brushes and scrapers that come into contact
with food, must be of a contrasting colour to the food and
be regularly inspected/monitored for wear and damage.
R 7.5.1 Base Construction All food contact materials e.g. work in progress
packaging /trays, production belts, chopping boards, food
contact utensils etc must comply with legislation for
“material and articles intended to come in contact with
food" Regulations (EC) 1935/2004 or equivalent; as
applied in the country of manufacture and intended
country of sale.

A written declaration of compliance must be available.
O 7.5.2 High Construction Equipment in high care/risk must be designed to allow Quick release mechanisms for belts.
easy and quick strip down for detailed cleaning. Good access for inspection and
manual cleaning inside equipment.
Electrical cabling and air pressure lines must be
considered.
O 7.6 Base Location Equipment must be sited to give access under, inside and
around to allow cleaning and servicing.
Equipment must be sited away from potential risks of

contamination (e.g. not to close to a hand wash sink).
O 7.7 Base Mobile Mobile equipment e.g. forklift trucks, pallet trucks Mobile equipment should be stored
Equipment scissor lifts and ladders must be clean, maintained and away from packaging and food
stored in a suitable area when not in use. ingredients, when not in use.
O 7.7.1 Medium Mobile Battery charging equipment must not be stored in open Equipment with maintenance free
Equipment food areas. Mobile equipment e.g. forklift trucks and batteries may be charged in these
pallet trucks that are used in open food areas must not be areas, provided they are stored
used outside. away from open food processes.

Section 8 Employee Facilities and Personal Protective Equipment

Base
Section Medium
No.
Aspiration
O 8.1 Base Employee Employee facilities (including rest area, toilets, locker Separate facilities are provided
Facilities areas and changing areas) must be provided and where appropriate e.g. Abattoir
maintained in a clean and hygienic condition. lairage employees separate.
Smoking areas where provided, must comply with in

country legislation. Where provided they must be
maintained in a clean condition and have bins for the tabs
/ butts (to prevent transfer into the factory on soles of
shoes). No tabs / butts can be disposed of on the floor.
O 8.2 Base Employee All sites must have a dedicated space to allow employees No personal items should be carried
Facilities to leave their own belongings and to change into and out by staff. Facilities should be secure,
of protective clothing. giving staff (including agency and
temporary workers) the confidence
Field workers should have suitable storage facilities. to leave their belongings.
Facilities must be provided for the collection of

used/dirty work wear (adequate for the number of staff
on site).
O 8.2.1 Medium Employee Changing areas and locker rooms must be sited so The same should be applied to
Facilities employees are not required to go outside after changing visitors/management and
into their protective clothing, including footwear (see visitor/management changing areas.
clause 8.14.1)
O 8.3 Base Employee Storage areas for work wear and laundry areas must be
Facilities clean and protected from contamination (and adequate
for the number of staff on site).
O 8.4 Base Employee Personal outdoor clothing must be segregated from work Lockers are clearly partitioned to
Facilities wear. segregate items.
Lockers must be kept clean and in good condition. Hooks are provided outside lockers

for work wear.
Lockers must be cleared regularly and not used to store
food.
O 8.4.1 Medium Employee Personal outdoor shoes must be segregated from work
Facilities shoes.
O 8.4.2 High Employee Lockers require sloping tops and to be raised off the floor
Facilities to prevent accumulation of rubbish and to facilitate
cleaning.
8.4.3 Base Employee Where staff are required to change footwear, floors must
Facilities be kept clean and be dried adequately after cleaning.
O 8.4.4 ASPN Employee Lockers in all areas (base & medium) should have
Facilities sloping tops and be raised off the floor to prevent
accumulation of rubbish and to facilitate cleaning.
Locker rooms should be warm and have adequate seats/

benches to making changing clothing easy.
R O 8.4.5 ASPN Employee Locker inspection/audits are carried out at a defined Inspections are undertaken to check
Facilities frequency. compliance with site rules (e.g.
factory PPE in outdoor clothing
lockers). Employee should be
present.
O 8.5 Base Employee Toilets must be segregated from production and storage
Facilities areas by a minimum of 2 doors with an intervening
ventilated space.
The doors must be self closing.
The toilet area must be ventilated.
Hand wash sinks and drying facilities must be present.
Hand washing signs must be displayed in toilet areas.

Coat hooks must be located outside the toilet area.
P 8.5.1 Base Employee Where showers are provided for employees there must be Legionnaires’ Disease: The control
Facilities a system in place to ensure the shower heads do not pose of Legionella bacteria in water
a potential contamination / health risk to employees (see systems. Approved Code of
also 17.1). Practice and Guidance 2000
(www.hse.gov.uk)
O 8.5.2 ASPN Employee Toilets must be ‘fit for purpose’ for the ethnicity of staff.
Facilities
O 8.5.3 ASPN Employee Taps in toilet facilities should be mixer taps not be hand
Facilities operated.
R 8.6 Base Canteen / Rest Sites providing food service must complete a
Area documented HACCP for this service.
If a contractor is used, their HACCP must be reviewed.

P R 8.7 Base Canteen / Rest Basic hygiene and food safety audits must be completed
Area on a scheduled basis by an appropriately trained person.
R O 8.7.1 Base Canteen / Rest Canteen staff must have medical screening prior to
commencement of work and be suitably trained in basic
food hygiene.
Hairnets covering ears must be worn.

O 8.8 Base Canteen / Rest Hygienic storage facilities, including refrigeration must Food left by employees should be
Area be provided for employees bringing their own food. removed as necessary.
The temperature of refrigeration equipment must be Temperature of refrigeration

monitored. equipment is checked at a defined
frequency.
Where preparation equipment (e.g. microwave) is
provided it must be inspected and cleaned regularly.
Consumption and storage of food must only be in

designated areas.

A cool box is provided to allow
Field workers should have basic storage facilities for staff to leave their lunch in a
food, provided. hygienic location.
O 8.9 Base Head Covering Head covering must be worn by all personnel. (If food is A clean company issue hat that is
not exposed, head covering and beard snoods are not regularly laundered / disposable.
required).
O 8.9.1 Medium Hair Covering Hair and ears must be fully enclosed by the hair Single use hairnets or mop caps
covering. worn.
Beard snoods must be worn to cover beards and

moustaches.
Warm fabric style hats (if permitted at the site), turbans

or other headdresses must be fully covered by the hair
covering.
Where face masks are worn, staff must wash hands after
touching / readjusting them.
O 8.9.2 High Hair Covering Single use disposable hairnets or mop caps must be High care / risk hairnets should be
worn. placed over the top of low risk
hairnets rather than constant
No cloth (washable) hair covering is worn without a removal.
hairnet.
P O 8.10 Base Protective Protective clothing must be supplied and worn to A full complement of different
Clothing minimise the risk of product contamination. coloured PPE should be worn i.e.
coats and footwear (including
Protective clothing must be visually distinctive for staff gloves and aprons where worn).
in specific areas / roles where appropriate i.e.
maintenance and cleaning personnel. Coats may be distinguished by
coloured collars.
Protective clothing must be maintained in good clean
condition. A procedure must be in place to manage Coats should be free of rips, tears,
repairs including the control of pins and needles. loose threads and missing poppers
etc

O 8.10.1 Medium Protective Protective clothing must cover all personal clothing Hoods on personal clothing must be
Clothing above knee height. Arms must not be exposed, unless under the protective clothing.
risk assessment deems there is a risk to product safety
from coat sleeves. Consideration should be given to
not wearing factory coats in
Protective clothing must be free from external pockets, engineering workshops.
buttons and not have access to own pockets.
Engineers should not wear their workshop coats in the

factory during production.
O 8.10.2 High Protective High risk / high care coats must be captive to the area A bulk bag containing individual
Clothing and be protected from contamination until transferred sealed bags from the laundry.
into the area.
Protective coats must be visually distinctive and be close Coats incorporating head covering
fitting at the neck and cuffs. in use.
P O 8.11 Base Protective Coats/jackets must be removed before entering toilets,
Clothing canteen/rest areas, smoking areas and offices (outside
production areas).
O 8.11.1 Medium Protective Protective clothing worn above the knee must be
Clothing removed in non-production areas (excluding footwear).
Where knee length coats are not worn, staff should

change out of company issue trousers.
Exemption requires written permission from the Tesco

Category Technical Manager (Tesco CTM).
O 8.11.2 ASPN Protective All-in-one boiler suits should be phased out.
Clothing
R O 8.12 Base Protective Frequency of changing protective clothing (including re- Frequency determined by visual
Clothing usable aprons, gloves, high visibility vests and hard hats) assessment.
and disposable items must be defined and verified.

R O 8.12.1 Medium Protective Coats must be changed daily. The frequency of changing Frequency is determined and
Clothing protective clothing (including re-usable aprons, gloves, verified through bacterial swabbing
high visibility vests and hard hats) and disposable items or contact plates.
must be defined and verified.
R O 8.12.2 High Protective Coats must be frequently changed (minimum daily). The
Clothing frequency of coat laundering and changing of disposable
items throughout the production shift must be verified
through bacterial swabbing or contact plates.
O 8.12.3 High Liner Gloves If liner gloves are worn in high care/risk under
disposable gloves, these must be controlled limiting the
time worn. Liner gloves must be either disposable daily
or collected daily and laundered.
Liner gloves must not be taken in toilet or canteen areas.

R O 8.13 Base Laundry Effective laundering of protective clothing must be Where external laundry providers
completed in a hygienic environment and verified. are utilised, these should be
approved and a specification for the
Non-perfumed detergent to be used. garments held. Effective laundering
by visual assessment of PPE.
Protective clothing for engineering, hygiene (and where
applicable laboratory) staff must be laundered separately
to food production work wear (including canteen staff
PPE) to prevent possible foreign body contamination.
This may be in house or by an external company. In

certain circumstances home laundry programmes may be
permitted. Line drying is not permitted. Staff must not
wear protective clothing to and from work and it must be
transported in a clean bag.
P O 8.13.1 Medium Laundry Home laundering must not be permitted. Where external Bacterial swabbing or contact plates
laundry services are not available the site must provide are used to verify effectiveness.
an in house service.
P 8.13.2 High Laundry High risk / high care coats must be laundered separately
from coats used in other areas.

Laundry audits must be completed and include a
verification of the process. These must be available with
corrective action plans where applicable.
O 8.14 Base Footwear Suitable footwear must be worn (No open toes or high
heels). Footwear must be kept clean.
P R O 8.14.1 Medium Footwear Suitable footwear must be provided and remain captive
to the inside of the building. Short external walkways Where walkways are in place, they
may be acceptable if they are: should be identified with brightly
-clearly defined coloured paint (yellow). They
-well maintained e.g. smooth (non slip) hard surface should connect two distinct
-clean with no debris / pooling water (daily cleaning) locations.
-not connected to smoking areas
If employees enter toilets in their factory footwear, the Toilets area are regularly cleaned
toilets must be maintained to a high standard (i.e. clean and inspected.
floor) to prevent contamination of the production area.
Scheduled footwear cleaning must be in place.
Only disposable shoe coverings that do not rip or tear are

permitted.
P R O 8.14.2 High Footwear Footwear must remain captive to the area and be visually Insulated Wellington boots.
distinctive.
Shoes with laces and shoe covers must not be permitted.
Scheduled footwear cleaning must be in place (minimum

daily). Cleaning effectiveness and frequency must be
verified through swabbing and visual assessment.
O 8.14.3 Base Boot washing Where automated boot washing systems are employed, Boot washers and footbaths do not
these must not be positioned in production areas and negate the need for scheduled
must be cleaned to an adequate frequency. Where auto- cleaning.
dosing of chemical is incorporated, the concentration

should be regularly monitored.
P R O 8.14.4 Medium Footbaths Footbaths should be avoided.
However, where footbaths are in place they must pose no

risk to product and or processes. (e.g. separate room,
after using there is no requirement to use walkways
above product etc). The water and chemicals used must
be changed at defined frequencies throughout the day to
remain effective / active.
O 8.14.5 High Footbaths No footbaths.
O 8.14.6 ASPN Boot Washing Scheduled boot cleaning in place. No footbaths. A dedicated room for washing
boots.
O 8.15 Base Hand Washing Sufficient numbers of hand wash or sanitising facilities Water temperature will be suitably
must be suitably sited (with a logical flow) at all controlled via ring main systems or
entrances and throughout production and storage areas sink specific thermostats. Where
where required. paper towels are used, bins must be
provide at sinks. These bins do not
Where hand wash facilities are provided, they must have require lids but must be emptied
water at a suitable temperature to ensure effective hand regularly.
washing (e.g. approx 37 0C), liquid soap (bactericidal and
non-scented) and effective hand drying facilities. Hand wash water temperature
should be comfortable, neither too
Taps must not be hand operated. hot or too cold, so as to discourage
use.
Signage should be present at hand wash sinks giving
clear instruction on how to wash hands correctly. Elbow/Knee/Foot operated or
sensors in place.
O 8.15.1 Medium Hand Washing Paper towels or an effective alternative must be used for Paper towels should be suitable and
hand drying. If paper towel bins have lids, these must not not tissue like, which break-up
be hand operated. easily whilst drying hands.

Cloth roller towels must not be used. The colour of paper towels are blue
or of a contrasting colour.
R O 8.15.2 High Hand Washing Bactericidal liquid soap and hand sanitiser must be used. Alarm in the production area when
(see clause 10.2). Water temperature should be reapplication of sanitiser required.
monitored and recorded.
Hand washing facilities and/or hand sanitiser must be

located close to employee work stations.
Automatic hand dryers must not be used in production

areas.
P O 8.16 Medium Changing Protective clothing must not be worn without hair Beard Snoods and face masks
Procedure covering. should be put on prior to the final
hand wash.
• Hair covering
The procedure may follow the order below:
• Put on footwear
Where ear protection is worn hands
• Wash hands
should be washed after insertion
into ear.
• Put on coat
P O 8.16.1 High Changing Personnel must enter high risk / high care via a Photographs provided to illustrate
Procedure designated changing area and follow a changing and the changing procedures.
hand washing procedure.
• Put on a clean hair covering

The procedure must follow the order below: Unbreakable reflective surface
• Remove shoes
provided, for personnel to confirm
• Step over barrier or separation between low and high

that protective clothing is correctly
worn i.e. mirror not made from
glass.
• Put on clean high risk footwear
risk / high care areas.
• Wash and dry hands

• Put on coat
• Wash, dry and sanitise hands
• Enter Production area

• Remove coat
On exit the procedure must follow the order below:
• Remove footwear
• Step over barrier or separation between low and high
• Remove hair covering.

risk / high care areas.
P O 8.16.2 APSN Changing The procedure would be as described above (8.16.1) Alternatively automated turnstiles
Procedure however when the individual has put on their coat, they to prevent progress until hands had
would then enter the production hall and wash and been washed e.g. position hands in
sanitise their hands at a sink located just within this area wall sink, wash hands. This action
(away from production lines). then automatically opens the
turnstile / barrier to allow passage
This hand washing operation would then be clearly into the production area.
visible to any supervisor stationed within the production
area.
O 8.17 Base Surplus Stock Prior to any surplus Tesco labelled stock being made The site should have full control
available for purchase e.g. via staff sales, Tesco name over surplus stock and know the
must be removed. This will typically involve products quantities of product. This is
offered for sale being stripped of all Tesco packaging. In particularly important for
cases where it is not possible to remove the packaging, traceability and or product recall.
the Tesco branding and barcode must be masked by an
indelible marker or a non strip label.
(UK Only – If product is not stripped, Fareshare 1st and

Company Shop Ltd are the two authorised routes for
disposal of surplus stock in the UK. Fareshare 1st is a
national charity that re-distributes the food through a
community network to disadvantaged people.
If Tesco product is offered for sale by 'Company Shop

Ltd', it must be printed or stickered with the ‘Company
Shop’ name and address and meet all applicable food
legislation).

Section 9 Factory Hygiene

Base
Medium
P R O Section High Item Detail
Aspiration
O 9.1 Base General Hygiene Equipment and facilities must be maintained in a clean
condition (also see section 29 Cleaning Programme).
P O 9.2 Base General Hygiene The site must operate a ‘Clean as You Go’ Policy with E.g. the use of high pressure hoses
personnel responsible for maintaining a clean and tidy during production or the cleaning of
working area. high level areas without moving
product below.
Methods of cleaning must not pose a risk of
contamination or generate aerosols, which could
contaminate nearby products or surfaces.
P R O 9.3 Base Hygiene There must be a suitably trained manager accountable for Cleaning operations should be
Management overseeing in production cleaning and the standards managed to make sure they pose no
achieved. risk to product (e.g. making sure
hygiene operators move products
and equipment that may be affected
by the clean down process) and
correct methods of cleaning are used
for product type and environment.
P O 9.4 Base Cleaning Personnel must be responsible for keeping their cleaning
Equipment equipment in a good state of repair and in hygienic
condition, replacing when necessary.
O 9.5 Base Cleaning Cleaning equipment must be fit for purpose. Heat set bristles in brushes used on
Equipment food contact surfaces, single blade
Cleaning equipment must not be stored in contact with squeegees in favour of folded blade
the floor. type as these harbour debris and
bacteria.
Where food contact equipment is wall mounted it must
be at a height that poses no risk of contamination (e.g.
shoulder height and not touching the wall).

The floor contact end of cleaning equipment should be
below the height of boot tops.
Wall mounted cleaning equipment must be returned in a

clean condition.
Where floor cleaning equipment is wall mounted it must

be stored handles up.
O 9.5.1 Medium Cleaning The use of mops in open food areas must be risk
Equipment assessed. Multiple-use string mops are not permitted.
Where permitted they must be clean, in a good condition

and stored away from product and production processes.
O 9.5.2 High Cleaning High risk / high care cleaning equipment must be stored
Equipment dry or in disinfectant. Where disinfectant is used, it must
be changed regularly to maintain effectiveness.
Mops are not permitted.

O 9.6 Base Cleaning Separate equipment must be used for food contact and
Equipment floor cleaning. These must be stored separately from one
another.
Cleaning equipment used for other areas (e.g. toilets, Cleaning equipment may be
offices and outside) must be segregated and visually differentiated visually by type and or
distinctive. colour.
Colour coding of cleaning equipment must be

prominently displayed with equipment.
O 9.6.1 Medium Cleaning Cleaning equipment used in open food areas must not be
Equipment used outside. A system to control this must be in place.
P O 9.6.2 High Cleaning A colour coded system must be in place to identify and
Equipment segregate cleaning equipment between high care / high
risk and low risk areas.

O 9.7 Base Cleaning Hoses and chemical dosing equipment fitted to water
Equipment supply must have back flow prevention devices installed.
High pressure lines (>80 psi, 5.5 bar, 5.6 Kg/cm) do not
need backflow protection.
Hoses / cleaning lance ends must not be left on the floor

or in tanks when not in use.
O 9.7.1 High Cleaning High pressure hoses must not be used due to aerosol
Equipment generation/ movement of debris.
P O 9.8 Base Cleaning Cleaning chemicals must be suitable for a food No phenolic or scented products
Chemicals environment (including all toilet areas).
Cleaning chemicals must be kept in a ventilated,

designated store with restricted access.
The store must be bunded or have bunded pallets to

contain spillages.
Chemicals must be separated in storage to prevent

accident e.g. acids / chlorine based chemicals. Health &
Safety guidelines must be followed. Clear signage must
be in place.
O 9.8.1 Medium Cleaning Cleaning chemical storage in production areas must be
Chemicals kept to a minimum.
If they are required in production areas they must be Chemical containers are secured
secured. with a padlock.
O 9.9 Base Cleaning Cleaning chemicals must be used according to the
Chemicals manufacturers’ instructions including temperature and
dilution. (see clause 29.4)
P R O 9.10 Base Cleaning Chemical dilution checks must be completed at a defined
Chemicals frequency for all dosed equipment (manual/automatic)
based on risk assessment.

P O 9.11 Base Cleaning All containers for cleaning chemicals must be correctly
Chemicals labelled and used for their intended purpose only.
O 9.12 Base Cleaning Areas Designated cleaning areas must be kept in a hygienic Areas are sited so they present no
condition with obvious flow of equipment from dirty to risk to product integrity and or
clean. safety.
Areas must have sufficient extraction to minimise

condensation build up.
P O 9.12.1 High Cleaning Areas High risk / high care areas must have their own cleaning
facility.
Items must not be returned to low risk for cleaning,

unless the equipment goes through a heating or
disinfection process on return to high risk / care e.g.
through a heating cycle in an oven.
P O 9.13 Base Production Equipment must be cleaned off the floor (e.g. on racks or
Equipment stands, not on the floor).
P O 9.14 Base Production Sinks for cleaning production equipment must be clearly
Equipment identified and must not be used for floor cleaning
equipment.
Sinks must have hot water and the correct chemical at the
specified dilution.
P R O 9.15 Base Tray Wash Tray / rack wash equipment must be operating at the
correct temperature with correct chemical type and
dilution.
R O 9.15.1 Medium Tray Wash Tray / rack wash equipment must be monitored and
verified. Visual inspection and weekly checks
(minimum).
R O 9.15.2 High Tray Wash Tray / rack wash equipment must be monitored and
verified.
Frequency of chemical concentration checks / water

temperature must be determined by a formal study.
Regular bacterial swabbing is required.
The equipment must be suitable for a High Care / Risk

environment e.g. stainless steel, easy to clean with water
temperature monitoring systems.
O 9.16.1 Base Production Clean equipment must be stored in a manner which Clean utensils, change parts and
Equipment prevents re-contamination. mobile containers such as trays, tote
bins etc. are stored in a designated
area after cleaning, prior to use.
P O 9.16.2 High Production Where product contact equipment has been stored (even If a factory has not been producing
Equipment if visually clean) but is not in daily use, it must be re- over a weekend, holiday or shut-
disinfected immediately prior to use. down period equipment must be re-
disinfected before use.
A risk assessment must be in place where this is not
carried out.
O 9.16.3 Base Production Trays to contain part made product (known as Work In
Trays Progress -WIP) or finished product, must not be placed
directly on the floor (even if dirty and awaiting cleaning.)
Where pallets are used to store these trays, these should

be clean and free of potential contamination.
P O 9.17 Base Waste Waste must be collected in identified containers, Waste trays /containers / bags
correctly disposed of and must not pose a risk to the should be a separate type or different
environmental. colour to those used in production
for food.
Factory WIP or finished product trays can not be used to
collect waste even if labelled as waste.
P O 9.17.1 Base Waste Controlled waste (e.g. unfit meat) must be suitably
segregated and managed. Waste must be collected in
identified containers.
O 9.17.2 Medium Waste Waste must be removed from open food areas in such a
way that it does not present a cross contamination risk.

O 9.17.3 High Waste Waste must be removed from high risk / high care areas
through a one way system.
O 9.18 Base Waste External waste containers must be covered and
segregated.
In certain instances waste may be transported to waste

containers automatically. These containers must be
screened and managed to ensure a tidy pest free
environment.
P O 9.19 Base Waste Waste and effluent management must comply with local
enforcement requirements.
O 9.19.1 ASPN Waste Facilities should be in place for segregation and
collection of recyclable materials.
P R O 9.20 Base Waste Any rejected Tesco labelled product must be securely
disposed of through an authorised route or the Tesco
packaging must be removed.

Section 10 Personal Hygiene

Base
Medium
Aspiration
P R O 10.1 Base Personal Effective personal hygiene standards must be in place at
Hygiene the site.
Personal hygiene standards must be documented and

followed by all personnel, including visitors and
contractors.
Visitors and contractors must be required to read,

understand and accept health, hygiene and safety rules
prior to entering the production area.
P R O 10.2 Base Hand Washing Hand washing or sanitising must be completed on entry 1. Wet hands
to food handling areas and after the following (this is not 2. Apply soap
an exhaustive list): 3. Rub palms and back of hands/
• Eating
thumbs and between fingers -
• Smoking
repeat each area 5 times.
• Using the toilet

4. Rinse with water
5. Dry hands
• Coughing /sneezing into hands
• Touching the face / nose
• Touching or picking up items from the floor
• Tying laces
• Or handling unsuitable materials
• Using ladders
P R O 10.2.1 Base Hand Washing Non food handlers must wash hands (as per clause 10.2)
when they commence work but may subsequently use
hand sanitizer on entry to non food handling areas e.g.
despatch

P R O 10.2.2 Medium Hand Washing Hand washing and sanitising must be completed on entry 1. Wet hands
to food handling work areas. 2. Apply soap
3. Rub palms and back of hands/
The effectiveness of hygiene procedures with regard to thumbs, and between fingers –
hands must be checked at regular intervals. repeat each area 5 times.
4. Rinse with water
If gloves are worn, hygiene procedures (including 5. Dry hands
frequency of changing) must be in place to ensure that 6. Apply and rub in sanitizer.
they do not present a risk to product.
No nail brushes are to be used.
Hand swabs or contact plates are taken and assessed
following an unannounced but planned programme.
P O 10.3 Base Hygiene Personnel must not cough or sneeze over materials or
Procedure products.
Spitting must be prohibited in all areas.

P O 10.4 Base Hygiene Food / drink must not be consumed in production and
Procedure storage areas (except water when provided by site).
See also 6.16 for product sampling.
P O 10.5 Base Personal Procedures must be in place to control the use of
Medicines personal medicines.
R O 10.6 Base Plaster Control All cuts and grazes on exposed skin must be covered by a
waterproof blue metal detectable plaster / wound
dressing provided by the factory and issued by an
authorised person (a log must be kept). (Clearly where
metal detection is not used on site, the plaster does not
need to be metal detectable. They must still be blue.)
Procedures must be in place to highlight if a plaster is

lost and prompt an investigation to ensure that the plaster
has not contaminated product must be completed.
O 10.6.1 Medium Plaster Control In addition to the metal detectable plaster, a waterproof
finger stall or waterproof glove must be worn.

R O 10.6.2 High Plaster Control There should be plaster reconciliation at the end of the
day or shift.
P R O 10.6.3 ASPN First Aid Kits First aid kits should contain an inventory of contents, First aid box contents and quantities
which is checked at defined intervals. should be selected so as to minimise
the risk of product contamination.
P O 10.7 Base Personal Fingernails must be kept short, clean and unvarnished.
Hygiene
False fingernails (acrylic or other) must not be permitted.
P O 10.8 Base Personal All personnel must have a good standard of personal
Hygiene hygiene.
P O 10.9 Base Personal Excessive perfume or aftershave must not be worn.
Hygiene
P O 10.9.1 Medium Personal False eye lashes or excessive facial make-up must not be
Hygiene worn.
P O 10.10 Base Personal Personal items (e.g. keys, personal mobile phones and The exception being locker keys and
Hygiene coins) must not be carried on the person and be taken ID cards, where provided.
into production and storage areas.
Keys used within the factory (e.g.
metal detector reject boxes) should not
be treated as personal items and
attached to key rings or taken home.
These are best issued daily as part of
the QA kit.
Combination locks prevent the need

for keys.
P 10.11 Base Personal Procedures must be in place for the breakage/loss of
Hygiene glasses and contact lenses.
P O 10.12 Base Jewellery Jewellery must not be worn, with the exception of a
single plain band ring (i.e. one piece with no stone
settings or intricate design). Cufflinks and tie pins must
be considered as jewellery.

Watches must not be worn or brought into production
and storage areas.
Rings and studs in exposed parts of the body (including

the tongue) must not be worn.
Personal clothing and fashion accessories should not

pose a potential foreign body risk (e.g. decorative items
such as sequins should not be sewn on garments,
diamante settings in glasses etc).
P R O 10.13 Base Jewellery Additional jewellery may be permitted if it is worn for
medical or religious reasons.
In these circumstances a risk assessment must be

completed and the permitted jewellery must be strictly
controlled.
P O 10.13.1 Medium Jewellery Permitted medical or religious jewellery is not exposed Jewellery should be suitably covered
or pose any food safety risk. by the PPE (coat, sleeves and or
gloves)

Section 11 Process Controls

Base
Medium
Aspiration
R O 11.1 Base Process Control Raw materials, work in progress, finished product,
processes, storage and equipment, when they are critical
to product safety, legality or quality, must be controlled,
monitored and recorded.
P R O 11.2 Base Process Claims Records must be in place to substantiate all product
claims e.g. smoked, roasted, slow cooked.
P R O 11.2.1 Base Process Claims Where Quantitative Ingredient Declaration (QUID) is
applicable (EU only) and detailed in the Tesco
specification / present on the product label, this must be
verified at predetermined frequencies to confirm
accuracy.
R O 11.3 Base Process If the process deviates from specification / procedure,
Deviation then corrective action must be taken and documented.
If the product deviates from the agreed specification the

Tesco Technical Manager must be notified.
R O 11.3.1 ASPN Trend Analysis A trend analysis system should be used for monitoring
process deviation, to enable a reduction in non-
conformances and business/product improvement.
P R O 11.4 Base Hold and A documented ‘Hold and Release’ procedure must be in
Release place to manage non conforming materials or products.
As a minimum, this must include:
•
•
The nature of the incident
Time / date material or product is put on hold /
•
quarantined
•
How it is identified
The method to ensure all affected product has been

•
isolated
How and who has authority to release product, re-
grade or reject it
All decisions must be risk assessed in line with the nature

of the incident.
R O 11.4.1 ASPN Hold and A computer based system should be used for monitoring
Release product or material on hold / quarantined and the
outcome of the incident.
O 11.4.2 Base Hold and A defined area must be identified and marked out for the
Release storage of quarantined finished product. This can be via
portable / retractable barriers.
O 11.4.3 ASPN Hold and A defined area must be identified and marked out for the
Release storage of quarantined materials in all distinct areas of
the site e.g. intake, production, high care/risk and
finished product.
P R 11.5 Base Product Control Tesco must be notified immediately of any illegal and or
unsafe products which have been produced and
despatched.
P R O 11.6 Base Product Control Procedures must be in place to ensure materials and
products are used in the correct order and within the
allocated shelf-life.
P O 11.7 Base Shelf Life Systems for managing minimum and maximum shelf-life
when delivered to Tesco must be in place (e.g. minimum
number of days a product must have until the end of its
shelf life, when received by Tesco).
P O 11.7.1 Base Shelf Life The retention period and storage conditions for samples
must be agreed with the Tesco TM.
P R 11.8 Base Temperature A temperature monitoring system must be in place e.g.
Control manual documented checks.
The frequency of monitoring must be based on risk

assessment.

R 11.8.1 Medium Temperature All temperature controlled storage areas must be
Control continuously monitored using an automatic system.
The system must have an alarm which activates at

temperatures outside the set ranges and it must be
monitored outside of normal working hours.
P 11.9 Base Temperature Procedures must be in place for the handling of raw
Control material/product when the storage temperature is outside
the specified tolerance.
P O 11.10 Base Product Control Product segregation during processing and storage must
be in place for the control of materials with special
handling requirements
e.g. vegetarian, organic, meat species, Halal, dairy and
pungent materials (due to taint risk).
(Also reference section 13).
P R O 11.11 Base Product Control The use of re-work (see glossary) requires approval from
Tesco and must be detailed in the Tesco specification.
Where re-work is permitted, it must all be traceable. A

break in the re-work usage must occur at a defined
frequency.
A re-work shelf-life must be established.

R O 11.12 Base Product Control Open raw material life must be established and labelled Where products are received fresh
where necessary when the original pack physical state and subsequently frozen the product
has been changed e.g. de-canning, breaking of vacuum must be suitable for freezing, details
seal, freezing of fresh materials, de-frosting etc. must be included in the raw material
specification and it must have been
Work In Progress must be clearly labelled with internal in-life prior to freezing.
use/process by dates, time, product details and protected
from contamination where necessary.
Work In Progress shelf-life must be established with

reference to the maximum total product shelf-life.

P O 11.13 Base Product Control Effective outer packaging removal procedures must be in
place for raw materials and packaging (See section
14.28)
P R O 11.13.1 High Product Control Product/ingredients/packaging must be transferred to a
high risk/high care area using either heat treatment or
non-heat treatment.
• The use of straight through continuous ovens and

Heat treatment includes:
• Cooking items and then pumping through a wall into

frying equipment (fully fried not flash fried).
• Cooking items in open kettles, pans and transferring

the area
• Cooking items through a double door oven system

over a dividing barrier
• The use of disinfectant in troughs, tanks and spray

Non heat treatment includes:
• Transfer of packaging using double bagging

tunnels
• The use of Ultra Violet radiation (UV) and/or ozone

• Ingredients could also be pumped from large sealed
containers (palletainers) through to high care e.g.
cream, oil
All of the above processes must be validated, verified

and monitored.
P O 11.14 High Product Control Packed product must not return from low risk to high risk
/ high care areas without an appropriate decontamination
step occurring.
P R O 11.15 Base Product Control All Modified Atmosphere chilled foods must conform to
“Code of Practice For The Manufacture of Vacuum and
Modified Atmosphere Packaged Chilled Foods (second
edition) 2009”, Guideline No. 11 Campden BRI
(www.campden.co.uk)
P R O 11.16 Base Product Control All cooked bulk meats must conform to “ Identification
and Prevention of Hazards associated with slow cooling
of hams and other large cooked meats and meat products
1998”, Campden BRI Review R8
(www.campden.co.uk)
R O 11.17 Base Product Control At start up and changeovers production lines must be
clear of all previous product.

Section 12 Traceability

Base
Medium
Aspiration
P R 12.1 Base Traceability Procedures must be in place to enable traceability of Where sites have bulk storage on
System product from a finished pack back to all processes site (silos, tanks, bulk mixing) and
involved in the manufacture including the raw materials, they operate a system of topping up
work in progress and packaging used. with each delivery, they must be
able to demonstrate this in their
Full quantity checks must be included to demonstrate full traceability challenge. E.g. they were
reconciliation. aware of balance within tank prior to
filling with new delivery and
information relating to both
deliveries is submitted.
P R 12.2 Base Traceability Procedures must be in place to trace a batch of raw
System materials or packaging delivered, to all products it has
been used in.
P R O 12.3 Base Traceability The factory must be able to demonstrate that traceability The factory should keep all records
System and mass balance procedures work effectively by as evidence of completing
completing traceability / mass balance challenges on raw traceability tests and not just
materials and finished products (minimum twice per summarised outcomes.
year).
Where membership of a specific scheme requires

additional traceability exercises (e.g. some agricultural
schemes), the minimum requirement would be based on
the specific scheme.

O 12.3.1 Base Traceability Traceability exercises should be completed within 4 The trace from origin of raw
System hours. materials to finished products,
including records of all critical
processes, takes less than 4hrs to
gather relevant evidence for
presentation.
Farm records may take longer but all

suppliers must be identified within
the 4 hours.
R O 12.4 Base Traceability The factory should be able to demonstrate that
System traceability and mass balance procedures work
effectively for food contact packaging also (minimum
twice per year).

Section 13 Allergen Control

Base
Medium
Aspiration
P R O 13.1 Base Allergen COP All sites must comply with the requirements as detailed
in Tesco Code Of Practice 376 - Allergen Control.
P R O 13.1.1 Base Nut Control All sites must comply with Tesco Requirements in the
(UK only) Tesco Code Of Practice 177 - Nuts.
P R O 13.1.2 Base Allergen All sites must have a written allergen risk assessment Allergens risk assessed individually,
Controls which includes details of all processes, products and no grouping or hierarchy.
allergens (including details of physical form e.g. liquid or
powder) used on site. Where grouping has been employed
controls to minimise the risk of cross
Where allergens are used or stored the risk assessment contamination between allergens in
must establish the potential for cross contamination. The the group must be evident.
risk assessment must include all processes and areas of
the factory, including product transfer. The risk assessment must consider
the transfer and movement of used
If the Risk Assessment forms part of the HACCP it will equipment and partially used trays
need to be clearly demonstrated. of product, process aids, cleaning,
CIP, product development etc (not
an exhaustive list).
P R O 13.1.3 Base Allergen Sites whose products contain allergens must have a Where the same allergen is present
Controls documented, effective, risk based allergen management in all products this may not be
system to reduce the risk of cross contamination. required.
Controls must be in place to reduce contamination of non

allergen containing products.
R 13.2 Base Specifications Raw material specifications must detail all Tesco
recognised allergens handled on site. The specification
must provide detail of the risk of cross contamination.

P R O 13.2.1 Base Transport of Transport of raw material must not pose a risk of cross Consideration should be given to
Raw Materials contamination. vehicle loading/unloading and
cleaning.
Bulk tankers used for both allergenic and non allergenic
raw materials must be able to produce cleaning records.
P R O 13.3 Medium Cross Open product that has been in contact with allergenic E.g. On a line producing a cheese
Contamination material must be disposed of if not being used in like for and tomato sandwich, where the
like product. cheese is placed on the bread first
and tomato second. The handler of
the tomato would have contaminated
their product with cheese. The
tomato should be disposed of, unless
being used in a like for like product
or is used in only that product.
P O 13.4 Base Storage Segregation of allergens must be based on risk Allergenic materials stored on
assessment, i.e. product in unopen / fully sealed pallets at floor level to minimise the
packaging poses less risk than packaging that has been risk of cross contamination if
open and re-sealed or open / covered products. damaged.
However, nuts are the exception and must be stored This should be either locked storage,
separate in a restricted access area. out of reach (i.e. stored in racking)
of general persons, in an area of
limited access and not stored in
unsecured areas or where product
can be accessed by general persons.
P O 13.5 Base Identification Based on risk assessment raw materials, work in progress
and finished product containing allergens must be clearly
identified during storage and production.
P R O 13.6 Base Equipment Cleaning between the production of allergen and non Where tests are readily available, the
Cleaning allergen containing products and products containing cleaning procedures may be
different allergens must be thorough, and where possible validated with surface allergen
chemically cleaned to remove all visible debris. testing kits.
The cleaning must be verified by documented visual

inspections as a minimum.
A validation study must be available and reviewed

annually or after any change in the equipment or
procedures.
P R O 13.6.1 Base Equipment Sieves must be dedicated to individual allergenic Spare sets of sieves can be
Cleaning ingredients or cleaned immediately after allergenic maintained to allow clean dry sieves
material is sieved, where there is a risk of cross to be utilised, while soiled sieves are
contamination. removed and wet cleaned. Ideally
sieving of allergenic material should
Free standing sieving equipment must be dismantled to be in a separate or screened area.
remove all visible debris after allergenic material is
sieved. The area around the sieving operation must also
be cleaned.
Bulk or in-line sieving equipment must be cleaned to

remove all visible debris.
Where fitted, extraction equipment must be suitably

cleaned and managed to prevent any risk of cross
contamination.
O 13.7 Base Equipment Utensils used for handling allergen products must be Stainless steel is preferred as it’s
chemically cleaned after use or dedicated to specific easier to clean than acrylic
ingredients. equipment which can become
heavily scored over time.
P R O 13.7.1 Base Maintenance Maintenance activities on equipment handling allergens Separate tool boxes for nut areas.
must be risk assessed and appropriate controls defined
and implemented.
Movement of engineers and tools from one machine to

another should be considered.
P R O 13.8 Base Segregation If dedicated lines (for allergens) are not in place,
scheduling must take into consideration the allergen
content of the different products produced on the line.

Line cleaning and other controls must be employed as
determined necessary by risk assessment.
P R O 13.8.1 ASPN Segregation Products containing allergens should be produced on
dedicated lines or equipment.
P O 13.9 Base Rework Rework that contains allergenic ingredients must be
reworked only into products that contain that allergen.
E.g. chocolate containing hazelnuts only reworked into
other chocolate containing hazelnuts.
P O 13.10 Base Rework Based on risk assessment oils used for the frying of
allergenic foods (e.g. shellfish, fish and breaded
products) must not be subsequently used for frying
products not containing allergens.
All Tesco specs not containing the allergen must detail

this.
P O 13.11 Base Spillage Any spillage of allergenic material that occurs during
production, storage or distribution must be cleaned up
immediately to ensure no risk of cross contamination.
P O 13.12 Base Personnel All staff (including agency) must receive allergen
training as part of the site induction.
Where allergens are used, staff must be aware of the risks

regarding cross contamination.
P O 13.12.1 Medium Personnel Based on risk assessment personnel manufacturing Alternating the colour of the
allergenic product should be clearly identifiable e.g. disposable protective equipment as
through wearing / using coloured disposable protective the line changes between products.
equipment

Section 14 Foreign Body (FB) Controls

Base
Medium
Aspiration
P R 14.1. Base FB Controls & The site must have effective procedures in place to
Risk Assessment eliminate (so far as practically possible) potential foreign
body hazards.
P R 14.1.1 Base FB Controls & The site must have a documented risk assessment and
Risk Assessment corresponding policies and procedures for potential
foreign body hazards, including glass, hard plastic, wood,
metal, paper, string, tape, maintenance debris, personal
effects etc.
GLASS & HARD CLEAR PLASTIC

O 14.2 Base Glass Glass in production and storage areas must be replaced
with suitable alternatives, where possible.
If this is not possible, the glass items must be protected.

O 14.3 Base New Equipment Introduction of new equipment or modifications to
existing equipment must eliminate glass and clear plastic,
where possible.
R 14.4 Base Register All glass and hard clear plastic in production and storage
areas must be listed on a register.
R 14.4.1 ASPN Register Brittle coloured plastics should be considered for For example white plastics in dough
inclusion in the register, where they may pose a risk of production areas, red plastics in raw
product contamination. meat processing areas etc may be
included on the register.

R 14.5 Base Glass Audits Audits must be completed on all registered items at a
frequency determined by risk assessment.
The audit must record the condition of the item e.g.

intact, broken, damaged but intact, undamaged but not
working.
Any issues raised must be investigated to establish if the

glass breakage procedure has been followed and if not,
whether product has been put at risk.
A risk assessment must be completed to determine how

quickly repairs must be made.
P R 14.6 Base Glass Breakage A detailed procedure must be in place for the The site has a procedure that follows
management of glass and hard plastic breakages. This a logical sequence and has sufficient
should include: detail to manage the incident. E.g.
•
What equipment is used for the
•
Stopping of production clean up of breakage? (a specific
•
Restriction of movement through the affected area colour, type or dedicated for glass
breakage only) How it’s to be used?
•
Quarantine of affected materials
(glass maybe on equipment and
•
Report to management
Clean up of breakage and disposal / cleaning of floor) What happens with equipment
after use (cleaned and returned to an
•
cleaning equipment
office or disposed?)
•
Safe removal of glass from area
•
Repair or replacement of damaged item
The checking of PPE (including footwear) and
•
changing if necessary
Completion of an incident log and sign off that
production can restart, by a responsible/senior
•
person.
It may be practical to take a
A sample of broken glass should be retained in a safe photograph of a reassembled item
•
manner rather than retain sample in some
Corrective Action to prevent reoccurrence instances (e.g. item snapped in two)

R 14.7 Base Training All employees must be briefed on the glass breakage
procedure at induction.
All production / hygiene managers and engineers must be

trained to understand and apply the glass breakage
procedure.
P R O 14.7.1 Base Handling Glass Where glass containers are used as a packaging medium,
container detailed procedures must exists covering
-Intake checks
-General handling
-Breakage on line, specifically in automated filling
systems
P R O 14.7.2 Base Handling Glass All sites must comply with the requirements as detailed
container in Tesco Code Of Practice 374 - Handling of Glass
Containers (where glass containers are used as a
packaging medium).
WOOD
• Layer separation between pallets

P R O 14.8 Base Wood The use of wood within the site production and storage Controls may include:
areas where possible must be eliminated (e.g. hand tools,
• Coverage of materials stored

pencils, clip boards, furniture, brooms etc). and product
Where wood cannot be eliminated in production and under wooden pallets on racking
• Broken pallets removed from the

storage areas it must be minimised and suitably systems
controlled
• Wooden boxes where used in

system
good condition or system of
• Demarcation of where wooden

repair (e.g. potato storage boxes)
pallets are or are not permitted

within the site

P R O 14.9 Medium Wood Wood must not be permitted in open food areas.
Where wood is used in the process or integral to the

product it must be controlled (e.g. skewers, cheese
ripening shelves, salami poles, barrels, wood smoke
chips).
Sites should strive to eliminate all wood in processing

areas and be able to demonstrate that alternatives have
been evaluated and why these options were not suitable.
Controls for wood used in processing must be based on

risk assessment. They should include:
• Intake Checks
• Inspection for splinters/damage
• Procedures for handling of breakage
P R 14.10 Base Wood Wooden pallets destined for Tesco depots, must be in a
good condition and not pose a contamination risk.
METAL
P R O 14.11 Base Metal Control There must be appropriate systems in place for the
prevention of metal contamination.
• Reconciliation of numbers
R O 14.12 Base Metal Control Where metal is used in the process or integral to the Controls may include:
• Inspection of condition before

product (e.g. bag clips, staples on tea bags, cans and
other packaging materials) it must be suitably controlled.
and after production runs.

P R O 14.13 Base Equipment Knife, blade, scissors and needle control must be in
place and include:
• Only company issue, captive, identified and All knives / scissors issued will be
• No snap blade knives must be used

registered knives, blades and scissors must be used individually numbered to ensure
• Knives, blades and scissors must only be used for the

they can be accounted for.
• Equipment must be accounted for and the condition

task for which they were designed
Knife sharpening with steels is
checked and recorded (minimum start and end of acceptable, provided they are not
used over product.
• In the event of breakage or loss, all parts must be
production).
accounted for and the incident logged. Corrective Where sharpening devices are fixed
within butchery areas, the location
• Knife and blade sharpening must take place away
action must be taken to prevent re-occurrence.
and use must not pose a risk of
from production areas and equipment must be contamination.
returned in a clean condition
P O 14.13.1 Medium Equipment Knives and blades must not be stored in personal lockers, Shadow boards, magnetic holder,
knife blocks or plastic scabbards. These may only be secured clean storage
used for temporary storage.
P R O 14.14 Base Engineering Engineering activities must be controlled to avoid
compromising product safety or quality. (See section
27.6).
R O 14.14.1 Medium Engineering The following controls must be in place:
• Start up checks of equipment must identify damaged When purchasing small items, where
•
or missing parts possible they should be metal
In the event of damage or loss, all parts must be detectable at level of detection on
accounted for and the incident logged Corrective site
•
action must be taken to prevent re-occurrence.
Potential transfer of metal contamination from
engineering areas must be suitably controlled (e.g.
swarf mats)
After use the area where the wire
• Wire brushes and scourers must be in good condition brush / scourers was used must be
and stored away from the production process or inspected.
•
below product height when not in use
Mobile engineering work stations must not be used in
open food areas
OTHER FOREIGN BODIES

O 14.15 Base Foreign Body To minimise the risk of contamination from clear plastic
Control liners and bags a contrasting colour must be used where
possible.
P 14.16 Base Foreign Body Bags and film gauges must be specified and be
Control appropriate to avoid potential entrapment or tearing.
O 14.17 Base Foreign Body All unnecessary packaging must be removed prior to
Control transfer of materials into production areas. (Traceability
must be maintained.)
O 14.18 Base Foreign Body All wrapping must be removed from materials before
Control cutting (e.g. butter, cheese).
• Rejection at intake
P R O 14.19 Base Foreign Body Inspection procedures must ensure that all entrapped Procedures include:
• Controlled tempering
Control packaging materials are removed during decanting of
materials e.g. frozen.
If entrapped packaging is identified, corrective action An alternative supplier may be

must be taken to remove the packaging prior to the sourced.
material being used in production or the material must be
rejected.
O 14.20 Base Foreign Body Opening and re-sealing methods of containers and e.g. The use of scissors or sharp
Control packaging must minimise the risk of potential knives, not torn. A Bag opening
contamination. procedure
O 14.21 Base Foreign Body The correct type, grade, colour and quality of material Considerations may be given to the
• Freezing
Control must be selected for each application e.g. factory following:
• Blast chilling
containers and PPE.

•
•
Washing technique
•
Exposure to acid/alkali materials
•
Abrasion or impact damage
Contrasting colour to product
O 14.22 Base Foreign Body All damaged food / ingredient containers and trays
Control (including bulk palletainers) must be removed from the
system and corrective action implemented to prevent
reoccurrence.
P O 14.23 Base Foreign Body The use of food containers (e.g. plastic trays, cans, foil
Control trays etc) to store other materials e.g. nuts, bolts etc. must
not be permitted.
P O 14.24 Base Miscellaneous All pens used within production, storage and packing One piece (i.e. no lid) factory issue
Items areas must be site issued, one piece and of a contrasting pens with no clear plastic parts in
colour. production and storage.
Staples and drawing pins must not be permitted in Metal detectable pens, in sites where
production, packing or storage areas. metal detectors are used. (These may
be of the impregnated plastic type or
The number of miscellaneous items must be kept to a of metal construction)
minimum.
Alternatives to staples and drawing
Required miscellaneous items must be of a contrasting pins are available should be used
colour and managed e.g. calculators, rulers. wherever possible.
Metal detectable items in use.

PPE to be supplied without
unnecessary foreign objects (e.g.
rubbers band on sleeves or aprons,
no card inserts in aprons).
P 14.24.1 ASPN Utensils Utensils in open food areas should be metal detectable.
Plastic items with metal additions are available. (See

clause 4.9 regarding materials in contact with food)

P O 14.25 Base Foreign Body The type, condition and location of any labels used must
Control not pose a risk of contamination.
O 14.25.1 ASPN Foreign Body Paper labels in open food areas must be kept to a
Control minimum.
O 14.26 ASPN Foreign Body Where metal detectors are in use, traceability labels/tags Luggage type metal detectable labels
Control in open food areas must be metal detectable. in use.
O 14.27 Base Foreign Body All signage must be secure and effectively sealed against Magnetic signage is used
Control the wall e.g. to minimise the risk of debris collecting
between sign and wall.
All signage must be washable.

P O 14.28 Base Cardboard The use of cardboard in production areas must be Storage and packing areas are
Control managed / controlled. regularly swept to remove card
shards from packing boxes.
Cardboard boxes are opened correctly to prevent ripping.
P R O 14.28.1 Medium Cardboard A risk assessment must be conducted prior to the use of Cardboard is not used in the
Control cardboard in production areas. production area.
P R O 14.29 Base De-boxing / A procedure must be in place for the de-boxing and The method of opening and
Debagging debagging of raw materials and packaging, which aims to decanting should minimise the risk
minimise the risk of contamination. of contamination from the packaging
itself (e.g. paper, plastic, cardboard
Training of procedure must be documented. or string).
O 14.30 High De-boxing / Cardboard / paper sacks must not be used within high Cardboard is removed from all items
Debagging risk / high care. including PPE (e.g. disposable glove
boxes) prior to transfer to high risk /
high care.
Where it is not possible to remove

cardboard (e.g. winding tubes for
films and labels) it must be clean.

P R 14.31 Medium Foreign Body Foreign body audits should be completed at a frequency
Audits based on risk.

Section 15 Foreign Body Detection

Base
Medium
Aspiration
P R 15.1 Base Metal Detection All products must be examined through a metal detection Justification should be agreed with
or x-ray detection system. the Tesco TM, where the risk
assessment deems that metal
Documented justification, based on risk assessment must detection / x-ray is not required.
be given if metal detection (or X-ray) is not in place.
O 15.2 Base Tesco COP All sites must comply with the requirements as detailed
in Tesco Code Of Practice 375 - Metal Detector & X-Ray
Systems (where metal detectors are used).
P O 15.3 Base Equipment Foreign body detection equipment (metal detector, x-ray,
optical graders or magnets) must be specified as
appropriate for the products that are being examined.
Equipment must be upgraded to improve detection

sensitivity where advances in detection are developed.
The operation and sensitivity of the detector in use must

be well understood by relevant site personnel.
P O 15.4 Base Equipment – All metal detectors must have the capability of detecting
Metal Detectors ferrous, non-ferrous and stainless steel (with the
exception of foil packed products or similar metalized
films).
O 15.5 Base Equipment – All foreign body detectors must be located as close as
Foreign Body possible to the finished packaging point unless authorised
Detection by the Tesco Technical Manager.
O 15.6 Base Equipment – All foreign body detectors must have adequate security
Foreign Body devices, so only authorised personnel have access to alter
Detection settings.

P O 15.7 Base Equipment – A conveyor type detection system must have:
•
Conveyor
•
Systems An effective automatic rejection system
•
A locked box to receive rejected product
A fully enclosed area around the search head and
•
rejection box
A visual or audible alarm system in the event of
detection.
Belt stop systems may only be used for bulk or sensitive

items.
Where belt stop systems are in use these must have a

visual or audible alarm.
O 15.7.1 ASPN Equipment Foreign body detector systems should include: The system stops if a test has not
•
been completed.
A data capture system to show pack numbers
•
checked
•
The number of rejects, number and type of tests
Foreign body detector system should highlight when
•
tests are due
Visual or audible alarm system in the event of line
fault and fail safe activation
P O 15.8 Base Equipment – In line metal detectors e.g. pipe detectors must have a
In Line Systems visual or audible alarm and reject product into a
dedicated container.
R 15.9 Base Equipment The foreign body detection system must be serviced at
regular intervals, either by the equipment manufacturer
or trained contractors (minimum annually).
P R O 15.10 Base Testing of The foreign body detector must be fully operational at the
Equipment start of production.

An effective testing method must be in place and all
checks must be documented.
Detectors must be checked at the beginning and end of

production (for Tesco product) and minimum hourly
unless agreed otherwise with Tesco.
Conveyor Metal Detector Systems

Detectors must be checked using clearly identified test
packs at the same temperature as standard product
passing down the line and test pieces of a defined size
(based on risk assessment).
The test pieces must be passed through the detector as - A specific test piece and catch tray
close to the centre of the aperture as can be achieved with are fitted to the system.
the test pack. - A smaller test piece size is used if
the test piece cannot be placed in the
Test packs must be passed successfully through the metal centre of the aperture.
detector prior to being used for the check. Test packs
must be allowed to be rejected fully into the bin.
Consecutive leading and trailing checks must be

completed in long packs to ensure the reject mechanism
can successfully reject.
The test must be representative of how products would

normally travel through the detector during normal
production.
Inline Systems
An effective testing method must be in place for the
equipment. Refer to advice from the equipment
manufacturer.

X-Ray Detection Systems
The test pieces must be placed in the worst case scenario
area. Refer to advice from the equipment manufacturer.
R O 15.11 Base Fail Safe Detector fail safe systems where fitted, must be
Systems challenged at regular intervals (minimum start and end of
day) to make sure they are effective.
• Reject confirmation
• Bin full
• Air pressure low
• Search head failure
• Back-up sensor
P R 15.12 Base Plasters / Wound Each batch of metal detectable plasters must be checked Plasters are tested using worst case
Dressing/ to ensure they are detected by the lowest sensitivity metal scenario i.e. placed in the product.
Bandaids detector.
The checks must be recorded.

P R O 15.13 Base Detector Failure In the event of a metal detector test failing (whether due
to failure to detect a test piece or failure to reject product)
all material that has been checked since the previous
satisfactory test must be isolated and retested through a
unit that has been confirmed to be working correctly.
A detailed procedure must be in place to handle incidents

when metal is found in material.
A full investigation must take place to ensure the source

of contamination is identified and the risk of other
materials being contaminated must be assessed.
Corrective actions must be put in place to prevent a

recurrence. Record details of the investigation.

P R 15.14 Base Training All staff involved with foreign body detection must be
trained not only in the technical and operational aspects
but also the principles of metal and foreign body
detection to ensure full understanding of the purpose.
SIEVING/FILTERING
P 15.15 Base Risk Assessment Risk assessments must be completed to determine
whether a particular material requires sieving/filtering
(including liquids).
O 15.16 Base Sieving Where sieves and filters are used these must be metal
detectable or of a contrasting colour to the food.
P 15.17 Base Equipment Equipment used for sieving/filtering must have written
inspection procedures.
R O 15.18 Base Equipment Sieving/Filtering equipment must be inspected for
integrity at pre-defined intervals as identified in the risk
assessment and recorded.
Equipment must be accessible to enable inspection.
Mobile equipment must be uniquely identified to ensure

that the integrity of each sieve is being managed.
P R 15.19 Base Preventative Sieves and filters must be included on the preventative
Maintenance maintenance plan.
R 15.20 Base Training Training of personnel operating or inspecting the
sieving/filtering equipment must take place.
R O 15.21 Base Traceability Records must be in place to demonstrate when
ingredients have been sieved/ filtered (traceable to batch
level).
O 15.22 Base Storage Stored sieved ingredients must be protected to prevent
post sieving contamination

P 15.23 Base Sieving A sieve matrix must be in place detailing the type of
material, sieve size, frequency of inspection and sieve
location.
P R 15.24 Base Foreign Bodies Procedures must be in place for actions when foreign
bodies are found.
A full investigation must take place to ensure the source

of contamination is identified.
Details of the investigation must be recorded.

R 15.25 Base Sieve Tailings Sieve tailings must be checked and recorded at regular
intervals as defined in the risk assessment.

Section 16 Inspection and Analysis

Base
Medium
Aspiration
P R 16.1 Base Product Testing Product testing must be completed to ensure compliance The nutritional information is
with Tesco Product Specifications for microbiological, verified 6 weeks from launch to
chemical, physical, organoleptic and other specific ensure it is accurate. Nutritional
requirements (e.g. Free From and Nutritional Claims), information is tested annually
unless the site has written confirmation from the Tesco (unless there is a claim made. In this
TM. case refer to specification).
A sampling plan must be in place and followed, to ensure Product is sampled by run to
requirements are met. determine quality standards. Applies
to sites supplying Tesco UK only.
P R 16.2 Base Laboratories Testing must be conducted in accredited laboratories. For UK/ROI – Laboratories must
have a current accreditation (UKAS,
All tests performed by the laboratory must be accredited CLAS or LABCRED) and if
by their in country national accreditation body. applicable be registered on the
Tesco Approved Laboratory Scheme.
Accreditation must be by an internationally recognised
country body. All applicable Laboratories should
ideally register before June 2010 as
The scope of accreditation must cover all tests the deadline is Jan 2011.
undertaken.
Laboratories must participate in proficiency / correlation

testing.
Routine QC checks which are completed in a laboratory

environment such as measuring dimensions of the
product, quality sampling etc. do not need laboratory
accreditation.
(see 1.12 and 28.1)

R 16.2.1 Base Laboratories As of Jan 2011, all finished product testing for
(UK / ROI only) Salmonella, Listeria, E.coli O157 and Campylobacter
must be carried out at a laboratory that is approved by the
Tesco Laboratory Approval Scheme.
The manufacturer must be able to demonstrate that the

methods used for their product testing are included in the
scope of the laboratory approval.
P O 16.3 Base Microbiology On site laboratories which conduct pathogen testing must
Laboratories have controls in place to prevent cross contamination
from the lab to the production facility.
P 16.4 Base Sample Procedures must be in place detailing samples, sampling
Submission methods, type of tests to be conducted, durability
information etc.
P 16.5 Base Reporting Procedures must be in place to cover reporting of routine
results and out of specification results.
Out of specification pathogen results should be reported

back to the Tesco TM at the earliest opportunity.
P R 16.6 Base Action/ Action and investigation must be evident where results
Investigation fail to meet specified limits.
R 16.7 Base Trend Analysis Ongoing trend monitoring system must be in place.
P O 16.8 Base Laboratory Coats worn in on site microbiology laboratories (or
Personnel chemical laboratories where toxic chemicals are used)
must not be worn in any factory areas (including offices)
and should be distinguishable from normal factory
protective clothing (ideally a different colour).
These garments are laundered separately to factory

protective clothing (see 8.13)

Section 17 Water and Waste Water Management

Base
Medium
Aspiration
P R 17.1 Base Risk Assessment A risk assessment must be completed on water safety Assessment includes the
/quality. consideration of Legionella and
Cryptosporidium. (also see 8.5.1)
The composition of water delivered to the site must be
known and the standard required for use in production
as an ingredient (whether as water, ice or steam), for
cleaning or other uses must be defined.
The assessment scope must include source, storage,

handling, treatment, impact on environment and waste
management.
Water may be sourced from a Public (mains) supply or

from a private source.
P R O 17.2 Base Water Supply Water used in processing food, as an ingredient, for
washing materials or for cleaning must be potable.
Potability must meet local requirements as a minimum.
If non potable water is used on site it must be

segregated and controlled e.g. for toilet flushing.
P R 17.2.1 Base Water Supply Systems must be in place to manage notifications from Boil Water Notice risk assessment,
a Water Authority of contaminated water sources (e.g. Guideline 188 on TTL.
Boil Water Notice in the UK because of
Cryptosporidium). Systems are in place to manage
changes in water sources if they
could affect product safety or
quality.

R 17.3 Base Water Supply Potability testing must be completed by accredited
laboratories covering microbiological, chemical and
physical parameters. (see 16.2)
R 17.3.1 Base Water Supply - Where water is from a Public supply, certificates of
Public Water potability from the provider are acceptable.
Additional testing may be required based on risk

assessment. (Guidance should be sought from TTM
especially in locations where water may not be of
potable quality).
R 17.3.2 Base Water Supply - Where water is from a private source, the potability
Private Water must be demonstrated on a continuing basis.
Certificates of potability must be provided (minimum 6

monthly.
If certain water sources are only used seasonally, the

water must be tested at the start of each season until the
season is completed).
R 17.3.3 Base Water Supply - Ice Ice manufactured on site must be tested for All ice whether produced on site or
microbiological levels as per other water testing (at a purchased will be microbiologically
minimum of twice annually). tested against a set schedule.
Purchased ice must have an annual certificate of

potability.
R 17.3.4 High Water Supply Potable water in high care / high risk areas (including
ice) must be tested for microbiological levels
(minimum monthly).
R 17.3.5 ASPN Water Supply All points on the ring main system should be included It is good practice to run taps to
on a water testing schedule. flush the system at defined
frequencies if they are not used on a
daily/weekly basis.

R 17.4 Base Water Treatment Where water treatments are in place they must be A site using chlorination as a
monitored to ensure they remain effective through treatment has a system in place to
monitoring of critical parameters. monitor and record dosing levels,
free and total chlorine, contact time
and pH during use.
R 17.4.1 ASPN Water Treatment Automated controls and an alarm mechanism should be
in place to notify management if levels fall outside set
limits.
R 17.5 Base Water Plan There must be a schematic plan of all water circuits
within the site which is reviewed annually.
Potable and non-potable water lines must be identified

throughout the site. Dead ends on potable water lines
must be eliminated.
R O 17.6 Base Water Storage Bulk water storage facilities must be constructed from
approved materials, of a size that prevents stagnation
and designed to exclude light and pest entry.
Tanks must be inspected and cleaned at frequencies

determined by risk assessment.
O 17.7 Base Water System There must be a backflow prevention device fitted to
main water lines and on individual lines within
production areas.
R 17.8 Base Control of Steam All steam used for product manufacture or in contact
with product contact surfaces must be from “potable”
sources.
Documentation must be available that indicates all

boiler components meet approved boiler additive
standards.
P O 17.9 Base Waste Water Sewage disposal must not compromise food safety or
employee health.
Waste water and sewer drains must not be vented
inside the facility.

Section 18 Product Labelling and Coding

Base
Medium
Aspiration
P R 18.1 Base Packaging Packaging supplied to the production line must be An ‘Issued to line’ log is kept.
Supplied To Line controlled and checked to ensure it is correct and for
the right product.
P R 18.2 Base Packaging At start up and changeovers, the line must be clear of
Changeover any packaging not required for the next production run
(including promotional packaging).
R 18.3 Base Control of Coding All coding information applied to a product must be Coding information on the schedule is
correct and reflect the requirements as per the written in the same format as that on
specification. packaging
Coding schedules and promotional information must be The authorised person has been
cross-checked by an authorised person prior to issue. trained and assessed as competent.
The correct document controlled coding schedule must Changes in bold or in a contrasting
be available on line with the date information. colour.
Labels used for special promotions must be highlighted

on the coding schedule with start and end date of
labelling clearly stated.
Changes in month and year must be highlighted on the

coding schedule.
Records with actual copies of the label must be

authorised and retained.
O 18.3.1 ASPN Product Coding Real time is printed on product labels.

R 18.4 Base Control of Coding The time of any code changes must be agreed with
Tesco and documented (e.g. what time does the code
move to the next day e.g. midnight or start of shift).
R 18.5 Base Control of Off All off line printing must be controlled and checked. Printed labels must be kept from the
Line Printed start and end of the print run. These
Packaging The material must be stored in a restricted access area labels must be authorised.
until issued to the production line.
An ‘Issued to line’ log must be kept.

R 18.6 Base Control of Coded All unused coded packaging must be accounted for and
Packaging disposed of.
P R O 18.7 Base Product Labelling Product labelling and coding checks must be completed In the case of printed boxes/bags it is
and documented at start up, end of run, hourly acceptable to cut out and retain the
intervals, in between and after line disruption (e.g. reel coding information only for the
changes, fire-alarm, breakdown, breaks). purpose of traceability.
Coding checks must be completed for all runs Checks include the cross checking of
(including ‘top up’ runs) and records including product label information against
physical labels / sleeves retained. case/tray end labels.
A sample of the actual code printed on the packing The part of the packaging with the
from each check should be retained unless authorised printed code may be retained rather
by the Tesco Technical Manager. than all of the packaging.
P R O 18.7.1 Base Product Labelling Where product catch weight systems are place, (see
section 19) labelling and coding checks must also
include
•
•
Price per unit (e.g. per Kg)
•
Manual price confirmation
•
Barcode confirmation
Packaging tare

R O 18.8 Base Control of Barcodes on all packaging must be checked against Barcodes are verified using scanners
Barcodes Tesco issued information before the packaging is used. or in store for validation and the till
receipt should be checked and
On line printed bar codes must be checked and retained.
recorded at regular intervals.
P R 18.9 Base Control of Coding A labelling and coding procedure must be in place and
include action to be taken in the event of an error.
All personnel carrying out labelling and coding checks

must be trained against the procedure.
R 18.9.1 ASPN Verification For verification of date coding, the check should
include comment such as 'What is the third letter of the
month' rather than just a 'tick'.
R O 18.9.2 ASPN Verification An automated coding system may be in place
including:
• Single coding and price master data file controlled
•
by the technical department
Password protected system which identifies the
•
person using the machine
Prevention system for reversal of Display Until*
•
and Use By codes
Prevention system for incorrect coding at month
•
end.
Matching system for top and bottom labels or pots
and lids.
Checks must be in place in the event of a breakdown

e.g. power failure.
* where this is used on pack.

Section 19 Weight, Volume, Size and Count Checks

Base
Medium
Aspiration
P O 19.1 Base Procedure Sites must have a clear documented policy and
procedure for the management of weight, volume and
count for each product manufactured, which conforms
to legal requirements in the country of manufacture and
the intended country of sale.
Controls in place must meet the requirements as

detailed in the Tesco product specification.
O 19.2 Base Tesco COP All sites must comply with the requirements in Tesco
Code Of Practice 378 - Contents Control.
P R O 19.3 Base Weight Control Allowance may need to be made for weight loss during
transport and display. In the case of desiccating
products, if no allowance for desiccation is made, the
extent of desiccation in those products, over their entire
shelf life, must be documented.
These documented levels must accurate and based on

thorough testing.
P R O 19.4 Base Weight/Volume Where statistical methods are used to manage weight or
Control volume, appropriate procedures, equipment and
training must be in place.
Records must show the individual finished pack results Weight, volume and tare verification
for each batch. Procedures must detail the actions to be checks should be completed hourly
taken if the results fail to meet specification. (or more frequently with smaller
For products that comply to EU average weight / batch sizes).
volume legislation (agreed as part of the Tesco product
specification):

• Records must show the individual average and
•
upper / lower results for each check.
Procedures must detail the actions to be taken if the
mean average or upper / lower results for the batch
results fail to meet specification.
Line speeds (and batch sizes) must be taken into

account when determining frequency of weight and
volume checks.
Results should be signed off by a competent individual

at the end of each batch.
For products manufactured outside of the EU and not

destined for sale in the EU, the procedures for weight,
volume and count must conform to legal requirements
in the country of manufacture and the intended country
of sale e.g. Maximum Allowable Variance in the US.
P R O 19.4.1 ASPN Automated Products packed to either minimum or average pack
Weight Control weight (where applicable) should utilise automated
check weigh systems.
P R O 19.4.2 Base Automated Where ‘In-line’ check-weigh systems are used they
Weight Control must be capable of recording minimum or average
weight data (where the legislation is applicable) and
providing a printed record of weights [mean average,
standard deviation and control limits where the
legislation is applicable (e.g. T1 & T2 EU average
weight)] for samples and whole batches.
Systems controlling average weight should

dynamically measure batch compliance.
Where ‘In-line’ check-weigh systems are used and an

automatic reject system is in place, rejected products

must be rejected into a locked bin.
There should also be a “Bin full” sensor, which stops

the line after a pre-set number of items enters the bin or
is rejected.
A system should be in place to verify the pack rejection

mechanism is effective.
Where automatic reject systems are not in place

methods of identifying and segregating non conforming
products must be in place e.g. top labels are not applied
and dedicated personnel remove these packs from the
line. Similar systems may be utilised for catch weight
product where defined weight bands are required.
Records should be signed off at the end of each batch.

P R O 19.5 Base Weight Control All scales and equipment used for finished product
weight control must have documented checks at a
minimum twice per production day as part of the
verification process.
(For catch weight system see clause 18.7.1)

P R O 19.6 Base Volume Control Volume measurement must be established via the
physical measurement of contents (via a calibrated
container) and not established via measurements taken
from the packaging e.g. fill level of a bottle, unless
Measuring Container Bottles are in use.
R 19.7 Base Verification of Where required, weight checking equipment must be
Weight Control approved by the relevant Government Inspection or
Enforcement officer.
The weights used to verify this must be calibrated or

checked against calibrated weights on a predetermined

frequency.
P R 19.8 Base Count Control Procedures must be in place to ensure that the correct Dedicated personnel are in place to
number of items are present in the pack when a number count the items on the line.
has been declared.
Documented checks of product count must be in place.

P R 19.8.1 ASPN Count Control An automated system should be in place to ensure that A check-weigher or automatic
the count is correct. counter is in place.
P R O 19.9 Base Drained Weight All products stating drained weight must be verified at
predetermined frequencies to confirm accuracy.
O 19.10 Base Equipment All automated content control equipment must have
Settings / Security adequate security devices, so only authorised personnel
have access to alter settings.
P R O 19.11 Base Training All personnel involved in the management of product
weight, volume and count must be trained in the correct
use of the documented procedures.

Section 20 Training

Base
Medium
Aspiration
P R O 20.1 Base Training The site must ensure that all personnel are adequately
trained, instructed and supervised commensurate with
their activity and are demonstrably competent to carry
out their activity.
P R O 20.2 Base Literacy The level of language understanding must be known for This may be in the form of a literacy
all personnel (including agency or temporary personnel). test.
R 20.3 Base Training Training must be delivered by competent and capable ‘Train the trainer’ qualified trainers.
trainers.
R 20.4 Base Training The site must provide information, instruction, training
and supervision in an understandable format for all
workers, irrespective of their national origins, first
language or literacy. (This may be translated documents,
pictorial training aids, use of a translator)
R 20.4.1 ASPN Demonstration A test should be in place to demonstrate understanding of Where tests are used, wrong answers
of information in the induction package. Re-training should should be closed-out to demonstrate
Understanding be given in areas that are not understood. full understanding.
• Food safety
R 20.5 Base Induction / Food A documented induction training programme must be The induction includes:
• Personnel hygiene procedures

Handler given to all new starters, including agency and temporary
Training personnel before they start work.
• Glass breakage procedure

and rules
Induction training records must be available for all
personnel. • Health and safety
• Quality policy
All personnel must have a basic understanding of food • Allergens and allergen controls
safety before they start work.

R 20.5.1 Medium Induction / Food All personnel must complete recognised food safety
Handler training e.g. Basic Food Hygiene within 3 months of
Training starting work (UK).
R 20.5.2 ASPN Induction / Food Where the induction package has been updated, evidence
Handler that all personnel have been trained in the new package
Training should be available.
P R 20.5.3 ASPN Induction There should be a defined time period during which the
new starter has a 'training buddy' or extra supervision.
At the end of the initial training period the employees’

competence to do their job should be assessed.
R O 20.6 Base Job Descriptions All personnel must have a clear understanding of what is
expected of them in their job roles.
Documented and agreed job descriptions (or working

instructions) must be available for all personnel.
R 20.7 Base Specific Records of further hygiene, specialist or job specific
Training training must be available. (Copies of certificates may
form part of these records e.g. Safe use of chemicals,
pesticide application, use of certain types of equipment).
R 20.8 Base Training Records must be signed and dated by the trainer and
Records trainee.
R 20.8.1 ASPN Training A training matrix should be available showing which
Records employees are trained in which activities. (Matrix should
also demonstrate those untrained, in training, trained and
able to train others).
R 20.9 Base Review The competency of employees must be reviewed at
defined intervals or following significant changes in
procedures and re-training undertaken where necessary.
P R 20.9.1 ASPN Review All employee appraisals should be completed and records
retained (minimum annually).

Section 21 Quality Management System

Base
Medium
Aspiration
P 21.1 Base Quality The site must have a Quality Management System The site will conduct a gap analysis
Management (QMS), which is maintained and regularly reviewed. against the current site QMS
System The QMS must contain procedures / records as required systems and the TFMS
by the TFMS.
There should be a documented
action plan in place to address
anomalies identified.
The site uses a site plan to define the

areas of the factory (i.e. base,
medium etc.). The site contacts their
Tesco Technical manager if any
clarification is required.
P O 21.2 Base Quality Policy A Quality Policy Statement must be in place stating the
company's intentions to produce safe, legal and quality
products.
The policy must be authorised by senior management.
All employees must be aware of the policy by displaying

it in employee areas.
P 21.3 Base Quality Manual A quality manual must be in place and available to key
employees outlining company policies and procedures.
P R 21.4 Base Document All documents must be adequately controlled, authorised

Control and be of the correct version.
Alterations to records must be appropriately authorised.

P 21.5 Base Organisational An organisational structure chart must be in place
Structure showing management authority.
P 21.6 Base Deputising Details of deputising cover for personnel with As well as Senior management
Cover responsibility for legal, safety and quality issues must be cover the site should be able to
documented. demonstrate they have sufficient
cover for operatives who are
responsible for CCPs.
P 21.7 Base Document All documentation and records must be retained for a
Retention defined period and available for review within 4 hours
from the request.
R 21.8 Base Record All records must be accurate and fully complete.
Completion

Section 22 Product Development

Base
Medium
Aspiration
R 22.1 Base Factory Trials The site must undertake factory trials and complete
thorough testing to verify product formulation and
manufacturing processes are capable of producing safe
and legal products (e.g. Fo values, cook/chill,
microbiological testing, label claims, risk of allergens,
suitability of packaging etc).
All factory trials should be documented and records

retained.
P R 22.2 Base Nutritional Nutritional analysis must be carried out and checked
Analysis against proposed product label and specification prior to
launch. (Recently reviewed literature sources can be
used in some instances, where agreed by TTM).
Where a nutritional claim is made e.g. <2% fat, high in

omega 3 etc such claims should be challenged and
verified using worst case scenarios.
R 22.3 Base Formulation Changes in formulation must be adequately assessed for
Changes legal and safety issues, communicated to Tesco and
documented.
P R 22.4 Base Shelf Life Shelf life must be established, taking into account
product formulation, microbiological growth,
organoleptic quality, packaging process (e.g. gas
flushing) and material, factory environment and
subsequent storage conditions.
Shelf life trials must be completed to meet Tesco

requirements and trial results documented and retained.

R 22.5 Base Product Claims Where product claims are made, documentary evidence
must be available on site to substantiate these claims.
R 22.6 Base Transit Trials Transit trials must be completed, where appropriate.
O 22.7 Base Development All development materials e.g. ingredients, packaging,

Materials equipment must be clean, clearly identified & durability
date marked (if necessary).

Section 23 Product Recall/Incident Management

Base
Medium
Aspiration
P 23.1 Base Incident Procedures must be in place to manage all incidents and Any issue that impacts on supply or
Management potential emerging issues which could affect food safety, affects the brand integrity should be
legality and quality. reported to Tesco.
• Disruptions to distribution, water and energy supplies,

Including: (this is not an exhaustive list)
• Fire, flood and other natural disasters

labour and communications
• Sabotage and malicious contamination

• Vandalism and terrorism
• Food safety, legality and quality issues.
The likelihood of the occurrence of the above issues must

be risk assessed.
R 23.2 Base Contacts Key contact information must be maintained including:
(not an exhaustive list)
• Internal contacts (in and out of hours)

• Customers (in and out of hours)
• Suppliers (raw materials and services)
• Government / Enforcement bodies
• Certification Bodies / Schemes
P 23.3 Base Communication A communication plan must be in place to manage
potential incidents.
P 23.4 Base Recall Plan Each site must have a recall plan in the event that food Any communication with regulatory
safety, legality is in doubt. bodies such as the UK Food Standards
Agency (regarding Tesco branded
The procedure must include in detail: products) will be co-ordinated by

•
•
How to report an incident to Tesco Tesco.
The full process of traceability identifying key points in
production and distribution
• How product will be withdrawn or recalled from

distribution and sale
All affected products must be located within 4 hours of the

withdrawal / recall being started.
Reconciliation of product must be verified against

production records.
The withdrawal / recall of Tesco brand products from

Tesco stores will be managed by Tesco.
R 23.5 Base Training There must be a trained incident management / recall team
with named deputies. There must be contactable cover at
all times.
R 23.6 Base Mock Recall/ A mock recall (or mock incident) must be undertaken to The site should retain all records as
Incident test the effectiveness of, and the Incident Management evidence of completing mock incident
Teams understand of, the Recall Plan and Incident challenges and not just a summarised
Management Procedures (minimum annually). outcome.
The results of the test must be investigated and where The site should not confuse mock
corrective action is required this must be implemented. recall with traceability. This process is
to test effectiveness of procedures.
P 23.6.1 ASPN Mock Recall/ The recall plan should be tested outside of normal office
Incident hours.
R 23.7 Base Review The detail contained within the Recall Plan / Incident
Management Procedures e.g. internal and external contact
details (including Tesco specific contacts details) must be
reviewed (minimum annually). This can form part of the
undertaken mock recall / incident undertaken.
Section 24 Internal Audits

Base
Medium
Aspiration
P R 24.1 Base Quality Internal Audits of the Quality System must verify
Management whether activities comply with the documented
System Audits procedures, policies and work instructions to ensure
food safety, legality and quality are maintained.
Audits must also evaluate the effectiveness of the
procedures.
All elements must be audited at a defined frequency

(minimum annually).
• The HACCP Plan and CCPs

P R 24.2 Base Internal Audits As a minimum internal audits must include:
• All aspects of the Prerequisite Programme

• Good Manufacturing Practices (where not
• Allergen Controls (where applicable)

included as prerequisites)
• Process Controls
• Cleaning (to include an inspection during the
• Site fabrication
main cleaning operation)
• Traceability
• Employment Agency
• Recall Plan / Incident Management Controls
• Off site storage of raw materials /packaging
/finished product
P R 24.2.1 ASPN Internal Audits All 35 sections of the TFMS are audited. The audits
are scheduled throughout the whole year.

P R 24.3 Base Audit Schedule Audits must be scheduled throughout the production
year and the scope and frequency of each one
established. Audits must be completed to schedule.
P 24.3.1 ASPN Audit Schedule The audit schedule should be based on a risk
assessment. Some sections will be scheduled more
than once per year.
P R 24.4 Base Auditors Audits must be conducted by trained auditors with
experience of the processes or area being assessed.
R 24.4.1 ASPN Auditors Auditors should be independent of the area being
audited, but have good knowledge of the
processes and area.
R 24.5 Base Audit Records Written records of audits results must be available.
Audit reports must detail non-conformances and

recommendations. These must be brought to the
attention of the person responsible for the activity
audited.
R 24.5.1 ASPN Audit Records Evidence of all documentation used or seen must be
recorded or copied and retained with the audit.
P R 24.6 Base Corrective Actions Timescales and corrective actions must be agreed by The timescales should be appropriate
both parties. The completion of corrective actions to the food safety risk.
within agreed timescales must be verified.
R 24.7 Base Corrective Actions A non-conformance log should be maintained
detailing all non-conformances and used to manage
corrective action completion and trend analysis.
R 24.8 ASPN Audit Trend Audits trend analysis should take place where Sites within a group should consider
Analysis possible (e.g. Good Manufacturing Practice and sharing learnings.
Foreign Body Audits)
Results should be used as key performance indicators

for the business, highlighting trends and areas where
improvement is necessary.

R 24.9 Base Third Party / Agreed corrective actions arising from audits
Tesco Audits conducted by third parties / Tesco must be
implemented in agreed timescales and verified.

Section 25 Customer Complaints

Base
Medium
Aspiration
P 25.1 Base Complaints A complaints policy and procedure to handle A certain number of complaints linked
Procedure complaints must be in place. This must be part of or by complaint type, product or
linked to the site Incident Management Procedures production line will trigger a review.
where necessary.
P 25.2 Base Complaints Complaints from all sources must be covered in the
Procedure procedure e.g.:
•
•
Customer representatives
•
Stores
•
Central buying departments
•
Retailer customer complaints departments
•
Law enforcement bodies
Internal departments (e.g. operational
• Output from quality assurance processes e.g.

departments)
taste panels.
• Nature of complaint
P R 25.3 Base Complaint Complaints from all methods of reporting (e.g. post, Complaint log includes:
• Product information
Handling telephone, and email) must be captured on a logging
• Durability
system.
Each complaint must have a unique reference • Whether product sample has been
number. requested etc
P R 25.4 Base Complaint All complaints must be investigated in detail by All instances of foreign body
Handling competent personnel. contamination, alleged illness and
trends need to be investigated. Isolated
The investigation must determine whether the incidences where a customer doesn’t
complaint is product specific or an issue which may like the taste or there is a quality
affect more than one product. perception issue may not require a full

investigation; however they do need to
The complaint handling procedure must identify be monitored.
what information to check depending on complaint
type.
Complaint types can include examples such as:

Foreign Bodies, Alleged Illness, Taste, Quality,
Correct Quantity etc.
Full records must be kept and the outcome of the

investigation promptly reported to relevant personnel
and departments.
Corrective actions must be effective to prevent a re-

occurrence.
Where requested the full corrective actions must be

reported to Tesco.
P R 25.5 Base Complaint Complaint trends must be monitored.
Monitoring
Complaint numbers must be tracked against units
sold and complaint type.
An increase in complaints must prompt an

investigation.
The site must set targets and have a plan in place to

reduce complaint levels in general and for worst
offending categories/products.
R O 25.6 Base Trend Analysis Information from trend analysis of complaints must
be communicated to the site management and
production teams.

R 25.6.1 ASPN Trend Analysis Complaint trend information should be graphically
displayed on suitable notice boards at site access
points.
Complaint examples may also be displayed to

increase awareness e.g. foreign bodies.
Mechanisms should be in place for briefing and
discussing preventative action with production
teams.
P 25.7 Base Product If a withdrawal/recall is required Tesco must be
Withdrawal notified using the incident management procedures
(see section 23.4).

Section 26 Pest Control

Base
Medium
Aspiration
P R O 26.1 Base Pest Control The site must have an effective pest control
programme covering the whole site and product must
not be at risk from pest activity.
Tesco must be informed of continual / persistent pest

activity at a site.
P 26.2 Base Pest Control The pest control programme must be based on risk
Programme assessment. The risk assessment must consider the
location, products produced, type of materials
handled and pest control methods to be employed.
The Pest Control Provider (PCP) may be a specialist

company or a trained employee.
P 26.2.1 ASPN Pest Control The PCP provider is an independent specialist
Contractor contractor.
P 26.3 Base Pest Control A current documented pest control programme must e.g. rodents, flying insects, crawling
Programme be available. The programme must stipulate the insects, stored product insects, birds
following as a minimum: etc.
• The pest control provider

• The procedures used for pest control
If the site is vulnerable to nocturnal
• The pests covered within scope. The type covered

pests e.g. cockroaches, night
inspections should be included.
• A minimum number of visits must be specified

is dependant on country.
8-12 service inspections (evenly
• Material Safety Data Sheets must be included for spaced throughout the year) and 4 in
depth inspections from a field
• Emergency call out details
all chemicals used
biologist per annum.
• Details of the site area included in the programme
Same day service dependant on risk.
This includes high / low levels,

e.g. whole site and any off site storage. within dead spaces.
R 26.4 Base Training Copies of the PCPs valid training certificates and Where the PCP is a specialist
licence must be available. company, the company is a member
of a recognised trade association
Company employees engaged as PCPs must have (applicable in the country that they
proof of appropriate training and licence as required are operating in).
by state or local regulations.
P R 26.5 Base Management & A trained company employee and nominated deputy
Supervision must be accountable for managing the pest control
programme. These employees must ensure that the
visit schedule is maintained and that the PCP is
contacted where deviation from the arranged
schedule occurs.
Training of company employees can be by the PCP

or other qualified experts.
Where electronic / paperless systems are in

operation, the designated individual and their
nominated deputy must have access to the system
(e.g. the password is known by more than one
individual).
R 26.5.1 ASPN Management & Site personnel should shadow the PCP during visits /
Supervision treatments (if specialist companies are employed).
P R 26.6 Base Review The pest control programme must be reviewed and
audited (minimum annually).
P O 26.7 Base Pest Plan A full and detailed plan indicating positions and type
(i.e. toxic/non-toxic) of all baits and monitoring
equipment (internal and external), must be kept in
the pest control file.

All points must be appropriately sited. Baits must be
secured to walls or floors to prevent removal.
Bait boxes must be robust and tamper proof (to

prevent removal of bait other than by PCP or pest
activity).
Toxic baits must not be used routinely in open

product and storage areas.
Toxic baits are only used where there
Where an infestation is evident, a concession (to use is clear evidence of a problem (e.g.
toxic baits) is required from the relevant TTM before actual sightings of rodents or recent
toxic baits are used. droppings).
P O 26.7.1 Medium Pest Plan Toxic baits must not be used in open food
processing, storage and associated areas (unless these
are situated inside enclosed access panels to service
areas / risers).
P O 26.8 Base Flying Insects The position of Electric flying insect killers (EFK) Located at all entrances (not in direct
must be determined by risk assessment. sight of) to the production and storage
areas or based on risk.
The position of EFK units must not pose a
contamination risk to product. Those which electrify the insect must
not be positioned over lines, and
Bulbs in EFK units must be protected (shatterproof those with catch trays must not be
tubes) and changed (minimum annually) with positioned where the insects may be
records available. blown out by air movement.
Risk assessment must determine the location of

pheromone traps where deemed necessary.
Pheromone must be replaced on predetermined

frequency to ensure effectiveness.

O 26.9 Base Birds Activities to control birds (e.g. use of bird scarers,
shooting, netting etc) must comply with in country
legislation and not put product at risk of
contamination.
Where sites have bird activity, canopies e.g. at

loading bays etc. must be sufficiently proofed /
netted to prevent nesting birds.
R 26.10 Base Schedule PCPs visits must be conducted to the agreed
schedule.
During routine visits all traps, bait stations, and other

monitoring equipment must be opened and inspected.
P R O 26.11 Base Service Record / During each visit activity/action reports must be
Visit Report completed by the PCP, including documentation of
chemicals used, work completed, observations of
activity and recommendations.
All pests and or evidence of pests must be reported,

if noted during the inspection (even if the pest type is
not specified in the programme).
The PCP must report any proofing requirements

identified, any hygiene / housekeeping conditions
likely to effect pest prevention and any access
difficulties / ‘lost’ baits.
Corrective actions and reports must be signed off by

personnel responsible for pest control on site (or a
designated deputy).
Where serious infestations are identified, the PCP

must ensure the site representative understands the
extent of the infestation and potential for product

contamination.
P R O 26.11.1 ASPN Service Record / Records of service verification or bar code should be
Visit Report on the inside of the traps, bait stations or other
monitoring equipment.
R O 26.12 Base Visit Follow Up There must be a full programme of follow up visits
to ensure complete eradication of the issue e.g.
Rodents
-Alternate days until no evidence on 3 consecutive Alternate day follow ups are
visits e g: Wed / Fri /Sun. specifically for internal areas.
- In depth inspection of affected area plus all However, where there is infestation
adjoining areas (including above and below) externally and additional baiting is in
- Clear up every dropping every visit place then follow up visits should
also be considered (this may not be
SPI (Stored products insects) alternate days).
- After deep cleaning and insecticide application
where deemed essential
- Lay new Insect Monitors
- Weekly Follow-up inspections
Cockroaches
-Treatment weekly for six weeks
-Thereafter, monthly night-time inspections for 6
months.
Follow up and verification of all corrective actions
must be documented.
P R 26.13 Base Trend Analysis Trend analysis of pest control data must be evident
Where activity is measurable, acceptable limits
should be established with action evident when
levels fall outside specified limits.

P R 26.14 Base Pest Control Where used, live catch systems must be inspected UK requirements are that live catch
daily or more frequently where required by in systems such as, sticky boards, are
country legislation. inspected every 12 hrs.
Records need to be in place to

demonstrate compliance, where used.
Sticky traps are banned from use in

some countries!

Section 27 Maintenance

Base
Medium
Aspiration
P R O 27.1 Base Equipment and The structure and fabric of the buildings and Timescales should be based on risk.
Facilities equipment must be maintained in good condition with
repairs completed.
A system must be in place to prioritise repairs that may

impact on food safety, legality and quality. All repairs
must be completed in agreed timescales.
P R 27.2 Base Preventative There must be a planned preventative maintenance
Maintenance (PPM) program that covers all equipment critical to
safety, legality and quality, which is fully
implemented.
P 27.2.1 ASPN Preventative A computer based risk assessed PPM programme
Maintenance should be in place that details all equipment, highlights
when activities are required and enables equipment
history and trend information to be obtained.
P R 27.3 Base Records A system must be in place to record all maintenance
work requested and PPM work completed.
Work must be completed in the agreed timescales.
Procedures must be in place to manage work not

completed within agreed timescales.
P R 27.4 Base Foreign Body A system must be in place to identify and correct
Risks potential sources of foreign bodies or hygiene hazards
e.g. flaking paint, damaged surfaces.
R 27.4.1 ASPN Trend Analysis Trend analysis information should be used for on
going trend analysis to identify and act on areas for
improvement.

P R 27.5 Base Equipment Repairs to or servicing of equipment must be
completed by trained engineers, approved contractors
or the equipment manufacturer.
P R 27.6 Base Engineering Engineering activities must be controlled.
Risk assessments must be completed prior to work

commencing to ensure product and packaging is not
put at risk.
P O 27.7 Base Engineering Engineering work areas (including stores) must have
good standards of fabrication, hygiene and
housekeeping.
The areas must be within the scope of the site Pest

Control Programme.
Production or food containers must not be used as

general storage containers in these areas.
O 27.7.1 Medium Engineering Wherever possible, engineering work must take place
away from production areas.
Engineering and maintenance areas that access directly

into production areas must have restricted access.
P R O 27.8 Base Engineering Welding, drilling, riveting and soldering etc. must not
take place on equipment being used for production or
on any equipment immediately adjacent, unless
suitable hygienic screening is in place.
P O 27.9 Base Engineering Temporary repairs must be controlled to ensure
product is not put at risk.
The material used must be suitable e.g. no sticky tape.
Permanent repairs must be made promptly.

O 27.10 Base Tools Tools must be kept clean, well maintained
and replaced when necessary.

O 27.10.1 Medium Tools Tools must be captive to site or adequately cleaned
prior to transferring into open food areas.
O 27.10.2 High Tools Tools must be captive to high risk / high care areas or
disinfected into the area.
In the event of electrical items being required they

must be clean and wrapped so that the item is
waterproof, and then disinfected into the area.
P R O 27.11 Base Tools Engineers completing repairs in production areas must
be provided with lockable metal or plastic tool box.
P O 27.12 Base Tools All tools and parts must be controlled. A system must
highlight and initiate an investigation if a tool or part is
missing.
P R O 27.12.1 Medium Tool Boxes Tool boxes must contain an inventory of items they
contain.
P R O 27.12.2 Medium Tool Boxes Tool box contents should be checked at a defined
frequency against the inventory.
All small items must be separately contained within

the tool box.
O 27.12.3 Medium Parts Whilst engineers work on production equipment, small
parts should be stored in sealed marked containers,
magnetic mats or trays to reduce the risk of product
contamination.
P R O 27.13 Base Engineers/ Engineers and Contractors must comply with
Contractors necessary Health and Safety requirements and
operational GMP of the site, including wearing of
protective clothing.
A list of approved contractors who have been briefed

on site controls must be in place.

R 27.13.1 Medium Engineering A permit to work system must be in operation if the
maintenance work required poses a potential risk to
product (e.g. welding, cutting etc.) or individuals e.g.
in confined spaces.
P R O 27.14 Base Engineering After engineering work has been completed, a system
must be in place to assess cleaning requirements prior
to use in production.
Where cleaning is required following maintenance,

this must be undertaken before production commences
and must be recorded.
Equipment must be checked and signed back to

production by the engineer and production / QA
(depending on sites procedures) following work and
any necessary cleaning.
P O 27.15 Base Engineering Only food grade lubricants may be used on food
handling/contact equipment. Information must be
available to demonstrate food grade suitability for
materials used.

Section 28 Calibration

Base
Medium
Aspiration
P 28.1 Base Calibration Measuring and monitoring equipment critical to
product safety, legality and quality must be checked
for accuracy at pre-determined frequencies.
A contingency or back-up device should be available

in the event of CCP / legal measuring equipment being
out of service or away for repair.
P R 28.2 Base Calibration All measuring and monitoring equipment must be Temperature probes are externally
calibrated to National Standards where possible or calibrated to National Standards
have documented calibration records traceable to annually and then verified
National Standards. internally throughout the year.
Alternatively, a reference probe is

externally calibrated to National
Standards annually and factory
temperature probes are verified
against the probe at a defined
frequency.
R 28.3 Base Verification Verification checks across the normal operating range
must be conducted on calibrated equipment that is
critical to food safety and legality, based on risk
assessment.
All portable/handheld CCP equipment is verified on a

daily basis e.g. temperature probes.
R 28.4 Base Master List A master list / calibration matrix of all measuring and The master list / calibration matrix
monitoring equipment requiring calibration must be may include:
•
maintained.
Serial numbers and / or ID

•
numbers of equipment
•
Frequency of calibration
•
Date of last calibration
•
Date next calibration is due
Frequency of internal
•
verification
Acceptable equipment
tolerances
P 28.5 Base Procedures Measuring and monitoring equipment must be
calibrated/verified for accuracy against written
procedures detailing:
• Frequency of calibration/verification
• Method of calibration/verification
• Acceptable equipment tolerances
• Corrective action to be taken if outside tolerance
R 28.6 Base Calibration Calibration certificates and records of verification must
Records be available and up to date.
P O 28.7 Base Equipment Measuring and monitoring equipment must be

protected from unauthorised adjustment, damage,
deterioration and misuse.
P R O 28.8 Base Equipment Equipment that is operating outside of specified limits
must be taken out of service, replaced or sent for
repair.
Documented corrective action must be evident where

inaccurate measuring or monitoring equipment has
been used.
P R O 28.8.1 ASPN Equipment Where equipment is out of service or away for repair a
back up device is available for use.
R 28.9 Base Temperature Temperature probes must be calibrated / verified at the
probes temperature range at which they are used.

R 28.10 Base Weights Standard weights that are used for verification must be
of the same weight range as the products being
produced.
P R 28.11 Base Equipment Equipment e.g. flow meters, counting devices, timer
devices and ovens etc. must be calibrated at a
frequency at least as recommended by the equipment
manufacturer.
R 28.12 Base Training All calibration / verification must be carried out by
trained personnel only.

Section 29 Cleaning Programme

Base
Medium
Aspiration
R O 29.1 Base Hygiene There must be a suitably trained manager accountable
Management for overseeing all cleaning functions and the standards
achieved.
Site management meetings must review factory

hygiene. (Reference to section 9.3 is recommended)
R O 29.2 Base Hygiene Where cleaning contractors are utilised, all related
Management sections such as training, personal hygiene, medical
screening etc are still applicable.
There must be a formal handover each day of the

‘clean’ factory.
P 29.3 Base Cleaning The site must have documented cleaning procedures for
Procedures equipment, production storage, maintenance, employee
facilities and external areas.
P 29.4 Base Cleaning Cleaning procedures must contain the following:
•
Procedures
Details on how to strip equipment and to what
• Required equipment and chemicals (including

level
• Cleaning methods
dilution and temperature)
• How to re-assemble equipment and changing parts
• The replacement of damaged “O” rings where

if necessary
fitted
P 29.4.1 High Cleaning Cleaning procedures should have a unique reference

Procedures number that links to site cleaning schedules / records.
Cleaning procedures should include photographs

showing key inspection points.
P R 29.5 Base Cleaning Cleaning schedules must be in place for all areas.
Schedules
Schedules must be determined by risk assessment. The
risk assessment must be used to determine the different
types and levels of cleaning required on specific
equipment between batches, between shifts, daily,
weekly, monthly etc.
P 29.5.1 ASPN Cleaning A wall planner or computer based system may be used
Schedules to plan periodic cleaning, highlighting when items are
due for cleaning.
R O 29.6 Base Cleaning Resource Sufficient manpower and production downtime must be
provided to ensure the cleaning schedule can be
completed in full.
The necessary resources to complete the cleaning

operation in an effective manner must be provided e.g.
personnel, cleaning equipment, chemicals, protective
clothing.
Cleaning personnel must be trained in the use and

handling of chemicals and against cleaning procedures.
Cleaning schedule should be fully integrated in the

production scheduling / planning process.
R 29.6.1 ASPN Cleaning Resource Calculations to determine hygiene manpower
requirement should be based on scheduled cleaning
frequencies and time allocations for each cleaning
should be available.
R 29.7 Base Cleaning Safety data sheets must be available for all chemicals
Chemicals used on the site.

The factory must be able to demonstrate how chemicals
were selected i.e. their suitability for the method and
food product type e.g. high fat, cooking residue etc.
P R 29.8 Base Cleaning Records Checklists must be completed to demonstrate what

cleaning has been completed and by whom.
It must be the responsibility of the management to

verify cleaning is completed to specified schedules and
standards.
Visual hygiene standards must be checked by

production prior to start-up and documented.
P R 29.8.1 Medium Swabbing Hygiene standards must be verified by equipment
swabbing according to a risk assessed plan.
Swabs must be tested by the laboratory a maximum of

24 hours after sampling.
P R 29.8.2 ASPN Swabbing ATP test kits should be used to release key items of
equipment post cleaning prior to use.
P R 29.9 Base Cleaning Records All re-cleans and corrective actions following visually
unsatisfactory cleaning or out of specification swab
results must be clearly documented.
R 29.10 Medium Swabbing Trends of swab results must be reviewed on an ongoing
basis. Action must be evident for adverse trends.
P R 29.11 Medium Swabbing Environmental swabbing must be conducted in

accordance with the Tesco Environmental Swab Policy
(51) or the equivalent where in existence.
Swabbing of the environment and contact surfaces for

pathogen harbourage (e.g Listeria Spp.) must be
completed to a risk assessed schedule.
P O 29.12 Base Cleaning The site must have a documented procedure for
Procedure handling blocked drains in the production areas.
O 29.13 Base Cleaning Drain cleaning equipment must be designated for
Equipment production / storage areas.
O 29.13.1 High Cleaning Drain cleaning equipment must be designated for high
Equipment risk/high care areas.
R 29.14 Base CIP System Clean In Place (CIP) systems for pipe work, tanks and Where a CIP system has been in
instrumentation must be designed by specialist place for a number of years and no
engineers. commissioning documentation
evidence is available or where the
Evidence must be available of commissioning and system has not been designed by
process verification. specialists, 3rd party verification
should be available.
P R O 29.15 Base CIP COP Site conforms to the Tesco COP 409 “Code of Practice
for Cleaning In Place Systems”.
P R O 29.16 Base CIP Documents Procedures must be in place for the monitoring of
concentration of chemicals, time and temperature.
All records must be readily available.
Where applicable, documented test results must be

available to demonstrate that chemicals have been
effectively flushed from pipes and tanks.
R 29.17 Base CIP Training The CIP system is operated by trained personnel.
Training is updated and recorded where modifications

are made.

P R 29.18 Base CIP Maintenance Spray devices, valves, gaskets etc are removed and
inspected as per manufacturer’s recommendations and
results recorded.
P R 29.19 Base CIP Calibration Calibration of instrumentation is carried out at least
annually or more frequently if defined by risk
assessment and or the manufacturer.
29.30 ASPN CIP Systems New CIP installations should be fully automatic.

Section 30 Transport

Base
Medium
Aspiration
O 30.1 Base Transport All vehicles used for transportation must ensure the
food safety, legality and quality of materials e.g. raw
materials, packaging, work in progress and finished
goods.
P R 30.2 Base Third Parties If a third party haulage contractor is used, all the
requirements must be defined within a contract and
effectively managed.
This should include storage facilities where used as

part of the contract.
Haulage contractors must be formally approved by

recognised schemes where required e.g. animal welfare
standards / farm assurance.
O 30.3 Base Maintenance Vehicles used for transportation must be well
and Hygiene maintained and in a good hygienic condition.
P R 30.4 Base Maintenance Documented maintenance and hygiene procedures

and Hygiene must be in place for all vehicles (including pipe work
e.g. milk tankers).
P 30.5 Base Contamination Procedures must be in place to minimise the risk of
cross contamination (including taint) during
transportation.
O 30.6 Base Loading Where materials are susceptible to weather damage,
vehicles must be unloaded / loaded in covered bays or
materials suitably covered to protect the materials.
Chilled/frozen materials must be loaded and unloaded

in temperature controlled bays, or ways of working
must be such that temperature is not compromised.
P R 30.7 Base Security Procedures must be in place to ensure product is held

under secure conditions during transport.
P R 30.8 Base Temperature Where temperature controlled transport is required,
Control documented procedures must be in place to ensure the
temperature requirements are met.
Transport must be capable of maintaining product

temperature within specification, under maximum
load.
R O 30.8.1 Base Temperature Temperature controlled transport must incorporate
Control temperature data logging devices which can be
inspected to confirm temperature conditions or a
manual system must be in place to validate the correct
operation of refrigerated equipment.
P 30.9 Base Breakdown Procedures must be in place in case of breakdown of
vehicle refrigeration.
All incidences of refrigeration equipment breakdown

must be recorded and corrective actions documented.

Section 31 Medical Screening

Base
Medium
Aspiration
P 31.1 Base Medical Medical screening procedures (or the equivalent
Screening in specific countries) must be in place for
personnel entering storage or production areas to
minimise risk to product safety.
In countries where food handling screening is

required by government, the site may not have its
own systems in place.
P R O 31.2 Base Pre-Employment All personnel must be assessed for health risks
Medical before entering the food production / storage area
Screening for the first time.
A structured questionnaire must form the basis for

assessment, which is signed and dated by the
applicant.
The questionnaire must be used as background

information for a trained person to verify
personnel are fit to work as a food handler.
Where a risk is identified further medical

screening may be required before permission is
granted to enter production / storage areas e.g.
stool testing.
P R 31.3 Base Visitors / Before being allowed into food production /
Contractors storage areas, visitors and contractors must
complete a medical questionnaire.
Questionnaires must be checked and signed by

trained personnel.
P R 31.4 Base Reporting Illness The site must have a procedure for the
notification by personnel, including temporary
personnel, of any relevant infectious diseases or
condition which they may be suffering from, or
have been in contact with.
P R 31.5 Base Reporting Illness Where the site is aware of a person who has The areas where the individual has been
entered the site was suffering from a condition working should be assessed to enable the
which could have compromised food safety, steps potential risk to product to be
must be taken to minimise any risk to food safety established.
e.g. an operative has been diagnosed with food
poisoning.
P R 31.6 Base Reporting Illness Employees must report any illness to their line
manager as soon as it occurs.
A decision must be made as to whether the

employee can continue to work in the existing or
another job. (e.g. employee may be restricted to
low risk areas until medical confirmation
received).
Employees suffering diarrhoea or vomiting must

be excluded from any work on site.
P R 31.7 Base Return To Work A procedure for return to work after illness must Return to work forms are assessed by a
be in place. trained manager.
A risk assessment must be completed prior to

employees commencing work.
People who have suffered from diarrhoea must

not enter the production / storage areas until they
are symptom free (minimum 48 hours).

P R 31.8 Base Procedures Procedures must be in place for all employees, Return to work procedure after foreign
visitors or contractors who have been working in travel.
or visiting areas where product safety could be
compromised (e.g. restricted zones due to Inclusion of areas previously visited on
outbreaks). the visitor questionnaire e.g. farms or
slaughter houses.
P R 31.9 Base Procedures Procedures must be in place for managing any
bodily fluid spillages e.g vomiting, bleeding etc.
within the production and storage areas.
P R 31.10 Base Emergency Entry Procedures must be in place for people that Procedure for how the area would be
require entry to food handling areas in emergency cleaned prior to production
situations (e.g. medical or fire personnel). recommencing.

Section 32 Employment Agencies

Base
Medium
Aspiration
P 32.1 Base Employment The agency policies, procedures and activities
Agency must meet the legal requirements in the operating
country.
32.1.1 Base Employment In the UK agencies supplying workers for If in doubt as to wether an agency
Agency agricultural and food processing jobs must have a requires a license, sites should
(Tesco UK only) GLA (Gangmaster Licensing Authority) license. contact the GLA on 0845 602 5020 or
The licence number must be provided. enquiries@gla.gsi.gov.uk
GLA licenses are required for all agencies

providing workers involved in agriculture,
horticulture, shellfish gathering and food and
drink processing and packaging.
O 32.1.2 ASPN Employment Site is registered on the Government Gateway
Agency website for the Active Checks service, so that they
(Tesco UK only) are informed immediately if the agency’s license
is revoked.
R 32.1.3 ASPN Employment The agency is a member of a recognised trade
Agency body (in the country in which it is operating) and
complies with a Best Practice protocol.
P 32.2 Base Employment The site must have procedures in place to
Agency demonstrate that they manage employment
agencies.
O 32.2.1 ASPN Employment Employment agency workers are not used in high
Agency care / risk areas or in roles dealing with live
animals (from a welfare perspective).
P 32.3 Base Agency Contract A contract between agency and site must be In addition to the Contract, a “Service
documented and signed by both parties. Level Agreement” outlines standards
and processes for the supply of
The contract must be reviewed regularly and labour, including: Training, H & S
include reference to expectations on minimum management, Accident and Injury
wage and working hours etc. reporting, Checking right to work and
Monitoring of working hours.
In the UK, the site must pay at least the GLA
minimum charge rate, as listed on
www.gla.gov.uk (under “Information for Labour
Providers”)
P R 32.4 Base Audits The Agency must have been approved by a Auditors have a good understanding
competent auditor from or on behalf of the site of employment law and experience
prior to commencing supply of personnel to site. auditing personnel records.
Once approved, further audits must be completed Audits include a review of payslips
to ensure compliance, both at the agency site and and tax and National Insurance
through questioning of personnel (twice per year payments.
minimum).
Timescales and corrective actions must be agreed

by both parties. The completion of corrective
actions within agreed timescales must be verified.
R 32.5 Base Interviews The agency must conduct face to face interviews
with potential employees. This must include:
•
•
Employment history (previous assignments)
•
Literacy
Ability to understand the local language and
•
communicate
•
Confirming legality to work at the site
Confirmation of any disability
Records must be kept to confirm this (date and

name of interviewer)
P R 32.6 Base Medical Screening Agency personnel must complete and sign a This should include confirming that
medical screening questionnaire and Food hearing and eyesight are good where
Handlers Agreement (requiring personnel to this is important for their job.

report certain medical conditions they have
suffered from while away from site)
P R 32.7 Base Employment The site and the agency must be able to identify Names and numbers of workers on
Agency the individual agency personnel that are on site at site at any one time should be kept
any time. (for fire evacuation purposes)
The site and agency must be able to identify what

job each agency employee is doing in any one
day.
P R 32.8 Base Employment The site must be responsible for fully briefing
Agency agencies on the site standards regarding hygiene,
product safety, personal hygiene rules,
disciplinary procedures, health and safety
(standards and requirements) and health screening
procedures.
In addition to any off site briefing, agency

personnel must be given appropriate instructions
and guidance at the site as soon as they arrive e.g.
fire escape routes, first aid locations etc.
P R 32.9 Base Employment Agency personnel must be physically shown
Agency procedures relating to basic food safety by a
trained site based individual (e.g. hand washing,
changing procedures, etc.).
Records must be kept to confirm that they have

received and understood it.
P R 32.10 Base Personnel Files The agency must hold a file for each employee
which includes:
•
•
Evidence of eligibility to work in the country
•
Literacy information
•
Training records
A signed contractual agreement between the

•
agency and operative
A completed and signed Food Handlers
• A signed medical screening questionnaire

agreement
• Recent photograph of the worker

P 32.11 Base Supervision Agency personnel must be suitably trained for all
work activities that they will carry out and
supervised to an appropriate level.
P R 32.11.1 ASPN Supervision The number of agency personnel utilised before a
site-based agency employed supervisor is
required should be agreed by the site.
The ratio of agency personnel to site based

supervisors should be documented, audited and
the effectiveness challenged.
P R 32.12 Base Training The agency must train their personnel using the Training materials may be required in
same criteria as the site training. the employees’ first language and the
use of interpreters if necessary.
Records must be signed off by the trainer and
trainee.
Records must confirm that the employee has

received and understood the training given.
P R 32.13 Base Training Agency personnel must not be operating in a job
that could be potentially dangerous in the absence
of suitable training and supervision e.g. CCP job.
The site must verify performance themselves and

provide appropriate training. Records must be
retained.

Section 33 Environment

Base
Medium
Aspiration
P 33.1 Base Policy A site specific Environmental Policy must be in
place, detailing responsibility for meeting local
legislative requirements, minimising overall
environmental impact and how this is measured.
P 33.2 Base Quality The Quality Management System must ensure
Management environmental matters are identified and managed
System (e.g. waste control, recycling, use of water etc)
R 33.3 Base Risk A documented assessment must have been

Assessment completed to identify any potential environmental
risks and how they are being controlled.
R O 33.4 Base Potential Where measures have been put in place to protect
Contaminants the site from potential contaminants (e.g. from
neighbours or ground contamination), these must
be regularly reviewed to ensure they continue to
be effective.
O 33.5 Base Environment Consideration must have been given to the local
environment to ensure that site operations do not
(potentially) adversely impact on any sensitive
local environmental conditions.
Where in place these must be regularly reviewed

to ensure they continue to be effective.
R O 33.6 Base Independent Where the site has had an independent
Audits environmental audit completed, any non-
conformances raised must be effectively
managed.

Section 34 Ethical Trading

Base
Medium
Aspiration
P R 34.1 Base Corporate Management must have knowledge of the The policy makes reference to the ETI
Commitment to Ethical Trading Initiative (ETI) Base Code and Base Code and is signed by the owner or
Ethical Trading Tesco ethical trading requirements in the Tesco director
Ethical Code of Practice. The site must comply
with Tesco requirements for ethical trade audits The policy is mentioned at induction, in
(where deemed necessary). site newsletters and displayed on staff
notice boards.
Management must have knowledge of all
applicable local labour laws.
A written ethical trading policy statement must

be in place which must be communicated to the
workforce.
Management must be aware of their ethical risk

rating (available from Tesco Technical
Manager).
The site must be registered with SEDEX (where

required by the relevant Tesco operating
country). The self assessment information must
be completed and kept up to date.
If rated as High Risk, the site must have an

ethical audit conducted by a Tesco recognised
auditor prior to supply and every year.
If rated Medium Risk, the site must have an

ethical audit prior to supply and every 2 years.

All non-compliances raised in an ethical audit
must be resolved within the timeframes outlined
in the Corrective Action Plan.
P R O 34.2 Base ETI Base Code The site must comply with the ETI base code.
P R O 34.2.1 Base ETI Base Code The site can demonstrate that employment is Jobs are openly advertised or open to all
freely chosen. who meet the personal criteria.
P R O 34.2.2 Base ETI Base Code Workers are allowed freedom of association. Union membership allowed and/or
worker councils present.
P R O 34.2.3 Base ETI Base Code Working conditions are safe and hygienic. Qualified safety person used to assess
safety risks. Safety committees meet and
Designated persons (adequately trained) minutes kept.
responsible for health and safety, and health and
safety risk assessments undertaken, where
appropriate.
P R O 34.2.4 Base ETI Base Code Worker welfare facilities adequate. Changing rooms, toilets, eating areas and
first aid facilities provided and well
maintained
P R O 34.2.5 Base ETI Base Code No child labour. The age of all workers is known and
there is a system in place to manage the
work completed by under 18 year olds.
P R O 34.2.6 Base ETI Base Code Wages are enough to meet the basic needs and The site pays the minimum wage and
provide some discretionary income, or comply overtime premiums. The site has a
with minimum wage legislation, where it exists. system to monitor working hours.
P R O 34.2.7 Base ETI Base Code Working hours do not exceed 48 hours (unless Site has a system in place for monitoring
employee has chosen to opt out). working hours.
P R O 34.2.8 Base ETI Base Code The site operates an Equal Opportunities policy
and does not discriminate on race, caste, age,
gender, religion or union membership etc.

P R O 34.2.9 Base ETI Base Code Work is on the basis of a recognised Site has contracts of employment.
employment relationship.
P R O 34.2.10 Base ETI Base Code No harsh or inhumane treatment of staff. Site has a disciplinary, appeal and
grievance procedure.
P R 34.3 ASPN Ethical Trading Suppliers should have policies and procedures A risk-based compliance programme for
in the supply in place for managing ethical trading standards ethical trading standards, based on the
chain with their own suppliers. ETI Base Code, using competent and
independent ethical auditors, and
managed through the Sedex website.

Section 35 Management Control

Base
Medium
Aspiration
O 35.1 Base Site Management The site must have suitable management control
systems in place in to ensure the safety, legality
and quality of the products supplied to Tesco.
R O 35.2 Base Senior The site must have systems in place to ensure
Management that the relevant senior manager is notified of
Notification any safety, legality and quality issues that are
identified with Tesco product.
R O 35.3 Base Senior Systems must be in place to ensure that the This review may form part of regular
Management senior management team regularly review the scheduled management meetings, where
Review safety, legality and quality of product supplied the Technical / Quality department
to Tesco and the GMP standards of the provide information on site performance
production facility. e.g. Key Performance Indicators (KPIs)
R O 35.4 Base Corrective Action The senior management team must ensure that
where the need for corrective action is
identified, that this corrective action is
effectively implemented.

Appendix 1 Raw Material Specifications
RAW MATERIAL SPECIFICATIONS
All raw materials (including packaging) to be used in Tesco products must be brought against a specification. This specification must cover the
following minimum requirements where relevant.
- Product description and quality standards.
- Raw material supplier’s address, telephone and other contact details (including country of origin, and emergency contact details) where
the source may impact on legality and food safety.
- Process details (including HACCP, safety, legal and quality critical control points) and Process controls and QA procedures.
- Weight
- Packaging, labelling and coding details (such that codes can be interpreted)
- Product life and conditions of use.
- Distribution and storage requirements. Specified delivery temperature parameters.
- Process controls and QA procedures.
- Foreign body controls (including screening, metal detection, wood and glass control)
- Product protection details (including segregation of nuts and seeds; vegetarian, non-genetically modified and organic materials; raw and
cooked material).
- Finished product ingredients (including processing aids).
- Microbiological, chemical and physical standards (including pesticide residues, migration data, species testing where appropriate).

- Food intolerance data.
- Genetically Modified status (including plant source and ‘Identity Preserved’ source)
- Certification proof if e.g. organic supplier, or British meat supplier, British eggs, etc.
- Animal welfare standards.
- Reconstitution weights, if applicable.
- Physical standard tolerances and photographic standards (based on Red, Amber, Green standards)
- Lead times
- Seasonal variation if applicable – and subsequent effect on quality and availability.
- Where applicable, compliance with compositional standard regulations (e.g.: meat content)
- Specific attributes/standards when relevant to specific food groups, e.g.: meat (maturation, pH, kill date, specific cut details). Cheese
(slow vat controls), Potato (glycoalkaloids), etc.
- Nutritional information – confirm whether analytical or theoretical.
- Vegetarian – if material is to be used for vegetarian product, ensure supplier can confirm to vegetarian requirements
- Adherence to nut and seed code of practice,

Appendix 2 Document Review
The review has involved a large number of changes which can be found in the table below. It is recommended that suppliers carry out a Gap Analysis
to identify any changes in the Tesco Requirements. Very minor changes e.g. change to clause layout or corrections of spelling errors have not been
included in the following table. The introduction (pages 3 – 7) has been rewritten to help the reader understand the requirements.
Section No. Section Clause Amends

1 HACCP 1.2 Addition to WGLL– With support from Product Development, Purchasing,
Distribution etc as appropriate added and “not exhaustive list”.
1.2.1 New ASPN – At least one member of the HACCP team has completed a
recognised qualification in Advanced HACCP.
1.2.2 New ASPN – Refresher training of the HACCP team is undertaken annually,
regardless of any change in production processes.
1.6 Change in wording – now states “A flow diagram covering all steps in the
operation including rework, water where used and waste must be constructed”
1.8 Change in wording – now states “Presence or production of toxins, chemicals or
foreign bodies and allergens”.
1.9 Change in wording – now states “The HACCP team must also consider what
control measures (if any exist) for the remaining hazards, can be applied to
prevent, eliminate or reduce the risk to acceptable levels”.
1.9.1 New Base – previously ASPN
1.10 Removed – Definition of a CCP
Note. As it’s in the Glossary
1.14 Addition to Clause - If the risk assessment deems the product to be safe it must
not be supplied to Tesco without first discussing the issue and submitting
documented evidence to support product safety with the relevant Tesco TM.
1.14.1 New Base - The HACCP must be reviewed at the earliest opportunity following
accepted deviation from the defined critical limits.
1.18 Addition to Clause – Two more examples of review changes added and “not
exhaustive list”.
2 Finished Product Specifications 2.1 Addition to WGLL - For the UK/ROI/US all TTL specifications should be active
on or before the point at which products are on sale.
2.2 Addition to WGLL - The content within the specification should be current and
contain all relevant product information including full details of rework and how
its used (e.g. percentage to each batch, used in like for like product only, life and
break in use of rework), WIP, testing etc
2.7 Addition to WGLL - The key email contact for the alerts, cascades the
information to the correct person/department in a timely manner.
3 Raw Material & Secondary Site 3.2 Change to wording – now states “Corrective actions have been followed up and
Management completed”.
3.2.1 New Base - Where a contingency raw material/supplier is required, the site must
first contact the Tesco TM for acceptance.
Where agreed the site must have the following information about the product and
supplier (as a minimum):
•
•
•
•
Documentation to demonstrate compliance with Tesco COPs
Contingency suppliers are those used at very short notice, generally as a one off
due to approved suppliers being unable to supply.
Raw material must be on a like for like basis (e.g. Not using coloured cheddar
cheese in place of white cheddar cheese)
3.3 Addition to WGLL - The third party audit report will provide the site with
details of non-conformances, which will assist in the site being able to make a full
and proper risk assessment. (e.g. the report may show a number of failings in
Quality Management systems, which the site may wish to verify for themselves)
A certificate does not necessarily demonstrate closure of non-conformances. Not

all third party Food Safety schemes issue certificates on the closure of all non-
conformances. Some verify at next audit.
Where electronic systems are used by Certification Bodies for site reports and
certificates, these may be used to negate the need to print relevant information.
Site however, should be able to demonstrate they can navigate the system.

This information may be held on-site or centrally (e.g. head office).
3.6 Change in wording – now states “Supplier audits must be completed by trained
auditors with an understanding of processes and the risks associated with the
product area/site being assessed”.
3.8 Addition to WGLL - Electronic signatures are acceptable.(previously part of the
clause).
3.11 Change in wording - now states “All Meat and meat ingredients must be
sourced from Tesco Approved Agricultural Supplier List (203) unless authorised
by the Tesco Technical Manager (Tesco UK only)
Fresh Produce must be sourced from Tesco Approved Sources e.g. Nurture
Certificated unless authorised by the Tesco Technical Manager (Tesco UK only).
There may be other in country approved lists. Sites need to demonstrate

compliance where these exist”.
3.12 Change in wording – now states “Date/Lot coding (meets specification and
matches COA where received)”.
3.13 Addition to Clause - In some instances e.g. with fresh produce, maturity may be
used to determine the order of use.
Note. This addition was previously part of clause 11.6

3.16 Addition to Clause - Hazardous materials e.g. citric acid, alcohol, flammable
flavourings/aromas, must be suitably stored and controlled to reduce the risk of
contamination, taint and injury to persons.
4 Packaging 4.2.1 New Base - Where a contingency packaging supplier is required, the site must
first contact the Tesco TM for acceptance.
Where agreed the site must have the following information about the product and
supplier (as a minimum):
•
•
• Test results (micro, chemical), where appropriate

• Documentation to demonstrate compliance with any Tesco COPs
Contingency suppliers are those used at very short notice, generally as a one off
due to approved suppliers being unable to supply.
Packaging must be on a like for like basis

4.3 Addition to WGLL - The third party audit report will provide the site with
details of non-conformances, which will assist in the site being able to make a full
and proper risk assessment. (e.g. the report may show a number of failings in
Quality Management systems, which the site may wish to verify for themselves)
A certificate does not necessarily demonstrate closure of non-conformances. Not

all third party Food Safety schemes issue certificates on the closure of all non-
conformances. Some verify at next audit.
Where electronic systems are used by Certification Bodies for site reports and
certificates, these may be used to negate the need to print relevant information.
Site however, should be able to demonstrate they can navigate the system.
4.6 Change in wording – now states “Supplier audits must be completed by trained
auditors with an understanding of processes and the risks associated with the
packaging/site being assessed”.
4.8 Addition to Clause – Requirement now includes, Supplier Name, Address and
Artwork.
Addition to WGLL - Electronic signatures are acceptable.

4.9 Addition to WGLL - Sites should keep themselves up to date on the legislation,
as amends are made on an almost annual basis.
The regulations cover the packaging material, inserts, printing materials (e.g.
inks) and adhesives which are in direct contact with the product.
4.13 Addition to WGLL - For example similar recipes (cookies with/without nuts),
different pack sizes (may only have different bar codes), promotional flash labels
etc should be segregated or suitably controlled.

Good segregation may take the form of product labels separated by a promotional
label, dedicated pallet spaces in the case of large quantities or post office style
sorting box.
4.14 Addition to Clause - Part-used packaging should be returned to storage and
suitably covered to protect from contamination after use.
Based on risk assessment bulk packaging (e.g. films, plastic for bases) which is
used daily for all products may be left on line provided it is suitably covered to
protect from contamination and is removed and covered during cleaning.
5 External Areas and Site Security 5.2 Addition to WGLL - Where no fencing exists (e.g. the site is on a business park,
isolated location in countryside etc) the site should be secure to prevent
unauthorised public access, domestic animals and unlawful entry.
5.3 Change in wording – now states “External areas must be kept tidy and free from
unnecessary items that could provide potential pest harbourage”.
Change to WGLL – now states “No redundant or stored equipment stored

outside”.
5.3.1 New Base – previously part of 5.3
5.3.2 New ASPN - External drains should be visually identified as factory effluent,
surface water or sewage and show direction of flow.
Addition to WGLL - Painted colour coded arrows on the drain covers, showing
direction of flow and waste type.
5.4 Change in wording – now states “When present, vegetation must be kept
trimmed and clear from the production and storage buildings (approximately 1
metre clearance, to prevent pest harbourage).
Where this is out of the sites control (e.g. site is rented or neighbouring site is
close and they don’t keep vegetation at bay) there should be evidence of
persistent communications and management of potential issues”.
5.5 Change in wording – now states “External units (including silos, tanks, chillers
& freezers) must be kept locked and have restricted access”.
5.5.1 New ASPN - Other external units (e.g. portacabins) which are close to the
ground, with large inaccessible voids underneath should be made inaccessible to

rodents.
Addition to WGLL - Units should be sited on a concrete base and or sealed at

base to prevent pest ingress.
5.6 Change in wording – now states “Where unavoidable, items must be in a
hygienic condition and protected from deterioration, contamination, pests and
must be inspected in detail prior to transfer to the site. This includes all Tesco
reusable product crates”.
6 Design and Construction of Premises 6.5 Change in wording – now states “All sinks in production areas must not be
constructed from porous or breakable material”.
6.6. Change in wording – now states “Drains must be accessible for cleaning and
fitted with screens or traps to prevent pest entry and odours”.
6.8.1 Change in wording – now states “Windows designed to be open, must be
suitably proofed to prevent pest entry (including canteens, toilets and locker
facilities that adjoin the factory)”.
6.9 Addition to WGLL - Good door control should be in place (i.e. doors not being
left open for long periods to temperature controlled areas, or allowing free access
to birds)
Strip curtains should be full length and intact. Curtains which part (slide) on
opening of main door are preferred, as these do not trail over forklift trucks and
products and are therefore easier to keep clean and less prone to damage.
6.11 Change in wording – now states “Ventilation and extraction systems must be
effective at preventing condensation, excessive dust, pest entry and not pose a risk
to product (e.g. its location in respect of product and processes)”.
Addition to WGLL - Risk assessment may need to be used in order to determine

that where condensate is present, samples may need to be sent away for
microbiological and heavy metal screening e.g. chocolate manufacture.
6.11.2 Addition to Clause - Positive air pressure (>5 Pascals) must be in place in high
risk areas and monitored at defined frequencies.
Addition to WGLL - Note: Grades are based on the efficiency of the filter to trap
defined particle sizes. F7 grade is 80% efficient and F9-H11 is 98% efficient.

Generally 5-25 air changes per hour are sufficient, however in areas with large
doors/hatches that are frequently opened, up to 40 changes may be required.
6.11.3 New Base – previously High
6.11.4 New High – previously part of 6.11.3
Addition to Clause- High Risk and Low Risk air socks should be washed
separately.
6.12 Addition to Clause - All services (pipework for water/gas/steam/compressed air,
electrical cabling/conduit/sockets, ventilation ducting, compressors/pumps, fire
extinguishers/sprinkler systems etc) should be designed from material suitable for
the purpose and appropriate to the area where used, intact and allow easy and
effective cleaning. (Health and Safety requirements in the country of manufacture
must be adhered to).
Note. Item has been renamed as “Services”

6.13 Addition to WGLL - Racking where fitted should be far enough away from the
wall, to prevent pallets being pushed up tight against the wall.
There should be enough space to allow walking access between materials and
walls for inspection.
6.14 Addition to Clause - Condensate pipes must flow to drain and not drip on
product, materials, packaging or production equipment.
Addition to WGLL - Pipe should end a few centimetres above the drain and not
ducted directly into the drain.
6.14.1 Addition to WGLL - Traps are “U” or “S” type which, contain water, thus
preventing air to be drawn back.
There should be no break in the pipe work.

6.14.2 Removed - Condensate pipes must have a trap in the pipe work to prevent a back
flow of air from the drains and condensate must be channelled directly out of the
area to a drain in fully enclosed pipe work.

Note. This is 6.14.1
Addition to WGLL - Sanitising rings do not negate the need to maintain the
evaporators and pipe work properly.
6.14.4 Addition to Clause - Temperature controlled areas must be capable of
maintaining the required temperature.
6.15 Change in wording – now states “Eating and drinking is not permitted in these
offices, with the exception of plain drinking water”.
Addition to WGLL - Offices should have basic equipment (desk, chair, storage,
computer etc) which is of an easy to clean construction.
They should not be adorned with personal items (e.g. collectables, cups, bottles
etc)
Stationary items should be consistent with site rules and GMP (e.g. factory issue
pens, no staples, no drawing pins etc)
Guidance Addition to Guidance - Campden BRI Guidelines on air quality standards for the
food industry No 12 (www.campden.co.uk)
7 Design and Construction of Equipment 7.1 Addition to Clause - The layout must not pose a risk of contamination.
Addition to WGLL - Equipment should not be located too close to sinks, waste
units, allergen production, washing etc
7.3 Addition to WGLL - Food contact surfaces should have continuous welds, be
free of inaccessible crevices, excessive scratches and pitting to prevent the
trapping of food debris.
7.5 Change in wording – now states “regularly inspected/monitored for wear and
damage”
7.6 Addition to Clause - Equipment must be sited away from potential risks of
contamination (e.g. not to close to a hand wash sink).
7.7 Addition to WGLL - Mobile equipment should be stored away from packaging
and food ingredients, when not in use.
7.7.1 Addition to WGLL - Equipment with maintenance free batteries may be charged
in these areas, provided they are stored away from open food processes.

8 Employee Facilities and Personal 8.1 Addition to Clause - Smoking areas where provided, must comply with in
Protective Equipment country legislation. Where provided they must be maintained in a clean condition
and have bins for the tabs / butts (to prevent transfer into the factory on soles of
shoes). No tabs / butts can be disposed of on the floor.
8.2 Change to WGLL – now states “No personal items should be carried by staff.
Facilities should be secure, giving staff (including agency and temporary
workers) the confidence to leave their belongings”.
8.2.1 Addition to Clause – (see clause 8.14.1)
Removed - (Systems must be in place to allow waste to be removed e.g. medium
to low, low to external areas.)
Addition to WGLL - The same should be applied to visitors/management and

visitor/management changing areas.
8.4.5 New ASPN - Locker inspection/audits are carried out at a defined frequency.
Employee should be present.

8.5 Addition to Clause - Hand washing signs must be displayed in toilet areas. Coat
hooks must be located outside the toilet area.
Note. First sentence was previously in 10.2

8.5.1 Addition to WGLL - Legionnaires’ Disease: The control of Legionella bacteria
in water systems. Approved Code of Practice and Guidance 2000
(www.hse.gov.uk)
8.5.2 Change in wording – now states “Toilets must be ‘fit for purpose’ for the
ethnicity of staff”.
8.5.3 New ASPN - Taps in toilet facilities should be mixer taps not be hand operated.
8.8 Addition to WGLL - Food left by employees should be removed as necessary.
8.9 Change in wording – now states “Head covering must be worn by all personnel.
(If food is not exposed, head covering and beard snoods are not required)”.
8.9.2 New High - Single use disposable hairnets or mop caps must be worn.
No cloth (washable) hair covering is worn without a hairnet.

Addition to WGLL - High care / risk hairnets should be placed over the top of
low risk hairnets rather than constant removal.
8.10 Change in wording – now states “Protective clothing must be maintained in
good clean condition. A procedure must be in place to manage repairs including
the control of pins and needles”.
Removed - No personal items must be carried in pockets (see 10.10).
Note. Covered in 10.10
Addition to WGLL - A full complement of different coloured PPE should be

worn i.e. coats and footwear (including gloves and aprons where worn).
Coats may be distinguished by coloured collars.
Coats should be free of rips, tears, loose threads and missing poppers etc
8.10.1 Addition to Clause - Protective clothing must cover all personal clothing above
knee height. Arms must not be exposed, unless risk assessment deems there is a
risk to product safety from coat sleeves.
Protective clothing must be free from external pockets, buttons and not have
access to own pockets.
Engineers should not wear their workshop coats in the factory during production.
Addition to WGLL - Hoods on personal clothing must be under the protective

clothing.
Consideration should be given to not wearing factory coats in engineering

workshops.
8.11 Change in wording – now states “Coats/jackets must be removed before entering
toilets, canteen/rest areas, smoking areas and offices (outside production areas)”.
8.11.1 Change in wording – now states “Protective clothing worn above the knee must
be removed in non-production areas (excluding footwear).

Where knee length coats are not worn, staff should change out of company issue
trousers”.
8.13 Change in wording – now states “Protective clothing for engineering, hygiene
(and where applicable laboratory) staff must be laundered separately to food
production work wear (including canteen staff PPE) to prevent possible foreign
body contamination
This may be in house or by an external company. In certain circumstances home

laundry programmes may be permitted. Line drying is not permitted. Staff must
not wear protective clothing to and from work and it must be transported in a
clean bag”.
8.14.1 Change in wording – now states “Suitable footwear must be provided and
remain captive to the inside of the building. Short external walkways may be
acceptable if they are:
-clearly defined
-well maintained e.g. smooth (non slip) hard surface
-clean with no debris / pooling water (daily cleaning)
-not connected to smoking areas
If staff, enter toilets in their factory footwear: the toilets must be maintained to a
high standard (i.e. clean floor) to prevent contamination of the production area.
Scheduled footwear cleaning must be in place.
Only disposable shoe coverings that do not rip or tear are permitted”.
Addition to WGLL - Where walkways are in place, they should be identified

with brightly coloured paint (yellow). They should connect two distinct locations.
Toilets area are regularly cleaned and inspected

8.14.2 Change in wording – now states “Footwear must remain captive to the area and
be visually distinctive.

Shoes with laces and shoe covers must not be permitted”.
8.14.3 Removed - Foot baths must not be used (unless specified by local in country
regulation).
Note. Now have Medium, High and ASPN footbath clauses
Addition to WGLL - Boot washers and footbaths do not negate the need for
scheduled cleaning.
8.14.4 New Medium – Footbaths should be avoided. However, where footbaths are in
place they must pose no risk to product and or processes. (e.g. separate room,
after using there is no requirement to use walkways above product etc)
The water and chemicals used must be changed at defined frequencies throughout
the day.
8.14.5 New High - No footbaths.
8.14.6 New ASPN –Scheduled boot cleaning in place. No footbaths.
Addition to WGLL - A dedicated room for washing boots.
8.15 Change in wording – now states “Sufficient numbers of hand wash or sanitising
facilities must be suitably sited (with a logical flow) at all entrances and
throughout production and storage areas where required”.
Addition to Clause - Signage should be present at hand wash sinks giving clear
instruction on how to wash hands correctly.
Addition to WGLL - Hand wash water temperature should be comfortable,

neither too hot or too cold, so as to discourage use.
8.15.1 Addition to Clause - Cloth roller towels must not be used.
Addition to WGLL - Paper towels should be suitable and not tissue like, which
break-up easily whilst drying hands.
The colour of paper towels are blue or of a contrasting colour.

8.15.2 Addition to Clause – Automatic hand dryers must not be used in production
areas.

8.16 Addition to Clause – previously WGLL
Addition to WGLL - Beard Snoods and face masks should be put on prior to the
final hand wash.
Where ear protection is worn hands should be washed after insertion into ear.
8.16.2 Change in wording – now states “The procedure would be as described above
(8.16.1) however when the individual has put on their coat, they would then enter
the production hall and wash and sanitise their hands at a sink located just within
this area (away from production lines)”.
Addition to WGLL – previously part of the clause

8.17 Change in wording – now states “(UK Only – If product is not stripped,
Fareshare 1st and Company Shop Ltd are the two authorised routes for disposal
of surplus stock in the UK. Fareshare 1st is a national charity that re-distributes
the food through a community network to disadvantaged people.
If Tesco product is offered for sale by 'Company Shop Ltd', it must be printed or
stickered with the ‘Company Shop’ name and address and meet all applicable
food legislation)”.
Addition to WGLL - The site should have full control over surplus stock and
know the quantities of product. This is particularly important for traceability and
or product recall.
9 Factory Hygiene 9.2 Addition to WGLL - E.g. the use of high pressure hoses during production or the
cleaning of high level areas without moving product below.
9.3 Change in wording – now states “There must be a suitably trained manager
accountable for overseeing in production cleaning and the standards achieved”.
Note. this has been done to differentiate between 29.1
Addition of WGLL - Cleaning operations should be managed to make sure they

pose no risk to product (e.g. making sure hygiene operators move products and
equipment that may be affected by the clean down process) and correct methods

of cleaning are used for product type and environment.
9.5 Addition to Clause - Where food contact equipment is wall mounted it must be
at a height that poses no risk of contamination (e.g. shoulder height and not
touching the wall).
Where floor cleaning equipment is wall mounted it must be stored handles up.
The floor contact end of cleaning equipment should be below the height of boot
tops.
Wall mounted cleaning equipment must be returned in a clean condition.
Addition to WGLL - Heat set bristles in brushes used on food contact surfaces,
single blade squeegees in favour of folded blade type as these harbour debris and
bacteria.
9.5.1 Change in wording – now states “The use of mops in open food areas must be
risk assessed. Multiple-use string mops are not permitted.
Where permitted they must be clean, in a good condition and stored away from
product and production processes”.
9.5.2 Addition to Clause - Mops are not permitted.
9.6 Change in wording – now states “Cleaning equipment used for other areas (e.g.
toilets, offices and outside) must be segregated and visually distinctive”.
Removed – “Where in place” from last sentence.
Addition to WGLL - Cleaning equipment may be differentiated visually by type

and or colour.
9.8 Addition to WGLL - No phenolic or scented products (including all toilet areas).
9.12 Addition to WGLL - Areas are sited so they present no risk to product integrity
and or safety.
9.14 Removed - Sinks (in production areas) must not be constructed from porous or
breakable material and waste water must be ducted directly to drain.

Note. This is in 6.5
9.16.2 Addition to Clause - A risk assessment must be in place where this is not carried
out.
Change to WGLL – now states “If a factory has not been producing over a
weekend, holiday or shut-down period equipment must be re-disinfected before
use”.
9.17 Change to WGLL – now states “Waste trays /containers / bags should be a
separate type or different colour to those used in production for food”.
10 Personal Hygiene 10.2 Removed - Hand washing signs must be displayed in toilet areas.
Note. Now in 8.5
Change in wording – now states “Touching or picking up items from the floor
and using ladders”.
10.2.2 Change in wording – now states “Hand swabs or contact plates are taken and
assessed following an unannounced but planned programme”.
10.4 Addition to Clause - See also 6.16 for product sampling.
10.6.2 New High – previously ASPN
10.6.3 New ASPN - First aid kits should contain an inventory of contents, which is
checked at defined intervals.
Addition to WGLL - First aid box contents and quantities should be selected so
as to minimise the risk of product contamination.
10.7 Change in wording – now states “False fingernails (acrylic or other) must not be
permitted”.
10.10 Change in wording – now states “Personal items (e.g. keys, personal mobile
phones and coins) must not be carried on the person and be taken into production
and storage areas”.
Addition to WGLL - The exception being locker keys and ID cards, where
provided.
Keys used within the factory (e.g. metal detector reject boxes) should not be
treated as personal items and attached to key rings or taken home. These are best

issued daily as part of the QA kit.
Combination locks prevent the need for keys.

10.12 Change in wording – now states “Jewellery must not be worn, with the
exception of a single plain band ring (i.e. one piece with no stone settings or
intricate design). Cufflinks and tie pins must be considered as jewellery.
Rings and studs in exposed parts of the body (including the tongue) must not be
worn.
Personal clothing and fashion accessories should not pose a potential foreign
body risk e.g. decorative items such as sequins should not be sewn on garments,
diamante settings in glasses etc”.
10.13.1 New Medium - Permitted medical or religious jewellery is not exposed or pose
any food safety risk.
Addition to WGLL - Jewellery should be suitably covered by the PPE (coat,

sleeves and or gloves)
11 Process Controls 11.1 Change in wording – now states “Raw materials, work in progress, finished
product, processes, storage and equipment, when they are critical to product
safety, legality or quality, must be controlled, monitored and recorded”.
11.6 Removed - In some instances e.g. with fresh produce, maturity may be used to
determine the order of use.
Note. Now an addition to clause 3.13

11.7.1 New Base - The retention period and storage conditions for samples must be
agreed with the Tesco TM.
11.12 Change in wording – now states “Open raw material life must be established and
labelled where necessary when the original pack physical state has been changed
e.g. de-canning, breaking of vacuum seal, freezing of fresh materials, de-frosting
etc”.
Addition to WGLL - Where products are received fresh and subsequently frozen
the product must be suitable for freezing, details must be included in the raw

material specification and it must have been in-life prior to freezing.
11.15 Change in wording – now states “All Modified Atmosphere chilled foods must
conform to Code of Practice For The Manufacture of Vacuum and Modified
Atmosphere Packaged Chilled Foods (second edition) 2009, Guideline No. 11
Campden BRI”
11.16 Change in wording – now states “All cooked bulk meats must conform to
Identification and Prevention of Hazards associated with slow cooling of hams
and other large cooked meats and meat products 1998, Campden BRI Review
R8”
11.17 Removed – reference to packaging as this is covered in 18.2.
12 Traceability 12.1 Addition to WGLL - Where sites have bulk storage on site (silos, tanks, bulk
mixing) and they operate a system of topping up with each delivery, they must be
able to demonstrate this in their traceability challenge. E.g. they were aware of
balance within tank prior to filling with new delivery and information relating to
both deliveries is submitted.
12.3 Removed – The 4 hour time requirement is now 12.3.1
Addition to WGLL - The factory should keep all records as evidence of

completing traceability tests and not just summarised outcomes.
12.3.1 New Base – see 12.3
12.4 New Base – previously High
Change in wording – now states “(minimum twice per year)”.
Removed - Traceability exercises should be completed within 4 hours. see 12.3.1

13 Allergen Control 13.1.2 Change in wording – now states “All sites must have a written allergen risk
assessment which includes details of all processes, products and allergens
(including details of physical form e.g. liquid or powder) used on site.
Where allergens are used or stored the risk assessment must establish the potential
for cross contamination. The risk assessment must include all processes and areas
of the factory, including product transfer.
If the Risk Assessment forms part of the HACCP it will need to be clearly

demonstrated.”
Addition to WGLL - Allergens risk assessed individually, no grouping or

hierarchy.
Where grouping has been employed controls to minimise the risk of cross
contamination between allergens in the group must be evident.
The risk assessment must consider the transfer and movement of used equipment
and partially used trays of product, process aids, cleaning, CIP, product
development etc (not an exhaustive list).
13.1.3 Moved and Change of wording – now states “Sites whose products contain
allergens must have a documented, effective, risk based allergen management
system to reduce the risk of cross contamination.
Controls must be in place to reduce contamination of non allergen containing

products.”
Note. Previously 13.1.2
Addition to WGLL - Where the same allergen is present in all products this may
not be required.
13.2.1 New Base - Transport of raw material must not pose a risk of cross
contamination.
Bulk tankers used for both allergenic and non allergenic raw materials must be
able to produce cleaning records.
Addition to WGLL - Consideration should be given to vehicle

loading/unloading and cleaning.
13.3 New Medium - Open product that has been in contact with allergenic material
must be disposed of if not being used in like for like product.
Addition to WGLL - E.g. On a line producing a cheese and tomato sandwich,

where the cheese is placed on the bread first and tomato second. The handler of
the tomato would have contaminated their product with cheese. The tomato
should be disposed of, unless being used in a like for like product or is used in
only that product.
13.4 Change in wording – now states “Segregation of allergens must be based on risk
assessment, i.e. product in unopen / fully sealed packaging poses less risk than
packaging that has been open and re-sealed or open / covered products.
However, nuts are the exception and must be stored separate in a restricted access
area.”
Addition to WGLL - Allergenic materials stored on pallets at floor level to

minimise the risk of cross contamination if damaged.
This should be either locked storage, out of reach (i.e. stored in racking) of
general persons, in an area of limited access and not stored in unsecured areas or
where product can be accessed by general persons.
13.5 Change in wording – now states “Based on risk assessment raw materials, work
in progress and finished product containing allergens must be clearly identified
during storage and production”.
13.6 Change in wording – now states “Cleaning between the production of allergen
and non allergen containing products and products containing different allergens
must be thorough, and where possible chemically cleaned to remove all visible
debris.
The cleaning must be verified by documented visual inspections as a minimum.
A validation study must be available and reviewed annually or after any change in
the equipment or procedures”.
Addition to WGLL - Where tests are readily available, the cleaning procedures
may be validated with surface allergen testing kits.
13.6.1 Change in wording – now states “Sieves must be dedicated to individual
allergenic ingredients or cleaned immediately after allergenic material is sieved,

where there is a risk of cross contamination.
Free standing sieving equipment must be dismantled to remove all visible debris
after allergenic material is sieved. The area around the sieving operation must
also be cleaned.
Bulk or in-line sieving equipment must be cleaned to remove all visible debris.
Where fitted, extraction equipment must be suitably cleaned and managed to

prevent any risk of cross contamination.”
Addition to WGLL - Ideally sieving of allergenic material should be in a

separate or screened area.
13.7 Change in wording – now states “Utensils used for handling allergen products
must be chemically cleaned after use or dedicated to specific ingredients”.
Addition to WGLL - Stainless steel is preferred as it’s easier to clean than

acrylic equipment which can become heavily scored over time.
13.7.1 New Base - Maintenance activities on equipment handling allergens must be risk
assessed and appropriate controls defined and implemented. Movement of
engineers and tools from one machine to another should be considered.
13.8 Change in wording – now states “If dedicated lines (for allergens) are not in
place, scheduling must take into consideration the allergen content of the different
products produced on the line.
Line cleaning and other controls must be employed as determined necessary by

risk assessment”.
13.10 Change in wording – now states “Based on risk assessment oils used for the
frying of allergenic foods (e.g. shellfish, fish and breaded products) must not be
subsequently used for frying products not containing allergens.
All Tesco specs not containing the allergen must detail this”.
13.12 Change in wording – now states “All staff (including agency) must receive
allergen training as part of the site induction.

Where allergens are used, staff must be aware of the risks regarding cross
contamination”.
13.12.1 New Medium – previously ASPN
Addition to WGLL - Alternating the colour of the disposable protective

equipment as the line changes between products.
14 Foreign Body Controls 14.4.1 New ASPN - Brittle coloured plastics should be considered for inclusion in the
register, where they may pose a risk of product contamination.
Addition to WGLL - For example white plastics in dough production areas, red
plastics in raw meat processing areas etc may be included on the register.
14.6 Change in wording – now states “Completion of an incident log and sign off that
production can restart, by a responsible/senior person”.
Addition to WGLL - The site has a procedure that follows a logical sequence
and has sufficient detail to manage the incident. E.g. What equipment is used for
the clean up of breakage? (a specific colour, type or dedicated for glass breakage
only) How it’s to be used? (glass maybe on equipment and floor) What happens
with equipment after use (cleaned and returned to an office or disposed)
It may be practical to take a photograph of a reassembled item rather than retain

sample in some instances (e.g. item snapped in two)
14.7 Change in wording – now states “All production / hygiene managers and
engineers must be trained to understand and apply the glass breakage procedure”.
14.8 Addition to WGLL - Wooden boxes where used in good condition or system of
repair (e.g. potato storage boxes). Demarcation of where wooden pallets are or are
not permitted within the site
14.8.1 Removed – now forms part of 14.9
14.9 Addition to Clause - Wood must not be permitted in open food areas.
Note. Previously 4.8.1
14.13 Addition to WGLL - Knife sharpening with steels is acceptable, provided they
are not used over product.

Where sharpening devices are fixed within butchery areas, the location and use
must not pose a risk of contamination.
14.14 Change in wording – now states “Engineering activities must be controlled to
avoid compromising product safety or quality”.
14.24 Removed - (other than in locked and managed display cabinets).
Note. As they do pose a risk in these areas and alternatives are available globally.
Addition to WGLL - One piece (i.e. no lid) factory issue pens with no clear
plastic parts in production and storage.
Metal detectable pens, in sites where metal detectors are used. (These may be of
the impregnated plastic type or of metal construction)
Alternatives to staples and drawing pins are available should be used wherever
possible.
14.25 New Base – The type, condition and location of any labels used must not pose a
risk of contamination.
14.25.1 New ASPN – previously Medium
14.26 New ASPN – previously High
14.29 Change in wording – now states “A procedure must be in place for the de-
boxing and debagging of raw materials and packaging, which aims to minimise
the risk of contamination”.
Note. Part of the clause has also moved into WGLL and been slightly reworded.
14.30 Addition to WGLL - Cardboard is removed from all items including PPE (e.g.
disposable glove boxes) prior to transfer to high risk / high care.
Where it is not possible to remove cardboard (e.g. winding tubes for films and
labels) it must be clean.
14.31 Change in wording – now states “Foreign body audits should be completed at a
frequency based on risk”.
15 Foreign Body Detection 15.1 Addition to WGLL - Justification should be agreed with the Tesco TM, where
the risk assessment deems that metal detection / x-ray is not required.
15.2 Change in wording – now states “Code Of Practice 375 - Metal Detector & X-

Ray Systems”.
15.7.1 Addition to Clause - Visual or audible alarm system in the event of line fault and
fail safe activation
15.10 Change in wording – now states “The test pieces must be passed through the
detector as close to the centre of the aperture as can be achieved with the test
pack”.
15.12 Addition to WGLL - Plasters are tested using worst case scenario i.e. placed in
the product.
16 Product Inspection and Analysis 16.1 Change in wording – now states “Product testing must be completed to ensure
compliance with Tesco Product Specifications for microbiological, chemical,
physical, organoleptic and other specific requirements (e.g. Free From and
Nutritional Claims), unless the site has written confirmation from the Tesco TM”.
16.2 Change to WGLL - For UK/ROI – Laboratories must have a current
accreditation (UKAS, CLAS or LABCRED) and if applicable be registered on the
Tesco Approved Laboratory Scheme.
All applicable Laboratories should ideally register before June 2010 as the
deadline is Jan 2011.
16.2.1 New Base (UK/ROI only)- As of Jan 2011, all finished product testing for
Salmonella, Listeria, E.coli O157 and Campylobacter must be carried out at a
laboratory that is approved by the Tesco Laboratory Approval Scheme.
The manufacturer must be able to demonstrate that the methods used for their
product testing are included in the scope of the laboratory approval.
16.3 Removed – reference to the guidance, as no longer applicable.
16.4 Removed – reference to the guidance, as no longer applicable.
16.5 Addition to the Clause - Out of specification pathogen results should be reported
back to the Tesco TM at the earliest opportunity.
17 Water and Waste Water Management 17.1 Addition to WGLL - Assessment includes the consideration of Legionella and
Cryptosporidium. (also see 8.5.1)
17.2 Change in wording – now states “Water used in processing food, as an
ingredient, for washing materials or for cleaning must be potable”.
17.2.1 New Base - Systems must be in place to manage notifications from a Water
Authority of contaminated water sources (e.g. Boil Water Notice in the UK
because of Cryptosporidium).
Addition to WGLL - Boil Water Notice risk assessment, Guideline 188 on TTL.
Systems are in place to manage changes in water sources if they could affect
product safety or quality.
17.3.5 Addition to WGLL - It is good practice to run taps to flush the system at defined
frequencies if they are not used on a daily/weekly basis.
17.5 Removed - All pipes and fixtures must be designed from material suitable for the
purpose and kept in good condition.
Note. Now part of 6.12

18 Product Labelling and Coding 18.2 Change in wording – now states “At start up and changeovers, the line must be
clear of any packaging not required for the next production run (including
promotional packaging)”.
18.7 Addition to Clause - (e.g. reel changes, fire-alarm, breakdown, breaks).
A sample of the actual code printed on the packing from each check should be
retained unless authorised by the Tesco Technical Manager.
Addition to WGLL - In the case of printed boxes/bags it is acceptable to cut out

and retain the coding information only for the purpose of traceability.
Checks include the cross checking of product label information against case/tray
end labels.
The part of the packaging with the printed code may be retained rather than all of
the packaging.
18.13.1 New ASPN - Real time is printed on product labels.
19 Weight, Volume and Count Checks 19.1 Addition to Clause - Sites must have a clear documented policy and procedure
for the management of weight, volume and count for each product manufactured,
which conforms to legal requirements in the country of manufacture and the
intended country of sale.
Note. Previously 19.2

19.2.1 Removed – now 19.2
19.4.1 Change in wording – now states “Products packed to either minimum or average
pack weight (where applicable) should utilise automated check weigh systems”.
Note. This was previously WGLL. See also 19.4.2

19.4.2 Addition to Clause - Systems controlling average weight should dynamically
measure batch compliance.
There should also be a “Bin full” sensor, which stops the line after a pre-set
number of items enters the bin or is rejected.
Records should be signed off at the end of each batch.
Note. These were previously part of 19.4.1

19.5 Change in wording – now states “All scales and equipment used for finished
product weight control must have documented checks at a minimum twice per
production day as part of the verification process”.
20 Training 20.4.1 Addition to WGLL - Where tests are used, wrong answers should be closed-out
to demonstrate full understanding.
20.9 Addition to Clause - The competency of employees must be reviewed at defined
intervals or following significant changes in procedures and re-training
undertaken where necessary.
21 Quality Management System 21.1 Addition to WGLL - There should be a documented action plan in place to
address anomalies identified.
The site uses a site plan to define the areas of the factory (i.e. base, medium etc.).
The site contacts their Tesco Technical manager if any clarification is required.
21.6 Change in wording – now states “Details of deputising cover for personnel with
responsibility for legal, safety and quality issues must be documented”.
Addition to WGLL - As well as Senior management cover the site should be

able to demonstrate they have sufficient cover for operatives who are responsible
for CCPs.
22 Product Development 22.1 Change in wording – now states “(e.g. Fo values, cook/chill, microbiological

testing, label claims, risk of allergens, suitability of packaging etc)”.
Addition to Clause - All factory trials should be documented and records

retained.
23 Product Recall/Incident Management 23.1 Addition to WGLL - Any issue that impacts on supply or affects the brand
integrity should be reported to Tesco.
23.2 Addition to Clause - Certification Bodies / Schemes
23.6 Addition to WGLL - The site should retain all records as evidence of completing
mock incident challenges and not just a summarised outcome.
The site should not confuse mock recall with traceability. This process is to test
effectiveness of procedures.
24 Internal Audits 24.2 Addition to Clause - Off site storage of raw materials /packaging /finished
product
24.4 Change in wording – now states “Audits must be conducted by trained auditors
with experience of the processes or area being assessed”.
24.4.1 Change in wording – now states “Auditors should be independent of the area
being audited, but have good knowledge of the processes and area”.
24.6 Addition to WGLL - The timescales should be appropriate to the food safety
risk.
24.7 New Base – previously ASPN
24.8 Change in wording – now states “Audits trend analysis should take place where
possible (e.g. Good Manufacturing Practice and Foreign Body Audits)
Results should be used as key performance indicators for the business,

highlighting trends and areas where improvement is necessary”.
Addition to WGLL - Sites within a group should consider sharing learnings.

25 Customer Complaints 25.4 Change in wording – now states “All complaints must be investigated in detail
by competent personnel”.
Addition to WGLL - All instances of foreign body contamination, alleged illness

and trends need to be investigated. Isolated incidences where a customer doesn’t
like the taste or there is a quality perception issue may not require a full

investigation; however they do need to be monitored.
26 Pest Control 26.5 Change in wording – now states “A trained company employee and nominated
deputy must be accountable for managing the pest control programme. These
employees must ensure that the visit schedule is maintained and that the PCP is
contacted where deviation from the arranged schedule occurs”.
26.7 Change in wording – now states “Toxic baits must not be used routinely in open
product and storage areas”.
26.7.1 Change in wording – now states “Toxic baits must not be used in open food
processing, storage and associated areas”
26.8 Addition to WGLL - Located at all entrances (not in direct sight of) to the
production and storage areas or based on risk.
Those which electrify the insect must not be positioned over lines, and those with
catch trays must not be positioned where the insects may be blown out by air
movement.
26.9 Addition to Clause - Activities to control birds (e.g. use of bird scarers, shooting,
netting etc) must comply with in country legislation and not put product at risk of
contamination.
Change in wording – now states “Where sites have bird activity, canopies e.g. at
loading bays etc. must be sufficiently proofed / netted to prevent nesting birds”.
26.11 Change in wording – now states “Corrective actions and reports must be signed
off by personnel responsible for pest control on site (or a designated deputy)”.
26.12 Addition to WGLL - Alternate day follow ups are specifically for internal areas.
However, where there is infestation externally and additional baiting is in place
then follow up visits should also be considered (this may not be alternate days).
26.14 Addition to WGLL - UK requirements are that live catch systems such as, sticky
boards, are inspected every 12 hrs.
Records need to be in place to demonstrate compliance, where used.
Sticky traps are banned from use in some countries.

27 Maintenance 27.1 Addition to WGLL - Timescales should be based on risk.
27.7 Change in wording – now states “Engineering work areas (including stores)

must have good standards of fabrication, hygiene and housekeeping”.
27.13 Change in wording – now states “Engineers and Contractors must comply with
necessary Health and Safety requirements and operational GMP of the site,
including wearing of protective clothing”.
28 Calibration 28.1 Addition to Clause - A contingency or back-up device should be available in the
event of CCP measuring/ legal equipment being out of service or away for repair.
28.3 Addition to Clause - All portable/handheld CCP equipment is verified on a daily
basis e.g. temperature probes.
Note. Previously WGLL

28.4.1 Removed – now included as WGLL in 28.4
28.11 Change in wording – now states “frequency at least as recommended by the
equipment manufacturer”.
29 Cleaning Programme 29.4 Change in wording – now states “How to re-assemble equipment and changing
parts if necessary and The replacement of damaged “O” rings where fitted”.
29.4.1 New High – previously ASPN
29.6 Addition to Clause - Cleaning schedule should be fully integrated in the
production scheduling / planning process.
Note. Previously part of 29.6.1

29.8 Change in wording – now states “Visual hygiene standards must be checked by
production prior to start-up and documented”.
29.14 New Base – Clean In Place (CIP) systems for pipe work, tanks and
instrumentation must be designed by specialist engineers.
Evidence must be available of commissioning and process verification.
Addition to WGLL - Where a CIP system has been in place for a number of
years and no commissioning documentation evidence is available or where the
system has not been designed by specialists, 3rd party verification should be
available.
29.15 New Base - Site conforms to the Tesco COP 409 “Code of Practice for Cleaning

In Place Systems”.
29.16 New Base - Procedures must be in place for the monitoring of concentration of
chemicals, time and temperature.
All records must be readily available.
Where applicable, documented test results must be available to demonstrate that

chemicals have been effectively flushed from pipes and tanks.
29.17 New Base - The CIP system is operated by trained personnel.
Training is updated and recorded where modifications are made.

29.18 New Base - Spray devices, valves, gaskets etc are removed and inspected as per
manufacturer’s recommendations and results recorded.
29.19 New Base - Calibration of instrumentation is carried out at least annually or more
frequently if defined by risk assessment and or the manufacturer.
29.30 New ASPN - New CIP installations should be fully automatic.
30 Transport 30.2 Addition to Clause - This should include storage facilities where used as part of
the contract.
30.8.1 New Base – previously Medium
31 Medical Screening 31.1 Addition to Clause - In countries where food handling screening is required by
government, the site may not have its own systems in place.

31.2 Addition to Clause - The questionnaire must be used as background information
for a trained person to verify personnel are fit to work as a food handler.
Where a risk is identified further medical screening may be required before

permission is granted to enter production / storage areas e.g. stool testing.

31.2.1 Removed – now part of 31.1 and 31.2
32.1.1 Change in wording – now states “In the UK agencies supplying workers for
agricultural and food processing jobs must have a GLA (Gangmaster Licensing
Authority) license. The licence number must be provided.

GLA licenses are required for all agencies providing workers involved in
agriculture, horticulture, shellfish gathering and food and drink processing and
packaging”.
Addition to WGLL - If in doubt as to wether an agency requires a license, sites

should contact the GLA on 0845 602 5020 or enquiries@gla.gsi.gov.uk
32 Employment Agencies 32.1.2 New ASPN - Site is registered on the Government Gateway website for the Active
Checks service, so that they are informed immediately if the agency’s license is
revoked.
32.1.3 New ASPN – previously 32.1.2
32.3 Addition to Clause - In the UK, the site must pay at least the GLA minimum
charge rate, as listed on www.gla.gov.uk (under “Information for Labour
Providers”)
Addition to WGLL - In addition to the Contract, a “Service Level Agreement”

outlines standards and processes for the supply of labour, including: Training, H
& S management, Accident and Injury reporting, Checking right to work and
Monitoring of working hours.
32.4 Change of wording – now states “The Agency must have been approved by a
competent auditor from or on behalf of the site prior to commencing supply of
personnel to site”.
Addition to WGLL - Auditors have a good understanding of employment law

and experience auditing personnel records.
Audits include a review of payslips and tax and National Insurance payments.
33 Environment
34 Ethical Trading 34.1 Change in wording - now states “Management must have knowledge of the
Ethical Trading Initiative (ETI) Base Code and Tesco ethical trading requirements
in the Tesco Ethical Code of Practice. The site must comply with Tesco
requirements for ethical trade audits (where deemed necessary)”.
Addition to Clause - Management must have knowledge of all applicable local

labour laws.
Management must be aware of their ethical risk rating (available from Tesco
Technical Manager).
If rated as High Risk, the site must have an ethical audit conducted by a Tesco
recognised auditor prior to supply and every year.
If rated Medium Risk, the site must have an ethical audit prior to supply and
every 2 years.
All non-compliances raised in an ethical audit must be resolved within the

timeframes outlined in the Corrective Action Plan.
35 Management Controls
Note: there have also been some changes to the Glossary of Terms on page 180.

GLOSSARY OF TERMS
Agent A Person, firm, company or other entity who acts on behalf of a supplier, and to whom a
Tesco purchase order is addressed.
Aw Water activity - a measure of available water.
Base Requirements for all production facilities irrelevant of the product or process type. See
Page 3 for definition.
BRC IOP The British Retail Consortium and Institute of Packaging Technical Standard and Protocol
for Companies Manufacturing and Supplying Food Packaging Materials for Retailer Brand
Products.
Captive Not removed from the area
CCP Process step at which control is required to prevent or eliminate a food safety hazard or
reduce it to an acceptable level
CCTV Closed Circuit Television
Codex Codex Alimentarius Revision 4 (2003)
Contract Packer Company contracted/paid by a supplier or primary site to pack the product produced by the
supplier or primary site into retail packaging.
Critical Limit A Criterion which separates acceptability from unacceptability
EU European Union
F0 Value Critical measurement for the canning industry
HACCP A system which identifies evaluates and controls hazards which are significant for food
safety.
HACCP Study The operations carried out to implement HACCP
High Additional requirements for sites producing high care / high risk products. See Page 4 for
definition.
High Risk An area designed to a high standard of hygiene where practices relating to personnel,
ingredients, equipment and environment are managed to minimise microbiological
contamination of ready-to-eat product comprising only cooked ingredients.
High Care An area designed to a high standard of hygiene where practices relating to personnel,
ingredients, equipment and environment are managed to minimise microbiological
contamination of a ready-to-eat or ready-to-reheat product containing cooked and
uncooked ingredients (e.g. salad leaves).
High Product This is generally a chilled, processed, ready-to-eat (or re-heat) product with a short shelf
life. It may not have any other safety factors which control the growth or survival of
pathogenic bacteria (e.g. Aw or pH). High products will be produced / packed in a high
care / high risk area (after the product or ingredients have been decontaminated in order to
reduce cross contamination).
Importer A Person, firm, company or other entity who imports Tesco products.
Low Risk A Low Risk environment will normally be in place/ designated as such, where a factory
(Environment) also has either a High Care or High Risk facility. It is an area of a factory that handles raw
materials that will be further processed prior to consumption. Often materials are
transferred from Low Risk into High Care / High Risk via continuous ovens, water flumes
(chlorinated) sanitization tunnels etc. These are some of the methods used to
decontaminate products / materials to prevent transfer into the High Care / High Risk
environment. There will be a physical barrier (e.g. a wall) between Low Risk and High
Care / High Risk. Although good hygiene standards are important, there is a general
acceptance that Low Risk areas may not be free of all pathogens.
Medium Additional requirements for open food and associated areas/processes. See Page 4 for
definition.
Nominated A nominated expert is a person having a special skill or knowledge in a particular product
Expert and/or technology.
Palletainer A pallet with a container attached to it, which is used for the transport of liquids.
Pascal Pascal (Pa) is a unit of pressure measurement equal to 1 Newton per square metre.
PCP Pest Control Provider
PET Polyethylene Terephthalate
pH A measure of the level of acidity in a product
PPE Personal Protective Equipment

PPM Planned Preventative Maintenance
Pre-Requisite A basic environmental or operating condition that is necessary for the production of safe,
legal food.
Primary Any packaging that is in direct contact with the product. E.g soft drink bottles, sweet
Packaging wrappers or the inner bag of cereal boxes.
Primary Site A site supplying Tesco that is manufacturing, processing, assembling or packing and which
is named as the primary site on the product specification.
Re-Work Material left over from production, which is reused to make the same or a similar product
SALSA Safe and Local Supplier Approval
Secondary Site A site supplying Tesco that is approved, monitored and controlled by a primary site. A
secondary site does not supply product to Tesco directly.
Sedex Supplier Ethical Data Exchange (ethical trading database)
Supplier A Person, firm, company or other entity to whom a Tesco purchase order is addressed.
T1 Tolerable negative weight value
T2 Minimum tolerable negative weight value
Trader An Agent
TTL/ TTM/ CTM Tesco Technical Library / Tesco Technical Manager / Tesco Category Technical Manager
Validation A process of obtaining evidence to demonstrate controls are effective
Valid IT A database of raw material suppliers who can guarantee that their products do not contain
genetically modified ingredients or “Sudan” dyes
Verification The application of methods, procedures, tests and other evaluations in addition to
monitoring to determine compliance

Appendix 3 -Documents Required for the Traceability Assessment
Product ……………………………………………………………………………………………………………
Weight/Count/Volume ……………………………………………………………………………………………
Display Until/Use-By Date/Additional Codes ………………………………………………………………….
To facilitate the completion of the audit the documents below will be required. These documents
must relate to the above product/production.
Section Documents √/X

Specification Authorised Tesco Product Specification
• Copies of all raw material specifications
• Supplier audit risk assessment and schedule
• Audit reports and corrective actions (including third party information)
Raw Materials • Incoming raw material records including any microbiological testing,
vehicle temperature checks, vehicle condition checks, goods receipt
information, certificates to prove source or claims of material, COC's,
COA's
• Copies of all packaging specifications
• Supplier audit risk assessment and schedule
Packaging • Audit reports and corrective actions (including third party information)
• Incoming packaging records including any testing, checking of quality,
vehicle condition checks, goods receipt information, certificates to
demonstrate compliance to legislative standards, e.g. migration
• HACCP manual with HACCP plan, training, scope
HACCP
• Documented records for all CCP's identified for the product
Product Labelling • All records relating to the control of product, labelling and coding
and Coding • Taste panel/quality records
Weight, Volume • All records relating to the control of weight, volume or count throughout
the process
and Count
• Any checkweigher calibration/start-up records
Foreign Body • e.g. metal detection/x-ray detection
Detection • Records of any testing, including start and end of run
• Sieve/filter records
Foreign Body
• Knife/blade/scissor/needle integrity checks, etc.
Controls
• Start-up checks
• Vehicle temperature and cleanliness records
Transport
• All despatch records to depot
• All recipe/product controls and records relating to the run
Process Controls • Room temperature records for any storage and production areas, e.g.
manual and automatic monitoring
• Any chemical, nutritional, microbiological testing results for this batch or
Product nearest to production date if applicable
Inspection and • Microbiological and organoleptic shelf life data relating to this batch or
Analysis nearest to production date
• Any trending results for chemical, nutritional, micro tests
Product • Trial results and procedure for managing products
Development • Any validation records for food safety

Document Audit
Completion of the document audit may require the following to be viewed - please note this is
not an exhaustive list and is a guide only
Section Documents √/X

Quality • Quality Policy
Management • Quality manual
System • Document Control
• Policy and procedures
Complaints • Trend analysis documents internal and Tesco
• Customer complaint investigations
• Scope and schedule
Internal Audits
• Audit reports and corrective actions
• Scope
• Inspection and treatment reports/recommendations
Pest Control • EFK analysis and records of bulb changes
• Evidence that EFK bulbs are shatterproof
• Safety data sheets for chemicals used
• Wood/glass/hard plastic policy
• Glass breakage procedure
Foreign Body
• Glass/hard plastic records and registers
Controls
• Foreign body detection procedures
• Hand back procedure following equipment repair
• Procedures for all equipment
• Up-to-date calibration certificates
Calibration
• Calibration/verification register
• Records of verification
• Cleaning schedules
Cleaning
• Cleaning and CIP records with verification, e.g. audits and swabbing
Programmes
• Cleaning chemical concentration records
Water and Waste • Programme and risk assessment for testing
Water • Records of testing
Management • Corrective action taken if outside of specification
Product Analysis • Laboratory accredication certificate and scope of accreditation
• Policy
Environment • Procedures to manage environmental matters
• Copies of any audits
• Proof registered with SEDEX and risk assessment
Ethics • Ethical policy and equal opportunities policy
• Copies of any ethical audit reports
• Copy of contract and audit reports
Employment
• Personal files selected by the auditor to include permit to work, medical
Agencies
screening, induction records, etc.
• Planned Preventative Maintenance schedule and records
Maintenance
• Air filtration changes/inspections/positive air for high risk
• Pre-employment screening
Medical Screening
• Reporting illness and return to work procedures
• Copy of induction programme
Training • Training records to be viewed will include induction, basic food safety.
Specific training programmes - auditor will select names of records to be
• Procedures for managing recalls and incidents
Product Recall
• Evidence that procedures are tested

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Food Manufacturing Standard

Author: Terence Wilde ` Applicable to: Product: All Food

Legal and Technical Document Matrix No: 347

Food Manufacturing Standard

Tesco Food Manufacturing Standard Version 4.0 Page 1 of 183

Introduction to the Tesco Food Manufacturing Standard

Quality Systems Audit

21 Quality Management System 103

Appendix 1 – Raw Material Specifications 147

Tesco Food Manufacturing Standard Version 4.0 Page 2 of 183

The Arrangement and Configuration of the TFMS

The Sections and Layout

Tesco Food Manufacturing Standard Version 4.0 Page 3 of 183

Example 1: An ingredients warehouse (ambient or temperature controlled) is likely to be a Base

Example 1: The assembly and packaging of a chilled ready-meal is High.

Tesco Food Manufacturing Standard Version 4.0 Page 4 of 183

Example of a factory layout for chilled RTE products

Base Area Medium Area Base Area

Tesco Food Manufacturing Standard Version 4.0 Page 5 of 183

P = Procedure. - A documented procedure that has been fully implemented.

Auditing of the Standard

• Minor – A deficiency which requires attention to improve Good Manufacturing Practice

Tesco Food Manufacturing Standard Version 4.0 Page 6 of 183

Country Specific Requirements

TFMS Category Guidelines

Tesco Food Manufacturing Standard Version 4.0 Page 7 of 183

X What Good Looks Like

The HACCP Plan must include a detailed scope

A programme of refresher training to ensure up to date

Tesco Food Manufacturing Standard Version 4.0 Page 8 of 183

The control measures and monitoring procedures for the

• Treatment and processing

• Packaging (e.g. modified atmosphere, vacuum)

• Storage and distribution conditions

• Durability and required shelf-life

• Instructions for use

Tesco Food Manufacturing Standard Version 4.0 Page 9 of 183

Hazards identified must be specific to the process step,

• Likely occurrence and severity

• Survival or multiplication of micro-organisms

• Potential for adulteration/deliberate contamination

The HACCP team must also consider what control

If no control measures have been identified the product

Tesco Food Manufacturing Standard Version 4.0 Page 10 of 183

Critical limits must be measurable and justification for

The monitoring system must be able to demonstrate control

The precision limits and tolerances of the monitoring

Monitoring procedures must contain details on how the

Tesco Food Manufacturing Standard Version 4.0 Page 11 of 183

Product and or materials must be disposed of if the safety

If the risk assessment deems the product to be safe, it must

• Review of customer complaints

• Review of hazard measurements e.g. microbiological

Tesco Food Manufacturing Standard Version 4.0 Page 12 of 183

• Supply or specification of raw materials

• Change in factory layout or product flow

Tesco Food Manufacturing Standard Version 4.0 Page 13 of 183

X What Good Looks Like

Copies of the specifications must be accessible on all