The first step in the process is to inventory and properly document all glass and brittle plastics in areas where foods and ingredients are stored or handled. This must include the warehouse, production and packaging areas. When conducting the inventory, the location of glass or plastic must be noted along with the type of glass or plastic (if possible) and whether it is shielded or strengthened in any way. When conducting this inventory, it must also include the area or areas where glass packaging materials are stored. This inventory must include all glass and brittle plastic, including but not limited to gauge covers, lights on fork lifts, lights, monitoring devices, clocks and thermometers. The materials being inventoried will vary with each and every food processing facility. It is a good idea to assign a number or some other designation to each item in the inventory. There is often more than one specific item in a room, and it is imperative that each and every piece in the inventory can be clearly identified. For example, if the warehouse has 50 overhead lights, make sure each is identified and appropriately flagged.
Once the inventory has been completed and is properly documented, the HACCP Team or another group should conduct a risk assessment on each item on the list. The objective is to determine whether any of the items in the inventory pose a significant risk to food safety or quality. Situations that pose a significant threat (high risk) shall be addressed as soon as possible and corrective actions noted in the master list. Corrective actions may include, but need not be limited to, the use of shields or covers on overhead lights, replacement of some plastics with those that are stronger or shatterproof, or removal of the item in question from the production or holding area. More and more processors are adopting shatterproof glass lighting in the operations, especially since long-life shatter-proof LEDs are now available. The inventory list will serve as the basis for regular audits of the glass and brittle plastic in the facility. If cracked, damaged or broken glass or brittle plastic is observed during audits, internal inspections, routine examinations of operations or during normal operations, it must be noted and evaluated immediately. Repairs shall be prioritized based on potential risk to the business. These incidents should be recorded in the glass breakage log. Note that the term “normal operations” is used. This implies that all persons in the plant are responsible for what goes on during process operations. If a line worker observes damaged glass or plastic or some other issue, he or she should report it to management. This also means that management needs to include glass and brittle plastic in the employee orientation and refresher training sessions.