7th Week

Material Storage

I visited the material storage area at Lihni Seafoods (Pvt) Ltd, which is systematically organized to support production efficiency and hygiene compliance. The storage includes a wide range of items categorized as follows:

• Primary Packaging Materials: These include items that come into direct contact with fish or fish pieces such as wasabi papers, fabric poplin cloths, airlaid papers, and mac foils.

• Secondary Packaging Materials: Used for outer packaging and protection during transport, such as vacuum bags, black printed polythene bags, corrugated cartons, and Styrofoam boxes.

• Color-Coded Tapes and Polyethene: Utilized for easy identification and segregation of fish boxes according to shipment requirements.

• Other Supporting Materials: Gel frost packs for temperature control during transport, as well as tissue papers, hair nets, face masks, and hand gloves to support hygiene practices during handling and processing.

The storage conditions were regularly monitored to ensure that materials are kept in a clean, dry, and organized environment, following FIFO (First-In-First-Out) principles and good storage practices.

Labelling Review

I reviewed the labelling practices followed at the facility for both inner packages and master cartons, ensuring compliance with regulatory and customer standards. The labels are designed to provide essential information that supports the safe handling, storage, display, and use of the product by customers or end users.

Each inner package and master carton label typically includes: factory name and address, EU registration number, product type, storage conditions, net weight, product traceability details, production and expiry dates.

Labels are verified and approved by the production and packing supervisors before being applied to each production batch. Additionally, when a new fish species or product is introduced, or if there are changes in supplier legislation or customer requirements, the production manager re-evaluates and approves the labels accordingly.

The storekeeper is responsible for the initial label verification at the purchasing stage, ensuring that the correct version of the label is used in alignment with current specifications. This multi-level approval and verification process helps maintain labelling accuracy, regulatory compliance, and traceability across all product lines.

Task - Label Preparation 

At Dives Foods (Pvt) Ltd, labels for day-to-day packaging sessions are typically prepared in-house. After printing the label templates, essential product information such as price, weight, manufacturing date, expiry date, batch code, and registration number is filled in manually before being affixed to product packages.

On this particular day, I was tasked with preparing a label urgently for a specific customer order. This involved gathering all necessary details related to the product, customer specifications, and legal requirements. I verified the correct format and content for the label and ensured that it complied with the company’s labeling procedures. This experience helped me better understand the importance of accurate, clear, and compliant labeling in the value-added food industry.

3rd Party Testing Procedures

As part of the comprehensive food safety management system at the facility, a range of third-party testing procedures are conducted to ensure product quality, environmental hygiene, and compliance with regulatory standards. These procedures include:

Product Testing

1. • Chemical Testing: Analysis for heavy metals (e.g., mercury), histamine levels, and residues of contaminants or non-permitted additives.

   • Microbiological Testing: Evaluation for pathogens such as Salmonella, Listeria monocytogenes, E. coli, and Staphylococcus aureus in final products to ensure food safety.
     
     

Environmental Monitoring

1. • Swab Testing: Surface swabs are collected from processing areas and equipment to detect microbial contamination and verify cleaning effectiveness.

   • Air Quality Monitoring: Conducted to assess the presence of airborne microbial contaminants in critical production areas.
     
     

Water and Ice Testing

1. • Chemical Testing: Includes analysis for residual chlorine, heavy metals, and overall water quality parameters.

   • Microbiological Testing: Checks for the presence of coliforms, E. coli, and other microbial indicators in both water and ice used in processing.
     
     

Employee Health Screening

1. • Stool Testing for Salmonella: Conducted periodically for food-handling staff to prevent the risk of contamination from asymptomatic carriers.
     
     

All third-party testing is performed by accredited laboratories to ensure accuracy, traceability, and alignment with national and international food safety standards. The results are reviewed and documented by the Quality Assurance department, and necessary corrective actions are taken if non-conformities are detected.

Sample Collection for SWAB Testing

SWAB testing is conducted as part of the environmental monitoring program, to assess the microbial quality and hygiene status of food-contact and non-food-contact surfaces within the processing facility. During my internship, I had the opportunity to observe the sample collection procedure for SWAB testing, which included the following key areas; fish ball preparation machine, cutting boards and stainless steel bowls, strip curtains at entry points, drainage lines in processing areas. 

I observed how trained personnel collected swab samples using sterile swab sticks and pre-moistened solutions, ensuring aseptic technique to prevent contamination. I also learned about the sample preservation methods, such as immediate storage in cooled containers to maintain integrity during transport to the lab.

The swabbing tool kit included sterile swabs, transport media, gloves, labels, and sample tracking forms. Post-collection, the samples are sent for microbiological analysis to detect the presence of indicators such as Total Plate Count, Yeasts and Molds, Coliforms, and Listeria spp..

Air Quality Testing

The air quality testing procedure conducted at the sausage production facility evaluated the microbial load present in the processing environment. The method used was passive air sampling, which involves the exposure of prepared agar plates (commonly Tryptic Soy Agar or Nutrient Agar) at selected locations within the plant. 

SGS Lanka

At Lihini Seafoods (Pvt) Ltd, several food safety and environmental monitoring procedures—third-party testing activities are conducted in collaboration with SGS Lanka. SGS is globally recognized as a leading Testing, Inspection, and Certification (TIC) company, with a reputation for ensuring quality, safety, and regulatory compliance across industries. 

Click SGS to view their services in food industry. 

Solid Waste Management 

Solid and liquid waste generated at the factory is managed and disposed of following strict hygienic practices to maintain food safety and environmental sustainability.

• Waste Segregation: Rubbish from processing areas, offices, external premises, stores, and maintenance rooms is collected in closed, labelled dustbins. Waste is sorted into polythene, paper, glass, and metal for proper recycling or disposal.

• Offal Disposal: Fish offal is collected in a designated offal room and is removed daily by authorized third-party collectors, who utilize the material for dry fish production.

• Trimming and By-product: Trimmings are collected in polythene bags.
    Fish heads are placed in separate bins.
  Fish, crustacean, and mollusk waste are collected and stored separately   to avoid cross-contamination.

• Non-Conforming Product Disposal: Fish rejected due to high histamine levels, mercury content, elevated temperature, or lack of freshness are either returned to suppliers or immediately disposed of through approved waste procedures, preventing any risk of unfit material entering the production line.

• Canteen waste: Food waste is collected in closed dustbins and removed by an assigned personel for animal feed.