Operations Hub
Brand System v10.0 -- Manufacturing Operations
Mfg
Operations
Reference
Operations
Reference
Processes. Equipment. Compliance. Production.
Complete manufacturing operations reference for GFS facilities -- Edgewood NY (HQ/warehouse/distribution) and Hermitage PA (manufacturing/cold storage). HACCP plans, GMP protocols, equipment catalogs, and production scheduling.
Processing
Packaging
HACCP
GMP
Yield
01Manufacturing Processes
GFS Manufacturing Process Cards -- Edgewood NY & Hermitage PA
Cheese Cutting
EquipmentWire cutter, portioner
Output2,000 lbs/hr
Temp Req38-42F ambient
CCPMetal detection
CertsSQF, USDA, Kosher
Cheese Repacking
EquipmentVac sealer, shrink, labeler
Output1,500 units/hr
Temp Req36-40F product
CCPSeal integrity, metal det
CertsSQF, USDA
Sandwich Assembly
EquipmentAssembly line, wrapper
Output800 units/hr
Temp Req36-40F ambient
CCPAllergen control, metal det
CertsSQF, FDA registered
VFFS (Vertical Form Fill Seal)
EquipmentVFFS machine, weigh filler
Output60 bags/min
Temp ReqAmbient (product frozen)
CCPCheckweigh, metal det
CertsSQF, USDA
Horizontal Flow Wrap
EquipmentFlow wrapper, infeed belt
Output120 packs/min
Temp ReqAmbient or refrigerated
CCPSeal integrity check
CertsSQF
Frozen Repack
EquipmentBlast freezer, case packer
Output500 cases/hr
Temp Req0F product, -30F blast
CCPTemp verify, metal det
CertsSQF, USDA
Kit Assembly
EquipmentAssembly table, QC station
Output400 kits/hr
Temp Req36-40F ambient
CCPVisual inspect, weight
CertsSQF, FDA
Mixing / Blending
EquipmentRibbon mixer, hopper
Output3,000 lbs/batch
Temp ReqPer formulation
CCPAllergen, metal det
CertsSQF, Kosher, Halal
All manufacturing processes operate under GFS HACCP plan and SQF Level 2 certification. Edgewood NY: Lines 01-06. Hermitage PA: Lines 01-04.
02Equipment Catalog
GFS Equipment Inventory -- Standardized Icons & Specifications
Walk-in Freezer
Capacity: 10,000 cu ft
Temp: -20F to 0F
Defrost: Auto, 4x daily
Monitoring: Wireless IoT
Temp: -20F to 0F
Defrost: Auto, 4x daily
Monitoring: Wireless IoT
Walk-in Cooler
Capacity: 8,000 cu ft
Temp: 33-40F
Humidity: 85-95% RH
Strip curtain doors
Temp: 33-40F
Humidity: 85-95% RH
Strip curtain doors
Cheese Wire Cutter
Cut sizes: 1oz to 40lb
Throughput: 20 cuts/min
Wire: Stainless .012"
Pneumatic operation
Throughput: 20 cuts/min
Wire: Stainless .012"
Pneumatic operation
Vacuum Sealer
Bag sizes: 6x8 to 24x36"
Cycle time: 15-25 sec
Vacuum: 99.5%
Double seal bar
Cycle time: 15-25 sec
Vacuum: 99.5%
Double seal bar
Shrink Tunnel
Dimensions: 24"W x 12"H
Temp: 250-350F
Speed: 40 ft/min
Conveyor integrated
Temp: 250-350F
Speed: 40 ft/min
Conveyor integrated
Label Applicator
Label types: Pressure-sens.
Speed: 200 labels/min
Accuracy: +/-1mm
Auto splice capable
Speed: 200 labels/min
Accuracy: +/-1mm
Auto splice capable
Metal Detector
Ferrous: 1.0mm
Non-ferrous: 1.2mm
Stainless: 2.0mm
Auto reject, data log
Non-ferrous: 1.2mm
Stainless: 2.0mm
Auto reject, data log
Checkweigher
Range: 0.5oz to 50lb
Accuracy: +/-0.1oz
Reject: Air blast/pusher
Speed: 200 ppm
Accuracy: +/-0.1oz
Reject: Air blast/pusher
Speed: 200 ppm
Case Erector
Case sizes: RSC 8-24"
Speed: 15 cases/min
Auto tape/glue bottom
Magazine: 200 blanks
Speed: 15 cases/min
Auto tape/glue bottom
Magazine: 200 blanks
Pallet Wrapper
Wrap cycles: 3-5 revs
Film gauge: 60-80 ga
Auto pre-stretch 250%
Turntable: 6,000 lb cap
Film gauge: 60-80 ga
Auto pre-stretch 250%
Turntable: 6,000 lb cap
VFFS Machine
Bag sizes: 2oz to 5lb
Fill weights: 1-80oz
Speed: 60 bags/min
Film: BOPP, PE, Lam
Fill weights: 1-80oz
Speed: 60 bags/min
Film: BOPP, PE, Lam
Flow Wrapper
Product: 2" to 12" long
Film: OPP, BOPP, PE
Speed: 120 packs/min
Servo-driven, no-product no-bag
Film: OPP, BOPP, PE
Speed: 120 packs/min
Servo-driven, no-product no-bag
Equipment maintained per OEM specifications. Preventive maintenance schedules in NetSuite. All critical equipment on backup power (generator).
03HACCP Plan Summary
HACCP Flow Diagram -- GFS Operations
Receiving
CCP1
Hazard
Pathogen growth from temperature abuse during transit
Critical Limit
Refrigerated: <41F / Frozen: <0F at receiving dock
Monitoring
Probe thermometer on every inbound load, logged in receiving system
Corrective Action
Reject load, notify supplier, document deviation. QA hold if borderline.
Verification
Calibrate thermometers daily. Review logs weekly. Supplier COAs quarterly.
Records
Receiving temp log, BOL, rejection forms
Storage
CCP2
Hazard
Temperature abuse leading to microbial growth or quality loss
Critical Limit
Coolers: 33-40F / Freezers: 0F or below. Continuous monitoring.
Monitoring
Automated IoT sensors every 15 min. Alarm to QA manager phone/email.
Corrective Action
Transfer product to backup unit. Maintenance call. Quality hold if >2hr deviation.
Verification
Manual temp check 2x/shift. Sensor calibration monthly. Alarm test weekly.
Records
Continuous temp data, alarm logs, calibration records
Processing
CCP3
Hazard
Metal, glass, or hard plastic contamination from equipment
Critical Limit
Metal detector: Fe 1.0mm, Non-Fe 1.2mm, SS 2.0mm. 100% of product scanned.
Monitoring
Test standards every 30 min and at start/end of each run. Auto reject + alarm.
Corrective Action
Stop line. Isolate product since last good test. Re-run through detector. Investigate source.
Verification
Test piece verification 2x/shift. Annual detector calibration by OEM. Review reject data.
Records
Metal detector log, test piece results, reject log, maintenance records
Packaging
CCP4
Hazard
Compromised seal allowing contamination, oxygen ingress, pathogen growth
Critical Limit
Vacuum sealed: <1% oxygen. Seal strength: min 3 lbs/inch. No visible channels.
Monitoring
Visual inspection every package. Destructive seal test every 30 min or start of run.
Corrective Action
Adjust sealer temperature/time. Repackage affected product. Hold and re-inspect lot.
Verification
Burst test 1x/shift. Sealer maintenance per PM schedule. Film supplier COA review.
Records
Seal integrity log, burst test results, sealer settings log
Shipping
CCP5
Hazard
Temperature abuse during loading or transit. Cross-contamination in trailer.
Critical Limit
Trailer pre-cool: Refrig <40F, Frozen <0F before loading. Unit running, verified.
Monitoring
Probe trailer air temp before loading. GPS/temp tracker activated on sealed unit.
Corrective Action
Do not load if trailer above limit. Re-cool and re-verify. Reject unit if defective.
Verification
Review pulp temp of last loaded product. Cross-reference GPS data at delivery. Carrier audits annually.
Records
Shipping temp log, BOL, trailer inspection, GPS temp data
HACCP plan developed per Codex Alimentarius and USDA FSIS guidelines. Annual review and validation required. Team: QA Manager, Plant Manager, Maintenance Lead, Production Supervisor.
04GMP Visual Guide
Good Manufacturing Practices -- 21 CFR 117 (cGMP)
Handwashing
20 seconds minimum with soap and warm water. Before entry, after breaks, after touching face/hair/phone. Hand sanitizer does NOT replace washing.
Hair Restraints
Hairnet required at all times in production. Beard net for facial hair. No exposed hair. Replace if torn or loose.
No Jewelry
No rings, watches, earrings, necklaces, or bracelets in production areas. Plain wedding bands allowed with glove only. Medical alert: notify QA.
Clean Uniforms
White coat or smock, clean daily. Company-laundered preferred. No production clothing worn outside facility. Change if soiled.
No Food in Production
Personal food and beverages prohibited in production areas. Designated break rooms only. Water bottles allowed in non-production zones only.
Sanitize Equipment
Full sanitation between product runs and at shift changes. Allergen clean required when switching allergen-containing products. Verify with ATP swab.
Pest Exclusion
Doors closed when not in use. Air curtains on dock doors. No standing water. Monthly pest control service. ILTs (insect light traps) at entry points.
Chemical Storage
Locked cabinet, separate from food. SDS (Safety Data Sheets) available at point of use. Chemicals in original labeled containers only. Spill kit nearby.
Allergen Separation
Dedicated lines for major allergens or full allergen clean between runs. Color-coded utensils. Schedule allergen-free products first in production day.
First In First Out
FIFO rotation mandatory. Date labels on all product. Oldest stock pulled first. Receiving dates visible on all pallets. Weekly rotation audit.
Floor Maintenance
Clean, dry, no cracks or standing water. Epoxy-coated floors in production. Squeegee after wet cleaning. Repair cracks within 24 hours.
Visitor Protocol
Full PPE required: hairnet, beard net, smock, shoe covers. Escort at all times. Sign in/out log. No personal items in production. Allergen questionnaire.
GMP training required for all employees upon hire and annually thereafter. Violations documented and addressed per progressive discipline policy. Reference: 21 CFR Part 117 Subpart B.
05Production Schedule Template
Week of May 19, 2026 -- Edgewood NY Production Schedule
| Day | Line | Product | Batch Size | Start | End | Changeover | Status |
|---|---|---|---|---|---|---|---|
| Monday 05/19 |
Line 01 | Barrel Cheddar Cutting | 10,000 lbs | 06:00 | 11:00 | -- | Complete |
| Line 02 | Block Cheddar Repack | 3,000 units | 06:00 | 14:00 | -- | Complete | |
| Tuesday 05/20 |
Line 01 | Mozzarella LMPS Repack | 8,000 lbs | 06:00 | 12:00 | 45 min allergen clean | Complete |
| Line 03 | Provolone Slicing | 2,000 lbs | 07:00 | 13:00 | -- | In Progress | |
| Wednesday 05/21 |
Line 02 | Sandwich Assembly | 4,800 units | 06:00 | 12:00 | 60 min full sanitation | Scheduled |
| Line 04 | Kit Assembly (Snack Kits) | 2,400 units | 06:00 | 12:00 | -- | Scheduled | |
| Thursday 05/22 |
Line 01 | USDA Pancake Packaging | 6,000 units | 06:00 | 14:00 | 90 min allergen clean | Scheduled |
| Line 05 | Frozen Veg Repack | 500 cases | 08:00 | 12:00 | -- | Scheduled | |
| Friday 05/23 |
Line 01 | Swiss Cheese Cutting | 4,000 lbs | 06:00 | 10:00 | 30 min standard clean | Scheduled |
| Line 02 | Cream Cheese Repack | 1,500 units | 06:00 | 10:00 | -- | Scheduled |
CompleteProduction finished, QA released
In ProgressCurrently running on line
ScheduledConfirmed, materials staged
ChangeoverLine cleaning/setup between runs
Schedule managed in NetSuite Manufacturing module. Changeover times include sanitation, allergen cleaning, and equipment setup. All times Eastern.
06Yield & Waste Tracking
Production Yield Dashboard -- May 2026 MTD
Yield Rate by Product (Target: 98.0%)
Target line (98.0%)
Above target
Below target
Critical
Waste by Category -- May 2026
Scrap (unusable product)
0.4%
Rework (reprocessable)
0.8%
Giveaway (overweight)
0.3%
Trim (usable byproduct)
0.6%
Total Waste
2.1%
Cost of Waste -- Monthly Trend
JAN
FEB
MAR
APR
MAY
$4.2K$3.8K$4.5K$3.1K$2.8K
Top 5 Waste Reduction Opportunities
| # | Opportunity | Impact | Priority |
|---|---|---|---|
| 1 | Calibrate checkweighers weekly (reduce giveaway) | -$400/mo | High |
| 2 | Optimize sandwich bread cutting template | -$350/mo | High |
| 3 | Improve block cheddar wire alignment | -$280/mo | Medium |
| 4 | Reduce kit assembly component mismatch | -$200/mo | Medium |
| 5 | Upgrade vacuum sealer sensors (reduce rejected seals) | -$150/mo | Low |
Yield data from NetSuite Manufacturing module. Target: 98% yield across all product lines. Waste cost calculated at product standard cost. Review at weekly production meeting.
07Sanitation Schedule Template
The Master Sanitation Schedule (MSS) defines every cleaning task for the Edgewood facility, organized by frequency and zone. All tasks follow GFS SSOPs (Sanitation Standard Operating Procedures) and are verified by QA before production resumes.
Daily Sanitation Tasks
Weekly Sanitation Tasks
Monthly Deep Clean Tasks
HVAC System
Replace filters, clean evaporator coils, check condensate drains, verify positive pressure in production area. Log temperature differential.
Pest Control Audit
Inspect all bait stations, replace sticky traps, review pest sighting log, exterior perimeter walk, check door seals and air curtains.
Equipment Teardown
Full disassembly of slicers, mixers, and portioning equipment. Deep clean all gaskets, bearings, and hard-to-reach surfaces. Reassemble and verify calibration.
Sanitation verification protocol. All daily tasks verified by ATP swab testing (pass < 150 RLU). Weekly tasks verified by visual inspection + documentation. Monthly tasks require QA sign-off form. Records retained 2 years per SQF requirements. Any failed swab triggers re-clean + re-test before production resumes.
Master Sanitation Schedule maintained in NetSuite Manufacturing module. Updated annually or upon equipment/process changes. SQF auditor reviews during certification audit. Chemical SDS sheets filed in production office.
08Allergen Changeover Procedure
When production switches from a product containing a specific allergen to one that does not, a full allergen changeover must be completed. This procedure ensures zero cross-contact and protects consumers with food allergies. Every changeover is documented and verified before the new product run begins.
Step 1: Stop Production Line
Step 2: Remove All Product & Packaging
Step 3: Disassemble Equipment
Step 4: Allergen Clean (Full SSOP)
Step 5: Visual Inspection (QA Required)
Step 6: ATP Swab Test (<150 RLU)
Step 7: Allergen-Specific Test (If Required)
Step 8: QA Sign-Off & Resume Production
Allergen Changeover Log
Allergen changeover is a CRITICAL food safety procedure. Never skip any step. If ATP test fails (>150 RLU), the entire clean-sanitize-test cycle must restart from Step 4. Allergen-specific lateral flow tests (e.g., milk protein, gluten) are required when changing from dairy to non-dairy or wheat to gluten-free. Records retained 2 years minimum.
Allergen changeover records filed by date and line. SQF auditor reviews during annual certification. Cross-contact risk assessment updated with each new product introduction. Refer to GFS Allergen Control Plan (GFS-ACP-2026).
09Batch Record Template
Every production run at GFS generates a Batch Record that documents all inputs, process parameters, quality checks, and outputs. The batch record is the primary traceability document and must be completed in real-time during production — never after the fact.
Batch records are legal documents. All entries must be in ink, never pencil. Errors are corrected with a single line strikethrough, initials, and date — never whiteout. Blank fields get "N/A" with initials. Records scanned to NetSuite within 24 hours of batch completion. Originals filed in production office, retained 2 years per SQF + FDA 21 CFR 117.
Batch records link to NetSuite work orders. QA review must be completed before product ships. Any deviation from target parameters triggers a non-conformance report (NCR). Batch number format: BPR-YYYY-NNNNN (sequential).