# Food Processing Quality Inspection Checklist (FSSAI & Export Compliance)
This checklist is designed for QA managers, food safety officers, and compliance teams in food processing facilities. It covers the key inspection areas required under FSSAI (Food Safety and Standards Authority of India) regulations and common requirements for export to major markets (EU, USA, Middle East).
Use this checklist for:
- •Internal monthly/quarterly audits
- •Pre-FSSAI inspection readiness
- •Pre-shipment quality checks
- •New supplier or co-packer qualification
Rating Scale: ✅ Compliant | ⚠️ Partial / Needs Improvement | ❌ Non-Compliant | N/A Not Applicable
Section 1: Licensing & Documentation
| # | Checkpoint | Rating | Remarks |
|---|---|---|---|
| 1.1 | Valid FSSAI license displayed at premises (Central/State as applicable) | ||
| 1.2 | License covers all product categories manufactured on site | ||
| 1.3 | License renewal date tracked; renewal initiated ≥60 days before expiry | ||
| 1.4 | Food Safety Management System (FSMS) plan documented and current | ||
| 1.5 | Designated Food Safety Supervisor (FSS) appointed and trained | ||
| 1.6 | Product-wise specifications and standards documented | ||
| 1.7 | Supplier approval records maintained for all raw material vendors | ||
| 1.8 | Batch manufacturing records (BMR) maintained for all production runs | ||
| 1.9 | Recall and withdrawal procedure documented and tested | ||
| 1.10 | Export certificates (Health Certificate, COA, Phytosanitary if applicable) process defined |
Section Score: _____ / 10 compliant
Section 2: Premises & Infrastructure (GMP)
| # | Checkpoint | Rating | Remarks |
|---|---|---|---|
| 2.1 | Facility layout prevents cross-contamination (raw vs. processed areas separated) | ||
| 2.2 | Floors, walls, and ceilings are smooth, non-porous, and cleanable | ||
| 2.3 | Adequate lighting (min. 220 lux in work areas, 540 lux at inspection points) | ||
| 2.4 | Ventilation adequate; no condensation dripping onto product or surfaces | ||
| 2.5 | Pest control program active; records of treatments and inspections maintained | ||
| 2.6 | Drains flow away from processing areas; no backflow risk | ||
| 2.7 | Glass and brittle plastic policy in place; breakage log maintained | ||
| 2.8 | Maintenance work orders tracked; no open maintenance issues in food zones | ||
| 2.9 | Waste disposal areas clearly designated and regularly cleared | ||
| 2.10 | Cold storage temperatures logged continuously (or min. 2x daily) |
Section Score: _____ / 10 compliant
Section 3: Personal Hygiene & Personnel Practices
| # | Checkpoint | Rating | Remarks |
|---|---|---|---|
| 3.1 | All food handlers wear clean uniforms, hairnets, and appropriate footwear | ||
| 3.2 | No jewellery, watches, or loose items worn in processing areas | ||
| 3.3 | Handwashing stations available at entry points and near toilets; soap and sanitiser stocked | ||
| 3.4 | Handwashing procedure posted at all wash stations | ||
| 3.5 | Medical fitness certificates current for all food handlers | ||
| 3.6 | Illness reporting policy in place; sick workers excluded from food contact roles | ||
| 3.7 | Visitor and contractor hygiene rules enforced (sign-in, PPE provided) | ||
| 3.8 | Food and drink restricted to designated areas only | ||
| 3.9 | Smoking prohibited in all food handling and storage areas | ||
| 3.10 | Annual food hygiene training records maintained for all staff |
Section Score: _____ / 10 compliant
Section 4: Raw Material & Ingredient Control
| # | Checkpoint | Rating | Remarks |
|---|---|---|---|
| 4.1 | Incoming raw materials inspected against approved specifications before acceptance | ||
| 4.2 | Certificate of Analysis (COA) received and verified for each lot | ||
| 4.3 | Rejected materials clearly labelled and quarantined immediately | ||
| 4.4 | FIFO (First In, First Out) or FEFO (First Expired, First Out) system followed | ||
| 4.5 | Allergen-containing ingredients stored separately and clearly labelled | ||
| 4.6 | Packaging materials inspected for damage, contamination, and compliance | ||
| 4.7 | Water used in processing tested per FSSAI Schedule IV limits (min. annually) | ||
| 4.8 | Food additives used are FSSAI-permitted and within prescribed limits | ||
| 4.9 | Traceability system links each batch to specific raw material lots | ||
| 4.10 | Temperature-sensitive ingredients stored at correct conditions on receipt |
Section Score: _____ / 10 compliant
Section 5: Processing & Production Controls
| # | Checkpoint | Rating | Remarks |
|---|---|---|---|
| 5.1 | Critical Control Points (CCPs) identified and monitored per HACCP plan | ||
| 5.2 | CCP monitoring records complete with no unexplained gaps | ||
| 5.3 | Critical limits defined for each CCP (e.g., pasteurisation temp/time) | ||
| 5.4 | Corrective actions taken and recorded whenever CCP limits are breached | ||
| 5.5 | Equipment calibration records current (weighing scales, thermometers, pH meters) | ||
| 5.6 | Metal detection / X-ray inspection operational; test pieces used each shift | ||
| 5.7 | In-process quality checks performed and recorded at defined intervals | ||
| 5.8 | Rework controlled: labelled, segregated, and used within defined limits | ||
| 5.9 | Cleaning and sanitation schedules followed; records signed off | ||
| 5.10 | Sanitation effectiveness verified (ATP swabs or microbiological swabs) periodically |
Section Score: _____ / 10 compliant
Section 6: Finished Product & Labelling Compliance
| # | Checkpoint | Rating | Remarks |
|---|---|---|---|
| 6.1 | Finished product tested against specification before release | ||
| 6.2 | Retain samples held for each batch per defined retention period | ||
| 6.3 | Product labels include all FSSAI-mandatory declarations (FSSAI licence no., veg/non-veg symbol, MRP, net weight, date of manufacture, best before) | ||
| 6.4 | Nutritional information panel present and accurate | ||
| 6.5 | Allergen declarations complete and accurate on label | ||
| 6.6 | For export: destination country labelling requirements verified (language, format, claims) | ||
| 6.7 | Batch/lot coding legible and traceable to production records | ||
| 6.8 | No misleading claims on label (health claims comply with FSSAI regulations) | ||
| 6.9 | Packaging integrity checked (seal strength, leak test, drop test as applicable) | ||
| 6.10 | Certificate of Analysis issued for each export consignment |
Section Score: _____ / 10 compliant
Section 7: Export-Specific Compliance
| # | Checkpoint | Rating | Remarks |
|---|---|---|---|
| 7.1 | **EU:** Product complies with EC 178/2002 traceability requirements | ||
| 7.2 | **EU:** Pesticide residue levels within EU MRL limits (if applicable) | ||
| 7.3 | **USA (FDA):** Foreign Supplier Verification Program (FSVP) documentation available for US importer | ||
| 7.4 | **USA:** Facility registered with US FDA (Food Facility Registration current) | ||
| 7.5 | **Middle East / Gulf:** Halal certification valid and covers all ingredients | ||
| 7.6 | **Middle East:** Arabic labelling requirements met for GCC markets | ||
| 7.7 | APEDA registration current (for agricultural/processed food exports from India) | ||
| 7.8 | EIC (Export Inspection Council) approval obtained where mandatory | ||
| 7.9 | Pre-shipment inspection arranged as required by destination country | ||
| 7.10 | Import permits / phytosanitary certificates arranged for destination country |
Section Score: _____ / 10 compliant
Inspection Summary
| Section | Max Score | Actual Score | % Compliance |
|---|---|---|---|
| 1. Licensing & Documentation | 10 | ||
| 2. Premises & Infrastructure | 10 | ||
| 3. Personal Hygiene | 10 | ||
| 4. Raw Material Control | 10 | ||
| 5. Processing Controls | 10 | ||
| 6. Finished Product & Labelling | 10 | ||
| 7. Export Compliance | 10 | ||
| **TOTAL** | **70** |
Overall Rating
| Score | Rating |
|---|---|
| 63–70 (90–100%) | ✅ Excellent - Ready for audit / shipment |
| 56–62 (80–89%) | ⚠️ Good - Minor gaps; corrective actions within 30 days |
| 42–55 (60–79%) | ⚠️ Fair - Significant gaps; corrective actions within 14 days |
| Below 42 (<60%) | ❌ Unsatisfactory - Hold production/shipment; immediate corrective action required |
Corrective Action Summary
List all ❌ Non-Compliant and ⚠️ Partial findings here:
| Finding Ref | Description | Priority | Assigned To | Due Date | Closed Date |
|---|---|---|---|---|---|
| High / Medium / Low | |||||
| High / Medium / Low | |||||
| High / Medium / Low |
Sign-Off
| Role | Name | Signature | Date |
|---|---|---|---|
| Inspector / QA Officer | |||
| Production / Plant Manager | |||
| Food Safety Supervisor |
*Checklist version 1.0 - IdeaSprout Quality Assurance Suite. Verify against current FSSAI regulations and destination country requirements before use.*
food safetyFSSAIGMPexport compliance