Procedure for Sampling, Lot Inspection and Collection of Samples

1. Purpose:
This document is to describe the methodology for the inspection, sampling of
standard packages of prepackaged coffee.
2. Scope:
The methodology is applicable to all prepackaged coffee produced and/or
sold by the Mavis Bank Coffee Factory.
3. Responsibility:
i.
The quality assurance manager is responsible for establishing the
master schedule, planning the sampling, verifying the equipment,
ensuring the exact execution of this procedure, maintaining the records
generated and taking appropriate action for the control of nonconforming products.
ii.
The quality assurance officer is responsible for the exact execution of
the procedure, accurately recording the results of the test and the
immediate reporting of results to the quality assurance manager.
4. Frequency:
This procedure is performed on each sample of product that is collected at
any point in the production or distribution chain.
5. Definitions Average- the sum of a number of individual measurement
values divided by the number of values. The sum of the individual weights of
12 packages divided by 12 would be the average weight of those packages
i.
Batch Code- Traceability number that indicates the raw materials as
well as the production condition.
ii.
Gravimetric Test Procedure- An analytical procedure that involves
measurement by mass or weight.
iii.
Gross weight- The weight of the package including contents, packing
material, labels.
iv.
Inspection Lot- The collection of identically labeled (random
packages, in some cases, are exempt from identity and labeled
quantity when determining the inspection lot) packages available for
inspection at one time. This collection will pass or fail as a whole based
on the results of the test on a sample drawn from this collection.
v.
Location of Test- Location where test will be carried out.
vi.
Lot size- The number of units in the inspection lot
vii.
Lot Description- The product characteristics such as, declared
weight, package type, packaging method.
viii.
Package- The first container in which product is placed.
ix.
Package Product - Product or commodity put up in any manner in
advance of sale suitable for either wholesale or retail sale.

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Product Batch (Lot)- The total collection of packages defined by the

packager, usually consisting of those packages produced within a
given unit of time and coded identically.
Hourly Production Run size- The amount of newly package articles
produced each hour.
Random Sample Selection- The process of selecting sample
packages such that all packages under consideration have the same
probability of being selected. An acceptable method of random
selection is to use a table of random numbers.
Range- The difference between the largest and the smallest of a set of
measured values.
Sample- A group of packages taken from a larger collection of
packages and providing information that can be used to make a
decision concerning the larger collection of the packages or the
package production process. A sample provides a solid basis for
decision only when it is random.
Sample Error Limit- Means a statistical value computed by
multiplying the sample standard deviation times the sample correction
factor from Column 3 of Table 2-1. Category A - Sampling Plans for the
appropriate sample size. The SEL value allows for the uncertainty
between the average error of the sample and the average error of the
inspection lot with an approximately 97 % level of confidence.
Sample Fail- The number of packages in the sample which are
allowed to exceed the MAV has been exceeded.
Sample Size- The number of packages in a sample
Sample Plan- A specific plan that states the number of packages to
be checked and the associated decision criteria.

6. Safety Considerations
i.

Lab coats and protective shoes should be worn as appropriate at all

times in the laboratories.

7. Apparatus and Materials:

i.
Container for transportation of samples
8. Procedure:
Summary of Procedure
Steps:
1. Identify and define the inspection lot.
2. Select the sampling plan.
3. Select the random sample.

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Lot Identification and Sample Selection

Factory
Identify the inspection lot size by counting or verifying the count the
number of packages comprising the inspection lot. (Refer to the
Operators output sheet)
The inspection lot is the hourly production run on each packing
machine.
The inspection lot size is taken as the total number of produce in the
hourly production run.
Collect the sample reserved for cupping from the production floor.
Ensure that each cupping sample is minimum of 100 grams (a quarter
of a 16 oz plastic bag)
From the CV230 collect a total of 12 samples irrespective of size at
each hourly inspection. Ensure that equal amounts of units are taken
from each size/type of product packaged.
Collect 12 samples from the GL18 at each hourly in inspection when
machine is in operation.
Collect 12 samples from the Direct Heat Sealer at each hourly in
inspection when machine is in operation.
Label each sample collected with a sequential number that represents
the order in which the sample was taken.
Record the following information, the date of the inspection, the test
number, batch code of the samples taken, name of the machine from
which the samples were taken, name of the machine operator, the
location the size of the product and a general product description.
Operations Manager or designate signs release log for the samples.
Samples are taken to the Quality Lab for Analysis.
Products Sampled from Warehouses, Wholesale and Retail
The inspection lot in an external warehouse or retail is the entire
inventory of the product that is in storage.
The inspection lot in a warehouse is the entire inventory.

Selecting Sample Plan

Use the sampling plan to determine how many test sample packages
to collect from the production floor or distribution chain as per the
Sampling Plan shown below.

Inspection Lot
Size

Table 2-1 Sampling Plan for Category A

Sample Size
Sample
Number of Minus
Correction
Package Errors
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Initial Tare
Sample Size

Factor

Allowed to exceed
MAV

1
1
Apply MAV
2
2
8.985
3
3
2.484
4
4
1.591
5
5
1.242
6
6
1.049
7
7
0.925
0
2**
8
8
0.836
9
9
0.769
10
10
0.715
11
11
0.672
12 t0 250
12
0.635
251-3200
24
0.422
More than 3200
48
0.290
1
*Adopted from the NIST Handbook Checking the Net Contents of
Prepacked Foods

i.

Select Random Sample

Select samples randomly form the totes. Ensure that samples are
taken at different depths and sides.

9. Corrective Action
i.
When samples are not collected in accordance with this plan the
samples are not representative of the lot and as such must be returned
to the production.
ii.
Resample the batch taking samples in accordance to section 8 in this
procedure whether or secondary or tertiary packaging has taken place.
10.
Reference Document
i. NIST Handbook Checking the Net Contents of Prepackage Foods
11.
Records
i.
Hourly Inspection Log Book

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