Packhouse best practice guide
Five areas decide whether a packhouse passes audits and keeps customers: storage hygiene, consistent QC, automatic traceability, exact shipping records and food-contact surfaces.
Key points
- Label incoming stock before it is stored – never after.
- QC must be the same inspection, with the same thresholds, on every shift.
- Know exactly which lots went to which customer on which invoice and PO.
- Food-contact surfaces must be smooth, non-absorbent, drainable and cleanable.
Storage
Store produce in areas free of debris, pests, droppings and chemical residue. Check cool-room temperatures continuously, calibrate gassing and ripening rooms on a schedule, and use airflow to control humidity in non-refrigerated storage. Label every incoming bin or pallet before it goes into storage so traceability starts at the door.
Quality control that is consistent
Use the same inspection template, sample size and defect thresholds on every shift. Photos attached to each result settle disputes with suppliers and customers, and alerts on failed inspections get corrective action started the same day. Suppliers who know their product is measured consistently tend to send better product.
Traceability without manual effort
Traceability that depends on people writing lot numbers fails on busy days. Scan produce and packaging materials into each batch so every finished carton links back to its inputs automatically. A mock recall should take minutes and give the same answer every time.
Shipping records
For every load, record which pallets – ideally which cases – went to which customer, on which invoice, against which customer PO. Without this, a recall has to cover every customer who received product in the date range, which can turn a small problem into a very expensive one.
Food-contact surfaces and the building
- Cover packing materials to prevent contamination.
- Remove bird nests; use spikes or covers over exposed product areas.
- Tables, conveyors, wash tanks, knives and bins must be smooth, non-absorbent, drain freely, resist corrosion and be easy to sanitise.
- Water used for cleaning and sanitising food-contact surfaces must meet drinking-water microbial standards.
Certification options
GLOBALG.A.P. Produce Handling Assurance (PHA) certifies post-harvest packing, cooling and storage and is GFSI-recognised; it helps US-bound suppliers demonstrate FSMA Produce Safety Rule and CGMP requirements. In New Zealand, United Fresh and HortNZ publish food safety guidelines for packhouses.
Frequently asked questions
What is GLOBALG.A.P. PHA?
Produce Handling Assurance is a GLOBALG.A.P. standard for post-harvest handling – packing, cooling and storage – with a HACCP focus. It is GFSI-recognised and accepted by many US and international buyers.
How often should a mock recall be run?
Most schemes and retailers require at least one per year; many packhouses run them quarterly. With scanned lots a mock recall takes minutes, so running them more often costs little.
