Beer Proceass

Generic Hazard Analysis
and
Critical Control Points
(HACCP)
Plan for the
Canadian Brewing Industry
A Project of
Brewers Association of Canada

HACCP Working Group
Revision Date: November 2009
www.brewers.ca
Table of Contents
Introduction.............................................................................................................
HACCP Principle 1 - Hazard Identification.............................................................
HACCP Principle 2 - Critical Control Points..........................................................
HACCP Principle 3 - Critical Limits.......................................................................
HACCP Principle 4 - Establish Monitoring Procedures........................................
HACCP Principle 5 - Establish Deviation Procedures..........................................
HACCP Principle 6 - Establish Verification Procedures.......................................
HACCP Principle 7 - Establish Record Keeping/Documentation.........................
BAC Generic HACCP Program.............................................................................
Form 1: Product/Process Description..................................................................
Form 2: List of Product Ingredients and Incoming Materials...............................
Form 3: Process Flow Diagram...........................................................................
Form 4: Schematic Diagram................................................................................
Form 5: Hazard Identification Biological Hazards................................................
Form 6: Hazard Identification Chemical Hazards................................................
Form 7: Hazard Identification Physical Hazards..................................................
Form 8: Critical Control Points.............................................................................
Form 3A: Process Flow Diagram with CCPs.....................................................
Form 5A: Biological Hazards Control & CCPs...................................................
BAC Generic HACCP Model
Page 3 of 252
Table of Contents (Continued)

Form 6A: Chemical Hazards Control & CCPs...................................................
Form 7A: Physical Hazards Controls & CCPs...................................................
Form 9: Hazards not Controlled by Brewery.....................................................
Form 10: HACCP Plan.......................................................................................
HACCP Plan Appendices....................................................................................
Appendix 1- Form 3 - Information used for Flowcharts......................................195
Appendix 2- Form 8 Critical Control Points.....................................................213
Appendix 3 - Form 10 - Additions for Low Alcohol Beer.....................................217
Appendix 4 Diagrams for Hazard Identification & CCP Decision Tree............221
Appendix 5 BAC Glass Inclusion Reference...................................................225
Appendix 6 Blank Forms 1 - 10.......................................................................229
Appendix 7 Reference Literature.....................................................................243

Page 4 of 252
Introduction
HACCP (Hazard Analysis Critical Control Point) systems are required under
proposed Health Canadas Good Manufacturing Practices Regulations for Food.
Specifically, manufacturers must develop procedures to ensure products
manufactured do not pose a health risk.
The HACCP program is a world-wide recognized systematic and preventative
approach that addresses biological, chemical and physical hazards through
anticipation and prevention, rather than by finished production inspection.
This document is a working guide to preparing a customized program of hazard
analysis and identification of critical control points (CCP) for brewers, as an aid to
consistent compliance and inspection by the Canadian Food Inspection Agency
(CFIA). This document is not a customized model per se. Each brewer using this
working guide is responsible for producing his or her own customized model.
Prior to the development and implementation of a HACCP program,
establishments must have developed, documented and implemented programs
to control factors that may not be directly related to manufacturing controls but
support the HACCP plans and the Good Manufacturing Practices (GMP). These
programs are called Pre-requisite programs. These are discussed in detail in
another document (see BAC- Generic Pre-requisite Programs).
There are 12 basic steps to implementing a HACCP program. They are:
1.
Assemble the HACCP team;
2.
Describe the product;
3.
Identify intended uses;
4.
Construct process Flow Diagram and Plant Schematic;
5.
Verify on site the Flow Diagram and Plant Schematic;

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Introduction (Continued)
6.
List hazards associated with each step (Principle 1);
7.
Determine Critical Control Points (Principle 2);
8.
Establish Critical Limits (Principle 3);
9.
Establish Monitoring Procedures (Principle 4);
10. Establish Deviation Procedures (Principle 5);

11. Establish Verification Procedures (Principle 6); and
12. Establish record keeping/documentation for Principles one through six
(Principle 7).
This manual deals in detail with steps 1 through 8, which include Principles 1
through 3 of HACCP system elements. It also discusses in general terms the
follow-up requirements that make up steps 9 through 12.

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Instructions for Companies

It is suggested that the user of this document becomes acquainted with the BAC
Food Safety Toolkit Introduction document before attempting to proceed with
applying the recommendations herein.
There are also other BAC guidance documents that are to be used along with
this BAC - Generic HACCP Plan model. They are:
BAC/HACCP Plan Workbook; and
BAC/HACCP Plan Glossary.
Pre-requisite programs should be established before attempting to implement the

HACCP program.
Each company will determine the appropriate internal procedures to follow to
ensure that the programs are implemented as described and are effective.
Reminder - This document is not a customized model per se. Each brewery using
this working guide is responsible for producing its own customized HACCP
program.

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HACCP Working Group Members

The BAC HACCP Working Group was established under the direction of the
Product Integrity Committee of the Brewers Association of Canada.
These Pre-requisite Programs have been developed by the Brewers Association
of Canada (BAC) with a Technical Committee comprised of industry members,
government
representatives
and
food
safety
consultants.
The
BAC
acknowledges the committee members for their outstanding contribution to the

BAC/HACCP project.
We also extend our appreciation and gratitude to Agriculture and Agri-Food
Canada and the Canadian Food Inspection Agency for their financial and
technical support of this project.
Mr. B. Andrews
Molson Canada
Ms. E. Bounsall
Brasserie McAuslan
Ms. S. Buttenham
Sleeman Breweries Ltd.
Ms. M. Dewar
Dr. T. Dowhanick
Labatt Breweries of Canada
Ms. A. Fuller
Great Western Brewing Company
Mr. L Harford
Mr. M. Ligas
Magnotta Brewery
Mr. G. Muise
Pump House Brewery
Mr. R. Savage
Molson Canada
Mr. A. Kassianenko
Canadian Food Inspection Agency
Mr. G. Sundeen
Canadian Food Inspection Agency
Mr. F. Schreurs
Guelph Food Technology Centre
Mr. P. Medeirois
Mr. K. McMillan
Ms. A. Brown
Ms. M. Harris-Bailey

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HACCP Principle 1 - Hazard Identification

Principle 1: Conduct a hazard analysis.
A product safety hazard is any biological, chemical, or physical

property that may cause beer to be unsafe for human consumption.
Breweries determine the product safety hazards and identify the

preventive measures the plant can apply to control these hazards.
On the basis of available information for each of the ingredients used in beer and
for each of the process steps in brewing, potential biological, physical and
chemical hazards are identified.
Information sources include published
databases, scientific literature, company records, external and internal audits etc.
In addition to identifying potential hazards, Forms 5, 6 and 7 are used to identify
the control points.
Diagrams for Hazards Identification and CCP Decision Tree
Critical Control Points for breweries are determined using the HACCP Decision
Tree. The Decision Tree was first developed by a Codex Alimentarius working
group on HACCP in June 1991. This Decision Tree has been slightly modified to
include a prescreening question and preliminary instructions.
Pre-screening question = Determine if (hazard) fully controlled by Pre-requisite
Programs. If yes, indicate Pre-requisite Program(s) and proceed to the next
identified hazard. If no, proceed to Question 1. (See Appendix)

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HACCP Principle 2 - Critical Control Points

Principle 2: Identify critical control points.
A critical control point (CCP) is a point, step, or procedure in a food process at
which control can be applied and, as a result, a food safety hazard can be
prevented, eliminated, or reduced to an acceptable level.
Using the Decision Tree, Form 8 is completed. The last column is where Critical
Control Points are identified. CCPs are labelled numerically with a category
qualifier for Biological, Physical and Chemical (B, P or C) hazard and expected
outcome of the control measure (elimination of risk(e), prevention (p), or
minimize or reduce (r)). In this model, the Critical Control Points in breweries
were identified as follows:
Step
CCP #
Empty Bottle Inspection
CCP1-P
Empty Bottle Inspection/ Residual Liquid Detector
CCP1-C
Filling (Auto-Flush Only)
CCP2-P
Internal Cleaning (Manual)
CCP3-C
Hazards identified on Forms 5, 6 and 7 are either controlled at some point in the
brewing process or cannot be controlled by the facility. Form 9 is intended to
identify control measures that do not take place in the brewery but are controlled
elsewhere. No such hazards were identified in the analysis of breweries.

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HACCP Principle 3 - Critical Limits

Principle 3: Establish critical limits for each critical control point.
A critical limit is the maximum or minimum value to which a

physical, biological, or chemical hazard must be controlled at a
critical control point to prevent, eliminate, or reduce to an
acceptable level.
For each Critical Control Point, critical limits were established. These are values
which separate acceptability from unacceptability. They are intended to meet
government regulations, industry standards or other scientific data.
HACCP Principle 4 - Establish Monitoring Procedures

Principle 4: Establish critical control point monitoring requirements.
Monitoring is the act of conducting a planned sequence of observations or
measurements of control parameters to assess whether a CCP is under control.
Monitoring activities are necessary to ensure that the process is

under control at each critical control point. Each monitoring
procedure and its frequency will be listed in the HACCP plan.
At each CCP, the monitoring requirements and the means to ensure that the CCP
remains within the critical limits are specified. Monitoring procedures generally
relate to on-line processes and are usually by observation or by measurement.
The frequency of testing, who is responsible for carrying out the testing, and the
testing procedures must also be specified. The monitoring specifications are
written on Form 10 for each CCP.
Each brewery will develop its own
specifications, where required.

Monitoring tracks the system's operation and allows for action to be taken in the
event of a loss of control or where there is a trend toward the loss of control. It
provides information to a brewery on a timely basis, allowing for decisions on the
acceptability of the lot at a particular stage in the process. Monitoring procedures
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HACCP Principle 4 - Establish Monitoring Procedures (Continued)

performed in the establishment during operation will result in written
documentation that will serve as an accurate record of the operating conditions.
If any of the critical limits is out of control as determined by the monitoring
procedures, the CCP will be out of control. Lack of control at a CCP is defined as
being a critical defect or a deviation. Deviations will result in the production of a
hazardous or unsafe product Therefore, adequate and effective monitoring
procedures are essential due to the serious consequences arising from
deviations. Most monitoring procedures for CCPs must be rapid because they
relate to on-line processes and there is not sufficient time for lengthy analytical
testing. Physical and chemical measurements or visual observations are
preferred because they can be done rapidly. All monitoring equipment must be
properly calibrated for accuracy. Examples of some physical and chemical
measurements taken to monitor the critical limits are: temperature, time and pH.
There are many ways to monitor critical control points. Monitoring can be done
on a continuous or batch basis. The reliability of continuous monitoring (100 % is
preferred where feasible). The established monitoring frequency must be
sufficient to substantiate that the hazard is under control. Responsibility for
monitoring is clearly identified and individuals monitoring the CCPs must be
trained in the testing procedure and must fully understand the purpose and
importance of monitoring. The individual must have ready access to the
monitoring activity and must be unbiased in monitoring and reporting. Finally the
individual must accurately report the monitoring activity.
All operational records and documents that are associated with CCP monitoring
must be properly completed and signed by the person doing the monitoring and
verified/signed by a responsible official of the company.

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HACCP Principle 5 - Establish Deviation Procedures

Principle 5: Establish corrective actions.
These are actions to be taken when monitoring indicates a

deviation from an established critical limit. The final rule requires a
plant's HACCP plan to identify the corrective actions to be taken if a
critical limit is not met. Corrective actions are intended to ensure
that no product injurious to health or otherwise adulterated as a
result of the deviation enters commerce.
A deviation is defined as failure to meet the specified critical limits. Deviation

procedures are pre-determined and document the set of corrective actions that
are implemented when a deviation occurs.
All deviations must be corrected by taking appropriate corrective action(s) to
control the non-compliant product and to correct the cause of non-compliance.
The corrective action(s) taken must be recorded and filed.
A deviation procedure must describe the acceptable corrective action(s) for a
deviation. The diversity of possible deviations at each CCP means that more than
one corrective action may be necessary at each CCP. The corrective action(s)
must correct the cause of the deviation and must control the actual or potential
hazard resulting from the deviation. Product control includes proper identification,
and handling of the affected lots. The deviation procedures at each CCP are
written on Form 10. These procedures will be developed by each brewery in
accordance with the brewerys requirements.
Corrective actions are prescribed and formalized so that employees responsible
for critical control point monitoring understand and are able to perform the
appropriate corrective action(s) in the event of a deviation.

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HACCP Principle 5 - Establish Deviation Procedures (Continued)

When a deviation occurs, it will most likely be noticed during the routine
monitoring of a CCP. A deviation results when the pre-determined critical limit for
a CCP is out of compliance. If the proper corrective action is not taken the
deviation may result in an unacceptable health risk.
HACCP Principle 6 - Establish Verification Procedures

Principle 6: Establish procedures for verifying the HACCP system is working as
intended.
Validation ensures that the plans do what they were designed to do;
that is, they are successful in ensuring the production of safe
product. Plants will be required to validate their own HACCP plans.
Verification ensures the HACCP plan is adequate, that is, working

as intended. Verification procedures may include such activities as
review of HACCP plans, CCP records, critical limits and analytical
data
Verification activities are methods, procedures and tests used to determine if the
HACCP plans for that establishment are valid and are operating properly.
Verification activities are generally involved and may include analytical testing. In
carrying out the verification activities, the establishment may find that some
hazards were overlooked or they may discover new or unexpected hazards. In
this case, the plan needs to be modified appropriately. The verification
procedures at each CCP are written on Form 10 by each brewery in accordance
with the brewery requirements. Both the establishment and the CFIA will have a
role in verifying HACCP plan compliance and will carry out activities to verify that
the HACCP plan is operating properly. Verification activities differ from monitoring
activities. Results from verification activities are not intended to make decisions
on the acceptability of lots of product. Verification activities involve for example,
analytical testing or auditing of the monitoring procedures, product sampling,
audits of monitoring and verification records.

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HACCP Principle 7 - Establish Record Keeping/ Documentation

Principle 7: Establish record keeping procedures.
The HACCP program requires that all plants maintain certain

documents, including its hazard analysis and written HACCP plan,
and records documenting the monitoring of critical control points,
critical limits, verification activities, and the handling of critical limit
deviations.
The HACCP records are defined as the record keeping that is done at each CCP
and that contain the information required to ensure that the HACCP plan is
followed.
Records are essential in determining the compliance of the establishment in
following the agreed-upon HACCP plan. The HACCP records differ from the
records that are kept to ensure compliance to the pre-requisite program
requirements. The required HACCP records to be kept at each CCP are written
on Form 10 by each brewery in accordance with the brewery requirements.
Monitoring results are documented together with any deviations and corrective
action taken. Failure to document the control of a CCP would be a critical
departure from the HACCP plan. Verification activities are also to be recorded.
Records must specify who recorded the information and must indicate who
reviewed and signed off the information.
A record may be in any form (processing chart, written record, computerized
record) and show the historical record of the process, the monitoring, the
deviations and the corrective actions (including disposition of product) that
occurred at the identified CCP. The information contained in the records is used
to establish the product's processing profile that would be used if there are any
subsequent problems. Accurate records allow for trace back of the actual
manufacturing conditions which will aid in troubleshooting if a problem arises.

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HACCP Principle 7 - Establish Record Keeping/ Documentation

(Continued)
The importance of records to the HACCP program must be emphasized. The
records are an important tool that is
used to ensure that the establishment is
following the agreed upon HACCP plan. It will be imperative that the
establishment maintain up-to-date, properly filed, and accurate records.

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BAC GENERIC HACCP

PROGRAM

Page 17 of 252

Page 18 of 252
FORM 1:
PRODUCT/PROCESS
DESCRIPTION

Page 19 of 252

Page 20 of 252
HACCP Plan - Form 1

Page 1 of 1
Title: Form 1 Product Description

Completed By: BAC TC
Approved By: BAC TC
BAC Generic
Date:
Date:
Process/Product Name: BEER

1. Product Name(s)
Beer, Ale, Stout, Malt Liquor

As defined in the Food and Drug Regulations B.02.130 to
B.02.132.
3. How it is to be used
Consumer product - Alcoholic beverage
4. Packaging
Glass bottles
Lined aluminum bottles
Lined cans
Stainless steel kegs
Plastic bottles (PET etc.)
5. Shelf Life
Shelf Life Information required.
6. Where it will be sold
2. Important Product
Characteristics
(aw, pH, PRESERVATIVES..)
7. Labelling Instructions
8. Special Distribution
Control
Government sales provisions apply - licensed retailers, hotels

etc.
On premise and off premise
Food and Drug Regulations (i.e. alcohol content labelling)
Consumer Packaging and Labelling Legislative/Regulatory
requirements
Claims allowed by Health Canada (i.e. energy value)
Inspection done on third party carriers and carriers dedicated to

food

Page 21 of 252

Page 22 of 252
FORM 2:
LIST OF PRODUCT
INGREDIENTS AND
INCOMING MATERIALS

Page 23 of 252

Page 24 of 252
HACCP Plan - Form 2

Page 1 of 1
BAC Generic
Title: Form 2 List of Product Ingredients and Incoming Materials

Date:
Approved By: BAC TC
Date:
Product Name: BEER

LIQUID INGREDIENTS
DRY INGREDIENTS
(allowable)
PRIMARY PACKAGING
MATERIALS
Potable water
Barley malt B C P
New Glass P
- City Water B C P
Wheat malt B C P
Used glass B C P
- Well/ Surface Water B C P
Hops BC P
Lined aluminum cans P
- Purchased Water B C
Cereal grain e.g. wheat

(non-malted), corn, oats,
rice B C P
Lined aluminum bottles P
New stainless steel kegs P
Used stainless steel kegs None
Plastic bottles e.g. PET None
Crowns , Closures and Can

Ends None
OTHER INGREDIENTS (allowable)
OTHER INGREDIENTS
(allowable)
OTHER INGREDIENTS
(allowable)
Caramel C P
Preservatives C
Yeast B C
Dextrin C P
Food enzymes C
- Ascorbic Acid, Calcium

Ascorbate, Potassium
Metabisulphite, Sodium
Metabisulphite
Carbohydrate matter, e.g.

sucrose, syrup Honey
Salt C P
Hop oil C P
- Manganese Sulphate,
Phosphoric Acid, Zinc
Sulphate, Ammonium
Persulphate (brewers yeast)
Hop extract C P
Carbon dioxide C
- Regenerated CO2
- Amylase, Glucoamylase,
Glucanase, Papain,
Pentosanase, Protease
Stabilizing agents C
- Calcium Alginate,
Carrageenan, Propylene
Glycol Alginate
Water preparation
agents C
- Ammonium Phosphate,
dibasic, Calcium Chloride,
Calcium Hydroxide,
Calcium Sulphate, Citric
Acid, Lactic Acid,
Magnesium Sulphate,
Phosphoric Acid,
Sulphuric Acid
Yeast foods C
Processing aids B C
- Irish Moss Seaweed;

Activated Carbon;
Magnesium Silicate;
Cellulose; China Clay;
Diatomaceous Earth; Gelatin;
Silica Gel;
Polyvinylpolypyrrolidone;
Wood Shavings derived from
oak, beech, hazelnut or
cherry wood;
Dimethylpolysiloxane (wort),
Hydrogen Peroxide (mash);
- Purchased CO2
Liquid wheat extract C P
Nitrogen/ Oxygen/ Compressed

Air C
B/ C/ P = Biological (B) or Chemical (C) or Physical (P) hazard(s) identified.

Page 25 of 252
HACCP Plan - Form 2

Page 1 of 1

Page 26 of 252

Page 27 of 252
FORM 3:
PROCESS FLOW DIAGRAM

Page 28 of 252

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HACCP Plan - Form 3
BAC GENERIC HACCP PLAN FORM 3

Approved By: BAC HACCP Technical Committee
Approval Date:
Total # of Pages Including Key = 12
Page 1 of 12
KEY
Box with no fill = Process Step

Blue Filled Box = Input
Yellow Filled Box = Output
Dotted Line = Optional Step
Red Filled Circle = Last step in process
Open-ended Box = Chemical/ Material used
that is not an ingredient or processing aid
that does not contact the product directly .
B
Biological Hazard identified at this step
Chemical Hazard identified at this step

Physical Hazard identified at this step
Page 30 of 252
HACCP Plan - Form 3
MASTER FLOWCHART OF
MAJOR PROCESS STEPS (PS) FOR MAKING BEER (Page 2 of 12)
FULL TANKER
(Step T6) B C
RECEIVING
(PS1) B C P
STORAGE & HANDLING

(Step PS2) B C P
Water & Dry

Ingredients
Yeast,
Processing
Aids
FULL TANKER
UNLOADING
(Step T7) B C
BREWING
(Step PS3) C
MILLING/ MASHING/ LAUTERING
KETTLE/ WHIRLPOOL/ COOLING
FERMENTATION
(Step PS4) C
Processing
Aids, CO2
AGING
(Step PS5) C
CLARIFICATION/ FILTERING
BRIGHT BEER STORAGE

(Step PS6) C
Bottles, Cans, Kegs,

Crowns, Tankers
New
Bottles
Prep
PS8 (NB)
CP
Returned
Bottles
Prep
PS8 (RB)
BCP
BRIGHT BEER
PROCESSING
(Step PS7) C
PACKAGING
(Step PS8)
BOTTLING
Step PS8 (BT) C P
CANNING
Step PS8 (C) B C
KEGGING
Step PS8 (K) C
- Washing
- Inspection
- Filling
- Flushing
- Rinsing
- Filling
- Packing
- Cleaning
- Filling
- Palletizing
TANKERING
Step PS8 (T) B C
- Filling
WAREHOUSING/ SHIPPING
(Step PS9)

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HACCP Plan - Form 3
PS3 - BREWING (Page 3 of 12)
RECEIVING
(Step B1) B C P
Storage
(Step B2) B C P
Milling
(Step B3) C
Cereal Cooker
(Step B4)
Mashing
(Step B5)
Lautering
(Step B6)
Holding Tank
(Step B7)
Kettle
(Step B8)
Whirlpool
(Step B9)
Oxygen
Wort Cooling
(Step B10)
Next Process - PS4
Fermentation

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HACCP Plan - Form 3
PS4 - FERMENTATION
(Page 4 of 12)
COLD WORT
Oxygen/ Sterile
Air
WORT OXYGENATION/
WORT AERATION
(Step F1 )
Yeast Propagation
(Step Y1)
Yeast Storage
(Step Y2)
Acid Washing
(Step Y3)
YEAST
FERMENTATION
(Step F2)
CO2
Cooling
(Step F3) C
Yeast
Removal
GREEN BEER
(Step F4)

Next Process - PS5 -Aging/

Page 33
Clarification/ Filtration
of 252
HACCP Plan - Form 3
PS5 - AGING/ CLARIFICATION/ FILTRATION (Page 5 of 12)
GREEN BEER
COOLING
(Step A1) C
Buffer tank
(Step A2)
Centrifuge
(Step A3)
Processing aids,
Stabilizers,
CO2, Preservatives
Yeast,
By-products
Buffer tank
(Step A4)
CO2
Cooling tank
(Step A5) C
CO2, Hops
Aging Tank
(Step A6) C
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives
Caramel & other
ingredients,
Processing aids,
Stabilizers, CO2,
Preservatives
Beer,
Spent Hops, CO2
Secondary Storage
(Step A7) C
CO2, Spent
Yeast
Surge/ Buffer Tank

(Step A8) C
Filtration
(Step A9) C
CO2
CO2, Spent
Yeast
Deaerated water,
CO2, Nitrogen
Bright Beer Storage

(Step A10 = PS6) C
CO2
Next Process - PS7 Bright BeerProcessing

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HACCP Plan - Form 3
PS7 (BBP) - BRIGHT BEER PROCESSING
PS7 (SF)
STERILE FILTRATION
CO2
(Page 6 of 12)
PS7 (P)
FLASH PASTEURIZATION
Bright Beer Tank

(Step SF1) C
Bright Beer Tank

(Step FP1) C
Filtration
(Step SF2) C
Flash Pasteurization
(Step FP2) C
Sterile Beer Tank

(Step SF3)
Pasteurized Beer Tank

(Step FP3)
Next Process - PS8 -Packaging

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HACCP Plan - Form 3

Page 36 of 252
HACCP Plan - Form 3
Process Step 8
PS8 (RB) - RETURNED BOTTLES PREP
(Page 7 of 12)
Receiving/ Storage
(Step RB1) P
Caustic
Hydro Jet Sprays
(Step RB8) B C P
De-Palletizing
(Step RB2) P
De-Casing & Inspection

(Steps RB3-4) P
Post Soak
(Step RB9 C P
Bottle Wash Loading

(Step RB5) P
External Flush
(Step RB10) P
Pre-Rinse
(Step RB6) P
Water,
Chemicals &
Steam
External Rinse
(Step RB11) P
Soak Tanks (caustic)
(Step RB7) C P
Water
Interior Rinse
(Steps RB12) C P
Water
FINAL RINSE
(Step RB13) C P
Next: (PS8- BT) Bottling

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HACCP Plan - Form 3
Process Step 8
PS8 (NB) - NEW BOTTLES PREP
(Page 8 of 12)
Receiving
(Step NB1) P
Preliminary Inspection
(Step NB2) P
Storage
(Step NB3-6) P
Inspection
(Step NB7) P
RINSE
(Steps NB8-9) C P

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HACCP Plan - Form 3

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HACCP Plan - Form 3
Process Step 8
PS8 (BT) - BOTTLING (Page 9 of 12)
BOTTLES - See
Returned Bottles Prep
& New Bottle Prep
Air
Drying
(Step BT11)
(Steps BT1) C P
Water
Down Bottle Filler In-Feed Control

(Steps BT2) P
Label & Code
(Steps BT12-13)
Bright Beer,
CO2, Compressed Air
Water
Filling
(Steps BT3-5) C P
CO2,
Glass
Filled Bottle Inspection
(Step BT14)
Crowns, Compressed Air

Water
Crowning
(Step BT6 ) C P
Water
Bottle Flush (External)

(Steps BT7-8)
Steam
& Chemicals
Pasteurize
(Step BT9)
Foam Inspection/ Candling

(Step BT10) P
Packing & Sealing

(Steps BT15-18)
Secondary Code & Full Case

Inspection
(Steps BT19-20)
Palletize
(Step BT21)
Storage
(Step BT22)
Live Load
SHIPPING
(Step BT23)

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HACCP Plan - Form 3

Page 41 of 252
HACCP Plan - Form 3
Process Step 8
PS8 (K) - KEGGING (Page 10 of 12)
KEGS
Receiving
(Step K1)
Racking
(Step K7)
Storage, Handling,
De-palletizing
(Steps K2-3)
Internal Cleaning
Manual
(Steps K8-12) C
Internal Cleaning
Automated
(Steps K8-12) C
Filling (Step K18) C
Barnes Neck Wash &

Sanitize
(Step K19-21)
External Inspection
(Step K4 )
Sterilize & Hold
(Step K13)
Dust Cap Applied

(Steps K22)
Purge to Empty &

Counter Pressure
(Steps K14-15)
Air Dry
(Step K23)
Barnes Neck Sanitize &

Inspect
(Step K16-17)
Code
(Step K24)
External Cleaning
(Steps K5-6)
Weigh & Palletize

(Steps K25-26)
Storage
(Step K27)
Live Load
SHIPPING
(Step K28)

Page 42 of 252
HACCP Plan - Form 3

Page 43 of 252
HACCP Plan - Form 3
Process Step 8
PS8 (C) - CANNING (Page 11 of 12)
CANS
Drying (Steps C16-17)
Receiving
(Step C1)
Coding
(Step C6)
Storage & Handling

(Step C2) B C
Fill Height Inspection

(Step C18)
Rinser
(Step C7) C
Depalletizing/ Pallet ID
(Steps C3-4 )
Inspection
(Step C5)
Divert to Packers
(Steps C19)
Bright
Beer,
CO2
Filling
(Steps C8- 10)
CO2
Hi Cone Machine
(Step C20)
Can Ends
Water
Seaming
(Steps C11-13) C
External Flush
(Step C14)
Pastuerizer
(Step C15)
Case Packers
(Steps C21)
Inspection
(Step C22)
Tray Machine & Code

(Steps C23-24)
Palletize
(Step C25)
Storage
(Step C26)
Live Load
SHIPPING
(Step C27)

Page 44 of 252
HACCP Plan - Form 3

Page 45 of 252
HACCP Plan - Form 3
Process Step 8
PS8 (T) - TANKERING (Page 12 of 12)
Empty Tanker
(Step T1) C
Caustic, Water,
Acid
CO2
Tanker Washing
(Step T2) C
Tanker Purge
(Step T3) C
CO2
Bright Beer,
CO2
Tanker Filling
(Step T4) B C
Tanker Shipping
(Step T5)
Full Tanker Receiving

(Step T6) B C
FULL TANKER UNLOADING

(Step T7) B C

Page 46 of 252
FORM 4:
SCHEMATIC DIAGRAM

Page 47 of 252

Page 48 of 252
HACCP Plan - Form 4

Page 1 of 1
BAC Generic
Title: Form 4 Schematic Diagram

Approved By: BAC TC
Date:
Date:
Note: Each brewery must be individually assessed at the time of implementation

to ensure identified hazards have been addressed.
Schematic Diagram
TO BE COMPLETED

Page 49 of 252

Page 50 of 252
FORM 5:
HAZARD IDENTIFICATION
BIOLOGICAL HAZARDS

Page 51 of 252

Page 52 of 252
HACCP Plan - Form 5
BAC Generic
Title: Form 5 Hazard Identification - Biological Hazards

Date:
Approved By: BAC TC
Date:
List all biological hazards

related to ingredients,
incoming material,
processing, product flow,
etc.
Identified biological
hazards (Bacteria,
parasites, viruses,
etc.)
Controlled at:
INGREDIENTS
LIQUID INGREDIENTS
City Water
Coliform, E. Coli
Purchased Water
Coliform, E. Coli
Well/ Lake/ Surface/ Water
Coliform, E. Coli,
Parasites
DRY INGREDIENTS
Barley malt
Micro (fecal
contamination from birds,
mice)
Wheat (malted/ non-malted),
Micro (fecal
mice)
Cereal Grain, e.g. corn, oats,

rice
Micro (fecal
mice)
Hops
Fecal contamination
(E. coli)
OTHER INGREDIENTS
Yeast
Cross contaminated e.g.

Salmonella
Carbohydrate Matter
(e.g. sucrose, syrup,
honey)
Clostridium

Page 53 of 252
HACCP Plan - Form 5
OTHER INGREDIENTS (Continued)
Yeast

Salmonella
Carbohydrate Matter
honey)
Clostridium
Salt
None identified
Hop Oil
None identified
Hop Extract
None identified
Nitrogen/ Oxygen/
Compressed Air
Purchased CO2
None Identified
Regenerated CO2
None identified
Liquid Wheat Extract
None identified
Caramel
None identified
Dextrin
None Identified
Food Enzymes
None identified
Stabilizing Agents
None identified
Water preparation agents
None identified
Preservatives
None Identified
Yeast Foods
None Identified
Processing aids
Examples Gelatin, Irish
Moss, Wood Shavings
Fecal contamination (e.g.

Gelatin, Irish Moss)
PRIMARY PACKAGING MATERIAL

New glass
None identified
Used glass
Bacteria
Lined aluminum cans and

bottles
None identified

Page 54 of 252
HACCP Plan - Form 5
New Kegs
None identified
PRIMARY PACKAGING MATERIAL (Continued)

Used Kegs
None identified
Plastic Bottles, e.g. PET
None Identified
Crowns
None identified
Closures & Can Ends
None Identified
PROCESS STEPS
PS1- RECEIVING
Micro contamination from

receiving open containers
(e.g. bird droppings).
PS2- STORAGE/ HANDLING
Mold growth from

improper storage
conditions
Insect or pest infestation
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
None identified
B4 - Cereal Cooker
None identified
B5 - Mashing (Mash Mixer,

Mash Cooker)
None identified
B6 - Lautering (Lauter Tun,

Mash Filter removal of spent
grains
None identified
B7 Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified
B10 - Wort Cooling (Heat

Exchanger)
None identified
PS4 -FERMENTATION
Page 55 of 252
HACCP Plan - Form 5
Cold Wort (from B10)
None identified
PROCESS STEPS (Continued)

F1 Wort Oxygenation/ Wort
Aeration
None identified
F2 - Fermentation
None identified
F3 - Cooling
None identified
F4 - Green Beer
None identified
PS4 SUB-PROCESS YEAST

PREPARATION
Y1 Propagation
None identified
Y2 Storage
None identified
Y3 Acid Washing
None identified
PS5 - AGING/ CLARIFICATION/

FILTRATION
A1 - Cooling
None identified
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
None identified
A6 - Aging Tank
None identified
A7 - Secondary Storage
None identified
A8 - Surge/ buffer Tank
None identified
A9 Filtration
None identified
A10 Bright Beer Storage
(See PS6 below)
PS6 BRIGHT BEER STORAGE
None identified
PS7 BRIGHT BEER PROCESSING
PS7 (SF) Sterile Filtration

Page 56 of 252
HACCP Plan - Form 5
SF1 - Bright Beer Tank
None identified

SF2 - Filtration
None identified
SF3 - Sterile Beer Tank
None identified
PS7(FP) Flash Pasteurization

FP1 - Bright Beer Tank
None identified
FP2 - Pasteurization
None identified
FP3 - Pasteurized Beer Tank
None identified
PS8 RB
RETURNED BOTTLES PREP
(FLOAT GLASSWARE PREP)
RB1 - Receiving/ Storage
None identified
RB2 - De-palletizing
None identified
RB3- RB4 - De-casing &

Inspection (visual)
None identified
RB5 - Bottle Wash Loading
None identified
RB6 - Pre-rinse sprays
None identified
RB7 - Soak Tanks With Caustic
None identified
RB8 - Hydro Jet Sprays
Spray malfunction and

debris is left in bottle (e.g.
pathogenic Clostridium,
Listeria, Hepatitis (A/B/C)
RB9- Post-Soak
None identified
RB10 - External Flush
None identified
RB11 - Ext. Rinse
None identified
RB12 - Interior Rinse
None identified
RB13 - Final Rinse
None identified
PS8 NB NEW BOTTLES (GLASSWARE)

PREP
NB1- NB2 - Receiving &


None identified
Page 57 of 252
HACCP Plan - Form 5
NB3 NB 6 Storage (Pallet

Prep, De-palletize)
None identified

NB7 Inspection (Human,
visual)
None identified
NB8 - Bottle Loading,
None identified
NB9 - Bulk Glass Rinser
None identified
PS8 BT - BOTTLING
BT1
(Human or Machine inspection)
None identified
BT2 Down Bottle Filler In-Feed

Control
None identified
BT3 BT5 Filling (Purges ,

Filling, Fobbing)
None identified
BT6 - Crowning
None identified
BT7 BT 8 Bottle Flush (Full

Bottle Wash - external)
None identified
BT9
Pasteurize
None identified
BT10 - Foam Inspection &/or

Candling
None identified
BT11 Drying (Bottle Drying

and Air Knives)
None identified
BT12 BT13 Labelling, Coding
None identified
BT14 Filled Bottle Inspection
None identified
BT15 BT18 Packing & Sealing

(Divert to packers, Carton, Case
Pack, Sealing)
None identified
BT19 BT20 Secondary Code & None identified

Inspection (Secondary
Packaging, Code/Inspection)

Page 58 of 252
HACCP Plan - Form 5
BT21
Palletize
None identified

BT22 - Storage (or Live Load)
None identified
BT23 - Shipping
None identified
PS8 (K) - KEGGING
K1 - Receiving (See PS1)
None identified
K2 K3 Storage & Handling ,

De-palletizing (See PS2)
None identified
K4 - External Inspection
None identified
K5 K6 External Cleaning (Ext

Wash/Inspection)
None identified
K7
Racking
None identified
K8 K12 Internal Cleaning

(Purge, Flush, Wash, Purge,
Rinse)
None identified
K13 - Sterilize & Hold
None identified
K14 K 15 Purge to Empty &

Counter pressure
None identified
K 16 - K17 Barnes Neck Sanitize None identified

& Inspect
K18 - Filling
None identified
K19 K 21 Barnes Neck, Wash

& Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product Code Applied
None identified
K25 K 26 Weigh (In-line

weighing) & Palletize
None identified

Page 59 of 252
HACCP Plan - Form 5
K27 - Storage
None identified
K28 - Shipping
None identified

PS8 (C) - CANNING
C1 - Receiving
None identified
C2 - Storage & Handling
Bacterial contamination
from leaking roof or pipes
C3 C 4 De-palletize / Pallet ID
(Collect & Timestamp Can Pallet
ID, De-palletize)
None identified
C5 - Online visual inspection
None identified
C6 - Primary code applied
None identified
C7 - Bulk in-line rinser
None identified
C8 C 10 Filling (preevacuation & beer fill)
None identified
C11 C13 Seaming
None identified
C14 - External Can Flush
None identified
C15
Pasteurizer
None identified
C16 C17 Drying
None identified
C18 - Fill Height Inspection
None identified
C19 - Divert to Packers
None identified
C20 - Hi-Cone Machine
None identified
C21 - Case Packers
None identified
C22 Inspection (Human,

visual) Inspection
None identified
C23 C24 Tray Machine &

Code
None identified

Page 60 of 252
HACCP Plan - Form 5
C25
Palletize
None identified
C26 - Storage (or Live Load)
None identified

C27
Shipping
None identified
PS8 T TANKERING
T1 - Empty Tanker (Receiving)
None identified
T2 - Tanker Washing/ Rinsing
None identified
T3 - Tanker Purging
None identified
T4 - Tanker Filling/ Loading

of hoses
T5 Tanker Shipping
None identified
T6 T7 Full Tanker Receiving &

Unloading

of hoses

Page 61 of 252
HACCP Plan - Form 5
Date:

Approved by:
Page 62 of 252

Page 63 of 252
FORM 6:
CHEMICAL HAZARDS

Page 64 of 252

Page 65 of 252
HACCP Plan - Form 6
BAC Generic
Title: Form 6 Hazard Identification - Chemical Hazards

Date:
Approved By: BAC TC
Date:
List all chemical hazards related

to ingredients, incoming
material, processing, product
flow, etc.
Identified chemical hazards
Controlled at:
INGREDIENTS
LIQUID INGREDIENTS
City Water
Pesticides, Heavy metals
Purchased Water
Cleaning chemicals, cross

contamination from previous
load
DRY INGREDIENTS
Barley malt
Pesticides, Mycotoxins,
Allergen (cross-contamination
from carrier), NDMA
Allergen, NDMA

rice
Allergen (cross-contamination
from carrier), NDMA
Hops
Pesticides, Mycotoxins
OTHER INGREDIENTS
Yeast
Heavy Metals, cleaning

chemicals (used in tankers)
Carbohydrate Matter
honey)
Antibiotic residue, heavy

metal (honey)
Salt
Non-food grade
Hop Oil
Residual solvents, Non-food

grade

Page 66 of 252
HACCP Plan - Form 6
Hop Extract
Residual solvents, Non-food

grade
Nitrogen/ Oxygen/
Compressed Air
Purchased CO2
Chemical non-volatile gases,

Non-food grade
Regenerated CO2
Contamination from oil (from

the compressor)
Allergen
Caramel
Non-food grade
Dextrin
Non-food grade
Food Enzymes
Non-food grade
Stabilizing Agents
Heavy metals, Non-food

grade

grade
Preservatives
Allergens (Sulphites), Nonfood grade
Yeast Foods

grade
Processing aids
Moss, Wood Shavings

grade

New glass
None identified
Used glass
Lubricants, mycotoxins

bottles
None identified
New Kegs
None identified
Used Kegs
None identified

Page 67 of 252
HACCP Plan - Form 6

None identified
Crowns
None identified
Closures & Can Ends
None identified
PROCESS STEPS
PS1- RECEIVING
Chemical Contamination
from truck (damage, leaks,
odors)
Chemical - Crosscontamination from allergens

(e.g. wheat)
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
Chemical Allergen crosscontamination (e.g. from

residues in the mill)
B4 - Cereal Cooker
None identified

Mash Cooker)
None identified

grains
None identified
B7 Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified

Exchanger)
None identified
PS4 -FERMENTATION
None identified

Aeration
None identified

Page 68 of 252
HACCP Plan - Form 6

F2 - Fermentation
None identified
F3 - Cooling
Coolant leak
F4 - Green Beer
None identified

PREPARATION
Y1 Propagation
None identified
Y2 Storage
None identified
Y3 Acid Washing
None identified

FILTRATION
A1 - Cooling
Coolant leak
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
Coolant leak
A6 - Aging Tank
Coolant leak
Coolant leak
Sulphites as an allergen
A9 Filtration
(See PS6 below)
Coolant leak
Cleaning chemicals
PS7 BRIGHT BEER

PROCESSING


Coolant leak
Cleaning chemicals
Page 69 of 252
HACCP Plan - Form 6

SF2 - Filtration
None identified

Coolant leak
Cleaning chemicals
Contamination from coolant
None identified
PS8 RB
None identified
None identified

Inspection (visual)
None identified
None identified
None identified
RB7 - Soak Tanks With

Caustic
Too concentrated, too low, no

caustic, wrong chemical
Bottle unable to drain
RB9- Post-Soak
None identified
RB11 - Ext. Rinse
None identified
Spray malfunction
Bottle plugged unable to drain
RB13 - Final Rinse

PREP

Page 70 of 252
HACCP Plan - Form 6

None identified

Prep, De-palletize)
None identified

visual)
None identified
None identified
Contaminated air, sanitizing

spray
PS8 BT - BOTTLING
BT1
(Human or Machine
inspection)
MACHINE:
Failure of the system to detect
residual liquid and caustic
BT2 Down Bottle Filler InFeed Control
None identified

Filling, Fobbing)
CIP chemicals in bottle
BT6 - Crowning
Lubricants

None identified
BT9
Pasteurize
None identified
BT10 - Foam Inspection &/ or

Candling
None identified

and Air Knives)
None identified
BT12 BT13 Labelling,

Coding
Product not coded or not

correctly coded
None identified

HUMAN:
Failure of personnel to detect
residual liquid
Page 71 of 252
HACCP Plan - Form 6

BT15 BT18 Packing &
Sealing
(Divert to packers, Carton,
Case Pack, Sealing)
None identified
BT19 BT20 Secondary Code

& Inspection (Secondary

correctly coded
BT21
Palletize
None identified
None identified
BT23 - Shipping
None identified
PS8 (K) - KEGGING
None identified

None identified
None identified
K5 K6 External Cleaning
(Ext Wash/Inspection)
Old codes not effectively

removed
K7
Racking
None identified

Rinse)
Automated
Cleaning solution not
effectively removed.
Manual
None identified

Counter pressure
None identified
K 16 - K17 Barnes Neck

Sanitize & Inspect
None identified
K18 - Filling
CIP solution

Page 72 of 252
HACCP Plan - Form 6

K19 K 21 Barnes Neck,
Wash & Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
Incorrect or missing code

None identified
K27 - Storage
None identified
K28 - Shipping
None identified
PS8 (C) - CANNING
C1 - Receiving
None identified
Contamination from leaking

roof or pipes
C3 C 4 De-palletize / Pallet
ID
(Collect & Timestamp Can
Pallet ID, De-palletize)
Incorrect or missing code on

pallet
None identified
Chemicals from compressed

air or water
None identified
C11 C13 Seaming
Chemicals, Lubricants
None identified
C15
Pasteurizer
None identified
C16 C17 Drying
None identified
None identified

Page 73 of 252
HACCP Plan - Form 6

None identified
None identified
C21 - Case Packers
None identified

visual) Inspection
None identified

Code
C25
Palletize
None identified
None identified
C27
Shipping
None identified
PS8 T TANKERING
Cleaning chemicals and/ or

sanitizer

sanitizer
T3 - Tanker Purging
Contaminated CO2
Cross contamination from

using hose on non-food
material
T5 Tanker Shipping
None identified
T6 T7 Full Tanker Receiving

& Unloading
Cross contamination with

chemicals from the supplier
material
Date:

Approved by:
Page 74 of 252

Page 75 of 252
FORM 7:
PHYSICAL HAZARDS

Page 76 of 252

Page 77 of 252
BAC Generic
Title: Form 7 Hazard Identification - Physical Hazards

Date:
Approved By: BAC TC
Date:
List all physical

hazards related to
ingredients, incoming
material, processing,
product flow, etc.
Identified physical
hazards
Controlled at:
INGREDIENTS
LIQUID INGREDIENTS
City Water
Silt
Purchased Water
None identified
Silt
DRY INGREDIENTS
Barley malt
Glass, Metal
Wheat (malted/ nonmalted),
Glass, Metal
Cereal Grain, e.g. corn,

oats, rice
Glass, Metal
Hops
Insects, metal
OTHER INGREDIENTS
Yeast
None identified
Carbohydrate Matter
(e.g. sucrose,
syrup, honey)
None identified
Salt
Rocks
Hop Oil
Plastic
Hop Extract
Plastic
Nitrogen/ Oxygen/
Compressed Air
Purchased CO2
None identified

Page 78 of 252
Regenerated CO2
None identified
Plastic (from packaging)
Caramel
Plastic (from container)
Dextrin
Food Enzymes
None identified
Stabilizing Agents
None identified
None identified
Preservatives
None identified
Yeast Foods
None identified
Processing aids
Moss, Wood Shavings
None identified

New glass
Critical Glass Defects , Glass
Used glass
Critical Glass Defects , Dirt,

Dust, Glass, Syringes, Medical
Patches
Lined aluminum cans

and bottles
Metal Shavings
New Kegs
Metal Shavings
Used Kegs
None identified
None identified
Crowns
None identified
Closures & Can Ends
None identified
PROCESS STEPS
PS1- RECEIVING

Pests in hoses used for

transferring material, Bulk
Receiving
Page 79 of 252

PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
None identified
B4 - Cereal Cooker
None identified

Mash Cooker)
None identified

Mash Filter removal of
spent grains
None identified
B7 Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified

Exchanger)
None identified
PS4 -FERMENTATION
None identified

Aeration
None identified
F2 - Fermentation
None identified
F3 - Cooling
F4 - Green Beer
None identified
PS4 SUB-PROCESS
YEAST PREPARATION
Y1 Propagation
None identified
Y2 Storage
None identified

Page 80 of 252
Y3 Acid Washing
None identified
PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
None identified
A6 - Aging Tank
None identified
None identified
None identified
A9 Filtration
None identified
None identified
PS6 BRIGHT BEER

STORAGE
None identified
PS7 BRIGHT BEER

PROCESSING
PS7 (SF) Sterile

Filtration
None identified
SF2 - Filtration
None identified
None identified
PS7(FP) Flash
Pasteurization
None identified
None identified
None identified

Page 81 of 252

PS8 RB
Damage to bottles
Damage to bottles

Inspection (visual)
Damage to bottles
Damage to bottles
Damage to bottles (e.g.

Temperature shock due to
storage)

Caustic
Damage to bottles
Damage to bottles
Bottle contains foreign object
(spray malfunction)
(plugged but sprays cannot clear
object)
RB9- Post-Soak

Temperature shock)
Bottle plugged

Temperature shock)
RB11 - Ext. Rinse
Damage to bottles
(e.g. Temperature shock)
Damage to bottles
(spray malfunction)
object)

Page 82 of 252

RB13 - Final Rinse
Damage to bottles
(spray malfunction)
object)
PS8 NB NEW BOTTLES

(GLASSWARE) PREP

Damage to bottles

Prep, De-palletize)
Damage to bottles

visual)
Missed critical glass defects
Damage to bottles
Spray malfunction
(e.g. plugged sprays)
PS8 BT - BOTTLING
BT1
(Human or Machine
inspection)
MACHINE:
Failure of the system to detect
foreign matter, glass defects,
bottle damage
HUMAN:
glass damage
BT2 Down Bottle Filler InFeed Control
Glass inclusions from breakage

of down bottle at filler in-feed

Filling, Fobbing)
Chipping of bottles (e.g. from

filling equipment), glass
inclusion
Auto-Flush
Burst bottle leading to glass
inclusion
Manual Flush
inclusion

Page 83 of 252

BT6 - Crowning
Bottle finish damage

(leading to glass inclusions)
BT7 BT 8 Bottle Flush

(Full Bottle Wash - external)
None identified
BT9
Pasteurize
None identified
BT10 - Foam Inspection

&/or Candling
HUMAN:
Physical Failure to detect
foreign matter (including glass)
MACHINE:
foreign matter (including glass)
BT11 Drying (Bottle

Drying and Air Knives)
None identified

Coding

correctly coded
BT14 Filled Bottle

Inspection
None identified
BT15 BT18 Packing &

Sealing
None identified

Case Pack, Sealing)
BT19 BT20 Secondary
Code & Inspection
(Secondary Packaging,
Code/Inspection)
Product not coded, or not

correctly coded
BT21
Palletize
None identified
BT22 - Storage (or Live

Load)
None identified
BT23 - Shipping
None identified
PS8 (K) - KEGGING

None identified
Page 84 of 252

K2 K3 Storage & Handling
, De-palletizing (See PS2)
None identified
None identified
K5 K6 External Cleaning
(Ext Wash/Inspection)

removed
K7
Racking
None identified

(Purge, Flush, Wash,
Purge, Rinse)
None identified
None identified
K14 K 15 Purge to Empty

& Counter pressure
None identified

Sanitize & Inspect
None identified
K18 - Filling
None identified

Wash & Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified

None identified
K27 - Storage
None identified
K28 - Shipping
None identified
PS8 (C) - CANNING
C1 - Receiving
None identified
None identified

Page 85 of 252

C3 C 4 De-palletize /
Pallet ID

pallet
C5 - Online visual
inspection
None identified
C6 Primary code applied
None identified
None identified
C11 C13 Seaming
None identified
None identified
C15
Pasteurizer
None identified
C16 C17 Drying
None identified
None identified
None identified
None identified
C21 - Case Packers
None identified

visual) Inspection
None identified

Code
C25
Palletize
None identified
C26 - Storage (or Live

Load)
None identified
C27
Shipping
None identified

Page 86 of 252

PS8 T TANKERING
T1 - Empty Tanker
(Receiving)
None identified
T2 - Tanker Washing/
Rinsing
None identified
T3 - Tanker Purging
None identified
None identified
T5 Tanker Shipping
None identified
T6 T7 Full Tanker
Receiving & Unloading
None identified
Date:

Approved by:
Page 87 of 252
FORM 8:
CRITICAL CONTROL
POINTS

Page 88 of 252

Page 89 of 252
Critical Control Points - Form 8
BAC Generic
Incoming
material/ process
step/ hazards on
schematic
diagram
Title: Form 8 Critical Control Points

Approved By: BAC TC
Category
and
identified
hazard.
Determine if fully controlled by

Pre-requisite program.
*If yes = indicate Pre-requisite
Program and proceed to next
identified hazard.
*If no = proceed to question1 (Q1).
Date:
Date:
Q1. Could a
control
measure(s)
be used by
the operator
at any
process
step?
If NO = not a
CCP +
identification
on how this
hazard will be
controlled
before and
after the
process
+ proceed to
the next
identified
hazard
If YES =
description +
next question
(Q2)

Q2. Is it
likely that
contaminati
on with the
identified
hazard
could
occur in
excess of
the
acceptable
level or
could
increase to
an
unacceptab
le level?
Q3. Is this
process
step
specificall
y
designed
to
eliminate/
reduce
the likely
occurrenc
e of the
identified
hazard to
an
acceptabl
e level?
If NO = not
a CCP +
proceed to
the next
identified
hazard
If NO =
next
question
(Q4)
If YES =
next
question
(Q3)
Page 90 of 252
If YES =
CCP + go
to last
column
Q4. Will a
subsequen
t step
eliminate
the
identified
hazard or
reduce
likely
occurrenc
e to an
acceptable
level?
CCP
Number
+ proceed
to next
identified
hazard
If NO = CCP + go to last
column
If YES =
not a CCP
+ identify
subsequent
step +
proceed to
the next
identified
hazard
INGREDIENTS
LIQUID INGREDIENTS
WATER
City Water
Biological Coliform, E.
Coli
PP Premises, Water Quality (BAC

A4.1) All Hazards
Chemical Pesticides,
Heavy metals
Physical
Silt
Purchased Water
Coli
Chemical
Cleaning
chemicals,
cross
contamination
from previous
load
Well/ Lake/
Surface/ Water
Coli, Parasites
PP Premises, Water Quality

(BAC A4.1)
PP - Transportation Receiving &
Storage (BAC B1.1)
- COA/ Supplier Audits

(BAC A4.1)
Chemical Pesticides,
Heavy metals
Physical
Silt

Page 91 of 252
DRY INGREDIENTS
Barley malt
Biological
Micro (faecal
contamination
from birds,
mice)
Chemical
Pesticides,
Mycotoxins,
Allergen
(crosscontamination
from carrier),
NDMA

Storage (BAC B1.1)
- COA from supplier
Storage (BAC B1.1)
- COA / Letter of Guarantee
Storage (BAC B1.1) - Receiving
Inspection (screens, magnets)
Physical
Glass, Metal

Page 92 of 252
Wheat (malted/
nonmalt
ed),
Biological
Micro (faecal
contamination
from birds,
mice)
Chemical
Pesticides,
Mycotoxins,
Allergen,
NDMA
Physical
Glass, Metal

Storage (BAC B1.1)
+ COA from supplier
Storage (BAC B1.1)
+ COA / Letter of Guarantee,
Allergen Management Program
Storage (BAC B1.1)
+ Receiving Inspection (screens,
magnets)
Cereal Grain,
e.g.
corn
,
oats,
rice
Biological
Micro (faecal
contamination
from birds,
mice)
Chemical
Pesticides,
Mycotoxins,
Allergen
(crosscontamination
from carrier),
NDMA
Physical
Glass, Metal


Storage (BAC B1.1)
+ COA from supplier
Storage (BAC B1.1)
Storage (BAC B1.1)
magnets)
Page 93 of 252
Hops
Biological
Faecal
contamination
(E. coli)

Storage (BAC B1.1)
Chemical
Pesticides,
Mycotoxins
PP Transportation, Receiving &

Storage (BAC B1.1)
Physical
Insects, metal
+ COA
+ COA
Storage (BAC B1.1)
+ COA, Inspection
OTHER INGREDIENTS
Yeast
Biological
Cross
contaminated
e.g.
Salmonella
Chemical
Heavy Metals,
cleaning
chemicals
(used in
tankers)

Storage (BAC B1.1)
Physical
None
identified

Storage (BAC B1.1)
+ COA
+ COA, Wash Tickets

Page 94 of 252
Carbohydrate
Matt
er
(e.g. sucrose,
syru
p,
hone
y)
Biological
Clostridium
Chemical
Antibiotic
residue,
heavy metal
(honey)

Storage (BAC B1.1)
Physical
None
identified

Storage (BAC B1.1)
+ COA
+ COA
Salt
Biological
None
identified
Chemical
Non-food
grade
Yes
Screens,
filters,
inspection
No

Storage (BAC B1.1)
+ COA
(Partially Controlled)
Physical
Rocks

Storage (BAC B1.1)
+ Inspection

Page 95 of 252
Hop Oil
Biological
None
identified
Chemical
Residual
solvents, Nonfood grade
+ PP Transportation, Receiving &

Storage (BAC B1.1)
Physical
Plastic

Storage (BAC B1.1)
COA
+ COA, Inspection
Hop Extract
Biological
None
identified
Chemical
Residual
solvents, Nonfood grade

Storage (BAC B1.1)
Physical
Plastic

Storage (BAC B1.1)
+ COA
+ COA, Inspection

Page 96 of 252
Nitrogen/
Oxygen/
Compressed Air
Biological
None
Identified
Purchased CO2
Chemical
Chemical nonvolatile gases,
Non-food
grade

Storage (BAC B1.1)
+ COA, QC Testing
Physical
None
identified
Regenerated
CO2
from oil (from
the
compressor)

PP - Equipment (BAC C1.2)
Page 97 of 252
Liquid
Extract
Wheat
Biological
None
identified
Chemical
Allergen
Physical
Plastic (from
packaging)

Storage (BAC B1.1)
+ COA
Caramel
Biological
None
identified
Chemical
Non-food
grade

Storage (BAC B1.1)
+ COA
Physical
Plastic (from
container)

Storage (BAC B1.1)
+ COA

Page 98 of 252
Dextrin
Biological
None
identified
Chemical
Non-food
grade

Storage (BAC B1.1)
+ COA
Physical
Plastic (from
container)

Storage (BAC B1.1)
+ COA
Food Enzymes
Biological
None
identified
Chemical
Non-food
grade
Physical
None
identified


Storage (BAC B1.1)
+ COA
Page 99 of 252
Stabilizing
Agents
Biological
None
identified
Chemical
Heavy metals,
Non-food
grade + COA

Storage (BAC B1.1)
+ COA
Physical
None
identified
Water
preparation
agents
Biological
None
identified
Chemical
Heavy metals,
Non-food
grade + COA

Storage (BAC B1.1)
+ COA
Physical
None
identified

Page 100 of 252
Preservatives
Biological
None
identified
Chemical
Allergens
(Sulphites),
Non-food
grade
Physical
None
identified
Yeast Foods

Storage (BAC B1.1)
+ COA,
Biological
None
identified
Chemical
Heavy metals,
Non-food
grade

Storage (BAC B1.1)
+ COA,
Physical
None
identified

Page 101 of 252
Processing aids
Examples
Gelatin,
Irish
Moss,
Wood
Shavings
Biological
Faecal
contamination
(e.g. Gelatin,
Irish Moss)
Chemical
Heavy metals,
Non-food
grade

Storage (BAC B1.1)
Physical
None
identified

Storage (BAC B1.1)
+ COA
+ COA
New glass
Q1
Q2
Q3
Q4
Yes Bottle
Rinse
Yes
No
YesEmpty
Bottle
Inspection
BiologicalNone
identified
Chemical
None
identified
Physical Critical Glass
Defects ,
Glass
Storage (BAC B1.1)
+COA, Inspection

Page 102 of 252
Used glass
BiologicalBacteria
Yes
Pasteurization
No
No (no
pathogens
known to
survive in
final product
due to
properties of
beer, e.g.
low pH,
alcohol
content see
Form 1)
Yes
Chemical
Lubricants,
mycotoxins
Storage (BAC B1.1)
Yes Bottle
Rinse
Yes
No
+ Inspection,
Yes
Empty
Bottle
Inspection/
RLD
Physical Critical Glass

Defects , Dirt,
Dust, Glass,
Syringes,
Medical
Patches,

No
Yes Bottle
Wash
Page 103 of 252
No
Yes
Empty
Bottle
Inspection
Lined aluminum
cans and bottles
Biological
None
identified
Chemical
None
identified
Physical
Metal
Shavings

Storage (BAC B1.1)
Yes Rinse
No
Yes - Rinse
No
+COA
New Kegs
Biological
None
identified
Chemical
None
identified
Physical
Metal
Shavings

Rinse
Page 104 of 252
Used Kegs
Biological
None
identified
Chemical
None
identified
Physical
None
identified
Plastic Bottles,
e.g. PET
Biological
None
identified
Chemical
None
identified
Physical
None
identified
Crowns
Biological
None
identified
Chemical
None
identified
Physical
None
identified

Page 105 of 252
Closures & Can

Ends
Biological
None
identified
Chemical
None
identified
Physical
None
identified

Page 106 of 252
PROCESS STEPS
PS1- RECEIVING
Biological
Micro
contamination
from receiving
open
containers (e.g.
bird droppings).
PP Premises (BAC A1.1 & BAC

A2.1)
Chemical
Contamination
from truck
(damage,
leaks, odors)

Storage (BAC B1.1)
Physical
Pests in hoses
used for
transferring
material, Bulk
Receiving
PP - Pest Control (BAC E2.1)

Storage (BAC B1.1)
+ Seal Integrity
PP Personnel (BAC D1.2)
+ Training

Page 107 of 252
PS2- STORAGE/
HANDLING
Biological Mold growth

from improper
storage
conditions
PP - Premises (BAC A2.1)
Chemical Crosscontamination
from allergens
(e.g. wheat)
Physical &
Biological Insect or pest
infestation
PP - Sanitation (BAC E1.1)
PS3 - BREWING
B1 - Receiving
(See PS1
above)
B2 - Storage
(See PS2
above)
B3 - Milling
Chemical
Allergen crosscontamination
(e.g. from
residues in the
mill)
B4 - Cereal
Cooker

None identified

Page 108 of 252
B5 - Mashing
(Mash Mixer,
Mash Cooker)
None identified
B6 - Lautering
(Lauter Tun, Mash
Filter removal of
spent grains
None identified
B7 Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified
B10 - Wort
Cooling (Heat
Exchanger)
None identified
PS4
-FERMENTATION
Cold Wort (from
B10)
None identified
F1 Wort
Oxygenation/
Wort Aeration
None identified
F2 - Fermentation
None identified
F3 - Cooling
Chemical Coolant leak
F4 - Green Beer
None identified

PP Equipment (BAC C1.2)
Page 109 of 252
PS4 SUBPROCESS
YEAST
PREPARATION
Y1 Propagation
None identified
Y2 Storage
None identified
Y3 Acid
Washing
None identified
PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
A6 - Aging Tank

Page 110 of 252
A7 - Secondary
Storage
Sulphites as an
allergen
A8 - Surge/ buffer
Tank
Chemical Sulphites as an
allergen
A9 Filtration
Chemical Sulphites as an
allergen
A10 Bright Beer

Storage
(See PS6
below)
PS6 BRIGHT
BEER STORAGE
Chemical
Coolant leak
Sulphites as an
allergen
Cleaning
chemicals
PS7 BRIGHT
BEER
PROCESSING
PS7 (SF)
Sterile Filtration

Page 111 of 252
SF1 - Bright Beer

Tank
Chemical
Coolant leak
Sulphites as an
allergen
Cleaning
chemicals
SF2 - Filtration
Sulphites as an
allergen
SF3 - Sterile Beer

Tank
None identified
PS7(FP) Flash
Pasteurization
FP1 - Bright Beer
Tank
Chemical
Coolant leak
Sulphites as an
allergen
Cleaning
chemicals

Page 112 of 252
FP2 Pasteurization
Chemical
Contamination
from coolant
FP3 - Pasteurized
Beer Tank
None identified
PS8 RB
RETURNED
BOTTLES PREP
(FLOAT
GLASSWARE
PREP)
RB1 - Receiving/
Storage
Physical Damage to
bottles

Storage (BAC B1.1)
Training
RB2 - Depalletizing
Physical Damage to
bottles

Storage (BAC B1.1)
Training

Page 113 of 252
RB3- RB4 - Decasing &

Inspection (visual)
Physical Damage to
bottles

Training
RB5 - Bottle
Wash Loading
Physical Damage to
bottles

Training
RB6 - Pre-rinse
sprays
RB7 - Soak Tanks

With Caustic
Physical Damage to
bottles (e.g.
Temperature
shock due to
storage)
Physical Damage to
bottles
Chemical
Too
concentrated,
too low, no
caustic, wrong
chemical
Chemical Bottle unable to

drain
Training


Storage (BAC B1.1)

Storage (BAC B1.1)
No
Yes (EBI/
RLD)
Yes
Page 114 of 252
No
Yes(EBI/
RLD)
RB8 - Hydro Jet

Sprays
Biological
Spray
malfunction
and debris is
left in bottle
(e.g.
pathogenic
Clostridium,
Listeria,
Hepatitis
(A/B/C)
Physical Damage to
bottles,
Physical Bottle contains
foreign object
(spray
malfunction)
Physical
Bottle contains
foreign object
(plugged but
sprays cannot
clear object)
Chemical
Bottle unable to
drain
No
Yes (EBI)
Yes
No
Yes (EBI)
Yes
No
Yes (EBI)
Yes
No
Yes (EBI/
RLD)
Yes (EBI)
No
No

Yes (no
pathogens
known to
survive in final
product
properties of
beer, e.g. low
pH, alcohol
content see
Form 1)
Yes (EBI/
RLD)
Page 115 of 252
RB9- Post-Soak
Physical Damage to
bottles (e.g.
Temperature
shock),
Physical Bottle plugged
Chemical
Bottle unable to
drain
Yes (EBI)
Yes
No
Yes (EBI)
Yes (EBI)
Yes
No
Yes (EBI)
Yes (EBI/
RLD)
Yes
No
Yes (EBI/
RLD)
Yes (EBI)
Yes
No
Yes (EBI)
Yes (EBI)
Yes
No
Yes (EBI)

Training
No
No
RB10 - External
Flush
RB11 - Ext. Rinse
Physical Damage to
bottles (e.g.
Temperature
shock)
Physical Damage to
bottles
(e.g.
Temperature
shock)


Training

Training
Page 116 of 252
RB12 - Interior
Rinse
Physical Damage to
bottles
Yes (EBI)
Yes
No
Yes (EBI)
No
Yes (EBI)
Yes
No
Yes (EBI)
Yes (EBI/
RLD)
Yes
No
Yes (EBI/
RLD)

foreign object
(spray
malfunction)
Physical
Bottle contains
foreign object
(plugged but
sprays cannot
clear object)
Chemical
Spray
malfunction
Chemical Bottle plugged
unable to drain
No

Page 117 of 252
RB13 - Final
Rinse
Physical Damage to
bottles,
foreign object
(spray
malfunction)
Physical
Bottle contains
foreign object
(plugged but
sprays cannot
clear object)
Yes (EBI)
Yes
No
Yes (EBI)
No
Yes (EBI)
Yes
No
Yes (EBI)
No
Yes (EBI/
RLD)
Yes
No
Yes (EBI/
RLD)
Chemical
Bottle unable to
drain
PS8 NB NEW BOTTLES

(GLASSWARE)
PREP
NB1- NB2 Receiving &
Preliminary
Inspection
Physical Damage to
bottles


Storage (BAC B1.1)
Training
Page 118 of 252
NB3 NB 6
Storage (Pallet
Prep, Depalletize)
Physical Damage to
bottles
NB7 Inspection
(Human, visual)
Physical
Missed critical
glass defects
Physical
Damage
bottles
NB8 Loading,
Bottle

Training
to
Yes (EBI)
Yes

Training

Training
NB9 - Bulk Glass

Rinser
Physical
Spray
malfunction
(e.g. plugged
sprays)
Chemical
Contaminated
air, sanitizing
spray

PP Personnel
Training
(BAC
D1.2)
PS8 BT BOTTLING

Page 119 of 252
No
Yes (EBI)
BT1
MACHINE:
MACHINE:
Empty Bottle
Inspection
Physical Failure of the

system to
detect foreign
matter, glass
defects, bottle
damage
Human or
Machine
inspection (EBI/
RLD)
Yes (EBI)
Yes
Yes
CCP1-P
Yes (EBI/
RLD)
Yes
Yes
CCP1-C
Yes (EBI)
Yes
Yes
CCP1-P
Yes (EBI
Yes
Yes
CCP1-C

Training
Chemical Failure of the

system to
detect residual
liquid and
caustic
HUMAN:
Physical Failure of
personnel to
detect foreign
matter, glass
defects, glass
damage
Chemical Failure of
personnel to
detect residual
liquid
Training
HUMAN:
Training, SOP (personnel rotation)
Training
, SOP (personnel rotation)

Page 120 of 252
BT2 Down
Bottle Filler InFeed Control
Physical
Glass
inclusions from
breakage of
down bottle at
filler in-feed


Page 121 of 252
BT3 BT5 Filling

(Purges , Filling,
Fobbing)
Physical
Chipping of
bottles (e.g.
from filling

Training
equipment),
glass inclusion
Auto-Flush:
Physical
Burst bottle
leading to glass
inclusion
Auto-Flush:
Yes (SOP
Burst Bottle
Detection
System/ Filler
Flush/ Auto
Flush)
Yes
Manual Flush:
Physical
Burst bottle
leading to glass
inclusion

Training
Storage (BAC B1.1)
Yes (SOP on
Burst Bottle
Monitoring
and Reject &
Flush)
Manual Flush:

Page 122 of 252
Yes
CCP2-P
BT3 BT5 Filling

(Purges , Filling,
Fobbing)
(Continued)
Yes
No
Yes
(Foam
Inspectio
n&/or
Candling)
Yes
No
Yes
(Foam
Inspectio
n
&/or
Candling)

Training
Chemical
CIP chemicals
in bottle

Storage (BAC B1.1)

Training
BT6 - Crowning
Physical
Bottle
finish
damage
(leading
to
glass
inclusions)
Chemical
Lubricants
Yes
(SOP,
Foam
Inspection
&/or Candling)

PP Personnel
Training
(BAC
D1.2)

Page 123 of 252
BT7 BT 8 Bottle
Flush (Full Bottle
Wash - external)
None identified
BT9
Pasteurize
None identified
BT10 - Foam
Inspection &/or
Candling (Human)
Physical
Failure to
detect foreign
matter
(including
glass)
Note: Automated
Foam Inspection
is not within the
scope of this
generic model.
BT11 Drying
(Bottle Drying and
Air Knives)
None identified
BT12 BT13
Labelling, Coding
Product not
coded or not
correctly coded
BT14 Filled
Bottle Inspection
None identified
BT15 BT18
Packing & Sealing
(Divert to packers,
Carton, Case
Pack, Sealing)
None identified


Training
Yes (increase
number of
inspectors)
No
PP - Recall (BAC F1.2)

Page 124 of 252
BT19 BT20
Secondary Code
& Inspection
(Secondary
Packaging,
Code/Inspection)
Product not
coded, or not
correctly coded
BT21
Palletize
None identified
BT22 - Storage
(or Live Load)
None identified
BT23 - Shipping
None identified

PS8 (K) KEGGING

K1 - Receiving
(See PS1)
None identified
K2 K3 Storage
& Handling , Depalletizing (See
PS2)
None identified
K4 - External
Inspection
None identified
K5 K6 External
Cleaning (Ext
Wash/Inspection)
Old codes not

effectively
removed
K7
Racking
None identified

Page 125 of 252
K8 K12 Internal
Cleaning (Purge,
Flush, Wash,
Purge, Rinse)
Automated
Automated
Chemical
Cleaning
solution not
effectively
removed.
Manual:
Chemical
Cleaning
solution not
effectively
removed.

Training
No
Yes
Manual:
Training
K13 - Sterilize &

Hold
None identified
K14 K 15 Purge
to Empty &
Counter pressure
None identified
K 16 - K17
Barnes Neck
Sanitize & Inspect

Page 126 of 252
Yes
Yes
CCP3-C
K18 - Filling
Chemical
CIP solution

Training
K19 K 21
Barnes Neck,
Wash & Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product
Code Applied
Incorrect or
missing code

Training
K25 K 26 Weigh
(In-line weighing)
& Palletize
None identified
K27 - Storage
None identified
K28 - Shipping
None identified
PS8 (C) CANNING

C1 - Receiving
None identified

Page 127 of 252
C2 - Storage &
Handling
Biological
Bacterial
contamination
from leaking
roof or pipes

A2.1)
from leaking
roof or pipes

A2.1)
C3 C 4 Depalletize / Pallet
ID
(Collect &
Timestamp Can
Pallet ID, Depalletize)
Incorrect or
missing code
on pallet
C5 - Online visual
inspection
None identified
C6 - Primary code
applied
Incorrect or
missing code

Training

Training
C7 - Bulk in-line
rinser
Chemical
Chemicals from
compressed air
or water

PP Premises (BAC A4.1)

Page 128 of 252
C8 C 10 Filling
(pre-evacuation &
beer fill)
None identified
C11 C13
Seaming
Chemical
Chemicals,
Lubricants
C14 - External
Can Flush
None identified
C15
Pasteurizer
None identified
C16 C17 Drying
None identified
C18 - Fill Height

Inspection
None identified
C19 - Divert to
Packers
None identified
C20 - Hi-Cone
Machine
None identified
C21 - Case
Packers
None identified
C22 Inspection
(Human, visual)
Inspection
None identified


Training
Page 129 of 252
C23 C24 Tray

Machine & Code
Incorrect or
missing code

Training
C25
Palletize
None identified
C26 - Storage (or

Live Load)
None identified
C27
Shipping
None identified
PS8
T
TANKERING
T1 - Empty
Tanker
(Receiving)
Chemical
Cleaning
chemicals and/
or sanitizer

Storage (BAC B1.1)
COA, Wash Ticket,
Training
T2 - Tanker
Washing/ Rinsing
Chemical
Cleaning
chemicals and/
or sanitizer

Training

Page 130 of 252
T3 - Tanker
Purging
Chemical
Contaminated
CO2
For Regenerated CO2 PP

Equipment (BAC C1.2)
Training
For Purchased CO2 - PP
Transportation, Receiving &
Storage (BAC B1.1)
COA
T4 - Tanker
Filling/ Loading
T5 Tanker
Shipping
Biological
Insect or pest
infestation of
hoses
No
Chemical
Cross
contamination
from using
hose on nonfood material

Training
Yes (no
pathogens
known to
survive in final
product due to
the properties
of beer, e.g.
low pH, see
Form 1)
No
None identified

Page 131 of 252
T6 T7 Full
Tanker Receiving
& Unloading
Biological
Insect or pest
infestation of
hoses
No
Chemical
Cross
contamination
with chemicals
from the
supplier

Storage (BAC B1.1)
Chemical
Cross
contamination
from using
hose on nonfood material

Training
Date:

Yes (no
pathogens
known to
survive in final
product due to
the properties
of beer, e.g.
low pH,
alcohol
content see
Form 1)
No
+ COA
Approved by:
Page 132 of 252

Page 133 of 252
FORM 3A:

WITH CCPS

Page 134 of 252

Page 135 of 252
HACCP Plan - Form 3A
BAC GENERIC HACCP PLAN FORM 3a

Approved By: BAC HACCP Technical Committee
Approval Date:
Total # of Pages Including Key = 12
Page 1 of 12
KEY
Box with no fill = Process Step

Blue Filled Box = Input
Yellow Filled Box = Output
Dotted Line = Optional Step
Red Filled Circle = Last step in process
Open-ended Box = Chemical/ Material used
that is not an ingredient or processing aid
that does not contact the product directly .
CCP

Critical Control Point
Page 136 of 252
MASTER FLOWCHART OF
MAJOR PROCESS STEPS (PS) FOR MAKING BEER (Page 2 of 12)
FULL TANKER
(Step T6)
RECEIVING
(PS1)
STORAGE & HANDLING

(Step PS2)
Water & Dry

Ingredients
Yeast,
Processing
Aids
FULL TANKER
UNLOADING
(Step T7)
BREWING
(Step PS3)
MILLING/ MASHING/ LAUTERING
KETTLE/ WHIRLPOOL/ COOLING
FERMENTATION
(Step PS4)
Processing
Aids, CO2
AGING
(Step PS5)
CLARIFICATION/ FILTERING
BRIGHT BEER STORAGE

(Step PS6)
Bottles, Cans, Kegs,

Crowns, Tankers
New
Bottles
Prep
PS8 (NB)
Returned
Bottles
Prep
PS8 (RB)
BRIGHT BEER
PROCESSING
(Step PS7)
PACKAGING
(Step PS8)
BOTTLING
Step PS8 (BT)
CCP1-C,P
CCP2-P
- Washing
- Inspection
- Filling
- Flushing
CANNING
Step PS8 (C)
KEGGING
Step PS8 (K)
CCP3-C
- Rinsing
- Filling
- Packing
- Cleaning
- Filling
- Palletizing
TANKERING
Step PS8 (T)
- Filling
WAREHOUSING/ SHIPPING
(Step PS9)

Page 137 of 252
PS3 - BREWING
(Page 3 of 12)
RECEIVING
(Step B1)
Storage
(Step B2)
Milling
(Step B3)
Cereal Cooker
(Step B4)
Mashing
(Step B5)
Lautering
(Step B6)
Holding Tank
(Step B7)
Kettle
(Step B8)
Whirlpool
(Step B9)
Oxygen
Wort Cooling
(Step B10)
Next Process - PS4
Fermentation

Page 138 of 252
PS4 - FERMENTATION
(Page 4 of 12)
COLD WORT
Oxygen/ Sterile
Air
WORT OXYGENATION/
WORT AERATION
(Step F1 )
Yeast Propagation
(Step Y1)
Yeast Storage
(Step Y2)
Acid Washing
(Step Y3)
YEAST
FERMENTATION
(Step F2)
CO2
Cooling
(Step F3)
Yeast
Removal
GREEN BEER
(Step F4)
Next Process - PS5 -Aging/

Clarification/ Filtration

Page 139 of 252
PS5 - AGING/ CLARIFICATION/ FILTRATION
GREEN BEER
(Page 5 of 12)
COOLING
(Step A1)
Buffer tank
(Step A2)
Centrifuge
(Step A3)
Processing aids,
Stabilizers,
CO2, Preservatives
Yeast,
By-products
Buffer tank
(Step A4)
CO2
Cooling tank
(Step A5)
CO2, Hops
Aging Tank
(Step A6)
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives
Beer,
Spent Hops, CO2
Secondary Storage
(Step A7)
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives
CO2, Spent
Yeast
Surge/ Buffer Tank

(Step A8)
Caramel & other

ingredients,
Processing aids,
Stabilizers, CO2,
Preservatives
Filtration
(Step A9)
CO2
CO2, Spent
Yeast
Deaerated water,
CO2, Nitrogen
Bright Beer Storage

(Step A10 = PS6)
CO2
Next Process - PS7 Bright BeerProcessing

Page 140 of 252
PS7 (BBP) - BRIGHT BEER PROCESSING
PS7 (SF)
STERILE FILTRATION
CO2
(Page 6 of 12)
PS7 (P)
FLASH PASTEURIZATION
Bright Beer Tank

(Step SF1)
Bright Beer Tank

(Step FP1)
Filtration
(Step SF2)
Flash Pasteurization
(Step FP2)
Sterile Beer Tank

(Step SF3)
Pasteurized Beer Tank

(Step FP3)

Page 141 of 252
Process Step 8
PS8 (RB) - RETURNED BOTTLES PREP (Page 7 of 12)
Receiving/ Storage
(Step RB1)
Caustic
Hydro Jet Sprays
(Step RB8)
De-Palletizing
(Step RB2)
De-Casing & Inspection

(Steps RB3-4)
Post Soak
(Step RB9)
Bottle Wash Loading

(Step RB5)
External Flush
(Step RB10)
Pre-Rinse
(Step RB6)
Water,
Chemicals &
Steam
External Rinse
(Step RB11)
Soak Tanks (caustic)
(Step RB7)
Water
Interior Rinse
(Steps RB12)
Water
FINAL RINSE
(Step RB13)

Page 142 of 252
Process Step 8
PS8 (NB) - NEW BOTTLES PREP
(Page 8 of 12)
Receiving
(Step NB1)
(Step NB2)
Storage
(Step NB3-6)
Inspection
(Step NB7)
RINSE
(Steps NB8-9)

Page 143 of 252
Process Step 8
PS8 (BT) - BOTTLING (Page 9 of 12)
BOTTLES - See
Returned Bottles Prep
& New Bottle Prep
Air
Drying
(Step BT11)
(Steps BT1)
Water
CCP1-C, P
Down Bottle Filler In-Feed Control

(Steps BT2)
Label & Code
(Steps BT12-13)
Bright Beer,
CO2, Compressed Air
Filling
(Steps BT3-5)
Water
CCP2-P
CO2,
Glass
(Step BT14)
Crowns, Compressed Air

Water
Crowning
(Step BT6 )
Water
Bottle Flush (External)

(Steps BT7-8)
Steam
& Chemicals
Pasteurize
(Step BT9)

(Step BT10)
Packing & Sealing

(Steps BT15-18)
Secondary Code & Full Case

Inspection
(Steps BT19-20)
Palletize
(Step BT21)
Storage
(Step BT22)
Live Load
SHIPPING
(Step BT23)

Page 144 of 252
Process Step 8
PS8 (K) - KEGGING (Page 10 of 12)
KEGS
Receiving
(Step K1)
Racking
(Step K7)
Storage, Handling,
De-palletizing
(Steps K2-3)
Internal Cleaning
Manual
(Steps K8-12)
CCP3-C
Internal Cleaning
Automated
(Steps K8-12)
Filling (Step K18)
Barnes Neck Wash &

Sanitize
(Step K19-21)
External Inspection
(Step K4 )
Sterilize & Hold
(Step K13)
Dust Cap Applied

(Steps K22)
Purge to Empty &

Counter Pressure
(Steps K14-15)
Air Dry
(Step K23)
Barnes Neck Sanitize &

Inspect
(Step K16-17)
Code
(Step K24)
External Cleaning
(Steps K5-6)
Weigh & Palletize

(Steps K25-26)
Storage
(Step K27)
Live Load
SHIPPING
(Step K28)

Page 145 of 252
Process Step 8
PS8 (C) - CANNING (Page 11 of 12)
CANS
Drying (Steps C16-17)
Receiving
(Step C1)
Coding
(Step C6)
Storage & Handling

(Step C2)

(Step C18)
Rinser
(Step C7)
Depalletizing/ Pallet ID
(Steps C3-4 )
Inspection
(Step C5)
Divert to Packers
(Steps C19)
Bright
Beer,
CO2
Filling
(Steps C8- 10)
CO2
Hi Cone Machine
(Step C20)
Can Ends
Water
Seaming
(Steps C11-13)
External Flush
(Step C14)
Pastuerizer
(Step C15)
Case Packers
(Steps C21)
Inspection
(Step C22)
Tray Machine & Code

(Steps C23-24)
Palletize
(Step C25)
Storage
(Step C26)
Live Load
SHIPPING
(Step C27)

Page 146 of 252
Process Step 8
PS8 (T) - TANKERING (Page 12 of 12)
Empty Tanker
(Step T1)
Caustic, Water,
Acid
CO2
Tanker Washing
(Step T2)
Tanker Purge
(Step T3)
CO2
Bright Beer,
CO2
Tanker Filling
(Step T4)
Tanker Shipping
(Step T5)

(Step T6)
FULL TANKER UNLOADING

(Step T7)
Date: _______________ Approved by: ________________________________

Page 147 of 252
FORM 5A:
BIOLOGICAL HAZARDS
CONTROL & CCPS

Page 148 of 252

Page 149 of 252
BAC Generic
Title: Form 5A Hazard Identification - Biological Hazards

Control & CCPs
Date:
Approved By: BAC TC
Date:
Note No CCPs were identified for biological hazards in Beer.

List all biological hazards related
to ingredients, incoming material,
processing, product flow, etc.
Identified biological
hazards (Bacteria,
parasites, viruses, etc.)
Controlled at:
City Water
Coliform, E. Coli

(BAC A4.1)
Purchased Water
Coliform, E. Coli

(BAC A4.1)
Coliform, E. Coli,
Parasites

(BAC A4.1)
Micro (fecal
mice)
PP - Transportation
Receiving & Storage (BAC
B1.1)
INGREDIENTS
LIQUID INGREDIENTS
DRY INGREDIENTS
Barley malt
- COA from supplier
Micro (fecal
mice)
PP - Transportation
B1.1)
+ COA from supplier

rice
Micro (fecal
mice)
PP - Transportation
B1.1)
+ COA from supplier
Hops
Fecal contamination (E.

coli)
PP - Transportation
B1.1)
+ COA

Page 150 of 252
OTHER INGREDIENTS
Yeast

Salmonella
PP Transportation,
B1.1)
+ COA
Carbohydrate Matter
honey)
Clostridium
PP Transportation,
B1.1)
+ COA
Salt
None identified
Hop Oil
None identified
+ PP Transportation,
B1.1)
+COA
Hop Extract
None identified
Nitrogen/ Oxygen/
Compressed Air
Purchased CO2
None Identified
Regenerated CO2
None identified
None identified
Caramel
None identified
Dextrin
None Identified
Food Enzymes
None identified
Stabilizing Agents
None identified
None identified
Preservatives
None Identified
Yeast Foods
None Identified
Processing aids
Moss, Wood Shavings
Fecal contamination (e.g.

Gelatin, Irish Moss)
PP Transportation,
B1.1)
+ COA

Page 151 of 252

New glass
None identified
Used glass
Bacteria

bottles
None identified
New Kegs
None identified
Used Kegs
None identified
None Identified
Crowns
None identified
Closures & Can Ends
None Identified
No pathogens known to survive

in final product due to
properties of beer, e.g. low pH,
alcohol content see Form 1
PROCESS STEPS
PS1- RECEIVING
Micro contamination from

receiving open containers
(e.g. bird droppings).
PP Premises (BAC A1.1 &

BAC A2.1)
Mold growth from

improper storage
conditions
PP - Premises (BAC A2.1)
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
None identified
B4 - Cereal Cooker
None identified

Mash Cooker)
None identified

grains
None identified

Page 152 of 252

B7 Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified

Exchanger)
None identified
PS4 -FERMENTATION
None identified

Aeration
None identified
F2 - Fermentation
None identified
F3 - Cooling
None identified
F4 - Green Beer
None identified

PREPARATION
Y1 Propagation
None identified
Y2 Storage
None identified
Y3 Acid Washing
None identified

FILTRATION
A1 - Cooling
None identified
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
None identified
A6 - Aging Tank
None identified
None identified

Page 153 of 252
None identified
A9 Filtration
None identified
(See PS6 below)
None identified
PS7 BRIGHT BEER PROCESSING

None identified
SF2 - Filtration
None identified
None identified

None identified
None identified
None identified
PS8 RB
None identified
None identified

Inspection (visual)
None identified
None identified
None identified
RB7 - Soak Tanks With Caustic
None identified
Spray malfunction and

debris is left in bottle (e.g.
pathogenic Clostridium,
Listeria, Hepatitis (A/B/C)
Also, no pathogens known to
survive in final product
alcohol content see Form 1.

Page 154 of 252
RB9- Post-Soak
None identified
None identified
RB11 - Ext. Rinse
None identified
None identified
RB13 - Final Rinse
None identified

PREP

None identified

Prep, De-palletize)
None identified

visual)
None identified
None identified
None identified
PS8 BT - BOTTLING
BT1
(Human or Machine inspection)
None identified
BT2 Down Bottle Filler In-Feed

Control
None identified

Filling, Fobbing)
None identified
BT6 - Crowning
None identified

None identified
BT9
Pasteurize
None identified
BT10 - Foam Inspection &/or

Candling
None identified

Page 155 of 252

and Air Knives)
None identified
BT12 BT13 Labelling, Coding
None identified
None identified
BT15 BT18 Packing & Sealing

(Divert to packers, Carton, Case
Pack, Sealing)
None identified
BT19 BT20 Secondary Code & None identified

Inspection (Secondary
BT21
Palletize
None identified
None identified
BT23 - Shipping
None identified
PS8 (K) - KEGGING
None identified

None identified
None identified
K5 K6 External Cleaning (Ext

Wash/Inspection)
None identified
K7
Racking
None identified

Rinse)
None identified
None identified

Counter pressure
None identified
K 16 - K17 Barnes Neck Sanitize None identified

& Inspect

Page 156 of 252
K18 - Filling
None identified
K19 K 21 Barnes Neck, Wash

& Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
None identified

None identified
K27 - Storage
None identified
K28 - Shipping
None identified
PS8 (C) - CANNING
C1 - Receiving
None identified
Bacterial contamination
from leaking roof or pipes
C3 C 4 De-palletize / Pallet ID
(Collect & Timestamp Can Pallet
ID, De-palletize)
None identified
None identified
None identified
None identified
None identified
C11 C13 Seaming
None identified
None identified
C15
Pasteurizer
None identified
C16 C17 Drying
None identified
None identified
PP Premises (BAC A1.1 &

BAC A2.1)

Page 157 of 252
None identified
None identified
C21 - Case Packers
None identified

visual) Inspection
None identified

Code
None identified
C25
Palletize
None identified
None identified
C27
Shipping
None identified
PS8 T TANKERING
None identified
None identified
T3 - Tanker Purging
None identified

of hoses
T5 Tanker Shipping
None identified
T6 T7 Full Tanker Receiving &

Unloading

of hoses
Date:



Approved by:
Page 158 of 252

Page 159 of 252
FORM 6A:
CHEMICAL HAZARDS
CONTROL & CCPS

Page 160 of 252

Page 161 of 252
BAC Generic
List all chemical

hazards related to
ingredients,
incoming
material,
processing,
product flow, etc.
Title: Form 6A
Hazard Identification - Chemical Hazards Control & CCPs
Date:
Approved By: BAC TC
Date:
Identified chemical hazards
Controlled at:
INGREDIENTS
LIQUID INGREDIENTS
City Water

A4.1)
Purchased Water
Cleaning chemicals, cross

contamination from previous load

Storage (BAC B1.1)
- COA/ Supplier Audits
Well/ Lake/
Surface/ Water

A4.1)
Barley malt
Pesticides, Mycotoxins, Allergen

(cross-contamination from carrier),
NDMA

Storage (BAC B1.1)- COA / Letter of
Guarantee
Wheat (malted/
nonmalte
d),
Pesticides, Mycotoxins, Allergen,

NDMA

Storage (BAC B1.1)
DRY INGREDIENTS

Cereal Grain,
e.g.
corn,
oats,
rice
Pesticides, Mycotoxins, Allergen

(cross-contamination from carrier),
NDMA
Hops
Pesticides, Mycotoxins

Storage (BAC B1.1)
Storage (BAC B1.1)
+ COA

Page 162 of 252
Yeast
Heavy Metals, cleaning chemicals

(used in tankers)

Storage (BAC B1.1)
+ COA, Wash Tickets
Carbohydrate
Matte
r
(e.g.
sucro
se,
syrup,
honey
)
Antibiotic residue, heavy metal

(honey)
Salt
Non-food grade

Storage (BAC B1.1)
+ COA

Storage (BAC B1.1)
+ COA
Hop Oil
Residual solvents, Non-food grade
+ PP Transportation, Receiving &

Storage (BAC B1.1)
COA
Hop Extract
Residual solvents, Non-food grade

Storage (BAC B1.1)
+ COA
Nitrogen/
Oxygen/
Compressed Air
Chemical non-volatile gases, Nonfood grade

Storage (BAC B1.1)
+ COA, QC Testing
Purchased CO2
Regenerated
CO2
Contamination from oil (from the

compressor)
PP - Equipment (BAC C1.2)
Liquid Wheat
Extract
Allergen
Caramel
Non-food grade

Storage (BAC B1.1)
+ COA
Dextrin
Non-food grade

Storage (BAC B1.1)
+ COA

Page 163 of 252
Food Enzymes
Non-food grade

Storage (BAC B1.1)
+ COA
Stabilizing
Agents
Heavy metals, Non-food grade

Storage (BAC B1.1)
+ COA
Water
preparation
agents
Preservatives
Allergens (Sulphites), Non-food

grade

Storage (BAC B1.1)
+ COA
Storage (BAC B1.1)
+ COA,
Yeast Foods

Storage (BAC B1.1)
+ COA
Processing aids
Examples
Gelatin, Irish
Moss, Wood
Shavings

Storage (BAC B1.1)
+ COA

New glass
None identified
Used glass
Lubricants, mycotoxins

Storage (BAC B1.1) (Partially
Controlled)
+ Inspection,
+ EBI (Empty Bottle Inspection) /
RLD(Residual Liquid Detector)
Lined aluminum cans

and bottles
None identified
New Kegs
None identified

Page 164 of 252
Used Kegs
None identified
None identified

Crowns
None identified
Closures & Can Ends
None identified
PROCESS STEPS
PS1- RECEIVING
from truck (damage, leaks,
odors)

Storage (BAC B1.1)
PS2- STORAGE/
HANDLING
Chemical - Crosscontamination from

allergens (e.g. wheat)
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
Chemical Allergen crosscontamination (e.g. from

residues in the mill)
B4 - Cereal Cooker

None identified
B5 - Mashing (Mash Mixer, None identified

Mash Cooker)
B6 - Lautering (Lauter
Tun, Mash Filter removal
of spent grains
None identified
B7 Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified

Exchanger)
None identified
PS4 -FERMENTATION

None identified
Page 165 of 252
F1 Wort Oxygenation/
Wort Aeration
None identified
PROCESS STEPS
F2 - Fermentation
None identified
F3 - Cooling
Coolant leak
F4 - Green Beer
None identified
PS4 SUB-PROCESS
YEAST PREPARATION
Y1 Propagation
None identified
Y2 Storage
None identified
Y3 Acid Washing
None identified
PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling
Coolant leak
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
Coolant leak
A6 - Aging Tank
Coolant leak
Coolant leak
A9 Filtration
(See PS6 below)
PS6 BRIGHT BEER

STORAGE
Coolant leak
Cleaning chemicals

Page 166 of 252
PS7 BRIGHT BEER

PROCESSING

PS7 (SF) Sterile
Filtration
Coolant leak
Cleaning chemicals
SF2 - Filtration
None identified
PS7(FP) Flash
Pasteurization
Coolant leak
Cleaning chemicals
Contamination from coolant
None identified
PS8 RB
RETURNED BOTTLES
PREP (FLOAT
GLASSWARE PREP)
None identified
None identified

Inspection (visual)
None identified
RB5 - Bottle Wash

Loading
None identified
None identified

Caustic
Too concentrated, too low,

no caustic, wrong chemical


Storage (BAC B1.1)
Page 167 of 252
PP Personnel (BAC D1.2) Training

EBI (Empty Bottle

Inspection)/RLD(Residual Liquid
Detector)
RB9- Post-Soak
EBI/RLD
None identified
RB11 - Ext. Rinse
None identified
Spray malfunction
Bottle plugged unable to

drain
EBI/ RLD
EBI/ RLD
RB13 - Final Rinse

PS8 NB NEW BOTTLES
(GLASSWARE) PREP

None identified
NB3 NB 6 Storage
(Pallet Prep, De-palletize)
None identified

visual)
None identified
None identified
Contaminated air, sanitizing

spray
MACHINE:
Failure of the system to
detect residual liquid and
caustic
MACHINE:
PS8 BT - BOTTLING
BT1
(Human or Machine
inspection)

CCP1-C
HUMAN:
Failure of personnel to
detect residual liquid
HUMAN:
SOP (personnel rotation)

Page 168 of 252
CCP1-C
BT2 Down Bottle Filler
In-Feed Control
None identified
BT3 BT5 Filling

(Purges , Filling, Fobbing)
CIP chemicals in bottle

BT6 - Crowning
Lubricants

(Full Bottle Wash external)
None identified
BT9
Pasteurize
None identified

&/or Candling
None identified
BT11 Drying (Bottle

None identified

Coding

correctly coded
BT14 Filled Bottle

Inspection
None identified
BT15 BT18 Packing &

Sealing
None identified


Case Pack, Sealing)
BT19 BT20 Secondary
Code & Inspection
Code/Inspection)

correctly coded
BT21
Palletize
None identified

Load)
None identified


Page 169 of 252
BT23 - Shipping
None identified

PS8 (K) - KEGGING
None identified
K2 K3 Storage &
Handling , De-palletizing
(See PS2)
None identified
None identified
K5 K6 External
Cleaning (Ext
Wash/Inspection)

removed
K7
Racking
None identified
K8 K12 Internal
Cleaning (Purge, Flush,
Wash, Purge, Rinse)
Automated
Automated


Manual
Manual

CCP3-C
None identified
K14 K 15 Purge to
Empty & Counter pressure
None identified

Sanitize & Inspect
None identified
K18 - Filling
CIP solution


Page 170 of 252

Wash & Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product Code

Applied


None identified
K27 - Storage
None identified
K28 - Shipping
None identified
PS8 (C) - CANNING
C1 - Receiving
None identified
Contamination from leaking

roof or pipes
PP Premises (BAC A1.1 & BAC A2.1)
Pallet ID

on pallet
C5 - Online visual
inspection
None identified

Chemicals from
compressed air or water
None identified
C11 C13 Seaming
Chemicals, Lubricants

PP Premises (BAC A1.1 & BAC A2.1)

Page 171 of 252

None identified
C15
Pasteurizer
None identified
C16 C17 Drying
None identified
C18 - Fill Height

Inspection
None identified
None identified
None identified
C21 - Case Packers
None identified

visual) Inspection
None identified
C23 C24 Tray Machine

& Code

C25
Palletize
None identified
C26 Storage
(or Live Load)
None identified
C27
Shipping
None identified
PS8 T TANKERING
T1 - Empty Tanker
(Receiving)

sanitizer

Storage (BAC B1.1)
COA, Wash Ticket,
Rinsing


sanitizer

Page 172 of 252

T3 - Tanker Purging
Contaminated CO2
For Regenerated CO2 PP Equipment

(BAC C1.2)
For Purchased CO2 - PP
Transportation, Receiving & Storage
(BAC B1.1)
COA
T4 - Tanker Filling/
Loading

material
T5 Tanker Shipping
None identified
T6 T7 Full Tanker
Cross contamination with

chemicals from the supplier

Storage (BAC B1.1)

material
+ COA
Date:

Approved by:
Page 173 of 252
FORM 7A:
PHYSICAL HAZARDS
CONTROLS & CCPS

Page 174 of 252

Page 175 of 252
BAC Generic
Title: Form 7A
Hazard Identification - Physical Hazards Control & CCPs
Date:
Approved By: BAC TC
Date:
List all physical hazards

related to ingredients,
incoming material,
processing, product flow,
etc.
Identified physical
hazards
Controlled at:
City Water
Silt

A4.1)
Purchased Water
None identified
Silt

A4.1)
Barley malt
Glass, Metal

Storage (BAC B1.1) - Receiving
Inspection (screens, magnets)
Wheat (malted/ nonmalted),
Glass, Metal

Storage (BAC B1.1)
INGREDIENTS
LIQUID INGREDIENTS
DRY INGREDIENTS

magnets)
Cereal Grain, e.g. corn,

oats, rice
Glass, Metal

Storage (BAC B1.1)
magnets)
Hops
Insects, metal

Storage (BAC B1.1)
+ COA, Inspection

Page 176 of 252
OTHER INGREDIENTS
Yeast
None identified

Storage (BAC B1.1)
+ COA, Wash Tickets
Carbohydrate Matter
(e.g. sucrose,
syrup, honey)
None identified
Salt
Rocks

Storage (BAC B1.1)
+ COA
Storage (BAC B1.1)
+ Inspection
Hop Oil
Plastic

Storage (BAC B1.1)
+ COA, Inspection
Hop Extract
Plastic

Storage (BAC B1.1)
+ COA, Inspection
Nitrogen/ Oxygen/
Compressed Air
Purchased CO2
None identified
Regenerated CO2
None identified
Plastic (from packaging)

Storage (BAC B1.1)
+ COA
Caramel

Storage (BAC B1.1)
+ COA
Dextrin

Storage (BAC B1.1)
+ COA
Food Enzymes

None identified
Page 177 of 252
Stabilizing Agents
None identified
None identified
Preservatives
None identified
Yeast Foods
None identified
Processing aids
Moss, Wood Shavings
None identified

New glass
Critical Glass Defects ,

Glass
Storage (BAC B1.1)
+COA, Inspection
+ EBI (Empty Bottle Inspection)
Used glass

bottles
Critical Glass Defects , Dirt,

Dust, Glass, Syringes,
Medical Patches,
+ Bottle Wash
Metal Shavings
(Partially Controlled) PP
Transportation, Receiving & Storage
(BAC B1.1)
+ EBI (Empty Bottle Inspection)
+COA
+ Rinse
New Kegs
Metal Shavings
Rinse
Used Kegs
None identified
None identified
Crowns
None identified
Closures & Can Ends
None identified

Page 178 of 252
PROCESS STEPS
PS1- RECEIVING
PS2- STORAGE/
HANDLING
Pests in hoses used for

transferring material, Bulk
Receiving
+ Training
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
None identified
B4 - Cereal Cooker
None identified
B5 - Mashing (Mash Mixer, None identified

Mash Cooker)
B6 - Lautering (Lauter
Tun, Mash Filter removal
of spent grains
None identified
B7 Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified

Exchanger)
None identified
PS4 -FERMENTATION
None identified
F1 Wort Oxygenation/
Wort Aeration
None identified
F2 - Fermentation
None identified
F3 - Cooling
F4 - Green Beer
None identified
PS4 SUB-PROCESS
YEAST PREPARATION
Page 179 of 252

Y1 Propagation
None identified
Y2 Storage
None identified
Y3 Acid Washing
None identified
PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
None identified
A6 - Aging Tank
None identified
None identified
None identified
A9 Filtration
None identified
None identified
PS6 BRIGHT BEER

STORAGE
None identified
PS7 BRIGHT BEER

PROCESSING
PS7 (SF) Sterile

Filtration
None identified
SF2 - Filtration
None identified
None identified
PS7(FP) Flash
Pasteurization
None identified
Page 180 of 252

None identified
None identified
PS8 RB
RETURNED BOTTLES
PREP (FLOAT
GLASSWARE PREP)
Damage to bottles

Storage (BAC B1.1)
Damage to bottles

Storage (BAC B1.1)

Inspection (visual)
Damage to bottles
RB5 - Bottle Wash

Loading
Damage to bottles

Temperature shock due to
storage)

Caustic
Damage to bottles
Damage to bottles,

(spray malfunction)

(plugged but sprays cannot
clear object)

Temperature shock),
RB9- Post-Soak

Bottle plugged

Storage (BAC B1.1)
+EBI

+EBI

Page 181 of 252


Temperature shock)
+EBI
RB11 - Ext. Rinse
Damage to bottles
(e.g. Temperature shock)

+EBI
Damage to bottles

(spray malfunction)

+EBI

clear object)
RB13 - Final Rinse
Damage to bottles,

(spray malfunction)

+EBI

clear object)
PS8 NB NEW BOTTLES
(GLASSWARE) PREP

Damage to bottles

Storage (BAC B1.1)
NB3 NB 6 Storage
(Pallet Prep, De-palletize)
Damage to bottles

visual)
Missed critical glass defects

+EBI

Page 182 of 252

Damage to bottles

Spray malfunction (e.g.

plugged sprays)
MACHINE:
Failure of the system to
detect foreign matter, glass
defects, bottle damage
MACHINE:
PS8 BT - BOTTLING
BT1
(Human or Machine
inspection)

CCP1-P
HUMAN:
glass damage
HUMAN:
PP Personnel (BAC D1.2) Training,
SOP (personnel rotation)
CCP1-P
BT2 Down Bottle Filler
In-Feed Control
Glass inclusions from

breakage of down bottle at
filler in-feed
BT3 BT5 Filling

(Purges , Filling, Fobbing)
Chipping of bottles (e.g. from

filling equipment), glass
inclusion
Auto-Flush
Auto-Flush

inclusion

Storage (BAC B1.1)
CCP2-P
Manual Flush
Manual Flush

inclusion
Storage (BAC B1.1)
+ Foam Inspection

Page 183 of 252

BT6 - Crowning
Bottle finish damage

(leading to glass
inclusions)
+ Foam Inspection/ Candling

(Full Bottle Wash external)
None identified
BT9
Pasteurize
None identified

&/or Candling
HUMAN
T11 Drying (Bottle

None identified

Coding

correctly coded
BT14 Filled Bottle

Inspection
None identified
BT15 BT18 Packing &

Sealing
Case Pack, Sealing)
None identified
BT19 BT20 Secondary

Code & Inspection
Code/Inspection)
Product not coded, or not

correctly coded
BT21
Palletize
None identified

Load)
None identified
BT23 - Shipping
None identified


foreign matter (including
glass)


Page 184 of 252

PS8 (K) - KEGGING
None identified
K2 K3 Storage &
Handling , De-palletizing
(See PS2)
None identified
None identified
K5 K6 External
Cleaning (Ext
Wash/Inspection)

removed
K7
Racking
None identified
K8 K12 Internal
Cleaning (Purge, Flush,
Wash, Purge, Rinse)
None identified
None identified
K14 K 15 Purge to
Empty & Counter pressure
None identified

Sanitize & Inspect
None identified
K18 - Filling
None identified

Wash & Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product Code

Applied


None identified
K27 - Storage
None identified

Page 185 of 252

K28 - Shipping
None identified
PS8 (C) - CANNING
C1 - Receiving
None identified
None identified
Pallet ID

pallet
C5 - Online visual
inspection
None identified


None identified
None identified
C11 C13 Seaming
None identified
None identified
C15
Pasteurizer
None identified
C16 C17 Drying
None identified
C18 - Fill Height

Inspection
None identified
None identified
None identified
C21 - Case Packers
None identified

visual) Inspection
None identified

Page 186 of 252
C23 C24 Tray Machine

& Code

C25
Palletize
None identified
C26 - Storage (or Live

Load)
None identified
C27
Shipping
None identified
PS8 T TANKERING
T1 - Empty Tanker
(Receiving)
None identified
Rinsing
None identified
T3 - Tanker Purging
None identified
T4 - Tanker Filling/
Loading
None identified
T5 Tanker Shipping
None identified
T6 T7 Full Tanker
None identified
Date:

Approved by:
Page 187 of 252
FORM 9:
HAZARDS NOT CONTROLLED

BY BREWERY

Page 188 of 252

Page 189 of 252
HACCP Plan - Form 9
BAC Generic
Title: Form 9 Hazards not Controlled by Brewery

Date:
Approved By: BAC TC
Date:
Hazards not controlled by Brewery

Hazards (B = Biological, C=Chemical, P= Physical)
Indicate the way the Hazard could be

Addressed (Cooking Instructions,
Public Education, Use Before Date,
etc.)
Hazard Descriptions

Page 190 of 252

Page 191 of 252
FORM 10:
HACCP PLAN

Page 192 of 252

Page 193 of 252
HACCP Plan - Form 10
PRODUCT
Process
Steps
Empty Bottle
Inspection- EBI
(Step BT1)
NAME:
CCP/
Hazard
Number
CCP1-P
Hazard
Description
Critical
Limits
Monitoring
procedures
Deviation
Procedures
Verification
Procedures
HACCP
Records
Physical Failure of the

system to
detect foreign
matter, glass
defects, bottle
damage
EBI test
bottle failure
Who Packaging
Operator/ QA
personnel
If the CCP test fails,

the line is stopped by
Packaging Operator/
QA. Manager/
Supervisor is
notified.
Pre-start
check
completed on
system by
electricians.
EBI Test Bottle

Monitoring
Records
(i.e. 100%
test bottle
rejection)
Frequency At start
up, hourly and at end
of shift
Refer to SOP
describing EBI testing.
The Packaging
Operator or QA
personnel signs and
dates the EBI Test
Bottle Monitoring
Form.

BEER
Hold product from

last successful test
100% inspection of
product since last
successful test is
done (accept/ reject
product).
Repair/ fix equipment
and verify.
Page 194 of 252
Line
Supervisor
reviews
records after
each shift or
daily and
signs & dates
records.
Monthly QA
record
review.
Corrective
Action Records
Verification
Records
Product Hold &
Inspection
Records
Product
Destruction
Records
Process
Steps
Empty Bottle
Inspection
/Residual Liquid
Detector
CCP/
Hazard
Number
CCP1-C
EBI/RLD
Hazard
Description
Critical
Limits
Monitoring
procedures
Deviation
Procedures
Verification
Procedures
HACCP
Records
Chemical Failure of the

system to
detect residual
liquid and
caustic
RLD test
bottle failure
Who Packaging
Operator/ QA
personnel
If the CCP test fails,

the line is stopped by
Packaging Operator/
QA. Manager/
Supervisor is notified.
Pre-start
check
completed on
system by
electricians.
RLD Test Bottle

Monitoring
Records
Hold product from

last successful test
Line
Supervisor
reviews
records after
each shift or
daily and
signs & dates
records.
(i.e. 100%
test bottle
rejection)
Frequency At startup, hourly and at end

of shift
(Step BT1)
Refer to SOP
describing RLD
testing.
Product is discarded.
The Packaging
Operator or QA
personnel signs and
dates the RLD Test
Bottle Monitoring
Form.

Page 195 of 252
Monthly QA
record
review.
Corrective
Action Records
Verification
Records
Product
Destruction
Records
Process
Steps
CCP/
Hazard
Number
Filling
CCP2-P
(Auto-Flush
Only)
(Steps BT 3BT5)
Hazard
Description
Critical
Limits
Monitoring
procedures
Deviation
Procedures
Verification
Procedures
HACCP
Records
Physical
Burst bottle
leading to
glass inclusion
100%
functioning
auto-flush
(That is, the
flushing
spray is on,
short fill
cycle, reject
pattern to
specification).
Who Packaging
Operator
If:
Line
Supervisor
reviews
records after
each shift or
daily and
signs & dates
records.
Auto-Flush
Monitoring
Records
Frequency
Hourly test and at end
of production ; bottle
burst
Refer to SOP Autoflush Monitoring
Procedure
Document on AutoFlush Monitoring
Form. Sign and date.
- System failed hourly

test
or
- Bottle burst and
system did not catch it
The Operator will:
- Shut off line
- Run suspect bottles to
reject
- Flush filler
- Hold product from last
successful check
- Re-inspect 100% of
product since last
successful check
(accept / reject
product).

Page 196 of 252
Monthly QA
record
review.
Annual
validation of
auto-flush.
Corrective
Action Records
Verification
Records
Annual Autoflush Validation
Records
Product Hold &
Inspection
Records
Process
Steps
Internal
Cleaning
(Manual)
CCP/
Hazard
Number
CCP3-C
(Steps K8 K12)
Hazard
Description
Critical
Limits
Monitoring
procedures
Deviation
Procedures
Verification
Procedures
HACCP
Records
Chemical
Cleaning
solution not
effectively
removed.
Rinse water
visible in
sight glass of
test keg.
Who - Kegging
Operator
If the CCP fails:
QA personnel
will perform a
sodium check
on the test
keg from the
start of each
production
run.
Keg Cleaning
Records
Sodium in the
test keg
sample must
meet the
Canadian
Drinking
Water
Guidelines of
<200mg/L of
sodium.
Verification
Reports
No
detectable
caustic carryover based
on
phenolphthal
ein check.
Frequency Start up,

*every 24 kegs and at
the completion of
kegging operation
Perform a visual check
for rinse water and
phenolphthalein check
for caustic carry over
Refer to SOP for
details.
Note: Frequency of
every 24 Kegs is for
example purposes
only. Frequency
should be determined
based off current
operations (i.e. rate
and number of bottles
produce)

The Kegging Operator

notifies the Line
Supervisor and
describes the failure.
If the rinse water is not
visible through the sight
glass and/or the
phenolphthalein check
is positive for caustic
(turns pink), the
Kegging Operator
performs 2 additional
test keg runs and if
either of the re-test fails
a CCP failure has
occurred. If both re-test
passes, production may
resume.
Production may resume
when the problem has
been corrected and
confirmed by 2
consecutive test keg
runs.
Page 197 of 252
The
Supervisor
verifies the
keg rinse
reports daily.
Analytical
Results
Corrective
Action Report
CCP Monthly
Audit
CCP Training
Records
Process
Steps
Internal
Cleaning
(Manual)
CCP/
Hazard
Number
Hazard
Description
Critical
Limits
Monitoring
procedures
CCP3-C
(Steps K8 K12)
Deviation
Procedures
Verification
Procedures
If the CCP failure

occurs during
production, production
is stopped and all kegs
are put on hold back to
the last good check.
QA performs
a CCP audit
on a monthly
basis.
All held product is 100%

discarded.
Deviations and
Corrective Actions are
recorded on the
Corrective Action
Report by the
Supervisor.
Date:

Approved by:
Page 198 of 252
HACCP
Records

Page 199 of 252
HACCP PLAN
APPENDICES

Page 200 of 252

Page 201 of 252
APPENDIX 1
FORM 3
INFORMATION USED FOR
FLOWCHARTS

Page 202 of 252

Page 203 of 252
Information Used to Create Flowcharts
Major Process Steps (Ps) for Making Beer
INPUT
PROCESS STEP/ ID
Dry Ingredients
PS1
Receiving
PS2
Storage & Handling
Barley Malt, Wheat Malt,

Cereal Grains, Water, Water
Preparation Agents, Hops,
Other ingredients
PS3
Brewing - Milling
- Mashing
- Lautering
- Kettle
- Whirlpool
- Cooling
Spent grains (byproduct), Hot Water,

Trub, Wort, Cold
Water
Other
Ingredients( processing
aids), Yeast
PS4
Fermentation
Yeast, Pitching Yeast
Other
Ingredients( processing
aids)
PS5
Aging
Beer, CO2
(collection, waste)
- Clarification
- Filtration
OUTPUT
Bulk Beer
CO2
Packaging Materials,
PS6
Bright Beer Storage
PS7
Bright Beer Processing
PS8
Packaging
PS9
Warehousing/Shipping
Bright Beer
New Bottles (NB), Returned

Bottles (RB), Kegs, Tankers,
Cans

Page 204 of 252
Ps3 - Brewing
INPUT
PROCESS STEP/ ID
Liquid/ Dry/ Bulk

Compressed Air
B1
Receiving (See PS1)
B2
Storage (See PS2)
Barley Malt, Wheat Malt
B3
Milling
Malt Dust, Grist
Cereal, Prepared
Brewing Water, Steam
B4
Cereal Cooker
Cooked Cereal
Prepared Brewing
Water,Steam, Grist
B5
Mashing (Mash Mixer, Mash

Cooker)
Mash
Sparge water, Steam
B6
Lautering (Lauter Tun, Mash

Filter removal of spent grains
Spent Grains, Sweet

Water
B7
Holding Tank
B8
Kettle
B9
Whirlpool/ Centrifuge/ Hot Wort

Tank
B10
Wort Cooling (Heat Exchanger)
Hops, Hop oil, other

ingredients (eg. syrup),
Steam
Oxygen
OUTPUT
Cooled Wort
Next process - PS4 Fermentation

Page 205 of 252
Ps4 - Fermentation
INPUT
PROCESS STEP/ ID
OUTPUTS
Oxygen or sterile air,
F1
Wort
Oxygenation/
Wort Aeration
Aerated/ Oxygenated Wort
Cooled aerated wort, Dry Hop,

Pitching yeast (See PS3
Brewing)
F2
Fermentation
CO2
(Cooling Step)
F3
Cooling
Yeast
F4
Green Beer
Green Beer,
Cold Wort
Next Process PS5 Aging (Primary Storage)
Sub-Process - Yeast Preparation

INPUT
PROCESS STEP/ ID
OUTPUTS
Yeast Source, New Culture
Y1
Propagation
Pitching Yeast
Pitching Yeast
(Cooling Step)
Y2
Storage
Waste Yeast
Acids, Phosphoric, Sulphuric
Y3
Acid Washing
Pitching Yeast
Waste Yeast
Oxygenated Wort, Aerated Wort,

Nutrients
Next Process F2 Fermentation

Page 206 of 252
Ps5 - Aging/Clarification/Filtration
INPUT
PROCESS STEP/ ID
Green Beer (See

PS4 - Fermentation)
A1
Cooling
A2
Buffer Tank
A3
Centrifuge
Yeast/ Spent Waste

(by-product)
A4
Buffer tank
CO2
A5
Cooling
CO2, Hops
A6
Aging Tank
Beer, Spent Hops,

CO2
De-aerated Water,
Processing Aids,
Stabilizers, CO2
A7
Secondary Storage
Spent Yeast, CO2
A8
Surge/ buffer Tank
CO2
A9
DE Pre-filter/ Filter Trap/ Sheet

Filter/ Membrane Filter/ PVPP
Filter
Spent DE, Spent

Yeast, Spent Hops,
CO2,
A10
Bright Beer Storage
Bright Beer, O2
Processing Aids,
Stabilizers, CO2
OUTPUTS
Preservatives
Preservatives
De-aeration Water,
Processing Aids,
Stabilizers, CO2
Preservatives
Caramel and other
ingredients,
Processing Aids,
Stabilizers, CO2,
Nitrogen
Preservatives
CO2, De-aerated
Water, Nitrogen
Next Process PS7 Bright Beer Processing

Page 207 of 252
Ps7 - Bright Beer Processing

A Sterile Filtration
INPUT
PROCESS STEP/ ID
OUTPUTS
Filter Preparation
(Membrane Filters, Candle
Filters, Integrity Test, Re-chill)
SF1
Bright Beer
Tank
Effluent
SF2
Sterile
Filtration
Sterile Beer
SF3
Sterile Beer
Tank
CIP Chemicals, Steam, Water,

Coolant, Sterile Gases
Bright Beer, CO2
Next Process PS8 Packaging
B Flash Pasteurization
INPUT
PROCESS STEP/ ID OUTPUTS
Bright Beer
FP1
Flash
Pasteurized Beer
pasteurization
Steam , hot water, coolant,

CO2
Effluent
FP2
Pasteurized
Beer Tank
Next Process PS8 Packaging

Page 208 of 252
Packaging Processes - Ps8 (RB)

Returned Bottles Prep (Float Glassware Prep)
INPUT
PROCESS STEP/ ID
OUTPUT
Returned (Float) Glassware
RB1
Receiving/ Storage
RB2
De-palletizing
Pallets, Straps, Film,

Twine
RB3
De-casing
Foreign materials,
Scrap cartons, Scrap
Partitions, Damaged
Broken Glass,
crowns
RB4
Human (Visual)
Inspection
Foreign materials,
Scrap cartons, Scrap
Partitions, Damaged
Broken Glass,
crowns
RB5
Bottle Wash Loading
Waste beer, debris
First Post Soak
RB6
Pre-rinse sprays
Straws, butts, waste

water
Steam, water, chemicals
RB7
Soak Tanks With

Caustic
Label pulp, Caustic

(Sodium Hydroxide),
Plastic
Caustic Solution
RB8
Hydro Jet Sprays
Receive Ext Flush
RB9
Post-Soak
Recovered post soak

(effluent)
Recovered External/
Internal
RB10
External Flush
Recovered external
flush
Recovered Final Rinse
RB11
External and internal

Rinse
Recovered external
rinse, label pulp
carryover
Potable Water
RB12
Interior Final Rinse
Recovered final rinse
Potable Water
RB13
External Final Rinse
Recovered final rinse

Washed Glassware
Next Process PS8 BT - Bottling

Page 209 of 252
Packaging Processes - Ps8 (NB)

New Bottles (Glassware) Prep
INPUT
PROCESS STEP/ ID
New Glassware
NB1
Receiving
NB2
NB3
Storage
NB4
Collect the Manufacturing Pallet

tags
NB5
Pallet prep
Straps, film
NB6
De-palletize
Top frame, tier sheet,

pallets
NB7
Visual Inspection
Rejects, damaged
glassware
NB8
Bottle Loading
NB9
Bulk Glass Rinser
Potable Water,
Compressed Air
OUTPUT
Reject loads and

pallets
Rinsed glassware
Rinse Water effluent
Next Process PS8 BT - Bottling

Page 210 of 252
Packaging Processes - Ps8 (BT)

Bottling
INPUT
PROCESS STEP/ ID
OUTPUT
Washed and Finished

Glass, (New or Float)
BT1
Rejects, Finished
Water and Lube
BT2
Down bottle filler in-feed

control
Rejects
BT3
Purges & Evacuation &

Positive Pressure
Glass, debris,
shards
Compressed Air,
Conveyor Lubricant,
Conveyor Flush Water,
CO2, Compressed Air,

Potable Water, Lube
Water
CO2, Counter pressure
bowl, Bright Beer, Hot
Pressurized Water, Filter
Pressurized Water
CO2
BT4
Filling
Bottle breakage,
CO2
BT5
Fobbing
Beer foam overflow
Packaging Materials,
Crowns, Compressed air,
City Water flush,
Lubricants
BT6
Crowning
Damaged crowns,
water effluent, bottle
breakage, spilled
beer
City Water Flush
BT7
Crowner Flush (external)
Water and beer

effluent
City Water
BT8
Filled Bottle wash external
Rejects
Water, Steam, Chemicals
BT9
Pasteurize
Effluent, broken
glass
BT10

Inspection
Rejects

Page 211 of 252
Packaging Processes - Ps8 (BT) (Continued)

Bottling (Continued)
INPUT
PROCESS STEP/ ID
Ambient air blower
BT11
Bottle Drying and Air

Knives
Packaging material,
adhesive, compressed air
BT12
Labelling
Bottle breakage,
labels, adhesive,
beer
Packaging material (ink)
BT13
Primary Packaging, Coding
Inks, Cleaning
Solutions
BT14
Rejects
BT15
Divert to packers
BT16
Carton Forming
Rejects, damaged
BT17
Case Packing
Bottle breakage,
beer, damage
Packaging Material Adhesive
BT18
Case Sealing
Bottle breakage,
beer, damage
Packaging Material Ink
BT19
Secondary Packaging
Code
Inks, Cleaning
Solutions
BT20
Full Case Inspection
Rejects
Pallets, Tier sheets, trays,

straps, shrink wrap, pallet
ID
BT21
Palletize
Finished Goods
Finished Goods
BT22
Storage (or Live Load)
BT23
Shipping
Packaging material,
cartons, adhesive,
partitions (inserts)

OUTPUT
Page 212 of 252
Packaging Processes - Ps8 (K)

Kegging
INPUT
PROCESS STEP/ ID
Keg Float, Keg Caps,

Bright Beer
K1
Receiving (See PS1)
K2
Storage & Handling (See PS2)
K3
K4
External Inspection
Rejected Kegs
K5
Ext Wash
Dust caps,
labels, effluent
K6
Post Wash Inspection
Temporary
storage
Kegs Temperature
Storage
K7
Racking
Compressed Air
K8
Purge to Empty
Waste beer,
rejected kegs
Potable Water
K9
Flush
Rinsings
Acid Steam & Sodium

Hydroxide
K10
Wash
Drain or recover
Compressed Air
K11
Purge to empty
Residual CIP
solution
Heated Water
K12
Rinse
Rinsings to drain
Steam
K13
Sterilize & Hold
CO2
K14
Purge to Empty
Residual Water,
CO2
CO2
K15
Counter Pressure
CO2
Steam
K16
Barnes Neck Sanitize
Fill
K17
Inspect
Rejected Keg
Water & Detergents

OUTPUT
Page 213 of 252
Packaging Processes - Ps8 (K) (Continued)

Kegging (Continued)
INPUT
PROCESS STEP/ ID
OUTPUT
Bright Beer, Clean Kegs

from storage
K18
Filling
Waste Beer
Steam
K19
Sterilize Barnes Neck
Condensate
Chlorinated Water
K20
Final Rinse Dome
Chlorinated
water to drain
Sanitation chemicals
K21
Chemical Sanitize Barnes Neck
Packaging Material
K22
Dust Cap
Plant air
K23
Air Dry
Packaging Material
K24
Product Code Applied
K25
In-line weighing
K26
Palletize
K27
Storage or Live Load
K28
Shipping

Full goods
storage
Page 214 of 252
Packaging Processes - Ps8 (C)

Canning
INPUT
PROCESS STEP/ ID
OUTPUT
Cans, Can ends, Bright

Beer (from Ps7)
C1
Receiving
Damaged Cans
C2
Storage & Handling
C3
Collect & Timestamp Can

Pallet ID
Straps (to scrap/

recycle)
C4
De-palletize to mass
conveyor
Pallet, frame (top),

tier sheet
C5
Online visual inspection
Non-conforming
cans (rejects)
Packaging Material (ink)
C6
Primary code applied
Ink
Treated water filtered
C7
Bulk in-line rinser
Rinse water 1(Bulk

Rinse discharge
water)
CO2 & Bright beer
C8
Filling (pre-evacuation &

beer fill)
Open filled cans
Open filled cans & CO2
C9
Bubble breakers
CO2
CO2
C10
Under Cover Gassing
CO2
Can ends
C11
Collect manufacturing lot

detail for ends
Paper sleeves to
baler
Continuous lubrication
C12
Double seaming
Excess/ surplus
lube, Beer
C13
Filler valve monitor
Reject cans
C14
External Can Flush
Water to sewer
Rinse water (Bulk Rinse

discharge water)
Output from one step may be used as input to another step (indicated by bolded print)

Page 215 of 252
Packaging Processes - Ps8 (C) (Continued)

Canning (Continued)
INPUT
PROCESS STEP/ ID
OUTPUT
Heating, City Water, Water

Treatment
C15
Pasteurizer
Second cooling
water to drain
Ambient Air
C16
Pre-Blower Station
Compressed Air, Ambient

Air
C17
Final Dryer Station
C18
Reject cans
C19
Divert to Packers
Finished Cans
Open Format 6s & 8s, HiCone Web, Finished

Cans
C20
Hi-Cone Machine
Closed format 12s & 24s,

cartons, Finished Cans
C21
Case Packers
C22
Visual Inspection
Rejects, cans, Hicone, cartons
Trays, Hot Melt
C23
Tray Machine
Reject Trays
Packaging Material (ink)
C24
Secondary Code applied
Ink
Pallets & Stretch film
C25
Transfer to Palletizer
Finished Pallets
Finished Pallets
C26
Storage (or Live Load)
C27
Shipping

Page 216 of 252
Ps8 (T)
Tankering
INPUT
PROCESS STEPS/ ID
T1
Empty Tanker
Caustic Water, Acid
T2
Tanker Washing
City Water, CO2
T3
Tanker Purging
Bright Beer, Clean

Tanker
T4
Tanker Filling
T5
Tanker Shipping
T6
T7
Full Tanker Unloading

OUTPUT
Clean Tanker, CO2
Page 217 of 252
Other Sub-Process - Co2

(No Flowchart)
INPUT
PROCESS STEP/ ID
Collected CO2
CO1
Increase Pressure (Booster)
CO2
Scrubbers (remove water soluble

compounds)
CO3
Carbon Filters - Deodorizer
CO4
Carbon Filters Dust Filters
CO5
Compressor
CO6
Dryers
Moisture
CO7
Particulate Filter
Particulate Material
CO8
CO2 Condensers
CO9
Liquid Storage
CO10
Vaporization
CO11
High Pressure Carbon Filters
CO12
Particulate Filters
CO2 Purchase

OUTPUTS
Water soluble
compounds
Particulate Material
CO2, Particulate
Material
Page 218 of 252
Other Sub-Process - Water Processing

(No Flowchart)
INPUT
PROCESS STEPS
OUTPUTS
Water Source City, Well,

Purchased
W2 Purification:
Purified Water
(2)
Purified Water (2)
W3 Storage
Acids, Salts, Steam
W4 Brewing Water Preparation, pH

adjustments, Salts addition
Mash Water
W5 De-aeration, Cooling, Carbonation
Line Packing or
Push Water
Purified Water
CO2
Reverse Osmosis, UV, Ozonation,

Chlorination, Filtration (Sand, DE,
Activated carbon, multimedia)
Sparge Water
Dilution Water for

High Gravity
CO2

Page 219 of 252
APPENDIX 2
FORM 8
CRITICAL COTNROL
POINTS
(LOW ALCOHOL BEER)

Page 220 of 252

Page 221 of 252
HACCP Plan - Appendix 2

Form 8 Critical Control Points for Low Alcohol Beer
BAC Generic
Incoming
material/ process
step/ hazards on
schematic
diagram
Title: Form 8 Critical Control Points (Low Alcohol Beer)

Approved By: BAC TC
Category
and
identified
hazard.
Determine if fully controlled by

Pre-requisite program.
*If yes = indicate Pre-requisite
Program and proceed to next
identified hazard.
*If no = proceed to question1 (Q1).
Q1. Could a
control
measure(s)
be used by
the operator
at any
process
step?
If NO = not a
CCP +
identification
on how this
hazard will be
controlled
before and
after the
process
+ proceed to
the next
identified
hazard
If YES =
description +
next question
(Q2)

Date:
Date:
Q2. Is it
likely that
contaminati
on with the
identified
hazard
could
occur in
excess of
the
acceptable
level or
could
increase to
an
unacceptab
le level?
Q3. Is this
process
step
specificall
y
designed
to
eliminate/
reduce
the likely
occurrenc
e of the
identified
hazard to
an
acceptabl
e level?
If NO = not
a CCP +
proceed to
the next
identified
hazard
If NO =
next
question
(Q4)
If YES =
next
question
(Q3)
Page 222 of 252
If YES =
CCP + go
to last
column
Q4. Will a
subsequen
t step
eliminate
the
identified
hazard or
reduce
likely
occurrenc
e to an
acceptable
level?
CCP
Number
+ proceed
to next
identified
hazard
If NO = CCP + go to last
column
If YES =
not a CCP
+ identify
subsequent
step +
proceed to
the next
identified
hazard

Form 8 Critical Control Points for Low Alcohol Beer
Process Step (For Low Alcohol Beer Only)

PS3 - AGING/
CLARIFICATION/
FILTRATION
A10 Bright
Beer Storage
Biological
Inadequate
pH
adjustment
to control
Clostridia
growth
downstream
No
Yes
Yes
Chemical
None
identified
Physical
None
identified
Date:

Approved by:
Page 223 of 252
Yes
CCP4-B
APPENDIX 3
FORM 10
ADDITIONS FOR
LOW ALCOHOL BEER

Page 224 of 252

Page 225 of 252

Form 10 - Additions for Low Alcohol Beer
LOW ALCOHOL BEER ONLY

PRODUCT NAME:
Process
Steps
CCP/Hazar
d Number
Hazard
Description
Critical
Limits
Monitoring
procedures
Deviation
Procedures
Verification
Procedures
HACCP
Records
Bright Beer
Storage (Step
A10)
CCP4-B
Inadequate pH
adjustment to
control
Clostridia
growth
downstream
pH <4.5
pH analysis of
wort in kettle by
QA
pH must be less
than 4.4 at kettle
wort sample in
kettle
pH analysis performed on each kettle

wort cooler sample & result reviewed
by QA manager or designate (if
greater than pH 4.5 will reprocess and
recheck)
Lab
reports
(Note: This
is an
arbitrary
number.
CCP
numbering
will depend
on the
number of
CCPs
found in
individual
breweries
CCPs)
- If pH greater than
or equal to 4.4
will add additional
acid to kettle &
recheck.
- If pH greater than
or equal to 4.4
QA manager (or
designate)
notified and a
deviation report
must be
completed
pH analysis performed on each BBT &

result reviewed by QA manager or
designate (if greater than pH 4.5 will
reprocess and recheck)
pH analysis performed on each filler
start up sample & result reviewed by
QA manager or designate (if greater
than pH 4.5 will dump product)
Calibration of pH meter & control
checks of 5 samples prior to run.
After each production the QA Manager
or designate verifies the calibration
records for BBT approvals.
QA Manager conducts yearly audit of
lab analyses.
Date:

Approved by:
Page 226 of 252
Calibratio
n records
Audit
records

Page 227 of 252
APPENDIX 4
DIAGRAMS FOR
HAZARD IDENTIFICATION &
CCP DECISION TREE

Page 228 of 252

Page 229 of 252
Diagrams for Hazard Identification and CCP Decision Tree

Critical Control Points for breweries were determined using the HACCP Decision
Tree. The Decision Tree was first developed by a Codex Alimentarius working
group on HACCP in June 1991.
4.1 Hazard Determination
These questions are to be answered for each potential hazard at each step:
Is the presence of a potential hazard in the
line or the environment probable?
Is the presence of a potential

hazard in raw material
probable?
YES
NO
NO
YES
No Hazard*
YES
Is an unacceptable level,
survival, persistence or
increase at this step
probable?
NO
Is an unacceptable
contamination at this step
probable?
NO
YES
No Hazard*
YES
Is reduction, if any at a
further step adequate?
NO
HAZARD
* Not a hazard to be controlled at this step.

Page 230 of 252
4.2 CCP Decision Tree

Pre-screening question
Determine if (hazard) fully controlled by Pre-requisite programs. If yes,
indicate Pre-requisite Program(s) and proceed to the next identified
hazard. If no, proceed to Question 1 below.
Q1
Could a control measure(s) be used by the operator at any process step?
No C.M. exists
C.M.(S) exists
Not a CCP. Identify how this hazard will
be controlled before or after the process
and proceed to next identified hazard.
Q2
Is it likely that contamination with the identified hazard could occur in excess of
the acceptable level or could increase to an unacceptable level?
No
Yes
Not a CCP. Proceed to next
identified hazard.
Q3
Is this process step specifically designed to eliminate or reduce the likely

occurance of this identified hazard to an acceptable level?
No
Q4
Yes = CCP
Will a subsequent step eliminate the identified hazard or reduce its likely
occurance to an acceptable level?
Yes
No = CCP
Not a CCP. Proceed to next identified hazard.

Page 231 of 252
APPENDIX 5
BAC GLASS INCLUSION

REFERENCE

Page 232 of 252

Page 233 of 252
BAC Glass Inclusion Reference

The Critical Control Points for the brewing industry have been identified through
analysis as described in preceding sections.
In 1988, a BAC Glass Integrity Task Force developed a manual entitled Good
Manufacturing Practice on the Prevention of Glass Inclusion in Finished Product.
As its name implies, it was intended to ensure that product entering the market
contained no glass contaminants. The GMP was updated 1998 to deal with
changes in the industry and technology in the last 10 years.
The GMP deals specifically with:
Environmental Controls
Preventive Measures
Regular Maintenance Checks
Prewash Bottle Handling
Preventive Measures
Corrective Measures
Bottle Washing
Preventive Measures
Bottle Conveying Systems
Preventive Measures
Corrective Actions
Washed Bottle Inspection
Inspection Methods
Maintenance Measures
Corrective Measures
Page 234 of 252
BAC Glass Inclusion Reference (Continued)

Filling and Crowning Operations
Corrective Measures for Glass Inclusions

Continual Incident Levels
Filled Bottle Inspections
Uncrowned, Improperly Crowned and Low-Filled Bottles

Foam-Picking
Candling
Filtration
Reaction to Inclusions
Verification and Monitoring for GMP
Written Procedures
Setup and Maintenance Checklists
Production Records
Quality Checklists
Consumer Incidents Correlation
This document will be helpful in developing individual brewery HACCP Programs.
Copies of the manual may be obtained by contacting:
100 Queen Street, Suite 650
Ottawa, Ontario K1P 1J9
Page 235 of 252
Telephone: (613) 232-9601 Fax: (613) 232-2283

E-mail: office@brewers.ca

Page 236 of 252
APPENDIX 6
BLANK FORMS 1 - 10

Page 237 of 252

Page 238 of 252
PRODUCT DESCRIPTION
FORM 1
PROCESS/PRODUCT TYPE NAME:
1. Product Name(s)
2. Important Product Characteristics
(Aw, Ph, Preservatives,...)

3. How it is to be Used
4. Packaging
5. Shelf Life
6. Where it will be Sold
7. Labelling Instructions
8. Special Distribution Control
Date:

Approved by:
Page 239 of 252
LIST OF PRODUCT INGREDIENTS

AND INCOMING MATERIALS
FORM 2
PRODUCT NAME:
Date:
Approved by:
Page 240 of 252

FORM 3
PRODUCT NAME(S):
Date:
Approved by:
Page 241 of 252
PLANT SCHEMATIC
FORM 4
PRODUCT NAME(S):
Date:
Approved by:
Page 242 of 252
HAZARDS IDENTIFICATION
FORM 5
PRODUCT NAME(S)
List all biological hazards related to ingredients, incoming material, processing, product
flow, etc.
IDENTIFIED BIOLOGICAL HAZARDS
CONTROLLED AT
(Bacteria, Parasites, Viruses...)
Date:

Approved by:
Page 243 of 252
FORM 6
PRODUCT NAME(S)
List all chemical hazards related to ingredients, incoming material, processing, product
flow, etc.
IDENTIFIED CHEMICAL HAZARDS
Date:

CONTROLLED AT
Approved by:
Page 244 of 252
FORM 7
PRODUCT NAME(S)
List all physical hazards related to ingredients, incoming material, processing, product
flow, etc.
IDENTIFIED PHYSICAL HAZARDS
Date:

CONTROLLED AT
Approved by:
Page 245 of 254
CCP DETERMINATION
FORM 8
Process Step/
Incoming Material
Category and
identified Hazard
Fully controlled by
Pre-requisite
program?
*If yes indicate and

proceed to next
identified hazard
*If no proceed to
(Q1)
Date:
Q1. Could a control

measure(s) be
used at any
process step?
*If no = not CCP.

Identify how this
hazard will be
controlled before
and after the
process and proceed
to next identified
hazard.
*If yes = describe

and proceed to (Q2)
Q2. Is it likely that

contamination with
the identified
hazard could occur
in excess of the
acceptable level or
could increase to
an unacceptable
level?
Q3. Is this process

step specifically
designed to
eliminate/reduce
the likely
occurrence of the
identified hazard to
an acceptable
level?
Q4. Will a
subsequent step
eliminate the
hazard or reduce
its likely
occurrence to an
acceptable level?
CCP Number
*If no = CCP. Go to
last column
*If no = not CCP.
Proceed to next
identified hazard
*If yes = proceed to

(Q3)
Approved by:
*If no = proceed to
(Q4)
*If yes = CCP. Go to

last column
*If yes = not a CCP.

Identify subsequent
step and proceed to
the next identified
hazard
*Proceed to the next

identified hazard
HAZARDS NOT CONTROLLED BY OPERATOR

FORM 9
PRODUCT NAME(S)
List here any biological, chemical and physical hazards which are not controlled by the
Operator.
HAZARDS
Date:

INDICATE THE WAY THE

HAZARD COULD BE
ADDRESSED (COOKING
INSTRUCTIONS PUBLIC
EDUCATION, USE BEFORE
DATE,..).
Approved by:
Page 248 of 254
HACCP PLAN
FORM 10
PRODUCT NAME:
Process
Steps
CCP/Hazard
Number
Date:

Hazard
Description
Critical
Limits
Monitoring
Procedures
Approved by:
Page 249 of 254
Deviation
Procedures
Verification
Procedures
HACCP
Records
APPENDIX 7
REFERENCE LITERATURE

Page 250 of 254

Page 251 of 254
References
Procedures to Implement the Hazard Analysis Critical Control Point System.
International Association of Milk, Food and Environmental Sanitarians, Inc. Ames, Iowa.
1991
Micro-organisms in foods, Book 4. Application of the hazard analysis critical control
point (HACCP) system to ensure microbiological safety and quality. The International
Commission on Microbiological Specifications for Foods (ICMSF). Blackwell Scientific
Publications. Oxford. 1988.
Food Safety Enhancement Program. Volumes 1 - 4. Agriculture Canada. 1993-7.
A Simple Guide to Understanding and Applying The Hazard Analysis Critical Control
Point Concept. 2nd edition. international Life Sciences Institute. 1997
CFIA Generic HACCP Plan Models
http://www.inspection.gc.ca/english/fssa/polstrat/haccp/manue/ch2sec3-45e.shtml#2.4

Page 252 of 252

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Generic Hazard Analysis

Brewers Association of Canada

Table of Contents (Continued)

BAC Generic HACCP Model

Assemble the HACCP team;

Describe the product;

Identify intended uses;

Construct process Flow Diagram and Plant Schematic;

Verify on site the Flow Diagram and Plant Schematic;

BAC Generic HACCP Model

List hazards associated with each step (Principle 1);

Determine Critical Control Points (Principle 2);

Establish Critical Limits (Principle 3);

Establish Monitoring Procedures (Principle 4);

10. Establish Deviation Procedures (Principle 5);

BAC Generic HACCP Model

Instructions for Companies

BAC/HACCP Plan Workbook; and

BAC/HACCP Plan Glossary.

Pre-requisite programs should be established before attempting to implement the

BAC Generic HACCP Model

HACCP Working Group Members

acknowledges the committee members for their outstanding contribution to the

Sleeman Breweries Ltd.

Brewers Association of Canada

Labatt Breweries of Canada

Great Western Brewing Company

Brewers Association of Canada

Pump House Brewery

Canadian Food Inspection Agency

Canadian Food Inspection Agency

Guelph Food Technology Centre

Guelph Food Technology Centre

Guelph Food Technology Centre

Guelph Food Technology Centre

Guelph Food Technology Centre

BAC Generic HACCP Model

HACCP Principle 1 - Hazard Identification

A product safety hazard is any biological, chemical, or physical

Breweries determine the product safety hazards and identify the

Information sources include published

BAC Generic HACCP Model

HACCP Principle 2 - Critical Control Points

Empty Bottle Inspection

Empty Bottle Inspection/ Residual Liquid Detector

Filling (Auto-Flush Only)

Internal Cleaning (Manual)

BAC Generic HACCP Model

HACCP Principle 3 - Critical Limits

A critical limit is the maximum or minimum value to which a

HACCP Principle 4 - Establish Monitoring Procedures

Monitoring activities are necessary to ensure that the process is

Each brewery will develop its own

specifications, where required.

HACCP Principle 4 - Establish Monitoring Procedures (Continued)

BAC Generic HACCP Model

HACCP Principle 5 - Establish Deviation Procedures

These are actions to be taken when monitoring indicates a

A deviation is defined as failure to meet the specified critical limits. Deviation

BAC Generic HACCP Model

HACCP Principle 5 - Establish Deviation Procedures (Continued)

HACCP Principle 6 - Establish Verification Procedures

Verification ensures the HACCP plan is adequate, that is, working