GP Foods - HACCP Manual

GARUDA POLYFLEX FOODS PVT LTD.
Rev No: 00
HACCP Manual
Page Number Document No: GPFPL/FSMS/HM/001 Issue Date
1 of 71 20.12.2018
TABLE OF CONTENTS
Sl:NO Description Page No

1.0 Introduction to GPFPL 01
1.1 Unit descriptions 02
1.2 Products & Packages 04
1.3 Plant Quality System 09
1.4 Status of Quality Mangement System 09
2.0 Introduction to HACCP System 10
3.0 Advantages of HACCP 13
4.0 Good manufacturing practices guidlines 14
5.0 Flow chart for the Application of HACCP 22
6.0 Definitions 24
7.0 HACCP Documentation and Implementation 29
7.1 Mangement Commitment 29
7.2 Food Safety Policy 30
7.3 Scope 31
7.4 HACCP Team and Responsibilities 31
7.5 FSMS Team Leader & HACCP Co-ordinator 35
7.6 Training & Awareness 35
7.7 Prerequisite Programs for HACCP 36
7.8 HACCP Documentation Management 38
7.9 Requirements as per Codex Alimentarius Guidelines 40
7.10 Internal Audit and Corrective action 70
7.11 Management Review 70
7.12 HACCP Resources 70
7.13 HACCP Validation 70
7.14 HACCP Verification 71
7.15 Applicable legislation 71
8.0 Product Description Annexure
9.0 Process Flow chart Annexure
10.0 Risk and Severity Analysis Annexure
11.0 Decision Tree Worksheet Annexure
12.0 HACCP Plan Annexure
13.0 Unit Organogram Annexure
14.0 Plant layout Annexure
Prepared By: Approved By:

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“ BUSINESS CONFIDENTIAL”
NIRANJAN D S L RAMESH
FSTL / Asst Manager - QA Factory Manager
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1. Introduction to GARUDA POLYFLEX FOODS PVT LTD., BENGALURU.
1.1 Unit description
Garuda Polyflex Foods Pvt. Ltd is a joint venture established in the year 2011 between
Garuda Food of Indonesia and the Polyflex Group of India. .
Garuda Food is a $500 Million, 25 year old food and Beverage Company. It is a part of the
Tudung Group which deals in Agribusiness, Food and beverage manufacturing and
distribution. It has 11 production plants, 18 beverage contract manufacturers, 6 food
contract manufacturers in Indonesia and over 20,000 employees. .
Garuda Food has a strong portfolio in food and beverage, offering an extensive and
innovative range of snacks, confectioneries, biscuits, liquid milk drinks, fruit flavored
drinks and juices that are widely distributed across many countries in Asia, Europe, Middle
East, Africa, North America, Australia and Pacific Ocean nations. .
Garuda Food has received many awards and accolades like Indonesia Customer Service
Award (ICSA), Indonesia Best Brand Award (IBBA), Top Brand Award, Top Brands For Kids
Awards, Original Indonesia Brand Award and many more. According to Euro Monitor, the
Garuda Food Group maintained the leading position in sweet and savory snacks. The Group
dominated the nuts Market and was a strong leader in the sweet and savory snack segment.
.
Garuda Polyflex Food's endeavor is to provide best in class and innovative offering in
food and beverage segment, which will give consumers more delightful experiences. In this
pursuit the joint venture has launched Gone Mad Choco sticks in the chocolate Segment,
Gone Mad Jelly Drink and Gone Mad Chocolate Drink in the beverage segment and Gone
Mad Sugar Cheese Cracker in the biscuit segment. GP Foods is in the process of rolling out
exciting new product innovations.
Gone Mad is the endearing expression of the inherent need in all of

us to be free. The philosophy that drives the brand Gone Mad - helps
it deny order and routine and 'break the normal' in a fun yet lovable
way. Gone Mad appeals to the lighter side of everyone, and allows
everyone to express their inner inanities.
The "Gone Mad" word is playful, spontaneous, entertaining, engaging and youthful
world where you can let loose your unabashed love for food.
Armed with its innovative product, "Gone Mad" promises to kill monotony and offer
differentiated delight.

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"Gone Mad" gives you the license to escape into a spontaneous world and leave your
boring, straight-jacketed life behind.
Vision:
Build a sustainable FMCG business in India with brands that create new
market; constantly ushering in new consumption experience and
leveraging our Global Portfolio.
Mission
We are a transformation making company creating value to society by

values of caring, team work, continuous improvement and high degree of
customer delight.
Quality
Quality is at the forefront of our work process something that

dictates every activity performed. From procurement to storage to
mixing, and until the final packaging, there are stringent quality checks
at every step. It is the last but most crucial quality control measure-an
expert squad judges, the true worth of the products by the most incisive
examinations. So each product is precision tested and stands testimony
to the prudent efforts taken by the team of adept professionals.
Address:
M/s: Garuda Polyflex Foods Pvt Ltd.,

No. 11, Jigani Link Road, Bommasandra Industrial Area,
Anekal Taluk, Bangalore – 560 105.
Office: +91 80 2801 0500

Website: www.gpfoods.co.in

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1.2 Products and Packages
Brand: Gone Mad is the endearing expression of the inherent need in all of us to be
free. The philosophy that drives the brand Gone Mad - helps it deny order and routine
and 'break the normal' in a fun yet lovable way. Gone Mad appeals to the lighter side of
everyone, and allows everyone to express their inner inanities .
The "Gone Mad" word is playful, spontaneous, entertaining, engaging and youthful
world where you can let loose your unabashed love for food .
Armed with its innovative product, "Gone Mad" promises to kill monotony and offer
differentiated delight "Gone Mad" gives you the license to escape into a spontaneous
world and leave your boring, straight-jacketed life behind.
CHOCO STICK
The king of our stable, the Choco Stick, rules the roost among youngsters, kids,
young adults, moms and pretty much everyone else! With a smooth chocolate filling
cased in a crunchy wafer, this product has been delighting taste buds since it was
launched.
CHOCO STRAWBERRY STICK
You can’t really go wrong with chocolate and strawberry. But we think we’ve
perfected the combo! Our Choco-strawberry Stick is what happens when the yummiest
chocolate meets the best strawberry Flavour. All this, wrapped in our signature Gone
Mad crunchy wafer.

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CASHEW MITHAI STICK
We went one step further, and reimagined the Indian favorite, Kaju Mithai as a modern
Choco stick! The result is sheer Gone Madness! Taste years of typical Hindustani
Flavour - robust kaju Mithai, wrapped in our crunchy wafer stick. We dare you to stop
at eating just one!
PREMIUM WAFER STICK
1) PREMIUM COFFEE STICK

Coffee Sticks are a fresh and tasty treat at every bite. It is a premium indulgence
product with the rich taste of coffee that helps in keeping you fresh and energized
anywhere and anytime
2) PREMIUM BADAM STICK
We went one step further, and reimagined the Indian favorite, Badam as a modern
Choco stick! The result is sheer Gone Madness! Taste years of typical Hindustani
Flavour - Badam, wrapped in our crunchy wafer stick. We dare you to stop at eating
just one!
3) PREMIUM DARK CHOCO STICK
Dark Chocolate Sticks are a fresh and tasty treat at every bite. It is a premium
indulgence product with dark chocolate that has flavonoids and health-
boosting nutrients. Dark Chocolates are one of the best sources of
antioxidants.

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PREMIUM COFFEE PREMIUM BADAM PREMIUM DARK CHOCO

STICK STICK STICK

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CRACKERS:
1) SUGAR CHEESE CRACKER

Sugar, Cheese and Everything NICE!! Meet the latest addition in the Gone Mad product
stable. After conquering taste buds across the world, the Sugar Cheese cracker has
finally reached the Indian shores. The two sided cracker has Sugar on one side,
French cheese on the other and crispy cracker in the middle. Bite into this crunchy
and delightful Sugar Cheese Cracker and let the yummy French cheese transport you
to the by lanes of Paris.
2) COCONUT CRACKER
These coconut biscuits by Gone Mad are crunchy crackers with coconut cream on one
side and delicious coconut sprinkles on the other side. Bite into this crunchy and
delightful coconut cream with a hint of yummy coconut sprinkles.

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FESTIVE GIFT PACKS
Discover your entire favorite gone mad products inside; this gift pack is designed to be
loved by everyone. A perfect gift for occasions like anniversary, birthday to
celebrate with delectable variants of Gone Mad products packed together to shower
joy.
CHOCO STICK 1+1
The king of our stable Choco Stick, is made as sharing pack for loved ones which
rules the roost among youngsters, kids, young adults, moms and pretty much everyone
else! With a smooth chocolate filling cased in a crunchy wafer, this product has been
delighting taste buds since it was launched.

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1.3 Plant Quality System
This Quality System manual defines the Quality Management System adopted by Garuda
Polyflex Foods Pvt Ltd., Bengaluru Unit. This manual list down the procedures and
measures stipulated for ensuring the quality of product and services provided by the
company.
The HACCP Food Safety Management System is also a part of Quality management
System of Garuda Polyflex Foods Pvt Ltd., Bengaluru Unit.
1.4 Status of Quality Management Systems
Our unit has continued to implement and monitor the ISO 22000 system & other Quality
Management systems in place subsequently.
1.5. CSR - CORPORATE SOCIAL RESPONSIBILITY
At GP Foods we believe in helping our local communities with an emphasis on employee

voluntary services. GP Foods has been actively involved in various corporate social
responsibility activities. We remain committed to making a positive impact on our world
by investing financial and human capital in the issues that matter to society. It is always
our responsibility to apply our collective knowledge, talent and energies to the
challenges we all face in our workplace, our communities and our environment.
We are currently supporting the Government Primary school located at Wabasandra
by sponsoring a computer, building toilets for the students, distributing chocolates
for students during national festivals and aiding the school by providing material
regularly.
We have also conducted voluntary blood donation camps with the help of Lions
Blood Bank

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2. Introduction to HACCP System.
The Food and Drug Administration has adopted a food safety program developed
nearly 30 years ago for astronauts and is applying it to seafood. The agency intends
to eventually use it for much of the U.S. food supply. The program for the astronauts’
focuses on preventing hazards that could cause food-borne illnesses by applying
science-based controls, from raw material to finished products. FDA’s new system
will do the same.
Traditionally, industry and regulators have depended on spot-checks of

manufacturing conditions and random sampling of final products to ensure safe
food. This approach, however, tends to be reactive, rather than preventive, and can be
less efficient than the new system.
The new system is known as Hazard Analysis and Critical Control Point, or HACCP
pronounced as “Hassip”. Many of its principles already are in place in the FDA-
regulated low-acid canned food industry. And, in a 1995 final rule that took effect in
December 1997, FDA established HACCP for the seafood industry. Also, FDA has
incorporated HACCP into its Food Code, a document that gives guidance to and serves
as model legislation for state and territorial agencies that license and inspects food
service establishments, retail food stores, and food vending operations in the United
States.
The U.S. Department of Agriculture has established HACCP for meat and poultry
processing plants, as well. Most of these establishments were required to start using
HACCP by January 1999. Very small plants have been given time until January 25, 2000.
(USDA regulates meat and poultry; FDA all other foods.)
In April 1998, FDA proposed requirement of HACCP controls for fruit and vegetable
juices. FDA now is considering developing regulations that would establish HACCP as
the food safety standard throughout other areas of the food industry, including
both domestic and imported food products.
To help determine the degree to which such regulations would be feasible, the agency
is conducting pilot HACCP programs with volunteer food companies. The programs
have involved cheese, frozen dough, breakfast cereals, salad dressing, fresh and
pasteurized juices, bread, flour and other products.
HACCP has been endorsed by the National Academy of Sciences, the Codex
Alimentarius Commission (an international food standard-setting organization), and
the National Advisory Committee on Microbiological Criteria for Foods. A number of

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U.S. food companies already use the system in their manufacturing processes, and it is
in use in other countries, including Canada.
What is HACCP?
The HACCP approach is based on The seven basic principles of HACCP are:
seven principles aimed at
identifying hazards food 1. Identify the hazards and list preventive
in
production, controlling measures to control them.
hazards at critical control 2. Determine the critical control points.
points in the process, and 3. Establish limits at each critical control
verifying that the system is point.
working properly. key 4. Establish procedures to monitor the
The
element of the HACCP system is critical control points.
its preventive nature meaning 5. Establish corrective action to be taken in
that potential food safety case of a deviation.
hazards are controlled 6. Establish procedures to verify that the
throughout the process. The systems are working correctly.
application of HACCP principles 7. Establish effective record-keeping.
in the production of food is
recommended by Codex
Alimentarius, the international
standard-setting organization
for food.
1. Analyze hazards: Potential hazards associated with a food and measures to

control those hazards are identified. The hazard could be biological, such as a
microbe; chemical, such as a toxin; or physical, such as ground glass or metal
fragments.

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2. Identify critical control points: These are points in a food’s production

process—from its raw state through processing and shipping to consumption by
the consumer—at which the potential hazard can be controlled or eliminated.
Examples are cooking, cooling, packaging, and metal detection.
3. Establish preventive measures with critical limits for each control point: For a
cooked food, for example, this might include setting the minimum cooking
temperature and time required to ensure the elimination of any harmful
microbes.
4. Establish procedures to monitor the critical control points: Such procedures
might include determining how and by whom pasteurization time and temperature
should be monitored.
5. Establish corrective actions to be taken when monitoring shows that a critical
limit has not been met: For example, reprocessing or disposing of food if the
minimum cooking temperature is not met.
6. Establish procedures to verify that the system is working properly: For
example, testing time-and-temperature recording devices to verify that a cooking
unit is working properly.
7. Establish effective record keeping to document the HACCP system: This would
include records of hazards and their control methods, the monitoring of
safety requirements and action taken to correct potential problems. Each of
these principles must be backed by sound scientific knowledge: for example,
published microbiological studies on time and temperature factors for
controlling food borne pathogens.
Need for HACCP
New challenges to the Indian food supply have prompted the industries to
consider adopting a HACCP-based food safety system on a wider basis. One of the
most important challenges is the increasing number of new food pathogens. For
example, between 1973 and 1988, bacteria not previously recognized as important

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causes of food-borne illness—such as Escherichia coli O157:H7 and Salmonella

enteritis became more widespread.
There also is increasing public health concern about chemical contamination

of food: for example, the effects of lead in food on the nervous system.
Another important factor is that the size of the food industry and the diversity
of products and processes have grown tremendously—in the amount of domestic
food manufactured and the number and kinds of foods imported. At the same time,
central government, state government and local agencies have the same limited
level of resources to ensure food safety.
The need for HACCP is further fueled by the growing trend in international
trade for worldwide equivalence of food products and the Codex Alimentarius
Commission’s adoption of HACCP as the international standard for food safety.
3. ADVANTAGES OF HACCP:
 Hazard Analysis & Critical Control Point (HACCP) is a proactive system that when
properly applied, understood and implemented, ensures food safety.
 It is used as an optimal system for preventing food safety problems
 HACCP System will better ensure the prevention of manufacturing problems
relative to any known quality control system
 It provides a more specific & critical approach in the control of micro-biological
hazards in foods than that provided by traditional inspection approaches
 It is used as tool for regulatory programs to control food safety & is not only
related to food safety but also equally applied to other aspects of food quality
 It is a cost effective system & include better use of resources & more timely
response to the problems
 It is primarily applied by the food industry, but is equally applicable through out
the food chain from the primary producer to the final consumer

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 The most important advantage is “ Safety”, Wholesomeness & Prevention of

economic Adulteration
 It provides a platform for continuous improvement & to improve day to day handling
of tasks. It also improves the company’s quality and reputation & thus increases
profitability
 It is a scientific approach for identifying Food Hazards & applying results to
control or eliminate hazards
 It makes people aware of food hazards, & guides them on how to take corrective
actions
 It makes it unnecessary to engage in random sampling & end product testing which is
unreliable as it not uncommon to find contamination after the product has left the
food facility.
4. GOOD MANUFACTURING PRACTICES GUIDELINES

HACCP is only one part of a larger system of control procedures. It is based
on Good Manufacturing Practices.
Good Manufacturing Practices or pre-requisite programs are programs that

comprise the basic universal steps and procedures that control entire
operating conditions within establishments and ensure favorable conditions
for producing safe food. GMPs include the following programs:
 Premises - Outside Property, Building, Sanitary facilities, Water Quality
Programs
 Transportation and Storage - Food Carriers, Temperature Control,
Storage of Incoming Materials, Non-food Chemicals, Finished products
 Equipment - Design, Installation, Maintenance and Calibration
 Personnel – Training, Hygiene and Health Requirements
 Sanitation and Pest Control - Sanitation and Pest Control Program
 Recall Program
4.1 Premises

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 The premises include all elements in the building and building surroundings:
the outside property, roadways, building design and construction, product
flow, sanitary facilities, and water quality. They are designed, constructed
and maintained in a manner to prevent conditions that may result in the
contamination of food.
 Outside property all outside areas of the plant are free of debris and
refuse that might be a source of insects and/or rodent infestation or
cause objectionable odors, smoke, dust or other contaminants.
 Roadways, yards and parking lots, are properly graded, paved and
maintained. They should provide and permit good drainage.
 Building: Facilities are designed, constructed and maintained in good repair

to permit easy cleaning, prevent entrance and harboring of pest and
entrance of environmental contaminants.
 Floors, walls and ceilings are constructed of approved materials that are
durable, smooth, and cleanable.
 Walls are light colored, and floors sufficiently sloped for liquids to
drain to properly trapped outlets.
 Windows are properly screened if opened and doors should have smooth,
non-absorbent surfaces and be close fitting.
 Stairs, elevators, overhead structures and other structures are well

designed and constructed so that there is no contamination of food and
packaging materials.
 Adequate lighting is provided throughout the facility. Natural light /

Sunlight are provided wherever possible. Rest of the areas is complimented
with bulbs so that proper operation can be carried out. Light bulbs and
fixtures suspended over exposed food or packaging materials at any stage
of production are of a safety type or protected to prevent contamination
of food or packing materials due to breakage.
 Adequate ventilation is provided to prevent steam, condensation, dust and

heat build-up and to remove contaminated air.

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 Drainage and water disposal systems and facilities for waste storage are
designed and constructed so that the risk of contaminating food or
potable water supply is avoided. They should be equipped with appropriate
traps and vents.
 The traffic patterns of employees and equipment, materials and product are
such that the possibility of cross contamination between raw and
processed food is eliminated.
 Sanitary facilities
Washrooms, lunchrooms and change rooms are separate from and not lead
directly into food processing areas and are properly ventilated and
maintained.
Washrooms are equipped with hand washing facilities with a sufficient number
of properly installed sinks and plumbing with cold potable water. They have
soap solution, sanitizer, sanitary hand drying, and a cleanable waste
receptacle.
Areas where employees are in direct contact with microbiologically sensitive

foods contain conveniently located hand washing facilities. Notices are
posted in these areas requiring employees to wash their hands.
Water/Steam/Ice Quality program
Any water that contacts food or food-contact surfaces should be safe and
of adequate sanitary quality. Microbiological, chemical and physical quality
of source and in-plant water is controlled regularly, from various points of
usage in the facility. Records are maintained on file.
Running water at suitable temperature, and under pressure as needed, are

provided in all areas for food processing, for cleaning of equipment, utensils,
and food-packaging materials, or for employees sanitary facilities.
There is no cross-contamination between potable water and non-potable

water systems. All hoses, taps, cross connections or other areas of possible
contamination are equipped with anti-backflow devices. Non-potable water is
never used in food processing, handling, packaging or storage areas.

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All water treatment chemicals used are approved for such use and stored
properly.
4.2 Transportation and Storage
All ingredients, raw material, packaging material or other incoming material

and finished product are handled, stored and transported in a sanitary manner
and at appropriate temperatures to avoid contamination, rapid proliferation of
microorganisms, spoilage or damage. Sensitive ingredients and packaging
materials are stored under appropriate conditions.
The facility is maintaining stock rotation of raw material, ingredients,

packaging material and finished product, namely “first expiry first out” or
“first in, first out”.
Food carriers are suitable for transport of food and made from material
suitable for food contact. They are loaded, arranged and unloaded in a
manner that prevents damage and contamination of the food, ingredients and
packaging materials.
Chemicals are received and stored in a dry, well-ventilated area, separate from
all food handling areas. All chemicals are properly labeled and stored,
handled only by authorized and properly trained plant employees.
4.3 Equipment performance and maintenance
All plant equipment and utensils for food handling or production are
designed and installed in such a way as to facilitate its cleaning and sanitizing
including the adjacent areas and also its maintenance and inspection.
Equipment and utensils are constructed of corrosion resistant material.
Equipment that is used in the processing or food handling areas and does not
come into contact with food is so constructed that it can be kept in a clean
condition.
All food contact surfaces are non-absorbent, non-toxic, smooth, free of

pitting and able to withstand repeated cleaning and sanitizing.
Any chemicals, coating or lubricants used in or on the equipment/utensils are

approved and used as labeled.

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Routine maintenance activities are performed to ensure that

equipment/utensils are operating as intended. A preventive maintenance
program is in place that lists all equipment/utensils and preventive measures
and procedures. The program specifies the necessary servicing for the
equipment and frequency including replacement of parts, responsible person,
methods of monitoring, verification activities and records maintained.
Control instruments used for measuring, regulating, or recording

temperature, pH, acidity, water activity, or other conditions are accurate,
calibrated and adequately maintained, and adequate in number for their
designated uses.
4.4 Personnel
The plant is having an adequate written program in place to monitor and

control all elements in this section, and maintain the appropriate records.
Personnel responsible for identifying sanitation failures or food

contamination are having the necessary background education, training or
experience, or a combination of all the three, to provide a level of competency
necessary for production of clean and safe food.
Food handlers and supervisors receive appropriate training in proper food

handling techniques and food-protection principles and are informed of the
danger of poor personal hygiene and sanitary practices. All training activities
are documented including who received the training, the date and the type of
training delivered.
Any person who, by medical examination or supervisory observation, is shown

to have, or appears to have, an illness, open lesion, including boils, sores, or
infected wounds, or any other abnormal source of microbial contamination by
which there is a reasonable possibility of food, food contact surfaces, or
food packaging material becoming contaminated is excluded from any
operations which may be expected to result in such contamination until the
condition is corrected.
Personnel are instructed to report any abnormal health condition to their

supervisors.
All persons working in food handling areas conform to hygiene practices

while on duty. They should:

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• Wear outer garments, protecting clothes, hair covering and footwear,

suitable for the operation.
• Wash hands thoroughly and sanitize before starting work, after each
absence from work station, after using toilet facilities, and at any time
after handling contaminated materials.
• Remove all unsecured Jewellery and other objects, which may fall into
or otherwise contaminate food. If any hand Jewellery cannot be
removed it should be covered by material which can be maintained in an
intact, clean and sanitary condition.
• Not smoke, eat or drink in food handling areas.
• Maintain gloves in an intact, clean, and sanitary condition, if they are

necessary in food handling.
• Store clothing and other personal belongings in areas other than

where food is exposed or equipment/utensils are washed.
• Maintain adequate personal hygiene.
4.5 Sanitation and Pest Control
Entire plant has a written, effective and safe sanitation and pest control
program.
The sanitation program include written cleaning and sanitizing procedures for
all equipment, utensils, overhead structure, floors, walls, ceilings, drains,
lighting devices, refrigeration units, and anything else impacting on the safety
of the food. The name of the person responsible is specified, the chemical used
(detergent/sanitizer), the procedures used and the frequency of cleaning and
sanitizing.
Cleaning and sanitizing equipment is designed for its intended use and properly
maintained and stored.
The facility use only approved chemicals and they are used according to the
guidelines or instructions (e.g. concentration, water temperature, dilution
factor) from the manufacturer or supplier.

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The effectiveness of sanitation programs are monitored and verified (using

different tests and methods) and records kept.
The pest control program contains written procedures to prevent insects,

rodents, birds and other animals from entering the plant.
The programs specify:

- The name of a contact person at the plant responsible for pest
control;
- The name and address of any extermination company used;
- A list of all chemicals and methods used for their application;
- A map of bait locations;
- Procedures and frequency of inspection;
- A pest survey; and
- control report form.
Pest control chemicals should be used according to instructions to prevent

contamination.
Measures should also be in place for verification of the effectiveness of the
pest control program. All records must be kept on file.
4.6 Recall Program
The plants has a written recall program where written recall procedures are
developed to ensure that identified food is removed from the market as
efficiently, rapidly and completely as possible and which can be put into
operation at any time.
A recall program contain at a minimum, the following elements:
 Documentation identifying the product coding system and product designation;

 Records of finished product distribution, kept for a period of time that exceeds
the shelf life of the product;
 The step by step procedures, to follow in the event of a recall, including the
extent and depth of the recall;
 A current list and addresses of people that will take part in any recall
activities;
 Means of notifying the affected customers, retailers, wholesalers;
 Control measures for the returned recall product;
 Means of assessing the progress and efficacy of the recall;

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 Means of coordinating recall with regulatory agencies.
Recall procedures is tested at an annual frequency to ensure that they

function properly.
When we initiate a recall of food, we notify the regulatory authorities and

submit the following information:
- Reason for recall,

- Amount of product involved (total distributed, total remaining in the
company, total recalled),
- Product codes,
- Areas of distribution,
- Contact person within the company
- Copies of any news release.
Distribution records should contain sufficient information to permit

traceability to a particular code or lot number. The following minimum
information is required:
- Product identification and size;
- Lot number or code; quantity;
- Customers’ names, address,
- Phone number to the initial level of product distribution.
4.7 Consumer Complaint Procedure
The plants have a detailed consumer complaint files and standard operation
procedures for handling, addressing consumer complaints.

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5. FLOWCHART FOR THE APPLICATION OF HACCP
Assemble
HACCP team
Establish
critical limits
for each CCP
Describe
product
Establish a
monitoring
system for each
Identify
Intended Use
CCP
Establish
corrective
Onsite
action
confirmation of
flow diagram
Establish
Verification
List all potential hazards,
conduct a hazard analysis, and
procedures
establish critical limits for each
CCP Onsite confirmation of flow
diagram
Establish
Documentation
Determine CCPs & Record
keeping
Procedure

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A Five-step Process
The five steps of hazard analysis are: In each case, the analysis must
consider all possible biological,
1. Review the incoming material,
chemical and physical hazards.
including ingredients and
packaging material. Once all hazards have been
2. Evaluate each step of the identified and analyzed, the next
processing operations. stage of the HACCP approach is to
3. Observe the actual operating determine the critical control
practices. points necessary to control the
4. Take accurate measurements. hazards.
5. Analyze the measurements.
Critical Control Points (CCP)
A Critical Control Point (CCP) is a point or step in the manufacturing process at

which control can be applied and a food safety hazard can be prevented, eliminated
or reduced to an acceptable level. For example, a specified heat process, applied
for a prescribed time and temperature to destroy bacteria, is a CCP.
Determining CCPs required to control identified hazards is the second major

principle of a Hazard Analysis Critical Control Point (HACCP) system. CCPs are
located at any point in the food processing sequence where biological, physical
and chemical hazards can be eliminated or controlled. CCPs can include
processing, chilling, sanitizing, formulation control, prevention of cross-
contamination, employee hygiene and environmental hygiene.
It is very important that CCPs are developed and documented carefully. The
success of controlling hazards depends on the care taken in determining the
CCPs, the critical limits that are to be met at each point, the monitoring
procedures used to control each CCP and the corrective action taken when there
is a deviation identified as a CCP. Plant verification of each CCP will ensure that
monitoring procedures are in place and are effective in controlling the potential
hazard.

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6. DEFINITIONS:
 Action Limit Value: A criterion deduced from the Critical Limit value that
indicates an intervention in the process is required.
 Adequate means that which is needed to accomplish the intended purpose in

keeping with good public health practices.
 CCP Decision Tree: A logical sequence of questions asked at each process step
that will assist to determine CCPs
 Commercially sterile: The condition of a product or package, which renders the

product or package free from viable forms of microorganisms having public
health significance, as well as any microorganisms of non-health significance
capable of reproducing in the food under normal non-refrigerated conditions
of storage and distribution.
 Consequence: Impact of a food safety incident
 Control Measure: Any Action and activity that can be used to prevent or
eliminate a Food Safety Hazard or reduce it to an acceptable level
 Control: It is the state where in correct procedures are being followed and
criteria are being met.
 Corrective Action: Any action to be taken when the results of monitoring at the
CCP indicate a loss of control.
 Corrective Measure: Measure in relation to Food Safety, taken to eliminate the

cause of an existing deviation, defect or any other undesired situation in order
to prevent recurrence.
 Critical Control Point (CCP): A step at which control can be applied and is
essential to prevent or to eliminate a food safety hazard or reduce it to an
acceptable level.
 Critical control point means a point or a step in a food process where there is a
high probability that improper control may cause, allow, or contribute to a hazard
or to filth in the final food or decomposition of the final food.
 Critical Limit: A criterion which separates acceptability from unacceptability of

a product or parameter
 FEFO: ‘First Expiry First Out’, utilization of materials in chronological order

of their Expiry / Best before Date.

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 FIFO: ‘First In First Out’, utilization of materials in chronological order of

their procurement or production.
 Food means food as defined in section 201(f) of the act and includes raw
materials and ingredients.
 Food-contact surfaces are those surfaces that contact human food and those
surfaces from which drainage onto the food or onto surfaces that contact
the food ordinarily occurs during the normal course of operations. "Food-
contact surfaces" includes utensils and food-contact surfaces of equipment.
 Food Hygiene: All Conditions and Measures those are necessary to ensure the
safety and Suitability of Food at all stages of the Food Chain.
 Food Safety: Assurance that food will not cause harm to the consumer when it
is prepared and /or eaten according to its intended use
 Good Manufacturing Practices: A combination of manufacturing procedures, in

particular aimed at hygiene and to prevent product switches and exchanges.
 HACCP (Hazard Analysis and Critical Control point): Hazard Analysis and
Critical Control Point. Concept which systematically identifies evaluates and
controls (Potential) hazards that are significant for food safety.
 HACCP Audit: A systematic and independent examination to determine whether

the HACCP system, including the HACCP plan and related results , comply with
planned arrangements , are implemented effectively and are suitable for the
achievements of its objectives
 HACCP based Food Safety System: The Organizational structure, Procedures,

Processes, and Resources needed to execute HACCP Plan to meet its
Objectives.
 HACCP Plan: A document prepared in accordance with the Principles of HACCP

to ensure control of Hazards, which are significant for Food safety in the
Segment of the Food Chain under consideration.
 HACCP Team: Group of individuals (multi – disciplinary) who develop, implement
and maintain a HACCP System
 Hazard Analysis: The process of collecting and evaluating information on

hazards and conditions leading to their presence to decide which are significant
for Food safety and should therefore be addressed in the HACCP Plan.

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 Hazard: A Biological, Chemical or Physical agent in or condition of, food

stuffs with the potential to cause an adverse health effect.
 High Hygiene Zones: Direct contact of personnel with food products in the
processing areas. Mainly processing areas are kept at positive pressure using
air handling unit with an air exchange cycle of 15 – 20 cycles/hr and Strip
curtains provided at each entry point .At most personnel hygiene is to be
ensured. Microbiology Laboratory & Media preparation & Storage Area comes
under this category.
 Intrinsic Factors: These are Certain Basic, Integral aspects of a product such
as pH, acidity, salt concentration etc.
 Likelihood: Frequency / Time interval that a food safety incident may happen.
 Limits (Tolerance): Values which delimit the range of acceptable variations in

the results of measurements of critical process parameters, to ensure that the
process step is controlled and will provide for safe food stuffs.
 Lot means the food produced during a period of time indicated by a specific
code.
 Low Hygiene Zones: All other areas which are not covered under High & Medium
Hygiene Zones ( e.g. warehouse , empties storage areas )
 Medium Hygiene Zones: Raw Material & Packaging Material Storage Area,
Finished Product handling areas, Utilities Areas.
 Microorganisms means yeasts, molds, bacteria, and viruses and includes, but is
not limited to, species having public health significance. The term "undesirable
microorganisms" includes those microorganisms that are of public health
significance, that subject food to decomposition, that indicate that food is
contaminated with filth, or that otherwise may cause food to be adulterated
within the meaning of the act. Occasionally in these regulations, FDA used the
adjective "microbial" instead of using an adjectival phrase containing the word
microorganism.
 Monitoring: To conduct a planned sequence of observations or measurements

of control parameters to assess whether the CCPs are controlled
 Pest refers to any objectionable animals or insects including, but not limited
to, birds, rodents, flies, and larvae.
 Plant means the building or facility or parts thereof, used for or in connection
with the manufacturing, packaging, labeling, or holding of human food.

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 Potable Water: Water fit for the purpose of drinking
 Pre - Requisite Program (PRP): Any specified and documented activity or facility
implemented in accordance with the Codex general principles of Food Hygiene,
Good manufacturing practice and appropriate Food legislation in order to
establish basic conditions that are suitable for the production and handling of
safe food at all stages of the Food Chain. Best practices or prerequisite
programs, sometimes also referred to as support programs or foundation
programs or those programs essential to the successful implementation of a
HACCP System.
 Preventive Measure: Factors, which may be used to remove or reduce the
identified Hazard to an acceptable level
 Primary Production: Those steps in food chain up to and including harvesting,

hunting, fishing, milking and all stages of animal production prior to slaughter.
 Process Flow Diagram: A diagram showing in detail the sequence of operations

to be undergone in the process.
 Product Integrity: The safety, quality and fitness for use of ingredients,
packaging materials, final products, including product contact surfaces of
equipment and pipework.
 Quality control operation means a planned and systematic procedure for

taking all actions necessary to prevent food from being adulterated within the
meaning of the act.
 Rework means clean, unadulterated food that has been removed from
processing for reasons other than unsanitary conditions or that has been
successfully reconditioned by reprocessing and that is suitable for use as
food.
 Risk: Risk is Product of Likelihood and Consequence. This is a measure to

identify the importance of the process step. The probability of exposure to a
particular potential danger of injury / loss/ other adverse effect
 Safe-moisture level is a level of moisture low enough to prevent the growth of

undesirable microorganisms in the finished product under the intended
conditions of manufacturing, storage, and distribution. The maximum safe
moisture level for a food is based on its water activity (aw). An aw will be
considered safe for a food if adequate data are available that demonstrate
that the food at or below the given aw will not support the growth of
undesirable microorganisms.

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 Sanitize means to adequately treat food-contact surfaces by a process that is

effective in destroying vegetative cells of microorganisms of public health
significance, and in substantially reducing numbers of other undesirable
microorganisms, but without adversely affecting the product or its safety for
the consumer.
 Shall is used to state mandatory requirements
 Should is used to state recommended or advisory procedures or identify

recommended equipment.
 Standard (Target value): A standard is the value targeted, within the action
value limits the measurement results of the critical process parameters may
vary to ensure a safe product.
 Target Limit: A value set with in Critical limits to be used for tracking action to
prevent any deviation
 Validation: Confirmation by examination and provision of objective evidence that

the particular requirements for a specific intended use are fulfilled
 Verification: The application of methods, procedures, tests and other

evaluations in addition to monitoring to determine compliance with specified
requirement
 Water activity (aw) is a measure of the free moisture in a food and is the quotient
of the water vapor pressure of the substance divided by the vapor pressure of
pure water at the same temperature.

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7. HACCP DOCUMENTATION & IMPLEMENTATION
7.1 MANAGEMENT COMMITMENT
We at Garuda Polyflex Foods Pvt Ltd., Bengaluru are committed to deliver

product meeting all quality and consumer safety requirements. All associates
of this unit are committed to adhere to the HACCP plan designed & developed by
our HACCP Team and follow all the GMP (Good Manufacturing Practices) and
GHP (Good Hygiene Practices).
The Management will take all the responsibility to effectively communicate,

motivate and facilitate all the associates of the unit, and provide necessary
resources for an effective implementation of the program.
Safety & Quality of our Products would always be maintained and remain as the
top concern at our manufacturing facility.
Mr. Niranjan D S, Working as Asst Manager - QA in our Company is nominated as

HACCP Coordinator and FSMS Team Leader for the implementation of ISO
22000 requirements.
Mr. L Ramesh Working as Factory Manager in our Company is nominated as

Management Representative for the implementation of ISO 22000 requirements.
Board of Director,
Garuda Polyflex Foods Pvt Ltd.,

Bengaluru.

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7.2 FOOD SAFETY POLICY
To Ensure Food Safety and Total Customer satisfaction, we

at Garuda Polyflex Foods Pvt Ltd., Bangalore - Manufacturers of Wafer
sticks are committed to Quality by adopting Food Safety Initiatives and
Good Manufacturing Practices and by continually improving our
processes and systems throughout the supply chain. We are committed
to abide by all the applicable ISO Standards, legal, regulatory &
Customer requirements.
Indicators Goal/Target Strategies Responsibility Target

Date
 Conduct Monthly GMP Cross 31st Dec
audits Functional 2019
 Implement the proposed Heads
To achieve corrective actions
GMP Audit plant overall within the specified
GMP rating of timelines
80 and above  Verify the effectiveness
by the end of of the corrective
the Dec 2018. actions taken
 Improve Processes and
Systems
Motivation of associates by
rewards and recognition
 Adherence to Training HR Manager, Quarterl

Training To achieve a Plans y basis
all the Minimum of 4  Awareness training for Asst. Manager
staff on Hours / year. the Newly Recruited - QA
GMP and staff and Refresher
FSMS training for the regular
staff periodically

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7.3 SCOPE
The Scope for the application of HACCP System in Garuda Polyflex Foods Pvt Ltd,
Bengaluru,
“MANUFACTURING (CREAM AND BATTER PREPARATION, BAKING,
WAFER STICK FORMATION AND CREAM FILLING) AND PACKING OF
WAFER STICKS IN RETAIL AND WHOLESALE PACKAGES”
7.3.1 PRODUCT DESCRIPTION & INTENDED USE – Annexure (GPFPL/FSMS/MR/PD- 01)
7.4 HACCP TEAM & RESPONSIBILITIES
Following are the criteria for the selection of the HACCP TEAM Members
 The Member should be a permanent employee of the company.
 All members should be Graduate or Diploma holder in any discipline and have
specific knowledge and at least 01 year of experience in the industry.
 The HACCP Team comprises of members from all functional areas which is multi-
disciplinary in nature.
 All team members (From each Department) must undergo Basic Training to
understand the system.
 Please Refer HACCP Team Members list (GPFPL / FSMS/ MR – 01)
Hazard Analysis: Hazard Analysis of each hazard is carried out based on their severity
of effect caused and the likelihood of appearance.
The three parameters for assessing severity and likelihood are
 Low
 Medium
 High

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Validation Team Members:
Please Refer HACCP Team Members list (GPFPL / FSMS/ MR – 01)
Task and Responsibilities of Management Team Members in process area:
Person Task Responsibility Authority
Responsible to carry out: Has an authority to:

1. Servicing of the To take corrective
machineries action in case of
deviation in the
2. Monitoring of
Maintaining the specifications.
parameters in operation of
working condition machineries and corrective
Maintenance of all machineries To stop the
actions as and when
Team machineries if there
used for required.
is any deviation &
Members processing. Follow GMP, Good inform immediate
housekeeping and good supervisor for the
hygienic practices necessary
corrective action.
Responsible for: Has an authority to:

1. Receipt of raw/package Increase inventory
materials levels and inform to
Receiving, storing Maintain and monitor the immediate
Store and supply of raw storage conditions etc., supervisor if any
2. Follow FIFO/Stock uncomfortably for
Executive material/ rotation, ensure that supplying the
ingredients labeling of materials and material.
status identification is
To take corrective
followed,
action if any
3. Follow GMP, Good
deviation in the
housekeeping and good storage condition
hygienic practices

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Responsible for: Has an authority to

Ensure all the 1.Inventory Management To change the
materials are supplier if any
Purchase procured from 2.Control of raw/package quality issue with the
materials supply of material.
Executive approved and
authorized 3.Purchase of To go to his works
suppliers raw/package materials to investigate the
from the approved and process at any point
authorized suppliers of the time.
Responsible for: Has an authority to

1.Design and implementing Design and
warehouse systems and implementing
improvement warehouse systems
2.Warehousing, and improvement
transportation and Warehousing,
finished goods inventory transportation and
Ensure the
control activities finished goods
received finished 3.Handling and storage of inventory control
product is stored finished products under activities
Logistic and dispatched as ideal conditions Handling and
per the standard 4.Follow FIFO in the ware storage of finished
Team house products under
procedures and
practices 5.Follow product release ideal conditions
procedures Follow FIFO in the
6.Follow GMP, Good ware house
housekeeping and good Follow product
hygienic practices release procedures
Follow GMP, Good
housekeeping and
good hygienic
practices
To prevent the IMT members are Has an authority to
distribution and responsible to handle the
use of Non- situation (Product
Recall/Voluntary
Incident confirming withdrawal) in case it
Management Materials in the causes any serious Quality,
Team production safety and/or any other
process or in any impacts.
other place in
plant. Plant Q.C Personnel are
responsible for Carry out To take necessary
action to recall the

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the quality related product if any

activities to conform the deviation in the
products is not under product quality.
acceptable limits.
To ask the
Production and Shipping laboratory to check
Team members are any parameter any
responsible for keeping time to conform the
the non-conforming quality.
Product away from the
other products To keep ON HOLD the
product if any
Production Executive is suspect ion in the
responsible for the final quality of the
disposition of suspected product.
non-conforming products
Responsible for: Has an authority
1. Carrying out of
Medical/Health Checkups
To schedule the
2. Training and awareness training /awareness
to the employees
program for the
3. Implementation of associate with the
Personnel Hygiene co-ordination of the
Practices particular Dep’t
head.
Ensure the
HR & Admin associates are To take corrective
Executive healthy and action on any
hygienic associate when they
deviate the GHP.
To do counseling
for the associate if
one continuously
deviating the GHP.
To sanction leave
for associate when
one is not in good
health.

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7.5 FSMS TEAM LEADER & HACCP COORDINATOR
Mr. Niranjan D S, Asst Manager - QA at Garuda Polyflex Foods Pvt Ltd.,

Bangalore will coordinate the development, implementation and maintenance of
the HACCP & ISO system requirements at our unit.
The HACCP Coordinator will coordinate the development, implementation and

maintenance of the HACCP system, be the leader of the HACCP team and one
point contact between the management and other associates during the
development and implementation phases.
HACCP Team will be responsible for designing Training, implementing &

validating the HACCP system on a regular basis. The HACCP Team also confirms
that the HACCP system is representative of the establishment conditions,
implemented as described and effective on an ongoing basis. The HACCP system
must be maintained to represent current establishment conditions and will
require changes in line with any alterations to the establishment, the process,
the machineries or the product
7.6 TRAINING & AWARENESS
The Management has been encouraging & supportive in ensuring that all the
associates are adequately trained to facilitate HACCP system development,
implementation and maintenance.
All the associates in GARUDA POLYFLEX FOODS PVT LTD., with HACCP
awareness Programs to facilitate the implementation of the designed HACCP
System.
The content of the training programs have emphasis on GHP, GMP and their
applications in their respective departments. The training of staff & operators
ensures that they understand their specific functions, duties, and how these are
to be performed under a HACCP system.
Records have been maintained for the training conducted.

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7.7 PRE REQUISITE PROGRAMS FOR HACCP:
The Unit has implemented the following PRPs for effective implementation of
HACCP Pro
S.No. Program Document Number
1 MASTER CONTROL DOCUMENTS GPFPL/FSMS/MLD/FRM-01
2 Procedure for employee hiring GPFPL / FSMS /HR - SOP-01
3 Incoming Materials Inspection program GPFPL / FSMS /QA /FRM -01
4 Control of Documents & Records GPFPL / FSMS /SOP- 04
5 Internal Audit Program GPFPL / FSMS /SOP- 06
6 Corrective Action Program GPFPL / FSMS /SOP- 07
7 Preventive Action Program GPFPL / FSMS /SOP- 08
8 Good Manufacturing Program GPFPL / FSMS /SOP- 09
9 Good Housekeeping Program GPFPL / FSMS /SOP- 10
10 Personnel Hygiene Program GPFPL / FSMS /SOP- 11
11 Cleaning & Sanitation program GPFPL / FSMS /SOP- 12
12 Pest Control Program GPFPL / FSMS /SOP- 13
13 Product Recall GPFPL / FSMS /SOP- 15
Incident Management & Emergency

14 GPFPL / FSMS /SOP- 16
Procedure
15 Handling of Non Confirming Products GPFPL / FSMS /SOP- 17

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16 GPF Handling of Allergens GPFPL / FSMS /SOP- 19
17 Internal SITE Security GPFPL / FSMS /SOP- 25
18 Maintenance & Calibration Procedures GPFPL / FSMS /SOP- 27
19 Quality Inspection & Testing Procedure GPFPL / FSMS /SOP- 29

procedure for conduction of Management
20 GPFPL / FSMS /SOP- 39
Review
21 Health & Safety Procedure GPFPL / FSMS /HR - SOP-04
22 Procedure for Change Management

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HACCP DOCUMENTATION MANAGEMENT
The document management and control system adopted by the plant for ISO
implementation is extended to the documents relating to HACCP as well. The
documents are available to the employees of the organization in the form of
hard copies with functional head. These are the controlled copies and the list
of copyholders is updated in the Master Control Document
The MR ensures that the appropriate items, at the correct revision levels, are
issued to all who need them within the Company. The distribution of standard
documents is controlled and recorded on Distribution Lists, which also show
the current issue status. The Distribution Lists are reviewed and updated as
changes occur. (Master Control Document)
All changes to documents are reviewed and approved by the Functional Heads
and changes are intimated to the MR through a Change request form.
 Master copies of the revised documents are retained as records of the changes
and renewed as necessary to ensure clarity.

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Document Management 6.9.

GMP
New or Updated
Document Needed require
ments
Submit a
Document
Make Necessary as e
Changes
Request Form Yes
Agree With Notify Reason Agree on

No No End
Request ? for Rejection Changes?
Yes
Assign Document
Number
Prepare Document
Update Revision
Draft (See Tool #2)
Record
Review Draft for

Completeness and
Format Distribute the
Document
Circulate Draft for

Comment
Stamp Obsolete
Is This a New Collect Old
No Old Version and
Document? Copies
Archive
Review Comments and

Yes
Make Changes as Needed
All Old
Copies
Verify Document Contact Recipient No
Accounted
Has Been
For?
Received
Review and Approve
Document Yes
Update Tracking Destroy Old

Record Copies
Make Controlled Copies
for All Locations
End

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7.9 Requirements as per Codex Alimentarius Guidelines
1. Primary Production
1.1 Environmental 1.1.1 Primary food production shall not be carried out in areas
hygiene where the presence of potentially harmful substances will lead to
an unacceptable level of such substances in food. Potential
sources of contamination from the environment shall be
considered.
Remarks :- All GMP construction guidelines of the Company is maintained while
constructing the Unit. All process areas are protected from
external source of contamination. Facility designed so as that
source of contamination like drain line, etc are constructed away
from process block.
Reference:
Program on Good House Keeping: GPFPL / FSMS /SOP- 10
Program on Cleaning and Sanitation: GPFPL / FSMS /SOP- 12
Program on Good Manufacturing Practices: GPFPL/FSMS /SOP- 09
1.2 Hygienic 1.2.1 The potential effects of primary production activities on the
production of food safety and suitability of food shall be considered at all times. In
sources particular, this includes identifying any specific points in such
activities where a high probability of contamination may exist and
taking specific measures to minimize that probability.
1.2.2 As far as practicable, measures shall be implemented to:
- control contamination from air, soil, water, feedstuffs,
fertilizers (including natural fertilizers), pesticides, veterinary
drugs or any other agent used in primary production;
- control plant and animal health so that it does not pose a
threat to human health through food consumption, or adversely
affect the suitability of the product;
- Protect food sources from fecal and other contamination.

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1.2.3 In particular, care shall be taken to manage waste and store

harmful substances appropriately.
1.2.4 On-farm programs which achieve specific food safety goals
are becoming an important part of primary production and shall be
encouraged.
Remarks :- Adequate controls exist to ensure possible contaminants from

ingredients due to the controlled primary operation at the supplier
end.
Process areas completely prohibited for use of Insecticides &
pesticides.
Separation from external contamination by wall and strip curtains
with air curtain and rolling shutter protection.
A well-defined program on Waste Management is In place
Reference:
Program on Good Manufacturing Practices: GPFPL/FSMS /SOP- 09
Program on Waste Management : GPFPL / FSMS /SOP- 26
1.3 Handling, 1.3.1 Procedures shall be in place to:
storage and - sort food and food ingredients to segregate material which is
transport evidently unfit for human consumption;
- dispose of any rejected material in a hygienic manner;
- Protect food and food ingredients from contamination by pests,
or by chemical, physical or microbiological contaminants or
other objectionable substances during handling, storage and
transport.
1.3.2 Care shall be taken, so far as is reasonably practicable, to
prevent deterioration and spoilage through appropriate measures
which may include
Controlling temperature, humidity, and/or other controls.

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Remarks:- - Labeling of each ingredient/product with status Identification is

in place
- Raw materials / Ingredients are separated from chemicals in use
- Control of non conforming materials and Products are in place
- Non conforming materials / products will be disposed of after due
verification through an approved vendor after due approval from
QA personnel and Management.
- FIFO is followed to prevent deterioration of food products
Reference:
Program on handling of Non-conforming materials: GPFPL / FSMS
/SOP- 17
Program on Material Status Identification: GPFPL / FSMS /SOP-
31/32/33
1.4 Cleaning, 1.4.1 Appropriate facilities and procedures shall be in place to
maintenance and ensure that:
personal hygiene
- any necessary cleaning and maintenance is carried out
effectively;
- An appropriate degree of personal hygiene is maintained.
Remarks:- The Unit has well defined and implemented systems on Cleaning and
sanitation where equipment exteriors are cleaned as per the pre-
determined frequency.
Plant has a well-defined Housekeeping program with checklists
includes each and every area/ activity.
- Regular GMP Audits are in place
- Regular cleaning of process areas and its surrounding.
- Program on Personnel Hygiene and Personnel Practices are in
place e.g. Wearing of Caps/hairnet, Washing of hands
Reference:
Program on Cleaning and Sanitation: GPFPL / FSMS /SOP- 12

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Program on Personnel Hygiene:

Program on Good Manufacturing Practices:
2 Establishment: design and facilities
2.1 Location
2.1.1 2.1.1.1 Establishments shall not be located anywhere where it is
Establishments clear that there is a threat to food safety or suitability. In
particular, establishments shall normally be located away from:
- environmentally polluted areas and industrial activities which
pose a serious threat to contamination of food;
- areas subject to flooding unless sufficient safeguards are
provided;
- areas prone to infestations of pests;
- Areas from which waste, either solid or liquid, cannot be
removed effectively.
Remarks:- - Plant located in a commercial area, but there is no threat of
contamination from neighboring buildings and pollutants from
outside. The area is not prone to infestation by pest.
2.1.2 Equipment - 2.1.2.1 Equipment shall be located so that it:
- permits adequate maintenance and cleaning;
- functions in accordance with its intended use;
- Facilitates good hygiene practices, including monitoring.
Remarks:- - The layout of the equipment’s in the plant allows adequate
maintenance and cleaning activity and is maintained to deliver the
desirable parameters, under hygienic conditions.
Reference:
Program on Equipment preventive Maintenance: GPFPL / FSMS
/SOP- 20
2.2 Premises and rooms
2.2.1 Design and 2.2.1.1 Where appropriate, the internal design and layout of food

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layout establishments shall permit good food hygiene practices, including

protection against harmful cross-contamination.
Remarks:- - Process areas are clearly demarcated and separated from each
other. Where ever there is an opening / door, self-closing doors
with air curtain facility is provided. All process areas can be
maintained in hygienic condition.
2.2.2 Internal 2.2.2.1 Structures within food establishments shall be soundly
structures and built of durable materials and be easy to maintain, clean and where
fittings
appropriate, disinfect.
2.2.2.2 The surfaces of walls, partitions and floors shall be made
of impervious materials with no toxic effect in intended use.
2.2.2.3 Walls and partitions shall have a smooth surface up to a
height appropriate to the operation.
2.2.2.4 Floors shall be constructed to allow adequate drainage
and cleaning.
2.2.2.5 Ceilings and overhead fixtures shall be constructed and
finished to minimize the buildup of dirt and condensation and the
shedding of particles.
2.2.2.6 Windows shall be easy to clean, constructed to minimize
buildup of dirt and where necessary, fitted with removable and
cleanable insect-proof screens. Where necessary windows shall be
fixed.
2.2.2.7 Doors shall have smooth, non-absorbent surfaces and shall

be easy to clean and disinfect.
2.2.2.8 Working surfaces that come into direct contact with food
shall be of sound condition, durable and easy to clean, maintain and
disinfect. They shall be made of smooth, non-absorbent materials
and inert to food, detergents and disinfectants under normal
operating conditions.

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Remarks:- The Plant design/construction criteria meets all the said

requirements under this clause.
Reference:
Program on Housekeeping : GPFPL / FSMS /SOP- 10
Layout drawing of the plant :
2.2.3 Temporary / 2.2.3.1 Premises and structures shall be located, designed and
mobile premises; constructed to avoid, as far as is reasonably practicable,
vending machines contaminating food and harbouring Pests.
2.2.3.2 Any food hygiene hazards associated with such facilities

shall be adequately identified and controlled to ensure the safety
and suitability of food.
Remarks:- We don’t have any mobile premises or vending machine inside the
plant premises.
2.3 Equipment
2.3.1 General 2.3.1.1 Equipment and re-usable containers coming into contact
with food shall be designed and constructed to ensure that, where
necessary, they can be adequately cleaned, disinfected and
maintained to avoid the contamination of food.
2.3.1.2 Equipment and containers shall be made of materials with no

toxic effect in intended use.
2.3.1.3 Where necessary, equipment is durable and movable or

capable of being disassembled to allow for maintenance, cleaning,
disinfection, monitoring and, for example, to facilitate inspection
for pests.

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Remarks:- - All food contact surfaces are of food grade quality supplied by
recognized and authorized suppliers. These include SS 304/316,
glass, rubber gaskets, Teflon based parts etc.
Reference:
Program on Cleaning & Sanitation: GPFPL / FSMS /SOP- 12
2.3.2 Food control 2.3.2.1 In addition to the general requirements in paragraph 2.3.1,
and monitoring equipment used to cook, heat treat, cool, store or freeze food
equipment shall be designed to achieve the required food temperatures as
rapidly as necessary in the interests of food safety and suitability,
and to be effectively maintained.
2.3.2.2 Such equipment shall also be designed to allow

temperatures to be monitored and controlled. Where necessary,
such equipment shall have effective means of controlling and
monitoring humidity, air-flow and any other condition likely to have
a detrimental effect on the safety or suitability of food.
Remarks:- Equipment’s are designed such a way to meet the requirements
Reference:
Program on Maintenance & Calibration: GPFPL / FSMS /SOP- 27
2.3.3 Containers 2.3.3.1 Containers for waste, by-products, and inedible or

for waste and dangerous substances shall be identifiable, suitably constructed
inedible substances and where appropriate made of impervious material.
2.3.3.2 Containers used to hold dangerous substances shall be

identified and, where appropriate, shall be lockable to prevent
malicious or accidental contamination of food.

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Remarks:- Containers for keeping waste, by products and other used

chemicals are stored only in the designated area with identification
marks.
All products at raw, intermediate or finished stage are protected

from any cross contamination with dangerous materials.
Non-conforming products are disposed as per defined system

without causing any contamination to the process environment
2.4 Facilities
2.4.1 Water supply 2.4.1.1 An adequate supply of potable water with appropriate
facilities for its storage, distribution and temperature control,
shall be available whenever necessary. Potable water shall, as a
minimum, meet the specifications published in the WHO Guidelines for
Drinking Water Quality.
2.4.1.2 Separate non-potable water systems (e.g. fire control, steam

production, refrigeration) shall be identified and shall not
connect with, or allow reflux into, potable water systems.
Remarks:- Water used for processing is of Portability standards. Water used

for cleaning and sanitation process of product contact surfaces
meet IS10500 & WHO Potable standards as well.
2.4.2 Drainage and 2.4.2.1 Drainage and waste disposal systems shall be available,
waste disposal designed, constructed and maintained in such a way as to avoid
contamination of food products and potable water supply.
Remarks:- Drainage systems constructed so as they always flow from the

process area to Common effluent treatment plant.
Prevention of contamination is ensured by all drains is

underground nature (RCC). The effluents are treated prior to
disposal and meet the legal requirements. Solid wastes are
managed by collection, segregation and disposal in a manner that
prevents cross contamination with any raw, intermediate or finished
product.

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Reference:
Program on Waste Management: GPFPL / FSMS /SOP- 26
2.4.3 Cleaning 2.4.3.1 Adequate facilities, suitable designated, are provided for
cleaning food utensils and equipment. If necessary these facilities
shall have an adequate supply of hot and cold potable water.
Remarks:- Arrangements are made to clean food utensils and equipment’s

adequately. An approved Food Grade chemical with the entire
required document is being used in the areas of processing.
Reference:
2.4.4 Personnel 2.4.4.1 Adequate means of hygienically washing and drying hands,
hygiene facilities including wash basins and a supply of cold and hot (suitable
and toilets temperature) water are provided.
2.4.4.2 Lavatories of appropriate hygienic design are provided.
2.4.4.3 Adequate changing facilities for personnel are provided.
2.4.4.4 The afore-mentioned facilities are suitable located and

designated.
Remarks:- Toilets, Change rooms etc. are provided away from the process
block.
Toilets are provided with Hand wash facility and disinfectant soap
solutions.
Reference:
Program on Personnel Hygiene: GPFPL / FSMS /SOP- 11

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2.4.5 Temperature 2.4.5.1 Facilities for heating, cooling or freezing food products, or
control storing refrigerated or frozen foods are suitable to meet the
specified conditions for ensuring food safety.
Remarks:- Not Applicable
2.4.6 Air quality and 2.4.6.1 Mechanical or natural ventilation ensures:

ventilation
- minimization of air-borne contamination of food (e.g. from
aerosols and condensation droplets)
- control of ambient temperatures
- control of humidity
2.4.6.2 Ventilation systems are designed and constructed so that
air does not flow from contaminated areas to clean areas and they
can be adequately maintained and cleaned.
Remarks:- Processing areas are provided with Industrial exhaust fans to

maintain a positive pressure atmosphere in side.
2.4.7 Lighting 2.4.7.1 The intensity and colour of the lighting is sufficient to
ensure the production and handling of safe food products.
2.4.7.2 Where appropriate, lighting fixtures are protected to ensure

that food products are not contaminated by breakage.
Remarks:- We have defined in the plant construction and design criteria the
lighting intensity requirements in various process areas. The
Inspection station is provided with the required intensity of light.
The Plant records the readings periodically and meets all the
requirements
2.4.8 Storage 2.4.8.1 Adequate facilities for storage of food ingredients and non-
food materials (e.g. cleaning materials, lubricants, fuels) are
provided.
2.4.8.2 Food storage facilities are designed and constructed to:
- permit adequate maintenance and cleaning ;

- avoid pest access and harborages;
- enable food to be effectively protected from contamination;
- Provide the necessary environment to prevent spoilage.

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2.4.8.3 Facilities for storage are designed, constructed and

maintained to ensure that malicious or accidental contamination of
food products with harmful materials is prevented.
Remarks:- - Ingredient storage facilities are clearly separated with chemicals

storage and proper labeling practices are in place.
- Planned and professional Pest control program is in place inside

as well as outside the plant to contain any risk.
The access control prevents entry to insects, pests, rodents,

unauthorized personnel, dust and dirt or trash. The UV light
insecticutor systems are in place at strategic locations to ensure
further safety of products from accidental entry of flying insects.
Reference:
Program on Pest Control: GPFPL / FSMS /SOP- 13
Program on Storage of Ingredients RM/PM: GPFPL / FSMS /SOP-

31
Program on Material storage and identification: GPFPL / FSMS

/SOP- 32/33
3 Control of operation
3.1 Control of food 3.1.1 Food business operators shall control food hazards
hazards through the use of systems such as HACCP. These systems shall be
applied throughout the food chain to control food hygiene
throughout the shelf life of the product.
Remarks:- The Plant has implemented HACCP and ISO requirements (in the
process of applying for certification)
3.2 Key aspects of hygiene control systems

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3.2.1 Time and 3.2.1.1 Control systems for temperature and time during heating,
temperature cooling and storage are in place where necessary for the
control production and handling of safe food. Control systems include
critical limits, registration and testing of accuracy of measuring
equipment.
3.2.2 Specific 3.2.2.1 Other steps which contribute to food hygiene (and which
process steps must therefore be considered) may include chilling, thermal
processing, irradiation, and drying, chemical preservation, vacuum
or modified atmospheric packaging.
3.2.3 3.2.3.1 Where microbiological, chemical or physical specifications

Microbiological and are relevant for food safety, such specifications shall be based on
other specifications sound scientific principles and state, where appropriate, monitoring
procedures, action limits and analytical methods.
Remarks:- - Microbiological Testing of Coliform, Yeast & Mold, and Total

Plate Count are monitored.
- Monitoring of Microbiology include all sources like Raw Material,

packaging, Intermediate products to finished products etc. as per
FSSAI Requirements with a frequency of once in a month in the In-
house Laboratory and Once in 6 months from External NABL
Accredited Laboratory.
The cleaning and sanitation effectiveness is also verified

microbiologically by swab tests. The air microbiology in the filling
area is also monitored.(Annually)
Reference:
Program on Corrective Action: GPFPL / FSMS /SOP- 07
3.2.4 3.2.4.1 Where appropriate, effective separation of raw,

Microbiological unprocessed food from processed food applies.

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cross- 3.2.4.2 Where appropriate, access to processing areas are

contamination restricted or controlled. Access and control procedures are
defined and documented.
3.2.4.3 All surfaces, utensils, equipment, fixtures and fittings are

cleaned and where necessary, disinfected after contact with raw
food, to prevent contamination.
Remarks:- - The Programs on Access Control, Microbiology and Cleaning &

Sanitation are in place to prevent any microbial cross
contamination.
Reference:
3.2.5 Physical and 3.2.5.1 Systems are in place to prevent contamination of food
chemical products by foreign bodies (e.g. glass, metal, dust, harmful fumes)
contamination and hazardous chemicals.
3.2.5.2 Suitable and effective detection or screening devices are

used where necessary.
Remarks:- -Appropriate measures to eliminate the risk of contamination is in

place
Reference:
3.3 Incoming materials requirements
3.3.1 Specifications 3.3.1.1 No raw material or ingredient shall be accepted by an

establishment if it is known to contain parasites, undesirable micro-
organisms, pesticides, veterinary drugs or toxic, decomposed or
extraneous substances which would not be reduced to an
acceptable level by normal sorting and/or processing. Where
appropriate, specifications for raw materials shall be identified and
applied.

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Remarks:- - Supplies are from approved sources only. Raw materials are tested
and accepted as per the specifications. A well-defined program on
Incoming Material Inspection is in place.
Periodical supplier assessment in place to ensure supplier integrity
All major raw materials are accepted with Certificate of Analysis

from the supplier.
Reference:
Program on Incoming Material Inspection: GPFPL / FSMS /SOP- 29
3.3.2 Control at 3.3.2.1 Raw materials or ingredients shall, where appropriate, be

reception inspected and sorted before processing. Where necessary,
laboratory tests shall be carried out to establish fitness for use.
Only sound, suitable raw materials or ingredients shall be used.
Remarks:- - All the raw materials and ingredients are being tested and
accepted only they found satisfactory.
Reference:
Program on Incoming Material Inspection: GPFPL / FSMS /SOP- 29
3.3.3 Stock rotation 3.3.3.1 Stocks of raw materials and ingredients shall be subject to
effective stock rotation.
Remarks:- - All raw materials and ingredients received are labeled with lot
numbers and a First In First Out System is followed for the
rotation.
3.4 Packaging
3.4.1 Design and 3.4.1.1 Packaging design and materials shall provide adequate
materials protection for products to minimize contamination, prevent damage
and accommodate proper labelling.
Remarks:- Meets the requirements

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3.4.2 “Food-grade” 3.4.2.1 Packaging materials and gases shall be non-toxic and not
materials and gases pose a threat to the safety and suitability of food under the
specified conditions, storage and use.
Remarks:- Meets the requirements – Food Grade certificate from the Supplier
available.
3.4.3 Reusable 3.4.3.1 Re-usable packaging shall be suitably durable, easy to clean
packaging and, where necessary, disinfect.
3.5 Water
3.5.1 Water in 3.5.1.1 Only potable water shall be used in food handling and
contact with food processing, with the following exceptions:
- for steam production, fire control and similar purposes not

connected with food
- In certain processes (e.g. chilling) and in food handling areas
provided it does not constitute a hazard to the safety of food
Remarks:- Meets the requirement
3.5.2 Reuse of re- 3.5.2.1 Re-circulated water for re-use shall be treated and
circulated, treated maintained in such a condition that no hazards for food safety
water occur. The treatment process shall be effectively monitored.
3.5.3 Reuse of re- 3.5.3.1 Re-circulated water which has received no further
circulated, non- treatment and water recovered from processing of food by
treated water evaporation or drying may be used, provided its use does not
constitute a risk to the safety and suitability of food.
3.5.4 As an 3.5.4.1 Portable water shall be used.

ingredient

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3.5.5 Ice and steam 3.5.5.1 Ice shall be made from water complying with section 2.4.1.
Ice and steam shall be produced, handled and stored to protect
them from contamination.
3.5.5.2 Steam used in direct contact with food or food contact

surfaces shall not contain any agent which is hazardous for food
safety.
3.6 Management and supervision
3.6.1 Type of 3.6.1.1 The type of control and supervision needed will depend on
control and the size of the business, the nature of its activities and the types of
supervision food involved.
Remarks:- Well defined organization structure is in place. Roles and

responsibilities of each and every associate are defined.
3.6.2 Knowledge 3.6.2.1 Managers and supervisors shall have enough knowledge of
required food hygiene principles and practices to be able to judge potential
risks, take appropriate preventive and corrective action, and ensure
that effective monitoring and supervision takes place.
Remarks:- All the managerial and supervisory staff are trained in the recent
past (Not more than 12 months) and aware of the latest food safety
and hygiene.
Reference:
Training Program: gpfl/fsms/f-04
3.7 Documentation and records
3.7.1 Retain records 3.7.1.1 Where necessary, appropriate records of processing,

production and distribution shall be kept and retained for a period
that exceeds the shelf life of the product.

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Remarks:- Records are retained as per the FSSAI / ISO standard requirement.
Shelf Samples are retained for a total of 24 Months / 6 months

more than shelf life - whichever is higher.
Reference:
Program on control of documents & Records: GPFPL / FSMS /SOP-

04
3.7.2 Effectiveness 3.7.2.1 Documentation can enhance the credibility and

and credibility effectiveness of the food safety control system.
Remarks:-*** Document Management Program : GPFPL / FSMS /SOP- 01
3.8 Recall procedures
3.8.1 Effective 3.8.1.1 Managers shall ensure that effective procedures are in
procedures place to deal with any food safety hazard and to enable the
complete, rapid recall of any implicated batch of finished food
from the market.
Remarks:- A well-defined Product Recall Program is in place and the FSTL is

over responsible for the product recall
All the finished products are coded with their manufacturing date
and its batch number and there is two way traceability.
Tested at a frequency of once in 12 month’s at least.
Reference:
Incident management program: GPFPL / FSMS /SOP- 16
3.8.2 Tracing & 3.8.2.1 Where a product has been withdrawn because of an immediate
tracking health hazard, other products which are produced under similar
conditions, and which may present a similar hazard to public health,
shall be evaluated for safety and may need to be withdrawn. The
need for public warnings shall be considered.

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Remarks:- A well-defined Product Recall Program is in place and the MD is

over responsible for the product recall
All the finished products are coded with their manufacturing date
and its batch number with two way traceability.
Reference:
Program on product recall : GPFPL / FSMS /SOP- 15
3.8.3 Destroy or 3.8.3.1 Recalled products shall be held under supervision until
reprocess they are destroyed, used for purposes other than human
consumption, determined to be safe for human consumption, or
reprocessed in a manner to ensure their safety.
Remarks:- Program on Control of non-conforming products is in place.

Quarantine products are segregated in designated areas under
supervision. Destruction and disposal of non-conforming products
happens as per the system requirement.
Reference:
Program on handling of Non-conforming material & Product;

GPFPL / FSMS /SOP- 17
4 Establishment: maintenance and sanitation
4.1 Maintenance and cleaning
4.1.1 General 4.1.1.1 Establishments and equipment shall be kept in an appropriate

state of repair and condition to:
- facilitate all sanitation procedures;

- function as intended, particularly at critical steps;
- Prevent contamination of food, e.g. from metal shards, flaking
plaster, debris and chemicals.
4.1.1.2 Cleaning shall remove food residues and dirt that may be a
source of contamination. The necessary cleaning methods and
materials will depend on the nature of the food business.
Disinfection may be necessary after cleaning.

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4.1.1.3 Cleaning chemicals shall be handled and used carefully and

in accordance with manufacturers’ instructions
4.1.1.4 Cleaning chemicals shall be stored, where necessary,

separately from food, in clearly identified containers to avoid the
risk of (malicious or accidental) contamination of food.
Remarks:- A System of Cleaning & Sanitation is available. Chemical stored at

designated areas separately under lock & Control under the
custody of Asst Manager - QA / QC Team Members.
Reference:
4.1.2 Cleaning 4.1.2.1 The cleaning and disinfecting method(s) shall be specified
procedures and and documented. The water used will comply with section 2.4.1.
methods Contamination of food with cleaning chemicals shall be prevented.
Remarks:- A well-defined cleaning and sanitation program is in place. All

cleaning and sanitation chemicals are listed out and are procured
from only authorized suppliers
Reference:
4.2 Cleaning programs

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4.2.1 Specifications 4.2.1.1 Cleaning and disinfection programs shall ensure that all
parts of the establishment are appropriately clean, and shall
include the cleaning of
Cleaning equipment.
Where documented cleaning programs are used, they shall specify:
- areas, items of equipment and utensils to be cleaned;
- responsibility for particular tasks;
- method and frequency of cleaning;
- monitoring arrangements.
Where appropriate, programs shall be drawn up in consultation
with relevant expert advisors.
Remarks:- The specifications meet all the requirements
Reference:
Authorized Testing methods and frequencies supplied by Corporate
Office.
4.2.2 Monitoring and 4.2.2.1Cleaning and disinfection programs shall be continually and
verification effectively monitored for their suitability and effectiveness and
where necessary, documented.
Remarks:- Each cleaning activities are monitored by the area in-charges. The
QA Manager is overall responsible for the effectiveness of the
program.
Reference:
4.3 Pest control
4.3.1 General 4.3.1.1 Good hygiene practices shall be employed to avoid creating
an environment conducive to pests. Good sanitation, inspection of
incoming materials and effective monitoring can minimize the
likelihood of infestation and thereby limit the need for pesticides.

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Remarks:- Pest control program in place including Infestation, Rodent

control. Use of non-residual and approved chemicals only.
Professional licensed services provider is being utilized.
Professional Service provider with contractual agreement are
used. Documents available for inspections at all given point of time
in the site.
Reference:
Program on Good Manufacturing Practices: GPFPL / FSMS /SOP-

09
4.3.2 Preventing 4.3.2.1 Buildings shall be kept in good repair and condition to
access prevent pest access and to eliminate potential breeding sites.
4.3.2.2 Holes, drains and other places where pests are likely to gain
access shall be kept sealed. Where sealing is not possible (e.g. open
windows, doors and ventilators) measures like wire mesh screens
shall be in place to reduce the problem of pest entry.
4.3.2.3 Animals shall, wherever possible, be excluded from the

grounds of factories and food processing plants.
Remarks:- Window panes of process area are permanently closed. Doors

provided with Strip curtains wherever required.
Reference:
4.3.3 Harbourage 4.3.3.1 Potential food sources shall be stored in pest-proof

and infestation containers and/or stacked above the ground and away from walls.
4.3.3.2 Areas both inside and outside food premises shall be kept
clean.
Where appropriate, refuse shall be stored in covered, pest-proof

containers.

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Remarks:- Good Housekeeping practices in place. No water stagnation

allowed near process area
Reference:
Program on Pest control : GPFPL / FSMS /SOP- 13
4.3.4 Monitoring and 4.3.4.1 Records of regular examination of establishments and

detection surroundings shall be available.
Remarks:- Pest control activity records are available
Reference:
4.3.5 Eradication 4.3.5.1 Pest infestations shall be dealt with immediately and shall
be carried out without posing a threat to the safety or suitability of
food.
Remarks:- Use of Non residual chemical. Process areas excluded from use of
chemicals
Reference:
Program on Pest control; GPFPL / FSMS /SOP- 13
4.4 Waste management
4.4.1 Removal, Suitable provision must be made for the removal and storage of
storage waste.
Waste must not be allowed to accumulate in food handling, food

storage,
and other working areas and the adjoining environment except so

far as is
Unavoidable for the proper functioning of the business.

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Remarks:- Collection and storage of waste at defined intervals and storage

places. Disposal as per written procedures is in place. The waste
materials are discarded through authorized vendor where in the
company has a written valid agreement
Reference:
Program on Waste Management: GPFPL / FSMS /SOP- 26
4.4.2 Cleaning Waste stores must be kept appropriately clean.
4.5 Sanitation systems
4.5.1 Monitoring 4.5.1.1 Sanitation systems shall be monitored for effectiveness
Remarks:- Sanitation Systems are In Place
Reference:
4.5.2 Verification 4.5.2.1. Sanitation systems shall be periodically verified by

inspections or, where appropriate, by microbiological sampling of
environment and food contact surfaces and regularly reviewed
and adapted to reflect changed circumstances.
Remarks:- Verification by microbiology monitoring as per the FSSAI / ISO

Standard.
Reference:
HACCP Documents
4.5.3 Review 4.5.3.1 Sanitation systems shall be regularly reviewed and adapted
to reflect changed circumstances.
Remarks:- Reference:

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5 Establishment: personal hygiene
5.1 Health status
5.1.1 Access 5.1.1.1 A system shall be in place to prevent access to any food
prevention handling area by people known, or suspected to be suffering from,
or to be a carrier of, a disease or illness likely to be transmitted
through food.
5.1.1.2 Any person so affected shall immediately report illness or
symptoms of illness to the management. Medical examination of a
food handler shall be carried out if clinically or epidemiologically
necessary.
Remarks:- Regular Medical Check up to all the associates on a yearly basis as
per the guidelines of FSSAI. The plant has made the workmen aware
to report illness to their respective supervisors. The management
decides to locate the suffering workman in non-sensitive work
areas.
Appropriate procedures are in place
Reference:
Program on Personnel Hygiene : GPFPL / FSMS /SOP- 11
5.2 Illness and injuries
5.2.1 Conditions to 5.2.1.1 Conditions which shall be reported to management in order

be reported to assess the need for medical examination and/or possible
exclusion from food handling, include:
- jaundice
- diarrhoea
- vomiting
- fever
- sore throat with fever
- Visibly infected skin lesions (boils, cuts, etc.)
- discharges from the ear, eye or nose

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Remarks:- Medical Examination reveals any diseases that are exist at that time.
Regular observation by area supervisors will lead to further
actions required. All the food handlers have been administered the
vaccination as per the requirements of the FSSAI requirements.
Reference:
5.3 Personal cleanliness

5.3.1 Protective 5.3.1.1 Food handlers shall maintain a high degree of personal
clothing cleanliness and, where appropriate, wear suitable protective
clothing, head covering and foot wear.
Remarks:- Hair covering is mandatory to access process area. Protective
Equipment like Masks, Ear Plugs and safety equipment are mandatory
wherever applicable inside the plant
Reference:
Program on Good manufacturing Practices: GPFPL / FSMS /SOP-09
5.3.2 Cuts and 5.3.2.1 When personnel with a minor injury are permitted to
wounds continue working, cuts and wounds shall be covered by suitable
waterproof dressings.
Remarks:- Area supervisors will act on these issues as and when arises
5.3.3 Washing hands 5.3.3.1 Personnel shall always wash their hands when personal
cleanliness may affect food safety, for example:
- at the start of food handling activities;
- immediately after using the toilet; after handling raw food or any
contaminated material which could result in contamination of
other food items; they shall avoid handling ready-to-eat food, where
appropriate.

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Remarks:- Wash facilities provided at toilets and at process areas entrance
Reference:
Program on good Manufacturing Practices: GPFPL / FSMS /SOP-09
5.4 Personal behavior
5.4.1 Smoking, 5.4.1.1 People engaged in food handling activities shall refrain
eating, sneezing from behaviour which could result in contamination of food, for
example:
smoking;
spitting;
chewing or eating;
sneezing or coughing over unprotected food.
Remarks:- Smoking, Spitting, Chewing, eating activities are strictly prohibited

inside the plant and process areas except designated areas. The
areas are specifically marked.
Reference:
5.4.2 Jewellery 5.4.2.1 Personal effects such as jewellery, watches, pins or other
items shall not be worn or brought into food handling areas if they
pose a threat to the safety and suitability of food.
Remarks:- Personnel working in the process areas are not allowed to wear
loose jewellery.
Reference:
5.5 Visitors

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5.5.1 Cleanliness 5.5.1.1 Visitors to food manufacturing, processing or handling

and behaviour areas shall, where appropriate, wear protective clothing and adhere to
the other personal
Hygiene provisions in this section.
Remarks:- Visitors wear caps and assigned to the respective area

supervisors/chemists and permitted by following GM practices
strictly.
6 Transportation
6.1 General 6.1.1 Food shall be adequately protected during transport to

assure food safety.
Remarks:- Intact packing material will be used for finished products during
transportation
6.2 Requirements 6.2.1 Where necessary, conveyances and bulk containers shall be
designed and constructed so that they:
- do not contaminate foods or packaging;
- can be effectively cleaned and, where necessary, disinfected;
- permit effective separation of different foods or foods from non-

food items where necessary during transport;
- provide effective protection from contamination, including dust

and fumes;
- can effectively maintain the temperature, humidity, atmosphere and

other conditions necessary to protect food from harmful or
undesirable microbial growth and deterioration likely to render it
unsuitable for consumption;
- allow any necessary temperature, humidity and other conditions to

be checked.
Remarks:- Food will be stored in solid intact LDPE Materials with secondary
package of woven sac bags. Defective packages will be removed at
on line inspection stage it self

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6.3 Use and 6.3.1 Conveyances and containers for transporting food shall be
maintenance kept in an appropriate state of cleanliness, repair and condition.
6.3.2 Where the same conveyance or container is used for

transporting different foods or non-foods, effective cleaning and,
where necessary, disinfection shall take place between loads.
6.3.3 Where appropriate, particularly in bulk transport, containers

and conveyances shall be designated and marked for food use only
and be used only for that purpose.
7 Product information and consumer awareness

7.1 Batch 7.1.1 Batch identification is essential in product recall and also
identification helps effective stock rotation (section 3.2.3). Each container of
food shall be permanently marked to identify the producer and the
batch (see: Codex General Standard for the Labelling of Pre-
packaged Foods, Codex STAN 1-1985).
Remarks:- All incoming and finished products are identified by its batch codig
system
7.2 Product 7.2.1 All food products shall be accompanied by or bear adequate
information information to enable the next person in the food chain to handle,
display, store, prepare and use the product safely and correctly.
Remarks:- Products are accompanied with adequate information as per legal

& Statutory requirements.
7.3 Labelling 7.3.1 Pre-packaged foods shall be labelled with clear instructions
to enable the next person in the food chain to handle, display, store
and use the product safely (see: Codex General Standard for the
Labelling of Pre-packaged Foods, Codex STAN 1-1985).
Remarks:- Not applicable

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7.4 Consumer 7.4.1 Health education programs shall cover general food hygiene.
education Such programs shall enable consumers to understand the
importance of any product information, follow any instructions
accompanying products and make informed choices. In particular,
consumers shall be informed of the relationship between
time/temperature control and food-borne illness.
Remarks:- Information provided regarding ingredients, etc wherever

applicable and as per regulatory requirement
8 Training
8.1 Awareness and 8.1.1 All personnel shall be aware of their role and responsibility
responsibilities in protecting food from contamination or deterioration.
8.1.2 Food handlers shall have the necessary knowledge and skills
to enable them to handle food hygienically. Those who handle
strong cleaning chemicals or other potentially hazardous
chemicals shall be instructed in safe handling techniques.
Remarks:- All employees are trained on food safety and their roles and
responsibilities in handling food products to prevent any
contamination or deterioration.
Training on HACCP to all employees is being conducted.
Reference:
Program on Training: GPFPL/FSMS/F-04
8.2 Training 8.2.1 Factors to take into account in assessing the level of training
programs required include:
- the nature of the food, in particular its ability to sustain growth

of pathogenic or spoilage micro-organisms;
- the manner in which the food is handled and packed, including
the probability of contamination;
- the extent and nature of processing or further preparation
before final consumption;
- the conditions under which the food will be stored;
- the expected length of time before consumption.

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Remarks:- The training on HACCP Food Safety includes all the said
requirements
Reference:
8.3 Instruction and 8.3.1 Periodic assessments of the effectiveness of training and
supervision instruction program shall be carried out, as well as routine
supervision and checks to ensure that procedures are being
implemented effectively.
8.3.2 Managers and supervisors of food processes shall have the

necessary knowledge of food hygiene principles and practices to be
able to judge potential risks and take the necessary action to
remedy deficiencies (see section 3.5).
Remarks:- A well-defined Training Program is in place and the effectiveness of

the training is being assessed periodically.
Supervisory and Managerial level Staff are aware of Food Safety

Management System (ISO 22000) requirement
Reference:
8.4 Refresher 8.4.1 Training programs shall be routinely reviewed and updated
training where necessary.
8.4.2 Systems shall be in place to ensure that food handlers remain

aware of all procedures necessary to maintain the safety and
suitability of food.
Remarks:- Based on the Skill Gap Analysis, the associates are evaluated. Based
on the Skill Matrix, the associates being provided with a required
awareness/ refresher training.
Reference:

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7.10. Internal Audit and Corrective Action:
Internal Audits of HACCP will be carried out on a Half yearly basis as similar to
the to the requirements of Codex Alimentarius . Refer the Program on Internal
Audit
7.11 Management Review
Management Review committee meeting is scheduled once in 6 months where in

the top Management will discuss and review the HACCP System Implementation
and its effectiveness along with other Systems which are in place.
7.12 Resources:
The management is committed to give any of the following resources, as

appropriate, for the effective implementation of HACCP System:
 Internal and External Experts

 Staff Training
 Purchasing materials/equipment related to process improvements/monitoring
 Manpower
Also refer to Management Commitment (Clause 6.1) of the HACCP manual.
 External Information
7.13 HACCP Validation
HACCP validation is performed to ensure that the hazards are originally

identified by the HACCP teams are complete and correct and that they will be
effectively controlled under the proposed plan. HACCP validation will be
conducted each time when the food business operation changes in a manner that
could adversely affect food safety.
Reference: Quality manual
Validation report

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7.14 HACCP Verification
The purpose of verification is to determine compliance with the specifications

of the HACCP system and to confirm that the HACCP system is working
effectively through the application of auditing methods, procedures, tests etc.
The organization has established documented procedure for verification of the

HACCP system.
Reference: Quality manual.
7.15 Applicable Legislation:
FSSAI Requirements.
Legal Metrology Requirements, Govt of India.
Regional area guidelines (Corporation/ BBMP, etc.)

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GARUDA POLYFLEX FOODS PVT LTD.

Sl:NO Description Page No

Prepared By: Approved By:

1. Introduction to GARUDA POLYFLEX FOODS PVT LTD., BENGALURU.

1.1 Unit description

Gone Mad is the endearing expression of the inherent need in all of

Prepared By: Approved By:

We are a transformation making company creating value to society by

Quality is at the forefront of our work process something that

M/s: Garuda Polyflex Foods Pvt Ltd.,

Office: +91 80 2801 0500

Prepared By: Approved By:

1.2 Products and Packages

CHOCO STRAWBERRY STICK

Prepared By: Approved By:

CASHEW MITHAI STICK

PREMIUM WAFER STICK

1) PREMIUM COFFEE STICK

2) PREMIUM BADAM STICK

3) PREMIUM DARK CHOCO STICK

Prepared By: Approved By:

PREMIUM COFFEE PREMIUM BADAM PREMIUM DARK CHOCO

Prepared By: Approved By:

1) SUGAR CHEESE CRACKER

Prepared By: Approved By:

FESTIVE GIFT PACKS

CHOCO STICK 1+1

Prepared By: Approved By:

1.3 Plant Quality System

1.4 Status of Quality Management Systems

1.5. CSR - CORPORATE SOCIAL RESPONSIBILITY

At GP Foods we believe in helping our local communities with an emphasis on employee

Prepared By: Approved By:

2. Introduction to HACCP System.

Traditionally, industry and regulators have depended on spot-checks of

Prepared By: Approved By:

1. Analyze hazards: Potential hazards associated with a food and measures to

Prepared By: Approved By:

2. Identify critical control points: These are points in a food’s production

Need for HACCP

Prepared By: Approved By:

causes of food-borne illness—such as Escherichia coli O157:H7 and Salmonella

There also is increasing public health concern about chemical contamination

Prepared By: Approved By:

 The most important advantage is “ Safety”, Wholesomeness & Prevention of

4. GOOD MANUFACTURING PRACTICES GUIDELINES

Good Manufacturing Practices or pre-requisite programs are programs that

 Premises - Outside Property, Building, Sanitary facilities, Water Quality

Prepared By: Approved By:

 Building: Facilities are designed, constructed and maintained in good repair

 Stairs, elevators, overhead structures and other structures are well

 Adequate lighting is provided throughout the facility. Natural light /

 Adequate ventilation is provided to prevent steam, condensation, dust and

Prepared By: Approved By:

Areas where employees are in direct contact with microbiologically sensitive

Water/Steam/Ice Quality program

Running water at suitable temperature, and under pressure as needed, are

There is no cross-contamination between potable water and non-potable

Prepared By: Approved By:

4.2 Transportation and Storage

All ingredients, raw material, packaging material or other incoming material

The facility is maintaining stock rotation of raw material, ingredients,

4.3 Equipment performance and maintenance