HACC Plan For Majdi

FAMILIES, SUB FAMILIES & EQUIPMENTS (According to the product cards)
Sl.No. Family Sub Family whole spices ANISEED BLACK PEPPER CARDAMOM CARAWAY CASSIA CHILLI CHILLI EXTRA HOT CINNAMON CORIANDER CUMIN FENNEL FENUGREEK GARLIC GINGER KHOLINJAN MACE NUTMEG PIMENTO ONION FLAKES TAMARIND DILL SEEDS SESAME KHALONJI CASSIA CORIANDER CUMIN FENNEL FENUGREEK CHILLI GINGER BLACK PEPPER CARDAMOM PIMENTO Products Equipment
SPICES
Ground Spices
WHOLE GROUND
BERYANI SPICES BEYANI SEASONING CURRY SEASONING KUWAITI SEASONING SEAFOOD SEASONING CHICKEN SEASONING MEAT SEASONING KABSA SEASONING TANDOORI SEASONING
MIXED SPICES
HERBS
SAFFRON THYME CAMOMILE SUMMAC OREGANO SAGE LEAVES BAY LEAVES MINT LEAVES LEMON GRASS ROSEMARY BASIL LEAVES PARSLEY LEAVES DILL LEAVES FENUGREEK LEAVES MARJORAM CORIANDER LEAVES HABISCUS MOLOKIYA LEAVES BLACK EYE BEANS LIMA BEANS WHITE BEANS SOYA BEANS LIGHT RED KIDNEY BEANS LUPINES CHANNA DAL CHANNA WHOLE BLACK JUMBO CHICK PEAS MASOOR DAL RED MASOOR BROWN MUNG BEANS BLACK MOUNG BEANS GREEN MUNG DAL GREEN MUNG DAL YELLOW RED CHAWLI URID DAL
BEANS
GRAINS
BURGUL WHEAT POPCORN PINE NUTS RAISINS DRY LEMON COCONUT D/C CRUSHED COCONUT D/C FINE LUMP SUGAR ICING SUGAR SAGO CITRIC ACID SAFFRON COLOR MEAT TENDERIZER AJENO MOTTO CORN STARCH HONEY
DRY FRUITS
FOOD ADDITIVES
HACCP Plan 01
Family Name Products in family
1 2
spices ( As linked )
3
Sub family- whole spices
Process Flow
4 5 6 Potential hazards introduced, controlled or enhanced at this step. 7 Are any potential foodsafety hazards significant? (Yes/No)
Sev. 10 Raw materail Receving Certificate of Analysis ; Accpetance Criteria Warehouse Manager /QA Technnician Incoming inspection Report Biological : pathogens ; Hygiene indicators ; insects, microbes Chemical : Pesticides ;Hormones High Occ. Low Con. Yes
Process #
Process steps
Control Measure
Responsibility
Ref. doc/ record
High
Low
Yes
Physical : Glass , Dust , metal particles , etc 20 Storing Cleanliness Store controller Stock register Biological : Personal Hygiene
High
Low
Yes
High
Low
Yes
High Chemical : marking ink Physical : Packing material or cutting equipment particles , etc 30 cleaning removal of extraneous matters Operator cleaning room register Biological : Personal Hygiene Chemical : Nil High
Low
Yes
Low
Yes
High High
Low Low
Yes x
High Physical : Dust , metal particles , etc
Low
Yes
40
Packing
accuracy of weight
Operator
PRP - SOP
Biological : Personal Hygiene Chemical : Bins / container cross contamination, Printing ink
High
Low
Yes
High
Low
High Physical : previous items 50 cartoning number of pieces operator SOP Biological : Personal Hygiene Chemical : Nil Physical : Nil High x x
Low
yes
Low x x
Yes x x
60
Weighting
accuracy of weight
Foreman
Machine Log
Biological : Nil Chemical : Bins / containers cross contamination
x High
x Low
x Yes
x Physical : Nil 70 Storing & transportation Temperature Store controller SOP Biological : Chemical : Nil Physical : Nil Nil x x x
x x x
x x x
Hazard Analysis
8 9 10 11 12 Critical limits for each preventive measure Significant What control measures can be Justify your decisions for column Is this step a Critical hazards applied to prevent the significant 7. Control Point? related to hazards? CCP
(Yes/No) Possible contamination of food with Approved Supplier; Receiving pathogenic microorganism like inspection;cleaning,Cooking before Salmonella spp. consumption Because the food may be farmed at suppler end. which may be contaminated Metal pieces can be present in product at suppler end. Also during receiving chances of physical contamination are more Handling of products may cause pathogenic contamination ink used in the marker may introduced if not properly handled Approved Supplier; Receiving inspection; Subsequent step cleaning & Metal detecting will remove all physical pieces. PRP & SSOP No x x
Corrective Action planning
Process Monitoring
Corrective actions Who x x
Records Verifications
What x
How x
Frequency x
No
No
No
PRP & SSOP
No
Subsequent step cleaning & Metal Metal / packing pieces can be detecting will remove all physical present in product from supplier end pieces. Handling of products may cause pathogenic contamination x Improper cleaning/change of bins/container.Metal /packing pieces can be present during unpacking PRP & SSOP x Subsequent step Metal detecting will remove all physical pieces.
No
No x Cross Contaminatio n No Foreign particles Cleanlin produc Re inspection. CCP Daily record ess of proces tion 100% Remove / Monitorin review by containe s check inspection Superv Reject g log QA rs isor
Yes ( CCP 1)
Handling of products may cause pathogenic contamination Printing ink may be introduced if not properly handled previously packed item may be introduced if the packing machine not cleaned properly Handling of products may cause pathogenic contamination x x
PRP & SSOP
No
PRP & SSOP
No
PRP & SSOP
No
PRP & SSOP x x
x No x
x improper cleanliness or change of of Bins / Containers
x PRP & SSOP
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x
Yes ( CCP 1)
x x x
Cross Contaminatio n x x x
No Foreign particles
Cleanlin produc Re inspection. CCP Daily record ess of proces tion 100% Remove / Monitorin review by containe s check inspection Superv Reject g log QA rs isor x x x x x x x x x x x x x x x x x x x x x
x x x
x x x
x x x
HACCP Plan 02
1 2
Mixed Spices ( As linked )
Process Flow
3 4 5 6 Potential hazards introduced, controlled or enhanced at this step. 7
Hazard Analysis
8 9 10 Are any potential foodWhat control measures can be Justify your decisions for column Is this step a Critical safety hazards applied to prevent the significant 7. Control Point? significant? (Yes/No) hazards?
Sev. Occ. Low Con. Yes Possible contamination of food Approved Supplier; Receiving with pathogenic microorganism like inspection;Cooking before Salmonella spp. consumption Because the food may be farmed at suppler end. which may be contaminated Metal pieces can be present in product at suppler end. Also during receiving chances of physical contamination are more Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Approved Supplier; Receiving inspection; Subsequent step Washing & Metal detecting will remove all physical pieces. PRP & SSOP (Yes/No) No
Process #
Process steps
Control Measure
Responsibility
Ref. doc/ record
10
Raw materail Receving
Certificate of Analysis ; Accpetance Criteria
Production Supervisor /QA Technnician
Incoming inspection Report
Biological : pathogens ; Hygiene indicators ;Nematodes Chemical : Antibiotics ; Pesticides ;Hormones
High
High
Low
Yes
No
Physical : Glass , Dust , metal particles , etc 20 Unpacking No foreign parts Operator Daily Hygiene Check list Biological : Personal Hygiene
High
Low
Yes
No
High
Low
Yes
No
High Chemical : Physical : Packing material or cutting equipment particles , etc 30 cleaning removal of extraneous matters Operator cleaning room register Biological : Personal Hygiene Chemical : Nil High
Low
Yes
PRP & SSOP
No
Low
Yes
Subsequent step Washing & Metal Metal / packing pieces can be detecting will remove all physical present in product during unpacking pieces. Handling of products may cause pathogenic contamination x Improper cleaning/change of bins/container.Metal /packing pieces can be present during unpacking Handling of products may cause pathogenic contamination improper cleanliness or change of of Bins / Containers x Handling of products may cause pathogenic contamination x Wear & tear of machine parts ( direct food contact surfaces ) temperature abuse ,may cause bacterial growth Sanitizer used for cleaning of equipment may remain Wear & tear of machine parts ( direct food contact surfaces ) PRP & SSOP x Subsequent step Metal detecting will remove all physical pieces.
No
High High High
Low Low Low
Yes x Yes
No x
Physical : Dust , metal particles , etc 40 Weighting accuracy of weight Foreman Machine Log Biological : Personal Hygiene Chemical : Bins / containers cross contamination Physical : Nil 50 Mixing sequence & timing Supervisor SOP Biological : Personal hygiene Chemical : Nil Physical : Machine internal spear parts particles Biological : Bacterial growth Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles
Yes ( CCP 1)
No
High
Low
Yes
PRP & SSOP
High x High High High High High High
Low x Low Low Med. Low Low Med.
Yes x Yes Yes Yes Yes Yes Yes
PRP & SSOP x PRP & SSOP PRP & SSOP PRP & SSOP PRP & SSOP PRP & SSOP PRP & SSOP
No
x
x
No No No No N0
60
Grinding
powdering
Operator
SOP
70
Mixing
sequence & timing
Supervisor
SOP
Biological : Change in test or colour Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles
High
Low
Yes
High
Low
Yes
High
Med.
Yes
temperature abuse or cnage or delay in mixing may cause bacterial growth Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) temperature abuse or change or delay may cause bacterial growth Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) Handling of products may cause pathogenic contamination
PRP & SSOP
no
No
PRP & SSOP
PRP & SSOP
No
80
bagging
Wieght per bag
Operator
Standrad Product wight SOP Biological : Bacterial growth Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
PRP & SSOP
No
High
Med.
Yes
PRP & SSOP
No
90
storing
Temperature
Operator
SOP
Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Machine particles , etc
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
High
Low
Yes
Sanitizer used for cleaning of PRP & SSOP equipment may remain, if not allowed proper drying time Metal / packing pieces can be Subsequent step Metal detecting will present in product during unpacking remove all physical pieces. Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x x x x temperature abuse ,may cause bacterial growth x x PRP & SSOP
No
No
100
Packing
number of pieces
Operator
PRP - SOP
Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil
High
Low
Yes
No
High x Nil x x x High x x
Low x x x x Low x x
Yes x x x x Yes x x
PRP & SSOP x x x x PRP & SSOP x x
No x x x x No x x
110
Cartuning
number of pieces
operator
SOP
120
Storing & transportation
Temperature
Store controller
SOP
Biological : Chemical : Nil Physical : Nil Biological : Bacterial growth Chemical : Nil Physical : Nil

11 Significant hazards related to CCP 12 Critical limits for each preventive measure
What x x x How x
Process Monitoring
Frequency x
Who x
Corrective actions x
Records x
Verifications x
Cross Contamination
Cleanliness of production process check 100% inspection containers Supervisor
Re inspection. Remove / Reject
CCP Monitoring log
Daily record review by QA
x x x x x x X X
x x x x x x X X
x x x x x x X X
x x x x x x X X
x x x x x x X X
x x x x x x X X
x x x x x x X X
x x x x x x X X
x x x x x x X X
Change in test or colour
As per Reciep plan
Test & colour
Sequence & time x
100 % inspection x
production Supervisor x
Rework / Reject
CCP Monitoring log x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
HACCP Plan 03
1 2
Herbs ( As linked )
Process Flow
Hazard Analysis
Sev. Occ. Low Con. Yes Possible contamination of food Approved Supplier; Receiving with pathogenic microorganism like inspection;Cooking before Salmonella spp. consumption Because the food may be farmed at suppler end. which may be contaminated Metal pieces can be present in product at suppler end. Also during receiving chances of physical contamination are more Handling of products may cause pathogenic contamination improper cleanliness or change of of Bins / Containers Approved Supplier; Receiving inspection; Subsequent step Washing & Metal detecting will remove all physical pieces. PRP & SSOP (Yes/No) No
Process #
Process steps
Control Measure
Responsibility
Ref. doc/ record
10
High
High
Low
Yes
No
Physical : Glass , Dust , metal particles , etc 60 Weighting accuracy of weight Foreman Machine Log Biological : Personal Hygiene
High
Low
Yes
No
High
Low
Yes
No
Chemical : Bins / containers cross contamination
High
Low
Yes
PRP & SSOP
Yes ( CCP 1)
x Physical : Nil 110 Packing number of pieces Operator PRP - SOP Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil 120 Cartuning number of pieces operator SOP Biological : Chemical : Nil Physical : Nil Biological : Bacterial growth Chemical : Nil Physical : Nil Nil High
x Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x x x x temperature abuse ,may cause bacterial growth x x
Low
Yes
PRP & SSOP
No
High x x x x High x x
Low x x x x Low x x
Yes x x x x Yes x x
No x x x x No x x
130
Temperature
Store controller
SOP

What x x x How x
Process Monitoring
Frequency x
Who x
Records x
Verifications x
Cross Contamination
Cleanliness of production process check 100% inspection containers Supervisor
Re inspection. Remove / Reject
CCP Monitoring log
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
HACCP Plan 04
1 2
Beans ( As linked )
Process Flow
Hazard Analysis
Process #
Process steps
Control Measure
Responsibility
Ref. doc/ record
10
High
High
Low
Yes
No
High
Low
Yes
No
High
Low
Yes
No
Chemical : Sanitizer for Machines Physical : Packing material or cutting equipment particles , etc 30 Weighting accuracy of weight Foreman Machine Log Biological : Personal Hygiene Chemical : Bins / containers cross contamination Physical : Nil 40 Cleaning Visual Inspection Operator Daily Hygiene Check list Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil 50 Weighting accuracy of weight Foreman Machine Log Biological : Personal Hygiene Chemical : Bins / containers cross contamination Physical : Nil 60 Packing number of pieces Operator PRP - SOP Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
Subsequent step Washing & Metal Metal / packing pieces can be detecting will remove all physical present in product during unpacking pieces. Handling of products may cause pathogenic contamination improper cleanliness or change of of Bins / Containers x Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x Handling of products may cause pathogenic contamination improper cleanliness or change of of Bins / Containers x Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x PRP & SSOP
No
High
Low
Yes
No
High x High
Low x Low
Yes x Yes
PRP & SSOP x PRP & SSOP
Yes ( CCP 1)
x No
High x High
Low x Low
Yes x Yes
No x No
High x High
Low x Low
Yes x Yes
Yes ( CCP 1)
x No
High x
Low x
Yes x
PRP & SSOP x
No x
70
Cartuning
number of pieces
operator
SOP
80
Temperature
Store controller
SOP
Biological : Chemical : Nil Physical : Nil Biological : Bacterial growth Chemical : Nil Physical : Nil
Nil
x x x High x x
x x x Low x x
x x x Yes x x
x x x temperature abuse ,may cause bacterial growth x x
x x x PRP & SSOP x x
x x x No x x

What x x x How x
Process Monitoring
Frequency x
Who x
Records x
Verifications x
Cross Contamination x
No Foreign particles x
Cleanliness of production process check 100% inspection containers Supervisor x x x x
Re inspection. Remove / Reject x
Daily record review by QA x
Cross Contamination x x
No Foreign particles x x
Cleanliness of production process check 100% inspection containers Supervisor x x x x x x x x
Re inspection. Remove / Reject x x
CCP Monitoring log x x
Daily record review by QA x x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x x x x x
x x x x x x
x x x x x x
x x x x x x
x x x x x x
x x x x x x
x x x x x x
x x x x x x
x x x x x x
HACCP Plan 05
1 2
Dry Fruits ( As linked )
Process Flow
Hazard Analysis
Process #
Process steps
Control Measure
Responsibility
Ref. doc/ record
10
High
High
Low
Yes
No
High
Low
Yes
No
High
Low
Yes
No
Chemical : Sanitizer for Machines Physical : Packing material or cutting equipment particles , etc 40 Cleaning Visual Inspection Operator Daily Hygiene Check list Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil 60 Weighting accuracy of weight Foreman Machine Log Biological : Personal Hygiene Chemical : Bins / containers cross contamination Physical : Nil 110 Packing number of pieces Operator PRP - SOP Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil 120 Cartuning number of pieces operator SOP Biological : Chemical : Nil Physical : Nil Biological : Bacterial growth Chemical : Nil Nil
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
Subsequent step Washing & Metal Metal / packing pieces can be detecting will remove all physical present in product during unpacking pieces. Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x Handling of products may cause pathogenic contamination improper cleanliness or change of of Bins / Containers x Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x x x x temperature abuse ,may cause bacterial growth x PRP & SSOP
No
High
Low
Yes
No
High x High
Low x Low
Yes x Yes
No x No
High x High
Low x Low
Yes x Yes
Yes ( CCP 1)
x No
High x x x x High x
Low x x x x Low x
Yes x x x x Yes x
PRP & SSOP x x x x PRP & SSOP x
No x x x x No x
130
Temperature
Store controller
SOP
Physical : Nil

What x x x How x
Process Monitoring
Frequency x
Who x
Records x
Verifications x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
HACCP Plan 06
1 2
Food Additives ( As linked )
Process Flow
Hazard Analysis
Process #
Process steps
Control Measure
Responsibility
Ref. doc/ record
10
High
High
Low
Yes
No
High
Low
Yes
No
High
Low
Yes
No
Chemical : Sanitizer for Machines Physical : Packing material or cutting equipment particles , etc 30 Weighting accuracy of weight Foreman Machine Log Biological : Personal Hygiene Chemical : Bins / containers cross contamination Physical : Nil 40 Packing number of pieces Operator PRP - SOP Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil 50 Cartuning number of pieces operator SOP Biological : Chemical : Nil Physical : Nil Biological : Bacterial growth Chemical : Nil Physical : Nil Nil
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
Subsequent step Washing & Metal Metal / packing pieces can be detecting will remove all physical present in product during unpacking pieces. Handling of products may cause pathogenic contamination improper cleanliness or change of of Bins / Containers x Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x x x x temperature abuse ,may cause bacterial growth x x PRP & SSOP
No
High
Low
Yes
No
High x High
Low x Low
Yes x Yes
Yes ( CCP 1)
x No
Low x x x x Low x x
Yes x x x x Yes x x
No x x x x No x x
60
Temperature
Store controller
SOP

What x x x How x
Process Monitoring
Frequency x
Who x
Records x
Verifications x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
HACCP Plan 07
1 2
( As linked )
Process Flow
Hazard Analysis
Process #
Process steps
Control Measure
Responsibility
Ref. doc/ record
10
High
High
Low
Yes
No
High
Low
Yes
No
High
Low
Yes
No
Chemical : Sanitizer for Machines Physical : Packing material or cutting equipment particles , etc 40 Cleaning / Pilling of veigitables Visual Inspection Operator Daily Hygiene Check list Biological : Personal Hygiene
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
Subsequent step Washing & Metal Metal / packing pieces can be detecting will remove all physical present in product during unpacking pieces. Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x Water used for cleaning may have bacteria Not correct proportion for sanitizer Water used for cleaning may have dust / sand particles Handling of products may cause pathogenic contamination improper cleanliness or change of of Bins / Containers x temperature abuse ,may cause bacterial growth Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) PRP & SSOP
No
High
Low
Yes
No
50
Washing & Sanitizing
removal of dust or any solid particles
Hygiene Supervisor
Chemical : Sanitizer for Machines Physical : Nil Biological : Daily Hygiene Check list ( QA/F Bacteria Chemical : Sanitizer & Water Physical : dust / sand particles
High x High High High High
Low x Low Low Med. Low
Yes x Yes Yes Yes Yes
PRP & SSOP x Water purification System PRP & SSOP Water purification System PRP & SSOP
No x No No No No
60
Weighting
accuracy of weight
Foreman
Machine Log
Biological : Personal Hygiene Chemical : Bins / containers cross contamination Physical : Nil Biological : Bacterial growth Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles
High x High High
Low x Low Low
Yes x Yes Yes
PRP & SSOP x PRP & SSOP PRP & SSOP
Yes ( CCP 1)
x No No
70
Minceng
small piceces
Operator
SOP
High
Med.
Yes
PRP & SSOP
N0
80
Mixing
sequence & timing
Supervisor
SOP
Biological : Change in test or colour Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles
High
Low
Yes
temperature abuse or cnage or delay in mixing may cause bacterial growth Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) temperature abuse or change or delay may cause bacterial growth Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) X
PRP & SSOP
Yes ( CCP 2)
No
High
Low
Yes
PRP & SSOP
High
Med.
Yes
PRP & SSOP
No
90
Filling / Foreming
Wieght per pcs
Operator & QC Technician
Standrad Product wight SOP Biological : Bacterial growth Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
PRP & SSOP
No
High X High
Med. X Low
Yes X Yes
PRP & SSOP X
No X No
101
Cooking
Temperature
Operator
SOP
Biological : Chemical : Sanitizer for equipments
Nil
Physical : Equipment particles , etc 102 smoking Temperature Operator SOP Biological : Chemical : Sanitizer for equipments Physical : Equipment particles , etc 103 Cooling Temperature Operator SOP Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Machine particles , etc 105 Peeling Visual Inspection Operator SOP Biological : Personal Hygiene Chemical : Sanitizer for cutting tools Physical : cutting tools particles , etc 110 Packing number of pieces Operator PRP - SOP Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil 120 Cartuning number of pieces operator SOP Biological : Chemical : Nil Physical : Nil Biological : Bacterial growth Chemical : Nil Nil Nil
High X High
Low X Low
Yes X Yes
Sanitizer used for cleaning of PRP & SSOP equipment may remain, if not allowed proper drying time Metal / packing pieces can be Subsequent step Metal detecting will present in product during unpacking remove all physical pieces. X X
No X No
High
Low
Yes
Sanitizer used for cleaning of PRP & SSOP equipment may remain, if not allowed proper drying time Metal / packing pieces can be Subsequent step Metal detecting will present in product during unpacking remove all physical pieces. Handling of products may cause pathogenic contamination PRP & SSOP
No
High
Low
Yes
No
High
Low
Yes
High
Low
Yes
Sanitizer used for cleaning of PRP & SSOP equipment may remain, if not allowed proper drying time Metal / packing pieces can be Subsequent step Metal detecting will present in product during unpacking remove all physical pieces. Handling of products may cause pathogenic contamination PRP & SSOP
No
No
High
Low
Yes
No
High
Low
Yes
High
Low
Yes
Sanitizer used for cleaning of PRP & SSOP equipment may remain, if not allowed proper drying time Metal / packing pieces can be Subsequent step Metal detecting will present in product during unpacking remove all physical pieces. Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x x x x temperature abuse ,may cause bacterial growth x PRP & SSOP
No
No
High
Low
Yes
No
High x x x x High x
Low x x x x Low x
Yes x x x x Yes x
PRP & SSOP x x x x PRP & SSOP x
No x x x x No x
130
Temperature
Store controller
SOP
Physical : Nil
for sausages

What x x x How x
Process Monitoring
Frequency x
Who x
Records x
Verifications x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
Cross Contamination x x X
No Foreign particles x x X
Cleanliness of production process check 100% inspection containers Supervisor x x X x x X x x X x x X
Re inspection. Remove / Reject x x X
CCP Monitoring log x x X
Daily record review by QA x x X
As per Reciep plan
Test & colour
Sequence & time x
100 % inspection x
production Supervisor x
Rework / Reject
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x
HACCP Plan 08
1 2
( As linked )
Process Flow
Hazard Analysis
Process #
Process steps
Control Measure
Responsibility
Ref. doc/ record
10
High
High
Low
Yes
No
High
Low
Yes
No
High
Low
Yes
No
Chemical : Sanitizer for Machines Physical : Packing material or cutting equipment particles , etc 30 Pre-Labelling Visual Inspection QC Technician & Production Supervisor SOP Biological : Personal Hygiene Chemical : nil Physical : Dust , metal particles , etc 40 Pilling of veigitables Visual Inspection Operator Daily Hygiene Check list Biological : Personal Hygiene
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
Subsequent step Washing & Metal Metal / packing pieces can be detecting will remove all physical present in product during unpacking pieces. Handling of products may cause pathogenic contamination x Packing material may have dust Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x Water used for cleaning may have bacteria Not correct proportion for sanitizer Water used for cleaning may have dust / sand particles Handling of products may cause pathogenic contamination improper cleanliness or change of of Bins / Containers x temperature abuse ,may cause bacterial growth PRP & SSOP x Subsequent step Metal detecting will remove all physical pieces. PRP & SSOP
No
High x High
Low x Low
Yes x Yes
No x No
High
Low
Yes
No
50
Hygiene Supervisor
No x No No No No
60
Weighting
accuracy of weight
Foreman
Machine Log
Biological : Personal Hygiene Chemical : Bins / containers cross contamination Physical : Nil Biological : Bacterial growth
High x High
Low x Low
Yes x Yes
Yes ( CCP 1)
x No
70
Minceng
small piceces
Operator
SOP
Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles 80 Mixing sequence & timing Supervisor SOP Biological : Change in test or colour Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles 90 Foreming Wieght per pcs Operator & QC Technician Standrad Product wight SOP Biological : Bacterial growth Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles 100 Freezing Temperature Operator SOP Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Machine particles , etc 110 Packing number of pieces Operator PRP - SOP Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil 120 Cartuning number of pieces operator SOP Biological : Chemical : Nil Physical : Nil Biological : Bacterial growth Chemical : Nil Physical : Nil Nil
High
Low
Yes
High
Med.
Yes
Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) temperature abuse or cnage or delay in mixing may cause bacterial growth Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) temperature abuse or change or delay may cause bacterial growth Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) Handling of products may cause pathogenic contamination
PRP & SSOP
No
PRP & SSOP
N0
High
Low
Yes
PRP & SSOP
Yes ( CCP 2)
No
High
Low
Yes
PRP & SSOP
High
Med.
Yes
PRP & SSOP
No
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
PRP & SSOP
No
High
Med.
Yes
PRP & SSOP
No
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
High
Low
Yes
No
No
High
Low
Yes
No
Low x x x x Low x x
Yes x x x x Yes x x
No x x x x No x x
130
Temperature
Store controller
SOP
For Kabba

What x x x How x
Process Monitoring
Frequency x
Who x
Records x
Verifications x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
X Sequence & time x
X 100 % inspection x
X production Supervisor x
X CCP Monitoring log x
As per Reciep plan
Test & colour
Rework / Reject
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
HACCP Plan 09
1 2
( As linked )
Process Flow
Hazard Analysis
Process #
Process steps
Control Measure
Responsibility
Ref. doc/ record
10
High
High
Low
Yes
No
High
Low
Yes
No
High
Low
Yes
No
Chemical : Sanitizer for Machines Physical : Packing material or cutting equipment particles , etc 30 Pre-Labelling Visual Inspection QC Technician & Production Supervisor SOP Biological : Personal Hygiene Chemical : nil Physical : Dust , metal particles , etc 40 Pilling of veigitables Visual Inspection Operator Daily Hygiene Check list Biological : Personal Hygiene
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
Subsequent step Washing & Metal Metal / packing pieces can be detecting will remove all physical present in product during unpacking pieces. Handling of products may cause pathogenic contamination x Packing material may have dust Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time x Water used for cleaning may have bacteria Not correct proportion for sanitizer Water used for cleaning may have dust / sand particles Handling of products may cause pathogenic contamination improper cleanliness or change of of Bins / Containers x Handling of products may cause pathogenic contamination PRP & SSOP x Subsequent step Metal detecting will remove all physical pieces. PRP & SSOP
No
High x High
Low x Low
Yes x Yes
No x No
High
Low
Yes
No
50
Hygiene Supervisor
No x No No No No
60
Weighting
accuracy of weight
Foreman
Machine Log
Biological : Personal Hygiene Chemical : Bins / containers cross contamination Physical : Nil
High x High
Low x Low
Yes x Yes
Yes ( CCP 1)
x No
61
Cutting
size
Foreman
PRP - SOP
Biological : Personal Hygiene
Chemical : Bins / containers cross contamination Physical : Cutting tools metal particles 71 cooking Temperature Operator SOP Biological : Personal Hygine
High
Low
Yes
improper cleanliness or change of of Bins / Containers
PRP & SSOP
No
High
Low
Yes
Metal / packing pieces can be Subsequent step Metal detecting will present in product during unpacking remove all physical pieces. Handling of products may cause pathogenic contamination Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) temperature abuse or cnage or delay in mixing may cause bacterial growth Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) temperature abuse or change or delay may cause bacterial growth Sanitizer used for cleaning of equipment may remain, if not allowed proper drying time Wear & tear of machine parts ( direct food contact surfaces ) Handling of products may cause pathogenic contamination PRP & SSOP
No
High
Low
Yes
No
Chemical : Sanitizer for High equipments Physical : cooking equip. parts High particles 80 Mixing sequence & timing Supervisor SOP Biological : Change in test or colour Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles 90 Filling /Foreming Wieght per casing Operator & QC Technician Standrad Product wight SOP Biological : Bacterial growth Chemical : Sanitizer for Machines Physical : Machine internal spear parts particles 100 Freezing Temperature Operator SOP Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Machine particles , etc 110 Packing number of pieces Operator PRP - SOP Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil 120 Cartuning number of pieces operator SOP Biological : Chemical : Nil Physical : Nil Biological : Bacterial growth Chemical : Nil Physical : Nil Nil High
Low Med. Low
Yes Yes Yes
PRP & SSOP PRP & SSOP PRP & SSOP
No N0
Yes ( CCP 2)
No
High
Low
Yes
PRP & SSOP
High
Med.
Yes
PRP & SSOP
No
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
PRP & SSOP
No
High
Med.
Yes
PRP & SSOP
No
High
Low
Yes
PRP & SSOP
No
High
Low
Yes
High
Low
Yes
No
No
High
Low
Yes
No
Low x x x x Low x x
Yes x x x x Yes x x
No x x x x No x x
130
Temperature
Store controller
SOP
For shawarma

What x x x How x
Process Monitoring
Frequency x
Who x
Records x
Verifications x
x x
x x
x x
x x
x x
x x
x x
x x
x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
x x x x
Cross Contamination x
No Foreign particles x
Cleanliness of production process check 100% inspection containers Supervisor x x x x
Re inspection. Remove / Reject x
Daily record review by QA x
X X Change in test or colour
X X As per Reciep plan
X X Test & colour
X X Sequence & time x
X X 100 % inspection x
X X production Supervisor x
X X Rework / Reject
X X CCP Monitoring log x
X X Daily record review by QA
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x

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FAMILIES, SUB FAMILIES & EQUIPMENTS (According to the product cards)

Sub family- whole spices

Ref. doc/ record

High Physical : Dust , metal particles , etc

Biological : Nil Chemical : Bins / containers cross contamination

Corrective Action planning

Corrective actions Who x x

PRP & SSOP

PRP & SSOP

PRP & SSOP

PRP & SSOP

PRP & SSOP x x

x improper cleanliness or change of of Bins / Containers

x PRP & SSOP

Mixed Spices ( As linked )

Ref. doc/ record

Raw materail Receving

Certificate of Analysis ; Accpetance Criteria

Production Supervisor /QA Technnician

Incoming inspection Report

Biological : pathogens ; Hygiene indicators ;Nematodes Chemical : Antibiotics ; Pesticides ;Hormones

PRP & SSOP

High High High

Low Low Low

PRP & SSOP

High x High High High High High High

Low x Low Low Med. Low Low Med.

Yes x Yes Yes Yes Yes Yes Yes

sequence & timing

PRP & SSOP

PRP & SSOP

PRP & SSOP

Wieght per bag

PRP & SSOP

PRP & SSOP

PRP & SSOP

PRP & SSOP

Biological : Personal Hygiene Chemical : Sanitizer for Machines Physical : Nil

High x Nil x x x High x x

PRP & SSOP x x x x PRP & SSOP x x

Storing & transportation

Corrective Action planning

Cleanliness of production process check 100% inspection containers Supervisor

Re inspection. Remove / Reject

CCP Monitoring log

Daily record review by QA

Change in test or colour

As per Reciep plan

Test & colour

Sequence & time x

CCP Monitoring log x

Daily record review by QA

Ref. doc/ record

Raw materail Receving

Certificate of Analysis ; Accpetance Criteria

Production Supervisor /QA Technnician

Incoming inspection Report

Biological : pathogens ; Hygiene indicators ;Nematodes Chemical : Antibiotics ; Pesticides ;Hormones

Chemical : Bins / containers cross contamination

PRP & SSOP

PRP & SSOP

PRP & SSOP x x x x PRP & SSOP x x

Storing & transportation