The document provides information about the Sincere Salad Dressing Company's HACCP program. It includes details about the company, products produced, organizational chart, HACCP team members, prerequisite programs in place, and a finished product profile. The company produces salad dressings and adheres to a HACCP plan and various prerequisite programs to control food safety hazards for its ready-to-eat products.
2. COMPANY INFORMATION
Company Name: Sincere Salad Dressing Company
123 Salad Shooter Way
Company Address:
Groveland, Kansas
Contact Person Name, Title: Renee Kerr, Quality Manager
Contact Phone Number: 555-555-5555 x000
Contact Fax Number: 550-550-5500
Contact Email: rkerr@sinceresalad.com
The Sincere Salad Dressing Company evolved from a country
Brief Company History:
vegetable market founded in 1927 in Medora, KS. A signature
salad dressing spice packet sold by Polk Farms grew in popularity
steadily becoming what is now a modern food processor. The
company principles for providing high quality products at a fair
price are practiced to this very day.
Types of Products Produced/ Salad Dressing/ Food Products
Type of Manufacturing:
Quality Policy: It is the quality policy of the Sincere Salad Company to provide
goods and services that consistently meet or exceed our customer’s
expectation.
Mission Statement: Our mission is to create distinctive value.
We will succeed in business only by creating value for our
customers, our suppliers, employees, shareholders, and neighbors.
We will build stronger customer relations and create solutions:
Explore, Discover, Create, Deliver!
Vision Statement: At Sincere Salad Dressing, we believe our most valuable assets are
our associates and our customers. Our goal is to create an
innovative, entrepreneurial environment that empowers great
ideas. We want our associates to have the creativity to see, the
freedom to develop, and the freedom to act. We will act with
integrity and responsiveness in all facets of our business.
4. HACCP Team
Name Position
Coordinator: Renee Kerr Quality Manager
Other Team
Members: Guermo Tank Plant Manager
Jeffrey Caine Maintenance
Supervisor
Eric Hale HR Manager
Jack Curtain Shipping / Receiving
Supervisor
Tom Coltrane Operations Manager
Corey Weathers Quality Technician
Michael Bland Purchasing Manager
Tim Scoffield Line Operator
HACCP Training Renee Kerr / Guermo Tank- certified by
Coordinator(s) : AIB International (HACCP on Demand). –
September 10, 2009.
5. Program Title: Master Cleaning Schedule/ SSOPs
Person Responsible: Renee Kerr / Quality Manager
Where Located: Quality Department
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur annually and if there are any
significant changes in equipment, cleaning
chemicals or methods, or if there is a program
failure.
Program Description:
Goal: Maintain a sanitary environment, necessary for the
production of safe and legal products. Ensure sanitation
activities do not pose a risk to product.
Scope: All areas, including processing, product storage areas,
support areas, and grounds.
Content: A Master Cleaning schedule has been created for all processing
and storage areas, which covers processing equipment, building
structure, and utensils. The CIP systems for cleaning the bulk
storage tanks, mixing, and pasteurization of product will have
documented cleaning frequencies, procedures, and verification
activities. The cleaning of product contact surfaces will be verified
as effective by visual start-up inspections, ATP testing, and
chemical concentration checks.
Training: Scope is outlined in plant work instructions and
controlled inspection forms. Training is provided by the
QA dept and records are maintained in Human
Resources.
6. Program Title: SSD Pest Control Program
Person Responsible: Michael Bland / Purchasing Manager
Where Located: Purchasing Department
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur annually and if there are any
significant changes in control methods or if
there is a program failure.
Program Description:
Goal: Manage pest population to minimize its potential for
product adulteration and/or contamination.
Scope: All areas, including processing, product storage areas,
support areas, and grounds.
The entire plant grounds will be maintained to prevent pest
Content: harborage, infestation, and potential product contamination.
All pesticides will be used according to the label and all
activities will be in compliance with the Federal Insecticide,
Fungicide, and Rodenticide Act (FIFRA). All pesticide
operators servicing the plant will be certified pesticide
operators with a valid license and insurance certificate. The
contracted service will maintain a pesticide usage chart, MSDS
file, pesticide sample labels, rodent trap checks, schematics,
record of pest activity, and the corrective action taken to
prevent reoccurrence. Pest monitoring devices will be
identified and checked by the plant PCO who has the overall
responsibility for evaluating the effectiveness of the pest
control program.
Training: Associates are trained during annual review or at new
hire. – Licensing and insurance are reviewed on annual
basis. Training records are maintained in HR.
Program Title: SSD CHEMICAL CONTROL PROGRAM
7. Person Responsible: Michael Bland/ Purchasing Manager
Where Located: First Aid Room
Revision Approval Authority: Guermo Tank / Plant Manager
Revision Timing: Reviews occur annually and if there are any
significant changes in chemical usage or if
there is a program failure.
Program Description:
Goal: Protect the product and process environment from
possible chemical contamination.
Scope: All chemicals, such as sanitation, maintenance,
production, and laboratory.
Content: The control of chemicals in raw materials and packaging materials will
be addressed separately by our supplier certification program and
ingredient hazard analysis. The plant maintains a control program for
cleaning compounds, maintenance chemicals, and pest control
chemicals. A running inventory of chemical usage is maintained by the
appropriate department head to note any unusual usage. All chemicals
purchased at the plant are reviewed by the purchasing department to
insure that they are appropriate for use in a food plant. All personnel
using chemicals will be trained for proper usage, application, and wear
safety equipment, where appropriate. CIP records to clean and sanitize
product zone areas will be maintained and reviewed by the QA
department as evidence of effective cleaning. The usage of cleaning
compounds and sanitizer for hand cleaning of equipment will be
maintained by using test strips to insure that the proper concentration
was used.
Training: All associates are trained as new hire and on annual
basis. Chemical inventory is audited on annual basis or if
a chemical is added or removed.
Program Title: Allergen Control Program
8. Person Responsible: Guermo Tank/ Plant Manger
Where Located: Plant Manager’s / Environmental Coordinator’s
Ofc.
Revision Approval Authority: N/A
Revision Timing: Reviews occur annually and if there are any
changes to government guidelines and
regulations, any change in allergen usage, or if
there is a program failure.
Program Description:
Goal: Is to ensure that the company meets and maintains all
local, state and federal requirements for this production
facility.
Scope: All EPA, OSHA, and Department of Natural Resources.
The product development and QA department will review and identify
Content: allergens in new raw materials and existing products produced at the
plant. The R & D department with the assistance of the purchasing
department will review existing and new raw materials for allergen
potential. The product label will clearly and accurately list all
ingredients. The production department with the cooperation of the sales
department will minimize the amount of changeovers from allergen to
non-allergen product due to the potential for cross contamination. The
QA department will audit the recipes, scaling, rework usage, and mixing
to insure that formulae and usage are accurate. The production
department will maintain an approved rework usage matrix and record
usage on the scaling reports. Where there is a potential for cross
contamination in scaling, processing, and packaging equipment, the
cleaning procedures and inspection will be documented on the pre-op and
operational inspections. The QA department will perform scheduled
testing for protein residue on product zones and finished to confirm that
the current programs are effective. When deficiencies are noted, the
program will be modified and reconfirmed by residue testing
9. Training: All associates are trained on an annual basis for FDA,
USDA, and other regulatory requirements. Training
records are maintained in HR ofc.
10. Program Title: SSD GOOD MANUFACTURING PRACTICES
Person Responsible: Eric Hale/ HR Manager
Where Located: Human Resource Office
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur annually and if there are any
significant changes in equipment, personnel, or
if there is a program failure.
Program Description:
Goal: Maintain an environment and encourage practices that
minimize the potential for product adulteration.
Scope: Personnel Practices, Plant Maintenance, Sanitation,
Glass Policy, Body Fluids Program, Transportation &
Storage.
Content: All personnel working at the plant will receive documented GMP
training for their given area of responsibility for food safety and
regulatory compliance. The building exterior and grounds will be
maintained to prevent pest problems and environmental issues, which
could affect the integrity of the product. All lights will be protected, air-
handling systems will be filtered, and the lines have been set up to
prevent any potentials for cross contamination. The water quality and
sanitary facilities will be checked for compliance. Employees have
been trained in proper hygienic practices and adequate hand washing
facilities have been provided. All transport vehicles will be inspected
for cleanliness prior to shipping and the temperature of product will be
controlled through the distribution chain. The equipment installation
and building design will be of sanitary design and a preventive
maintenance program will be in effect to ensure food safety and ongoing
process capability. Personnel will wear clean outer uniforms and a
policy for handling injuries or cuts will be in effect.
Training: Annual and new hire training. Visitors are trained at start
of visit. GMP forms are maintained by HR.
11. Program Title: SSD SUPPLIER CONTROL PROGRAM
Person Responsible: Michael Bland/ Purchasing Manager
Where Located: Purchasing Dept.
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur annually and if there is any
removal or addition of allergens to the program,
any change in point of allergen addition, or if
there is a program failure.
Program Description:
Goal: Control of incoming materials through Contract
Agreement, Letter of Continuing Guarantee, COA’s
Specification, etc.
Scope: All raw materials, including packaging material, coming
to the plant.
Content: The purchasing department will maintain a list of approved suppliers and
only buy from approved vendors. The supplier evaluation program will
be done by the material review team and consist of evaluating price,
adherence to specifications, performance defects, food safety
requirements, and service. A weighted average for the above criteria will
be used to score the suppliers. Suppliers of critical ingredients affecting
quality or food safety will be evaluated yearly. Ingredients that do not
affect quality or present food safety risk will be evaluated every two
years. Suppliers of critical ingredients such as milk products, egg
products, gelatin, soy, spices, dried vegetables etc., will be required to
submit certificates of guarantee and/or certificates of analysis. Critical
ingredient suppliers must have an annual AIB audit with a score of 800
and submit a copy of their HACCP plan.
Training: Training is accomplished through ISO work instructions
for purchasing, Shipping and Receiving.
12. Program Title: FOOD SAFETY CONSUMER COMPLAINTS
Person Responsible: Corey Weathers/ Quality Technician
Where Located: Quality Department
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur annually and if there is a
program failure.
Program Description:
Goal: Identification and resolution of complaints.
Scope: All complaints from customers and consumers, including
quality, service, and food safety issues.
The company will keep a separate file for food safety
Content: complaints. The customer service department will respond
back to the consumer. The Quality Department will require
documented investigations by the department responsible for
that activity with corrective action taken to prevent
reoccurrence. The Quality Department will track the number
and type of food safety complaints per units produced with
performance goals established to document continuous
improvement.
The HACCP and prerequisite programs will be reevaluated
Training: when food safety concerns are noted in the market place.
Associates are informed through food safety alerts posted at
the work stations and employee information boards.
13. Program Title: RECALL and TRACEABLITY PROGRAM
Person Responsible: Renee Kerr/ Quality Manager
Where Located: Quality Department
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur semi-annually (recall drills) and
if there are any significant changes to items, or
if there is a program failure.
Program Description:
Goal: Removal of suspect product, that is in violation of a
regulatory requirement, from the market in a timely and
effective manner.
Scope: All raw material, packaging material, processing aides,
work in progress, rework and finished product that may
pose suspect to consumers.
The plant has documented policies and procedures to recall product
Content: produced at the plant and distributed to the customers. The recall team
will test this program every six months and report on the effectiveness of
the program to management. When deficiencies are noted in the
program, the procedures will be revised and personnel will receive
further training. Traceability records for packaging material, raw
material usage, rework usage, packaging codes, and distribution records
will be kept to for two years. The proper coding of the manufactured
product on a day to day basis will be the responsibility of the production
department and verified by the QA department.
Training: Training is accomplished semi-annually with the primary
and alternate Recall team.
14. SINCERE SALAD DRESSING
PROCESSING FLOWCHART
BULK RECEIVING AND STORAGE PALLETIZED INGREDIENT AND
PACKAGING MATERIAL RECEIVING
X ray unit
DRY REFRIGERATED
DRY REFRIGERTED STORAGE STORAGE
STORAGE STORAGE
DUMP
STATION
BULK SCALING AND
MINOR INGREDIENT
ADDITION/ SIFTERS
GLASS STORAGE
GLASS INTRODUCTION OAKS MIXER
STATION
GLASS INVERSION
STATION PASTEURIZER REWORK
(1)
GLASS WASHING
STATION COOLING
GLASS
INSPECTION GLASS HOT FILL
X-Ray Unit
(2)
Metal Detector
LABELLING AND BOXING
Capper
(3)
REFRIGERATED
STORAGE
REFRIGERATED
SHIPPING
15.
16. HACCP FINISHED PRODUCT PROFILE
General Product Information:
Description of Product(s): Salad Dressing
Intended Use and Consumer/ Customer: Ready to eat/ General Public
Method of Storage and Distribution: 45 degrees Fahrenheit at the retail level/ 40
degrees Fahrenheit, refrigerated truck
Shelf-life/ Traceability information: 12 months unopened/ 6 months opened -
refrigerated
Technical Product Information:
Preservative(s): FD&C Yellow #5 (food coloring)
Water activity (aw): 9.5
pH/ titratable acidity: 5.5-7.0
Packaging requirements: glass jars, plastic, boxed pouches, and
single service foil packets.
Food Safety Information:
Potential for consumer/ customer misuse: Bacteria cross contamination if left
unrefrigerated.
Describe the potential food safety issues associated Allergens, glass, biological(people)
with this product/ process (be specific):
List any support programs or ingredient, product or Allergen control program, sanitation,
process parameters essential to preventing, supplier control program, metal detection,
controlling or eliminating each food safety issue
identified above: glass x ray unit, GMPs (Glass policy,
Personnel practices), sifters
Signature of Company Official: Guermo Tank
Title: Plant Manager Date: Sept. 10, 2009
17. RAW MATERIAL HAZARD ANALYSIS
Product or Process Name: Salad Dressing
Risk Assessment Is this a
List all raw materials Identify Critical Raw
used in the plant known hazards Likelihoo Material (1)
Severity
d
(Yes/No)?
B Bacteria – fecal coliform M M Y
Well water L-M L Y
C MTBE, nitrates, salts
P foreign material, rocks L L N
B Salmonella L-M M Y
Liquid, pasteurized eggs H H Y
C Allergen
P None N N N
B None N N N
sugar M L-M Y
C Pesticides
P large lumps, metal, glass M-H M Y
B None N N N
vinegar N N N
C None
P None N N N
B None N N N
salt N N N
C None
P large lumps, metal, glass M-H M Y
B None N N N
Dried milk powder H H Y
C Allergen
P large lumps, metal, glass M-H M Y
B None N N N
Yellow #5 food color M-H M Y
C tartrazine (Allergen)
P None N N N
B None N N N
Glass jars N N N
C None
P pieces/ shards M-H M Y
Hazards: B = Biological, C = Chemical, P = Physical
Risk Assessment: H = High, M = Medium, L = Low, N = Negligible
(1) Critical Raw Material: Any raw material, with the exception of those having negligible, L/L and/ or M/L (likelihood/
severity) in all three hazard risk assessments, must be considered critical. Any item identified as “Critical” must be
brought forward to Receiving on the Process Hazard Analysis form for further analysis.
18. PROCESS HAZARD ANALYSIS
(1) (2) (3) (4) (5)
List every Critical Ingredient Does this raw material or Is this hazard(s) Is this hazard ELIMINATED (reduced to an Can a viable product still be
identified in the Raw Material process step INTRODUCE CONTROLLED to the best acceptable level) at this or a later process produced if the process
Hazard Analysis. or INTENSIFY a potential of the plant’s ability by step? If NO, write “none” and continue to the step listed in Column 4
List every process step, from food safety hazard? If YES Support Programs? If next hazard or process step. If YES, identify fails? If YES, this step
Receiving to Shipping, shown identify hazard(s). (Be as YES, list all of the Support the last process step where it will be must be considered a CCP:
on the simplified Process Flow specific as possible when Programs that will control eliminated. identify the CCP number. If
Diagram. listing the hazard and its the introduction or If you are at that process step, proceed to NO, this is not a CCP: enter
source.) If no hazard is intensification of the Column 5; if not, go to the next hazard or NO.
Go to Column 2. identified, write “none.” hazard(s) identified in process step. (Note: If no control or
Note: If this is a last process Column 2. If NO, write elimination is identified in Column 3 or 4 and Go to the next hazard or
step identified in Column 4, list Go to column 3. “none.” these are necessary for food safety, you must process step.
the hazard eliminated in stop, modify the step, process, product, or
Column 2. Go to column 4. Support Programs.)
Well water B Bacteria Supplier control Pasteurizer
program
-Nanofiltration
C MTBE Supplier control Yes. Damage to above ground or
program -Quarterly underground tanks, and tanker spills
testing at state into soil.
certified laboratory.
P None None None
Liquid Pasteurized B Salmonella Supplier control Pasteurizer
eggs program
C Allergen Supplier control No
program
P None None None
Sugar B None None None
C pesticides Supplier control No
program
P large lumps, metal, Glass Policy Metal Detector/ Glass Xray Unit
glass
19. PROCESS HAZARD ANALYSIS
Salt B None None None
C Allergen Supplier Control No
Program
P large lumps, metal, Glass Policy Metal Detector/ Glass Xray
Unit
glass
20. PROCESS HAZARD ANALYSIS
(1) (2) (3) (4) (5)
List every Critical Ingredient Does this raw material or Is this hazard(s) Is this hazard ELIMINATED (reduced to an Can a viable product still be
identified in the Raw Material process step INTRODUCE CONTROLLED to the best acceptable level) at this or a later process produced if the process
Hazard Analysis. or INTENSIFY a potential of the plant’s ability by step? If NO, write “none” and continue to the step listed in Column 4
List every process step, from food safety hazard? If YES Support Programs? If next hazard or process step. If YES, identify fails? If YES, this step
Receiving to Shipping, shown identify hazard(s). (Be as YES, list all of the Support the last process step where it will be must be considered a CCP:
on the simplified Process Flow specific as possible when Programs that will control eliminated. identify the CCP number. If
Diagram. listing the hazard and its the introduction or If you are at that process step, proceed to NO, this is not a CCP: enter
source.) If no hazard is intensification of the Column 5; if not, go to the next hazard or NO.
Go to Column 2. identified, write “none.” hazard(s) identified in process step. (Note: If no control or
Note: If this is a last process Column 2. If NO, write elimination is identified in Column 3 or 4 and Go to the next hazard or
step identified in Column 4, list Go to column 3. “none.” these are necessary for food safety, you must process step.
the hazard eliminated in stop, modify the step, process, product, or
Column 2. Go to column 4. Support Programs.)
Dried milk powder B None None None
C Allergen Supplier control None
program
P large lumps, metal, Glass Policy Metal Detector/ Glass Xray Unit
glass
Yellow #5 food color B None None None
C tartrazine Supplier Control None
(Allergen) Program
P None None None
Glass jar B None None None
C None None None
P pieces / shards Glass policy Glass Xray Unit
B
C
P
21. PROCESS HAZARD ANALYSIS
(1) (2) (3) (4) (5)
List every Critical Ingredient Does this raw material or Is this hazard(s) Is this hazard ELIMINATED (reduced to an Can a viable product still be
identified in the Raw Material process step INTRODUCE CONTROLLED to the best acceptable level) at this or a later process produced if the process
Hazard Analysis. or INTENSIFY a potential of the plant’s ability by step? If NO, write “none” and continue to the step listed in Column 4
List every process step, from food safety hazard? If YES Support Programs? If next hazard or process step. If YES, identify fails? If YES, this step
Receiving to Shipping, shown identify hazard(s). (Be as YES, list all of the Support the last process step where it will be must be considered a CCP:
on the simplified Process Flow specific as possible when Programs that will control eliminated. identify the CCP number. If
Diagram. listing the hazard and its the introduction or If you are at that process step, proceed to NO, this is not a CCP: enter
source.) If no hazard is intensification of the Column 5; if not, go to the next hazard or NO.
Go to Column 2. identified, write “none.” hazard(s) identified in process step. (Note: If no control or
Note: If this is a last process Column 2. If NO, write elimination is identified in Column 3 or 4 and Go to the next hazard or
step identified in Column 4, list Go to column 3. “none.” these are necessary for food safety, you must process step.
the hazard eliminated in stop, modify the step, process, product, or
Column 2. Go to column 4. Support Programs.)
Bulk receiving and B Bacteria Supplier control Pasteurizer
storage program/ COA
C Allergens Supplier control None.
(X ray unit)
program/ COA
P metals, bones, Supplier control Metal Detector/ Glass Xray Unit
rocks, glass, sticks program/ COA
Dry storage (Bulk) B None
C None
P None
Refrigerated storage B None
(Bulk) C None
P None
Palletized ingredient B None
& packaging material
C Allergens Supplier control None
receiving program/ COA
P None
22. PROCESS HAZARD ANALYSIS
(1) (2) (3) (4) (5)
List every Critical Ingredient Does this raw material or Is this hazard(s) Is this hazard ELIMINATED (reduced to an Can a viable product still be
identified in the Raw Material process step INTRODUCE CONTROLLED to the best acceptable level) at this or a later process produced if the process
Hazard Analysis. or INTENSIFY a potential of the plant’s ability by step? If NO, write “none” and continue to the step listed in Column 4
List every process step, from food safety hazard? If YES Support Programs? If next hazard or process step. If YES, identify fails? If YES, this step
Receiving to Shipping, shown identify hazard(s). (Be as YES, list all of the Support the last process step where it will be must be considered a CCP:
on the simplified Process Flow specific as possible when Programs that will control eliminated. identify the CCP number. If
Diagram. listing the hazard and its the introduction or If you are at that process step, proceed to NO, this is not a CCP: enter
source.) If no hazard is intensification of the Column 5; if not, go to the next hazard or NO.
Go to Column 2. identified, write “none.” hazard(s) identified in process step. (Note: If no control or
Note: If this is a last process Column 2. If NO, write elimination is identified in Column 3 or 4 and Go to the next hazard or
step identified in Column 4, list Go to column 3. “none.” these are necessary for food safety, you must process step.
the hazard eliminated in stop, modify the step, process, product, or
Column 2. Go to column 4. Support Programs.)
Dry storage B None
(Palletized)
C None
P None
Refrigerated storage B None .
(Palletized)
C None
P None
Dump station B None
(palletized)
C None
P None
23. PROCESS HAZARD ANALYSIS
Bulk scaling & minor B Bacteria/ viruses GMPs- Personnel Pasteurizer
ingredient addition/ from employees practices
Sifters C cleaners, Chemical control None
sanitizers policy
P Lumps, glass, GMPs- Personnel Metal Detector/ Glass Xray Unit
metal practices, Glass
Policy
24. PROCESS HAZARD ANALYSIS
(1) (2) (3) (4) (5)
List every Critical Ingredient Does this raw material or Is this hazard(s) Is this hazard ELIMINATED (reduced to an Can a viable product still be
identified in the Raw Material process step INTRODUCE CONTROLLED to the best acceptable level) at this or a later process produced if the process
Hazard Analysis. or INTENSIFY a potential of the plant’s ability by step? If NO, write “none” and continue to the step listed in Column 4
List every process step, from food safety hazard? If YES Support Programs? If next hazard or process step. If YES, identify fails? If YES, this step
Receiving to Shipping, shown identify hazard(s). (Be as YES, list all of the Support the last process step where it will be must be considered a CCP:
on the simplified Process Flow specific as possible when Programs that will control eliminated. identify the CCP number. If
Diagram. listing the hazard and its the introduction or If you are at that process step, proceed to NO, this is not a CCP: enter
source.) If no hazard is intensification of the Column 5; if not, go to the next hazard or NO.
Go to Column 2. identified, write “none.” hazard(s) identified in process step. (Note: If no control or
Note: If this is a last process Column 2. If NO, write elimination is identified in Column 3 or 4 and Go to the next hazard or
step identified in Column 4, list Go to column 3. “none.” these are necessary for food safety, you must process step.
the hazard eliminated in stop, modify the step, process, product, or
Column 2. Go to column 4. Support Programs.)
Oaks mixer B Bacteria GMPs- Personnel Pasteurizer
practices
C cleaners, Chemical control None
sanitizers policy
P Lumps, glass, GMPs- Personnel Metal Detector/ Glass Xray Unit
metal practices, Glass
Policy
Pasteurizer B Bacteria/ GMPs- Personnel Product must be brought to 190 1
Salmonella practices degrees fahrenheit in order to destroy
possible bacteria/viruses introduced
from suppliers or SS employees.
C cleaners, Chemical control
sanitizers policy
P Lumps, glass, GMPs- Personnel Metal Detector/ Glass Xray Unit
metal practices, Glass
Policy
Cooling B None
C None
P None
26. (1) (2) (3) (4) (5)
List every Critical Ingredient Does this raw material or Is this hazard(s) Is this hazard ELIMINATED (reduced to an Can a viable product still be
identified in the Raw Material process step INTRODUCE CONTROLLED to the best acceptable level) at this or a later process produced if the process
Hazard Analysis. or INTENSIFY a potential of the plant’s ability by step? If NO, write “none” and continue to the step listed in Column 4
List every process step, from food safety hazard? If YES Support Programs? If next hazard or process step. If YES, identify fails? If YES, this step
Receiving to Shipping, shown identify hazard(s). (Be as YES, list all of the Support the last process step where it will be must be considered a CCP:
on the simplified Process Flow specific as possible when Programs that will control eliminated. identify the CCP number. If
Diagram. listing the hazard and its the introduction or If you are at that process step, proceed to NO, this is not a CCP: enter
source.) If no hazard is intensification of the Column 5; if not, go to the next hazard or NO.
Go to Column 2. identified, write “none.” hazard(s) identified in process step. (Note: If no control or
Note: If this is a last process Column 2. If NO, write elimination is identified in Column 3 or 4 and Go to the next hazard or
step identified in Column 4, list Go to column 3. “none.” these are necessary for food safety, you must process step.
the hazard eliminated in stop, modify the step, process, product, or
Column 2. Go to column 4. Support Programs.)
Glass introduction B None
station C None
P contamination/ Glass policy/ Glass Xray Unit
pieces Personnel Practices
Glass inversion B None
station C None
P contamination/ Glass policy Glass Xray Unit
pieces
Glass washing station B None
C None
P contamination/ Glass policy Glass Xray Unit
pieces
27. Glass inspection x- B None
ray unit C None
P contamination/ Glass policy Foreign material from Oakes mixer, 2
pieces, fragments bulk scaling, or glass introduction
stage
List every Critical Ingredient Does this raw material or Is this hazard(s) Is this hazard ELIMINATED (reduced to an Can a viable product still be
identified in the Raw Material process step INTRODUCE CONTROLLED to the best acceptable level) at this or a later process produced if the process
Hazard Analysis. or INTENSIFY a potential of the plant’s ability by step? If NO, write “none” and continue to the step listed in Column 4
List every process step, from food safety hazard? If YES Support Programs? If next hazard or process step. If YES, identify fails? If YES, this step
Receiving to Shipping, shown identify hazard(s). (Be as YES, list all of the Support the last process step where it will be must be considered a CCP:
on the simplified Process Flow specific as possible when Programs that will control eliminated. identify the CCP number. If
Diagram. listing the hazard and its the introduction or If you are at that process step, proceed to NO, this is not a CCP: enter
source.) If no hazard is intensification of the Column 5; if not, go to the next hazard or NO.
Go to Column 2. identified, write “none.” hazard(s) identified in process step. (Note: If no control or
Note: If this is a last process Column 2. If NO, write elimination is identified in Column 3 or 4 and Go to the next hazard or
step identified in Column 4, list Go to column 3. “none.” these are necessary for food safety, you must process step.
the hazard eliminated in stop, modify the step, process, product, or
Column 2. Go to column 4. Support Programs.)
Rework B Bacteria Supplier Control Pasteurizer
Program, Personnel
Practices
C Allergen control None
Allergen/sanitizers program, chemical
control policy
P Lumps, glass, GMPs- Personnel Metal Detector/ Glass Xray Unit)
metal practices, Glass
Policy
Glass Hot fill B None
C None
P None
28. Metal detector B None
Labeling & boxing C None
Capper. P metal fragments No. Metal pieces from equipment or 3
tooling.
Refrigerated Storage B None
C Nome
P None
(1) (2) (3) (4) (5)
List every Critical Ingredient Does this raw material or Is this hazard(s) Is this hazard ELIMINATED (reduced to an Can a viable product still be
identified in the Raw Material process step INTRODUCE CONTROLLED to the best acceptable level) at this or a later process produced if the process
Hazard Analysis. or INTENSIFY a potential of the plant’s ability by step? If NO, write “none” and continue to the step listed in Column 4
List every process step, from food safety hazard? If YES Support Programs? If next hazard or process step. If YES, identify fails? If YES, this step
Receiving to Shipping, shown identify hazard(s). (Be as YES, list all of the Support the last process step where it will be must be considered a CCP:
on the simplified Process Flow specific as possible when Programs that will control eliminated. identify the CCP number. If
Diagram. listing the hazard and its the introduction or If you are at that process step, proceed to NO, this is not a CCP: enter
source.) If no hazard is intensification of the Column 5; if not, go to the next hazard or NO.
Go to Column 2. identified, write “none.” hazard(s) identified in process step. (Note: If no control or
Note: If this is a last process Column 2. If NO, write elimination is identified in Column 3 or 4 and Go to the next hazard or
step identified in Column 4, list Go to column 3. “none.” these are necessary for food safety, you must process step.
the hazard eliminated in stop, modify the step, process, product, or
Column 2. Go to column 4. Support Programs.)
Refrigerated shipping B None
C None
P None
31. 1 Biological >190 degrees What: Product temperature must be at >190 All product since the Temperature must
Bacteria/ degrees for a degrees Fahrenheit. last good check will be be monitored Pasteurizer
viruses minimum of placed on hold for re every 2 hours, temperature
5 minutes. pasteurization monitor log must monitor log.
. be signed at each
Unit will be repaired check by a
or replaced with a qualified
known working unit. production
Repaired/ replaced associate.
unit shall be inspected Monitoring must
and verified by be observed and
qualified maintenance verified at least
personnel and QA four times a shift
before being placed by the supervisor
into service. and at least twice
a shift by QA.
How: : Temperature readings are taken every
2 hours with a calibrated thermometer. A
sample is obtained from the pasteurizer and
the temperature is verified and recorded.
Frequency: At the beginning of each shift and
at the end of each shift. Every 2 hours during
the shift
Who: Shift Supervisor. Monitoring will be
observed and verified by QA.
32. Signature of Company Official: Guermo Tank Title: Plant manager Date: 9/10/2009
HACCP MASTER PLAN
(1) (2) (3) (4) (5) (6) (7)
Significant Critical Monitoring Corrective
CCP Hazard Limits Action(s) Verification Records
33. 2 Glass 0.5mm or What: Glass X ray unit All product since the Unit must be
inclusion greater last good check will be monitored every 2 Glass X ray unit
placed on hold for re hours, monitor log monitor log
A working inspection through a must be signed at
Reject known good unit or each check by a
mechanism- destroyed. qualified
Product will production
be kicked out Unit will be repaired associate.
of the or replaced with a Monitoring must
process. known working unit. be observed and
Repaired/ replaced verified at least
unit shall be inspected four times a shift
and verified by by the supervisor
qualified maintenance and at least twice
personnel and QA a shift by QA.
before being placed
into service
How: Unit will be checked using verified test
samples to ensure unit is working properly.
Frequency: At the beginning of each shift and
at the end of each shift. Every 2 hours during
production, after maintenance, and after line
changes.
Who: Qualified Production associate and
shift supervisor. Monitoring will be observed
34. Signature of Company Official: Guermo Tank Title: Plant manager Date: 9/10/2009
HACCP MASTER PLAN
(1) (2) (3) (4) (5) (6) (7)
Significant Critical Monitoring Corrective
CCP Hazard Limits Action(s) Verification Records
35. 3 Metal 2.5 mm What: Metal detector All product since the Unit must be Metal detector
(ferrous last good check will be monitored every 2 monitor log
metals) placed on hold for re hours, monitor log
2.5 mm (non inspection through a must be signed at
ferrous known good unit or each check by a
metals) destroyed. qualified
4.0mm production
stainless Unit will be repaired associate.
steel. or replaced with a Monitoring must
known working unit. be observed and
A working Repaired/ replaced verified at least
Reject unit shall be inspected four times a shift
mechanism- and verified by by the supervisor
Product will qualified maintenance and at least twice
be kicked out personnel and QA a shift by QA.
of the before being placed
process. into service
How: Unit will be checked using verified test
samples to ensure unit is working properly.
Frequency: At the beginning of each shift and
at the end of each shift. Every 2 hours during
production, after maintenance, and after line
changes.
Who: Qualified Production associate and
shift supervisor. Monitoring will be observed
36. Signature of Company Official: Guermo Tank Title: Plant manager Date: 9/10/2009
HACCP DEVIATION REPORT
Date:____________________ Critical Control Point:___________________
Location:________________ Equipment:____________________________
Specified Range:__________ Actual Reading:_________________________
Past History:________________________________________________________
__________________________________________________________________
__________________________________________________________________
Current Corrective
Action:_____________________________________________
__________________________________________________________________
37. __________________________________________________________________
__________________________________________________________________
Future Corrective Action Needed:_______________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
Production Disposition:_______________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
Attach a copy of all records of the critical control point deviation.
HACCP CORRECTIVE ACTION REQUEST
t Major t Minor
Problem Noted:
Temporary Action Taken:
38. Long-Term Corrective Action:
Assigned To/Due Date:
Prepared by:_________________________ Date: ________
Reviewed by:________________________ Date:_________
Was the corrective action effective?_______________________________
Remarks:
Corrective Action t Open t Closed
NOTICE OF UNUSUAL OCCURRENCE
AND CORRECTIVE ACTION
(NUOCA)
This NUOCA contains trade secret/business confidential
information and is exempt from disclosure pursuant to applicable law.
Date:___________________________
Supplier:________________________
Product:_________________________ Product Lot Identifier:_____________________
DESCRIPTION OF UNUSUAL OCCURRENCE:
DESCRIPTION OF CRITICAL LIMITS EXCEEDED (if any):
(Identify by CCP Number)
PREDETERMINED CORRECTIVE ACTION PURSUANT TO HACCP PROGRAM:
◊ Product Segregation and Hold ◊ Product to be Destroyed
◊ Further Hazard Analysis (Describe below) ◊ Reconditioning /Alternative Use (Describe below)
ACTION TAKEN UPON FURTHER HAZARD ANALYSIS PURSUANT TO GENERIC CORRECTIVE
ACTION PLAN: (Describe in detail)
RECOMMENDED ACTION FOR REEVALUATION OR MODIFICATION OF HACCP PROGRAM: (Describe