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Sincere Salad Dressing[4]

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Sample HACCP plan

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Sincere Salad Dressing[4]

  1. 1. SINCERE SALAD DRESSING COMPANY HACCP PROGRAM
  2. 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.
  3. 3. Sincere Salad Dressing Organizational Chart General Manager Plant Plant Human Resource Sales Manager Quality Manager Purchasing Manager Controller Manager AIB Coordinator Manager Operations Accounting Clerk Executive Account (3) Customer Service Manager Manager Representatives Quality Technician Hourly Executive Account Employees Cost Accountant Manager (3) Shift Supervisors Account Manager Hourly Account Manager Employees Purchasing Supervisor Lead Maintenance Tech (3) Maintenance Technicians Planning & Scheduling Manager Shipping Coordinator (2) Shipping Clerks R&D department Graphics Manager Graphic Arts Specialist
  4. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 15. 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
  16. 16. 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.
  17. 17. 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
  18. 18. 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
  19. 19. 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
  20. 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.) 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
  21. 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.) 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
  22. 22. 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
  23. 23. 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
  24. 24. PROCESS HAZARD ANALYSIS B None Glass storage C None P pieces / shards Glass Xray Unit
  25. 25. (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
  26. 26. 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
  27. 27. 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
  28. 28. B C P B C P B C P
  29. 29. HACCP MASTER PLAN (1) (2) (3) (4) (5) (6) (7) Significant Critical Monitoring Corrective CCP Hazard Limits Action(s) Verification Records
  30. 30. 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.
  31. 31. 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
  32. 32. 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
  33. 33. 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
  34. 34. 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
  35. 35. 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:_____________________________________________ __________________________________________________________________
  36. 36. __________________________________________________________________ __________________________________________________________________ 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:
  37. 37. 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
  38. 38. in detail) ________________________________________ Signature REVIEWED BY: ________________________________________ Signature of HACCP Coordinator Date:_____________

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