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Bakery Haccp plan

This document provides an HACCP (Hazard Analysis and Critical Control Points) plan for a baked cream-filled bread product. It establishes an HACCP team, describes the product and intended use, develops process flow diagrams, identifies potential hazards at each process step, determines the significance of the hazards, and establishes preventive or control measures. Potential hazards include biological (e.g. pathogenic bacteria), chemical (e.g. decomposition), and physical (e.g. insect parts, foreign objects). Control measures focus on supplier assurance, inspections, sanitation standard operating procedures, time/temperature controls, and proper storage conditions. The plan conducts a thorough hazard analysis to ensure the safety of the finished product.

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HACCP PLAN FOR BAKED FOODS Department of Food Science and Technology Faculty of Agricultural Technology Bogor Agricultural University 2009
Langkah 1 : Establish the HACCP team Name Expertise/Position Position in the team Dewi Food Tech. & HACCP specialist/ Coordinator QA Mgr. Rahman Engineering/Production Mgr. Member Putri Microbiology/QC Mgr. Member Surya Chemistry/Warehouse Mgr. Member
Step 2 : Product Description • Name of product • Composition • Product characteristics • Methods of processing • Methods of preservation • Primary packaging • Conditions of storage • Method of distribution • Shelflife • Specific labelling • Instruction on the label : cream-filled bread : Susu skim, kultur BAL, glukosa : Susu kental, asam, pH 4.3 : pasteurisasi, fermentasi : fermentasi : cup Polyethylene : Suhu 4oC : Dalam truk beropendingin : 3 minggu : - : -
Step 3 : Identification of the Product’s Intended Use • Name of product • Intended use • Target consumer : Cream-filled bread : Directly consumed : General public
Step 4 : Establish Process Flow Diagram Process flow diagram for the bread : Weigh all ingredients (sugar, salt, skim milk, shortening, egg, wheat flour, yeast, cold water) Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-300C) Divide the dough and weigh 900 gram each Fermentation 2 (27-300 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
Step 4 : Establish Process Flow Diagram Process flow diagram for the cream : Weigh all the ingredients (jelly mallow, butter, shortening) Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
Step 5 : On-site Confirmation of Flow Diagram : Bread Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving (egg, water) Dry storage at room temperature (25-300 C) Storage at 5-150 C Weigh all ingredients Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-300C) Divide the dough and weigh 900 gram each Fermentation 2 (27-300 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
Step 5 : On-site Confirmation of Flow Diagram : Cream Receiving (jelly mallow, butter, shortening) Dry storage at room temperature (25-300 C) Weigh all the ingredients Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving of egg Storage of egg Weighing of all ingredients Mixing of sugar, salt, skim milk B B B P B P P Contaminated yeast (by spoilage or pathogenic m.o.) Insects Presence of pathogenic bacteria Eggshell (cracked/broken eggs) Growth of pathogenic bacteria Insect bone pieces Insect bone pieces, personal items
Process Step Potential Hazard(s) B/C/P Description of Hazard Adding egg and shortening Adding wheat flour, yeast and cold water Blending Rounding the dough Fermentation 1 Dividing the dough Fermentation 2 B P B P B P B B B B Contamination of pathogenic bacteria Eggshell Contamination of spoilage or pathogenic bacteria (from yeast and water) Insect bone pieces Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) B/C/P Description of Hazard Spreading with egg Baking Cooling Filling with cream Packaging Storage B B B B B B Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o. Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) B/C/P Description of Hazard Receiving jelly mallow, butter, shortening Storage Weighing all ingredients Mixing Beating Storage - B C - P P B - Contamination of spoilage m.o. Decomposition of chemical compound - Personal item Personal item Growth of spoilage m.o. Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Preventive or Control Measures Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) B Contaminated yeast (by spoilage or pathogenic m.o.) Quality assurance (certificate of analysis) from supplier Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) P Insects Proper storage conditions (dry, clean), sealed packaging of the ingredients. Receiving of egg, water B Presence of pathogenic bacteria Certificate of analysis from egg supplier, acceptable water source P Eggshell (cracked/broken eggs) Inspection of incoming eggs Storage of egg B Growth of pathogenic bacteria Refrigerated storage (5-15 0 C), Label expired date. Weighing of all ingredients P Insect bone pieces, personal items Inspection of the ingredients, SOP for production area (no personal items are wore) Mixing of sugar, salt, skim milk P Insect bone pieces, personal items Inspection of the ingredients, SOP for production area (no personal items are wore) Adding egg and shortening P Eggshell Inspection of the ingredients (cracked eggs) Adding wheat flour, yeast and cold water P Insect bone pieces Filtering of wheat flour Blending B Contamination of spoilage m.o. from the air SSOP P Personal item SOP for production area (no personal items are wore) Rounding the dough B Contamination of spoilage & pathogenic m.o. from the air & worker SSOP
Process Step Potential Hazard(s) Description of Hazard Preventive or Control MeasuresB/C/P Fermentation 1 B Contamination of spoilage m.o. from the air SSOP Dividing the dough B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Fermentation 2 B Contamination of spoilage m.o. from the air SSOP Spreading with egg B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Baking B Survival of spoilage m.o. Correct time and temperature Cooling B Contamination of spoilage m.o. from the air SSOP Filling with cream B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Packaging B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Storage B Contamination of spoilage molds Proper storage condition (dry, clean), expired date must be stated on the label Receiving jelly mallow, butter, shortening - Storage B Contamination of spoilage m.o. Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients Weighing all ingredients Mixing P Personal item SSOP Beating P Personal item SSOP Storage B Growth of spoilage m.o. Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight) Principle 1 : Hazard Analysis HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps (cont.) Name of Product : Cream-filled Bread
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Severity Significant hazard (Y/N) Preventive or Control Measures Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg, water Storage of egg Weighing of all ingredients B P B P B P Contaminated yeast (by spoilage/ pathogenic m.o.) Insects Presence of pathogenic bacteria Eggshell (Cracked / broken eggs) Growth of pathogenic bacteria Insect bone pieces, personal items l h m h l l M M M M L M N Y N Y N N Quality assurance (certificate of analysis) from supplier Proper storage conditions (dry, clean), sealed packaging of the ingredients. Certificate of analysis from egg supplier, acceptable water source Inspection of incoming eggs Refrigerated storage (5-150 C), Label expired date. Inspection of the ingredients, SOP for production area (no personal items are wore)
Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Mixing of sugar, salt, skim milk Adding egg and shortening Adding wheat flour, yeast and cold water Blending Rounding the dough Fermentation 1 P P P B P B B Insect bone pieces, personal items Eggshell Insect bone pieces Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air l m m m m l l M M M L M L L N N N N N N N Inspection of the ingredients, SOP for production area (no personal items are wore) Inspection of the ingredients (cracked eggs) Filtering of wheat flour SSOP SOP for production area (no personal items are wore) SSOP SSOP Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging of bread Storage and distribution B B B B B B B B Contamination of spoilage and pathogenic m.o. from the air, weigh- scale, and worker Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o. Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds m l m l m m m m L L H H M H H M N N Y N N Y Y N SSOP SSOP SSOP Correct time and temperature SSOP SSOP SSOP Proper storage condition (dry, clean), expired date must be stated on the label Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Receiving jelly mallow, butter, shortening Storage of jelly mallow, butter, shortening Weighing all ingredients Mixing Beating Storage of cream - B C - P P B - Contamination of spoilage m.o. Decomposition of chemical compound - Personal item Personal item Growth of spoilage m.o. - m m - l l m - H H - M M H - Y Y - N N Y - Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients - SSOP SSOP Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight) Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
Principle 2 : Establishment of Critical Control Point CCP HACCP Plan Worksheet 2A : Establishment of CCP in Ingredients Name of Product : Cream-filled Bread Ingredient Potential Hazard (s) P1 P2 P3 CCP? Sugar B P Y Y Y Y N N N N Wheat flour B P Y Y Y Y N N N N Yeast B Y Y N N Egg B C P Y Y Y Y N N N - - N Y Y Water B Y Y N N
Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Potential Hazard(s) P1 P2 P3 P4 P5 CCP? Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Storage of egg Weighing of all ingredients Mixing of sugar, salt, skim milk Adding egg and shortening Adding wheat flour, yeast and Cold water Blending B P B P B P P P P B P N Y N Y N N N N N N N - Y - Y - - - - - - - - N - N - - - - - - - - Y - Y - - - - - - - - N - N - - - - - - - N CCP N CCP N N N N N N N
Process Step Potential Hazard(s) P1 P2 P3 P4 P5 CCP? Rounding the dough Fermentation 1 Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging Storage and distribution of bread B B B B B B B B B B N N N N Y N N Y Y N - - - - Y - - Y Y - - - - - N - - N N - - - - - Y - - Y Y - - - - - Y - - N N - N N N N N N N CCP CCP N Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) P1 P2 P3 P4 P5 CCP? Storage of jelly mallow, butter, shortening Mixing Beating Storage of cream B C P P B Y Y N N Y Y Y - - Y N N - - N Y Y - - Y N N - - N CCP CCP - - CCP Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread
Principle 3: Establishment of Critical Limits HACCP Plan Worksheet 3 : Establishment of Critical Limits Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20-250 C Holding Time <10 min, T=20-250 C Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date
Principle 4: Establishment of Monitoring Procedures HACCP Plan Worksheet 4 : Establishment of Monitoring Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures What How Where Who Freq. Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90=92 Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20-250 C Holding Time <10 min, T=20-250 C Antibiotic residue on CoA Cracked/broken eggs Rh Storage time SSOP application Cracked/broken eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temp. Receiving site Receiving site Storage room / warehouse Receiving site Production area Production area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Area personnel Area personnel Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temp., check label Measure temp. check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day
Principle 5: Establishment of Corrective Actions HACCP Plan Worksheet 5 : Establishment of Corrective Actions (1) Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions What How Where Who Frequency Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure Rh,check storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperatur e Check/ measure time and temperatur e Receiving site Receiving site Storage room / warehouse Receiving site Production area Production area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Area personnel Area personnel Every receiving Every receiving Every day Every Receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr.
Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions What How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature, check label Measure temperature, check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Principle 5: Establishment of Corrective Actions HACCP Plan Worksheet 5 : Establishment of Corrective Actions (1) Name of Product : Cream-filled Bread
Principle 6: Establishment of Verification Procedures HACCP Plan Worksheet 6 : Establishment of Verification Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification ActivitiesWhat How Where Who Frequen cy Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/bro ken eggs Rh Storage time SSOP application Cracked/bro ken eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehou se mngr. Receiving personnel Productio n superviso r Productio n superviso r Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh- meter Inspection of insects contamination every 1 month Customer complaint Microb.analysisof products Microb. Analysis of products
Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification ActivitiesWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature, check label Measure temperature, check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day 1. Disposition of non- complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non- complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Principle 6: Establishment of Verification Procedures HACCP Plan Worksheet 6 : Establishment of Verification Procedures (cont.) Name of Product : Cream-filled Bread
Principle 7: Establishment of Record-keeping Procedures HACCP Plan Worksheet 7 : Establishment of Record-keeping Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification Activities RecordsWhat How Where Who Frequenc y Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Production supervisor Production supervisor Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh-meter Inspection of insects contamination every 1 month Customer complaint Microb. analysis of products Microb. Analysis of products Receiving log Warehouse log, Rh operation document, Rh calibration documents, Insects inspection document Receiving log Production log, microb. analysis document Production log, microbiological analysis document
Ingredient / Process Step CCP No. CL Monitoring Procedures Corrective Actions Verificatio n Activities RecordsWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature , check label Measure temperature , check label Wareho use Wareho use Warehous e mngr. Warehous e mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Warehouse log, microb. Analysis document Warehouse log, microb. Analysis document Principle 7: Establishment of Record-keeping Procedures HACCP Plan Worksheet 7 : Establishment of Record-keeping Procedures (cont.) Name of Product : Cream-filled Bread
HACCP Plan Cream-Filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification Activities RecordsWhat How Where Who Frequenc y Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Production supervisor Production supervisor Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh-meter Inspection of insects contamination every 1 month Customer complaint Microb. analysis of products Microb. Analysis of products Receiving log Warehouse log, Rh operation document, Rh calibration documents, Insects inspection document Receiving log Production log, microb. analysis document Production log, microbiological analysis document
Ingredient / Process Step CCP No. CL Monitoring Procedures Corrective Actions Verificatio n Activities RecordsWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature , check label Measure temperature , check label Wareho use Wareho use Warehous e mngr. Warehous e mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Warehouse log, microb. Analysis document Warehouse log, microb. Analysis document HACCP Plan (cont.) Cream-Filled Bread

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Bakery Haccp plan

  • 1.
    HACCP PLAN FORBAKED FOODS Department of Food Science and Technology Faculty of Agricultural Technology Bogor Agricultural University 2009
  • 2.
    Langkah 1 :Establish the HACCP team Name Expertise/Position Position in the team Dewi Food Tech. & HACCP specialist/ Coordinator QA Mgr. Rahman Engineering/Production Mgr. Member Putri Microbiology/QC Mgr. Member Surya Chemistry/Warehouse Mgr. Member
  • 3.
    Step 2 :Product Description • Name of product • Composition • Product characteristics • Methods of processing • Methods of preservation • Primary packaging • Conditions of storage • Method of distribution • Shelflife • Specific labelling • Instruction on the label : cream-filled bread : Susu skim, kultur BAL, glukosa : Susu kental, asam, pH 4.3 : pasteurisasi, fermentasi : fermentasi : cup Polyethylene : Suhu 4oC : Dalam truk beropendingin : 3 minggu : - : -
  • 4.
    Step 3 :Identification of the Product’s Intended Use • Name of product • Intended use • Target consumer : Cream-filled bread : Directly consumed : General public
  • 5.
    Step 4 :Establish Process Flow Diagram Process flow diagram for the bread : Weigh all ingredients (sugar, salt, skim milk, shortening, egg, wheat flour, yeast, cold water) Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-300C) Divide the dough and weigh 900 gram each Fermentation 2 (27-300 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
  • 6.
    Step 4 :Establish Process Flow Diagram Process flow diagram for the cream : Weigh all the ingredients (jelly mallow, butter, shortening) Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
  • 7.
    Step 5 :On-site Confirmation of Flow Diagram : Bread Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving (egg, water) Dry storage at room temperature (25-300 C) Storage at 5-150 C Weigh all ingredients Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-300C) Divide the dough and weigh 900 gram each Fermentation 2 (27-300 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
  • 8.
    Step 5 :On-site Confirmation of Flow Diagram : Cream Receiving (jelly mallow, butter, shortening) Dry storage at room temperature (25-300 C) Weigh all the ingredients Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
  • 9.
    Principle 1 :Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving of egg Storage of egg Weighing of all ingredients Mixing of sugar, salt, skim milk B B B P B P P Contaminated yeast (by spoilage or pathogenic m.o.) Insects Presence of pathogenic bacteria Eggshell (cracked/broken eggs) Growth of pathogenic bacteria Insect bone pieces Insect bone pieces, personal items
  • 10.
    Process Step Potential Hazard(s) B/C/P Descriptionof Hazard Adding egg and shortening Adding wheat flour, yeast and cold water Blending Rounding the dough Fermentation 1 Dividing the dough Fermentation 2 B P B P B P B B B B Contamination of pathogenic bacteria Eggshell Contamination of spoilage or pathogenic bacteria (from yeast and water) Insect bone pieces Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 11.
    Process Step Potential Hazard(s) B/C/P Descriptionof Hazard Spreading with egg Baking Cooling Filling with cream Packaging Storage B B B B B B Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o. Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 12.
    Process Step Potential Hazard(s) B/C/P Descriptionof Hazard Receiving jelly mallow, butter, shortening Storage Weighing all ingredients Mixing Beating Storage - B C - P P B - Contamination of spoilage m.o. Decomposition of chemical compound - Personal item Personal item Growth of spoilage m.o. Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 13.
    Principle 1 :Hazard Analysis HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Preventive or Control Measures Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) B Contaminated yeast (by spoilage or pathogenic m.o.) Quality assurance (certificate of analysis) from supplier Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) P Insects Proper storage conditions (dry, clean), sealed packaging of the ingredients. Receiving of egg, water B Presence of pathogenic bacteria Certificate of analysis from egg supplier, acceptable water source P Eggshell (cracked/broken eggs) Inspection of incoming eggs Storage of egg B Growth of pathogenic bacteria Refrigerated storage (5-15 0 C), Label expired date. Weighing of all ingredients P Insect bone pieces, personal items Inspection of the ingredients, SOP for production area (no personal items are wore) Mixing of sugar, salt, skim milk P Insect bone pieces, personal items Inspection of the ingredients, SOP for production area (no personal items are wore) Adding egg and shortening P Eggshell Inspection of the ingredients (cracked eggs) Adding wheat flour, yeast and cold water P Insect bone pieces Filtering of wheat flour Blending B Contamination of spoilage m.o. from the air SSOP P Personal item SOP for production area (no personal items are wore) Rounding the dough B Contamination of spoilage & pathogenic m.o. from the air & worker SSOP
  • 14.
    Process Step Potential Hazard(s) Description ofHazard Preventive or Control MeasuresB/C/P Fermentation 1 B Contamination of spoilage m.o. from the air SSOP Dividing the dough B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Fermentation 2 B Contamination of spoilage m.o. from the air SSOP Spreading with egg B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Baking B Survival of spoilage m.o. Correct time and temperature Cooling B Contamination of spoilage m.o. from the air SSOP Filling with cream B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Packaging B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Storage B Contamination of spoilage molds Proper storage condition (dry, clean), expired date must be stated on the label Receiving jelly mallow, butter, shortening - Storage B Contamination of spoilage m.o. Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients Weighing all ingredients Mixing P Personal item SSOP Beating P Personal item SSOP Storage B Growth of spoilage m.o. Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight) Principle 1 : Hazard Analysis HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 15.
    Principle 1 :Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Severity Significant hazard (Y/N) Preventive or Control Measures Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg, water Storage of egg Weighing of all ingredients B P B P B P Contaminated yeast (by spoilage/ pathogenic m.o.) Insects Presence of pathogenic bacteria Eggshell (Cracked / broken eggs) Growth of pathogenic bacteria Insect bone pieces, personal items l h m h l l M M M M L M N Y N Y N N Quality assurance (certificate of analysis) from supplier Proper storage conditions (dry, clean), sealed packaging of the ingredients. Certificate of analysis from egg supplier, acceptable water source Inspection of incoming eggs Refrigerated storage (5-150 C), Label expired date. Inspection of the ingredients, SOP for production area (no personal items are wore)
  • 16.
    Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likelyto occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Mixing of sugar, salt, skim milk Adding egg and shortening Adding wheat flour, yeast and cold water Blending Rounding the dough Fermentation 1 P P P B P B B Insect bone pieces, personal items Eggshell Insect bone pieces Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air l m m m m l l M M M L M L L N N N N N N N Inspection of the ingredients, SOP for production area (no personal items are wore) Inspection of the ingredients (cracked eggs) Filtering of wheat flour SSOP SOP for production area (no personal items are wore) SSOP SSOP Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 17.
    Process Step Potential Hazard(s) B/C/P Description ofHazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging of bread Storage and distribution B B B B B B B B Contamination of spoilage and pathogenic m.o. from the air, weigh- scale, and worker Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o. Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds m l m l m m m m L L H H M H H M N N Y N N Y Y N SSOP SSOP SSOP Correct time and temperature SSOP SSOP SSOP Proper storage condition (dry, clean), expired date must be stated on the label Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 18.
    Process Step Potential Hazard(s) B/C/P Description ofHazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Receiving jelly mallow, butter, shortening Storage of jelly mallow, butter, shortening Weighing all ingredients Mixing Beating Storage of cream - B C - P P B - Contamination of spoilage m.o. Decomposition of chemical compound - Personal item Personal item Growth of spoilage m.o. - m m - l l m - H H - M M H - Y Y - N N Y - Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients - SSOP SSOP Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight) Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 19.
    Principle 2 :Establishment of Critical Control Point CCP HACCP Plan Worksheet 2A : Establishment of CCP in Ingredients Name of Product : Cream-filled Bread Ingredient Potential Hazard (s) P1 P2 P3 CCP? Sugar B P Y Y Y Y N N N N Wheat flour B P Y Y Y Y N N N N Yeast B Y Y N N Egg B C P Y Y Y Y N N N - - N Y Y Water B Y Y N N
  • 20.
    Principle 2 :Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Potential Hazard(s) P1 P2 P3 P4 P5 CCP? Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Storage of egg Weighing of all ingredients Mixing of sugar, salt, skim milk Adding egg and shortening Adding wheat flour, yeast and Cold water Blending B P B P B P P P P B P N Y N Y N N N N N N N - Y - Y - - - - - - - - N - N - - - - - - - - Y - Y - - - - - - - - N - N - - - - - - - N CCP N CCP N N N N N N N
  • 21.
    Process Step Potential Hazard(s) P1 P2P3 P4 P5 CCP? Rounding the dough Fermentation 1 Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging Storage and distribution of bread B B B B B B B B B B N N N N Y N N Y Y N - - - - Y - - Y Y - - - - - N - - N N - - - - - Y - - Y Y - - - - - Y - - N N - N N N N N N N CCP CCP N Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 22.
    Process Step Potential Hazard(s) P1 P2P3 P4 P5 CCP? Storage of jelly mallow, butter, shortening Mixing Beating Storage of cream B C P P B Y Y N N Y Y Y - - Y N N - - N Y Y - - Y N N - - N CCP CCP - - CCP Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 23.
    Principle 3: Establishmentof Critical Limits HACCP Plan Worksheet 3 : Establishment of Critical Limits Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20-250 C Holding Time <10 min, T=20-250 C Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date
  • 24.
    Principle 4: Establishmentof Monitoring Procedures HACCP Plan Worksheet 4 : Establishment of Monitoring Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures What How Where Who Freq. Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90=92 Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20-250 C Holding Time <10 min, T=20-250 C Antibiotic residue on CoA Cracked/broken eggs Rh Storage time SSOP application Cracked/broken eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temp. Receiving site Receiving site Storage room / warehouse Receiving site Production area Production area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Area personnel Area personnel Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temp., check label Measure temp. check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day
  • 25.
    Principle 5: Establishmentof Corrective Actions HACCP Plan Worksheet 5 : Establishment of Corrective Actions (1) Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions What How Where Who Frequency Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure Rh,check storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperatur e Check/ measure time and temperatur e Receiving site Receiving site Storage room / warehouse Receiving site Production area Production area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Area personnel Area personnel Every receiving Every receiving Every day Every Receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr.
  • 26.
    Ingredient/ Process Step CCP No. CL MonitoringProcedures Corrective Actions What How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature, check label Measure temperature, check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Principle 5: Establishment of Corrective Actions HACCP Plan Worksheet 5 : Establishment of Corrective Actions (1) Name of Product : Cream-filled Bread
  • 27.
    Principle 6: Establishmentof Verification Procedures HACCP Plan Worksheet 6 : Establishment of Verification Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification ActivitiesWhat How Where Who Frequen cy Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/bro ken eggs Rh Storage time SSOP application Cracked/bro ken eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehou se mngr. Receiving personnel Productio n superviso r Productio n superviso r Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh- meter Inspection of insects contamination every 1 month Customer complaint Microb.analysisof products Microb. Analysis of products
  • 28.
    Ingredient/ Process Step CCP No. CL MonitoringProcedures Corrective Actions Verification ActivitiesWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature, check label Measure temperature, check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day 1. Disposition of non- complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non- complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Principle 6: Establishment of Verification Procedures HACCP Plan Worksheet 6 : Establishment of Verification Procedures (cont.) Name of Product : Cream-filled Bread
  • 29.
    Principle 7: Establishmentof Record-keeping Procedures HACCP Plan Worksheet 7 : Establishment of Record-keeping Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification Activities RecordsWhat How Where Who Frequenc y Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Production supervisor Production supervisor Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh-meter Inspection of insects contamination every 1 month Customer complaint Microb. analysis of products Microb. Analysis of products Receiving log Warehouse log, Rh operation document, Rh calibration documents, Insects inspection document Receiving log Production log, microb. analysis document Production log, microbiological analysis document
  • 30.
    Ingredient / Process Step CCP No. CL MonitoringProcedures Corrective Actions Verificatio n Activities RecordsWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature , check label Measure temperature , check label Wareho use Wareho use Warehous e mngr. Warehous e mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Warehouse log, microb. Analysis document Warehouse log, microb. Analysis document Principle 7: Establishment of Record-keeping Procedures HACCP Plan Worksheet 7 : Establishment of Record-keeping Procedures (cont.) Name of Product : Cream-filled Bread
  • 31.
    HACCP Plan Cream-Filled Bread Ingredient/ Process Step CCP No. CLMonitoring Procedures Corrective Actions Verification Activities RecordsWhat How Where Who Frequenc y Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Production supervisor Production supervisor Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh-meter Inspection of insects contamination every 1 month Customer complaint Microb. analysis of products Microb. Analysis of products Receiving log Warehouse log, Rh operation document, Rh calibration documents, Insects inspection document Receiving log Production log, microb. analysis document Production log, microbiological analysis document
  • 32.
    Ingredient / Process Step CCP No. CL MonitoringProcedures Corrective Actions Verificatio n Activities RecordsWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature , check label Measure temperature , check label Wareho use Wareho use Warehous e mngr. Warehous e mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Warehouse log, microb. Analysis document Warehouse log, microb. Analysis document HACCP Plan (cont.) Cream-Filled Bread