HACCP plan for bread making by Viduranga Nuvan

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Issue Date : 12 Dec 2023 Revision Date: ISO 22000:2018 FSMS
Issue No : 01 Revision No: Doc Ref:
XXX -FSMS-HACCP-1
HACCP PLAN FOR BREAD
Prepared By: Name: VidurangaNuvan Designation: Quality Assurance
Manager
Signature:
Reviewed
By:
Name: Designation: Signature :
Approved
By:
Name: Designation: Managing Director Signature:
HACCP PLAN FOR BREAD
MAKING
By
Viduranga Nuvan
Quality Assurance Manager, Sri Lanka
+94718040539
wickramapathirana@gmail.com
25 February 2024

2 | P a g e
Ingredients
Wheat Flour, Salt, Milk Powder, Water, Margarine, Yeast
Steps
• Kneading the following ingredients together in a dough mixer for 20 min: Wheat Flour, yeast, salt, milk
powder, water, margarine.
• Dividing into balls
• Proofing for 1h at room temperature
• Sheeting
• Panning
• Filling in greased pans
• Baking at 220 0
C for 20 min
• Cooling
• Packaging
• Metal Detecting
• Frozen Storage

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Product Characteristics-Raw Material, ingredients and product-contact
Materials- Bread
Biological, chemical
and physical
characteristics
Raw Material Biological Chemical Physical
Wheat Flour Semi-
perishable
Water:11.92/100g
Fat: 0.92/100g
Proteins: 15.40g/100g
Texture: Powdery
Color: White
pH:6-6.8
Margarine Perishable Percentage % Color: Light buttery
Smell: Mild smell
Flavor: Butter flavor
Texture: Butter like
pH: 3.6 – 6
aW: 0.87
Fat 70
Carbohydrates 2
Water 26
Yeast Semi-
perishable
C19H14O2 pH: 5.8
Texture: Granular
Color: Brown
Salt Non-
perishable
NaCl pH: 7
Texture: Crystalline
Color: White
Sugar Non-
perishable
C12H22O11 pH: 7
Texture: Granular
Color: White
Water Non-
perishable
H2O pH: 6.5-8.5
Texture: liquid
Color: Colorless
Milk Powder Semi-
perishable
wettability 13s, dispersibility33 g,
flowability 62.8° (angle of repose),
sinkability at 2 min 24% transmission,
packed bulk density 0.65 g/mL, free
fat 1.3% (as % of fat),
and solubility index 0.6 to 1.0 mL
pH: 6.5-6.7
Texture: Powdery
Color: White
Composition of
formulated
ingredients
Baking Powder: 250 White Sugar, 250 g All-Purpose Flour, 4-5 Eggs, 250 g Butter, 2 heaped
tablespoons of Brownson baking Powder, 2 table spoons of Brownson vanilla, 2 tablespoons of
Brownson Citrus Drop, 2 Table spoons of Lemon Zest
Place of origin Item Country of Origin Supplier (s)
Wheat Flour USA X company
Sugar India Y company
Margarine Sri Lanka Z company
Baking Powder Sri Lanka A company
Yeast Turkey B company
Milk Powder Sri Lanka C company
Salt Sri Lanka D company
Method of production Item Method of Production
Wheat Flour Secondary production
Sugar Secondary production
Margarine Secondary production
Baking Powder Secondary production
Yeast Secondary production
Milk Powder Secondary production
Salt Secondary production

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Packaging and
delivery method
Ingredient Packaging Method Delivery Method
Wheat Flour Packaged in containers which will
safeguard the hygienic, nutritional,
technological, and organoleptic qualities
of the product.
The containers, including packaging
material, shall be made of substances
which are safe and suitable for their
intended use.
They should not impart any toxic
substance or undesirable odor or flavor to
the product.
When the product is packaged in sacks,
these must be clean, sturdy and strongly
sewn or sealed.
Delivered to the plant
hygienically, safely and
conforming to storage
conditions by supplier vehicles
(No special time/ temperature
requirement)
Sugar Packaged in HDPE woven sacks with
ends being strongly sewn
conditions by supplier vehicles
(No special time/ temperature
requirement)
Margarine Primary Packaging: LDPE polythene
Secondary Packaging: Corrugated paper
carton
conditions by the approved
suppliers in temperature
controlled vehicles. During
transport temperature should
be maintained at 100
Cor
below.
Yeast vacuum-packed with aluminum-plastic
film into 500g/bag
suppliers in temperature
controlled vehicles.
Transport/ Storage temp ≤ 4
Milk Powder packed in laminate bags made of PET /Al
/ PE and filled with an inert gas, such as
N2
suppliers.
Transport condition:
controlled humidity, at room
temperature or AC
Salt Plastic bags made of LDPE, BOPP Delivered to the plant
suppliers.

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Storage condition and
shelf life
Item Storage Condition Shelf Life
Wheat Flour Transfer the flour from the original
package into a food-grade container
(plastic or glass) with a tight lid and store
in a cool, dry place protected from
sunlight to prevent moisture from
creeping in and to keep insects and other
pests out and to block odors and flavors
from other foods or products stored
nearby, which could affect the aroma or
taste of the flour.
Up to one year under ideal
conditions
Sugar Decanted from PP bags into
• Polyethylene bags
• Mylar-type bags or
• Food-grade plastic buckets
And store in a cool, dry location, not the
refrigerator as moisture makes granulated
sugar hard and lumpy.
Store in an odor free area as sugar can
absorb strong odors – even through
plastic packaging.
Up to 2 years under ideal
conditions
Margarine Store in a refrigerator at 40℉ (4℃) or
below.
Keep them in their original containers or
packaging, in an airtight container as air
is another contributor to making them go
bad.
Stop them from being exposed to light
and high temperatures which can make
them become spoiled and rancid.
Unopened: 3-4 months in a
refrigerator, 6-12 months in a
freezer
Opened: 1-2 months in a
refrigerator, 6-8 months in a
freezer
Yeast Store in a cool location, refrigerated or
frozen up to the recommended shelf life.
Unopened: Up to 2 years
Opened: In the refrigerator to
use within four months, and
six months – if kept in the
freezer.
Milk Powder Store at room temperature and keep away
from any moisture.
Unopened: By best before
Opened:
Salt At room temperature, away from direct
sunlight
Opened: By Exp. / Best
Before Date
Preparation and/or
handling before use
or processing
Wheat Flour End of the original package unstitched and transferred the content into a food
grade plastic container. Content taken subject to weighing and sifting before
use.
Sugar End of the original package unstitched and transferred the content into a food
grade plastic container. Content taken subject to weighing and direct use
Margarine Cut the required slice off after opening the original package or unwrapping the
cling film and let it to melt at room temperature or boil before use.
Yeast Once opened seal the opening between uses and store in chiller/ refrigerator
Milk Powder Once opened seal the opening between uses and store in cool dry place
Salt Store in a cool, dark and dry place

6 | P a g e
Food safety related
acceptance criteria or
specifications of
purchased materials
and ingredients
appropriate to their
intended use
All ingredients are purchased only from audited / approved suppliers. Inspect at receiving for
specific quality and safety characteristics as per specifications.

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Characteristics of End Product
Product Name or similar identification Sandwich Bread
Composition Wheat flour, yeast, Salt, Milk Powder, Water, Margarine
Biological, chemical and physical
characteristics relevant for food safety
Biological
Organoleptic characteristics:
Physical State : Airy, soft, spongy, elastic and crumb
Color : Light brown
Odor : Typical
Flavor : Typical
Microbiological characteristics:
• Aerobic plate Count <104
• Enterobacteriaceae <102
• Escherichia coli < 3
• Escherichia coli O157 n.d. in 25g
• Staphylococcus aureus and other
coagulase-positive staphylococci
<20
• Clostridium perfringens <102
• Bacillus cereus and other
pathogenic Bacillus spp
<102
• Campylobacterspp n.d. in 25g
• Salmonellaspp n.d. in 25g
• Listeria monocytogenes n.d. in 25g
• Fungi (Molds) and Yeasts ≤ 10² UFC/g
NOTE: The food sample shall be analyzed for all the parameters only if
any of the 3 parameters regularly tested-Total microorganisms,
Salmonella, or Fungi/molds- found in unacceptable levels.
Chemical:
Food additives used, if any, shall conform to either Sri Lankan or EU
regulations:
• Regulation (EC) No 1333/2008- EU
• Food (Preservatives) Regulations-2019- Sri Lnka
• Food (Additives - General) Regulations 2019 – Sri Lanka
Antioxidants used, if any, shall conform to the following regulation:
• Food (Antioxidants) Amended Regulations 2013 - 1809/4
Food flavorings used, if any, shall conform to:
• Regulation (EC)1334/2008- EU
• Or, Food (Flavoring Substances and Flavor Enhancers)
Regulations 2013 - No 1795/51- Sri Lanka
Food (Coloring Substances) used, if any, shall conform to:
• Food (Coloring Substances) Amendment Regulations 2011 -
1688/28

8 | P a g e
Chemical Cont’d from the previous page
Food (Flavoring Substances and Flavor Enhancers) used, if any, shall
conform to:
• Food (Flavoring Substances and Flavor Enhancers)
Regulations 2013 - No 1795/51
Contaminants, if present, shall be within safe limits as per (EC)
1881/2006
Pesticides shall not exceed the maximum recommended limit as per EU
pesticide database (Oct 2018)
Veterinary medicines, if present, shall be in safe limits as per
Regulation 37/2010 & Directive 96/22/EC
Heavy metals, if present, shall not exceed the max recommended limit
as per Regulation (EC) No 1881/2006
(Free from Environmental pollutants - such as industrial chemicals,
pesticides and many toxic elements, residues of agro-chemicals,
veterinary drugs and heavy metal organic or inorganic.)
Free from cleaning chemicals, pesticides (including those not applied in
or around food processing establishments), allergens, toxic metals,
nitrites and nitrates (when added to the product), plasticizers and
packaging migration, and chemical additives.
Physical:
Free from extraneous foreign materials (metals, glass, stones or any
non-edible), adulterants and filthy objects such as hair.
Intended Use No restrictions/General public
Intended shelf life and storage
condition
Storage Condition Shelf life
On the counter, at room temperature 3-4 days
In a fridge, at or below 4 0
C 5-8 days
In a freezer, at or below -18 0
C 3-6 months
Packaging Sealed in In LDPE/ BOPP bags
Labeling related to food safety and/or
instructions for handling , preparation
and usage
Ready –to-Eat
Compliance with Good Personnel Hygiene Practices, Maintain facilities
equipment and utensils for the operation (handling and preparation)
properly sanitized.
Method of distribution Distributed from the main warehouse in Pepiliyana to restaurant outlets
located in the suburbs of Colombo

9 | P a g e
• Wheat flour
• Margarine
• Yeast
• sugar
• salt
• water
• milk powder
• Mixing the following ingredients together in a dough mixer: Wheat Flour, Yeast, Salt, Milk Powder, Water,
Margarine and Sugar.
• Kneading for 20 minutes
• Division of dough into balls
• Proofing for 1 hr at room temperature
• Sheeting
• Panning
• Filling in greased pans
• Baking at 220 0
C for 30 minutes
• Cooling
• Packaging
• Metal Detecting
• Frozen Storage
Method of preparation for Sandwich Bread
Ingredients
Procedure

10 | P a g e
Not required unless stored frozen
Receiving wheat flour, yeast,
salt, milk powder, water,
Margarine
Quality Inspection
Kneading (20 min)
Kneaded Dough
Dividing into balls
Proofing for 1 hr at room
temperature
Fermentation 15 min @ 35-
400
Cwarm cupboard
Filling in greased pans
Baking
@2200
C for 30 min
Cooling (1 hour)
Frozen Storage
(@or below -18 0
C)
Solid
waste
Liquid
waste
Solid
waste
Dispos
al
To the
treatm
ent
plant
Packaging
Process Flow Diagram for manufacturing of Bread
Receiving Water
Quality
Inspection
Receiving
Margarine
Softening with
mild Heat
Metal Detecting
(Optional)
(
Receiving Wheat
Flour + Yeast
Weighing
Sieving
Receiving Milk
Powder
Quality
Inspection
Rebaking

11 | P a g e
Details of working at each step
Number Step Name Procedure of working and controlling
1 Receiving Water Daily check residual chlorine level in water by a Chlorine test kit
Follow X-FSMS-SOP-31(Receiving and quality inspection of water)
2 Receiving of wheat flour Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)
3 Receiving Yeast Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)
4 Receiving Sugar Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)
5 Receiving Milk Powder Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)
6 Receiving Salt Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)
7 Receiving Margarine Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)
8 Softening margarine with mild heat Perform the task quickly, hygienically and without interruptions.
Compliance with GHP. Keep facilities, equipment and utensils for the
operation properly sanitized.
9 Sieving flour and yeast Stiff the flour through a strainer with pore size less than 2mm in
diameter to screen all physical hazards.
10 Weighing and Mixing (Kneading)
ingredients- Wheat Flour, yeast,
Salt, Milk Powder, Water,
Margarine in a dough mixer for 20
min
Perform the task quickly, hygienically and without interruptions.
11 Stand (Proofing) Keep the mixture well packed in proper places, protected from
contamination. Compliance with Good Personnel Hygiene Practices,
Maintain facilities and equipment for the operation properly sanitized.
12 Dividing kneaded dough into balls Perform the task quickly, hygienically and without interruptions.
13 Fermentation (15 min @ 35-
400
Cwarm cupboard)
Compliance with GHP. Keep the mixture well packed in proper place,
protect from contamination.
Keep facilities, equipment and utensils for the operation properly
sanitized.
14 Filling in greased pans Perform the task quickly, hygienically and without interruptions.
15 Baking X-FSMS-SOP-3 (Procedure for Cooking)
16 Cooling Cool immediately. No need to follow 2 stage method because of its
nature
17 Metal Detecting
(Optional)
Insert the frozen bread into the metal detector
18 Packaging/Storing in freezer Compliance with good personnel Hygiene Practices (GHP), Perform the
task quickly, hygienically and without interruptions.
19 Baking (reheating) frozen Breads Hold for 20 min an oven preheated @230 C while wrapped on a
aluminum foil

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RISK ASSESSMENT PROCESS
• Severity (SAHE)
5 Can cause fatality
4 Can lead to serious illness/injury
3 Can cause product recall
2 Can generate customer complaint
1 Not significant
• Likelihood of occurrence (LOC)
5 Common Occurrence
4 Known to Occur (Has happened at our premises)
3 Could occur (Evidence in published material)
2 Not likely to occur
1 Practically impossible to occur
• LOC X SAHE=
<9
>9 or 9
Non-Significant PRPs
Significant
Decision Tree
OPRPs CCPs

13 | P a g e
HACCP PLAN-IDENTIFICATION AND CONTROL OF HAZARDS (B- Biological, C- Chemical, P- Physical)
No Raw Material/
Food Contact
Material/Process
Step
Potential Hazard Category
(B/C/P)
Control and preventative Measures Hazard Analysis
Probability Severity Risk
Level
1 Receiving Water Presence of pathogens of public
health significance in unacceptable
levels:
Campylobacterspp ≥ 500 bacteria
Verocytotoxigenic E. coli (VTEC):
about 10- 100 organisms
Enteric fever salmonellas
(Salmonella typhi and Salmonella
paratyphi): 102
-103
organisms
gastroenteritis salmonellas
(Salmonella enterica) ≥ 106
-108
organisms
Species of Shigella: around 102
organisms
Vibrio spp (Vibrio
parahaemolyticus, V. cholera):
103
-106
organisms
Emerging pathogens:
Helicobacter pylori
Francisellatularensis
Ref: (WHO, Bacteria of potential
health concern, 2013)
B Preventative: Use an approved source of water
satisfying the requirements of bacteriological
quality of water given in SLS 614:2013 (Potable
water Standard)
Controlled by sanitation measures and water
treatment processes
Certificate of analysis from water authority
For Tube well water:
Primary disinfection of tube well water with any
of the following disinfectants (chemical
oxidation process): chlorine, monochlorine,
chlorine dioxide, ozone, UV light and mixed
oxidants. Ref: (WHO, Inactivation
(disinfection) processes, 2004)
Chlorine disinfection:
Water pH: 6.5- 8.5
Disinfectant concentration: 0.5-2mg/L of
residual chlorine level.
Contact time: 30 min for residual chlorine level
of 0.5 ppm
Water temperature: 180
C to 370
C
UV disinfection:
UV-B and UV-C ranges of the spectrum (200–
310 nm), with maximum effectiveness around
265 nm.
For Municipal water:
Residual chlorine level 0.5- 2 ppm
3 1 3
Justification: Considering the
likelihood of occurrence of the
identified biological hazards prior
to application of control measures,
the following hazards could create
high to moderate level of severity:
Note: Water has multiple uses and
can contaminate product at any
stage. Intended use of water is
direct use (washing, cooling after
blanching)
High (Life threatening)
Salmonella typhi
Escherichia coli 0157:H7
Vibrio cholera
Moderate (Severe or chronic)
Campylobacter spp.
Salmonella spp.
Shigella spp.
(FAO, Pathogenic bacteria , 2020)

14 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
1 Receiving Water Presence of chemical contaminants
at levels over EPA’s safety
standards.
E.g. Disinfection byproducts,
solvents and pesticides,
radionuclides (such as radium), and
minerals (such as arsenic).
Ref: (Common Waterborne
Contaminants)
C Preventative: Initially and periodically check
water for chemical requirements; Table 2 of
SLS 614, toxic substances; Table 3 of SLS 614,
and verify that water source meets minimum
requirements.
Control measures :
In the event of a deviation from expected results
the following methods may apply
1. Reverse osmosis systems
(Reverse Osmosis Systems will remove
common chemical contaminants (metal ions,
aqueous salts), including sodium, chloride,
copper, chromium, and lead; may reduce
arsenic, fluoride, radium, sulfate, calcium,
magnesium, potassium, nitrate, and
phosphorous.)
2. Distillation Systems
Distillation Systems will remove common
chemical contaminants, including arsenic,
barium, cadmium, chromium, lead, nitrate,
sodium, sulfate, and many organic chemicals.
3. Water softners
(They can be used to remove iron and
manganese, heavy metals, some radioactivity,
nitrates, arsenic, chromium, selenium, and
sulfate.)
Ref: (CDC, A Guide to Drinking Water
Treatment Technologies for Household Use,
2014)
3 1 3
NOTE: The effect due to presence
of chemical contaminants in water
at levels over EPA’s safety
standards is not acute but chronic
meaning adverse effects occur if
consumed over the cause of many
years.

15 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
1 Receiving Water Presence of sediments and
particulates (pipe
materials, pipe liner materials,
sloughed biofilms or iron and
manganese films)
Ref: (Understanding the hazards
and threats )
P Preventative: Adhere to the requirements of table
1 of SLS 614: 2013 when choosing the water
source.
Control: Sedimentation and filtration.
Sedimentation by holding the raw water in ponds
or tanks.
Filtration: Cartridge filtration, rapid sand
filtration, multimedia sand filtration, and up-flow
filtration.
3 2 6
2 Receiving of
Wheat flour
Presence of mold and their
corresponding fungus species
such as Aspergillus spp.,
Penicillum spp., Fusarium spp.
and Alternaria spp.
Presence of dangerous toxic
metabolites called mycotoxins
such as aflatoxin, ochratoxin,
zearalenone, patulin,
deoxynivalenol, trichothecene
and fumonisin.
B Preventive:
Applicable at primary producer level and during
prolonged storage after receiving flour.
Follow Good Storage Practices(GSP):
RH of the environment should be below 62 % and
the material water content should be below 10 %.
Store at a low oxygen environment: 50% CO2 and
20% O2
Keep Water Activity at or below 0.80 and CO2
level over 30 %
Purchase from approved suppliers only.
Control:
Discard the affected lot
Controlled as a SOP
Note: Myvotoxins are completely destroyed at
their melting point: 164°C (327°F) for
Zearalenone, 170°C (338°F) for Rubratoxia., the
toxicity of aflatoxin B1 is reduced by 70%, and
that of aflatoxin B2 by 45%.
Pure aflatoxin B1 (AFB1) is destroyed by
temperatures above 160 °C
3 1 3

16 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
2 Receiving of
Wheat flour
Presence of Salmonella spp.,
Escherichia coli, Bacillus cereus
at an infectious dose: 1 log
cfu/g
B Control:
Purchase from approved/reputed/HACCP or ISO
22000 FSMS certified suppliers only.
Application of heat treatment to reach core
temperature of 750
C or equivalent, e.g. 700
C for 2
minutes to kill all viable cells.
2 2 4
Presence of pests such as
Sitophilus granaries L. (weevil),
S. oryzae L. (rice
louse),Trogodermagranarium
(Khapra beetle),
Rhizoperthadominica F. (crop
hump beetle),
Triboliumconfusum and T.
castaneum (half-blood lice),
Ptinus fur L. (white-spotted
spider mite),
Nemapogongranellus L. (crop
warehouse moth),
Ephestiakuehniella (mill moth),
Acarussiro L. (flour mite)
B Control:
Purchase from Approved/Reputed/ISO
22000FSMS/HACCP certified suppliers only
Keep the oxygen rate of the atmosphere inside the
storage lower than 2 % and/or the carbon dioxide
rate is higher than 12 %, to minimize the insect and
mice activity.
2 3 6
Presence of Pesticides used in
the businesses for insects and
rodents control, residues of
hygiene and sanitation products.
C Preventative: No preventative measures applicable
at receiving
Control: Purchase from Approved suppliers only
2 3 6
Presence of extraneous matter
such as metal fragments -
measures two millimeters or
more in size-detached from
blades in the milling process
P Preventative: No preventative measures
applicable at receiving
Control: Sieve through a strainer having mesh size
smaller than 2mm
2 3 6

17 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
3 Receiving Yeast Biological: No common hazards B - - - -
Chemical: No common hazards C - - - -
Physical: No common hazards P - - - -
4 Receiving of sugar No potential food safety hazards
identified
B Pathogenic bacterial survival, growth and toxin
production is unlikely at extremely low water
activity present in sugar, which retards microbial
activity under any given condition.
- - -
Chemical contamination of
sugar during storage from
cleaning and sanitizing agents,
pest excretions, etc
C Preventive:
Establish, implement, monitor and verify good
storage practices
e.g. Store cleaning and sanitizing chemicals
separately in a cupboard or room with restricted
access
Pest control activities: Pest proof design, chemical
free control methods, such as rat glue boards.
3 2 6
Chemical contamination of
sugar during storage from
cleaning and sanitizing agents,
pest excretions, etc
C Preventive:
storage practices
e.g. Store cleaning and sanitizing chemicals
separately in a cupboard or room with restricted
access
Pest control activities: Pest proof design, chemical
free control methods, such as rat glue boards
3 2 6
Physical contamination of sugar
during storage from extraneous
matter
P Preventive:
storage practices
e.g. Glass and hard plastic policy
3 2 6

18 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
5 Receiving Milk
Powder
Presence of spoilage microbes in such
amounts that results in rapid
deterioration of milk.
B Preventative: Preventative measures
applicable at manufacturer/processor level
only.
Control:
Purchase from HACCP/ISO 22000
certified/reputed/approved/SLS 731
certified suppliers only.
Presence of spores of pathogenic
microbes such as Bacillus cereus
Presence of Enterotoxigenic
Staphylococci aureus above 105
to
106
cfu/g or ml.
Presence ofClostridium
botulinumspores.
Presence of infectious dose of
viable Cronobacter spp count.
Presence of Enteric viruses,including
hepatitis virus, poliovirus, and
coronavirus
Presence of Enteric Viruses
including heatitus virus, poliovirus,
and coronavirus, which would have
been introduced through cross-
contamination.
Presence of pathogenic microbes such
as Listeria monocytogenese, Salmonella
and Shigellaabove infectious dose:
Salmonella> 1logcfu/g
B Preventative: Preventative measures
applicable at manufacturer/processor level
only.
Control:
Purchase from HACCP/ISO 22000/FSSC
22000/certified/reputed/approved/SLS 731
Controlled as a PRP: Purchasing
specifications
2 4 8

19 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
5 Milk Powder
receiving
Presence of intentionally added
substances such as adulterants:
detergents, urea, neutralizers, etc
C Preventative: Preventative measures applicable at
manufacturer/processor level only.
Check cleanliness of transport vehicles and
personnel. Control of integrity of the packaging,
labeling and shelf life. Maintain facilities and
equipment for the operation properly sanitized.
Control:
Purchase from HACCP/ISO 22000/FSSC
22000/certified/reputed/approved/SLS 731
Controlled as a PRP: Purchasing specifications.
2 4 8
Presence of mycotoxins
including aflatoxins,
ochratoxins, and fumonosins.
Presence of unintentionally
added contaminants: heavy
metals, drugs, antibiotic residue
or hormones
Presence of broken pieces of
glass or metal fragments.
P
6 Receiving Salt Presence of pathogenic bacteria
such as Pasteurella
parahaemolytica
B Purchase salt only from approved/reputed/HACCP,
ISO 22000 FSMS certified suppliers.
3 1 3
Presence of Heavy Metals above
Recommended Daily Intake of
Heavy Metal Elements:
As: 2.1 µg/kg body weight per
day
Cd: 175µg per person per day
Cr: 200mcg for adults per day
Hg: 0.1 µg/kg/day
Ni: 100 mcg/day
Pb: 6 µg/day
C Purchase salt from approved/reputed/HACCP, ISO
22000 FSMS certified suppliers only.
Controlled as a PRP: Purchasing specifications
for Salt
3 1 3
Presence of extraneous matters
such as plastic, polythene, metal
fragments, sand, mud, gravel,
etc.
P Purchased salt from approved/reputed/HACCP,
ISO 22000 FSMS certified suppliers only.
3 1 3

20 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
7 Receiving of
Margarine
Presence of S. aureus, their survival and
growth to the infective-dose level
NOTE: Temperature, pH and Aw
condition required to support the growth
of above species
Temp. pH Aw
7-45 0
C 4.2-9.3 0.86 or above
B Preventive: Purchase from Approved/
Certified suppliers only.
Compliance with GHP and GSP to reduce
the risk of cross-contamination
Maintain recommended cold-holding
temperatures to have a bactericidal effect.
Control: Heat, if possible to 75 0
C or above
for 15 sec to create a lethal effect for
vegetative cells.
3 2 6
Justification: Whether from
human hands, contaminated
equipment, or the environment the
level of bacterial contamination in
table spreads is likely to be very
low.
Presence of Listeria monocytogens,
Escherchia coli, Salmonella spp in
unacceptable levels or outgrowth to
unacceptable levels
.
NOTE: Temperature, pH and Aw
condition required to support the growth
of above species
Temp. pH Aw
Listeria monocytogens
2-450
C 4.8 – 9.6 0.95 or above
Escherchia coli
2.5-450
C 4.6 – 9.5 0.935 or above
Salmonella spp
6.5-450
C 4.5- NA 0.95 or above
B Preventive:
• Purchase from Approved/ Certified
suppliers only.
• Compliance with GHP and GSP to reduce
• Maintain recommended cold-holding
Control: Heat, if possible to 75 0
C or above
for 15 sec to create a lethal effect for
vegetative cells.
3 2 6
Justification: Whether from
human hands, contaminated
equipment, or the environment the
level of bacterial contamination in
table spreads is likely to be very
low.
This indicates a low risk of food
borne illness from incidental
contamination.
Food Code (FDA, 1999) defined
margarine as not a potentially
hazardous food
Ref: (Guentert & Linton, 2003)
Presence, survival and growth of
spoilage bacteria causing to become
rancid and spoiled.
B Preventive:
suppliers only.
• Compliance with GHP and GSP to reduce
• Maintain recommended cold-holding
3 1 3

21 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
7 Receiving of
Margarine
Mold growth B Preventive:
suppliers only.
• Prevent exposure to water and moisture
3 1 3
Presence of mycotoxins above
maximum safe limit:
Zearalenone> 200 µg/kg
Aflatoxins B1> 8 μg/kg
Aflatoxins (Sum of B1, B2, G1 and G2)>
15μg/kg
Fumonisins (Sum of B1 and B2)> 200
μg/kg
Ref: COMMISSION REGULATION
(EC) No 1881/2006
C Preventive:
suppliers only.
Control:
Request suppliers for a test report of
mycotoxin level per each batchduring quality
inspection to verify that lot confirm to set
limits of each type of mycotoxin likely to
present on Margarine.
And, periodically send randomly drawn
samples for an accredited laboratory to be
analyzed for mycotoxins
Irradiation of ingredients used to
manufacture margarine to control mold and
mycotoxin (applies to primary producers,
processers and manufacturers only)
3 1 3
Justification: No acute effect.
Only chronic effect due to
recurrent and prolonged exposure
above the safe limit: carcinogenic
effect
8 Melting margarine No common hazards identified B - - - -
No common hazards identified C - - - -
No common hazards identified P - - - -
9 Sieving flour and
yeast
B. No common hazards identified B - - - -
C: No common hazards identified C - - - -
Leaving behind extraneous matter
measures 2mm or above
P Preventive: Use a stiffer with pore size less
than 2mm
2 3 6

22 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
10 Weighing and
Mixing
(Kneading)
ingredients-
Wheat Flour,
yeast, Calcium
Propionate, Salt,
Milk Powder,
Water, Margarine
in a dough mixer
for 20 min
Introduction of pathogenic bacteria of
public health concern from the use of
equipment and utensils with
contaminated food contact surfaces
E.g. Dough mixer
B Keep facilities, equipment and utensils for
the operation properly sanitized.
Perform the task quickly, hygienically and
without interruptions. Compliance with
GHP. Always deploy trained workers.
3 3 9
Chemical contamination with residues
of cleaning and sanitizing chemicals
from molds
C Preventive: Use food grade cleaning/
sanitizing chemicals only
Control: Wash mixing bowl with potable
water before use
2 3 6
Introduction of metal fragments from
the rotating blades of the Dough Mixer.
P Preventative: Adhere to SOPs established
on Operation/maintenance/Repair of Dough
Mixer.
Control: Check the integrity of the mixer
spiral after each mixing cycle. Or;
Scan the product by X-RAY scanner or use
metal detectors or magnets to detect metal
fragments, if any.
NOTE: Metal detector must detect 2.0 mm
ferrous, 3.0 mm non-ferrous, and 3.5 mm
stainless steel
The existence of pieces of metal can be fatal
to the health of consumer.
3 4 12
11 Stand (Proofing) Microbial contamination (Salmonella,
Staphylococcus aureus and Escherichia
coli)
B Keep the mixture well packed in proper
places, protected from contamination.
Compliance with Good Personnel Hygiene
Practices, Maintain facilities and equipment
for the operation properly sanitized.
Controlled as a PRP: Verifying compliance
with GHP
3 2 6

23 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
11 Stand (Proofing) Introduction of Cleaning and Sanitizing
chemical residues left behind in the
Dough Mixer.
C Preventative: Adhere to SSOP guidelines on
Cleaning and Sanitizing.
Controlled as a SSOP/PRP
3 2 6
Contamination by foreign objects P Compliance with GHP. Keep the mixture
well packed in proper place, protect from
contamination.
3 2 6
C: No common hazards identified. C - - - -
12 Dividing kneaded
dough into balls
Microbial contamination (Salmonella,
coli)
B Perform the task quickly, hygienically and
GHP. Keep facilities, equipment and utensils
for the operation properly sanitized.
Controlled as a PRP: Compliance with GHP
3 2 6
P: No common hazards identified. C - - - -
13 Fermentation (15
min @ 35-
400
Cwarm
cupboard)
coli)
Compliance with GHP. Keep the mixture
well packed in proper place, protect from
contamination.
Keep facilities, equipment and utensils for
the operation properly sanitized.
The subsequent stage of baking eliminates
any microbial load that may be developed in
the product, so this step is not considered a
CCP.
3 2 6
P: No common hazards identified. C - - - -

24 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
14 Filling in greased
pans
Microbial contamination as a result of
incorrect hygiene practices:
(Salmonella,Staphylococcus aureus
and Escherichia coli)
B Preventive: Keep facilities, equipment and
utensils for the operation properly sanitized.
Perform the task quickly, hygienically and
GHP. Always deploy trained workers.
Control: Verifying compliance with
good hygiene practices
3 3 9
Chemical contamination with residues
of cleaning and sanitizing chemicals
from molds
C Preventive: Use food grade cleaning/
sanitizing chemicals only
Control: Wash molds with potable water
before use
- - -
Contamination by foreign objects (hair,
And sand) as a result of incorrect
hygiene practices
P Preventive: Compliance with good personal
hygiene practices
Control: Verifying compliance with good
hygiene practices.
- - -

25 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
15 Baking Microbial survival and multiplication:
(Salmonella, Yersinia,,
Shigella Norovirus,
Staphylococcusaureus, Listeria
monocytogenes
Escherichia coli O157:H7, Micrococcus
and Bacillus)
B Compliance with good personal hygiene
practices.
Given the time-temperature combinations to
achieve 6 log reduction of different types of
pathogenic bacterial strains as mentioned
below, meet binomial time/ temperature set
(10–12 minute sat 200–220ºC) for the
process so that at the interior is reached at
least a temperature of 70 ° C
Thermal destruction of vegetative cells of
disease-producing microorganisms occur
with a heat treatment as same as
pasteurization or above :72 for 15 seconds
Shigella : Rapidly inactivated at temperatures
above 650
C.
Baking at 190.6 °C oven temperature for
17 min reduced 5 log cycles of Salmonella.
Listeria monocytogenes: 63 0
C for 17 min or
85 0
C for 0.02 min for the process to achieve
a 6 log reduction of vegetative cells
Although there is some variation in the
published heat inactivation data for
E. coli 0157:H7, there is no strong evidence
that a heat treatment of 70°C for 2 min or the
equivalent, as recommended by the ACMSF,
fails to deliver a 6D reduction in
cells of E. coli0157:H7
Bacillus cereus: 70 0
C for 12 s to achieve a 6
log reduction of vegetative cells (Byrne &
Bolton, 2007)
3 3 9

26 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
15 Baking P: No common hazards identified. C - - - -
16 Cooling and
unmolding
Biological: Microbialcontamination
(Staphylococcus aureus) as a result if
incorrect hygiene practices
B Compliance with good personalhygiene
practices. Keepfacilities, equipment and
utensilsfor the operation properly sanitized
3 2 6
C - - - -
P - - - -
17 Metal Detecting B: No common hazards identified. B - - - -
Presence of hazardous extraneous
metallic material in the finished product
due to the failure of the metal detector
to detect metal and reject the product
when metal is detected.
P Metal detector must detect 2.0 mm ferrous,
3.0 mm non-ferrous, and 3.5 mm stainless
steel test samples when the test samples are
passed through the detector with the product.
The metal detector must reject the product.
3 4 12
18 Packaging &
Frozen Storage
coli)
B Compliance with good personnel Hygiene
Practices (GHP), keep facilities, equipment
and utensils for the operation properly
sanitized.
3 2 6
Mold growth due to temperature abuse/
fluctuation during cold storage
E.g. Rhizopus, Penicillium, Aspergillus,
Mucor, and Fusarium
B Maintain product temperature of -18°C or
colder with a minimum of fluctuation.
Place stock in the cold room in such a
manner that the circulation of cold air is not
impeded to the extent that the product
temperature is adversely affected.
3 3 9
decoration)
P Compliance with good personnel Hygiene
Practices (GHP), Perform the task quickly,
hygienically and without interruptions.
3 2 6
Development of mycotoxins due to
temperature fluctuation and resulting in
moisture imparting, which triggers mold
growth
C Maintain product temperature of -18°C or
colder with a minimum of fluctuation.
3 2 6

27 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
19 Baking
(reheating) frozen
Breads
Inadequate baking process results in
bread being left with high moisture
content which favors mold growth and
hence accelerated rate of stalling during
storage.
Aflatoxins generated can be toxic if
inhaled and allergic to mold.
B Preventive:
Take the bread out of the cling film and let it
thaw overnight in the fridge until it is no
longer frozen
Preheat the oven to 190 0
C and ‘refresh' the
bread for 3 to 5 minutes.
Or;
Place the frozen loaf in a 230-degree oven
while still wrapped in the foil.
Leave the loaf in there for 10 to 15 minutes
before removing the foil
Control:
Random check on freshness criteria at the
end of the baking process. Extend the baking
process/ repeat the process in the event of a
deviation from expected quality.
3 2 6
Toxin production of Bacillus cereus
from vegetative cells resulting due to
spore germination or outgrowth of
surviving viable cells. `
B Preventive:
Heat interior to minimum temperature of 60
C at least.
Control:
Extend the baking process/ repeat the process
in the event of a deviation from expected
quality.
3 3 9
No common hazards identified C/P - - - -

28 | P a g e
No Raw Material/
Food Contact
Material/Process
Step
(B/C/P)
Level
20 Dispatch and
delivery
coli)
B Compliance with good personnel Hygiene
Practices (GHP), keep facilities, equipment
and utensils for the operation properly
sanitized.
3 2 6
Moisture being imparted to bread
during delivery would be the trigger for
potential mold growth.
B Properly wrap in plastic bags
Transport bread in temperature and humidity
controlled conditions/ stable temperature in
air conditioned compartments
3 2 6
decoration)
P Compliance with good personnel Hygiene
Practices (GHP), Perform the task quickly,
hygienically and without interruptions.
3 2 6

29 | P a g e
No
- Question 4:
- Is there any failure of the control
measure with a high risk (likelihood x
severity)for the safety of the product?
- (8.5.2.4.1) Include the following:
•The effect on the hazard.
•Control measure specifically applied to
reduce to acceptable level?
•-Any subsequent control measures?
•-Single control measure or
combination?
Categorize the control measure as an OPRP.
1. Establish action criteria. (8.5.2.4.2)
2. Monitor (measure or observe) to detect failure.
The method and frequency shall be proportionate to likelihood and
severity of failure. (8.5.2.4.1)
3. In case of failure, assess the causes and consequences of the
failure
and when necessary manage effected product as potentially unsafe
(correction). (8.9.2.3)
STOP, proceed to next step in the process.
8.5.2.4 Selection and categorization of control measures
ISO 22000:2018. Decision tree for the selection and categorization of OPRPs and CCPs.
Implement control measures (a) by modifying your own process, or
(b) have control measures in the process of the supplier of your raw materials.
If (a) and (b) are not feasible:
inform your customer about the possible presence of the hazard. (7.4.2 b 2)
Question 3:
Are control measure already in place?
Question 2
Is it necessary to apply control measures at
this step? (8.5.2.2.2)
Apply PRPs as appropriate.
Question 1
Is there a significant (likelihood x severity)
hazard at this step? (8.5.2.3)
Document relevant food safety hazards and
decide what hazards are reasonably expected
to occur in relation to the type of product and
process and process environment (8.5.2.2.1).

30 | P a g e
Yes
No
Yes
Questions 5:
Is it feasible to establish measurable critical
limits and monitoring that enable timely
detection and correction of all failure?
(8.5.2.4.2)
Categorize the control measure as an OPRP.
1. Establish action criteria. (8.5.2.4.2)
2. Monitor (measure or observe) to detect failure. The method and
frequency shall be proportionate to likelihood and severity of failure.
(8.5.2.4.1)
3. In case of failure, assess the causes and consequences of the failure
and when necessary manage effected product as potentially unsafe
(correction). (8.9.2.3)
4. When possible, redesign the product, process or control measures.
5. Inform customers and/or consumers about the risk. (7.4.2 b 2)
6. Take action to reduce the likelihood and severity of failure
.
Categorize the control measure as a CCP.
1. Establish measurable critical limits. (8.5.4.2)
2. Monitor (measurement) to detect any failure to meet critical limits.
(8.5.4.3)
3. In case of failure, manage effected products as potentially unsafe.
(8.9.2.2)

31 | P a g e
HACCP PLAN-IDENTIFICATION OF CRITICAL CONTROL POINTS (CCPS) AND OPERATIONAL PREREQUISITE
PROGRAMS (OPRPs)
No Process Step Significant hazard
identified in the hazard
analysis
Q1
Is there a
significant
(likelihood x
severity) hazard at
this step?
If Yes move to Q2
If No STOP and
apply PRP as
appropriate
Q2
Is it necessary to
apply control
measures at this
step?
If Yes move to
Q3
If No Apply PRP
as appropriate
Q3
Are control
measures already
in place?
If Yes move to the
Q4
If No STOP and
implement control
measures
Q4
Is there any failure of
the control measure
with a high risk
(likelihood x severity)
for the safety of the
product?
If Yes move to Q5
If No, categorize the
control measure as an
OPRP
Q5
Is it feasible to establish
measurable critical limits
and monitoring that
enable timely detection
and correction of all
failure?
If Yes, categorize the
control measure as CCP
OPRP
10 Weighing and mixing
Kneading ingredients
Introduction of pathogenic
bacteria of public health
concern from the use of
equipment and utensils with
contaminated food contact
surfaces
Yes No
14 Filling in greased pans Microbial contamination as
a result of incorrect hygiene
practices:
(Salmonella,Staphylococcus
aureus and Escherichia
coli)
Yes No
15 Baking Microbial survival and
multiplication:
(Salmonella, Yersinia,,
Shigella Norovirus,
Staphylococcusaureus,
Listeria monocytogenes
Escherichia coli O157:H7,
Micrococcus and Bacillus)
Yes Yes Yes Yes Yes
CCP-1

32 | P a g e
No Process Step Significant hazard
identified in the hazard
analysis
Q1
Is there a
significant
(likelihood x
severity) hazard at
this step?
If Yes move to Q2
If No STOP and
apply PRP as
appropriate
Q2
Is it necessary to
apply control
measures at this
step?
If Yes move to
Q3
If No Apply PRP
as appropriate
Q3
Are control
measures already
in place?
If Yes move to the
Q4
If No STOP and
implement control
measures
Q4
Is there any failure of
the control measure
with a high risk
(likelihood x severity)
for the safety of the
product?
If Yes move to Q5
OPRP
Q5
Is it feasible to establish
measurable critical limits
and monitoring that
enable timely detection
and correction of all
failure?
If Yes, categorize the
control measure as CCP
OPRP
17 Metal Detecting Presence of hazardous
extraneous metallic
material in the finished
product due to the failure of
the metal detector to detect
metal and reject the product
when metal is detected.
Yes Yes Yes Yes No
OPRP-1
18 Packing/ Storing Mold growth due to
temperature abuse/
fluctuation during cold
storage
E.g. Rhizopus on bread
Yes Yes Yes No
OPRP-2
19 Baking (reheating)
frozen Breads
Toxin production of
Bacillus cereus from
vegetative cells resulting
due to spore germination or
outgrowth of surviving
viable cells.
Yes Yes Yes No
OPRP-3

33 | P a g e
No. Step Significant
Hazard
Control
Measure
Measurable or
observable
Action
Criteria
Monitoring Actions to implement Responsibil
ity and
authority
What How Where When Who Corrections Corrective
Actions
17 OPRP-1
(Optional)
Metal
detecting
Metal
contamination
not detecting
Metal detector
must detect 2.0
mm ferrous,
3.0 mm non-
ferrous, and 3.5
mm stainless
steel test
samples when
the test
samples are
passed through
the detector
with the
product. The
metal detector
must reject the
product.
Minimum
detectable
limit2.0 mm
ferrous, 3.0
mm non-
ferrous, and
3.5 mm
stainless steel
Equipment
check
(Metal
detectability)
1. Test the metal detector by
passing a sample piece of
metal through the detector to
ensure that it is operating
effectively and able to detect
metal present in the product.
2. Check metal samples of
2.0 mm ferrous, 3.0 mm non-
ferrous, and 3.5 mm stainless
steel, one at a time. Each
check must include all three
sample tests.
3. Sample into the middle of
the product and then pass the
product package, if available,
through the metal detector. A
properly operating metal
detector must detect the
metal sample in the product.
1. Each time a metal
contaminant is detected, the
metal detector belt must
retract and the rejected
product must drop into the
rejection box.
Record the metal sample
check as acceptable (“ ”)
(i.e., the metal detector is
operating correctly) or not
acceptable (“X”) (i.e., the
metal detector is not
operating correctly) on the
“Daily Metal Detector Check
Record,” including the date,
the time, and initials.
Dispatch Check before
starting
operations
each day
AND
Check every
four hours
during
operation;
AND
Check at the
end of
operations
each day;
AND
Check
whenever
there is an
equipment
malfunction
that could
increase the
likelihood
that metal
could be
introduced
into the food
Equipment
operator
Or
production
supervisor
or
A member
of the
quality
control
staff
Or,
a member
of the
maintenan
ce or
engineerin
g staff
or
Any other
person
who has
an
understand
ing of the
operation
of the
equipment
.
A. When the
metal detector
fails to detect a
metal test sample:
1. Immediately
halt all steps in
which rotating
metal blades
and/or sharp metal
cutting edges
involved until the
issue rectified.
2. Unless the
issue is rectified,
visually check the
equipment for
broken or missing
parts.
e.g. check integrity
of the mixer spiral
after each mixing
cycle
B. Destroy all
product produced
since the previous
satisfactory
equipment check;.
Or
Divert all product
produced since the
previous
satisfactory
equipment check
to a non-food use.
Metal detector
validation
assisted by the
manufacturer
Annual
calibration of
the metal
detector by
the
manufacturer
and
verification of
the calibration
report by a
qualified
individual
Correct the
cause to
prevent
recurrence
Monitoring:
Production
supervisor
Correction
and
Corrective
Action:
Hygiene
Manager
Record: Metal detector operation log
Establishing Measurable or Observable Action Criteria, monitoring practices, corrective actions and verifications for OPRPs

34 | P a g e
Hazard
Control
Measure
Measurable or
observable
Action Criteria
Monitoring Actions to implement Responsibilities
and
authorities
Actions
18 OPRP-2
(Optional)
Packing
and frozen
storage
Germination of
pathogenic
bacterial spores
and outgrowth
to infectious
level due to
time/
temperature
abuse
Maintain air /
product
temperature at
or below -18
0
C
Measurable:
Freezer air temp.
≤ -18 0
C
Air
temperat
ure
Visual inspection
of the temperature
display reading
Reefer
Container
Once in 2
hrs.
Maintenance
technician
Keep the reefer
container doors
closed until an
issue related to
temperature
deviation
rectified if it can
be solved within
6 hrs or else,
immediately
transfer goods to
a backup freezer.
Discard foods if
temperature of
any part of the
food has risen to
or above 10 0
C
and time of
exposure is more
than 2 hrs.
If the time of
exposure is not
more than 2 hrs
with a
temperature rise
at or below 10 0
C,
rapidly cool the
food at or below
4 0
C whilst
awaited to be
blast frozen or
blast freeze right
away.
Investigate the
root cause and
take measures to
prevent
recurrence.
Due adherence
to preventive /
Repair &
breakdown
maintenance
Assign
responsibility
based on
competency
Document all
actions taken
and define
responsibilities
Monitoring –
Maintenance
Technicians
Correction
and
Corrective
Actions –
Hygiene
Manager
Frozen
Nature of
food
Visual Inspection Reefer
Container
Daily, as
when
required
Dispatch
team
Non-
destructi
ve
temperat
ure
measure
ment
measure the
temperature
between packages
inside a carton
use sufficient
pressure to give
good thermal
contact, and
sufficient length
of probe inserted
to
minimize
conductivity
errors; and
use a probe with a
flat surface to
give good surface
thermal contact
between
frozen
packages
inside a
carton
Daily or as
when
required.
e.g. if an
issue is
suspected
QAM
Destructi
ve
temperat
ure
measure
ment
Make a hole in
the product to
insert the probe
using a pre-
cooled sharp
pointed metallic
device such as an
ice punch, hand
drill or an auger.
Insert the probe to
a minimum depth
of 2.5 cm from
the surface of the
product.
a minimum
depth of
2.5 cm
from the
surface of
the product.
Or
minimum
depth from
the surface
of 3 or 4
times the
diameter of
the probe.
Daily or as
when
required.
e.g. if an
issue is
suspected
QAM

35 | P a g e
Hazard
Control
Measure
Measurable or
observable
Action Criteria
and
authorities
Actions
19 OPRP-3
Reheating
frozen
bread
Toxin
production of
Bacillus cereus
from vegetative
cells resulting
due to spore
germination or
outgrowth of
surviving viable
cells.
Place the
frozen loaf in a
230-degree
oven while still
wrapped in the
foil.
Leave the loaf
in there for 10
to 15 minutes
before
removing the
foil
The goal is to
reach inside the
product
temperature at
or above 70 °
C.
The internal
temperature of
the product must
be at least 70°C
for a minimum
of 1 minute.
Internal
time
/temp of
the
product
Clock ovens /
Penetration
Thermometer.
Bakery
oven
Towards
the end of
baking,
Weekly
Chef in
charge
Correction:
Further bake/
start the process
afresh
In case of a oven
fault, start the
process again in
another preheated
oven
Correction
Action: Reset
the rebaking
time
/temperature
Do trials to
experiment the
most effective
time /
temperature
combination
respecting to
oven condition
Monitoring:
Oven operator
or employee
responsible
for baking
Correction:
Ex. Pastry
Chef / QAM
Corrective
Action:
QAM, Pastry
Chef

36 | P a g e
Hazard
Control Measure Measurable or
observable
Action Criteria
and
authorities
Actions
15 CCP-1
Baking
Microbial
survival and
multiplication:
(Salmonella,
Yersinia,,
Shigella Noro
virus,
Staphylococcus
aureus,
Listeria
monocytogenes
Escherichia
coli O157:H7,
Micrococcus
and Bacillus)
Compliance with
good personal
hygiene practices.
Meet binomial
time/ temperature
set (10–12 minutes
at 200–220ºC) for
the process so that
at the interior is
reached at least a
temperature of 70 °
C
The goal is to
reach inside the
product
temperature at or
above 70 ° C.
The internal
temperature of
the product must
be at least 70°C
for a minimum
of 1 minute.
Binomial
time /temp,
internal time
/temp of the
product
Clock ovens /
Penetration
Thermometer.
Bakery oven Towards
the end of
baking,
Weekly
Chef in
charge
Correction:
Extend or
shorten the
cooking time
to achieve the
desired end
product and
that inside the
product is
achieved a
temperature
above 70°C.
If the product
is not fit for
human
consumption,
must be
rejected, put in
place, and duly
identified as
nonconforming
product.
Correction
Action: Reset
the binomial
time
/temperature
Monitoring:
Oven operator
or employee
responsible
for baking
Hygiene
Manager
Corrective
Action:
Hygiene
Manager ,
Pastry Chef
Record: Baking Temperature Log

37 | P a g e
Process Step
(CCP/OPRP)
Verification Activities Recordkeeping Activities Validation
What Who Name of the record
OPRP-1
17. Metal
Detecting
At the end of each shift, review the “Daily Metal
Detector Check Record” to ensure that it has been
properly completed.
Once per week, ensure that the monitoring of the
metal detector follows the written monitoring
procedure.
If non-conformance is found during the
verification procedure, investigate the cause of
the non-conformance and take necessary
corrective actions to prevent reoccurrence.
Record all observations (e.g., whether or not the
detector is operating effectively, non-
conformances, and corrective actions taken) on
the “Daily Metal Detector Check Record,”
including the date, the time, and initials.
A trained designee Daily Metal Detector Check Record Metal detecting process:
Insert the metal sample into the middle of the
product and then pass the product through a
properly operating metal detector. If the
control measures are valid metal
contaminant is detected, the metal detector
belt retracted and the rejected product is
dropped into the rejection box.
Scientific literature citations:
Ministry of Health, B. C. (n.d.). SLICED
WHOLE WHEAT BREAD SAFETY PLAN.
Retrieved from www2.gov.bc.ca:
https://www2.gov.bc.ca/assets/gov/health/ke
eping-bc-healthy-safe/food-safety-
security/sliced_whole_wheat_bread.pdf?bcg
ovtm=CSMLS
Perform ongoing review of HACCP Plan in
response to deviations and/or System and product
Modification
FST Document Review log
Conduct biannual internal audits to assess whether
specified requirements have been fulfilled.
Trained auditor with
technical expertise who
is not directly involved
in the operation.
Internal Audit Reports
Nonconformity records
Quarterly analyze training related records to
ascertain that people are well trained, competent and
skilled to perform their assigned duties.
FST Training records
Training effectiveness evaluation record
Competency evaluation record
Correction Action Record
Interviewing employees Hygiene Manager Employee audit records.
Review of deviation reports FST Deviation reports
Review of past validation reports FST Validation reports
Assessment of corrective action effectiveness FST Food Safety Meeting minutes
Review of linkages between the Hazard Control plan
and PRP programmes
FST Hazard Control Plan review records.
Review control measures for their continued
suitability
FST HACCP Plan Review and Amendment Records

38 | P a g e
Process Step
(CCP/OPRP)
OPRP-3
19 Rebaking
Daily verification of monitoring & corrective action
records.
Baking Log
Corrective Action Log
Worst Case
Aseptically collect about 75 g of baked
bread/bun sample and get it analyzed by an
accredited laboratory for the presence/
survival of the following microbial
parameters and verify that the test results
conform to the specified limits shown
against each parameter
Total microorganisms (300
C):≤105
UFC/g
Enterobacteriaceaespp: ≤ 10² UFC/g
Staphylococcus aureus: ≤ 10² UFC/g
Salmonella spp: Absence in 25g
Listeria monocytogenes: Absence in 25g
Fungi (Molds) and Yeasts: ≤ 10² UFC/g
Units of 30 gr. and 48 gr.
Frequency: Biannual
Literature citation:
Once per week, ensure that the monitoring of the baking
process follows the written monitoring procedure.
If non-conformance is found during the verification
procedure, investigate the cause of the non-conformance
and take necessary corrective actions to prevent
reoccurrence.
Check penetration thermometer and/or oven
thermometer for accuracy and damage and to ensure that
it is operational before putting it into operation; perform
these same checks daily, at the beginning of operations;
and calibrate it once per year
Oven thermometer calibration
Record
Annually, perform heat distribution test on ovens to
ensure that binomial time/temperature can be achieved
everywhere in the oven.
If deviations reveal that heat is not uniformly distributed
and under-processing could occur on certain locations,
take necessary corrective actions and prevent recurrence.
Food Safety Team Heat Distribution Test Report
Conduct periodic internal audits on baking process to
ascertain whether it in compliant with specific food
safety requirements.
Trained auditor
who is not directly
involved in the
operation.
Monthly verification of repair and maintenance records
for ovens.
Manager,
supervisor, or
trained designee.
Maintenance and Repair Record
Preventive Maintenance Record
Perform ongoing review of HACCP Plan in response to
deviations and/or System and product Modification
Reassess baking process - annually by HACCP team. Food Safety Team
Monthly evaluate competency, awareness and training of
monitoring, measuring and calibrating persons to ensure
that human error accounting for likely deviations are
corrected and corrective actions taken upon.
Food Safety Team Training need evaluation record

39 | P a g e
Process Step
(CCP/OPRP)
CCP-1
15 Baking
Daily verification of monitoring & corrective action
records.
Baking Log
Worst Case
Aseptically collect about 75 g of baked
bread/bun sample and get it analyzed by
an accredited laboratory for the presence/
survival of the following microbial
parameters and verify that the test results
conform to the specified limits shown
against each parameter
Total microorganisms (300
C):≤105
UFC/g
Enterobacteriaceaespp: ≤ 10² UFC/g
Staphylococcus aureus: ≤ 10² UFC/g
Salmonella spp: Absence in 25g
Listeria monocytogenes: Absence in 25g
Fungi (Molds) and Yeasts: ≤ 10² UFC/g
Units of 30 gr. and 48 gr.
Frequency: Biannual
Literature citation:
Once per week, ensure that the monitoring of the
baking process follows the written monitoring
procedure.
If non-conformance is found during the verification
procedure, investigate the cause of the non-
conformance and take necessary corrective actions to
prevent reoccurrence.
Check penetration thermometer and/or oven
thermometer for accuracy and damage and to ensure
that it is operational before putting it into operation;
perform these same checks daily, at the beginning of
operations; and calibrate it once per year
Oven thermometer calibration Record
Annually, perform heat distribution test on ovens to
ensure that binomial time/temperature can be achieved
everywhere in the oven.
If deviations reveal that heat is not uniformly
distributed and under-processing could occur on
certain locations, take necessary corrective actions and
prevent recurrence.
Food Safety Team Heat Distribution Test Report
Conduct periodic internal audits on baking process to
ascertain whether it in compliant with specific food
safety requirements.
Trained auditor
who is not directly
involved in the
operation.
Monthly verification of repair and maintenance
records for ovens.
Manager,
supervisor, or
trained designee.
Maintenance and Repair Record
Preventive Maintenance Record
Perform ongoing review of HACCP Plan in response
to deviations and/or System and product Modification
Reassess baking process - annually by HACCP team. Food Safety Team
Monthly evaluate competency, awareness and training
of monitoring, measuring and calibrating persons to
ensure that human error accounting for likely
deviations are corrected and corrective actions taken
upon.
Food Safety Team Training need evaluation record

40 | P a g e
Bibliography
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perfringens vegetative cells and spores in pork luncheon roll. Retrieved 06 30, 2019, from
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Chintagari, S. (2009). DETERMINATION OF MINIMUM SAFE COOKING TEMPERATURES FOR SHRIMP TO
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E.coli. (n.d.). Retrieved from www.who.int: https://www.who.int/news-room/fact-sheets/detail/e-coli
Fish and Fishery Products Hazards and Controls Guidance. FDA.
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Food Safety Education. (n.d.). Retrieved from www.fsis.usda.gov:
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sheets/safe-food-handling/danger-zone-40-f-140-f/CT_Index
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perfringens from spores in acidified beef, pork, and poultry products during chilling.
M. S. (n.d.). Prevention and control of mycotoxins. Retrieved 10 18, 2014, from www.fao.org:
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Microbial and Hygienic aspects of Dry Milk Powder. (n.d.). Retrieved 01 20, 2018, from
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