hacc plan for majdi

8/3/2019 HACC Plan for Majdi

1/45

Sl.No. Family Sub Family Products Equipment

whole spices ANISEED

BLACK PEPPER

CARDAMOM

CARAWAY

CASSIA

CHILLI

CHILLI EXTRA HOT

CINNAMONCORIANDER

CUMIN

FENNEL

FENUGREEK

GARLIC

GINGER

KHOLINJAN

MACE

NUTMEG

PIMENTO

ONION FLAKES

TAMARIND

DILL SEEDS

SESAME

KHALONJI

CASSIA

CORIANDER

CUMIN

FENNEL

FENUGREEK

Ground Spices CHILLI

GINGER

BLACK PEPPER

CARDAMOM

PIMENTO

WHOLE BERYANI SPICES

GROUND BEYANI SEASONINGCURRY SEASONING

KUWAITI SEASONING

SEAFOOD SEASONING

CHICKEN SEASONING

MEAT SEASONING

KABSA SEASONING

TANDOORI SEASONING

SAFFRON

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

1 SPICES

2 MIXED SPICES


2/45

Family Name spices Sub family- whole spicesProducts in family ( As linked )

1 2 3 4 5 6

Potential hazards

introduced, controlled or

enhanced at this step.

Sev. Occ. Con.

10Raw materail

Receving

Certificate of Analysis ;

Accpetance Criteria

Warehouse Manager

/QA TechnnicianIncoming inspection Report

Biological :

pathogens ; Hygiene

indicators ; insects, microbes

High Low Yes

Chemical : Pesticides;Hormones

High Low Yes

Physical : Glass , Dust , metal

particles , etc

High Low Yes

20 Storing Cleanliness Store controller Stock register Biological :

Personal Hygiene

High Low Yes

Chemical : marking ink

High Low Yes

Physical : Packing material or

cutting equipment particles ,

etc

High Low Yes

30 cleaningremoval of extraneous

mattersOperator cleaning room register Biological :

Personal Hygiene

High Low Yes

Chemical : Nil High Low x

Physical : Dust , metal

particles , etc

High Low Yes

40 Packing accuracy of weight Operator PRP - SOP Biological :

Personal Hygiene

High Low Yes

Chemical : Bins / container

cross contamination, Printing High Low x

HACCP Plan 01

Process # Process steps Control Measure

Process Flow

Responsibility Ref. doc/ record

Are any potential food-

safety hazards

significant? (Yes/No)

7


3/45

60 Weighting accuracy of weight Foreman Machine Log Biological : Nil x x x

Chemical : Bins / containers

cross contamination

High Low Yes

Physical : Nil

x x x

70Storing &

trans ortationTemperature Store controller SOP

Biological : Nilx x x

Chemical : Nil x x x

Physical : Nil x x x


4/45


5/45

8 9 10 11 12

Justify your decisions for column

7.

What control measures can be

applied to prevent the significanthazards?

Is this step aCritical

Control Point?

Significant

hazards

related to

CCP

Critical limits

for each

preventive

measure

(Yes/No) What How Frequency Who

Possible contamination of food with

pathogenic microorganism like

Salmonella spp.

Approved Supplier; Receiving

inspection;cleaning,Cooking before

consumption

No x x x x x x x x

Because the food may be farmed at

suppler end. which may be

contaminated

Approved Supplier; Receiving

inspection;No x x x x x x x x

Metal pieces can be present inproduct at suppler end. Also during

receiving chances of physical

contamination are more

Subsequent step cleaning & Metal

detecting will remove all physical

pieces.

No x x x x x x x x

Handling of products may cause

pathogenic contaminationPRP & SSOP No X X X X X X X X

ink used in the marker may

introduced if not properly handledPRP & SSOP No X X X X X X X X

Metal / packing pieces can be

present in product from supplier end

Subsequent step cleaning & Metaldetecting will remove all physical

pieces.

No X X X X X X X X


pathogenic contaminationPRP & SSOP No

x x x

Improper cleaning/change of

bins/container.Metal /packing

pieces can be present during

unpacking

Subsequent step Metal detecting will

remove all physical pieces.Yes ( CCP 1)

Cross

Contaminatio

n

No Foreign

particles

Cleanlin

ess of

containe

rs

proces

s check

100%

inspection

produc

tion

Superv

isor

Re inspection.

Remove /

Reject

CCP

Monitorin

g log

Daily

revi

Q


pathogenic contaminationPRP & SSOP No

Printing ink may be introduced if

not properly handledPRP & SSOP No x x x x x x x x

previously packed item may be

introduced if the packing machine

not cleaned ro erl

PRP & SSOP No x x x x x x x x

Correctiveactions

RecordsProcess Monitoring

Corrective Action planning

Verifi

Hazard Analysis


6/45

x x x x x x x x x x x

improper cleanliness or change of of

Bins / ContainersPRP & SSOP x x x x x x x x x

x x Yes ( CCP 1)Cross

Contaminatio

n

No Foreign

particles

Cleanlin

ess of

containe

rs

proces

s check

100%

inspection

produc

tion

Superv

isor

Re inspection.

Remove /

Reject

CCP

Monitorin

g log

D

r





7/45

x x x x x x x x x x


8/45

temperature abuse


9/45

70 Mixing sequence & timing Supervisor SOP Biological :

Change in test or colour

High Low Yesp

delay in mixing may ca

Chemical : Sanitizer for

Machines

High Low YesSanitizer used for clean

equipment may remain

Physical : Machine internal

spear parts particlesHigh Med. Yes

Wear & tear of mach

direct food contact

80 bagging Wieght per bag Operator Standrad Product wight SOP Biological :

Bacterial growth

High Low Yestemperature abuse o

delay may cause bact


Machines



allowed ro er dr in


spear parts particles

High Med. YesWear & tear of mach

direct food contact

90 storing Temperature Operator SOP Biological :

Personal Hygiene

High Low YesHandling of products m

pathogenic contamina

Chemical : Sanitizer forMachines

High Low Yes

Sanitizer used for clean


allowed ro er dr in

Physical : Machine particles ,

etc

High Low YesMetal / packing pieces

present in product dur

100 Packing number of pieces Operator PRP - SOP Biological :

Personal Hygiene


pathogenic contamina


Machines



allowed ro er dr in

Physical : Nil x x x x

110 Cartuning number of pieces operator SOPBiological : Nil

x x x x

Chemical : Nil x x x xPhysical : Nil x x x x

120Storing &


Biological :

Bacterial growthHigh Low Yes

temperature abuse

bacterial ro

Chemical : Nil x x x x



10/45



11/45

11 12

Significant hazards

related to CCP

Critical limits for each

preventive measure

What How Frequency Who Corrective actions Records Verifications

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

X X X X X X X X X

X X X X X X X X X

X X X X X X X X X

Cross Contamination No Foreign particlesCleanliness of

containersprocess check 100% inspection

production

SupervisorRe inspection. Remove / Reject

CCP Monitoring

logDaily record review by QA

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

X X X X X X X X X

Process Monitoring


Ch i t t l A R i l T t & lSequence & 100 % production

R k / R j tCCP Monitoring

D il d i b QA


12/45

Change in test or colour As per Reciep plan Test & colourq

time inspection

p

SupervisorRework / Reject

g


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

HACCP Plan 03


13/45

Family Name Herbs

Products in family ( As linked )

1 2 3 4 5 6 8

Potential hazards

introduced, controlled orenhanced at this step.

Justify your decisions for co

7.

Sev. Occ. Con.

10Raw materail

Receving

Certificate of Analysis ;

Accpetance Criteria

Production Supervisor

/QA TechnnicianIncoming inspection Report

Biological :

pathogens ; Hygiene

indicators ;Nematodes

High Low Yes

Possible contamination of foo

with pathogenic microorganis

Salmonella spp.

Chemical : Antibiotics ;

Pesticides ;Hormones

High Low Yes

Because the food may be farm

suppler end. which may be

contaminated

Physical : Glass , Dust , metal

particles , etc

High Low Yes

Metal pieces can be present in

product at suppler end. Also d

receiving chances of physical

contamination are more

60 Weight ing accuracy of weight Foreman Machine Log Biological :

Personal Hygiene

High Low YesHandling of products may cau

pathogenic contamination

Chemical : Bins / containers

cross contamination

High Low Yesimproper cleanliness or chan

of Bins / Containers

Physical : Nil

x x x x

110 Packing number of pieces Operator PRP - SOP Biological :

Personal Hygiene

High Low YesHandling of products may cau

pathogenic contamination


Machines

High Low YesSanitizer used for cleaning of

equipment may remain, if not

allowed ro er dr in timePhysical : Nil x x x x


x x x x


130Storing &


Biological :


temperature abuse ,may ca

bacterial rowth



Control Measure Responsibility Ref. doc/ record

Are any potential food-

safety hazardssignificant? (Yes/No)

HACCP Plan 03

Process Flow Hazard Analys

7

Process # Process steps


14/45



15/45

11 12

Significant hazards

related to CCP


preventive measure


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x



production


CCP Monitoring


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

Process Monitoring


16/45


x x x x


17/45


80Storing &


Biological :


temperature abuse

bacterial ro




18/45

11 12



19/45

11 12

Significant hazards

related to CCP


preventive measure


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

X X X X X X X X X

X X X X X X X X X

X X X X X X X X X



production


CCP Monitoring


x x x x x x x x x

x x x x x x x x x



production


CCP Monitoring


x x x x x x x x x

x x x x x x x x x

Process Monitoring

x x x x x x x x x

x x x x x x x x x


20/45

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x


21/45



22/45


23/45

11 12



24/45

Significant hazards

related to CCP


preventive measure


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

X X X X X X X X X

X X X X X X X X X

X X X X X X X X X

x x x x x x x x x



production


CCP Monitoring


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

Process Monitoring

x x x x x x x x x


25/45


26/45


27/45


28/45

11 12



29/45

Significant hazards

related to CCP


preventive measure


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

X X X X X X X X X

X X X X X X X X X

X X X X X X X X X



production


CCP Monitoring


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

Process Monitoring


30/45


31/45



32/45

for sausages

11 12



33/45

Significant hazards

related to CCP


preventive measure


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

X X X X X X X X X

X X X X X X X X X

X X X X X X X X X

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x



production


CCP Monitoring


x x x x x x x x x

x x x x x x x x x

X X X X X X X X X

Process Monitoring

Change in test or colour As per Reciep plan Test & colourSequence &

time

100 %

inspection

production


CCP Monitoring



34/45

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x


35/45


36/45


Machines

High Low Yes Sanitizer used for cleanequipment may remain

Physical : Machine internal High Med. YesWear & tear of mach

di t f d t t


37/45

spear parts particlesg

direct food contact

80 Mixing sequence & timing Supervisor SOP Biological :

Change in test or colour


delay in mixing may ca


Machines



allowed ro er dr in t




direct food contact

90 Foreming Wieght per pcsOperator & QC

TechnicianStandrad Product wight SOP Biological :

Bacterial growth


delay may cause bacte


MachinesHigh Low Yes

Sanitizer used for clean





direct food contact

100 Freezing Temperature Operator SOP Biological :

Personal HygieneHigh Low Yes

Handling of products m

pathogenic contaminat


Machines



allowed ro er dr in t

Physical : Machine particles ,

etcHigh Low Yes

Metal / packing pieces

present in product duri

110 Packing number of pieces Operator PRP - SOP Biological :Personal Hygiene


pathogenic contaminat


Machines





x x x x


130Storing &


Biological :


temperature abuse ,

bacterial rowChemical : Nil x x x x



38/45

11 12

Significant hazards Critical limits for each



39/45

Significant hazards

related to CCP


preventive measure


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

X X X X X X X X X

X X X X X X X X X

X X X X X X X X X

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x



production


CCP Monitoring


x x x x x x x x x

Process Monitoring

X X X X X X X X X

X X X X X X X X X


40/45


time

100 %

inspection

production


CCP Monitoring


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x xx x x x x x x x x


41/45


42/45


43/45

11 12

Significant hazards Critical limits for eachProcess Monitoring



44/45

related to CCP preventive measure


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

X X X X X X X X X

X X X X X X X X X

X X X X X X X X X

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x



production


CCP Monitoring


x x x x x x x x x

Process Monitoring

x x x x x x x x x


45/45

x x x x x x x x x

X X X X X X X X X

X X X X X X X X X


time

100 %

inspection

production


CCP Monitoring


x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

x x x x x x x x x

hacc plan for majdi

Documents