pizza vending machine [eng]

Automatic Pizza Vending Machine

HACCP HYGIENIC AND SANITARY SELF-CONTROL MANUAL

PRIUS Srl Via Molini, 3

38027 Malè (TN)

© Copyright Sitos srl November 2008 edition rev. 04 July 2009 All rights reserved. No parts of this document can be copied or disseminated in any way without the written consent of Sitos srl

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SPS AUTOMATIC

PIZZA VENDING MACHINE

HACCP MANUAL

© Copyright Sitos November 2008 edition rev. 04 July 2009 All rights reserved. No parts of this document can be copied or disseminated in any way without the written consent of Sitos srl




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CONTENTS

1 Scope and field of application ............................................................... 5

1.1 General company data ..................................................................................................................... 5 1.2 Nomination of person responsible ................................................................................................. 5

SSOP 6

1.3 General information .......................................................................................................................... 6 1.4 Characteristics of activity ................................................................................................................ 6 1.5 Description of premises ................................................................................................................... 7 1.6 SOP (Standard Operative Procedure) ............................................................................................ 7 1.7 Premises ............................................................................................................................................. 7 1.8 Water supply for washing the machine ......................................................................................... 7 1.9 Effluent drainage ............................................................................................................................... 7 1.10 Maintenance ....................................................................................................................................... 7 1.11 Product supply and traceability ...................................................................................................... 8 1.12 Waste and process residue ............................................................................................................. 8 1.13 Rules to be followed prior to operation ......................................................................................... 8 1.14 Rules to be followed during operation ........................................................................................... 8 1.15 Supply of constituent materials ...................................................................................................... 9 1.16 Storage of constituent materials ..................................................................................................... 9 1.17 Swabbing ............................................................................................................................................ 9 1.18 Temperatures ..................................................................................................................................... 9 1.19 Prerequisite hygiene requirements ................................................................................................ 9

HYGIENIC DESIGN .................................................................................................................... 10

2 Sanification manual ............................................................................... 12

2.1 General cleaning and disinfection procedures .......................................................................... 12 2.2 Cleaning ............................................................................................................................................ 12 2.3 Disinfection ...................................................................................................................................... 12 2.4 Personal hygiene ............................................................................................................................ 12 2.5 Recommended hand washing procedure ................................................................................... 13 2.6 Instructions for the correct cleaning of the Automatic Pizza Vending Machine ................... 13

MIXER ............................................................................................................................... 13 HOPPER AND PRE-FORMER ......................................................................................... 14 PIZZA CONVEYOR .......................................................................................................... 15 PIZZA OUTFEED .............................................................................................................. 15 INTERNAL SPACES IN MACHINE .................................................................................. 16 TOMATO SAUCE DISTRIBUTOR ................................................................................... 16 REFRIGERATOR .............................................................................................................. 16 CLEANING THE OVEN AND HOOD ............................................................................... 17 WATER DISTRIBUTION PUMP ....................................................................................... 18 FLOUR DISTRIBUTOR .................................................................................................... 18

3 PART 2: HACCP (Hazard Analysis Critical Control Point) ............... 20

3.1 Hazard analysis and critical control points ................................................................................. 20

Automatic Pizza vending machine



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3.2 Preliminary steps ............................................................................................................................ 20 3.3 Principals .......................................................................................................................................... 20 3.4 Constitution of group ..................................................................................................................... 20 3.5 Description of product ................................................................................................................... 21 3.6 Identification of intended use of product .................................................................................... 21 3.7 Development of flow diagram ....................................................................................................... 22 3.8 Analysis of hazards associated to each step ............................................................................. 23 3.9 Identification of CCPs ..................................................................................................................... 24 3.10 Determination of critical limits ...................................................................................................... 24 3.11 Determination of CCP monitoring systems ................................................................................ 24 3.12 Determination of corrective actions ............................................................................................. 24 3.13 Documentation management ........................................................................................................ 24

4 Addenda ................................................................................................. 25

4.1 Addendum 0: monitoring form ...................................................................................................... 25 4.2 Addendum 1: list of suppliers ....................................................................................................... 26 4.3 Addendum 2: nonconformity report form ................................................................................... 27 4.4 Addendum 3: plan of premises ..................................................................................................... 28 4.5 Addendum 4: results (if any) of microbiological swabbing ...................................................... 29 4.6 Addendum 5: list of personnel ...................................................................................................... 30 Addendum 6: refrigerator control ........................................................................................................... 31 Addendum 7: Techincal details of detergents and disinfectants ...................................................... 32 4.7 List of addenda. ............................................................................................................................... 33




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1 SCOPE AND FIELD OF APPLICATION Description and analysis of system This manual has been drafted in accordance with CE Regulations n° 178/2002 - 852/2004 - 853/2004, regarding hygiene standards for foodstuffs, with the intention of describing the general criteria applied for the use of the pizza vending machine. The plan is based on the HACCP principles, a preventive control system that ensures constant wholesomeness and hygiene characteristics in products, with the constant control of both pre-processing and processing operations.

The manufacturer of the machine is Prius srl. Prius srl provides this manual as a facsimile that can be used to complete an already existing manual. This document describes the system devised by Sitos srl to achieve and maintain the hygienic-sanitary quality required to ensure the wholesomeness of the end products made with the “Automatic Pizza Vending Machine”.

The specifications in this Hygienic and Sanitary Self-control Manual are applicable to the machine components, the equipment and the pizza production process. The manager of the machine is required to read this manual and either complete it with his or her own data and apply it, or draw up his or her own plan, or implement the existing plan with the part regarding the automatic pizza vending machine.

1.1 General company data To be completed by the person managing the machine

Company name

Phone n°

Address

Manager

Business category

Health service authorisation

HACCP Manual drafting date

Contact person for distribution

1.2 Nomination of person responsible

I, the undersigned …………………………………………. proprietor of the business, nominate Mr

………………………………….......as the person responsible for the management of the machine

(supplies, cleaning, completion of HACCP forms, etc..)

Proprietor Person responsible for management of machine

___________________________ _______________________________ Place and date




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SSOP

1.3 General information The hygienic-sanitary quality of the pizzas made with the Automatic Pizza Vending Machine is the result of a set of activities designed to guarantee hygiene standards in the machine’s components, in the equipment, in the constituent materials, in the production environments, in the running of the processes and in the activities of the personnel. The combination of these activities determines a decrease in the risk of contamination of chemical, biological, microbiological and physical origin and the observance of hygiene standards in the sold end products.

These activities, implemented to guarantee hygienic-sanitary quality, include:

• design and construction of machine in line with Italian Law Decree 155/97 and Codex

Alimentarius requirements, and Regulation (CE) 852/04, 853/04 and subsequent amendments. • analysis of company structures and logistics in order to identify hazards and contamination risks

with regard to constituent materials, semi-finished goods and end products • definition and verification of hygiene standards with regard to constituent materials, semi-

finished goods and end products and with regard to contractors and transport companies (quality plans and technical specifications)

• description of production process with the use of graphical representations (flow diagrams) to highlight the single phases of the processes

• identification of hygiene hazards in processes and definition of critical control points • definition of methods, frequencies and acceptability limits for checks on constituent materials,

semi-finished goods and pizzas • definition of treatment procedures in the event of exceeding critical limits and corresponding

corrective actions to be taken • identification, segregation and definition of responsibilities for the treatment of products not

conforming to hygienic sanitary standards • definition, application and verification of cleaning and sanitizing plans for the machine and its

components and of equipment and environments • drawing up of operating instructions for carrying out cleaning activities and for the application of

the instructions • definition of machine operating and maintenance methods for customers and installers • personnel hygiene awareness training • implementation of cleaning systems • collection and management of waste from production and returns • definition of monitoring methods • drawing up of documentation for documentary evidence of activities performed.

1.4 Characteristics of activity The place where the Automatic Pizza Vending Machine is located must, as far as possible, allow the activities to be organised in the following way:

• One-directional flow of meals production line: a clear separation between incoming constituent material paths and food preparation and dispensing paths.

• Deliveries of constituent materials before the start of the processes. • Structural separation of food preparation activities: the constituent material reception tasks and

the storage, preparation and meals dispensing tasks must be separate from each other.




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1.5 Description of premises The complex is structured as described in the HACCP Manual for the activity, with the specific environments being structured as follows:

• Floors made of resistant, non-absorbent, washable and disinfectable materials. • Washable walls made of resistant, non-absorbent, and disinfectable materials. • Windows made of resistant, non-absorbent, washable and disinfectable materials. • Doors with smooth surfaces, easily washable and disinfectable.

1.6 SOP (Standard Operative Procedure) The handling of unpacked foodstuffs takes place during the filling of the machine.

The person responsible for the hygiene of the premises must check the expiry dates and wholesomeness of the constituent materials used for refilling the machine, as described in the subsequent chapters on pre-operative rules and traceability and, if nonconformities are found, he or she must complete the form (Addendum 2).

He or she must also verify the cleanness of the equipment used on a daily basis for preparing the food, as described in the section on Cleaning and Sanitizing.

1.7 Premises The layout of the premises is shown in the enclosed plans (addendum 3), with the place of installation of the Automatic Pizza Vending Machine highlighted.

1.8 Water supply for washing the machine The drinkable water is taken from the public water mains. All the water used for cleaning the Automatic Pizza Vending Machine and the premises, including bathrooms and toilets, must be drinkable water.

1.9 Effluent drainage The only effluent produced is that resulting from the cleaning of the machine.

1.10 Maintenance In order to prevent environmental contamination that could contaminate the automatic pizza vending machine, such as insects, mould or infestation, a maintenance plan for the premises must be implemented which must include: • taking corrective action to eliminate humidity and mould stains, loose plaster and paint and

cracks in walls and ceilings • repairing or replacing broken or loose tiles • checking and repairing loose fixtures • checking periodically for the presence of insects, animals and/or rodents with the use of glue

traps for rodents and crawling insects and UV lamps for flying insects. Corrective action to resolve any maintenance problems arising in premises where an “Automatic Pizza Vending Machine” is located. • In the event of problems with plaster, cracks in walls or broken tiles, the proprietor of the

business must ensure that the premises are kept in an excellent state of repair, with the help of specialists when necessary.




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• If rodents or infestations of animals or insects are discovered, either contact a specialist pest control company or put down rodent bait at points where the rodents cannot possibly carry it to the foodstuffs. The bait must be checked every day and replenished until the poison level remains constant.

In any event, if nonconformities occur, compete the form in the addendum.

1.11 Product supply and traceability All the constituent materials used for refilling the machine must be properly packed, labelled and provided by authorised suppliers. In particular, every pack must bear the expiry date and lot number in a visible position. For Traceability purposes, the documents accompanying the goods must bear the lot number.

1.12 Waste and process residue The waste consists of packaging and food waste. Boxes and glass are separated for recycling. The remaining waste is classified as solid urban waste and can be disposed of in normal rubbish bins.

1.13 Rules to be followed prior to operation The person responsible for the self-control must monitor the state of hygiene and cleanliness of the environments, equipment and persons and complete the monitoring form (Addendum 0), with reference to the following points in particular:

1. Check the Automatic Pizza Vending Machine and location premises thoroughly to ensure that they are at the same level of cleanliness-disinfection as when they were closed.

2. Check the external areas around the premises to ensure that there are no nonconformities (animal excrement, accumulated rubbish, etc.).

3. Remove rings, bracelets watches and other such items and wear suitable working clothes including a hat or head cover, making sure that all your hair is tucked away inside it.

4. Before starting to refill the Automatic Pizza Vending Machine, wash your hands thoroughly in detergent and hot running water then dry them completely with a single-use towel. Your nails must be kept short, clean and without varnish.

5. If any nonconformities are observed, the person responsible for the self-control must take the necessary measures and report them in a nonconformity report form (Addendum 2).

1.14 Rules to be followed during operation In order to prevent direct contamination, SSOPs (Sanification Standard Operating Procedures) must be put into practice. Given the type of machine, the SSOP activities regard the routine cleaning of the Automatic Pizza Vending Machine and taking great care when refilling the machine, with particular reference to: • the fresh ingredients used for making the pizzas must be procured exclusively from suppliers

who guarantee the wholesomeness of the constituent materials used and the obtaining of product of a quality that corresponds to contract specifications

• operators must abide strictly by the specifications stated in this manual and in the Use and Maintenance Manual

• whenever a nonconformity is observed, the person responsible for the HACCP must report it and complete the form in the addendum.




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1.15 Supply of constituent materials • Check the state of hygiene of transport vehicles and the temperatures of refrigerated transport

vehicles • Before unloading, check the accompanying documents, which must bear the product lot number

(for Traceability purposes) • Check the expiry date • Check the state of the packs • If there are nonconformities, the product must be returned to the sender and reported on a

nonconformity report form (addendum 2)

1.16 Storage of constituent materials • Keep the different categories of foodstuffs separate • Keep the products raised up from the floor • Take care not to damage the packs during handling operations • Keep to the warehouse and shelves cleaning plans • Take effective measures against pests and animals (flying and crawling insects, rats etc.) • Keep to the hygiene and cleaning plan • Isolate any nonconforming goods in a clearly defined zone in the warehouse, marked with the

notice “DO NOT USE: NONCONFORMING PRODUCTSI” until they are disposed of or returned to the supplier.

1.17 Swabbing The effectiveness of the cleaning is confirmed by microbiological tests carried out on different parts of the machine. The analyses are done in authorised laboratories. The results are attached to this manual. If nonconformities are found, the problem is evaluated and appropriate measures are taken.

1.18 Temperatures The organoleptic and microbiological qualities of the foodstuffs to be preserved at conditioned temperatures are maintained if these temperatures are kept under control.

1.19 Prerequisite hygiene requirements On the machine, a set of prevention activities (prerequisites) have been defined that make it possible to identify the phases in which hygienic-sanitary hazards for the end user may be generated. The following prerequisites are considered: 1. the machine’s hygienic design 2. the management of food products and waste 3. the cleaning of the machine and the work environments 4. the behaviour of personnel 5. supplies.




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HYGIENIC DESIGN

The hygienic design of the machine and its construction and installation characteristics are important for the following reasons: • they guarantee that the foodstuffs are protected against contamination • they rule out the possibility of the foodstuffs ceding to machine components • they avoid the build-up of dirt at dead points that are inaccessible for cleaning • they make cleaning and maintenance easier • they make access to the machine and its components easier from all sides, including the floor,

and they make it easier to inspect and disassemble • they exclude the formation of infestations in nooks and crannies, either externally or internally • they do not keep large quantities of foodstuffs ‘parked’ in the connecting tubing between

components.

As well as responding to general requirements, the materials used are corrosion-resistant, non-toxic and non-absorbent. The components in this zone are self-emtpying, with all liquid residues draining away by force of gravity and not remaining in blind alleys. There are no painted surfaces.

The material requirements and hygienic design are similar to those in the food contact zone, although less rigorous. There are no painted surfaces. The drive chains are easy to inspect and disassemble; “non-edible” lubricants can be used.

The exposed surfaces are made from corrosion-resistant materials. The surfaces are washable and, where possible, drain automatically. The motors and gearboxes are designed not to drip oil from any of their parts. The components of the machine are connected so that, wherever possible, the process is linear, in order to avoid cross contamination and product backflow.

SPLASH AREA

NON-FOOD AREA

PRODUCT FLOWS

FOOD CONTACT AREA




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CONSTRUCTION MATERIALS The construction materials used for the machine components in the Contact and Splash areas all comply with binding legislation on contact with foodstuffs.

Inert surfaces

All surfaces in contact with foodstuffs are inert and compatible, do not yield elements from contact with foodstuffs or detergents and disinfectants and do not transfer bad odours or abnormal colours.

Resistance All surfaces in contact with foodstuffs are resistant to the chemical agents used in sanitizing, so as to reduce the possible formation of roughness during the pizza-making process to a minimum.

Joints There are no fixed joints (welded superimposed metal-to-metal) in the product contact areas; special care has been taken to exclude gaps, hollows, fractures, protrusions, dead spaces and shadow zones that could jeopardise hygiene standards. There are no mobile metal-to-metal joins with gaskets or O-rings; the piping and tubing has been specially routed to avoid the danger of shadow zones. The connections between rigid and flexible materials have been designed so that the clamps are as near as possible to the product, to avoid the creation of interstices that the product can enter.

Fasteners Contact between the product and screw threads and between screws and supports has been avoided by using external gaskets and fasteners.

Internal edges

The internal edges and corners are designed to allow sanitizing.

Drainage The tanks and tubing are set at an angle (of at least 40°) to guarantee the outflow of the liquids inside them and to make them easier to empty; where necessary, plastic tubes are supported to avoid bending. Product contact surfaces are self-draining.

Insulation layers

The insulation layers (for insulating the refrigerator) have a gasket-free waterporoof coating to prevent the entry of water or product.

Tanks All receptacles containing foodstuffs are insulated externally (with a lid, or hermetically).




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2 SANIFICATION MANUAL The machine must be cleaned after one week of continuous work. The cleaning and sanitizing procedure involves the use of hot water, detergents and disinfectants. The cleaning procedures are described below and must be done by the proprietor of the business or by the person he/she has appointed as manager (see page 5).

2.1 General cleaning and disinfection procedures The following rules must be applied: • put any products safely out of the way • remove the thick of the dirt • clean with a tensioactive based detergent, diluted in hot water to the proportions stated on the

label • rinse with water • sanitize with a quaternary ammonium salt or chlorine based disinfectant diluted in hot water to

the proportions stated on the label • rinse with water • dry • store the cleaning products and equipment in a designated cupboard • keep to the specified use concentrations • choose the right products for the types of surfaces to be cleaned.

2.2 Cleaning Use the following products for cleaning, depending on the surfaces to be cleaned: • an ammonia based detergent • a non-ionic and anionic tensioactive based detergent • a detergent for hard surfaces with < 5% anionic tensioactive content.

2.3 Disinfection Use the following products for disinfection: • chloroactive disinfectant • quaternary ammonium salt based disinfectant The cleaning operations are performed on the basis of the methods and times described in the pages after the forms.

2.4 Personal hygiene Cuts and skin inflammations must be treated and well protected with waterproof coverings. The wearing of single-use disposable gloves is obligatory when there are wounds on the hands. The person responsible for the self-control is also responsible for ensuring that employees observe the personal hygiene rules stated by law and listed in the enclosed tables. clothing hygiene: uniforms must be kept in a clean and orderly state hand hygiene: you must wash your hands frequently during the day:

• after using the bathroom/toilet • before restarting work • after handling rubbish • after touching dirty packaging or surfaces • after blowing or wiping your nose.




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2.5 Recommended hand washing procedure

Equipment Products Dilution Nail brush Emollient sanitizer Pure Single-use paper

1. Make sure that liquid soap, nail brushes and paper towels are available. 2. Wet your hands and forearms with water at about 45°C. 3. Apply a enough detergent on your hands and scrub to form a sufficient amount of foam and

then scrub and brush your nails, fingers and the backs and palms of your hands vigorously (the mechanical action of the brush helps the dirt to detach and transfer to the foam).

4. Rinse your hands and forearms with lots of hot water. 5. Take another dose of detergent and wash your hands again, forming lots of foam and scrubbing

particularly thoroughly in the less accessible zones (such as between the fingers). 6. Wash off the foam by re-rinsing with lots of water. 7. Dry with paper towels, then dispose of them in a rubbish bin.

THE HYGIENE OF OUR PRODUCTS

DEPENDS ON THE HYGIENE OF OUR HANDS

Wash your hands: • Before starting to refill or clean the Automatic Pizza Vending Machine • after using the bathroom/toilet • after eating • when you come into contact with materials not related to the work process.

2.6 Instructions for the correct cleaning of the Automatic Pizza Vending Machine Clean the vending machine whenever it has been stopped. Always remember to wash and disinfect the sponges and replace them at least once a month. If rubber gloves are used, wash and disinfect them after each use.

MIXER Frequency: a) the mixer must be cleaned after a maximum of one week of continuous work, if

dough that has to be cleaned off is produced every 12h b) The mixer must be cleaned after 72h if dough that has to be cleaned off is not produced every 12h.




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Equipment Products Dilution Bucket Hot water

Detergent As stated on label

Sponge Chloroactive or quaternary ammonium salt based disinfectant

As stated on label

Single-use paper, sponge

Single-use gloves

Procedure: 1. Disassemble the mixer cover and whisk 2. Remove any large-size remnants 3. Thoroughly wash the surfaces, cover and whisk with detergent solution and sponge. 4. Rinse with water 5. Spray the sanitizing solution directly on to the components 6. Leave the disinfectant solution to act for at least 10 minutes 7. Rinse 8. Leave to dry 9. Leave the cloths and sponges to soak in disinfectant solution. 10. Reassemble the mixer as described in the User Manual.

HOPPER AND PRE-FORMER Frequency: weekly.

Equipment Products Dilution Scraper Bucket Hot water



As stated on label


Single-use gloves

Procedure: 1. Disassemble the hopper as described in the User Manual 2. Remove any large-size remnants 3. Thoroughly wash the surfaces with the detergent solution and a sponge 4. Rinse with water 5. Spray the sanitizing solution directly on to the component 6. Leave the disinfectant solution to act for at least 10 minutes 7. Rinse 8. Leave to dry 9. Leave the cloths and sponges to soak in disinfectant solution 10. Reassemble the hopper as described in the User Manual.




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PIZZA CONVEYOR Frequency: weekly.




As stated on label


Single-use gloves Procedure:

1. Disassemble the pizza conveyor system as described in the User Manual 2. Remove any large-size remnants with a scraper 3. Thoroughly wash the surfaces with the detergent solution and a sponge 4. Rinse with water 5. Spray the disinfectant on the items to be cleaned 6. Leave the disinfectant solution to act for at least 10 minutes 7. Rinse 8. Dry with single-use paper 9. Reassemble the conveyor as described in the User Manual.

PIZZA OUTFEED Frequency: weekly.




As stated on label



1. Remove the guard panel positioned between the oven and the pizza outfeed drawer 2. Remove any tomato sauce or cheese remnants from the rear part 3. Thoroughly wash the surfaces with the detergent solution and a sponge 4. Rinse with water 5. Spray the disinfectant on the items to be cleaned 6. Leave the disinfectant solution to act for at least 10 minutes 7. Rinse




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8. Dry with single-use paper 9. Reassemble pizza outfeed drawer guard panel after cleaning and disinfecting it as described in

the User Manual.

INTERNAL SPACES IN MACHINE Frequency: weekly (parts not in direct contact with food). Especially the tomato sauce zone, the presser zone and all the guards that catch the pieces of excess food and stop them from falling on to the other parts of the machine




As stated on label



1. Remove any large-size remnants with a scraper 2. Thoroughly wash the surfaces with the detergent solution and a sponge 3. Rinse with water 4. Spray the disinfectant on the items to be cleaned 5. Leave the disinfectant solution to act for at least 10 minutes 6. Rinse 7. Dry with single-use paper

TOMATO SAUCE DISTRIBUTOR Frequency: with every new refill and, in any event. after one week in which there has been tomato sauce in the machine. Procedure:

1. Remove the tomato sauce bag and tube 2. Insert a new bag and a new tube.

REFRIGERATOR Frequency: weekly (bottom of refrigerator).

every three months (refrigerator cabinet).

Before starting, move the goods into another refrigerator. Switch the refrigerator off before starting the cleaning.




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Sprayer Chloroactive or quaternary ammonium salt based disinfectant

As stated on label


Single-use gloves

Procedure: 1. Remove any powder and large-size remnants 2. Wash thoroughly, spreading the detergent solution around evenly 3. Rinse copiously with water 4. Spread the disinfectant solution with a sponge 5. Leave the disinfectant to act for at least 10 minutes 6. Rinse thoroughly with water 7. Dry with single-use paper 8. Before reloading the foodstuffs, make sure the operating temperature (4°C) has been reached.

CLEANING THE OVEN AND HOOD Frequency: every 50/100 pizzas replace the aluminium foil and clean the grill when necessary. monthly (oven tray, window, hood)




As stated on label


Single-use gloves

Procedure: 1. Remove any large-size remnants with a scraper 2. Thoroughly wash the surfaces with the detergent solution and a sponge 3. Rinse with water 4. Spray the disinfectant on the items to be cleaned 5. Leave the disinfectant solution to act for at least 10 minutes 6. Rinse 7. Dry with single-use paper.




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WATER DISTRIBUTION PUMP Frequency: every three months.



Sponge Chloroactive disinfectant

As stated on label


Single-use gloves

Procedure:

1. Operate the water distribution pump manually, as described in the User Manual 2. Prepare the disinfectant solution with water and chlorine based disinfectant, diluting as stated

on the label 3. Have the pump draw on the solution and operate it for at least 1 minute 4. Leave the solution in the pump for at least 10 min. 5. Rinse thoroughly with water, running it through the pump as described in the User Manual. Use

drinkable water 6. Reset the pump operating device to automatic, as described in the User Manual.

FLOUR DISTRIBUTOR Frequency: every three months.

Equipment Products Dilution Scraper

Bucket Hot water Detergent

As stated on label


As stated on label


Single-use gloves

Procedure:

1. Disassemble flour distributor as described in the User Manual 2. Remove any large-size remnants with a scraper 3. Thoroughly wash the surfaces with the detergent solution and a sponge 4. Rinse with water 5. Spray the disinfectant on the items to be cleaned 6. Leave the disinfectant solution to act for at least 10 minutes 7. Rinse




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8. Dry thoroughly with single-use paper, without leaving any damp zones 9. Reassemble flour distributor as described in the User Manual




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3 PART 2: HACCP (HAZARD ANALYSIS CRITICAL CONTROL POINT)

3.1 Hazard analysis and critical control points HACCP is a preventive control system for foodstuffs that aims to guarantee their safety from primary production right through to final consumption. This system makes it possible to identify potential hazards at each step in the production cycle, evaluate the risks and establish preventive measures to control them by means of the monitoring of predetermined critical points. The application of the HACCP system is based on the following stages:

3.2 Preliminary steps 1) Constitution of group 2) Description of product 3) Identification of intended use of product 4) Development of flow diagram

3.3 Principals 1) Analysis of hazards associated to each step 2) Identification of CCPs 3) Determination of critical limits 4) Determination of monitoring systems 5) Determination of corrective actions 6) Documentation management

3.4 Constitution of group The group is made up of either Mr Taucci Vittorio (head of TCS) or his colleagues, by the head of the Sitos company, given the qualified and essential role played by the company in the design of the Automatic Pizza Vending Machine, and by the manager of the machine. (give first name, surname and name of company) ________________________________________________________________________________ ________________________________________________________________________________

The Working Group, as a whole, has knowledge in the following areas: machine construction technology work process hygiene microbiology and chemistry of foodstuffs quality control techniques and relations with external laboratories machine construction materials constituent materials ingredients, packaging and services legislation and applicable standards production planning system and equipment maintenance sales organisation.

This Self-control Manual, drawn up by the Working Group, is included with the documents that accompany each machine.




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3.5 Description of product The product obtained as a result of the proper use and operation of the machine referred to in this document is a pizza. The preparation starts with the mixing of a dry mixture of flour and chemical leavening agents which, when mixed with water, produce a dough. This is topped with tomato sauce, cheese, salami and other toppings on request. The product is then baked in an oven at a temperature of above 300°C. The product thus obtained comes out of the oven and is positioned on a cardboard tray, ready to be taken out by the customer.

3.6 Identification of intended use of product The pizzas are made and baked in just a few minutes, when requested by a customer. The pizzas, the subject-matter of this HACCP study, are intended for consumption by end users who use a machine located on a customer’s premises; the HACCP study begins from the moment the ingredients are loaded and ends the moment the pizza is dispensed to the consumer.




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3.7 Development of flow diagram

The machine is assembled by qualified personnel, according to manufacturing instructions and GLP in workshops selected by SITOS (PRIUS). Before starting to produce pizzas, the machine must be washed as described in the cleaning and sanitizing section. The ingredients are loaded into the various metering systems by the proprietor of the business or his/her designated manager (see page 5). The quantity of ingredients is calculated to be sufficient for the production of 100 pizzas. If any ingredients are left over after the set time (see the section on cleaning and sanitizing) they must be thrown away in a rubbish bin. When a pizza is ordered, the machine measures out the flour and water into a mixing chamber and then forms the dough by stirring the mixture. The dough drops down into the pre-former, where it is given an initial pressing to form a semi-finished disk. From here the dough goes on to the lower presser plate (heated to about 140°C) where it is pressed again to form the pizza base. The disc goes under the tomato sauce metering system that puts a set amount of sauce on to it. After this, the topping is measured out. At this point the pizza goes into the oven, stays there for about 90 seconds and then, at the outfeed, is conveyed and served on a cardboard tray.

Choice of APS components

Construction of APS

Shipment, transport and installation on

customer’s premises

Cleaning

Taking ingredients

Opening containers and loading APS

Dosing flour and water

Dispensing pizza

Taking out pizza for end

consumer

1

2

3

4

5

6

7

8

Water

Ingredients

Taking unused ingredients Waste

Containers

Plastic film

Pizza trays

Cleaning

Sanitizing Effluent

Mixing

Preparing pre-formed dough and pressing

Dosing tomato sauce

Dosing cheese

Dosing topping

Baking

Transport

9

10

11

12

13

14

15

16

Start APS / pizza request

17




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3.8 Analysis of hazards associated to each step STEP HAZARD PREVENTIVE

MEASURES CRITICAL

LIMITS TYPE OF CHECK

FREQUENCY OF CHECKS

CORRECTIVE ACTION

TYPE OF REPORTING

CCP

Receiving constituent materials

Biological and microbiological: mould on yeast, animal infestations Chemical:aflatoxins, pesticides

Physical: extraneous material

Purchasing from reliable companies only.

Checking of products directly when unloading. When unloading the goods, the person in charge checks the conformity, cleanness and temperature of the transport vehicles.

No broken or soiled packs. No packs over expiry date. Clean transport vehicles. Suitable type of transport for product

Visual inspection. Check temperature with thermometer.

Each time goods are received

Non-acceptance of nonconforming products

Verbal report to supplier

Nonconformity report form

NO

Preservation Biological and microbiological: growth of pathogens Chemical: none Physical: soiled packs

Machine cleaning and disinfection procedure (see sanitizing manual). Integrity of packs Stock rotation

Correct implementation of cleaning plans Observance of expiry dates Suitable microclimate parameters (T°C and environment humidity)

Check observance of SSOP.


NO

Taking ingredients for loading machine

Biological and microbiological: growth of pathogens Chemical: none Physical: soiled packs

Withdraw the products with the oldest expiry dates to allow effective stock rotation. Cleaning and disinfection procedures. Effective personnel training

Temperature of refrigerator rising.

Check observance of SSOP. The machine has an automatic device that shuts it down if operating faults occur in the refrigerator.


NO

Baking

Biological and microbiological: survival of pathogens and spores Chemical: persistence of toxins

Baking times and temperatures Correct cleaning and sanitizing procedures Personnel training

Product core temperature >75°C Personnel and machine hygiene

Automatic: machine shutdown if oven not working.

At each step Eliminate nonconforming products


YES

Dispensing of pizza on cardboard trays

Biological and microbiological: cross-contamination. Chemical: none Physical: contamination by pieces of paper

Checking of trays on receiving: they must be packed in such a way as to avoid getting contaminated by soiling

Soiling of packs

Visual Each refill with new trays

Eliminate soiled trays


NO




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3.9 Identification of CCPs The CCPs are identified in the risk analysis and are as follows:

CCP regarding baking and efficient operation of oven

3.10 Determination of critical limits The critical limits are:

Baking CCP: Product core temperature greater than 75°C

3.11 Determination of CCP monitoring systems The daily CCP checks are carried out by the person responsible for hygiene and, if problems occur the machine shuts down automatically. Any nonconformities and the type of corrective action taken are described by the person responsible in the addendum. (Addendum 2)

3.12 Determination of corrective actions The corrective actions to be taken in the event of CCP nonconformities are listed in the table.

CCP Description Corrective action

Baking The machine goes in to an error state and pizza production is stopped

Machine maintenance Completion of nonconformity report form Addendum 2

3.13 Documentation management The documentation involves completing the forms in the addendum. All the forms must be completed and saved so that they can be seen by the officials of the relevant authorities for possible inspection.




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4 ADDENDA

4.1 Addendum 0: monitoring form Mark C (conforming) NC (nonconforming)

MON TUES WED THU FRI SAT SUN

Machine cleaning Pre Pre Pre Pre Pre Pre Pre

Personnel

Pre Pre Pre Pre Pre Pre Pre

Op Op Op Op Op Op Op

Environment on premises



Toilet facilities



Monitoring of rats, insects,

crawling animals



Signature

If nonconformities occur, complete the nonconformity report form (addendum 2).




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4.2 Addendum 1: list of suppliers The suppliers are those who supply the constituent materials used for refilling the machine, and the following details must be given about them:

- Company name - Person in charge of company or contact person - Address - Tel., fax, e-mail - Type of products purchased

Company name

Person in charge Address

Tel. Fax

E mail

Products purchased




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4.3 Addendum 2: nonconformity report form

NONCONFORMITY REPORT FORM

DATE_____________________________________TIME__________________________________ Description of nonconformity______________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________

SIGNATURE_________________________ Corrective action taken__________________________________________________________ ________________________________________________________________________________

Measures taken to prevent reoccurrence of problem____________________________________ SIGNATURE_________________________




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4.4 Addendum 3: plan of premises (Highlight the area where the machine is located)




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4.5 Addendum 4: results of microbiological swabbing (if performed) Laboratory tests Microbiological tests can be conducted with total microbe counts on the foodstuff contact areas to verify the correct application of foodstuff hygiene procedures.




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4.6 Addendum 5: list of personnel List of personnel

SURNAME AND NAME EMPLOYEE

PROFESSIONAL TRAINING

CERTIFIED BY IN-COMPANY TRAINING

DATE:

DATE OF ISSUE

EXPIRY DATE




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Addendum 6: refrigerator control The refrigerator has an automatic device that shuts down the machine if a cold chain maintenance anomaly occurs.




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Addendum 7: Techincal details of detergents and disinfectants Cleaning Use the following products for cleaning, depending on the surfaces to be cleaned:

• an ammonia based detergent • a non-ionic and anionic tensioactive based detergent • a detergent for hard surfaces with < 5% anionic tensioactive content.

Disinfection Use the following products for disinfection: • chloroactive disinfectant • quaternary ammonium salt based disinfectant. Always take careful note of the use concentrations stated on the labels. Handle the products with care, and only after reading the safety sheet.




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4.7 List of addenda. Addendum 0: monitoring form Addendum 1: list of suppliers Addendum 2: nonconformity report form Addendum 3: plan of premises Addendum 4: results of microbiological swabbing Addendum 5: list of personnel Addendum 6: refrigerator control Addendum 7: Techincal details of detergents and disinfectants used

pizza vending machine [eng]

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