Sincere Salad Dressing[4]
Transcript of Sincere Salad Dressing[4]
SINCERE SALAD DRESSING COMPANY
HACCP PROGRAM
COMPANY INFORMATION
Company Name: Sincere Salad Dressing Company
Company Address:123 Salad Shooter Way
Groveland, Kansas
Contact Person Name, Title: Renee Kerr, Quality Manager
Contact Phone Number: 555-555-5555 x000
Contact Fax Number: 550-550-5500
Contact Email: [email protected]
Brief Company History:The Sincere Salad Dressing Company evolved from a country vegetable market founded in 1927 in Medora, KS. A signature salad dressing spice packet sold by Polk Farms grew in popularity steadily becoming what is now a modern food processor. The company principles for providing high quality products at a fair price are practiced to this very day.
Types of Products Produced/ Type of Manufacturing:
Salad Dressing/ Food Products
Quality Policy: It is the quality policy of the Sincere Salad Company to provide goods and services that consistently meet or exceed our customer’s expectation.
Mission Statement: Our mission is to create distinctive value.
We will succeed in business only by creating value for our customers, our suppliers, employees, shareholders, and neighbors. We will build stronger customer relations and create solutions: Explore, Discover, Create, Deliver!
Vision Statement: At Sincere Salad Dressing, we believe our most valuable assets are our associates and our customers. Our goal is to create an innovative, entrepreneurial environment that empowers great ideas. We want our associates to have the creativity to see, the freedom to develop, and the freedom to act. We will act with integrity and responsiveness in all facets of our business.
Sincere Salad Dressing Organizational Chart
GeneralGeneralManager
PlantManager
PlantController
Human ResourceManager
Sales Manager
Operations Manager
(3) Shift Supervisors
Hourly Employees
Purchasing Supervisor
Lead MaintenanceTech
Accounting ClerkExecutive Account
ManagerExecutive Account
Manager
Account Manager
Planning & Scheduling Manager
HourlyEmployees
(3) MaintenanceTechnicians
ShippingCoordinator
Account Manager
(2) ShippingClerks
Cost Accountant
R&D department
(3) Customer ServiceRepresentatives
GraphicsManager
Graphic ArtsSpecialist
Quality ManagerAIB Coordinator
Quality Technician
Purchasing Manager
HACCP Team
Name Position
Coordinator: Renee Kerr Quality Manager
Other Team Members: Guermo Tank Plant Manager
Jeffrey Caine Maintenance Supervisor
Eric Hale HR ManagerJack Curtain Shipping / Receiving
SupervisorTom Coltrane Operations ManagerCorey Weathers Quality TechnicianMichael Bland Purchasing ManagerTim Scoffield Line Operator
HACCP Training Coordinator(s) :
Renee Kerr / Guermo Tank- certified by AIB International (HACCP on Demand). –September 10, 2009.
Program Title: Master Cleaning Schedule/ SSOPs
Person Responsible: Renee Kerr / Quality Manager
Where Located: Quality Department
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur annually and if there are any significant changes in equipment, cleaning chemicals or methods, or if there is a program failure.
Program Description:
Goal: Maintain a sanitary environment, necessary for the production of safe and legal products. Ensure sanitation activities do not pose a risk to product.
Scope: All areas, including processing, product storage areas, support areas, and grounds.
Content: A Master Cleaning schedule has been created for all processing and storage areas, which covers processing equipment, building structure, and utensils. The CIP systems for cleaning the bulk storage tanks, mixing, and pasteurization of product will have documented cleaning frequencies, procedures, and verification activities. The cleaning of product contact surfaces will be verified as effective by visual start-up inspections, ATP testing, and chemical concentration checks.
Training: Scope is outlined in plant work instructions and controlled inspection forms. Training is provided by the QA dept and records are maintained in Human Resources.
Program Title: SSD Pest Control Program
Person Responsible: Michael Bland / Purchasing Manager
Where Located: Purchasing Department
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur annually and if there are any significant changes in control methods or if there is a program failure.
Program Description:
Goal: Manage pest population to minimize its potential for product adulteration and/or contamination.
Scope: All areas, including processing, product storage areas, support areas, and grounds.
Content:The entire plant grounds will be maintained to prevent pest harborage, infestation, and potential product contamination. All pesticides will be used according to the label and all activities will be in compliance with the Federal Insecticide, Fungicide, and Rodenticide Act (FIFRA). All pesticide operators servicing the plant will be certified pesticide operators with a valid license and insurance certificate. The contracted service will maintain a pesticide usage chart, MSDS file, pesticide sample labels, rodent trap checks, schematics, record of pest activity, and the corrective action taken to prevent reoccurrence. Pest monitoring devices will be identified and checked by the plant PCO who has the overall responsibility for evaluating the effectiveness of the pest control program.
Training: Associates are trained during annual review or at new hire. – Licensing and insurance are reviewed on annual basis. Training records are maintained in HR.
Program Title: SSD CHEMICAL CONTROL PROGRAM
Person Responsible: Michael Bland/ Purchasing Manager
Where Located: First Aid Room
Revision Approval Authority: Guermo Tank / Plant Manager
Revision Timing: Reviews occur annually and if there are any significant changes in chemical usage or if there is a program failure.
Program Description:
Goal: Protect the product and process environment from possible chemical contamination.
Scope: All chemicals, such as sanitation, maintenance, production, and laboratory.
Content: The control of chemicals in raw materials and packaging materials will be addressed separately by our supplier certification program and ingredient hazard analysis. The plant maintains a control program for cleaning compounds, maintenance chemicals, and pest control chemicals. A running inventory of chemical usage is maintained by the appropriate department head to note any unusual usage. All chemicals purchased at the plant are reviewed by the purchasing department to insure that they are appropriate for use in a food plant. All personnel using chemicals will be trained for proper usage, application, and wear safety equipment, where appropriate. CIP records to clean and sanitize product zone areas will be maintained and reviewed by the QA department as evidence of effective cleaning. The usage of cleaning compounds and sanitizer for hand cleaning of equipment will be maintained by using test strips to insure that the proper concentration was used.
Training: All associates are trained as new hire and on annual basis. Chemical inventory is audited on annual basis or if a chemical is added or removed.
Program Title: Allergen Control Program
Person Responsible: Guermo Tank/ Plant Manger
Where Located: Plant Manager’s / Environmental Coordinator’s Ofc.
Revision Approval Authority: N/A
Revision Timing: Reviews occur annually and if there are any changes to government guidelines and regulations, any change in allergen usage, or if there is a program failure.
Program Description:
Goal: Is to ensure that the company meets and maintains all local, state and federal requirements for this production facility.
Scope: All EPA, OSHA, and Department of Natural Resources.
Content:The product development and QA department will review and identify allergens in new raw materials and existing products produced at the plant. The R & D department with the assistance of the purchasing department will review existing and new raw materials for allergen potential. The product label will clearly and accurately list all ingredients. The production department with the cooperation of the sales department will minimize the amount of changeovers from allergen to non-allergen product due to the potential for cross contamination. The QA department will audit the recipes, scaling, rework usage, and mixing to insure that formulae and usage are accurate. The production department will maintain an approved rework usage matrix and record usage on the scaling reports. Where there is a potential for cross contamination in scaling, processing, and packaging equipment, the cleaning procedures and inspection will be documented on the pre-op and operational inspections. The QA department will perform scheduled testing for protein residue on product zones and finished to confirm that the current programs are effective. When deficiencies are noted, the program will be modified and reconfirmed by residue testing
Training: All associates are trained on an annual basis for FDA, USDA, and other regulatory requirements. Training records are maintained in HR ofc.
Program Title: SSD GOOD MANUFACTURING PRACTICES
Person Responsible: Eric Hale/ HR Manager
Where Located: Human Resource Office
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur annually and if there are any significant changes in equipment, personnel, or if there is a program failure.
Program Description:
Goal: Maintain an environment and encourage practices that minimize the potential for product adulteration.
Scope: Personnel Practices, Plant Maintenance, Sanitation, Glass Policy, Body Fluids Program, Transportation & Storage.
Content: All personnel working at the plant will receive documented GMP training for their given area of responsibility for food safety and regulatory compliance. The building exterior and grounds will be maintained to prevent pest problems and environmental issues, which could affect the integrity of the product. All lights will be protected, air-handling systems will be filtered, and the lines have been set up to prevent any potentials for cross contamination. The water quality and sanitary facilities will be checked for compliance. Employees have been trained in proper hygienic practices and adequate hand washing facilities have been provided. All transport vehicles will be inspected for cleanliness prior to shipping and the temperature of product will be controlled through the distribution chain. The equipment installation and building design will be of sanitary design and a preventive maintenance program will be in effect to ensure food safety and ongoing process capability. Personnel will wear clean outer uniforms and a policy for handling injuries or cuts will be in effect.
Training: Annual and new hire training. Visitors are trained at start of visit. GMP forms are maintained by HR.
Program Title: SSD SUPPLIER CONTROL PROGRAM
Person Responsible: Michael Bland/ Purchasing Manager
Where Located: Purchasing Dept.
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur annually and if there is any removal or addition of allergens to the program, any change in point of allergen addition, or if there is a program failure.
Program Description:
Goal: Control of incoming materials through Contract Agreement, Letter of Continuing Guarantee, COA’s Specification, etc.
Scope: All raw materials, including packaging material, coming to the plant.
Content: The purchasing department will maintain a list of approved suppliers and only buy from approved vendors. The supplier evaluation program will be done by the material review team and consist of evaluating price, adherence to specifications, performance defects, food safety requirements, and service. A weighted average for the above criteria will be used to score the suppliers. Suppliers of critical ingredients affecting quality or food safety will be evaluated yearly. Ingredients that do not affect quality or present food safety risk will be evaluated every two years. Suppliers of critical ingredients such as milk products, egg products, gelatin, soy, spices, dried vegetables etc., will be required to submit certificates of guarantee and/or certificates of analysis. Critical ingredient suppliers must have an annual AIB audit with a score of 800 and submit a copy of their HACCP plan.
Training: Training is accomplished through ISO work instructions for purchasing, Shipping and Receiving.
Program Title: FOOD SAFETY CONSUMER COMPLAINTS
Person Responsible: Corey Weathers/ Quality Technician
Where Located: Quality Department
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur annually and if there is a program failure.
Program Description:
Goal: Identification and resolution of complaints.
Scope: All complaints from customers and consumers, including quality, service, and food safety issues.
Content:The company will keep a separate file for food safety complaints. The customer service department will respond back to the consumer. The Quality Department will require documented investigations by the department responsible for that activity with corrective action taken to prevent reoccurrence. The Quality Department will track the number and type of food safety complaints per units produced with performance goals established to document continuous improvement.
Training:The HACCP and prerequisite programs will be reevaluated when food safety concerns are noted in the market place. Associates are informed through food safety alerts posted at the work stations and employee information boards.
Program Title: RECALL and TRACEABLITY PROGRAM
Person Responsible: Renee Kerr/ Quality Manager
Where Located: Quality Department
Revision Approval Authority: Guermo Tank/ Plant Manager
Revision Timing: Reviews occur semi-annually (recall drills) and if there are any significant changes to items, or if there is a program failure.
Program Description:
Goal: Removal of suspect product, that is in violation of a regulatory requirement, from the market in a timely and effective manner.
Scope: All raw material, packaging material, processing aides, work in progress, rework and finished product that may pose suspect to consumers.
Content:The plant has documented policies and procedures to recall product produced at the plant and distributed to the customers. The recall team will test this program every six months and report on the effectiveness of the program to management. When deficiencies are noted in the program, the procedures will be revised and personnel will receive further training. Traceability records for packaging material, raw material usage, rework usage, packaging codes, and distribution records will be kept to for two years. The proper coding of the manufactured product on a day to day basis will be the responsibility of the production department and verified by the QA department.
Training: Training is accomplished semi-annually with the primary and alternate Recall team.
BULK RECEIVING AND STORAGEX ray unit
PALLETIZED INGREDIENT AND PACKAGING MATERIAL RECEIVING
SINCERE SALAD DRESSING PROCESSING FLOWCHART
DRY STORAGE
REFRIGERTED STORAGE
DRY STORAGE
REFRIGERATED STORAGE
DUMP STATION
BULK SCALING AND MINOR INGREDIENT ADDITION/ SIFTERS
OAKS MIXER
PASTEURIZER(1)
COOLING
GLASS HOT FILL
Metal DetectorLABELLING AND BOXING
Capper(3)
REFRIGERATED STORAGE
REWORK
GLASS INSPECTION
X-Ray Unit (2)
GLASS WASHING STATION
REFRIGERATED SHIPPING
GLASS INVERSION STATION
GLASS INTRODUCTIONSTATION
GLASS STORAGE
HACCP FINISHED PRODUCT PROFILE
General Product Information:Description of Product(s): Salad Dressing
Intended Use and Consumer/ Customer: Ready to eat/ General Public
Method of Storage and Distribution: 45 degrees Fahrenheit at the retail level/ 40 degrees Fahrenheit, refrigerated truck
Shelf-life/ Traceability information: 12 months unopened/ 6 months opened - refrigerated
Technical Product Information:Preservative(s): FD&C Yellow #5 (food coloring)
Water activity (aw): 9.5
pH/ titratable acidity: 5.5-7.0
Packaging requirements: glass jars, plastic, boxed pouches, and single service foil packets.
Food Safety Information:Potential for consumer/ customer misuse: Bacteria cross contamination if left
unrefrigerated.
Describe the potential food safety issues associated with this product/ process (be specific):
Allergens, glass, biological(people)
List any support programs or ingredient, product or process parameters essential to preventing, controlling or eliminating each food safety issue identified above:
Allergen control program, sanitation, supplier control program, metal detection,
glass x ray unit, GMPs (Glass policy, Personnel practices), sifters
Signature of Company Official: Guermo Tank
Title: Plant Manager Date: Sept. 10, 2009
RAW MATERIAL HAZARD ANALYSIS
Product or Process Name: Salad Dressing
List all raw materials used in the plant
Identifyknown hazards
Risk Assessment Is this a Critical Raw Material (1) (Yes/No)?Likelihood Severity
Well waterB Bacteria – fecal coliform M M Y
C MTBE, nitrates, salts L-M L Y
P foreign material, rocks L L N
Liquid, pasteurized eggsB Salmonella L-M M Y
C Allergen H H Y
P None N N N
sugarB None N N N
C Pesticides M L-M Y
P large lumps, metal, glass M-H M Y
vinegarB None N N N
C None N N N
P None N N N
saltB None N N N
C None N N N
P large lumps, metal, glass M-H M Y
Dried milk powderB None N N N
C Allergen H H Y
P large lumps, metal, glass M-H M Y
Yellow #5 food colorB None N N N
C tartrazine (Allergen) M-H M Y
P None N N N
Glass jarsB None N N N
C None N N N
P pieces/ shards M-H M Y
Hazards: B = Biological, C = Chemical, P = PhysicalRisk Assessment: H = High, M = Medium, L = Low, N = Negligible
(1) Critical Raw Material: Any raw material, with the exception of those having negligible, L/L and/ or M/L (likelihood/ severity) in all three hazard risk assessments, must be considered critical. Any item identified as “Critical” must be brought forward to Receiving on the Process Hazard Analysis form for further analysis.
PROCESS HAZARD ANALYSIS(1) (2) (3) (4) (5)
List every Critical Ingredient identified in the Raw Material
Hazard Analysis.
List every process step, from Receiving to Shipping, shown on the simplified Process Flow
Diagram.
Go to Column 2.
Note: If this is a last process step identified in Column 4, list
the hazard eliminated in Column 2.
Does this raw material or process step INTRODUCE or INTENSIFY a potential
food safety hazard? If YES identify hazard(s). (Be as specific as possible when listing the hazard and its source.) If no hazard is identified, write “none.”
Go to column 3.
Is this hazard(s) CONTROLLED to the best
of the plant’s ability by Support Programs? If
YES, list all of the Support Programs that will control
the introduction or intensification of the
hazard(s) identified in Column 2. If NO, write
“none.”
Go to column 4.
Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process
step? If NO, write “none” and continue to the next hazard or process step. If YES, identify
the last process step where it will be eliminated.
If you are at that process step, proceed to Column 5; if not, go to the next hazard or
process step. (Note: If no control or elimination is identified in Column 3 or 4 and
these are necessary for food safety, you must stop, modify the step, process, product, or
Support Programs.)
Can a viable product still be produced if the process step listed in Column 4 fails? If YES, this step
must be considered a CCP: identify the CCP number. If
NO, this is not a CCP: enter NO.
Go to the next hazard or process step.
Well water B Bacteria Supplier control program -Nanofiltration
Pasteurizer
C MTBE Supplier control program -Quarterly testing at state certified laboratory.
Yes. Damage to above ground or underground tanks, and tanker spills into soil.
P None None None
Liquid Pasteurized eggs
B Salmonella Supplier control program
Pasteurizer
C Allergen Supplier control program
No
P None None None
Sugar B None None None
C pesticides Supplier control program
No
PROCESS HAZARD ANALYSIS
P large lumps, metal, glass
Glass Policy Metal Detector/ Glass Xray Unit
Salt B None None None
C Allergen Supplier Control Program
No
P large lumps, metal, glass
Glass Policy Metal Detector/ Glass Xray Unit
PROCESS HAZARD ANALYSIS(1) (2) (3) (4) (5)
List every Critical Ingredient identified in the Raw Material
Hazard Analysis.
List every process step, from Receiving to Shipping, shown on the simplified Process Flow
Diagram.
Go to Column 2.
Note: If this is a last process step identified in Column 4, list
the hazard eliminated in Column 2.
Does this raw material or process step INTRODUCE or INTENSIFY a potential
food safety hazard? If YES identify hazard(s). (Be as specific as possible when listing the hazard and its source.) If no hazard is identified, write “none.”
Go to column 3.
Is this hazard(s) CONTROLLED to the best
of the plant’s ability by Support Programs? If
YES, list all of the Support Programs that will control
the introduction or intensification of the
hazard(s) identified in Column 2. If NO, write
“none.”
Go to column 4.
Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process
step? If NO, write “none” and continue to the next hazard or process step. If YES, identify
the last process step where it will be eliminated.
If you are at that process step, proceed to Column 5; if not, go to the next hazard or
process step. (Note: If no control or elimination is identified in Column 3 or 4 and
these are necessary for food safety, you must stop, modify the step, process, product, or
Support Programs.)
Can a viable product still be produced if the process step listed in Column 4 fails? If YES, this step
must be considered a CCP: identify the CCP number. If
NO, this is not a CCP: enter NO.
Go to the next hazard or process step.
Dried milk powder B None None None
C Allergen Supplier control program
None
P large lumps, metal, glass
Glass Policy Metal Detector/ Glass Xray Unit
Yellow #5 food color B None None None
C tartrazine (Allergen)
Supplier Control Program
None
P None None None
Glass jar B None None None
C None None None
P pieces / shards Glass policy Glass Xray Unit
B
C
PROCESS HAZARD ANALYSIS
P
PROCESS HAZARD ANALYSIS(1) (2) (3) (4) (5)
List every Critical Ingredient identified in the Raw Material
Hazard Analysis.
List every process step, from Receiving to Shipping, shown on the simplified Process Flow
Diagram.
Go to Column 2.
Note: If this is a last process step identified in Column 4, list
the hazard eliminated in Column 2.
Does this raw material or process step INTRODUCE or INTENSIFY a potential
food safety hazard? If YES identify hazard(s). (Be as specific as possible when listing the hazard and its source.) If no hazard is identified, write “none.”
Go to column 3.
Is this hazard(s) CONTROLLED to the best
of the plant’s ability by Support Programs? If
YES, list all of the Support Programs that will control
the introduction or intensification of the
hazard(s) identified in Column 2. If NO, write
“none.”
Go to column 4.
Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process
step? If NO, write “none” and continue to the next hazard or process step. If YES, identify
the last process step where it will be eliminated.
If you are at that process step, proceed to Column 5; if not, go to the next hazard or
process step. (Note: If no control or elimination is identified in Column 3 or 4 and
these are necessary for food safety, you must stop, modify the step, process, product, or
Support Programs.)
Can a viable product still be produced if the process step listed in Column 4 fails? If YES, this step
must be considered a CCP: identify the CCP number. If
NO, this is not a CCP: enter NO.
Go to the next hazard or process step.
Bulk receiving and storage
(X ray unit)
B Bacteria Supplier control program/ COA
Pasteurizer
C Allergens Supplier control program/ COA
None.
P metals, bones, rocks, glass, sticks
Supplier control program/ COA
Metal Detector/ Glass Xray Unit
Dry storage (Bulk) B None
C None
P None
Refrigerated storage (Bulk)
B None
C None
P None
Palletized ingredient & packaging material receiving
B None
C Allergens Supplier control program/ COA
None
PROCESS HAZARD ANALYSIS
P None
PROCESS HAZARD ANALYSIS(1) (2) (3) (4) (5)
List every Critical Ingredient identified in the Raw Material
Hazard Analysis.
List every process step, from Receiving to Shipping, shown on the simplified Process Flow
Diagram.
Go to Column 2.
Note: If this is a last process step identified in Column 4, list
the hazard eliminated in Column 2.
Does this raw material or process step INTRODUCE or INTENSIFY a potential
food safety hazard? If YES identify hazard(s). (Be as specific as possible when listing the hazard and its source.) If no hazard is identified, write “none.”
Go to column 3.
Is this hazard(s) CONTROLLED to the best
of the plant’s ability by Support Programs? If
YES, list all of the Support Programs that will control
the introduction or intensification of the
hazard(s) identified in Column 2. If NO, write
“none.”
Go to column 4.
Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process
step? If NO, write “none” and continue to the next hazard or process step. If YES, identify
the last process step where it will be eliminated.
If you are at that process step, proceed to Column 5; if not, go to the next hazard or
process step. (Note: If no control or elimination is identified in Column 3 or 4 and
these are necessary for food safety, you must stop, modify the step, process, product, or
Support Programs.)
Can a viable product still be produced if the process step listed in Column 4 fails? If YES, this step
must be considered a CCP: identify the CCP number. If
NO, this is not a CCP: enter NO.
Go to the next hazard or process step.
Dry storage (Palletized)
B None
C None
P None
Refrigerated storage (Palletized)
B None .
C None
P None
Dump station (palletized)
B None
C None
P None
Bulk scaling & minor ingredient addition/ Sifters
B Bacteria/ viruses from employees
GMPs- Personnel practices
Pasteurizer
C cleaners, sanitizers
Chemical control policy
None
PROCESS HAZARD ANALYSIS
P Lumps, glass, metal
GMPs- Personnel practices, Glass Policy
Metal Detector/ Glass Xray Unit
PROCESS HAZARD ANALYSIS(1) (2) (3) (4) (5)
List every Critical Ingredient identified in the Raw Material
Hazard Analysis.
List every process step, from Receiving to Shipping, shown on the simplified Process Flow
Diagram.
Go to Column 2.
Note: If this is a last process step identified in Column 4, list
the hazard eliminated in Column 2.
Does this raw material or process step INTRODUCE or INTENSIFY a potential
food safety hazard? If YES identify hazard(s). (Be as specific as possible when listing the hazard and its source.) If no hazard is identified, write “none.”
Go to column 3.
Is this hazard(s) CONTROLLED to the best
of the plant’s ability by Support Programs? If
YES, list all of the Support Programs that will control
the introduction or intensification of the
hazard(s) identified in Column 2. If NO, write
“none.”
Go to column 4.
Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process
step? If NO, write “none” and continue to the next hazard or process step. If YES, identify
the last process step where it will be eliminated.
If you are at that process step, proceed to Column 5; if not, go to the next hazard or
process step. (Note: If no control or elimination is identified in Column 3 or 4 and
these are necessary for food safety, you must stop, modify the step, process, product, or
Support Programs.)
Can a viable product still be produced if the process step listed in Column 4 fails? If YES, this step
must be considered a CCP: identify the CCP number. If
NO, this is not a CCP: enter NO.
Go to the next hazard or process step.
Oaks mixer B Bacteria GMPs- Personnel practices
Pasteurizer
C cleaners, sanitizers
Chemical control policy
None
P Lumps, glass, metal
GMPs- Personnel practices, Glass Policy
Metal Detector/ Glass Xray Unit
Pasteurizer B Bacteria/ Salmonella
GMPs- Personnel practices
Product must be brought to 190 degrees fahrenheit in order to destroy possible bacteria/viruses introduced from suppliers or SS employees.
1
C cleaners, sanitizers
Chemical control policy
P Lumps, glass, metal
GMPs- Personnel practices, Glass Policy
Metal Detector/ Glass Xray Unit
Cooling B None
C None
PROCESS HAZARD ANALYSIS
P None
Glass storageB None
C None
P pieces / shards Glass Xray Unit
(1) (2) (3) (4) (5)List every Critical Ingredient identified in the Raw Material
Hazard Analysis.
List every process step, from Receiving to Shipping, shown on the simplified Process Flow
Diagram.
Go to Column 2.
Note: If this is a last process step identified in Column 4, list
the hazard eliminated in Column 2.
Does this raw material or process step INTRODUCE or INTENSIFY a potential
food safety hazard? If YES identify hazard(s). (Be as specific as possible when listing the hazard and its source.) If no hazard is identified, write “none.”
Go to column 3.
Is this hazard(s) CONTROLLED to the best
of the plant’s ability by Support Programs? If
YES, list all of the Support Programs that will control
the introduction or intensification of the
hazard(s) identified in Column 2. If NO, write
“none.”
Go to column 4.
Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process
step? If NO, write “none” and continue to the next hazard or process step. If YES, identify
the last process step where it will be eliminated.
If you are at that process step, proceed to Column 5; if not, go to the next hazard or
process step. (Note: If no control or elimination is identified in Column 3 or 4 and
these are necessary for food safety, you must stop, modify the step, process, product, or
Support Programs.)
Can a viable product still be produced if the process step listed in Column 4 fails? If YES, this step
must be considered a CCP: identify the CCP number. If
NO, this is not a CCP: enter NO.
Go to the next hazard or process step.
Glass introduction station
B None
C None
P contamination/ pieces
Glass policy/ Personnel Practices
Glass Xray Unit
Glass inversion station
B None
C None
P contamination/ pieces
Glass policy Glass Xray Unit
Glass washing station B None
C None
P contamination/ pieces
Glass policy Glass Xray Unit
Glass inspection x-ray unit
B None
C None
P contamination/ pieces, fragments
Glass policy Foreign material from Oakes mixer, bulk scaling, or glass introduction stage
2
List every Critical Ingredient identified in the Raw Material
Hazard Analysis.
List every process step, from Receiving to Shipping, shown on the simplified Process Flow
Diagram.
Go to Column 2.
Note: If this is a last process step identified in Column 4, list
the hazard eliminated in Column 2.
Does this raw material or process step INTRODUCE or INTENSIFY a potential
food safety hazard? If YES identify hazard(s). (Be as specific as possible when listing the hazard and its source.) If no hazard is identified, write “none.”
Go to column 3.
Is this hazard(s) CONTROLLED to the best
of the plant’s ability by Support Programs? If
YES, list all of the Support Programs that will control
the introduction or intensification of the
hazard(s) identified in Column 2. If NO, write
“none.”
Go to column 4.
Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process
step? If NO, write “none” and continue to the next hazard or process step. If YES, identify
the last process step where it will be eliminated.
If you are at that process step, proceed to Column 5; if not, go to the next hazard or
process step. (Note: If no control or elimination is identified in Column 3 or 4 and
these are necessary for food safety, you must stop, modify the step, process, product, or
Support Programs.)
Can a viable product still be produced if the process step listed in Column 4 fails? If YES, this step
must be considered a CCP: identify the CCP number. If
NO, this is not a CCP: enter NO.
Go to the next hazard or process step.
Rework B Bacteria Supplier Control Program, Personnel Practices
Pasteurizer
C Allergen/sanitizers
Allergen control program, chemical control policy
None
P Lumps, glass, metal
GMPs- Personnel practices, Glass Policy
Metal Detector/ Glass Xray Unit)
Glass Hot fill B None
C None
P None
B None
Metal detector Labeling & boxing
Capper.
C None
P metal fragments No. Metal pieces from equipment or tooling.
3
Refrigerated Storage B None
C Nome
P None
(1) (2) (3) (4) (5)List every Critical Ingredient identified in the Raw Material
Hazard Analysis.
List every process step, from Receiving to Shipping, shown on the simplified Process Flow
Diagram.
Go to Column 2.
Note: If this is a last process step identified in Column 4, list
the hazard eliminated in Column 2.
Does this raw material or process step INTRODUCE or INTENSIFY a potential
food safety hazard? If YES identify hazard(s). (Be as specific as possible when listing the hazard and its source.) If no hazard is identified, write “none.”
Go to column 3.
Is this hazard(s) CONTROLLED to the best
of the plant’s ability by Support Programs? If
YES, list all of the Support Programs that will control
the introduction or intensification of the
hazard(s) identified in Column 2. If NO, write
“none.”
Go to column 4.
Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process
step? If NO, write “none” and continue to the next hazard or process step. If YES, identify
the last process step where it will be eliminated.
If you are at that process step, proceed to Column 5; if not, go to the next hazard or
process step. (Note: If no control or elimination is identified in Column 3 or 4 and
these are necessary for food safety, you must stop, modify the step, process, product, or
Support Programs.)
Can a viable product still be produced if the process step listed in Column 4 fails? If YES, this step
must be considered a CCP: identify the CCP number. If
NO, this is not a CCP: enter NO.
Go to the next hazard or process step.
Refrigerated shipping B None
C None
P None
B
C
P
B
C
P
B
C
P
HACCP MASTER PLAN
(1) (2) (3) (4) (5) (6) (7)Significant Critical Monitoring Corrective
CCP Hazard Limits Action(s) Verification Records
1 Biological >190 degrees degrees for a minimum of 5 minutes.
What: Product temperature must be at >190 degrees Fahrenheit.
All product since the last good check will be placed on hold for re
pasteurization.
Unit will be repaired or replaced with a
known working unit. Repaired/ replaced
unit shall be inspected and verified by
qualified maintenance personnel and QA
before being placed into service.
Temperature must be monitored every 2 hours,
monitor log must be signed at each
check by a qualified
production associate.
Monitoring must be observed and verified at least
four times a shift by the supervisor and at least twice
a shift by QA.
Bacteria/ viruses
Pasteurizer temperature monitor log.
How: : Temperature readings are taken every 2 hours with a calibrated thermometer. A sample is obtained from the pasteurizer and the temperature is verified and recorded.
Frequency: At the beginning of each shift and at the end of each shift. Every 2 hours during the shift
Who: Shift Supervisor. Monitoring will be observed and verified by QA.
Signature of Company Official: Guermo Tank Title: Plant manager Date: 9/10/2009
HACCP MASTER PLAN
(1) (2) (3) (4) (5) (6) (7)Significant Critical Monitoring Corrective
CCP Hazard Limits Action(s) Verification Records
2 Glass inclusion
0.5mm or greater
What: Glass X ray unit All product since the last good check will be placed on hold for re inspection through a known good unit or
destroyed.
Unit will be repaired or replaced with a
known working unit. Repaired/ replaced
unit shall be inspected and verified by
qualified maintenance personnel and QA
before being placed into service
Unit must be monitored every 2 hours, monitor log must be signed at each check by a
qualified production associate.
Monitoring must be observed and verified at least
four times a shift by the supervisor and at least twice
a shift by QA.
A working Reject mechanism- Product will be kicked out of the process.
Glass X ray unit monitor log
How: Unit will be checked using verified test samples to ensure unit is working properly.
Frequency: At the beginning of each shift and at the end of each shift. Every 2 hours during production, after maintenance, and after line changes.
Who: Qualified Production associate and shift supervisor. Monitoring will be observed and verified by QA.
Signature of Company Official: Guermo Tank Title: Plant manager Date: 9/10/2009
HACCP MASTER PLAN
(1) (2) (3) (4) (5) (6) (7)Significant Critical Monitoring Corrective
CCP Hazard Limits Action(s) Verification Records
3 Metal 2.5 mm (ferrous metals)
What: Metal detector All product since the last good check will be placed on hold for re inspection through a known good unit or
destroyed.
Unit will be repaired or replaced with a
known working unit. Repaired/ replaced
unit shall be inspected and verified by
qualified maintenance personnel and QA
before being placed into service
Unit must be monitored every 2 hours, monitor log must be signed at each check by a
qualified production associate.
Monitoring must be observed and verified at least
four times a shift by the supervisor and at least twice
a shift by QA.
Metal detector monitor log
2.5 mm (non ferrous metals)4.0mm stainless steel.
A working Reject mechanism- Product will be kicked out of the process.
How: Unit will be checked using verified test samples to ensure unit is working properly.
Frequency: At the beginning of each shift and at the end of each shift. Every 2 hours during production, after maintenance, and after line changes.
Who: Qualified Production associate and shift supervisor. Monitoring will be observed and verified by QA.
Signature of Company Official: Guermo Tank Title: Plant manager Date: 9/10/2009
HACCP DEVIATION REPORTDate:____________________ Critical Control Point:___________________Location:________________ Equipment:____________________________Specified Range:__________ Actual Reading:_________________________Past History:____________________________________________________________________________________________________________________________________________________________________________________________Current CorrectiveAction:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Future Corrective Action Needed:_____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Production Disposition:_____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Attach a copy of all records of the critical control point deviation.
HACCP CORRECTIVE ACTION REQUEST
o Major o Minor
Problem Noted:
Temporary Action Taken:
Long-Term Corrective Action:
Assigned To/Due Date:Prepared by:_________________________ Date: ________Reviewed by:________________________ Date:_________Was the corrective action effective?_______________________________Remarks:
Corrective Action o Open o Closed
NOTICE OF UNUSUAL OCCURRENCEAND CORRECTIVE ACTION(NUOCA)This NUOCA contains trade secret/business confidentialinformation and is exempt from disclosure pursuant to applicable law.Date:___________________________Supplier:________________________Product:_________________________ Product Lot Identifier:_____________________DESCRIPTION OF UNUSUAL OCCURRENCE:
DESCRIPTION OF CRITICAL LIMITS EXCEEDED (if any):(Identify by CCP Number)PREDETERMINED CORRECTIVE ACTION PURSUANT TO HACCP PROGRAM:Product Segregation and Hold Product to be DestroyedFurther Hazard Analysis (Describe below) Reconditioning /Alternative Use (Describe below)
ACTION TAKEN UPON FURTHER HAZARD ANALYSIS PURSUANT TO GENERIC CORRECTIVEACTION PLAN: (Describe in detail)
RECOMMENDED ACTION FOR REEVALUATION OR MODIFICATION OF HACCP PROGRAM: (Describein detail)
________________________________________Signature
REVIEWED BY:
________________________________________Signature of HACCP CoordinatorDate:_____________