HACCP PLAN FOR BAKED FOODS
Department of Food Science and Technology Technology Faculty of Agricultural Technology Bogor Agricultural University 2009
L a n g k a h 1 : E s t ab a b l i s h t h e H A C CP C P t e am am
Name Dewi
Expertise/Position Food Tech. & HACCP specialist/
Position in the team Coordinator
QA Mgr. Rahman
Engineering/Production Mgr.
Member
Putri
Microbiology/QC Mgr.
Member
Surya
Chemistry/Warehouse Mgr.
Member
L a n g k a h 1 : E s t ab a b l i s h t h e H A C CP C P t e am am
Name Dewi
Expertise/Position Food Tech. & HACCP specialist/
Position in the team Coordinator
QA Mgr. Rahman
Engineering/Production Mgr.
Member
Putri
Microbiology/QC Mgr.
Member
Surya
Chemistry/Warehouse Mgr.
Member
S t ep e p 2 : Pr Pr o d u c t D e s c r i p t i o n
•
Name of product
: cream-filled bread
•
Composition
: Susu skim, kultur BAL, glukosa
•
Product characteristics
: Susu kental, asam, pH 4.3
•
Methods of processing
: pasteurisasi, fermentasi
•
Methods of preservatio preservation n : fermentasi
•
Primary packaging
: cup Polyethylene
•
Conditions Conditio ns of storage
: Suhu 4oC
•
Method of distribution
: Dalam truk beropendingin
•
Shelflife
: 3 minggu
•
Specific labelling
:-
•
Instruction on the label
:-
Step 3 : Identification of the Product’s Intended Use
•
Name of product
: Cream-filled bread
•
Intended use
: Directly consumed
•
Target consumer
: General public
S t ep 4 : E s t a b l i s h P r o c e s s F l o w D i ag r a m Process flow diagram for the bread : Weigh all ingredients (sugar, salt, skim milk, shortening, egg, wheat flour, yeast, col d water) Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-30 0C) Divide the dough and weigh 900 gram each Fermentation 2 (27-300 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-30 0C) Filling with cream Packaging (PET bag/pouch)
S t ep 4 : E s t a b l i s h P r o c e s s F l o w D i ag r a m Process flow diagram for the cream :
Weigh all the ingredients (jelly mallow, butter, shortening) Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
S t ep 5 : O n -s i t e Co n f i r m a t i o n o f F l o w D i ag r a m : B r e a d Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast)
Receiving (egg, water)
Dry storage at room temperature (25-30 0 C) Weigh all ingredients
Storage at 5-150 C
Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-30 0C) Divide the dough and weigh 900 gram each Fermentation 2 (27-30 0 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-30 0C) Filling with cream Packaging (PET bag/pouch)
S t ep 5 : O n - s i t e C o n f i r m a t i o n o f F l o w D i a g r a m : C r e am Receiving (jelly mallow, butter, shortening) Dry storage at room temperature (25-300 C) Weigh all the ingredients Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
P r i n c i p l e 1 : H a z ar d A n a l y s i s HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps Name of Product : Cream-filled Bread Process Step Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast)
Potential Hazard(s) B/C/P B
Description of Hazard Contaminated yeast (by spoilage or pathogenic m.o.)
Storage (sugar, salt, skim milk, shortening, wheat flour, yeast)
B
Insects
Receiving of egg
B
Storage of egg
B
Presence of pathogenic bacteria Eggshell (cracked/broken eggs) Growth of pathogenic bacteria
Weighing of all ingredients
P
Insect bone pieces
Mixing of sugar, salt, skim milk
P
Insect bone pieces, personal items
P
P r i n c i p l e 1 : H a z ar d A n a l y s i s HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step
Adding egg and shortening Adding wheat flour, yeast and cold water
Potential Hazard(s) Description of Hazard B/C/P B Contamination of pathogenic bacteria P Eggshell
B
Contamination of spoilage or pathogenic bacteria (from yeast and water) Insect bone pieces
Blending
Rounding the dough
Fermentation 1
Dividing the dough
Fermentation 2
P
P B
Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker
B
Contamination of spoilage m.o. from the air
B
Contamination of spoilage and pathogenic m.o. from the air and worker
B
Contamination of spoilage m.o. from the air
B
P r i n c i p l e 1 : H a z ar d A n a l y s i s HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Spreading with egg
Potential Hazard(s) B/C/P B
Baking
B
Cooling
B
Filling with cream
B
Packaging
B
Storage
B
Description of Hazard Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o.
Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds
P r i n c i p l e 1 : H a z ar d A n a l y s i s HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Receiving jelly mallow, butter, shortening
Potential Hazard(s) B/C/P -
Description of Hazard -
Storage
B C
Weighing all ingredients
-
Contamination of spoilage m.o. Decomposition of chemical compound -
Mixing
P
Personal item
Beating
P
Personal item
Storage
B
Growth of spoilage m.o.
P r i n c i p l e 1 : H a z ar d A n a l y s i s HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps Name of Product : Cream-filled Bread Process Step Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving of egg, water
Storage of egg Weighing of all ingredients
Mixing of sugar, salt, skim milk
Adding egg and shortening Adding wheat flour, yeast and cold water Blending
Rounding the dough
Potential Hazard(s) Preventive or Control B/C/P Description of Hazard Measures B Contaminated yeast (by spoilage Quality assurance (certificate of or pathogenic m.o.) analysis) from supplier P Insects Proper storage conditions (dry, clean), sealed packaging of the ingredients. B Presence of pathogenic bacteria Certificate of analysis from egg supplier, acceptable water source P Eggshell (cracked/broken eggs) Inspection of incoming eggs 0 B Growth of pathogenic bacteria Refrigerated storage (5-15 C), Label expired date. P Insect bone pieces, personal Inspection of the ingredients, items SOP for production area (no personal items are wore) P Insect bone pieces, personal Inspection of the ingredients, items SOP for production area (no personal items are wore) P Eggshell Inspection of the ingredients (cracked eggs) P Insect bone pieces Filtering of wheat flour B Contamination of spoilage m.o. SSOP from the air P Personal item SOP for production area (no personal items are wore) B Contamination of spoilage & SSOP pathogenic m.o. from the air &
P r i n c i p l e 1 : H a z ar d A n a l y s i s HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Fermentation 1 Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging Storage
Potential Hazard(s) B/C/P Description of Hazard B Contamination of spoilage m.o. from the air B Contamination of spoilage and pathogenic m.o. from the air and worker B Contamination of spoilage m.o. from the air B Contamination of spoilage and pathogenic m.o. from the air and worker B Survival of spoilage m.o. B Contamination of spoilage m.o. from the air B Contamination of spoilage and pathogenic m.o. from the air and worker B Contamination of spoilage and pathogenic m.o. from the air and worker B Contamination of spoilage molds
Preventive or Control Measures SSOP SSOP SSOP SSOP Correct time and temperature SSOP SSOP SSOP Proper storage condition (dry, clean), expired date must be stated on the label
Receiving jelly mallow, butter, shortening Storage
B
Contamination of spoilage m.o.
Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients
Weighing all ingredients Mixing Beating Storage
P P B
Personal item Personal item Growth of spoilage m.o.
SSOP SSOP Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight)
-
P r i n c i p l e 1 : H a za r d A n a l y s i s HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps Name of Product : Cream-filled Bread Process Step Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast)
Potential Hazard(s) B/C/P B
Storage (sugar, salt, skim milk, shortening, wheat flour, yeast)
P
Receiving egg, water
B
P
Storage of egg
B
Weighing of all ingredients
P
Description of Hazard Contaminated yeast (by spoilage/ pathogenic m.o.) Insects
Presence of pathogenic bacteria Eggshell (Cracked / broken eggs) Growth of pathogenic bacteria Insect bone pieces, personal items
Reasonably Significant likely to Severity hazard occur (Y/N)
Preventive or Control Measures
l
M
N
Quality assurance (certificate of analysis) from supplier
h
M
Y
Proper storage conditions (dry, clean), sealed packaging of the ingredients.
m
M
N
h
M
Y
Certificate of analysis from egg supplier, acceptable water source Inspection of incoming eggs
l
L
N
Refrigerated storage (5-150 C), Label expired date.
l
M
N
Inspection of the ingredients, SOP for production area (no personal items are wore)
P r i n c i p l e 1 : H a za r d A n a l y s i s HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Mixing of sugar, salt, skim milk
Potential Hazard(s) B/C/P P
Description of Hazard Insect bone pieces, personal items Eggshell
Reasonably Significant Sevelikely to hazard rity occur (Y/N) l
M
N
m
M
N
Preventive or Control Measures Inspection of the ingredients, SOP for production area (no personal items are wore) Inspection of the ingredients (cracked eggs)
Adding egg and shortening
P
Adding wheat flour, yeast and cold water
P
Insect bone pieces
m
M
N
Filtering of wheat flour
Blending
B
Contamination of spoilage m.o. from the air Personal item
m
L
N
SSOP
m
M
N
Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air
l
L
N
SOP for production area (no personal items are wore) SSOP
l
L
N
SSOP
P Rounding the dough
B
Fermentation 1
B
P r i n c i p l e 1 : H a z ar d A n a l y s i s HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread Potential Reasonably Significant Preventive or SeveProcess Step Hazard(s) Description of Hazard likely to hazard Control rity occur (Y/N) Measures \B/C/P Dividing the dough B Contamination of spoilage and m L N SSOP pathogenic m.o. from the air, weighscale, and worker Fermentation 2 B Contamination of spoilage m.o. from the l L N SSOP air Spreading with egg B Contamination of spoilage and m H Y SSOP pathogenic m.o. from the air and worker Baking
B
Survival of spoilage m.o.
l
H
N
Cooling
B
m
M
N
Filling with cream
B
m
H
Y
SSOP
Packaging of bread
B
m
H
Y
SSOP
Storage and distribution
B
Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds
Correct time and temperature SSOP
m
M
N
Proper storage condition (dry, clean), expired date must be stated on the label
P r i n c i p l e 1 : H a z ar d A n a l y s i s HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Receiving jelly mallow, butter, shortening Storage of jelly mallow, butter, shortening
Potential Hazard(s) B/C/P -
B
Description of Hazard -
Reasonably Significant Sevelikely to hazard rity occur (Y/N) -
m
H
Y
m
H
Y
-
Weighing all ingredients
-
-
-
-
-
Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients -
Mixing
P
Personal item
l
M
N
SSOP
Beating
P
Personal item
l
M
N
SSOP
Storage of cream
B
Growth of spoilage m.o.
m
H
Y
Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight)
C
Contamination of spoilage m.o. Decomposition of chemical compound
Preventive or Control Measures
Principle 2 : Establishm ent of Critical Contro l Point CCP HACCP Plan Worksheet 2A : Establishment of CCP in Ingredients Name of Product : Cream-filled Bread Ingredient
Potential Hazard (s) B
P1
P2
P3
CCP?
Y
Y
N
N
Wheat flour
P B
Y Y
Y Y
N N
N N
Yeast Egg
P B B
Y Y Y
Y Y Y
N N N
N N N
C
Y
N
-
Y
P B
Y Y
N Y
N
Y N
Sugar
Water
P r i n c i p l e 2 : E s t ab l i s h m e n t o f C r i t i c a l C o n t r o l P o i n t (C C P) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread Potential Hazard(s) B
Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg
Process Step
P2
P3
P4
P5
CCP?
N
-
-
-
-
N
P
Y
Y
N
Y
N
CCP
Storage of egg
B P B
N Y N
Y -
N -
Y -
N -
N CCP N
Weighing of all ingredients
P
N
-
-
-
-
N
Mixing of sugar, salt, skim milk
P
N
-
-
-
-
N
Adding egg and shortening
P
N
-
-
-
-
N
Adding wheat flour, yeast and Cold water
P
N
-
-
-
-
N
Blending
B P
N N
-
-
-
-
N N
Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast
P1
P r i n c i p l e 2 : Es t a b l i s h m e n t o f C r i t i c al C o n t r o l P o i n t ( CC P ) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread Potential Hazard(s) B
Fermentation 1
Process Step
P2
P3
P4
P5
CCP?
N
-
-
-
-
N
B
N
-
-
-
-
N
Dividing the dough
B
N
-
-
-
-
N
Fermentation 2
B
N
-
-
-
-
N
Spreading with egg
B
Y
Y
N
Y
Y
N
Baking
B
N
-
-
-
-
N
Cooling
B
N
-
-
-
-
N
Filling with cream
B
Y
Y
N
Y
N
CCP
Packaging
B
Y
Y
N
Y
N
CCP
Storage and distribution of bread
B
N
-
-
-
-
N
Rounding the dough
P1
P r i n c i p l e 2 : Es t a b l i s h m e n t o f C r i t i c al C o n t r o l P o i n t ( C C P) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread Potential Hazard(s) B C
Mixing
Process Step
P2
P3
P4
P5
CCP?
Y Y
Y Y
N N
Y Y
N N
CCP CCP
P
N
-
-
-
-
-
Beating
P
N
-
-
-
-
-
Storage of cream
B
Y
Y
N
Y
N
CCP
Storage of jelly mallow, butter, shortening
P1
P r i n c i p l e 3: E s t ab l i s h m e n t o f C r i t i c a l L i m i t s HACCP Plan Worksheet 3 : Establishment of Critical Limits Name of Product : Cream-filled Bread Ingredient/ Process Step
CCP No. 1 (C) 2 (P)
CL Antibiotic residue = 0 Cracked / broken egg = 0
Storage (sugar, salt, skim milk, shortening, wheat flour, yeast)
3 (P)
Rh = 90-92% Time < 1 month SSOP = applied
Receiving egg
4 (P)
Cracked/broken egg = 0
Filling with cream
5 (B)
Holding Time <10 min, T=20-250 C
Packaging of bread Storage of jelly mallow, butter, shortening
6 (B) 7 (B) 8 (C)
Holding Time <10 min, T=20-250 C T = 5-150 C, label expired date
Storage of cream
9 (B)
T = 5-150 C, label expired date
Egg
P r in c i p l e 4 : Es t a b l i s h m en t o f M o n i t o r i n g P r o c e d u r e s HACCP Plan Worksheet 4 : Establishment of Monitoring Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step Egg
CCP CL No. 1 (C) Antibiotic residue =0 2 (P) Cracked / broken egg = 0 Storage (sugar, 3 (P) Rh = 90=92 salt, skim Time < 1 month milk, shortening, SSOP = applied wheat flour, yeast)
Monitoring Procedures What How Where Antibiotic residue Check the CoA Receiving on CoA site Cracked/broken Inspection of Receiving eggs incoming eggs site Rh Measure the Rh Storage Storage time Check storage time room / SSOP application Check the warehouse application of SSOP
Receiving egg
4 (P) Cracked/broken egg = 0 5 (B) Holding Time <10 min, T=20-250 C
Cracked/broken eggs Time and temperature
Packaging of bread Storage of jelly mallow, butter, shortening
6 (B) Holding Time <10 min, T=20-250 C 7 (B) T = 5-150 C, label 8 (C) expired date
Time and temperature Temperature, label of the ingredients
Storage of
9 (B) T = 5-150 C, label Temperature, expired date label of cream
Filling with cream
Who Receiving personnel Receiving personnel Warehouse mngr.
Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temp. Measure temp., check label
Receiving Receiving site personnel Production Area area personnel
Measure temp. check label
Warehouse Warehouse
Production Area area personnel Warehouse Warehouse mngr.
Freq. Every receiving Every receiving Every day
Every receiving Time : every 10 minutes T : Every 6 hours Every day
Every day
Principle 5: Establishm ent of Corrective Ac tion s HACCP Plan Worksheet 5 : E s t a b l i s h m e n t o f C o r r e c t i v e A c t i o n s ( 1) Name of Product : Cream-filled Bread Ingredient/ CCP CL Process Step No. Egg 1 (C) Antibiotic residue = 0 2 (P) Cracked / broken egg = 0 Storage 3 (P) Rh = (sugar, salt, 4 (P) Time < 1 month skim milk, 5 (B) SSOP = applied shortening, 6 (B) wheat flour, yeast)
Receiving egg
Monitoring Procedures What How Where Who Antibiotic Check the Receiving Receiving residue on CoA CoA site personnel Cracked/broke Inspection Receiving Receiving n eggs of incoming site personnel Rh eggs Storage Warehouse Storage time Measure room / mngr. SSOP Rh,check warehouse application storage time Check the application of SSOP Cracked/broken Cracked/broke Inspection Receiving Receiving egg = 0 n eggs of incoming site personnel eggs
Filling with cream
Holding Time <10 min, T=20250 C
Packaging of bread
Holding Time <10 min, T=20250 C
Time and temperature Time and temperature
Corrective Actions Frequency Every 1. Rejection of non-complying receiving ingredient Every 2. Write a report to warehouse mngr. receiving Every day 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr.
Every 1. Rejection of non-complying Receiving ingredient 2. Write a report to warehouse mngr.
Check/ Production Area measure area personnel time and temperatur e
Time : 1. Disposition of non-complying every 10 products minutes 2. Correct the cause to prevent T : Every 6 recurrences hours 3. Maintain record 4. Write a report to QA mngr.
Check/ Production Area measure area personnel time and temperatur e
Time : 1. Disposition of non-complying Every 10 products minutes 2. Correct the cause to prevent T : Every 6 recurrences hours 3. Maintain record
P r i n c i p l e 5: Es t a b l i s h m e n t o f C o r r e c t i v e A c t i o n s HACCP Plan Worksheet 5 : E s t a b l i s h m e n t o f C o r r e c t i v e A c t i o n s ( 1) Name of Product : Cream-filled Bread Ingredient/ CCP Process Step No. Storage of 7 (B) jelly mallow, 8 (C) butter, 9 (B) shortening
Storage of cream
CL T = 5-15 0 C, label expired date
What Temperature, label of the ingredients
T = 5-15 0 C, label expired date
Temperature, label of cream
Monitoring Procedures Corrective Actions How Where Who Frequency Measure Warehouse Warehouse Every day 1. Disposition of non-complying temperature, Warehouse mngr. ingredients check label 2. Correct the cause to prevent recurrences 3. Maintain record Measure temperature, check label
Warehouse Every day mngr.
1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record
P r i n c i p l e 6 : Es t a b l i s h m e n t o f Ve r i f ic a t i o n P r o c e d u r e s HACCP Plan Worksheet 6 : E s t a b l i s h m e n t o f V er i f i c a t i o n P r o c e d u r e s Name of Product : Cream-filled Bread Ingredient/ Process Step
CCP No.
CL What
Monitoring Procedures How Where Who
Corrective Actions
Frequen cy 1 (C) Antibiotic Egg Antibiotic Check the Receiving Receiving Every 1. Rejection of non-complying personnel receiving ingredient residue = 0 residue on CoA site CoA 2. Write a report to warehouse 2 (P) Cracked / Cracked/bro Inspection of Receiving Receiving Every mngr. broken egg = 0 ken eggs personnel receiving incoming site eggs Storage (sugar, 3 (P) Rh = 90-92% Rh Measure the Storage Warehou Every day 1. Disposition of contaminated Storage time Rh se mngr. ingredients salt, skim Time < 1 room / month milk, shortening, SSOP Check the warehous 2. Correct the cause to prevent application storage tim e e recurrences wheat flour, SSOP = 3. Maintain record yeast) applied Check the application 4. Write a report to warehouse of SSOP mngr.
Verification Activities Analysis of antibiotic residue every 1 year
Calibration of Rhmeter Inspection of insects contamination every 1 month
Receiving egg
4 (P) Cracked/broke Cracked/bro Inspection of Receiving Receiving Every 1. Rejection of non-complying ken eggs site personnel receiving ingredient n egg = 0 incoming eggs 2. Write a report to warehouse mngr.
Customer complaint
Filling with cream
5 (B) Holding Time Time and Check/ Productio Productio n area <10 min, T=20- temperature measure n 0 25 C time and superviso temperature r
Time : 1. Disposition of non-complying products every 10 minutes 2. Correct the cause to prevent recurrences T : Every 6 hours 3. Maintain record 4. Write a report to QA mngr.
Microb.analysisof products
Packaging
6 (B) Holding Time Time and Check/ Productio Productio n area <10 min, T=20- temperature measure n 250 C time and superviso temperature r
Time : 1. Disposition of non-complying Microb. Analysis of products products Every 10 minutes 2. Correct the cause to prevent recurrences T : Every 6 hours 3. Maintain record 4. Write a report to QA mngr.
P r i n c i p l e 6 : Es t a b l i s h m e n t o f Ve r i f ic a t i o n P r o c e d u r e s HACCP Plan Worksheet 6 : E s t a b l i s h m e n t o f V e r i f ic a t i o n P r o c e d u r e s ( c o n t . )
Name of Product : Cream-filled Bread Ingredient/ Process Step Storage of jelly mallow, butter, shortening
CCP CL Monitoring Procedures Corrective Actions No. What How Where Who Frequency 7 (B) T = 5-150 C, Temperature, Measure Warehouse Warehouse Every day 1. Disposition of non8 (C) label expired label of the temperature, mngr. complying ingredients date ingredients check label 2. Correct the cause to prevent recurrences 3. Maintain record
Verification Activities Microb. Analysis of ingredients
Storage of cream
9 (B) T = 5-150 C, Temperature, Measure Warehouse label expired label of temperature, date cream check label
Microb. Analysis of cream
Warehouse Every day mngr.
1. Disposition of noncomplying products 2. Correct the cause to prevent recurrences 3. Maintain record
P r i n c i p l e 7: Es t a b l i s h m e n t o f R ec o r d - k e ep i n g P r o c e d u r e s HACCP Plan Worksheet 7 : E s t a b l i s h m e n t o f Re c o r d - k e ep i n g P r o c e d u r e s Name of Product : Cream-filled Bread Ingredient/ CCP Process No. Step Egg 1 (C) 2 (P) 3 (P) 4 (P) Storage 5 (B) (sugar, salt, 6 (B) skim milk, shortening, wheat flour, yeast)
CL What Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied
Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time
Monitoring Procedures How Where Check the CoA
Who
Receiving site Receiving site Storage room / warehous e
Receiving personnel Receiving personnel Warehouse mngr.
SSOP application
Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP
Cracked/broke n eggs
Inspection of incoming eggs
Receiving site
Receiving personnel
Corrective Actions Verification Frequenc Activities Records y Every 1. Rejection of non-complying Analysis of Receiving log receiving ingredient antibiotic residue Every 2. Write a report to warehouse mngr. every 1 year receiving Every day 1. Disposition of contaminated Calibration of Warehouse log, ingredients Rh-meter Rh operation 2. Correct the cause to prevent Inspection of document, Rh recurrences insects calibration 3. Maintain record contamination documents, 4. Write a report to warehouse mngr. every 1 month Insects inspection document Every 1. Rejection of non-complying Customer Receiving log receiving ingredient complaint 2. Write a report to warehouse mngr.
Receiving egg
Cracked/broke n egg = 0
Filling with cream
Holding Time Time and <10 min, T=20- temperature 250 C
Check/ measure time and temperature
Productio n area
Production supervisor
Time : every 10 minutes T : Every 6 hours
1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr.
Microb. analysis of products
Production log, microb. analysis document
Packaging of bread
Holding Time Time and <10 min, T=20- temperature 250 C
Check/ measure time and temperature
Productio n area
Production supervisor
Time : Every 10 minutes T : Every 6 hours
1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr.
Microb. Analysis of products
Production log, microbiological analysis document
P r i n c i p l e 7: Es t a b l i s h m e n t o f R ec o r d - k e ep i n g P r o c e d u r e s HACCP Plan Worksheet 7 : E s t a b l i s h m e n t o f R e c o r d -k e e p i n g P r o c e d u r e s ( c o n t . ) Name of Product : Cream-filled Bread Ingredient CCP / Process No. Step Storage of 7 (B) jelly 8 (C) mallow, butter, shortening Storage of 9 (B) cream
CL
T = 5-150 C, label expired date
T = 5-150 C, label expired date
Monitoring Procedures How Where Who
Corrective Actions
Verificatio What Frequency Records n Activities Temperature, Measure Wareho Warehous Every day 1. Disposition of non-complying Microb. Warehouse label of the temperature use e mngr. ingredients Analysis of log, microb. ingredients , check label 2. Correct the cause to prevent ingredients Analysis recurrences document 3. Maintain record Every day Temperature, Measure Wareho Warehous 1. Disposition of non-complying Microb. Warehouse label of temperature use e mngr. products Analysis of log, microb. cream , check label 2. Correct the cause to prevent cream Analysis recurrences document 3. Maintain record
HACCP Plan Cream-Filled Bread Ingredient/ CCP Process No. Step Egg 1 (C) 2 (P) 3 (P) 4 (P) Storage 5 (B) (sugar, salt, 6 (B) skim milk, shortening, wheat flour, yeast)
CL What Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied
Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time
Monitoring Procedures How Where Check the CoA
Who
Receiving site Receiving site Storage room / warehous e
Receiving personnel Receiving personnel Warehouse mngr.
SSOP application
Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP
Cracked/broke n eggs
Inspection of incoming eggs
Receiving site
Receiving personnel
Corrective Actions Verification Frequenc Activities Records y Every 1. Rejection of non-complying Analysis of Receiving log receiving ingredient antibiotic residue Every 2. Write a report to warehouse mngr. every 1 year receiving Every day 1. Disposition of contaminated Calibration of Warehouse log, ingredients Rh-meter Rh operation 2. Correct the cause to prevent Inspection of document, Rh recurrences insects calibration 3. Maintain record contamination documents, 4. Write a report to warehouse mngr. every 1 month Insects inspection document Every 1. Rejection of non-complying Customer Receiving log receiving ingredient complaint 2. Write a report to warehouse mngr.
Receiving egg
Cracked/broke n egg = 0
Filling with cream
Holding Time Time and <10 min, T=20- temperature 250 C
Check/ measure time and temperature
Productio n area
Production supervisor
Time : every 10 minutes T : Every 6 hours
1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr.
Microb. analysis of products
Production log, microb. analysis document
Packaging of bread
Holding Time Time and <10 min, T=20- temperature 250 C
Check/ measure time and temperature
Productio n area
Production supervisor
Time : Every 10 minutes T : Every 6 hours
1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr.
Microb. Analysis of products
Production log, microbiological analysis document
