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HACCP PLAN FOR BAKED FOODS

Department of Food Science and Technology Faculty of Agricultural Technology Bogor Agricultural University 2009

Langkah 1 : Establish the HACCP team

Name Dewi Rahman


Putri Surya

Expertise/Position Food Tech. & HACCP specialist/


QA Mgr.

Position in the team Coordinator Member


Member Member

Engineering/Production Mgr.
Microbiology/QC Mgr. Chemistry/Warehouse Mgr.

Step 2 : Product Description

Name of product Composition Product characteristics Methods of processing Methods of preservation Primary packaging Conditions of storage Method of distribution Shelflife Specific labelling Instruction on the label

: cream-filled bread : Susu skim, kultur BAL, glukosa : Susu kental, asam, pH 4.3 : pasteurisasi, fermentasi : fermentasi : cup Polyethylene : Suhu 4oC : Dalam truk beropendingin : 3 minggu ::-

Step 3 : Identification of the Products Intended Use

Name of product Intended use Target consumer

: Cream-filled bread : Directly consumed : General public

Step 4 : Establish Process Flow Diagram


Process flow diagram for the bread :
Weigh all ingredients (sugar, salt, skim milk, shortening, egg, wheat flour, yeast, cold 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 27-300C) 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 (25-300C)

Filling with cream


Packaging (PET bag/pouch)

Storage and distribution at room temperature (25-300C) for a maximum 3-5 days

Step 4 : Establish Process Flow Diagram


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)

Step 5 : On-site Confirmation of Flow Diagram : Bread


Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving (egg, water)

Dry storage at room temperature (25-300 C) Weigh all ingredients


Mixing (sugar, salt and skim milk) Add shortening and egg

Storage at 5-150 C

Blending (into creamed mixture)


Add wheat flour, yeast, and cold water

Blending (into non-sticky dough)


Round the dough

Fermentation 1 (15 minutes at 27-300C)


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 (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days

Step 5 : On-site Confirmation of Flow Diagram : Cream


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)

Principle 1 : Hazard Analysis


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) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving of egg Potential Hazard(s) B/C/P B

Description of Hazard
Contaminated yeast (by spoilage or pathogenic m.o.)

Insects

B P

Storage of egg
Weighing of all ingredients Mixing of sugar, salt, skim milk

B
P P

Presence of pathogenic bacteria Eggshell (cracked/broken eggs) Growth of pathogenic bacteria Insect bone pieces Insect bone pieces, personal items

Principle 1 : Hazard Analysis


HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) Description of Hazard B/C/P B Contamination of pathogenic bacteria P Eggshell

Adding egg and shortening Adding wheat flour, yeast and cold water

Contamination of spoilage or pathogenic bacteria (from yeast and water) Insect bone pieces

Blending

Rounding the dough

B
P B

Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air

Fermentation 1

Dividing the dough

Fermentation 2

Principle 1 : Hazard Analysis


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

Description of Hazard
Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o.

Baking

Cooling
Filling with cream

B
B

Packaging

Storage

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

Principle 1 : Hazard Analysis


HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step
Receiving jelly mallow, butter, shortening Storage

Potential Hazard(s) B/C/P -

Description of Hazard
-

B C -

Weighing all ingredients

Contamination of spoilage m.o. Decomposition of chemical compound -

Mixing
Beating Storage

P
P B

Personal item
Personal item Growth of spoilage m.o.

Principle 1 : Hazard Analysis


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 & worker

Principle 1 : Hazard Analysis


HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps (cont.)
Name of Product : Cream-filled Bread
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

Process Step Fermentation 1 Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging Storage Receiving jelly mallow, butter, shortening Storage

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

Contamination of spoilage m.o.

Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients SSOP SSOP Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight)

Weighing all ingredients Mixing Beating Storage

P P B

Personal item Personal item Growth of spoilage m.o.

Principle 1 : Hazard Analysis


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) Description of Hazard Contaminated yeast (by spoilage/ pathogenic m.o.) Insects Reasonably Significant likely to Severity hazard occur (Y/N) l M N Preventive or Control Measures Quality assurance (certificate of analysis) from supplier

B/C/P B

Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg, water

Proper storage conditions (dry, clean), sealed packaging of the ingredients.

Storage of egg

Weighing of all ingredients

Presence of pathogenic bacteria Eggshell (Cracked / broken eggs) Growth of pathogenic bacteria Insect bone pieces, personal items

h l

M L

Y N

Certificate of analysis from egg supplier, acceptable water source Inspection of incoming eggs Refrigerated storage (5-150 C), Label expired date.

Inspection of the ingredients, SOP for production area (no personal items are wore)

Principle 1 : Hazard Analysis


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 Adding egg and shortening Potential Hazard(s) Description of Hazard Insect bone pieces, personal items Eggshell Reasonably Significant Sevelikely to hazard rity occur (Y/N) l 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)

B/C/P P

Adding wheat flour, yeast and cold water Blending

Insect bone pieces Contamination of spoilage m.o. from the air Personal item
Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air

Filtering of wheat flour

SSOP

P Rounding the dough B

m l

M L

N N

SOP for production area (no personal items are wore) SSOP

Fermentation 1

SSOP

Principle 1 : Hazard Analysis


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 \B/C/P occur (Y/N) Measures 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 Correct time and temperature SSOP

Cooling

Filling with cream


Packaging of bread Storage and distribution

B
B 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

m
m m

H
H M

Y
Y N

SSOP
SSOP Proper storage condition (dry, clean), expired date must be stated on the label

Principle 1 : Hazard Analysis


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 Description of Hazard Reasonably Significant Sevelikely to hazard rity occur (Y/N) Preventive or Control Measures -

B C

Contamination of spoilage m.o. Decomposition of chemical compound -

m m

H H

Y Y

Weighing all ingredients

Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients -

Mixing
Beating Storage of cream

P
P B

Personal item
Personal item Growth of spoilage m.o.

l
l m

M
M H

N
N Y

SSOP
SSOP Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight)

Principle 2 : Establishment of Critical Control Point CCP


HACCP Plan Worksheet 2A : Establishment of CCP in Ingredients

Name of Product : Cream-filled Bread Ingredient


Sugar Wheat flour Yeast Egg Potential Hazard (s) B

P1
Y

P2
Y

P3
N

CCP?
N

P B
P B B C

Y Y
Y Y Y Y Y Y

Y Y
Y Y Y N N Y

N N
N N N N

N N
N N N Y Y N

Water

P B

Principle 2 : Establishment of Critical Control Point (CCP)


HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.)
Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) B P1 P2 P3 P4 P5 CCP?

Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg
Storage of egg Weighing of all ingredients Mixing of sugar, salt, skim milk Adding egg and shortening

CCP

B P B
P P P

N Y N
N N N

Y -

N -

Y -

N -

N CCP N
N N N

Adding wheat flour, yeast and Cold water Blending

B P

N N

N N

Principle 2 : Establishment of Critical Control Point (CCP)


HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.)
Name of Product : Cream-filled Bread Process Step Rounding the dough
Fermentation 1 Dividing the dough Fermentation 2 Spreading with egg Potential Hazard(s) B B B B B

P1 N
N N N Y

P2 Y

P3 N

P4 Y

P5 Y

CCP? N
N N N N

Baking
Cooling Filling with cream

B
B B

N
N Y

N
N CCP

Packaging
Storage and distribution of bread

B
B

Y
N

Y
-

N
-

Y
-

N
-

CCP
N

Principle 2 : Establishment of Critical Control Point (CCP)


HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.)
Name of Product : Cream-filled Bread Process Step Storage of jelly mallow, butter, shortening Mixing Beating Storage of cream Potential Hazard(s) B C P P B P1 Y Y N N Y P2 Y Y Y P3 N N N P4 Y Y Y P5 N N N CCP? CCP CCP CCP

Principle 3: Establishment of Critical Limits


HACCP Plan Worksheet 3 : Establishment of Critical Limits
Name of Product : Cream-filled Bread
Ingredient/ Process Step Egg CCP No. 1 (C) 2 (P) 3 (P) CL Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broken egg = 0

Storage (sugar, salt, skim milk, shortening, wheat flour, yeast)

Receiving egg

4 (P)

Filling with cream


Packaging of bread Storage of jelly mallow, butter, shortening

5 (B)
6 (B) 7 (B) 8 (C)

Holding Time <10 min, T=20-250 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

Principle 4: Establishment of Monitoring Procedures


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) Receiving egg Filling with cream Packaging of bread Storage of jelly mallow, butter, shortening Storage of cream 4 (P) Cracked/broken egg = 0 5 (B) Holding Time <10 min, T=20-250 C 6 (B) Holding Time <10 min, T=20-250 C 7 (B) T = 5-150 C, label 8 (C) expired date 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 Cracked/broken eggs Time and temperature Time and temperature Temperature, label of the ingredients Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temp. Measure temp., check label Receiving site Production area Who Receiving personnel Receiving personnel Warehouse mngr. Freq. Every receiving Every receiving Every day

Receiving personnel Area personnel

Production Area area personnel Warehouse Warehouse mngr.

Every receiving Time : every 10 minutes T : Every 6 hours Every day

9 (B) T = 5-150 C, label Temperature, expired date label of cream

Measure temp. check label

Warehouse Warehouse mngr.

Every day

Principle 5: Establishment of Corrective Actions


HACCP Plan Worksheet 5 : Establishment of Corrective Actions (1)
Name of Product : Cream-filled Bread
Ingredient/ CCP Process Step No. Egg 1 (C) 2 (P) Monitoring Procedures How Where Who Frequency Check the Receiving Receiving Every CoA site personnel receiving Inspection Receiving Receiving Every of incoming site personnel receiving eggs Storage Warehouse Every day Measure room / mngr. Rh,check warehouse storage time Check the application of SSOP Cracked/broken Cracked/broke Inspection Receiving Receiving Every egg = 0 n eggs of incoming site personnel Receiving eggs What Antibiotic Antibiotic residue = 0 residue on CoA Cracked / Cracked/broke broken egg = 0 n eggs Rh = Rh Time < 1 month Storage time SSOP = applied SSOP application CL Corrective Actions

1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr.

Storage (sugar, salt, skim milk, shortening, wheat flour, yeast)

3 (P) 4 (P) 5 (B) 6 (B)

Receiving egg

1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr.

Filling with cream

Holding Time <10 min, T=20250 C

Time and temperature Time and temperature

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.
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.

Packaging of bread

Holding Time <10 min, T=20250 C

Check/ Production Area measure area personnel time and temperatur e

Principle 5: Establishment of Corrective Actions


HACCP Plan Worksheet 5 : Establishment of Corrective Actions (1)
Name of Product : Cream-filled Bread
Ingredient/ CCP Process Step No. Storage of 7 (B) jelly mallow, 8 (C) butter, 9 (B) shortening CL T = 5-150 C, label expired date

What Temperature, label of the ingredients

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 Warehouse Every day 1. Disposition of non-complying mngr. products 2. Correct the cause to prevent recurrences 3. Maintain record

Storage of cream

T = 5-150 C, label expired date

Temperature, Measure label of cream temperature, check label

Principle 6: Establishment of Verification Procedures


HACCP Plan Worksheet 6 : Establishment of Verification Procedures
Name of Product : Cream-filled Bread
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 time e recurrences wheat flour, SSOP = 3. Maintain record yeast) applied Check the application 4. Write a report to warehouse of SSOP mngr. Ingredient/ Process Step CCP No. What CL Monitoring Procedures How Where Who 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.
5 (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 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.

Customer complaint

Filling with cream

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.

Principle 6: Establishment of Verification Procedures


HACCP Plan Worksheet 6 : Establishment of Verification Procedures (cont.)

Name of Product : Cream-filled Bread


Ingredient/ CCP CL Monitoring Procedures Corrective Actions Verification What How Where Who Frequency Process Step No. Activities 0 Storage of jelly 7 (B) T = 5-15 C, Temperature, Measure Warehouse Warehouse Every day 1. Disposition of nonMicrob. Analysis mallow, butter, 8 (C) label expired label of the temperature, mngr. complying ingredients of ingredients shortening date ingredients check label 2. Correct the cause to prevent recurrences 3. Maintain record Storage of cream 9 (B) T = 5-150 C, Temperature, Measure Warehouse label expired label of temperature, date cream check label Warehouse Every day mngr. 1. Disposition of noncomplying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of cream

Principle 7: Establishment of Record-keeping Procedures


HACCP Plan Worksheet 7 : Establishment of Record-keeping Procedures
Name of Product : Cream-filled Bread
Ingredient/ CCP CL Process No. Step Egg 1 (C) Antibiotic 2 (P) residue = 0 3 (P) Cracked / 4 (P) broken egg = 0 Storage 5 (B) Rh = 90-92% (sugar, salt, 6 (B) Time < 1 month skim milk, SSOP = shortening, applied wheat flour, yeast) Receiving egg Cracked/broke n egg = 0 What Monitoring Procedures How Where Who Corrective Actions Frequenc y 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 receiving 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Verification Activities Records

Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time

Check the CoA

SSOP application Cracked/broke n eggs

Receiving site Inspection of Receiving incoming eggs site Measure the Rh Storage Check the storage room / time warehous Check the e application of SSOP
Inspection of incoming eggs

Receiving personnel Receiving personnel Warehouse mngr.

Analysis of Receiving log antibiotic residue every 1 year


Calibration of Rh-meter Inspection of insects contamination every 1 month Customer complaint Warehouse log, Rh operation document, Rh calibration documents, Insects inspection document Receiving log

Receiving Receiving site personnel

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

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

Microb. Analysis of products

Production log, microbiological analysis document

Principle 7: Establishment of Record-keeping Procedures


HACCP Plan Worksheet 7 : Establishment of Record-keeping Procedures (cont.)
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 What Monitoring Procedures How Where Who Frequency Verificatio Records n Activities 1. Disposition of non-complying Microb. Warehouse ingredients Analysis of log, microb. 2. Correct the cause to prevent ingredients Analysis recurrences document 3. Maintain record 1. Disposition of non-complying Microb. Warehouse products Analysis of log, microb. 2. Correct the cause to prevent cream Analysis recurrences document 3. Maintain record Corrective Actions

T = 5-150 Temperature, Measure Wareho Warehous Every day C, label label of the temperature use e mngr. expired ingredients , check label date Every day T= C, label expired date 5-150 Temperature, Measure Wareho Warehous label of temperature use e mngr. cream , check label

HACCP Plan Cream-Filled Bread


Ingredient/ CCP CL Process No. Step Egg 1 (C) Antibiotic 2 (P) residue = 0 3 (P) Cracked / 4 (P) broken egg = 0 Storage 5 (B) Rh = 90-92% (sugar, salt, 6 (B) Time < 1 month skim milk, SSOP = shortening, applied wheat flour, yeast) Receiving egg Cracked/broke n egg = 0 What Monitoring Procedures How Where Who Corrective Actions Frequenc y 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 receiving 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Verification Activities Records

Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time

Check the CoA

SSOP application Cracked/broke n eggs

Receiving site Inspection of Receiving incoming eggs site Measure the Rh Storage Check the storage room / time warehous Check the e application of SSOP
Inspection of incoming eggs

Receiving personnel Receiving personnel Warehouse mngr.

Analysis of Receiving log antibiotic residue every 1 year


Calibration of Rh-meter Inspection of insects contamination every 1 month Customer complaint Warehouse log, Rh operation document, Rh calibration documents, Insects inspection document Receiving log

Receiving Receiving site personnel

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

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

Microb. Analysis of products

Production log, microbiological analysis document

HACCP Plan (cont.) Cream-Filled Bread


Ingredient CCP / Process No. Step Storage of 7 (B) jelly 8 (C) mallow, butter, shortening Storage of 9 (B) cream CL What Monitoring Procedures How Where Who Verificatio Records n Activities 1. Disposition of non-complying Microb. Warehouse ingredients Analysis of log, microb. 2. Correct the cause to prevent ingredients Analysis recurrences document 3. Maintain record 1. Disposition of non-complying Microb. Warehouse products Analysis of log, microb. 2. Correct the cause to prevent cream Analysis recurrences document 3. Maintain record Corrective Actions

Frequency

T = 5-150 Temperature, Measure Wareho Warehous Every day C, label label of the temperature use e mngr. expired ingredients , check label date Every day T= C, label expired date 5-150 Temperature, Measure Wareho Warehous label of temperature use e mngr. cream , check label

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