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STP/ISP-0
HACCP PLAN
(CLAUSE 7.. of ISO 22000:2005)
Name
Designation
Prepared by:
Mr. Mujtaba
ISO Coordinator
Reviewed by:
Mr. Waqas
MR
Approved by:
MD
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Signature
Date
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STP/ISP-0
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DOCUMENT HISTORY
REV.
#
DATE
PAGE
#
SECTION
DCR#
NATURE OF AMENDMENT
* All changes made in the document are notified in the Document History. For details of
amendments, please refer to relevant DCR (Doc. Change Request).
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1. Purpose
The purpose of this procedure is to identify possible food safety hazards and
controls in place to make sure the food safety hazards are eliminated or controlled
to ensure acceptable levels.
2. Scope
This procedure applies to all activities at identified CCPs
3. Responsibilities
Management Representative and Food Safety Team Leader is responsible
for
1) The implementation of this procedure
2) Monitoring of the HACCP personnel deputed at CCPs
3) Verification and signing of HACCP records.
4. Procedure
4.1
Describing a product
A full description of the product with relevant safety information is
prepared as
given in Appendix II. Also information regarding how the product is to
be
packaged, stored and transported is also considered together with
facts
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The HACCP team next conducts a hazard analysis to identify for the
HACCP plan
which hazards are of such a nature that their elimination or reduction to
acceptable
levels is essential to the production of a safe food packaging.
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STP/ISP-0
Food safety hazards for HACCP plan have been classified into three types
of hazards:
1. Biological
2. Chemical
3. Physical
by the HACCP
team , according to their judgment , experience and knowledge of the
process.
Each process step identified in the flow diagram is considered in sequence.
The team will determine whether the hazard can occur at this step, and if so
whether control measures exist. If the hazard can be controlled adequately,
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and is not best controlled at another step, and is essential for food safety,
then this step is a CCP for the specified hazard.
The identification of critical control points has two consequences for the
HACCP team
which should then:
1. Ensure that appropriate control measures are effectively designed and
implemented.
2. Establish and implement a monitoring system at each critical point.
Production should cease until control measures are available and a CCP is
introduced.
4.7
Each control measure associated with a critical control point will give rise to
the
specification of critical limits. Critical limits correspond to the extreme
values acceptable with regard to product safety. They separate
acceptability from unacceptability. They are set for observable or
measurable parameters which can demonstrate that the critical point is
under control. It should be based on substantiated evidence that the chosen
values will result in process control.
4.8
Monitoring is the mechanism for confirming that critical limits at each CCP
are being
met. A frequency of observations or measurements which provides reliable
information is established.
The procedure describes the methods, the frequency of observations or
measurements
and the recording procedure and identify each critical point:
a. who is to perform monitoring and checking,
b. when monitoring and checking is performed,
c. how monitoring and checking is performed.
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Corrective Actions
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Hazard analysis;
CCP determination;
Critical limit determination;
Modifications to the HACCP system.
Record examples are:
CCP monitoring activities;
Deviations and associated corrective actions;
Verification activities.
4.12 Training
The Management representative and food safety team leader shall make
sure that all
personnel are aware of the hazards identified (if any), the critical points in
the
production, storage, transport and/or distribution process and the corrective
measures, the preventive measures and documentation procedures
applicable in
the operations of the company.
4.1 Related Documents
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STP/ISP-0
HACCP Team
Facility Name : Sprintech Packaging
Team Member
Position
HACCP Team
Role
Production
Member/Advisor
Waqas Hassan
Management
Representative
Advisor
Usman Shaukat
A.M Production
Member
Yasir Bilal
Incharge QA/
Product Safety
Team Leader
Imran Ameer
Printing
Supervisor
Member
Tariq Hussain
Lamination
Supervisor
Member
Irfan Sheikh
Lamination
Supervisor
Member
Khalid Imtiaz
Slitting
Supervisor
Member
Muhammad Hussain
Bag Making
Supervisor
Member
Waqas Junaid
Sleeve Making
Supervisor
Member
Naveed Khalid
Warehouse
Incharge
Member
Nadeem Ahmad
Dispatch
Assistant
Member
Kashif Mehmood
Maintenance
Engineer
Member
Purchase
Executive
Member
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Signatur
e
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STP/ISP-0
HACCP Objective
Facility Name : Sprintech
Date : September 23 ,
Packaging
2014
The purpose of the facility HACCP Team is to ensure safe
products for our customers and their consumers. The HACCP
Team will evaluate raw materials and processes to determine
Critical Control Points. Critical Control Points will be monitored
as will other points and processes. The team will provide
documented training for the facility. The facility HACCP Plan will
be re - assessed at least annually. Facility management will
provide adequate resources for the implementation and
maintenance of the HACCP Program.
Name
Production
Management
Representative
Waqas Hassan
A.M Production
Usman Shaukat
Yasir Bilal
Printing Supervisor
Imran Ameer
Lamination Supervisor
Tariq Hussain
Lamination Supervisor
Irfan Sheikh
Slitting Supervisor
Khalid Imtiaz
Muhammad
Hussain
Sleeve Making
Supervisor
Waqas Junaid
Warehouse Incharge
Naveed Khalid
Dispatch Assistant
Nadeem Ahmad
Maintenance Engineer
Kashif Mehmood
Purchase Executive
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Signature
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Date:
Product description:
Packaging Requirements
Labeling Requirements
Method of Distribution
Intended Use
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STP/ISP-0
Product
Date Conducted :
Conducted by
Validation Type
Validation (Reassessment) due to changes in the raw materials or source of raw materials , product formulation ,
processing method or system , including computer and their softwares, packaging , finished product distribution
systems or the intended use or the intended consumers of the finished product or type of consumer complaints.
YES
NO
If YES
Describe
Food Safety
Implication?
Formula changed?
Ingredients / Packaging
changed?
Equipment / software
changed?
Finished product
distribution changed?
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New or emerging hazards
STP/ISP-0
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Regulatory Agency
recommendation e.g.,
guidance
Any confirmed food
safety consumer
complaints
3. Evaluate adequacy of CCPs, critical limits, monitoring, corrective action, CCP verification, and record keeping
procedures. Review current CCP Documentation
Do the CCPs control the
hazards?
Do monitoring methods
and frequency
demonstrate control?
Do corrective actions
properly address
affected product?
Does validation include
review of consumer
complaints?
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Facility Name
:
HACCP Plan Name/Number and
Date :
During the reassessment of this plan, the person(s) responsible listed above has/have determined that
Changes, Additions, or Deletions were needed. Those changes are documented below. Also attached is
information used to support modification(s) of this plan.
Check One
CHANGE
ADDITION
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DELETION
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STP/ISP-0
Is this hazard
CONTROLLED by a
Pre-requisite
Program or
process step?
C =Chemical
P = Physical
B = Biological
No
Yes Foreign
Material
No
No
Yes Foreign
Material
P
B
Yes - Infestation
No
No
No
Yes Foreign
Material
Yes - Moulds
No
P
B
No
Yes Foreign
Materials &
Is this hazard
ELIMINATED by a
subsequent
process step?
If YES, this step is NOT a
CCP. Indentify the
subsequent process step
in Column 5 and proceed
to the next process step.
If the hazard is
eliminated at this step,
enter NO and go to
column 6 and assign CCP
#.
Yes Receiving
Inspections
Yes Receiving
Inspections
Yes Receiving
Inspections
Yes Chemical Control
Plan
Yes Receiving
Inspections
Yes Receiving
Inspections
Yes Receiving
Inspections
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5
Identify the last
process step that
will eliminate the
potential hazard.
6
Assign a CCP #
when the answer
in Column #4 is
NO.
(otherwise leave blank)
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STP/ISP-0
Infestation
2
Do this material /
ingredient
INTRODUCE a
potential food
safety hazard?
What is it?
C =Chemical
P = Physical
B = Biological
Receiving Inspections
Warehousing
Yes - Infestation
No
Yes Foreign
Material
Is this hazard
CONTROLLED by a
Pre-requisite
Program or
process step?
If YES, indentify the
program or process. If a
pre-requisite program or
process is identified, do
not complete Columns 46 and go to next process
step. If NO, go to column
4.
6
Assign a CCP #
when the answer
in Column #4 is
NO.
(otherwise leave blank)
Yes Receiving
Inspections
Yes Receiving
Inspections
Yes - Infestation
P
B
No
Yes
No
No
Yes Contamination /
infestation
Is this hazard
ELIMINATED by a
subsequent
process step?
Yes Receiving
Inspections
Yes Receiving
Inspections
Yes Incorrect
Design
Yes Line Clearance
No
Lamination
Solventless
No
Yes Foreign
Material
Printing
No
No
Line Clearance
CCP-1
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Line Clearance
CCP-2
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Lamination Solvent
Base
Slitting
Bag Making
Yes
No
Yes Contamination /
infestation
No
No
No
No
No
Yes Contamination /
infestation
No
B
C
P
B
C
Packaging
P
B
C
Warehousing
P
B
C
Dispatch/Shipping
P
B
No
Yes Contamination /
infestation
Yes Incorrect
palletizing (allergen)
No
Yes Contamination /
infestation
No
No
Yes Contamination /
Infestation
No
No
Yes Contamination /
infestation
STP/ISP-0
No
No
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Line Clearance
CCP-3
No
Visual Inspection
CCP-4
No
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CCP-5
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STP/ISP-0
CCP-1
Line
Clearance
CCP-2
Line
Clearance
CCP-3
Line
Clearance
CCP-4
Visual
Inspection
Significant
Hazard
Critical
Limit
Printed materials
from previous jobs
have not been fully
cleared.
No materials
from other
jobs allowed
in area.
Laminated materials
from previous jobs
have not been fully
cleared.
No materials
from other
jobs allowed
in area.
Laminated materials
from previous jobs
have not been fully
cleared.
No materials
from other
jobs allowed
in area.
Incorrect unitizing or
palletizing due to
inadvertent mixing of
bags results in
allergen risk due to
mixed product types
No mixing of
bags.
Monitoring
What
How
Printing
procedure
Operator
removes all
materials from
previous order
before new job
starts up.
Lamination
procedure
Operator
removes all
materials from
previous order
before new job
starts up.
Lamination
procedure
Operator
removes all
materials from
previous order
before new job
starts up.
Visual
Inspection
Frequency
Each
work order
Each
work order
Each
work order
Work
instructions for
operators /
helpers
Page 23 of 25
Each
carton
Who
Corrective
Action
Verificatio
n
Record(s)
Verified by
operator or
other coworker
Production
Records
Operator
Operator
removes
materials per
critical limits
and reinspects line.
Operator
Operator
removes
materials per
critical limits
and reinspects line.
Verified by
operator or
other coworker
Production
Records
Operator
Operator
removes
materials per
critical limits
and reinspects line.
Verified by
operator or
other coworker
Production
Records
Operator
removes
materials per
critical limits.
Verified by
operator or
other coworker
Production
Records
Operator
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CCP-5
Visual
Inspection
& Pallet
Control
Incorrect unitizing or
palletizing due to
inadvertent mixing of
bags results in mixed
product types
No mixing of
bags.
Visual
Inspection
coupled with
pallet
segregation.
STP/ISP-0
Work
instructions for
operators/
helpers
Page 24 of 25
Every
pallet
Operator
Segregate
affected
pallets.
Verified by
operator or
other coworker
Production
Records
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