HACCP for Chocolate Liquor

Finished Product Profile

Common Name:
(e.g. name, type, size)

Process:

Chocolate Liquor

Cocoa bean roasting and grinding

(e.g. heat treated, shelf stable, low moisture)

How is it to be used:
(e.g. ready to consume, heat and consume)

Type of packaging:
(e.g. plastic, glass, modified atmosphere)

Further processing required

Liquid in bulk tank and hauler ; blocked off as solid liquor

packaged in plastic lined corrugated boxes

Length of shelf life:

(e.g. length of time and temperature conditions)

Where will it be sold (intended

consumers):

Specific to process requirements

Sold to chocolate manufacturers

(e.g. general public, wholesalers, retail)

Labeling Instructions:
(e.g. preparation, best when used by date)

Is special distribution necessary:

(e.g. ambient, frozen, refrigerated)

HACCP Coordinator:

Detail Manufacturing and Best By code here

Heated storage and transport equipment approx. 118 F

Ambient conditions required (65F to 75F and less
than 55 % R.H. for blocked liquor

Add appropriate name and title here

HACCP for Chocolate Liquor

Ingredient Hazard Analysis
Preventive/Prerequisite programs

Ingredient in order
of quantity
Cocoa Beans

Known hazards

Likely Risk

in effect or corrective

High, Medium, or Low

action to assure

Probability

Severity

B: Salmonella

low

high

C: Pesticides ; lead

low

low

P: Foreign matter

low

low

finished product safety

COA; Bulk Ingred Receiving policy

Chocolate Liquor Hazard Analysis and CCP Justifications

Processing Step

Hazard Analysis (introduced,

Justification of decision and preventative measures

controlled, or enhanced here)

Cocoa bean receiving B: High microbial load, potential

for pathogens
C. Pesticides , lead
P: Infestation
Cocoa bean storage
B:High microbial load, potential
for pathogens
Cross Contamination of "clean"
areas by dust, personnel
C: None
P: Infestation
Foreign materials
Cocoa bean
B: None
cleaning
C: None
P: Foreign material
Cocoa bean weighing B: High microbial load, potential
for pathogens
C: None
P: Infestation
Cocoa bean roasting B: High microbial load, potential
for pathogens
(Salmonella)
C: None
P: None
Cooling
B: None
C: None
P: None
Winnowing
B: None
C. Lead
P: Shells not completely
removed from nibs
Liquor milling
B: Potential for cross
contamination due to
equiptment.handling
C: None

CCP

Proper roasting

No

Cocoa bean sourcing

Fumigation prior to delivery, GMPs
Proper roasting

No
No

Improper air flow, employee practices can track dust throughout plant GMPs and SSOPs

No

See prerequisite programs - Pest Control policy and Sanitation SOP's

Ingredient Receiving policy and Inspection/Testing SOP's

No
No

See prerequisite programs - Receiving procedures and Inspection/Testing SOP's

Proper roasting

No
No

See prerequisite programs - Pest Control policy and Sanitation SOP's

Proper roasting _time (min) and _ temperature (F)

No
Yes
CCP1

Acceptable shell to nib ratio

Quality control, not food safety

No
No

Prerequisite GMPs and Sanitation SOPs

No

Finished product
storage

P: Metal/Foreign Objects
B: Potential for cross
contamination due to
equiptment.handling

All liquor must pass through screens and magnets

GMPs ; separation of raw materials from finished products

Yes
No

Prerequisite GMPs and Sanitation SOPs

Yes

Shipping

C: Contamination from tankers

P: None
B: Potential for cross
contamination due to
equiptment.handling

GMPs ; separation of raw materials from finished products

no

C: Contamination from tankers

Prerequisite GMPs and Sanitation SOPs

Yes

P: None

HACCP for Chocolate Liquor

Hazard Analysis and CCP Justifications
Critical
Control
Point
Roasting

Significant Hazard
Pathogen survival

Critical Limit

Justify
decision what

Justify
decision how

Justify
decision frequency

Roasting beans to Monitor

Time and
Once per
a temperature of
internal
temperature hour during
__ F for __minutes bean
of roasting roasting
temperature
and time of
roasting

Justify
decision who
Roaster
operator

Corrective Action

Records

Re-roast, reject or
hold for evaluation

Bean roasting

Verification
Daily record review

Thermal
Quarterly process
process record validation
Hold notice

Calibration of probes
quarterly

Incident Report
Liquor
Milling

Liquor
Storage &
Shipping

Foreign material

Cross-contamination
from tankers

Liquor must pass

through a _mm
screen and
magnet cpable of
detecting 1.0 mm
Fe and 1.5 mm
Each tanker
certified as "clean"
and visual
inspection for
cleanliness/odor

Screens and Visual check

magnets
of screens,
check metal
sensitivity
with test
wand
Tanker
Visual
cleanliness inspection of
tankers and
certificate of
washout
verification

Before each
production
run and
every 2
hours during
each run
Before filling
each tanker

Process
operator

Shipping
Supervisor

Re-screen reject or Foreign object

hold for evaluation record
Hold notice

Reject any tanker

without washout
verification or
strong odors/dirty

Daily record review

Quarterly process
validation

Incident Report
Washout
Daily record review
verification
Tanker visual
Quarterly process
inspection chart validation
Incident Report
Hold notice