Company Company Issue Date : 12 Dec 2023 Revision Date: ISO 22000:2018 FSMS

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XXX -FSMS-HACCP-1
HACCP PLAN FOR BREAD

HACCP PLAN FOR BREAD

MAKING

By

Viduranga Nuvan

Quality Assurance Manager, Sri Lanka

+94718040539

[email protected]

25 February 2024

Prepared By: Name: VidurangaNuvan Designation: Quality Assurance Signature:

Manager
Reviewed Name: Designation: Signature :
By:
Approved Name: Designation: Managing Director Signature:
By:
Ingredients
Wheat Flour, Salt, Milk Powder, Water, Margarine, Yeast

Steps
• Kneading the following ingredients together in a dough mixer for 20 min: Wheat Flour, yeast, salt, milk
powder, water, margarine.
• Dividing into balls
• Proofing for 1h at room temperature
• Sheeting
• Panning
• Filling in greased pans
• Baking at 220 0C for 20 min
• Cooling
• Packaging
• Metal Detecting
• Frozen Storage

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Product Characteristics-Raw Material, ingredients and product-contact
Materials- Bread
Biological, chemical Raw Material Biological Chemical Physical
and physical
characteristics Wheat Flour Semi- Water:11.92/100g Texture: Powdery
perishable Fat: 0.92/100g Color: White
Proteins: 15.40g/100g pH:6-6.8

Margarine Perishable Percentage % Color: Light buttery

Smell: Mild smell
Fat 70
Flavor: Butter flavor
Carbohydrates 2 Texture: Butter like
Water 26 pH: 3.6 – 6
aW: 0.87
Yeast Semi- C19H14O2 pH: 5.8
perishable Texture: Granular
Color: Brown
Salt Non- NaCl pH: 7
perishable Texture: Crystalline
Color: White
Sugar Non- C12H22O11 pH: 7
perishable Texture: Granular
Color: White
Water Non- H2O pH: 6.5-8.5
perishable Texture: liquid
Color: Colorless
Milk Powder Semi- wettability 13s, dispersibility33 g, pH: 6.5-6.7
perishable flowability 62.8° (angle of repose), Texture: Powdery
sinkability at 2 min 24% transmission, Color: White
packed bulk density 0.65 g/mL, free
fat 1.3% (as % of fat),
and solubility index 0.6 to 1.0 mL
Composition of Baking Powder: 250 White Sugar, 250 g All-Purpose Flour, 4-5 Eggs, 250 g Butter, 2 heaped
formulated tablespoons of Brownson baking Powder, 2 table spoons of Brownson vanilla, 2 tablespoons of
ingredients Brownson Citrus Drop, 2 Table spoons of Lemon Zest
Place of origin Item Country of Origin Supplier (s)

Wheat Flour USA X company

Sugar India Y company
Margarine Sri Lanka Z company
Baking Powder Sri Lanka A company
Yeast Turkey B company
Milk Powder Sri Lanka C company
Salt Sri Lanka D company
Method of production Item Method of Production
Wheat Flour Secondary production
Sugar Secondary production
Margarine Secondary production
Baking Powder Secondary production
Yeast Secondary production
Milk Powder Secondary production
Salt Secondary production

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Packaging and Ingredient Packaging Method Delivery Method
delivery method
Wheat Flour Packaged in containers which will Delivered to the plant
safeguard the hygienic, nutritional, hygienically, safely and
technological, and organoleptic qualities conforming to storage
of the product. conditions by supplier vehicles
The containers, including packaging (No special time/ temperature
material, shall be made of substances requirement)
which are safe and suitable for their
intended use.
They should not impart any toxic
substance or undesirable odor or flavor to
the product.
When the product is packaged in sacks,
these must be clean, sturdy and strongly
sewn or sealed.
Sugar Packaged in HDPE woven sacks with Delivered to the plant
ends being strongly sewn hygienically, safely and
conforming to storage
conditions by supplier vehicles
(No special time/ temperature
requirement)
Margarine Primary Packaging: LDPE polythene Delivered to the plant
hygienically, safely and
Secondary Packaging: Corrugated paper
conforming to storage
carton
conditions by the approved
suppliers in temperature
controlled vehicles. During
transport temperature should
be maintained at 100Cor
below.

Yeast vacuum-packed with aluminum-plastic Delivered to the plant

film into 500g/bag hygienically, safely and
conforming to storage
conditions by the approved
suppliers in temperature
controlled vehicles.

Transport/ Storage temp ≤ 4

Milk Powder packed in laminate bags made of PET /Al Delivered to the plant
/ PE and filled with an inert gas, such as hygienically, safely and
N2 conforming to storage
conditions by the approved
suppliers.

Transport condition:
controlled humidity, at room
temperature or AC

Salt Plastic bags made of LDPE, BOPP Delivered to the plant

hygienically, safely and
conforming to storage
conditions by the approved
suppliers.

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Storage condition and Item Storage Condition Shelf Life
shelf life Wheat Flour Transfer the flour from the original Up to one year under ideal
package into a food-grade container conditions
(plastic or glass) with a tight lid and store
in a cool, dry place protected from
sunlight to prevent moisture from
creeping in and to keep insects and other
pests out and to block odors and flavors
from other foods or products stored
nearby, which could affect the aroma or
taste of the flour.
Sugar Decanted from PP bags into Up to 2 years under ideal
• Polyethylene bags conditions
• Mylar-type bags or
• Food-grade plastic buckets
And store in a cool, dry location, not the
refrigerator as moisture makes granulated
sugar hard and lumpy.
Store in an odor free area as sugar can
absorb strong odors – even through
plastic packaging.
Margarine Store in a refrigerator at 40℉ (4℃) or Unopened: 3-4 months in a
below. refrigerator, 6-12 months in a
freezer
Keep them in their original containers or
packaging, in an airtight container as air
Opened: 1-2 months in a
is another contributor to making them go
refrigerator, 6-8 months in a
bad.
freezer
Stop them from being exposed to light
and high temperatures which can make
them become spoiled and rancid.
Yeast Store in a cool location, refrigerated or Unopened: Up to 2 years
frozen up to the recommended shelf life.
Opened: In the refrigerator to
use within four months, and
six months – if kept in the
freezer.
Milk Powder Store at room temperature and keep away Unopened: By best before
from any moisture.
Opened:
Salt At room temperature, away from direct Opened: By Exp. / Best
sunlight Before Date
Preparation and/or Wheat Flour End of the original package unstitched and transferred the content into a food
handling before use grade plastic container. Content taken subject to weighing and sifting before
or processing use.
Sugar End of the original package unstitched and transferred the content into a food
grade plastic container. Content taken subject to weighing and direct use
Margarine Cut the required slice off after opening the original package or unwrapping the
cling film and let it to melt at room temperature or boil before use.
Yeast Once opened seal the opening between uses and store in chiller/ refrigerator
Milk Powder Once opened seal the opening between uses and store in cool dry place
Salt Store in a cool, dark and dry place

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Food safety related All ingredients are purchased only from audited / approved suppliers. Inspect at receiving for
acceptance criteria or specific quality and safety characteristics as per specifications.
specifications of
purchased materials
and ingredients
appropriate to their
intended use

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Characteristics of End Product
Product Name or similar identification Sandwich Bread

Composition Wheat flour, yeast, Salt, Milk Powder, Water, Margarine

Biological, chemical and physical Biological
characteristics relevant for food safety
Organoleptic characteristics:
Physical State : Airy, soft, spongy, elastic and crumb
Color : Light brown
Odor : Typical
Flavor : Typical

Microbiological characteristics:
• Aerobic plate Count <104
• Enterobacteriaceae <102
• Escherichia coli <3
• Escherichia coli O157 n.d. in 25g
• Staphylococcus aureus and other <20
coagulase-positive staphylococci

• Clostridium perfringens <102

• Bacillus cereus and other <102
pathogenic Bacillus spp
• Campylobacterspp n.d. in 25g
• Salmonellaspp n.d. in 25g
• Listeria monocytogenes n.d. in 25g
• Fungi (Molds) and Yeasts ≤ 10² UFC/g

NOTE: The food sample shall be analyzed for all the parameters only if
any of the 3 parameters regularly tested-Total microorganisms,
Salmonella, or Fungi/molds- found in unacceptable levels.
Chemical:
Food additives used, if any, shall conform to either Sri Lankan or EU
regulations:
• Regulation (EC) No 1333/2008- EU
• Food (Preservatives) Regulations-2019- Sri Lnka
• Food (Additives - General) Regulations 2019 – Sri Lanka
Antioxidants used, if any, shall conform to the following regulation:
• Food (Antioxidants) Amended Regulations 2013 - 1809/4
Food flavorings used, if any, shall conform to:
• Regulation (EC)1334/2008- EU
• Or, Food (Flavoring Substances and Flavor Enhancers)
Regulations 2013 - No 1795/51- Sri Lanka
Food (Coloring Substances) used, if any, shall conform to:
• Food (Coloring Substances) Amendment Regulations 2011 -
1688/28

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 Chemical Cont’d from the previous page
Food (Flavoring Substances and Flavor Enhancers) used, if any, shall
conform to:
• Food (Flavoring Substances and Flavor Enhancers)
Regulations 2013 - No 1795/51
Contaminants, if present, shall be within safe limits as per (EC)
1881/2006
Pesticides shall not exceed the maximum recommended limit as per EU
pesticide database (Oct 2018)
Veterinary medicines, if present, shall be in safe limits as per
Regulation 37/2010 & Directive 96/22/EC
Heavy metals, if present, shall not exceed the max recommended limit
as per Regulation (EC) No 1881/2006
(Free from Environmental pollutants - such as industrial chemicals,
pesticides and many toxic elements, residues of agro-chemicals,
veterinary drugs and heavy metal organic or inorganic.)
Free from cleaning chemicals, pesticides (including those not applied in
or around food processing establishments), allergens, toxic metals,
nitrites and nitrates (when added to the product), plasticizers and
packaging migration, and chemical additives.
Physical:

Free from extraneous foreign materials (metals, glass, stones or any

non-edible), adulterants and filthy objects such as hair.
Intended Use No restrictions/General public
Intended shelf life and storage Storage Condition Shelf life
condition On the counter, at room temperature 3-4 days
In a fridge, at or below 4 0C 5-8 days
In a freezer, at or below -18 0C 3-6 months
Packaging Sealed in In LDPE/ BOPP bags
Labeling related to food safety and/or Ready –to-Eat
instructions for handling , preparation Compliance with Good Personnel Hygiene Practices, Maintain facilities
and usage equipment and utensils for the operation (handling and preparation)
properly sanitized.
Method of distribution Distributed from the main warehouse in Pepiliyana to restaurant outlets
located in the suburbs of Colombo

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 Method of preparation for Sandwich Bread

Ingredients

• Wheat flour
• Margarine
• Yeast
• sugar
• salt
• water
• milk powder

Procedure

• Mixing the following ingredients together in a dough mixer: Wheat Flour, Yeast, Salt, Milk Powder, Water,
Margarine and Sugar.
• Kneading for 20 minutes
• Division of dough into balls
• Proofing for 1 hr at room temperature
• Sheeting
• Panning
• Filling in greased pans
• Baking at 220 0C for 30 minutes
• Cooling
• Packaging
• Metal Detecting
• Frozen Storage

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 Process Flow Diagram for manufacturing of Bread

Receiving Wheat Receiving Water Receiving wheat flour, yeast, Solid Liquid
Flour + Yeast salt, milk powder, water, waste waste
Margarine
Quality
Weighing Inspection
Quality Inspection

Sieving
Kneading (20 min)

Receiving Milk
Powder Kneaded Dough

Quality Proofing for 1 hr at room

Inspection temperature

Dividing into balls

Fermentation 15 min @ 35-

Receiving 400Cwarm cupboard
Margarine
Filling in greased pans
Softening with
mild Heat
Baking
@2200C for 30 min

Cooling (1 hour)

Packaging

Not required unless stored frozen

Metal Detecting
(Optional)
(
Frozen Storage Solid To the
(@or below -18 0C) waste treatm
Dispos ent
Rebaking al plant

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 Details of working at each step

Number Step Name Procedure of working and controlling

1 Receiving Water Daily check residual chlorine level in water by a Chlorine test kit
Follow X-FSMS-SOP-31(Receiving and quality inspection of water)
2 Receiving of wheat flour Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)

3 Receiving Yeast Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)

4 Receiving Sugar Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)

5 Receiving Milk Powder Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)

6 Receiving Salt Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)

7 Receiving Margarine Follow X-FSMS-SOP-11 (Receipt, delivery and unloading)

8 Softening margarine with mild heat Perform the task quickly, hygienically and without interruptions.
Compliance with GHP. Keep facilities, equipment and utensils for the
operation properly sanitized.
9 Sieving flour and yeast Stiff the flour through a strainer with pore size less than 2mm in
diameter to screen all physical hazards.
10 Weighing and Mixing (Kneading) Perform the task quickly, hygienically and without interruptions.
ingredients- Wheat Flour, yeast, Compliance with GHP. Keep facilities, equipment and utensils for the
Salt, Milk Powder, Water, operation properly sanitized.
Margarine in a dough mixer for 20
min
11 Stand (Proofing) Keep the mixture well packed in proper places, protected from
contamination. Compliance with Good Personnel Hygiene Practices,
Maintain facilities and equipment for the operation properly sanitized.
12 Dividing kneaded dough into balls Perform the task quickly, hygienically and without interruptions.
Compliance with GHP. Keep facilities, equipment and utensils for the
operation properly sanitized.
13 Fermentation (15 min @ 35- Compliance with GHP. Keep the mixture well packed in proper place,
400Cwarm cupboard) protect from contamination.
Keep facilities, equipment and utensils for the operation properly
sanitized.
14 Filling in greased pans Perform the task quickly, hygienically and without interruptions.
Compliance with GHP. Keep facilities, equipment and utensils for the
operation properly sanitized.
15 Baking X-FSMS-SOP-3 (Procedure for Cooking)

16 Cooling Cool immediately. No need to follow 2 stage method because of its

nature
17 Metal Detecting Insert the frozen bread into the metal detector
(Optional)
18 Packaging/Storing in freezer Compliance with good personnel Hygiene Practices (GHP), Perform the
task quickly, hygienically and without interruptions.
19 Baking (reheating) frozen Breads Hold for 20 min an oven preheated @230 C while wrapped on a
aluminum foil

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 RISK ASSESSMENT PROCESS
• Severity (SAHE)
5 Can cause fatality
4 Can lead to serious illness/injury
3 Can cause product recall
2 Can generate customer complaint
1 Not significant
• Likelihood of occurrence (LOC)
5 Common Occurrence
4 Known to Occur (Has happened at our premises)
3 Could occur (Evidence in published material)
2 Not likely to occur
1 Practically impossible to occur

• LOC X SAHE=

<9 Non-Significant PRPs

>9 or 9 Significant

Decision Tree

OPRPs CCPs

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 HACCP PLAN-IDENTIFICATION AND CONTROL OF HAZARDS (B- Biological, C- Chemical, P- Physical)
No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Material/Process
Probability Severity Risk
Step
Level
1 Receiving Water Presence of pathogens of public B Preventative: Use an approved source of water 3 1 3
health significance in unacceptable satisfying the requirements of bacteriological
levels: quality of water given in SLS 614:2013 (Potable
Justification: Considering the
Campylobacterspp ≥ 500 bacteria water Standard)
likelihood of occurrence of the
Verocytotoxigenic E. coli (VTEC): Controlled by sanitation measures and water identified biological hazards prior
about 10- 100 organisms treatment processes to application of control measures,
the following hazards could create
Enteric fever salmonellas Certificate of analysis from water authority high to moderate level of severity:
(Salmonella typhi and Salmonella For Tube well water:
paratyphi): 102-103 organisms Primary disinfection of tube well water with any Note: Water has multiple uses and
gastroenteritis salmonellas of the following disinfectants (chemical can contaminate product at any
(Salmonella enterica) ≥ 106-108 oxidation process): chlorine, monochlorine, stage. Intended use of water is
organisms chlorine dioxide, ozone, UV light and mixed direct use (washing, cooling after
oxidants. Ref: (WHO, Inactivation blanching)
Species of Shigella: around 102 (disinfection) processes, 2004)
organisms
High (Life threatening)
Chlorine disinfection:
Vibrio spp (Vibrio Salmonella typhi
Water pH: 6.5- 8.5
parahaemolyticus, V. cholera): Escherichia coli 0157:H7
Disinfectant concentration: 0.5-2mg/L of
103-106organisms Vibrio cholera
residual chlorine level.
Contact time: 30 min for residual chlorine level
Emerging pathogens: Moderate (Severe or chronic)
of 0.5 ppm
Helicobacter pylori Campylobacter spp.
Water temperature: 180C to 370C
Salmonella spp.
Francisellatularensis UV disinfection: Shigella spp.
UV-B and UV-C ranges of the spectrum (200–
Ref: (WHO, Bacteria of potential 310 nm), with maximum effectiveness around (FAO, Pathogenic bacteria , 2020)
health concern, 2013) 265 nm.
For Municipal water:
Residual chlorine level 0.5- 2 ppm

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No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P) Probability Severity Risk
Material/Process Level
Step
1 Receiving Water Presence of chemical contaminants C Preventative: Initially and periodically check 3 1 3
at levels over EPA’s safety water for chemical requirements; Table 2 of
standards. SLS 614, toxic substances; Table 3 of SLS 614,
and verify that water source meets minimum
E.g. Disinfection byproducts, requirements.
solvents and pesticides,
Control measures :
radionuclides (such as radium), and
In the event of a deviation from expected results
minerals (such as arsenic).
the following methods may apply
Ref: (Common Waterborne 1. Reverse osmosis systems
Contaminants) (Reverse Osmosis Systems will remove
common chemical contaminants (metal ions,
aqueous salts), including sodium, chloride,
copper, chromium, and lead; may reduce
arsenic, fluoride, radium, sulfate, calcium,
magnesium, potassium, nitrate, and
phosphorous.)
2. Distillation Systems
Distillation Systems will remove common
chemical contaminants, including arsenic,
barium, cadmium, chromium, lead, nitrate,
sodium, sulfate, and many organic chemicals.
3. Water softners NOTE: The effect due to presence
(They can be used to remove iron and of chemical contaminants in water
manganese, heavy metals, some radioactivity, at levels over EPA’s safety
nitrates, arsenic, chromium, selenium, and standards is not acute but chronic
sulfate.) meaning adverse effects occur if
consumed over the cause of many
Ref: (CDC, A Guide to Drinking Water years.
Treatment Technologies for Household Use,
2014)

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No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P) Probability Severity Risk
Material/Process Level
Step
1 Receiving Water Presence of sediments and P Preventative: Adhere to the requirements of table 3 2 6
particulates (pipe 1 of SLS 614: 2013 when choosing the water
materials, pipe liner materials, source.
sloughed biofilms or iron and
manganese films) Control: Sedimentation and filtration.
Sedimentation by holding the raw water in ponds
Ref: (Understanding the hazards or tanks.
and threats ) Filtration: Cartridge filtration, rapid sand
filtration, multimedia sand filtration, and up-flow
filtration.
2 Receiving of Presence of mold and their B Preventive: 3 1 3
Wheat flour corresponding fungus species Applicable at primary producer level and during
such as Aspergillus spp., prolonged storage after receiving flour.
Penicillum spp., Fusarium spp. Follow Good Storage Practices(GSP):
and Alternaria spp. RH of the environment should be below 62 % and
the material water content should be below 10 %.
Presence of dangerous toxic Store at a low oxygen environment: 50% CO2 and
metabolites called mycotoxins 20% O2
such as aflatoxin, ochratoxin, Keep Water Activity at or below 0.80 and CO2
zearalenone, patulin, level over 30 %
deoxynivalenol, trichothecene Purchase from approved suppliers only.
and fumonisin.
Control:
Discard the affected lot
Controlled as a SOP

Note: Myvotoxins are completely destroyed at

their melting point: 164°C (327°F) for
Zearalenone, 170°C (338°F) for Rubratoxia., the
toxicity of aflatoxin B1 is reduced by 70%, and
that of aflatoxin B2 by 45%.
Pure aflatoxin B1 (AFB1) is destroyed by
temperatures above 160 °C

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No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Material/Process
Step Probability Severity Risk
Level
2 Receiving of Presence of Salmonella spp., B Control: 2 2 4
Wheat flour Escherichia coli, Bacillus cereus Purchase from approved/reputed/HACCP or ISO
at an infectious dose: 1 log 22000 FSMS certified suppliers only.
cfu/g
Application of heat treatment to reach core
temperature of 750C or equivalent, e.g. 700C for 2
minutes to kill all viable cells.
Presence of pests such as B Control: 2 3 6
Sitophilus granaries L. (weevil), Purchase from Approved/Reputed/ISO
S. oryzae L. (rice 22000FSMS/HACCP certified suppliers only
louse),Trogodermagranarium
Keep the oxygen rate of the atmosphere inside the
(Khapra beetle),
storage lower than 2 % and/or the carbon dioxide
Rhizoperthadominica F. (crop
rate is higher than 12 %, to minimize the insect and
hump beetle),
mice activity.
Triboliumconfusum and T.
castaneum (half-blood lice),
Ptinus fur L. (white-spotted
spider mite),
Nemapogongranellus L. (crop
warehouse moth),
Ephestiakuehniella (mill moth),
Acarussiro L. (flour mite)
Presence of Pesticides used in C Preventative: No preventative measures applicable 2 3 6
the businesses for insects and at receiving
rodents control, residues of Control: Purchase from Approved suppliers only
hygiene and sanitation products.
Presence of extraneous matter P Preventative: No preventative measures 2 3 6
such as metal fragments - applicable at receiving
measures two millimeters or
Control: Sieve through a strainer having mesh size
more in size-detached from
smaller than 2mm
blades in the milling process

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No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Probability Severity Risk
Material/Process
Level
Step
3 Receiving Yeast Biological: No common hazards B - - - -
Chemical: No common hazards C - - - -
Physical: No common hazards P - - - -
4 Receiving of sugar No potential food safety hazards B Pathogenic bacterial survival, growth and toxin - - -
identified production is unlikely at extremely low water
activity present in sugar, which retards microbial
activity under any given condition.
Chemical contamination of C Preventive: 3 2 6
sugar during storage from Establish, implement, monitor and verify good
cleaning and sanitizing agents, storage practices
pest excretions, etc e.g. Store cleaning and sanitizing chemicals
separately in a cupboard or room with restricted
access

Pest control activities: Pest proof design, chemical

free control methods, such as rat glue boards.
Chemical contamination of C Preventive: 3 2 6
sugar during storage from Establish, implement, monitor and verify good
cleaning and sanitizing agents, storage practices
pest excretions, etc e.g. Store cleaning and sanitizing chemicals
separately in a cupboard or room with restricted
access

Pest control activities: Pest proof design, chemical

free control methods, such as rat glue boards

Physical contamination of sugar P Preventive: 3 2 6

during storage from extraneous Establish, implement, monitor and verify good
matter storage practices
e.g. Glass and hard plastic policy

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No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Probability Severity Risk
Material/Process
Level
Step
5 Receiving Milk Presence of spoilage microbes in such B Preventative: Preventative measures
Powder amounts that results in rapid applicable at manufacturer/processor level
deterioration of milk. only.

Control:
Purchase from HACCP/ISO 22000
certified/reputed/approved/SLS 731
certified suppliers only.
Presence of spores of pathogenic B Preventative: Preventative measures 2 4 8
microbes such as Bacillus cereus applicable at manufacturer/processor level
only.
Presence of Enterotoxigenic
Staphylococci aureus above 105to Control:
106cfu/g or ml. Purchase from HACCP/ISO 22000/FSSC
Presence ofClostridium 22000/certified/reputed/approved/SLS 731
botulinumspores. certified suppliers only.
Presence of infectious dose of
viable Cronobacter spp count. Controlled as a PRP: Purchasing
Presence of Enteric viruses,including specifications
hepatitis virus, poliovirus, and
coronavirus

Presence of Enteric Viruses

including heatitus virus, poliovirus,
and coronavirus, which would have
been introduced through cross-
contamination.

Presence of pathogenic microbes such

as Listeria monocytogenese, Salmonella
and Shigellaabove infectious dose:
Salmonella> 1logcfu/g

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No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Probability Severity Risk
Material/Process
Level
Step
5 Milk Powder Presence of intentionally added C Preventative: Preventative measures applicable at 2 4 8
receiving substances such as adulterants: manufacturer/processor level only.
detergents, urea, neutralizers, etc
Presence of mycotoxins Check cleanliness of transport vehicles and
including aflatoxins, personnel. Control of integrity of the packaging,
ochratoxins, and fumonosins. labeling and shelf life. Maintain facilities and
Presence of unintentionally equipment for the operation properly sanitized.
added contaminants: heavy
metals, drugs, antibiotic residue Control:
or hormones Purchase from HACCP/ISO 22000/FSSC
Presence of broken pieces of P 22000/certified/reputed/approved/SLS 731
glass or metal fragments. certified suppliers only.

Controlled as a PRP: Purchasing specifications.

6 Receiving Salt Presence of pathogenic bacteria B Purchase salt only from approved/reputed/HACCP, 3 1 3
such as Pasteurella ISO 22000 FSMS certified suppliers.
parahaemolytica
Presence of Heavy Metals above C Purchase salt from approved/reputed/HACCP, ISO 3 1 3
Recommended Daily Intake of 22000 FSMS certified suppliers only.
Heavy Metal Elements:
As: 2.1 µg/kg body weight per Controlled as a PRP: Purchasing specifications
day for Salt

Cd: 175µg per person per day

Cr: 200mcg for adults per day
Hg: 0.1 µg/kg/day
Ni: 100 mcg/day
Pb: 6 µg/day
Presence of extraneous matters P Purchased salt from approved/reputed/HACCP, 3 1 3
such as plastic, polythene, metal ISO 22000 FSMS certified suppliers only.
fragments, sand, mud, gravel,
etc.

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No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Probability Severity Risk
Material/Process
Level
Step
7 Receiving of Presence of S. aureus, their survival and B Preventive: Purchase from Approved/ 3 2 6
Margarine growth to the infective-dose level Certified suppliers only.
Compliance with GHP and GSP to reduce
NOTE: Temperature, pH and Aw the risk of cross-contamination Justification: Whether from
condition required to support the growth Maintain recommended cold-holding human hands, contaminated
of above species temperatures to have a bactericidal effect. equipment, or the environment the
Temp. pH Aw Control: Heat, if possible to 75 0C or above level of bacterial contamination in
0 for 15 sec to create a lethal effect for table spreads is likely to be very
7-45 C 4.2-9.3 0.86 or above
vegetative cells. low.
Presence of Listeria monocytogens, B Preventive: 3 2 6
Escherchia coli, Salmonella spp in
Justification: Whether from
unacceptable levels or outgrowth to • Purchase from Approved/ Certified human hands, contaminated
unacceptable levels suppliers only. equipment, or the environment the
. • Compliance with GHP and GSP to reduce level of bacterial contamination in
NOTE: Temperature, pH and Aw the risk of cross-contamination table spreads is likely to be very
condition required to support the growth • Maintain recommended cold-holding low.
of above species temperatures to have a bactericidal effect. This indicates a low risk of food
Temp. pH Aw
borne illness from incidental
Listeria monocytogens Control: Heat, if possible to 75 0C or above contamination.
2-450C 4.8 – 9.6 0.95 or above for 15 sec to create a lethal effect for Food Code (FDA, 1999) defined
Escherchia coli vegetative cells. margarine as not a potentially
2.5-450C 4.6 – 9.5 0.935 or above hazardous food
Salmonella spp
6.5-450C 4.5- NA 0.95 or above Ref: (Guentert & Linton, 2003)

Presence, survival and growth of B Preventive: 3 1 3

spoilage bacteria causing to become • Purchase from Approved/ Certified
rancid and spoiled. suppliers only.
• Compliance with GHP and GSP to reduce
the risk of cross-contamination
• Maintain recommended cold-holding
temperatures to have a bactericidal effect.

20 | P a g e
 No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Probability Severity Risk
Material/Process
Level
Step
7 Receiving of Mold growth B Preventive: 3 1 3
Margarine • Purchase from Approved/ Certified
suppliers only.
• Prevent exposure to water and moisture
Presence of mycotoxins above C Preventive: 3 1 3
maximum safe limit: • Purchase from Approved/ Certified
suppliers only.
Zearalenone> 200 µg/kg
Aflatoxins B1> 8 μg/kg Control:
Aflatoxins (Sum of B1, B2, G1 and G2)> Request suppliers for a test report of
15μg/kg mycotoxin level per each batchduring quality
Fumonisins (Sum of B1 and B2)> 200 inspection to verify that lot confirm to set
μg/kg limits of each type of mycotoxin likely to
present on Margarine.
Ref: COMMISSION REGULATION And, periodically send randomly drawn
(EC) No 1881/2006 samples for an accredited laboratory to be
analyzed for mycotoxins Justification: No acute effect.
Only chronic effect due to
Irradiation of ingredients used to recurrent and prolonged exposure
manufacture margarine to control mold and above the safe limit: carcinogenic
mycotoxin (applies to primary producers, effect
processers and manufacturers only)
8 Melting margarine No common hazards identified B - - - -
No common hazards identified C - - - -
No common hazards identified P - - - -
9 Sieving flour and B. No common hazards identified B - - - -
yeast
C: No common hazards identified C - - - -

Leaving behind extraneous matter P Preventive: Use a stiffer with pore size less 2 3 6
measures 2mm or above than 2mm

21 | P a g e
No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Probability Severity Risk
Material/Process
Level
Step
10 Weighing and Introduction of pathogenic bacteria of B Keep facilities, equipment and utensils for 3 3 9
Mixing public health concern from the use of the operation properly sanitized.
(Kneading) equipment and utensils with Perform the task quickly, hygienically and
ingredients- contaminated food contact surfaces without interruptions. Compliance with
Wheat Flour, GHP. Always deploy trained workers.
yeast, Calcium E.g. Dough mixer
Propionate, Salt, Chemical contamination with residues C Preventive: Use food grade cleaning/ 2 3 6
Milk Powder, of cleaning and sanitizing chemicals sanitizing chemicals only
Water, Margarine from molds
in a dough mixer Control: Wash mixing bowl with potable
for 20 min water before use
Introduction of metal fragments from P Preventative: Adhere to SOPs established 3 4 12
the rotating blades of the Dough Mixer. on Operation/maintenance/Repair of Dough
Mixer.
Control: Check the integrity of the mixer
spiral after each mixing cycle. Or;
Scan the product by X-RAY scanner or use
metal detectors or magnets to detect metal
fragments, if any.

NOTE: Metal detector must detect 2.0 mm

ferrous, 3.0 mm non-ferrous, and 3.5 mm
stainless steel
The existence of pieces of metal can be fatal
to the health of consumer.
11 Stand (Proofing) Microbial contamination (Salmonella, B Keep the mixture well packed in proper 3 2 6
Staphylococcus aureus and Escherichia places, protected from contamination.
coli) Compliance with Good Personnel Hygiene
Practices, Maintain facilities and equipment
for the operation properly sanitized.
Controlled as a PRP: Verifying compliance
with GHP
22 | P a g e
No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Probability Severity Risk
Material/Process
Level
Step
11 Stand (Proofing) Introduction of Cleaning and Sanitizing C Preventative: Adhere to SSOP guidelines on
chemical residues left behind in the Cleaning and Sanitizing.
3 2 6
Dough Mixer. Controlled as a SSOP/PRP
Contamination by foreign objects P Compliance with GHP. Keep the mixture 3 2 6
well packed in proper place, protect from
contamination.
C: No common hazards identified. C - - - -
12 Dividing kneaded Microbial contamination (Salmonella, B Perform the task quickly, hygienically and 3 2 6
dough into balls Staphylococcus aureus and Escherichia without interruptions. Compliance with
coli) GHP. Keep facilities, equipment and utensils
for the operation properly sanitized.

Controlled as a PRP: Compliance with GHP

P: No common hazards identified. C - - - -
C: No common hazards identified. C - - - -

13 Fermentation (15 Microbial contamination (Salmonella, Compliance with GHP. Keep the mixture 3 2 6
min @ 35- Staphylococcus aureus and Escherichia well packed in proper place, protect from
400Cwarm coli) contamination.
cupboard) Keep facilities, equipment and utensils for
the operation properly sanitized.

The subsequent stage of baking eliminates

any microbial load that may be developed in
the product, so this step is not considered a
CCP.
P: No common hazards identified. C - - - -
C: No common hazards identified. C - - - -

23 | P a g e
No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Material/Process Probability Severity Risk
Step Level
14 Filling in greased Microbial contamination as a result of B Preventive: Keep facilities, equipment and 3 3 9
pans incorrect hygiene practices: utensils for the operation properly sanitized.
(Salmonella,Staphylococcus aureus Perform the task quickly, hygienically and
and Escherichia coli) without interruptions. Compliance with
GHP. Always deploy trained workers.
Control: Verifying compliance with
good hygiene practices
Chemical contamination with residues C Preventive: Use food grade cleaning/ - - -
of cleaning and sanitizing chemicals sanitizing chemicals only
from molds
Control: Wash molds with potable water
before use
Contamination by foreign objects (hair, P Preventive: Compliance with good personal - - -
And sand) as a result of incorrect hygiene practices
hygiene practices
Control: Verifying compliance with good
hygiene practices.

24 | P a g e
No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Material/Process Probability Severity Risk
Step Level
15 Baking Microbial survival and multiplication: B Compliance with good personal hygiene 3 3 9
practices.
(Salmonella, Yersinia,,
Given the time-temperature combinations to
Shigella Norovirus,
achieve 6 log reduction of different types of
Staphylococcusaureus, Listeria
pathogenic bacterial strains as mentioned
monocytogenes
below, meet binomial time/ temperature set
Escherichia coli O157:H7, Micrococcus
(10–12 minute sat 200–220ºC) for the
and Bacillus)
process so that at the interior is reached at
least a temperature of 70 ° C
Thermal destruction of vegetative cells of
disease-producing microorganisms occur
with a heat treatment as same as
pasteurization or above :72 for 15 seconds

Shigella : Rapidly inactivated at temperatures

above 650C.
Baking at 190.6 °C oven temperature for
17 min reduced 5 log cycles of Salmonella.

Listeria monocytogenes: 63 0C for 17 min or

85 0C for 0.02 min for the process to achieve
a 6 log reduction of vegetative cells
Although there is some variation in the
published heat inactivation data for
E. coli 0157:H7, there is no strong evidence
that a heat treatment of 70°C for 2 min or the
equivalent, as recommended by the ACMSF,
fails to deliver a 6D reduction in
cells of E. coli0157:H7
Bacillus cereus: 70 0C for 12 s to achieve a 6
log reduction of vegetative cells (Byrne &
Bolton, 2007)

25 | P a g e
No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Material/Process Probability Severity Risk
Step Level
15 Baking P: No common hazards identified. C - - - -
C: No common hazards identified. C - - - -
16 Cooling and Biological: Microbialcontamination B Compliance with good personalhygiene 3 2 6
unmolding (Staphylococcus aureus) as a result if practices. Keepfacilities, equipment and
incorrect hygiene practices utensilsfor the operation properly sanitized
C - - - -
P - - - -
17 Metal Detecting B: No common hazards identified. B - - - -
C: No common hazards identified. C - - - -
Presence of hazardous extraneous P Metal detector must detect 2.0 mm ferrous, 3 4 12
metallic material in the finished product 3.0 mm non-ferrous, and 3.5 mm stainless
due to the failure of the metal detector steel test samples when the test samples are
to detect metal and reject the product passed through the detector with the product.
when metal is detected. The metal detector must reject the product.
18 Packaging & Microbial contamination (Salmonella, B Compliance with good personnel Hygiene 3 2 6
Frozen Storage Staphylococcus aureus and Escherichia Practices (GHP), keep facilities, equipment
coli) and utensils for the operation properly
sanitized.
Mold growth due to temperature abuse/ B Maintain product temperature of -18°C or 3 3 9
fluctuation during cold storage colder with a minimum of fluctuation.

E.g. Rhizopus, Penicillium, Aspergillus, Place stock in the cold room in such a
Mucor, and Fusarium manner that the circulation of cold air is not
impeded to the extent that the product
temperature is adversely affected.
Contamination by foreign objects (hair, P Compliance with good personnel Hygiene 3 2 6
decoration) Practices (GHP), Perform the task quickly,
hygienically and without interruptions.
Development of mycotoxins due to C Maintain product temperature of -18°C or 3 2 6
temperature fluctuation and resulting in colder with a minimum of fluctuation.
moisture imparting, which triggers mold
growth
26 | P a g e
No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Material/Process Probability Severity Risk
Step Level
19 Baking Inadequate baking process results in B Preventive: 3 2 6
(reheating) frozen bread being left with high moisture Take the bread out of the cling film and let it
Breads content which favors mold growth and thaw overnight in the fridge until it is no
hence accelerated rate of stalling during longer frozen
storage.
Aflatoxins generated can be toxic if Preheat the oven to 190 0C and ‘refresh' the
inhaled and allergic to mold. bread for 3 to 5 minutes.
Or;
Place the frozen loaf in a 230-degree oven
while still wrapped in the foil.

Leave the loaf in there for 10 to 15 minutes

before removing the foil

Control:
Random check on freshness criteria at the
end of the baking process. Extend the baking
process/ repeat the process in the event of a
deviation from expected quality.

Toxin production of Bacillus cereus B Preventive: 3 3 9

from vegetative cells resulting due to Heat interior to minimum temperature of 60
spore germination or outgrowth of C at least.
surviving viable cells. `
Control:
Extend the baking process/ repeat the process
in the event of a deviation from expected
quality.

No common hazards identified C/P - - - -

27 | P a g e
No Raw Material/ Potential Hazard Category Control and preventative Measures Hazard Analysis
Food Contact (B/C/P)
Material/Process Probability Severity Risk
Step Level
20 Dispatch and Microbial contamination (Salmonella, B Compliance with good personnel Hygiene 3 2 6
delivery Staphylococcus aureus and Escherichia Practices (GHP), keep facilities, equipment
coli) and utensils for the operation properly
sanitized.
Moisture being imparted to bread B Properly wrap in plastic bags 3 2 6
during delivery would be the trigger for Transport bread in temperature and humidity
potential mold growth. controlled conditions/ stable temperature in
air conditioned compartments
Contamination by foreign objects (hair, P Compliance with good personnel Hygiene 3 2 6
decoration) Practices (GHP), Perform the task quickly,
hygienically and without interruptions.

28 | P a g e
 ISO 22000:2018. Decision tree for the selection and categorization of OPRPs and CCPs.

Document relevant food safety hazards and

decide what hazards are reasonably expected
to occur in relation to the type of product and
process and process environment (8.5.2.2.1).

Question 1 Apply PRPs as appropriate.

Is there a significant (likelihood x severity)
hazard at this step? (8.5.2.3) STOP, proceed to next step in the process.

Question 2

Is it necessary to apply control measures at

this step? (8.5.2.2.2)

Implement control measures (a) by modifying your own process, or

(b) have control measures in the process of the supplier of your raw materials.
Question 3:
If (a) and (b) are not feasible:
Are control measure already in place?
inform your customer about the possible presence of the hazard. (7.4.2 b 2)

STOP, proceed to next step in the process.

8.5.2.4 Selection and categorization of control measures

- Question 4:

Categorize the control measure as an OPRP.

- Is there any failure of the control
measure with a high risk (likelihood x
1. Establish action criteria. (8.5.2.4.2)
severity)for the safety of the product?
2. Monitor (measure or observe) to detect failure.
The method and frequency shall be proportionate to likelihood and
- (8.5.2.4.1) Include the following: No severity of failure. (8.5.2.4.1)
• The effect on the hazard.
3. In case of failure, assess the causes and consequences of the
• Control measure specifically applied to
failure
reduce to acceptable level?
and when necessary manage effected product as potentially unsafe
• -Any subsequent control measures?
(correction). (8.9.2.3)
• -Single control measure or
combination?
STOP, proceed to next step in the process.

29 | P a g e
 Yes

Questions 5: Categorize the control measure as an OPRP.

Is it feasible to establish measurable critical 1. Establish action criteria. (8.5.2.4.2)

limits and monitoring that enable timely 2. Monitor (measure or observe) to detect failure. The method and
detection and correction of all failure? frequency shall be proportionate to likelihood and severity of failure.
(8.5.2.4.2) (8.5.2.4.1)
3. In case of failure, assess the causes and consequences of the failure
No
and when necessary manage effected product as potentially unsafe
(correction). (8.9.2.3)
4. When possible, redesign the product, process or control measures.
5. Inform customers and/or consumers about the risk. (7.4.2 b 2)
6. Take action to reduce the likelihood and severity of failure
.
STOP, proceed to next step in the process.

Categorize the control measure as a CCP.

Yes
1. Establish measurable critical limits. (8.5.4.2)
2. Monitor (measurement) to detect any failure to meet critical limits.
(8.5.4.3)
3. In case of failure, manage effected products as potentially unsafe.
(8.9.2.2)

STOP, proceed to next step in the process.

30 | P a g e
 HACCP PLAN-IDENTIFICATION OF CRITICAL CONTROL POINTS (CCPS) AND OPERATIONAL PREREQUISITE
PROGRAMS (OPRPs)

No Process Step Significant hazard Q1 Q2 Q3 Q4 Q5

identified in the hazard
analysis Is there a Is it necessary to Are control Is there any failure of Is it feasible to establish
significant apply control measures already the control measure measurable critical limits
(likelihood x measures at this in place? with a high risk and monitoring that
severity) hazard at step? (likelihood x severity) enable timely detection
this step? If Yes move to the for the safety of the and correction of all
If Yes move to Q4 product? failure?
If Yes move to Q2 Q3 If No STOP and If Yes move to Q5
If No STOP and If No Apply PRP implement control If No, categorize the If Yes, categorize the
apply PRP as as appropriate measures control measure as an control measure as CCP
appropriate OPRP
If No, categorize the
control measure as an
OPRP
10 Weighing and mixing Introduction of pathogenic Yes No
Kneading ingredients bacteria of public health
concern from the use of
equipment and utensils with
contaminated food contact
surfaces
14 Filling in greased pans Microbial contamination as Yes No
a result of incorrect hygiene
practices:
(Salmonella,Staphylococcus
aureus and Escherichia
coli)
15 Baking Microbial survival and Yes Yes Yes Yes Yes
multiplication:
(Salmonella, Yersinia,, CCP-1
Shigella Norovirus,
Staphylococcusaureus,
Listeria monocytogenes
Escherichia coli O157:H7,
Micrococcus and Bacillus)

31 | P a g e
No Process Step Significant hazard Q1 Q2 Q3 Q4 Q5
identified in the hazard
analysis Is there a Is it necessary to Are control Is there any failure of Is it feasible to establish
significant apply control measures already the control measure measurable critical limits
(likelihood x measures at this in place? with a high risk and monitoring that
severity) hazard at step? (likelihood x severity) enable timely detection
this step? If Yes move to the for the safety of the and correction of all
If Yes move to Q4 product? failure?
If Yes move to Q2 Q3 If No STOP and If Yes move to Q5
If No STOP and If No Apply PRP implement control If No, categorize the If Yes, categorize the
apply PRP as as appropriate measures control measure as an control measure as CCP
appropriate OPRP
If No, categorize the
control measure as an
OPRP
17 Metal Detecting Presence of hazardous Yes Yes Yes Yes No
extraneous metallic
material in the finished OPRP-1
product due to the failure of
the metal detector to detect
metal and reject the product
when metal is detected.
18 Packing/ Storing Mold growth due to Yes Yes Yes No
temperature abuse/
fluctuation during cold OPRP-2
storage

E.g. Rhizopus on bread

19 Baking (reheating) Toxin production of Yes Yes Yes No
frozen Breads Bacillus cereus from
vegetative cells resulting OPRP-3
due to spore germination or
outgrowth of surviving
viable cells.

32 | P a g e
 Establishing Measurable or Observable Action Criteria, monitoring practices, corrective actions and verifications for OPRPs

No. Step Significant Control Measurable or Monitoring Actions to implement Responsibil

Hazard Measure observable ity and
Action What How Where When Who Corrections Corrective authority
Criteria Actions
17 OPRP-1 Metal Metal detector Minimum Equipment 1. Test the metal detector by Dispatch Check before Equipment A. When the Metal detector Monitoring:
(Optional) contamination must detect 2.0 detectable check passing a sample piece of starting operator metal detector validation Production
not detecting mm ferrous, limit2.0 mm (Metal metal through the detector to operations fails to detect a assisted by the supervisor
Metal 3.0 mm non- ferrous, 3.0 detectability) ensure that it is operating each day Or metal test sample: manufacturer
detecting ferrous, and 3.5 mm non- effectively and able to detect AND Correction
mm stainless ferrous, and metal present in the product. Check every production 1. Immediately Annual and
steel test 3.5 mm four hours supervisor halt all steps in calibration of Corrective
2. Check metal samples of
samples when stainless steel during which rotating the metal Action:
2.0 mm ferrous, 3.0 mm non-
the test operation; or metal blades detector by Hygiene
ferrous, and 3.5 mm stainless
samples are AND and/or sharp metal the Manager
steel, one at a time. Each
passed through Check at the A member cutting edges manufacturer
check must include all three
the detector end of of the involved until the and
sample tests.
with the operations quality issue rectified. verification of
product. The 3. Sample into the middle of each day; control the calibration
metal detector the product and then pass the AND staff 2. Unless the report by a
must reject the product package, if available, Check issue is rectified, qualified
product. through the metal detector. A whenever Or, visually check the individual
properly operating metal there is an equipment for
detector must detect the equipment a member broken or missing Correct the
metal sample in the product. malfunction of the parts. cause to
that could maintenan e.g. check integrity prevent
1. Each time a metal increase the ce or of the mixer spiral recurrence
contaminant is detected, the likelihood engineerin after each mixing
metal detector belt must that metal g staff cycle
retract and the rejected could be
product must drop into the introduced or B. Destroy all
rejection box. into the food product produced
Record the metal sample Any other since the previous
check as acceptable (“ ”) person satisfactory
(i.e., the metal detector is who has equipment check;.
operating correctly) or not an
acceptable (“X”) (i.e., the understand Or
metal detector is not ing of the Divert all product
operating correctly) on the operation produced since the
“Daily Metal Detector Check of the previous
Record,” including the date, equipment satisfactory
the time, and initials. . equipment check
to a non-food use.
Record: Metal detector operation log

33 | P a g e
No. Step Significant Control Measurable or Monitoring Actions to implement Responsibilities
Hazard Measure observable and
What How Where When Who Corrections Corrective
Action Criteria authorities
Actions
18 OPRP-2 Germination of Maintain air / Measurable: Air Visual inspection Reefer Once in 2 Maintenance Keep the reefer Investigate the Monitoring –
(Optional) pathogenic product Freezer air temp. temperat of the temperature Container hrs. technician container doors root cause and Maintenance
bacterial spores temperature at ≤ -18 0C ure display reading closed until an take measures to Technicians
Packing and outgrowth or below -18 Frozen Visual Inspection Reefer Daily, as Dispatch issue related to prevent
0C
and frozen to infectious Nature of Container when team temperature recurrence. Correction
storage level due to food required deviation and
time/ rectified if it can Due adherence Corrective
temperature Non- measure the between Daily or as QAM be solved within to preventive / Actions –
abuse destructi temperature frozen when 6 hrs or else, Repair & Hygiene
ve between packages packages required. immediately breakdown Manager
temperat inside a carton inside a transfer goods to maintenance
ure carton e.g. if an a backup freezer.
measure use sufficient issue is Discard foods if Assign
ment pressure to give suspected temperature of responsibility
good thermal any part of the based on
contact, and food has risen to competency
sufficient length or above 10 0C
of probe inserted and time of Document all
to exposure is more actions taken
minimize than 2 hrs. and define
conductivity responsibilities
errors; and If the time of
use a probe with a exposure is not
flat surface to more than 2 hrs
give good surface with a
thermal contact temperature rise
Destructi Make a hole in a minimum Daily or as QAM at or below 10 0C,
ve the product to depth of when rapidly cool the
temperat insert the probe 2.5 cm required. food at or below
ure using a pre- from the 4 0C whilst
measure cooled sharp surface of e.g. if an awaited to be
ment pointed metallic the product. issue is blast frozen or
device such as an Or suspected blast freeze right
ice punch, hand minimum away.
drill or an auger. depth from
the surface
Insert the probe to of 3 or 4
a minimum depth times the
of 2.5 cm from diameter of
the surface of the the probe.
product.

34 | P a g e
No. Step Significant Control Measurable or Monitoring Actions to implement Responsibilities
Hazard Measure observable and
What How Where When Who Corrections Corrective
Action Criteria authorities
Actions
19 OPRP-3 Toxin Place the The internal Internal Clock ovens / Bakery Towards Chef in Correction: Correction Monitoring:
production of frozen loaf in a temperature of time Penetration oven the end of charge Further bake/ Action: Reset Oven operator
Reheating Bacillus cereus 230-degree the product must /temp of Thermometer. baking, start the process the rebaking or employee
frozen from vegetative oven while still be at least 70°C the Weekly afresh time responsible
bread cells resulting wrapped in the for a minimum product /temperature for baking
due to spore foil. of 1 minute. In case of a oven
germination or fault, start the Do trials to Correction:
outgrowth of Leave the loaf process again in experiment the Ex. Pastry
surviving viable in there for 10 another preheated most effective Chef / QAM
cells. to 15 minutes oven time /
before temperature Corrective
removing the combination Action:
foil respecting to QAM, Pastry
The goal is to oven condition Chef
reach inside the
product
temperature at
or above 70 °
C.

35 | P a g e
No. Step Significant Control Measure Measurable or Monitoring Actions to implement Responsibilities
Hazard observable and
Action Criteria What How Where When Who Corrections Corrective authorities
Actions
15 CCP-1 Microbial Compliance with The internal Binomial Clock ovens / Bakery oven Towards Chef in Correction: Correction Monitoring:
survival and good personal temperature of time /temp, Penetration the end of charge Extend or Action: Reset Oven operator
Baking multiplication: hygiene practices. the product must internal time Thermometer. baking, shorten the the binomial or employee
Meet binomial be at least 70°C /temp of the Weekly cooking time time responsible
(Salmonella, time/ temperature for a minimum product to achieve the /temperature for baking
Yersinia,, set (10–12 minutes of 1 minute. desired end
Shigella Noro at 200–220ºC) for product and Hygiene
virus, the process so that that inside the Manager
Staphylococcus at the interior is product is
aureus, reached at least a achieved a Corrective
Listeria temperature of 70 ° temperature Action:
monocytogenes C above 70°C. Hygiene
Escherichia If the product Manager ,
coli O157:H7, The goal is to is not fit for Pastry Chef
Micrococcus reach inside the human
and Bacillus) product consumption,
temperature at or must be
above 70 ° C. rejected, put in
place, and duly
identified as
Record: Baking Temperature Log nonconforming
product.

36 | P a g e
Process Step Verification Activities Recordkeeping Activities Validation
(CCP/OPRP) What Who Name of the record
OPRP-1 At the end of each shift, review the “Daily Metal A trained designee Daily Metal Detector Check Record Metal detecting process:
Detector Check Record” to ensure that it has been Insert the metal sample into the middle of the
17. Metal properly completed. product and then pass the product through a
Detecting properly operating metal detector. If the
Once per week, ensure that the monitoring of the
metal detector follows the written monitoring
control measures are valid metal
procedure. contaminant is detected, the metal detector
belt retracted and the rejected product is
If non-conformance is found during the dropped into the rejection box.
verification procedure, investigate the cause of
the non-conformance and take necessary Scientific literature citations:
corrective actions to prevent reoccurrence. Ministry of Health, B. C. (n.d.). SLICED
WHOLE WHEAT BREAD SAFETY PLAN.
Record all observations (e.g., whether or not the Retrieved from www2.gov.bc.ca:
detector is operating effectively, non- https://www2.gov.bc.ca/assets/gov/health/ke
conformances, and corrective actions taken) on
eping-bc-healthy-safe/food-safety-
the “Daily Metal Detector Check Record,”
including the date, the time, and initials.
security/sliced_whole_wheat_bread.pdf?bcg
Perform ongoing review of HACCP Plan in FST Document Review log ovtm=CSMLS
response to deviations and/or System and product
Modification
Conduct biannual internal audits to assess whether Trained auditor with Internal Audit Reports
specified requirements have been fulfilled. technical expertise who Nonconformity records
is not directly involved
in the operation.
Quarterly analyze training related records to FST Training records
ascertain that people are well trained, competent and Training effectiveness evaluation record
skilled to perform their assigned duties. Competency evaluation record
Correction Action Record
Interviewing employees Hygiene Manager Employee audit records.

Review of deviation reports FST Deviation reports

Review of past validation reports FST Validation reports

Assessment of corrective action effectiveness FST Food Safety Meeting minutes

Review of linkages between the Hazard Control plan FST Hazard Control Plan review records.
and PRP programmes
Review control measures for their continued FST HACCP Plan Review and Amendment Records
suitability

37 | P a g e
Process Step Verification Activities Recordkeeping Activities Validation
(CCP/OPRP) What Who Name of the record
OPRP-3 Daily verification of monitoring & corrective action Baking Log Worst Case
records. Corrective Action Log Aseptically collect about 75 g of baked
Once per week, ensure that the monitoring of the baking bread/bun sample and get it analyzed by an
19 Rebaking process follows the written monitoring procedure. accredited laboratory for the presence/
survival of the following microbial
If non-conformance is found during the verification
parameters and verify that the test results
procedure, investigate the cause of the non-conformance
conform to the specified limits shown
and take necessary corrective actions to prevent
against each parameter
reoccurrence.
Check penetration thermometer and/or oven Oven thermometer calibration Total microorganisms (300C):≤105UFC/g
thermometer for accuracy and damage and to ensure that Record Enterobacteriaceaespp: ≤ 10² UFC/g
it is operational before putting it into operation; perform Staphylococcus aureus: ≤ 10² UFC/g
these same checks daily, at the beginning of operations; Salmonella spp: Absence in 25g
and calibrate it once per year Listeria monocytogenes: Absence in 25g
Annually, perform heat distribution test on ovens to Food Safety Team Heat Distribution Test Report Fungi (Molds) and Yeasts: ≤ 10² UFC/g
ensure that binomial time/temperature can be achieved Corrective Action Log Units of 30 gr. and 48 gr.
everywhere in the oven.
If deviations reveal that heat is not uniformly distributed Frequency: Biannual
and under-processing could occur on certain locations,
take necessary corrective actions and prevent recurrence.
Conduct periodic internal audits on baking process to Trained auditor Internal Audit Reports Literature citation:
ascertain whether it in compliant with specific food who is not directly
safety requirements. involved in the
operation.
Monthly verification of repair and maintenance records Manager, Maintenance and Repair Record
for ovens. supervisor, or Preventive Maintenance Record
trained designee.
Perform ongoing review of HACCP Plan in response to FST Document Review log
deviations and/or System and product Modification

Reassess baking process - annually by HACCP team. Food Safety Team

Monthly evaluate competency, awareness and training of Food Safety Team Training need evaluation record
monitoring, measuring and calibrating persons to ensure Competency evaluation record
that human error accounting for likely deviations are Correction Action Record
corrected and corrective actions taken upon.

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Process Step Verification Activities Recordkeeping Activities Validation
(CCP/OPRP) What Who Name of the record
CCP-1 Daily verification of monitoring & corrective action Baking Log Worst Case
records. Corrective Action Log Aseptically collect about 75 g of baked
15 Baking Once per week, ensure that the monitoring of the bread/bun sample and get it analyzed by
baking process follows the written monitoring an accredited laboratory for the presence/
procedure. survival of the following microbial
parameters and verify that the test results
If non-conformance is found during the verification
conform to the specified limits shown
procedure, investigate the cause of the non-
against each parameter
conformance and take necessary corrective actions to
prevent reoccurrence.
Total microorganisms (300C):≤105UFC/g
Check penetration thermometer and/or oven Oven thermometer calibration Record Enterobacteriaceaespp: ≤ 10² UFC/g
thermometer for accuracy and damage and to ensure Staphylococcus aureus: ≤ 10² UFC/g
that it is operational before putting it into operation; Salmonella spp: Absence in 25g
perform these same checks daily, at the beginning of Listeria monocytogenes: Absence in 25g
operations; and calibrate it once per year Fungi (Molds) and Yeasts: ≤ 10² UFC/g
Annually, perform heat distribution test on ovens to Food Safety Team Heat Distribution Test Report Units of 30 gr. and 48 gr.
ensure that binomial time/temperature can be achieved Corrective Action Log
everywhere in the oven.
Frequency: Biannual
If deviations reveal that heat is not uniformly
distributed and under-processing could occur on
certain locations, take necessary corrective actions and Literature citation:
prevent recurrence.
Conduct periodic internal audits on baking process to Trained auditor Internal Audit Reports
ascertain whether it in compliant with specific food who is not directly
safety requirements. involved in the
operation.
Monthly verification of repair and maintenance Manager, Maintenance and Repair Record
records for ovens. supervisor, or Preventive Maintenance Record
trained designee.
Perform ongoing review of HACCP Plan in response FST Document Review log
to deviations and/or System and product Modification
Reassess baking process - annually by HACCP team. Food Safety Team
Monthly evaluate competency, awareness and training Food Safety Team Training need evaluation record
of monitoring, measuring and calibrating persons to Competency evaluation record
ensure that human error accounting for likely Correction Action Record
deviations are corrected and corrective actions taken
upon.

39 | P a g e
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