FSMS CHECKPOINTS
FOR
FROZEN SAMOSA MANUFACTURING
Ingredient Procurement
↓
Inspection of Ingredients
↓
Storage of Ingredients
↓
Preparation of Dough and Filling
↓
Shaping and Filling of Samosas
↓
Pre-Freezing Quality Check
↓
Blast Freezing
↓
Packaging
↓
Storage in Cold Chain
↓
Dispatch Inspection
↓
1. Ingredient Procurement
- Critical Control Points (CCP):
• Procurement of ingredients from FSSAI-certified vendors.
• RM meet specifications with Certificate of Analysis (COA).
• Inspection of incoming RM (visual, aroma, contamination) with more than 60% shelf life
remaining.
- FSMS Measures:
• Recordkeeping: COA, supplier certifications, and batch numbers.
• Verification: Checklists for RM inspection and Selection of lots based on standards.
• Control: Samples from batches for testing.
2. Storage of Ingredients
- CCP:
• Dry ingredients: 20–25°C, <60% humidity.
• Wet ingredients: In sealed container.
• Perishable ingredients: Cold storage below 4°C.
- FSMS Measures:
• Storage logs (temperature & humidity).
• FEFO (First Expiry, First Out).
• Pest control & hygiene records for contamination-free storage.
3. Manufacturing
- Dough and Filling Preparation:
• Ingredients (clean, free of contamination & properly mixed).
• Consistency & seasoning to established recipe.
- Shaping and Sealing:
• Uniform size & proper sealing to prevent leak during frying.
- FSMS Measures:
• Production log (mixing ratios & texture consistency).
• Batch-wise inspections for quality assurance.
4. Freezing
- CCP:
• Blast freezing at -18°C to -20°C (quick freezing & low ice crystal formation).
- FSMS Measures:
• Calibration of thermometers to monitor temperature.
• Logs for freezing time and batch details.
• Random checks for cracks, freezer burns & ice crystals on product.
5. Packaging
- Primary Packaging:
• Use FSSAI-approved food-grade materials.
- Secondary Packaging:
• Tamper-evident seals, proper labeling with details: batch number, expiry date, FSSAI license
number, and storage instructions.
- FSMS Measures:
• Inspection of packaging integrity.
• Mandatory labeling as per FSSAI Packaging and Labeling Regulations standard, 2011.
• Verification of weighing standards.
6. Storage
- CCP:
• Cold storage at -18°C or below.
- FSMS Measures:
• Digital temperature monitoring devices.
• Regular calibration of storage units.
• Recording of all deviations and corrective actions.
7. Dispatch
- CCP:
• Pre-dispatch inspections for packaging integrity & product quality.
• Cold chain maintenance during transport.
- FSMS Measures:
• Temperature-controlled vehicles & transport logs.
• Dispatch record: destination, vehicle temperature, and time.
• Monitoring of cold chain breakages.
8. Cleaning and Hygiene
- CCP:
• All equipment, tools, and surfaces cleaned & sanitized as per FSSAI standards before, during, and after
production.
- FSMS Measures:
• Approved food-safe sanitizers.
• Maintaining cleaning schedules and records.
• Implementation of personal hygiene practices.
9. Documentation
- FSMS Measures:
• Ingredient procurement records (supplier certifications, COA).
• Production logs (batch records, mixing, freezing).
• Storage logs (temperature, humidity).