Hazard Analysis form (Element 1,2,3,4,5)
B - Biological hazard P - Physical hazard C - Chemical hazard
Process
Food Safety Hazard
Risk of
Form
Step
occurence &
Servity
(Refer
to
hazard
matrix)
Receiving B: microbial growth during
2C-8
RS2
transport in unsuitable
temperature; initial microbial of
ingredients
P: initial contamination by foreign 2C-8
materials
Preparati
on
(Cleaning
&
sanitizing)
Dry
Storage
Cold
B: microbes contamination of
utensils with processing
environment after cleaning and
before food manufacturing
3D-17
C: chemical residues (e.g.
detergent)
4D-21
B: Yeast & mould, Pathogens
growth, microbial spores
2D-12
P: foreign objects (e.g. dust);
Pest, rodent, vermin
C: Pesticides
4D-21
B: Psychrophilic bacteria still
3C-13
CCP
QCP
N/A
Control Measure
Procedures
Monitoring Plan
Frequency
Responsibility
N/A
SP3
Visual inspection
Check for
foreign
materials
and spoilage
of
ingredients
Every delivery
Production
staff
RS1
N/A
Ensure there
is no
residues of
sanitizing
chemicals
Every time after
each equipment
and utensils are
cleaned and
sanitized
Production
staff
RS6
RS8
QCP
(T1)
SP2
Cleaning and
sanitizing work
area, equipment
and utensils using
antiseptic
detergent to
destroy pathogens
and rinsed properly
SP6
Visual inspection
Ensure the package
of ingredients are
well-protected
Check record
of the
relative
humidity of
the store
room;
check for
foreign
materials;
monitoring
of rodent
baits
Check record
Once a day
4D-21
RS6
QCP
SP2
Corrective Action Plan
Procedures
Responsibility
Reject product
that are
contaminated,
with damaged
containers
and with
foreign object
Rinse the work
area,
equipment
and utensils
again
Manager
Production
staff
Reject spoiled
product
Manager
Production
Adjust cooler
Manager
Manager
Once a week
Hourly
Storage
Weight
Beat
Boil
Mix
grows, cross contamination in the
fridge
(T2)
B: cross contamination with
processing environment;
pathogen introduction (e.g.
Salmonella in egg white); spoilage
from handling,
P: foreign objects (e.g. objects fall
in when tear the package bag,
metal fragments from canned
evaporated milk)
C: chemical residues (e.g.
detergent); allergens
3C-13
B: spoilage from handling;
Pathogen introduction(e.g.
Salmonella in egg white); cross
contamination with processing
environment
P: foreign objects (e.g. egg shell)
C: chemical residues (e.g.
detergent); allergens
P: foreign objects (e.g. glass,
metal, plastic)
C: chemical residues (e.g.
detergent)
2D-12
B: spoilage from handling;
Pathogen introduction; cross
contamination with processing
environment
3C-13
SP4
Visual inspection of
the storing area
of the
temperature
of the fridge,
Check if the
fridge is
cleaned
staff
SP1
Egg is handle with
care; consume
pasteurized eggs
Visual inspection
SP2
Observation
of food
handlers
comply with
hygiene
procedures;
Check for
foreign
materials
Frequently
Production
staff
Check for
foreign
materials
Frequently
Production
staff
Reject product
with foreign
object
Manager
Reject product
with foreign
object;
Reheat if the
temperature is
below
requirement
Reject product
with foreign
object;
Manager
Weekly
N/A
QCP
(Q1)
CCP1
N/A
QCP
(Q2,
Q3)
RS6
QCP
SP2
(T3)
Visual inspection
111±1°
C
Check for
foreign
materials
Frequently
Production
staff
N/A
QCP
(Q4)
Observation
of food
handlers
comply with
Frequently
Production
staff
2B-5
temperature;
Discard any
product that
Stored at a
incorrectly
temperature
for more than
6 hours
Reject product
with foreign
object
Manager
4D-21
Frappe
SP1
SP2
Visual inspection to
ensure no egg shell
contamination
2C-8
4D-21
4D-21
4D-21
SP1
Visual inspection
SP2
Manager
Temporar
y Storage
P: foreign objects (e.g. nails, hair,
metal)
C: chemical residues (e.g.
detergent)
4D-21
B: Cross contamination with
processing environment;
microbes growth
P: foreign objects(e.g. air, dust);
pest contamination
3C-13
4D-21
P: foreign objects(hair, metal,
plastic)
C: chemical residues (e.g.
detergent)
4D-21
Cool to
90°C
B: microbes growth , cross
contamination with processing
environment
P: foreign objects (e.g. glass,
metal, plastic)
B: spoilage from handling;
Pathogen introduction
P: foreign objects (e.g. glass,
metal, plastic)
2D-12
B: spoilage from handling;
Pathogen introduction; cross
contamination with processing
environment
P: foreign objects(e.g. stones,
hair, plastic)
3C-13
Mix
Group 2
N/A
Visual inspection
Frequently
Production
staff
Reject product
with foreign
object
Manager
Check for
foreign
materials;
Calibration
of
thermomete
r
Check for
foreign
materials
Frequently
Production
staff
Manager
Frequently
Production
staff
Reject product
with foreign
object;
Reheat if the
temperature is
below
requirement
Reject product
with foreign
object
Observation
of food
handlers
comply with
hygiene
Procedures;
check for
foreign
materials
Observation
of food
handlers
comply with
hygiene
Procedures;
check for
foreign
Frequently
Production
staff
Reject product
with foreign
object
Manager
Frequently
Production
staff
Reject product
with foreign
object
Manager
4D-21
Boil
Group 1
(mix &
blend)
Add
Group 2
N/A
hygiene
Procedures;
check for
foreign
materials
Check for
foreign
materials
RS4
RS6
4D-21
RS6
QCP
(T4)
90±1°
C
Visual inspection
N/A
QCP
(Q6)
SP1
Visual inspection
N/A
N/A
SP1
Visual inspection
4D-21
4D-21
Pan Fudge
CP
Visual inspection
120±1° SP5
C
QCP
(Q5)
4D-21
4D-21
Manager
Chop
Hazelnut
B: E.coli and S. aureus
contamination due to handling,
cross contamination from
processing environment
P: foreign objects (e.g. plastic,
metal)
C: chemical residues (e.g.
detergent)
B: spoilage from handling;
Pathogen introduction; cross
contamination with processing
environment
P: foreign objects (e.g. glass,
metal, plastic); Allergen
2D-12
Mix
B: spoilage from handling;
Pathogen introduction; cross
contamination with processing
environment
P: foreign objects(e.g. plastic,
glass, metal)
C: chemical residues (e.g.
detergent)
3C-13
N/A
Pour &
Cool
B: spoilage from handling;
Pathogen introduction; cross
contamination with processing
environment
P: foreign objects
C: chemical residues (e.g.
detergent)
3C-13
N/A
QCP
(Q10)
SP1
Visual inspection
SP2
B: spoilage from handling
P: foreign objects (e.g. metal
fragment of knife)
C: chemical residues (e.g.
3C-13
2B-5
N/A
QCP
(Q11)
SP1
Visual inspection
SP2
Add
Hazelnut,
Fondant,
Frappe
Cut &
Weigh
N/A
QCP
(Q7)
SP1
Visual inspection
SP2
N/A
QCP
(Q8)
(Q9)
SP1
Visual inspection
materials
Check for
foreign
materials
Frequently
Production
staff
Reject product
with foreign
object
Manager
Frequently
Production
staff
Reject product
with foreign
object
Manager
Frequently
Production
staff
Reject product
with foreign
object
Manager
Frequently
Production
staff
Reject product
with foreign
object
Manager
Frequently
Production
staff
Reject product
with foreign
object
Manager
4D-21
4D-21
3C-13
4D-21
1B-2
SP1
Visual inspection
SP2
4D-21
4D-21
4D-21
Observation
of food
handlers
comply with
hygiene
Procedures;
check for
foreign
materials
Observation
of food
handlers
comply with
hygiene
Procedures;
check for
foreign
materials
Observation
of food
handlers
comply with
hygiene
Procedures;
check for
foreign
materials
Observation
of food
handlers
comply with
detergent)
Package
& Label
Storage
B: spoilage from handling;
Pathogens inside bags
P: foreign inside package (plastic
bag)
1B:2
B: Yeast & mould;
Product deterioration due to
incorrect sealing Pathogens
growth, microbial spores
P: foreign objects (e.g. dust);
Pest, rodent, vermin
C: Pesticides
2D-12
4D-21
4D-21
RS5
RS6
RS8
QCP
(Q12)
(Q13)
CCP2
(R1)
SP1
ensure the package
is sealed tightly
Visual inspection
N/A
SP1
SP4
SP6
hygiene
Procedures;
check for
foreign
materials
Observation
of food
handlers
comply with
hygiene
Procedures;
check for
foreign
materials;
Check for
correct
labeling and
sealed
package
Check record
of the
relative
humidity of
the store
room;
check for
foreign
materials;
monitoring
of rodent
baits
Frequently
Production
staff,
Manager
Product
testing, reject
or discard
contaminated
package and
product with
improper
packaging
and labelling
Manager
Production
staff
Reject or
discard
contaminated
product
Manager
Each product
Once a day
Once a week
Control Point
Control points are preventive measures for CCPs. It is any step at which biological, physical or chemical factors can be controlled. It is usually a reading of a temperature,
time, pH or salt concentration.
1. Ensure the food is cooked to 120±1°C so that the temperature is high enough to kill Salmonella from egg and to ensure most harmful microorganisms are killed. It
can be done by calibration of thermometer.
Critical Control Point
A step that can be controlled in order to prevent, control, eliminate or reduce a hazard, or minimise the likelihood of its occurrence to an acceptable level.
1. Ensure no falling of metal parts when canned evaporated milk is opened
Physical contamination of metal fragments will cause a product recall. The metal fragment might contain microbes which are harmful to consumers and may cause
serious illness if consumed. Therefore, after pouring the evaporated milk, production staff will need to check if there is any present of metal fragments.
2. Regulatory Quality Control Points to ensure correct labeling
Correct label is critical (allergen advice) because allergens can cause fatality and serious illness; incorrect Best before date may also be harmful to consumers when
they eat. Therefore, allergen test must be done and label must be put in an appropriate position with correct Best before date.
Quality Control Points
Testing product quality to control factors such as colour or flavour
1. Temperature control
Temperature of cooking should be measured frequently to avoid over-cooked. Temperature must be reached to ensure harmful microorganisms are killed.
Cold, dry and finished product storage is must be maintained by regular temperature control. Fluctuation of temperature will promote growth of bacteria, yeast and
mould. Tolerance limits of temperature is ±1°C.
2. Weigh control
Electric balance must be zero before measuring and weigh of ingredients must be measured accurately.
3. Ensure no egg shell contamination
Egg shell may contain Salmonella which may cause serious sickness of customers if it is not cooked properly.
4. Operational control
All of the ingredients must be poured to prevent ingredient loss, ingredients that is adhere to the steel bowl or saucepan should be transfer by a spoon. Check all
ingredients are present.
5. Size control
Ensure the size of each serve is 3 x 8 cm and 60g.
6. Package control
Ensure the package is sealed properly and no foreign matter is present.
Appendix
Support programs (SP)
1. Personal Hygiene
2. Premises & equipment
 Cleaning schedule
3. Approved supplier
a. Supplier record
4. Storage Ingredients/Final product
 Storage time, temperature, relative humidity
5. Preparation
 Pre-operational review
 Process review
 Calibration of equipment
6. Pest control program
a. Rodent Activity Record
Record-keeping system (Element 6)
1. Hygiene
 Cleaning schedule
2. Supplier record
3. Product transportation Record
4. Preparation
 Pre-operational review
 Process review
 Calibration of equipment
5. Packaging record
6. Storage Ingredients/Final product
 Storage time, temperature, relative humidity
7. Employee training records
8. Rodent Activity Record
9. Maintenance schedule/report
10. Incident Record
11. Recall procedures
12. Disposed product record
Hazard matrix
Severity (consequence)
1.
2.
3.
4.
5.
Can cause fatality
Can lead to serious illness
Can cause a product recall
Can generate customer complaint
Not of significance
Risk (likehood)
A.
B.
C.
D.
E.
Common occurrence
Known to occur or has happened on the premises
Could occur or have heard of it happening (published information)
Not likely to occur
Practically impossible
Severity
1
2
3
4
5
A
1
3
6
10
15
B
2
5
9
14
19
Risk
C
4
8
13
18
22
D
7
12
17
21
24
E
11
16
20
23
25