Cyril Rodrigo
Restaurants Ltd
Issue Date :
01Apr 2021
Revision Date:
ISO 22000:2018 FSMS
Issue No :
01
Revision No:
Doc Ref:
GC -FSMS-HACCP-3
HACCP PLAN FOR PINEAPPLE GATEAU
Hazard Control Plan for
PINEAPPLE GATEAU
Prepared By:
Name: Viduranga Nuvan
Signature:
Name: Madhura
Designation: Quality Assurance
Manager
Designation: Pastry Chef
Reviewed
By:
Approved
By:
Name:Trevine Gomez
Designation: Managing Director
Signature:
Signature :
Ingredients
Item
Wheat flour
Sugar
Eggs
Margarine
Sweetened Condensed Creamer
Baking powder
Icing Sugar
Cocoa Powder
Pineapple
:
:
:
:
:
:
:
:
:
:
Quantity
5.25 kg
8.250 kg
150
750 g
300 g
80 g
Steps
Beat eggs and sugar in the dough mixer
Continue mixingafter baking powder and wheat flour being added to the same mixer
Separately heat Sweetened Condensed Creamer (Milkmaid) and sugarpine
Add the batter into the mold
Bake for 25 min (200 0C Upper side, 250 0C Underside)
Applying icing and pineapple layers
Product Characteristics-Raw Material, ingredients and product-contact
Materials Pineapple Gateau
Biological,
chemical and
physical
characteristics
Raw Material
Biological
Chemical
Physical
Wheat flour
Semi-perishable
Sugar
Non-perishable
Water:11.92/100g
Fat: 0.92/100g
Proteins: 15.40g/100g
C12H22O11
Eggs
Perishable
Texture: Powdery
Color: White
pH:6-6.8
pH: 7
Texture: Granular
Color: White
pH in White: 7.96
pH in Yolk: 6.10
Margarine
Sweetened
Condensed
Creamer
Baking Powder
Icing Sugar
Cocoa Powder
White%
Yolk %
Water
88.0
48.0
Protein
11.0
17.5
Fat
0.2
32.5
Perishable
Shelf stable
Perishable
Shelf stable
Shelf stable
Percentage %
Fat
70
Carbohydrates
2
Water
26
Characteristic
%
Total Milk Solids (%wt.)
Min
Fat (%wt.)
31
Sucrose (% wt.) Min
40
Acidity (%)lactic) Max
0.35
Bacterial Count (per g.)
500
Coliform Count (per.g)
-ve
Not less than 9
Yeast and Mold Count
10
(per.g)
The minimum sugar content: Not specified
(should be sufficient to avoid spoilage.)
Decomposes when heated to a temperature
greater than 50 0C
Alkaline and reacts with acids: Neutralizes
acidic odors (SO2 , H2S, NH3 )
C12H22O11
Characteristic
Carbohydrates
Fat
Value per 100 g
57.90 g
13.70 g
Protein
19.60 g
Texture: Liquid
Color: WhiteWhite, Yolk:
Yellow
Color: Light
buttery
Smell: Mild smell
Flavor: Butter
flavor
Texture: Butter like
pH: 3.6 – 6
aW: 0.87
Color: Browning
discoloration
Flavor: Cooked
flavor
aW: 0.83
pH: 8.3
Texture: Abrasive
Solubility: Dissolve
more quickly than
granulated sugar
Texture: Grainy
Taste: Sugar taste
Color: Dark brown
Flavor: Deep
chocolate flavor
Texture: grainy
Solubility:
Dissolvable
Biological,
chemical and
physical
characteristics
Raw Material
Pineapple
Biological
Highly perishable
Chemical
Physical
Characteristic
Value
pH
Sugar content
4.3 to 4.36
14.16 to 15.8
mg/100g
12.33 % to
15.12 %
TSS Value
Color: Yellow
Texture: Succulent
Flavor: Sweetfruity
Composition
of formulated
ingredients
Baking Powder: 250 White Sugar, 250 g All-Purpose Flour, 4-5 Eggs, 250 g Butter, 2
heaped tablespoons of Brownson baking Powder, 2 table spoons of Brownson vanilla, 2
tablespoons of Brownson Citrus Drop, 2 Table spoons of Lemon Zest
Place of
Origin
Sweetened Condensed Creamer: Nestle lankaPVT LTD
Wheat Flour:Prima Ceylon Pvt Ltd
Sugar:
Eggs:Lanka Egg center Pvt Ltd
Margarine: Pyramid Lanka Pvt Ltd
Baking Powder: Brownsons, No.114, N.H.M. Abdul Cader Road, Colombo 11
Icing Sugar: Thilina Confectionary, No. 514/1, Kotte Road, Pitakotte
Alkalized Cocoa Powder:
Pineapples: Domesticfarm lands
Sweetened Condensed Creamer: Addition of SMP, Full cream milk powder, butter oil, sugar and
water to reconstituted condensed milk
Homogenization
Pasteurization
Adding lactose
crystals and crystallization
Packaging
Method of
production
Wheat Flour:Harvesting and threshingStorageCleaning
Sieving
Sieving
Magnet
Separator
De-stoning
Scouring
Temporary storage
Conditioning
Blending
Grinding
Brushing
Milling
Packing
Sugar:Harvesting
Washing and Initial preparation
Juice Extraction
Purification of juice
Crystallization
Centrifugation
Drying and Packaging
Eggs:Produced in egg hatcheries
Margarine: PreparationHydrogenationCombining the ingredientsAgitation
Baking Powder: Production of raw materials (Sodium bicarbonate, tartaric acid)
Blending the
powders
Filling and Packing
Icing Sugar: Finely grinding granulated sugar
Alkalized Cocoa Powder: Dried cocoa beansCleaningMicronizingWinnowing and breaking
Alkalization
Roasting
Grinding
Cocoa Liquor
Pressing
Cocoa cake
Pulverizing
Cocoa Powder
Pineapples: Cutoff the green spiky top
Cut the skin off the sides, as close to the edge of the
pineapple as can be seen (Cut close to the edge exposes a bunch of brown, scraggly dots, called eyes,
that needs to be removed)
Cut slices as necessary
Packaging
and delivery
method
Ingredient
Packaging Method
Delivery Method
Sugar
Packaged in HDPE woven sacks
with ends being strongly sewn
Margarine
Primary Packaging: LDPE
polythene
Delivered to the plant hygienically, safely and
conforming to storage conditions by supplier
vehicles (No special time/ temperature
requirement)
Delivered to the plant hygienically, safely and
conforming to storage conditions by the
approved suppliersin temperature controlled
vehicles. During transport temperature should
be maintained at 100Cor below.
Delivered to the plant hygienically, safely and
conforming to storage conditions by the
approved suppliersin temperature controlled
vehicles. During transport temperature should
be maintained at 100Cto 210C or below.
Secondary Packaging: Corrugated
paper carton
Baking
Powder
Packaged in metal cans
Packaging
and delivery
method
Ingredient
Packaging Method
Delivery Method
Wheat flour
Packaged in containers which will
safeguard the hygienic, nutritional,
technological, and organoleptic
qualities of the product.
The containers, including
packaging material, shall be made
of substances 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.
Packed with clean and odorless
rice husks, wheat chaff or chopped
straw in a firm walled basket or
crate to reduce the risk of shell
damage.
Delivered to the plant hygienically, safely and
conforming to storage conditions by supplier
vehicles (No special time/ temperature
requirement)
Eggs
Sweetened
Condensed
Creamer
Icing sugar
Primary Packaging: Food grade
plastic cans
Secondary Packaging: Corrugated
paper carton
Packed airtight in flexible LDPE
containers
Cocoa
Powder
Packed airtight in flexible LDPE
containers
Pineapple
Not packaged
Received from supplier vehicles
The containers and packaging materials must be
such that the eggs are well protected against
mechanical damage.
Care should be taken at all stages of handling
and transport. Workers handling eggs should be
instructed so that they appreciate the need for
careful handling.
The provision of convenient loading platforms
at packing stations, loading depots and railing
stations, and handling aids, such as hand trucks
and lifts
The eggs must be protected at all times against
exposure to temperatures that cause
deterioration in quality as well as
contamination, especially tainting.
The permissible range of temperatures during
loading and transport depends on the local
climatic conditions and the duration of the
journey.
Care is needed to avoid excessive shaking,
especially where roads are bad. Egg containers
should be stacked tightly and tied down
securely to minimize movement. Covers should
be used to protect them from the heat of the sun,
rain and extreme cold where applicable.
Delivered to the plant hygienically, safely and
conforming to storage conditions by supplier
vehicles (No special time/ temperature
requirement)
Delivered to the plant hygienically, safely and
conforming to storage conditions by supplier
vehicles (specific temperature range not set)
Delivered to the plant hygienically, safely and
conforming to storage conditions by supplier
vehicles (No special time/ temperature
requirement)
Delivered to the plant hygienically, safely and
conforming to storage conditions by supplier
vehicles (No special time/ temperature
requirement)
Storage
conditions
and shelf life
Item
Margarine
Storage Condition
Store in a refrigerator at 40℉ (4℃)
or below.
Keep them in their original
containers or packaging, in an
airtight container as air is another
contributor to making them go bad.
Egg
Sugar
Wheat Flour
Sweetened
Condensed
Milk
Baking
powder
Stop them from being exposed to
light and high temperatures which
can make them become spoiled and
rancid.
Packing eggs with clean and
odorless rice husks, wheat chaff or
chopped straw in a firm walled
basket or crate greatly decreases
the risk of shell damage.
Decanted from PP bags into
 Polyethylene bags
 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.
Transfer the flour from the original
package into a food-grade
container (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
outand to block odors and flavors
from other foods or products stored
nearby, which could affect the
aroma or taste of the flour.
It can be stored in cans for very
long periods without refrigeration
— often up to a year.
Once opened, it must be kept in the
fridge, and its shelf life is
dramatically reduced to around two
weeks. Always check the
instructions on your can to
maximize freshness.
Store in a cool dark place
Shelf Life
Unopened: 3-4 months in a refrigerator, 6-12
months in a freezer
Opened: 1-2 months in a refrigerator, 6-8
months in a freezer
Room Temp.
Refrigerator
Freezer
1-3 weeks
4-5 weeks
Not
Recommended
Up to 2 years under ideal conditions
Up to one year under ideal conditions
Unopened: 2 years
Opened: In an airtight container in an area that’s
cool, dark and dry having ideal environmental
conditions: temperature between 10C° and 21°
Cwith a relative humidity level at or below
60%.
Storage
conditions
and shelf life
Item
Icing sugar
Storage Condition
Store it properly to prevent it from
catching an odor, losing its taste,
lumping or, worse, getting filled
with bugs.
Unopened package: store
anywhere away from sunlight and
heat.
Shelf Life
By best before date
Opened package: First transfer the
powdered sugar from the
packaging into a Ziplock freezer
bag, seal the bag and make sure to
push out all the air.Then, take the
bag filled with fine sugar and put it
in an empty, airtight jar.
Cocoa Powder
Preparation
and/ or
handling
before use or
processing
NOTE: Never store it in a
refrigerator since there is a lot of
humidity and the whole thing
will get ruined.
Store in a in a cool, dry area with a
tightly sealed lid
Unopened: 3 years
Opened container: 1 year if stored properly
Don’t keep it in the fridge or
freezer unless sealed airtight,
because both types of chill-chests
are relatively humid environments.
Humidity promotes mold, even on
cocoa.
Pineapple
Once trimmed and cut, cover in
Trimmed/ cut and refrigerated: 5 to 7 days
juice in an airtight container,
refrigerate and use within five to
seven days. Let the fruit return to
room temperature before eating to
improve flavor.
Icing sugar:Use directly after opening
Sweetened Condensed Milk:Quality inspection against specifications/ Use directly
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.
Wheat flour:End of theoriginal package unstitched and transferred the content into a food grade plastic
container. Content taken subject to weighing and sifting before use.
Sugar: End of theoriginal package unstitched and transferred the content into a food grade plastic
container. Content taken subject to weighing and direct use
Eggs: Scrub for a while with a soft sponge while washing under cold running water prior to break eggs
open
Baking Powder: Use directly after opening
Cocoa Powder: Use directly after opening
Pineapples: Cutoff the green spiky top .Cut the skin off the sides, as close to the edge of the pineapple
as can be seen (Cut close to the edge exposes a bunch of brown, scraggly dots, called eyes, that needs to
be removed)
Food safety
related
acceptance
criteria or
specifications
of purchased
materials and
ingredients
appropriate
to their
intended use
Margarine: Purchase only from audited / approved suppliers.Inspect at receiving for specific quality
and safety characteristics as per specifications
Icing Sugar: Conformance with the specificationfordry ingredient receiving and inspection
Sweetened Condensed Milk:Purchase only from audited / approved suppliers.Inspect at receiving for
specific quality and safety characteristics as per specifications
Wheat flour:Purchase only from audited / approved suppliers.Inspect at receiving for specific quality
and safety characteristics as per specifications
Sugar:Purchase only from audited / approved suppliers.Inspect at receiving for specific quality and
safety characteristics as per specifications
Eggs: Purchase only from audited / approved suppliers.Inspect at receiving for specific quality and
safety characteristics as per specifications
Baking Powder: Purchase only from audited / approved suppliers.Inspect at receiving for specific
quality and safety characteristics as per specifications
Cocoa Powder: Purchase only from audited / approved suppliers.Inspect at receiving for specific
quality and safety characteristics as per specifications
Pineapples: Purchase from reputed suppliers. Inspect at receiving for specific quality and safety
characteristics as per specifications
Characteristics of End Product: Pineapple Gateaux
Product Name or similar
identification
Composition
Pineapple Gateau
Biological, chemical and physical
characteristics relevant for food
safety
Biological
Wheat flour, Sugar, Eggs, Margarine, Sweetened Condensed Milk, Baking
Powder, Icing Sugar, Cocoa Powder, Pineapple
Organoleptic characteristics:
Physical State
:
Color
Odor
Flavor
:
:
:
Moist, airy, rich chocolate layer topped with
pineapple pieces
Light brown
Typical
Typical
Microbiological characteristics:





Aerobic plate Count
Enterobacteriaceae
Escherichia coli
Escherichia coli O157
Staphylococcus aureus and other
coagulase-positive staphylococci
<104
<102
<3
n.d. in 25g
<20


Clostridium perfringens
Bacillus cereus and other
pathogenic Bacillus spp
Campylobacterspp
Salmonellaspp
Listeria monocytogenes
Fungi (Molds) and Yeasts
<102
<102




n.d. in 25g
n.d. in 25g
n.d. in 25g
≤ 10² UFC/g
NOTE: Food samples are routinely analyzed for APC, E coli
and Salmonella only. If any of them falls out of acceptable
limit, full analysis will be done.
Chemical:
Food additives used, if any shall conform to either of the two standards:
 Regulation (EC) No 1333/2008
 Food (Preservatives) Regulations-2010
Food flavorings used, if any, shall conform to: Regulation (EC)1334/2008
Contaminants, if present, shall be in 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.
Intended Use
Intended shelf life and storage
condition
Packaging
Labeling related to food safety
and/or instructions for handling ,
preparation and usage
Method (s) of distribution and
delivery
Physical:
Free from extraneous foreign materials (metals, glass, stones or any nonedible), adulterants and filthy objects such as hair
General public with no exclusions
Shelf life:Stored at or below 4 0C in a chiller for a period of 7 days at
maximum
In a paper box
For local market, labelling in accordance with SLS 467: Part 1, 2 and 3
Marketed as a Ready-to-eat
Delivered by company-owned food transport vehicles from the main
production plant in Pepiliyana to be distributed to company-managed
network of outlets comprises of 15 outlets spread in and around Colombo
Process Flow Chart for preparation of Pineapple Gateau
2. Receiving of
eggs
1. Receiving of
water
6. Receiving of
Sugar
Quality
Inspection
Quality
Inspection
Quality
Inspection
Dry Store
Dry Store
8. Receiving
of wheat flour
lour
5. Receiving of
baking powder
Quality
Inspection
Quality
Inspection
Dry Store
Dry Store
Solid
Waste
Liquid
Waste
Solid
Waste
Disposal
To the
treatment
Plant
9. Sieving
Dry/Wet
Cleaning
21
19
18. Weighing
3. Sanitizing
Mixer
4. Breaking egg
shells
22. Putting into molds
20
23. Baking for 25 min
(Upper: 2000C, Under: 250 0C)
Whole egg
11
content
24. Unmolding
10. Receiving of
Margarine
Receiving of
Sweetened
condensed milk
25. Cutting off the top layer
26. Layering with pineapples
12 Quality Inspection
Quality
Inspection
11. Melting
28. Whip and put cream to
depositor
13. Receiving of
pineapples
Quality Inspection
Skin removal
27. Topping a 2nd cake layer
29. Frosting with chocolate
icing
7. Receiving of
Cocoa Powder +
Icing sugar
30. Topping with pineapples
31. Blast Chilling
Quality Inspection
32.Chill Storage
Cutting into pieces
33Metal Detecting
Blanching
Osmotic Dehydration
34. Dispatch and Distribution
T≤40C
Chill Storage in Outlets
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 DPD Free Chlorine test kit
2
Receiving eggs
Follow GC-FSMS-SOP-29
(SOP 29:Raw egg inspection)
Follow GC-FSMS-SOP-29
(SOP 29:Raw egg inspection)
3,4
Dry/ Wet cleaning and
sanitizing of eggs
5
Receiving of baking
powder
5
Breaking egg shells
6
Receiving of sugar
7
Receiving of Cocoa
Powder
8
Receiving of wheat
flour
9
Flour sieving
10
Receiving of
Margarine
11
Melting margarine
12
Receiving of
Sweetened condensed
milk
13
Receiving of
pineapples
Optional
Storage of raw
materials (Room
Temp.)
Optional
Storage of raw
materials
(refrigerated
Between 0 and 10
ºC)
Follow GC-FSMS-SOP-34
(SOP-34: Receiving from ISO 22000/ HACCP/ BRC/ FSSC 22000/ SLS
certified suppliers.)
Break the egg shell into two halves in one attempt so as not to break shell
further apart. Carefully observe and remove manually if a broken piece found
Follow GC-FSMS-SOP-34
(SOP-34:Receiving from ISO 22000/ HACCP/ BRC/ FSSC 22000/ SLS
certified suppliers.)
Follow GC-FSMS-SOP-34
(SOP-34:Receiving from ISO 22000/ HACCP/ BRC/ FSSC 22000/ SLS
certified suppliers.)
Follow GC-FSMS-SOP-34
(Receiving from ISO 22000/ HACCP/ BRC/ FSSC 22000/ SLS certified
suppliers.)
Stiff the flour through a strainer with pore size less than 2mm in diameter to
screen all physical hazards
Follow GC-FSMS-SOP-34
(SOP-34:Receiving from ISO 22000/ HACCP/ BRC/ FSSC 22000/ SLS
certified suppliers.)
Microwave, uncovered, on 100% power (high) until butter is melted, about 30
to 45 seconds depending on the amount of butter.
Or n a small pan on the stove placed over low heat, which takes a little
longer.
Allow the margarine to cool slightly before adding it to the cake mix, to
prevent ingredients, such as eggs from being cooked.
Follow GC-FSMS-SOP-34
(SOP-34:Receiving from ISO 22000/ HACCP/ BRC/ FSSC 22000/ SLS
certified suppliers.)
Wash with potable running water having residual chlorine level 0.5 ppm -1.5
ppm and sanitize afterwards with a food grade chlorine or quaternary
ammonium based sanitizer
Pest control plan.
Keep containersclosed and secured in proper place.
Compliance with good personalhygiene practices.
Keep facilities, equipmentand utensils for the operationproperly sanitized.
Perform FIFO (first in, first out) stock rotation
Keep containers securely closedand placed in proper location.
Controlling the integrity of packaging.
Control storage temperature.
Keep containers securely closedand placed in proper location.
Keep facilities, equipmentand utensils for the operationproperly sanitized.
Perform FIFO (first in, first out) stock rotation.
Verifying compliancewith good manufacturingand hygiene practices
Number Step Name
Optional
Procedure of working and controlling
Storage of
packaging/
Storage material
Microbialcontamination
(Pests– Leptospira) as a result of traces of pests and incorrecthygienepractices
Skin removal of
pineapples and cutting
into pieces
Perform the task quickly, hygienically and without interruptions. Compliance
with GHP. Keep facilities, equipment and utensils for the operation properly
sanitized.
Also use trained workers.
Check integrity of the knife after performing the taskand if a deviation in
integrity is detecteddue to a missing part, hold the entire batch while missing
part is located and discard the entire bath if the missing part is not recovered.
16
Blanching
Put pineapple pieces into boiling water and let it stand there for 5 minutes followed
by holding under cold running water until it cool enough to handle
17
Osmotic dehydration
18
Weighing ingredients
19
Beating sugar and eggs
in the dough mixer `
14, 15
20, 21
20. Add melted
margarine and
Sweetened
Condenser Creamer
to the above and
continue mixing
NOTE: Never immerse in cold water as it could result in loss of flavor
Use the blanching solution to prepare the sugar syrup solution
Dip in a solution containing 60 °Brix sugar syrup with 0.2% critic acid and 700 ppm
KMS (Potassium meta bi sulphite) was best for osmotic dehydration for the period of
24 h
Perform the task quickly, hygienically and without interruptions. Compliance with
GHP. Keep facilities, equipment and utensils for the operation properly sanitized.
Always deploy trained workers.
Perform the task quickly, hygienically and without interruptions. Compliance with
GHP. Keep facilities, equipment and utensils for the operation properly sanitized.
Always deploy trained workers.
Perform the task quickly, hygienically and without interruptions. Compliance with
GHP. Keep facilities, equipment and utensils for the operation properly sanitized.
Always deploy trained workers.
22.Add wheat flour
and baking powder
to the above and
continue mixing
22
Putting into molds
23
24
Baking
Cooling and
unmolding
Cutting off the top
layer
25
26
27,30
28
Layering with
pineapple pieces
Topping a 2nd cake
layer
Whip and put cream
to depositor
Perform the task quickly, hygienically and without interruptions. Compliance with
GHP. Keep facilities, equipment and utensils for the operation properly sanitized.
Always deploy trained workers.
Preheat the oven to process temperature and bake between 200 to 250 0C for 25 min
Wait until cool enough to handle. Always wear heat resistant gloves to avoid burn
injuries.
Perform the task quickly, hygienically and without interruptions. Compliance with
GHP. Keep facilities, equipment and utensils for the operation properly sanitized.
Always deploy trained workers.
Perform the task quickly, hygienically and without interruptions. Compliance with
GHP. Keep facilities, equipment and utensils for the operation properly sanitized.
Always deploy trained workers.
Perform the task quickly, hygienically and without interruptions. Compliance with
GHP. Keep facilities, equipment and utensils for the operation properly sanitized.
Always deploy trained workers.
Keep facilities, equipment and utensils for the operation properly sanitized.
Perform the task quickly, hygienically and without interruptions. Compliance
with GHP. Always deploy trained workers.
Number Step Name
29
Optional
Procedure of working and controlling
Frosting with
chocolate icing
Perform the task quickly, hygienically and without interruptions. Compliance with
GHP. Keep facilities, equipment and utensils for the operation properly sanitized.
Always deploy trained workers.
Temporary storage
on the table
(Waiting to be taken
to the blast chiller or
walk-in chiller)
Maintain exposure time to the danger zone to 1h max since the food is made
before being transferred into the blast chiller.
31
Blast chilling
33
Metal detecting
34
Dispatch and
Distribution
35
Unloading
36
Chill Storage in
outlets
If a blast chilling step not followed, the exposure time should be further
reduced taking into account the time taken by the chiller to bring down the
product temperature to 5°C or below.
Chill quickly to < 5°Cwithin 2 h max
Test the metal detector by passing a sample piece of metal through the
detector to ensure that it is operating effectively and able to detect metal
present in the product.
Compliance with good hygiene practices pertinent to transport and delivery of
food:
Adequately clean vehicles between loads
Properly protect food during transportation
Compliance with good hygiene practices pertinent to transport and delivery of
food:
Adequately clean vehicles between loads
Properly protect food during transportation
Compliance with good personal hygiene practices.
Protect the product from direct contact with customers and environmental
contamination
Maintain storage temperature <50C
Chilled foods held at > 50C for <2 hours should either be used immediately,
restored to a temperature of ≤50Cor discarded as appropriate after risk
assessment.
HACCP PLAN-IDENTIFICATION AND CONTROL OF HAZARDS
B- Biological, C- Chemical, P- Physical
No
1
Raw Material/
Food Contact
Material/Process
Step
Receiving Water
Potential Hazard
Presence of pathogens of public health
significance in unacceptable levels:
Campylobacterspp ≥ 500 bacteria
Verocytotoxigenic E. coli (VTEC):
about 10- 100 organisms
Enteric fever salmonellas (Salmonella
typhi and Salmonella paratyphi): 102103 organisms
gastroenteritis salmonellas
(Salmonella enterica) ≥ 106-108
organisms
Species of Shigella: around 102
organisms
Vibrio spp (Vibrio parahaemolyticus,
V. cholera): 103-106organisms
Emerging pathogens:
Helicobacter pylori
Francisellatularensis
Ref: (WHO, Bacteria of potential
health concern, 2013)
Cont’d in the next page
Category
(B/C/P)
Control and preventative Measures
B
Preventative: Use an approved source of
water satisfying the requirements of
bacteriological quality of water given in
SLS 614:2013 (Potable water Standard)
Controlled by sanitation measures and
water treatment processes
Certificate of analysis from water authority
For Tube well water:
Primary disinfection of tube well water
with any of the following disinfectants
(chemical oxidation process): chlorine,
monochlorine, chlorine dioxide, ozone,
UV light and mixed oxidants. Ref:
(WHO, Inactivation (disinfection)
processes, 2004)
Chlorine disinfection:
Water pH: 6.5- 8.5
Disinfectant concentration: 0.5-2mg/L of
residual chlorine level.
Contact time: 30 min for residual
chlorine level of 0.5 ppm
Water temperature: 180C to 370C
UV disinfection:
UV-B and UV-C ranges of the spectrum
(200–310 nm), with maximum
effectiveness around 265 nm.
Hazard Analysis
Probability
Severity
Risk
Level
3
4
12
Justification: Considering the
likelihood of occurrence ofthe
identified biological hazards prior
to application of control measures,
the following hazards could create
high to moderate level of severity:
Note: Water has multiple uses and
can contaminate product at any
stage. Intended use of water is
direct use (washing, cooling after
blanching)
High (Life threatening)
Salmonella typhi
Escherichia coli 0157:H7
Vibrio cholera
Moderate (Severe or chronic)
Campylobacter spp.
Salmonella spp.
Shigella spp.
(FAO, Pathogenic bacteria , 2020)
No
1
Raw Material/
Food Contact
Material/Process
Step
Receiving Water
Potential Hazard
Above identified pathogens applies
here, as well
Presence of chemical contaminants at
levels over EPA’s safety standards.
E.g. Disinfection byproducts, solvents
and pesticides, radionuclides (such as
radium), and minerals (such as arsenic).
Ref: (Common Waterborne
Contaminants)
Category
(B/C/P)
B
C
Control and preventative Measures
For Municipal water:
Residual chlorine level 0.5- 2 ppm
Preventative: Initially and periodically
check water for chemical requirements;
Table 2 of SLS 614, toxic substances;
Table 3 of SLS 614, and verify that water
source meets minimum requirements.
Control measures :
In the event of a deviation from expected
results the following methods may apply
1. Reverse osmosis systems
(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.
Cont’d in the next page
3. Water softners
(They can be used to remove iron and
manganese, heavy metals, some
radioactivity, nitrates, arsenic, chromium,
selenium, and sulfate.)
Ref: (CDC, A Guide to Drinking Water
Treatment Technologies for Household
Use, 2014)
Hazard Analysis
Probability
Severity
3
4
Risk
Level
12
3
1
3
NOTE: The effect due to presence
of chemical contaminants in water
at levels over EPA’s safety
standards is not acute but chronic
meaning adverse effects occur if
consumed over the cause of many
years.
No
1
Raw Material/
Food Contact
Material/Process
Step
Receiving Water
Potential Hazard
Category
(B/C/P)
Cont’d from the next page
C
Presence of sediments and particulates
(pipe
materials, pipe liner materials, sloughed
biofilms or iron and manganese films)
P
Control and preventative Measures
Preventative: Adhere to the
requirements of table 1 of SLS 614: 2013
when choosing the water source.
Hazard Analysis
Probability
Severity
3
1
Risk
Level
3
3
2
6
3
2
6
And, the same should be compliant with
COUNCIL DIRECTIVE 98/83/EC of 3
November 1998 on the quality of water
intended for human consumption.
Ref: (Understanding the hazards and
threats )
Control: Sedimentation andfiltration
Sedimentation by holding the raw water
in ponds or tanks.
Filtration: Cartridge filtration, rapid
sand filtration, multimedia sand filtration,
and up-flow filtration.
2
Receiving eggs
Ref: (FAO, Chapter 2 - WATER
QUALITY MONITORING,
STANDARDS AND TREATMENT)
Preventative: Purchase eggs from
approved/reputed/HACCP, ISO 22000
FSMS certified suppliers only.
And/or:
Use only clean eggs with unbroken shells
and discard any eggs that have become
unclean, cracked, broken or leaking.
Presence of egg interior being
contaminated with Salmonella
enteritidis at infectious dose of
>105 organisms
B
C:No common hazards identified
C
-
-
-
-
P :No common hazards identified
P
-
-
-
-
No
2
3
Raw Material/
Food Contact
Material/Process
Step
Storage of eggs
Dry cleaning/wet
cleaning and
sanitizing eggs
Potential Hazard
Category
(B/C/P)
Control and preventative Measures
Refrigerated storage (5-150 C)
Label expired date.
Hazard Analysis
Probability
Severity
3
2
Risk
Level
6
-
-
-
Growth of pathogenic bacteria:
Salmonella enteritidis
B
Unidentified
C
Eggshell (cracked/broken eggs)
P
Inspection of incoming eggs
3
2
6
Survival of pathogenic Salmonella
enteritidiswhich may present on
contaminated egg shells due to
inadequate cleaning / sanitization of
eggs cause egg interior to be
contaminated with during subsequent
storage and preparation.
B
Preventative: Dry clean eggs with a sand
sponge or a loofah.
Or wet clean if dry cleaning is not
enough before storing.
3
3
9
-
Note: If wet cleaning is done they require
refrigeration as the natural microbial
barrier bloom is removed.
C: No common hazards identified
C
For wet cleaning, wash eggs dipping
them in warm water at 32.2 - 49°C in
which a food grade liquid detergent is
dissolved until all visible soil is removed.
Rinse with warm running water at same
temperature and sanitize by dipping in a
solution of ½ of white distilled vinegar
and 2 cups of water for about 10 min.
Or, in unscented bleach solution of about
20-500 ppm for contact time of about 1
min and wash it off with potable running
water.
Dry immediately afterwards.
-
P: No common hazards identified
P
-
Justification: This step is
specifically designed to eliminate
or reduce the likely occurrence of
the identified hazard Salmonella
enteritidisto acceptable level and it
prevents egg interior from
contamination.
There is no need of having critical
limits, instead, acceptable criteria
is enough to control the hazard.
Failing to meet acceptable criteria
doesn’t result in a serious risk of a
food borne illness given that
subsequent cooking stages will
eliminate or reduce the hazard to
acceptable limits.
As such, this step is deemed as an
OPRP.
-
-
-
-
-
-
No
4
5
6
Raw Material/
Food Contact
Material/Process
Step
Breaking egg
shells
Receiving of
baking powder
Receiving of
sugar
Potential Hazard
Category
(B/C/P)
Control and preventative Measures
Contamination of the egg content during
breaking with bacterial pathogens of
public health significance that may
present on the egg shell as a result of
eggs not being properly cleaned/
sanitized to remove traces of fecal
matter eggs likely to have come into
contact with during laying.
Chemical contamination of egg content
from residues of cleaning / sanitizing
chemicals left on the egg shell after eggs
being cleaned and sanitized as in the step
3
Physical contamination of egg content
from broken pieces of egg shells and
foreign matter
e.g. feathers, dirt and filth
B: No common hazards identified
B
Hazard Analysis
Probability
Severity
Risk
Level
Controlled by the above step:
Dry cleaning/wet cleaning and sanitizing
eggs
2
3
6
C
Preventive: Use food grade cleaning and
sanitizing chemicals only.
Rinse with potable water after sanitizing
to remove traces of sanitizing agents
2
3
6
P
4
2
8
B
Preventive: Break the egg shell into two
halves in one attempt so as not to break
shell further apart. Carefully observe and
remove manually if a broken piece found
-
-
-
-
C: No common hazards identified
C
-
-
-
-
P: No common hazards identified
P
-
-
-
-
No potential food safety hazards
identified
B
-
-
-
Chemical contamination of sugar during
storage from cleaning and sanitizing
agents, pest excretions, etc
C
Pathogenic bacterial survival, growth and
toxin production is unlikely at extremely
low water activity present in sugar, which
retards microbial activity under any given
condition.
Preventive:
Establish, implement, monitor and verify
good storage practices
e.g. Store cleaning and sanitizing
chemicals separately in a cupboard or
room with restricted access
Cont’d to the next page
3
2
6
No
6
Raw Material/
Food Contact
Material/Process
Step
Receiving of
sugar
Potential Hazard
Category
(B/C/P)
Control and preventative Measures
Hazard Analysis
Probability
Cont’d from the previous page
Severity Risk
Level
3
2
6
3
2
6
Pest control activities: Pest proof design,
chemical free control methods, such as
rat glue boards
Chemical contamination of sugar during
storage from cleaning and sanitizing
agents, pest excretions, etc
C
Preventive:
Establish, implement, monitor and verify
good storage practices
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
7
Receiving of
Cocoa Powder
Physical contamination of sugar during
storage from extraneous matter
P
Preventive:
Establish, implement, monitor and verify
good storage practices
e.g. Glass and hard plastic policy
3
2
6
Presence of non-pathogenic spoilage
microflora in the genera Micrococcus
and Bacillus
Presence of salmonella contamination
above 0.005 CFU/g
Presence
Presence of Bacillus spore, the most
predominant microbiota in cocoa powder
B
Preventative: Nopreventive measures
available at this stage
Preventive measures exist only at
primary producer and processer level.
\
Control Measures:
Purchase from approved/ reputed
suppliers only
Or
Request lab results from supplier
(Certificate of analysis/ COA)
3
1
3
3
2
6
3
2
6
B
B
No
8
Raw Material/
Food Contact
Material/Process
Step
Receiving of wheat
Flour
Potential Hazard
Presence of mold and their
corresponding fungus species such as
Aspergillus spp., Penicillum spp.,
Fusarium spp. and Alternaria spp.
Category
(B/C/P)
Control and preventative Measures
B
Preventive:
Applicable at primary producer level and
during prolonged storage after receiving
flour.
Follow Good Storage Practices(GSP):
RH of the environment should be below
62 % and the material water content
should be below 10 %.
Store at a low oxygen environment: 50%
CO2 and 20% O2
Keep Water Activity at or below 0.80
and CO2 level over 30 %
Purchase from approved suppliers only.
Presence of dangerous toxic metabolites
called mycotoxins such as aflatoxin,
ochratoxin, zearalenone, patulin,
deoxynivalenol, trichothecene and
fumonisin.
Contd. Presence of mold and their
corresponding fungus
B
Presence of Salmonella spp.,
Escherichia coli, Bacillus cereus at an
infectious dose: 1 log cfu/g
B
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
Control:
Purchase from approved/reputed/HACCP
or ISO 22000 FSMS certified suppliers
only.
Application of heat treatment to reach
core temperature of 750C or equivalent,
e.g. 700C for 2 minutes to kill all viable
cells.
Hazard Analysis
Probability
Severity
Risk
Level
3
1
3
3
1
3
2
2
4
No
8
Raw Material/
Food Contact
Material/Process
Step
Potential Hazard
Receiving of wheat
Flour
Presence of pests such as Sitophilus
granaries L. (weevil), S. oryzae L. (rice
louse),Trogodermagranarium (Khapra
beetle), Rhizoperthadominica F. (crop
hump beetle), 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 the
businesses for insects and rodents
control, residues of hygiene and
sanitation products.
Presence of extraneous matter such as
metal fragments -measures two
millimeters or more in size-detached
from blades in the milling process
Category
(B/C/P)
Control and preventative Measures
Hazard Analysis
Probability
B
Control:
Purchase from Approved/Reputed/ISO
22000FSMS/HACCP certified suppliers
only
2
Severity Risk
Level
3
6
Keep the oxygen rate of the atmosphere
inside the storage lower than 2 % and/or
the carbon dioxide rate is higher than 12
%, to minimize the insect and mice
activity.
C
P
Preventative: No preventative measures
applicable at receiving
Control: Purchase from Approved
suppliers only
Preventative: No preventative measures
applicable at receiving
2
3
6
2
3
6
3`
3
9
Control: Sieve through a strainer having
mesh size smaller than 2mm
Controlled as SOP
9
Flour sieving
10
Receiving of
Margarine
B: No common hazards identified
C: No common hazards identified
Not screening extraneous matter and
insect parts
Presence of S. aureus, their survival and
growth to the infective-dose level
NOTE: Temperature, pH and Aw
condition required to support the
growth of above species
Temp.
pH
Aw
7-45 0C
4.2-9.3
0.86 or above
B
C
P
B
Sieving with a sifter with mesh size 2 by
2 mm
Preventive: Purchase from Approved/
Certified suppliers only.
Compliance with GHP and GSP to
reduce the risk of cross-contamination
Maintain recommended cold-holding
temperatures to have a bactericidal effect.
Control: Heat, if possible to 75 0C or
above for 15 sec to create a lethal effect
for vegetative cells.
3
2
6
Justification: Whether from
human hands, contaminated
equipment, or the environment the
level of bacterial contamination in
table spreads is likely to be very
low.
No
10
Raw Material/
Food Contact
Material/Process
Step
Receiving of
Margarine
Potential Hazard
Presence of Listeria monocytogens,
Escherchia coli, Salmonella spp and
their survival
(Given the microbial growth
characteristics as in the table below, the
potential for growth in the table spreads
is limited to S.aureus,but the potential
for survival is possible for all the
organisms. )
NOTE: Temperature, pH and Aw
condition required to support the
growth of above species
Temp.
pH
Aw
Listeria monocytogens
2-450C
4.8 – 9.6 0.95 or above
Escherchia coli
2.5-450C 4.6 – 9.5 0.935 or above
Salmonella spp
6.5-450C 4.5- NA 0.95 or above
Presence, survival and growth of
spoilage bacteria causing to become
rancid and spoiled.
Mold growth
Category
(B/C/P)
B
Control and preventative Measures
Preventive:
 Purchase from Approved/ Certified
suppliers only.
 Compliance with GHP and GSP to
reduce the risk of cross-contamination
 Maintain recommended cold-holding
temperatures to have a bactericidal
effect.
Control: Heat, if possible to 75 0C or
above for 15 sec to create a lethal effect
for vegetative cells.
Hazard Analysis
Probability
Severity
Risk
Level
3
2
6
Justification: Whether from
human hands, contaminated
equipment, or the environment the
level of bacterial contamination in
table spreads is likely to be very
low.
The inability of these table spreads
to support to support growth of
low level of each pathogenic
organism indicates a low risk of
food borne illness from incidental
contamination.
Food Code (FDA, 1999) defined
margarine as not a potentially
hazardous food
Ref: (Guentert & Linton, 2003)
B
B
Preventive:
 Purchase from Approved/ Certified
suppliers only.
 Compliance with GHP and GSP to
reduce the risk of cross-contamination
 Maintain recommended cold-holding
temperatures to have a bactericidal
effect.
Preventive:
 Purchase from Approved/ Certified
suppliers only.
 Prevent exposure to water and
moisture
3
1
3
3
1
3
No
10
Raw Material/
Food Contact
Material/Process
Step
Receiving of
Margarine
Potential Hazard
Presence of mycotoxins above
maximum safe limit:
Category
(B/C/P)
C
Zearalenone> 200 µg/kg
Aflatoxins B1> 8 μg/kg
Aflatoxins (Sum of B1, B2, G1 and G2)>
15μg/kg
Fumonisins (Sum of B1 and B2)> 200
μg/kg
12
Melting margarine
Receiving of
Sweetened
condensed milk
Preventive:
 Purchase from Approved/ Certified
suppliers only.
Hazard Analysis
Probability
Severity
Risk
Level
3
1
3
Control:
Request suppliers for a test report of
mycotoxin level per each batchduring
quality inspection to verify that lot
confirm to set limits of each type of
mycotoxin likely to present on
Margarine.
And, periodically send randomly drawn
samples for an accredited laboratory to
be analyzed for mycotoxins
Ref: COMMISSION REGULATION
(EC) No 1881/2006
11
Control and preventative Measures
No common hazards identified
P
Irradiation of ingredients used to
manufacture margarine to control mold
and mycotoxin (applies to primary
producers, processers and manufacturers
only)
-
No common hazards identified
B
No common hazards identified
Justification: No acute effect.
Only chronic effect due to
recurrent and prolonged exposure
above the safe limit: carcinogenic
effect
-
-
-
-
-
-
-
C
-
-
-
-
No common hazards identified
P
-
-
-
-
No pathogenic microbial growth
identified as the low water activity
(~0.83) or, rather, the high sugar
content prohibits growth of most but
not all microorganisms.
B
-
-
-
Bacterial spores cannot germinate in
sweetened condensed milk.
-
No
12
Raw Material/
Food Contact
Material/Process
Step
Receiving of
Sweetened
condensed milk
Potential Hazard
Deterioration due to the presence
ofosmophilic yeasts, most of which
belong to the genus Torulopsis .
Category
(B/C/P)
B
(The yeasts often cause gas formation
(bulging cans), a fruity flavor, and
coagulation of protein. Coagulation
may result from ethanol production. As
a result, the product becomes
unacceptable.)
Presence of residues of antimicrobial
agents: beta-lactams (e.g, penicillins
and cephalosporins), tetracyclines (e.g.,
Oxytetracycline, tetracycline and
chlortetracycline), amino glycosides
(e.g., streptomycine, neomycin and
gentamycin), macrolides (e.g.,
erythromycin) and sulfanomides (e.g.,
sulfamethazines)
MRLs of some veterinary drugs in milk
according to EU regulations:
Benzylpenicillin : 4 µg/kg
Tetracycline
:100- 200 µg/kg
Oxyteracycline
:100 µg/kg
Chlorotetracycline : 100 µg/kg
Trimethoprim
: 50 µg/kg
Sulphonamides : 100 µg/kg
C
Control and preventative Measures
Preventive: Purchase from Approved/
Certified suppliers only.
Control:
Keep as minimum air space as possible in
cans
 Seal the product in vacuum of 51cm,
below this mold will not grow.
 Store the product at 15°C or below.
 Inversion of condensed milk tins at
regular intervals.
Preventative: Purchase from
approved/reputable/HACCP or ISO
22000Certified suppliers only.
Check the supplier’s test reports whether
the product conforms to statutory and
regulatory requirements.
Control: Request suppliers for a test
report of antimicrobial agent level per
each batchduring quality inspection to
verify that lot confirm to set limits of
each type of antibiotic likely to present
on fresh milk.
And, periodically check randomly drawn
samples by an accredited laboratory for
the presence of antimicrobial agents.
Return to the supplier if test results found
unsatisfactory and suspend the supplier
until corrective actions taken proven
effective to regain compliance.
Hazard Analysis
Probability
Severity
Risk
Level
3
1
3
Justification: No acute effect.
Only chronic effect due to
recurrent and prolonged exposure
above the safe limit: carcinogenic
effect
3
1
3
No
12
Raw Material/
Food Contact
Material/Process
Step
Receiving of
Sweetened
condensed milk
Potential Hazard
Presence of residues of parasitic drugs
above MRLs:
Category
(B/C/P)
Control and preventative Measures
C
Preventative: Purchase from
approved/reputable/HACCP or ISO
22000Certified suppliers only.
Control: Request suppliers for a test
report of parasitic drugs level per each
batchduring quality inspection to verify
that lot confirm to set limits of each type
of parasitic drug likely to present on
fresh milk.
E.g. A provisional maximumresidue
limit for total albendazole residues of
100 ng ml-1 established within the
European Union (Fletouris et al., 1997).
Metabolites of Albendazole have a
mutagenic effect
Presence of residues of pesticides and
insecticides above MRLs:
HCB > 0.0037 mg kg-1of fat
Aldrindieldrin> 0.2 ng g-1
Dieldrin> 0.0039- 0.0068 mg kg-1of fat
HCH> 0.00865 mg kg-1of fat
DDT> 0.0021 mg kg-1of fat
C
And, periodically check randomly drawn
samples by an accredited laboratory for
the presence of parasitic drugs.
Return to the supplier if test results found
unsatisfactory and suspend the supplier
until corrective actions taken proven
effective to regain compliance.
Preventative: Purchase from
approved/reputable/HACCP or ISO
22000Certified suppliers only.
Control: Request suppliers for a test
report of pesticide residues per each
batchduring quality inspection to verify
that lot confirm to set limits of each type
of pesticide drug likely to present on
fresh milk.
And, periodically check randomly drawn
samples by an accredited laboratory for
the presence of pesticides.
Return to the supplier if test results found
unsatisfactory and suspend the supplier
until corrective actions taken proven
effective to regain compliance.
Hazard Analysis
Probability
Severity
Risk
Level
3
1
3
3
1
3
No
12
Raw Material/
Food Contact
Material/Process
Step
Receiving of
Sweetened
condensed milk
Potential Hazard
Presence of heavy metals above MRLs:
Category
(B/C/P)
C
Pb> 1.7 mg kg-1
Cd> 0.07 mg kg-1
Cu > 43.2 mg kg-1
Zn > 3177 mg kg-1
Control and preventative Measures
Preventative: Purchase from
approved/reputable/HACCP or ISO
22000Certified suppliers only.
Hazard Analysis
Probability
Severity
Risk
Level
3
1
3
-
-
-
3
2
6
Control: Request suppliers for a test
report of pesticide residues per each
batchduring quality inspection to verify
that lot confirm to set limits of each type
of pesticide drug likely to present on
fresh milk.
And, periodically check randomly drawn
samples by an accredited laboratory for
the presence of pesticides.
13
Receiving of
pineapples
No likely physical contaminants
identified
Presence of pathogens of public health
importance on the skin
E.g. Listeria monocytogenes
Escherichia coli O157:H7
P
B
Return to the supplier if test results found
unsatisfactory and suspend the supplier
until corrective actions taken proven
effective to regain compliance.
Preventive:
Purchase from approved /audited
suppliers whose facilities, premises and
practices satisfies GHPs, GSPs and
GTPs;
And, whose products are originated from
growers (primary producers) following
GAPs and GHPs
Control: Wash with potable running
water having residual chlorine level 0.5
ppm -1.5 ppm and sanitize afterwards
with a food grade chlorine or quaternary
ammonium based sanitizer
Presence of pathogens on the outer
skin doesn’t affect interior parts
which are consumed unless cross
infection of the internal parts
occurs through the skin during
cutting step
No
13
Raw Material/
Food Contact
Material/Process
Step
Potential Hazard
Category
(B/C/P)
Receiving of
pineapples
Cont’d
Optio
nal
Optio
nal
Optio
nal
Storage of raw
materials (Room
Temp.)
Storage of raw
materials
(refrigerated
Between 0 and 10
ºC)
Storage of
packaging/
Storage material
Microbial Contamination(Salmonella,
Staphylococcus aureus and Escherichia
coli; Pests– Leptospira) as a result of
Traces of pests and incorrect hygiene
practices
B
Unidentified
C
Contamination by foreign objects (hair
,decorations ,pieces of packaging,
insects) as a result of incorrect hygiene
practices
P
Microbial contamination and
multiplication as a result of inadequate
Storage temperature
B
Microbial contamination
(Pests– Leptospira) as a result of traces
of pests and incorrect hygiene practices
B
Control and preventative Measures
Hazard Analysis
Probability Severity
Risk
Level
Temperature of sanitizer solution should be
between 25 - 35 0C
Res. Chlorine level: 25 ppm – 200 ppm
Contact time ≥ 1 min
Pest control plan. Keep containers closed
and secured in proper place.
Compliance with good personal hygiene
practices.
Keep facilities, equipment and utensils for
the operation properly sanitized. Perform
FIFO (first in, first out) stock rotation.
-
3
2
6
3
2
6
-
-
-
Keep containers securely closed and placed
in proper location.
Controlling the integrity of packaging.
Compliance with good personal hygiene
practices
Control storage temperature.
Keep containers securely closed and placed
in proper location.
Keep facilities, equipment and utensils for
the operation properly sanitized. Perform
FIFO (first in, first out) stock rotation.
3
2
6
3
2
6
3
2
6
Control: Verifying compliance with good
manufacturing and hygiene practices
Keep containers properly closed and secured
in proper place, protected from
contamination.
Maintain facilities and equipment for the
operation properly sanitized. Pest Control
Plan.
Control: Verifying compliance with good
manufacturing and hygiene practices
No
Optio
nal
Raw Material/
Food Contact
Material/Process
Step
Storage of
packaging/
Storage material
14, 15 Skin removal of
pineapples and
cutting into pieces
Potential Hazard
Category
(B/C/P)
Control and preventative Measures
Unidentified
C
-
-
-
-
Unidentified
P
-
-
-
-
Pathogenic organisms likely to present
on the skin being transferred into the
interior parts through the knife/ cross
contamination
B
3
2
6
Bacterial contamination of the interior
parts of pineapple with harmful
pathogens likely to present on knife
surface
B
Cross-contamination of the edible parts
with residues of cleaning and sanitizing
chemicals from equipment and utensils
such as knife and cutting boards used
for skin removal.
Physical contamination of pineapples
with metal fragments likely to detach
from metal blade
C
Probability Severity
Always proceed to skin removal only after
being properly washed and sanitized
Proper adherence to the cleaning and
sanitizing conditions
P
Hazard Analysis
Perform the task quickly, hygienically and
without interruptions. Compliance with
GHP. Keep facilities, equipment and
utensils for the operation properly sanitized.
Also use trained workers.
Preventive: Use food grade cleaning and
sanitizing chemicals
Control: Wash knife with potable water
before use
Preventative: Use of good quality cutting
instruments, trained workers.
Control: Checking integrity of the knife
after performing the task and if a deviation
in integrity is detected due to a missing part,
hold the entire batch while missing part is
located and discard the entire bath if the
missing part is not recovered.
Risk
Level
Justification: pH of pineapples
ranging from 4.3 to 4.36 doesn’t
permit pathogenic microbial
growth and toxin production
and germination of spores.
However, they can survive and
remain dormant for some time,
during which time can infect a
person if pathogenic bacterial
count is at or above infectivedose level.
3
2
6
3
2
6
3
4
12
No
16
17
18
Raw Material/
Food Contact
Material/Process
Step
Blanching
Osmotic
dehydration
Weighing
ingredients
Potential Hazard
Category
(B/C/P)
Control and preventative Measures
Unidentified
B
-
-
-
Unidentified
Unidentified
No likely biological hazards identified
C
P
B
-
-
-
-
Introduction of chemical hazards from
additives used.
E.g. Environmental pollutants - such as
industrial chemicals, pesticides and
many toxic elements, residues of agrochemicals, veterinary drugs and heavy
metal organic or inorganic.
No likely physical contaminants
identified
Microbial contamination as a result of
incorrect hygiene practices
(Salmonella, Staphylococcus aureus
and Escherichia coli)
C
Use permitted preservatives complying with
the requirements of Food (Preservatives)
Regulation, 2019 as given under FOOD
ACT, No. 26 OF 1980
2
1
2
-
-
-
3
2
6
3
2
6
3
3
9
-
-
-
Contamination by foreign objects (hair,
decorations, pieces of packaging, stones
– salt)
Detergent residue as a result of
incorrect hygiene practices
19
Beating sugar and
eggs in the dough
mixer
Introduction of pathogenic bacteria of
public health concern from the use of
equipment and utensils with
contaminated food contact surfaces
E.g. Dough mixer
Unidentified
P
B
P
C
B
C
Hazard Analysis
Probability Severity
Or
Regulation (EC) No 1333/2008
Preventative: Perform the task quickly,
hygienically and without interruptions.
Compliance with good personal hygiene
practices. Keep facilities, equipment and
utensils for the operation properly sanitized.
Risk
Level
Control: Verifying compliance with good
hygiene practices,
Compliance with good personal hygiene
practices. Visual inspection of salt
Keep the sites, equipment and fixtures for
the operation properly sanitized.
Verifying compliance with good hygiene
practices
Keep facilities, equipment and utensils for
the operation properly sanitized.
Perform the task quickly, hygienically and
without interruptions. Compliance with
GHP. Always deploy trained workers.
-
No
Raw Material/
Food Contact
Material/Process
Step
20, 21 20. Add melted
margarine and
Sweetened
Condenser
Creamer to the
above and
continue mixing
Potential Hazard
Introduction of metal fragments from
the rotating blades of the Dough Mixer.
Category
(B/C/P)
P
Putting into molds
Preventative: Adhere to SOPs established
on Operation/maintenance/Repair of Dough
Mixer.
Hazard Analysis
Probability
Severity
Risk
Level
3
4
12
3
3
9
-
-
-
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.
22.Add wheat
flour and baking
powder to the
above and
continue mixing
22
Control and preventative Measures
NOTE: Metal detector must detect 2.0 mm
ferrous, 3.0 mm non-ferrous, and 3.5 mm
stainless steel
Microbial contamination as a result of
incorrect hygiene practices:
(Salmonella, Staphylococcu saureus
and Escherichia coli)
Chemical contamination with residues
of cleaning and sanitizing chemicals
from molds
Contamination by foreign objects (hair,
And sand) as a result of incorrect
hygiene practices
B
C
P
The existence of pieces of metal can be fatal
to the health of consumer.
Preventive: Keep facilities, equipment and
utensils for the operation properly sanitized.
Perform the task quickly, hygienically and
without interruptions. Compliance with GHP.
Always deploy trained workers.
Control: Verifying compliance with
good hygiene practices
Preventive: Use food grade cleaning/
sanitizing chemicals only
Control: Wash molds with potable water
before use
Preventive: Compliance with good personal
hygiene practices
Control: Verifying compliance with good
hygiene practices
No
23
Raw Material/
Food Contact
Material/Process
Step
Baking
Potential Hazard
Microbial survival and multiplication:
(Salmonella, Yersinia,,
Shigella Norovirus,Staphylococcus
aureus, Listeria monocytogenes
Escherichia coli O157:H7, Micrococcus
and Bacillus)
Category
(B/C/P)
B
Control and preventative Measures
Compliance with good personal hygiene
practices.
Given the time-temperature combinations to
achieve 6 log reduction of different types of
pathogenic bacterial strains as mentioned
below, meet binomial time/ temperature set
(10–12 minutes at 200–220ºC) for the
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)
Hazard Analysis
Probability
Severity
Risk
Level
3
3
9
No
23
24
Raw Material/
Food Contact
Material/Process
Step
Baking
Cooling and
unmolding
Unidentified
Unidentified
25
Cutting off the top
layer
Potential Hazard
Category
(B/C/P)
Control and preventative Measures
Unidentified
C
Unidentified
P
Biological: Microbia lcontamination
(Staphylococcus aureus) as a result if
incorrect hygiene practices
C
B
P
Introduction of pathogenic organisums
resulting from human hand contact:
Fecal viruses: Hepatitis A/E virus
Norovirus and noro-like viruses
Fecal Bacteria: Shigella, Salmonella,
L.monocytogens, E coli STEC
Fecal worms: A. lumbricoides
Protozoic fecal parasites; C.parvum,
E.hystolitica, C. cayatenensis,
Styphylococcus aureus
Cross contamination with pathogenic
microbes from contaminated
surfaces(Salmonella, Staphylococcus
aureus and Escherichia coli)
B
Hazard Analysis
Probability
Severity
Risk
Level
-
-
-
-
-
-
-
-
3
2
6
-
-
-
-
3
4
Compliance with good personal hygiene
practices. Keep facilities, equipment and
utensils for the operation properly sanitized
Preventive: Compliance with Good
Personnel Hygiene Practices, Maintain
facilities and equipment for the operation
properly sanitized.
Wear food grade gloves
Control: Controlled by proper
implementation of cleaning and sanitizing
programs and verification programs.
E.g. Conduct swab test on hands using an
approved technology such as Plate Count
Method, SWAB test kit or ATP monitoring
system and the detection of the presence of
food residues (generally protein) to verify
hygienic quality of hands after performing
hand washing.
Use above techniques to analyze the hygienic
quality of other food contact surfaces
involved in the mixing operation to
determine its compliance with expected
requirements
Cont’d in the next page
12
Potential Hazard
25
Cutting off the top
layer
Layering with
pineapple pieces
Control and preventative Measures
Hazard Analysis
Probability
Severity
Risk
Level
3
2
6
2
2
4
3
2
6
3
2
6
Using Plate Count Technique:
APC
< 50
Coliform SPP.
None
Escherichia coli
None
Listeria monocytogenes
None
Detergent residue as a result of incorrect
hygiene practices
C
Introduction of metal fragments from
knives.
P
Contamination by foreign objects (hair,
And sand) as a result of incorrect
hygiene practices
26
Category
(B/C/P)
Microbial contamination as a result of
incorrect hygiene practices:
(Salmonella, Staphylococcus aureus
and Escherichia coli)
P
B
Using ATP Monitoring system:
Any score of 10 RLU or less is a Pass.
Scores from 11 to 30 RLU are a Caution.
Any score greater than 30 RLU is a Fail.
Keep the sites, equipment and fixtures for the
operation properly sanitized.
Verifying compliance with good hygiene
practices
Preventative: Use of good quality cutting
instruments, trained workers.
Control: Checking integrity of the knife
after performing the task and if a deviation in
integrity is detected due to a missing part,
hold the entire batch while missing part is
located and discard the entire bath if the
missing not recovered.
Preventive: Compliance with good personal
hygiene practices
Control: Verifying compliance with good
hygiene practices
Preventive: Keep facilities, equipment and
utensils for the operation properly sanitized.
Perform the task quickly, hygienically and
without interruptions. Compliance with GHP.
Always deploy trained workers.
Control: Verifying compliance with
good hygiene practices
Osmotic-dehydrated pineapples
has low water activity which
cannot support pathogenic
microbial survival and growth
No
26
27
Raw Material/
Food Contact
Material/Process
Step
Layering with
pineapple pieces
Topping a 2nd cake
layer
Potential Hazard
Category
(B/C/P)
Control and preventative Measures
Detergent residue as a result of incorrect
hygiene practices
C
No potential physical hazards identified.
P
Introduction of pathogenic organisums
resulting from human hand contact:
Fecal viruses: Hepatitis A/E virus
Norovirus and noro-like viruses
B
Fecal Bacteria: Shigella, Salmonella,
L.monocytogens, E coli STEC
Fecal worms: A. lumbricoides
Protozoic fecal parasites; C.parvum,
E.hystolitica, C. cayatenensis,
Styphylococcus aureus
Cross contamination with pathogenic
microbes from contaminated
surfaces(Salmonella, Staphylococcus
aureus and Escherichia coli)
Hazard Analysis
Probability
Severity
Risk
Level
Keep the sites, equipment and fixtures for the
operation properly sanitized.
Verifying compliance with good hygiene
practices
-
3
2
6
-
-
-
Preventive:
Compliance
with
Good
Personnel Hygiene Practices, Maintain
facilities and equipment for the operation
properly sanitized.
Wear food grade disposable gloves
3
3
9
Control: Verifying compliance with good
hygiene practices
E.g. Conduct swab test on hands using an
approved technology such as Plate Count
Method, SWAB test kit or ATP monitoring
system and the detection of the presence of
food residues (generally protein) to verify
hygienic quality of hands after performing
hand washing.
Use above techniques to analyze the hygienic
quality of other food contact surfaces
involved in the mixing operation to
determine its compliance with expected
requirements
Using Plate Count Technique:
APC
< 50
Coliform SPP.
None
Escherichia coli
None
Listeria monocytogenes
None
Using ATP Monitoring system:
Any score of 10 RLU or less is a Pass.
Scores from 11 to 30 RLU are a Caution.
Any score greater than 30 RLU is a Fail.
No
27,30
Raw Material/
Food Contact
Material/Process
Step
Topping a 2nd cake
layer
Potential Hazard
Detergent residue as a result of
incorrect hygiene practices
Contamination by foreign objects (hair,
And sand) as a result of incorrect
hygiene practices
28
Whip and put
cream to depositor
Microbial cross-contamination as a
result of incorrect hygiene practices:
(Salmonella,Staphylococcus aureus
and Escherichia coli, Listeria)
Category
(B/C/P)
C
P
B
Control and preventative Measures
Hazard Analysis
Probability
Preventive: Use food grade
cleaning/sanitizing chemicals only
Control: Keep the sites, equipment and
fixtures for the operation properly
sanitized.
Verifying compliance with good hygiene
practices
Preventive: Compliance with good
personal hygiene practices
Control: Verifying compliance with good
hygiene practices
Preventive: Keep facilities, equipment and
utensils for the operation properly
sanitized.
Perform the task quickly, hygienically and
without interruptions. Compliance with
GHP. Always deploy trained workers.
Severity
Risk
Level
3
2
6
3
2
6
3
3
9
3
3
9
Hygiene training
29
Frosting with
chocolate icing
Contamination of spoilage and
pathogenic microbes from the air,
worker, equipment and utensils and
their multiplication
B
Control: Verifying compliance with
good hygiene practices
Preventive: Keep facilities, equipment and
utensils for the operation properly
sanitized.
Perform the task quickly, hygienically and
without interruptions. Compliance with
GHP. Always deploy trained workers.
Hygiene training
Control: Verifying compliance with
good hygiene practices
No
Optio
nal
Raw Material/
Food Contact
Material/Process
Step
Temporary storage
on the table
(Waiting to be
taken to the blast
chiller or walk-in
chiller)
Potential Hazard
Germination of bacterial spores of
pathogenic species and /or
multiplication of any number of
surviving pathogenic viable cell count
to unacceptable level as a result of the
food being exposed to the cumulative
effect of room temperature and
surrounding heat of the machinery
closer to the optimum microbial growth
temperature within the danger zone for
a period of 2 h or above.
(Salmonella,Staphylococcus aureus
and Escherichia coli, Listeria)
Germination of bacterial spores of
spoilage specie sand /or multiplication
of any number of surviving viable cell
count to unacceptable level which can
cause to undergo noticeable level of
deterioration as a result of the food
being exposed to the cumulative effect
of room temperature and surrounding
heat of the machinery closer to the
optimum microbial growth temperature
within the danger zone for a period of 2
h or above.
Unidentified
Contamination by foreign objects (hair,
And sand) as a result of incorrect
hygiene practices
Category
(B/C/P)
Control and preventative Measures
B
Maintain exposure time to the danger zone
to 1h max since the food is made before
being transferred into the blast chiller.
Hazard Analysis
Probability Severity
Risk
Level
4
3
12
4
2
`8
If a blast chilling step not followed, the
exposure time should be further reduced
taking into account the time taken by the
chiller to bring down the product
temperature to 5°C or below.
B
Maintain exposure time to the danger zone
to 1h max since the food is made before
being transferred into the blast chiller.
If a blast chilling step not followed, the
exposure time should be further reduced
taking into account the time taken by the
chiller to bring down the product
temperature to 5°C or below.
C
P
Preventive: Compliance with good
personal hygiene practices
Control: Verifying compliance with good
hygiene practices
Justification: Spoilage bacterial
activity doesn’t result in a risk of
food safety. It only alters product
quality
-
-
-
4
2
8
No
31
Raw Material/
Food Contact
Material/Process
Step
Blast chilling
Potential Hazard
Improper cooling results in bacterial
spore germination of pathogenic species
and \/or multiplication of any number of
surviving pathogenic viable count to
unacceptable level
Category
(B/C/P)
B
Control and preventative Measures
Chill quickly to < 5°Cwithin 2 h max
Hazard Analysis
Probabili
ty
Severity
Risk
Level
4
2
8
Justification: Salmonella ,
Staphylococcus aureus,
Escherichia coli and Listeria
doesn’t form spores.
Growth temperature for all
vegetative cells range from 5 to
45°C with an optimum growth
temperature of 35 – 37°C.
Detergent residue as a result of
incorrect hygiene practices
Contamination by foreign objects (hair,
And sand) as a result of incorrect
hygiene practices
C
P
Preventive: Use food grade
cleaning/sanitizing chemicals only
Control: Keep the sites, equipment and
fixtures for the operation properly
sanitized.
Verifying compliance with good hygiene
practices
Preventive: Compliance with good
personal hygiene practices
Control: Verifying compliance with good
hygiene practices
Unless there is a breakdown or
faulty operation, blast chiller
takes the product temperature
down fast enough to as low as 10
°C to minimize microbial growth
though, time tends to be longer
than 2 h before 5°C is reached
given the blast chiller’s state.
3
2
6
3
2
6
No
32
Raw Material/
Food Contact
Material/Process
Step
Chill Storage
Potential Hazard
Improper cold storage temperature(T >
50C) for more than 2h results in
bacterial spore germination of
pathogenic species and /or
multiplication of any number of
surviving pathogenic viable cell count
to unacceptable level
Category
(B/C/P)
B
Control and preventative Measures
Probability Severity
Preventive: Maintain storage temperature
<50C
Control: Chilled foods held at > 50C for <2
hours should either be used immediately,
restored to a temperature of ≤50Cor
discarded as appropriate after risk
assessment.
Chilled food held at >5 °C for between 2
and 4 hours, should be used immediately or
discarded.
Chilled food held at >5 °C for >4 hours,
should be discarded.
Unidentified
C
Hazard Analysis
-
4
3
Risk
Level
12
Justification: Salmonella ,
Staphylococcus aureus,
Escherichia coli and Listeria
doesn’t form spores.
Growth temperature for all
vegetative cells range from 5 to
45°C with an optimum growth
temperature of 35 – 37°C.
Given likely occurrence of
reported incidents of breakdowns
or faulty operation of the walk-in
chiller over the past year, which
resulted in products liable to be
disposed on safety grounds, the
probability rated at 4 to cover the
degree of uncertainty.
Severity depends on how soon the
deviation is detected and
corrected to bring back things
under control, which has a chance
of going unnoticed before product
quality/safety compromised. The
higher the time food being
exposed to temperature deviation,
the higher the viable cell count, so
is the severity.
Given product characteristics,
pineapple Gateau require
refrigeration to assure safety
-
No
32
33
34
Raw Material/
Food Contact
Material/Process
Step
Chill Storage
Metal detecting
Dispatch and
Distribution
Potential Hazard
Category
(B/C/P)
Contamination by foreign objects (hair,
And sand) as a result of incorrect
hygiene practices
P
Unidentified
B
Unidentified
C
Metal contamination not detecting
P
Microbial cross-contamination as a
result of incorrect hygiene practices:
(Salmonella, Staphylococcus aureus
and Escherichiacoli, Listeria)
B
Microbial growth due to incorrect
distribution temperature
B
Control and preventative Measures
Hazard Analysis
Probability Severity
Preventive: Compliance with good
personal hygiene practices
Risk
Level
3
2
6
-
-
-
-
-
-
-
Effective metal detection: Absent – ferrous
2.0 mg, non-ferrous 2.5 mg
Preventive: Compliance with good
hygiene practices pertinent to transport and
delivery of food:
Adequately clean vehicles between loads
Properly protect food during transportation
3
3
9
3
2
6
4
2
8
-
-
-
Control: Verifying compliance with good
hygiene practices
-
Control: Verifying compliance with good
hygiene practices during transport
Preventive: Properly refrigerate food
during transport to maintain product
temperature at or below 5 0C.
The transfer time between the
transportation means (e.g. truck) and the
storage facility should be less than 20 min
if there are no methods to control
temperature.
Food should be transferred to the
transporting vehicle already cooled to the
temperature at which it is to be transported.
Unidentified
C
Control: Verifying compliance with the
above requirements
-
No
34
35
36
Raw Material/
Food Contact
Material/Process
Step
Dispatch and
Distribution
Unloading
Chill Storage in
outlets
Potential Hazard
Contamination by foreign objects (hair,
And sand) as a result of incorrect
hygiene practices
Microbial cross-contamination as a
result of incorrect hygiene practices:
(Salmonella, Staphylococcus aureus
and Escherichia coli, Listeria)
Category
(B/C/P)
Control and preventative Measures
P
Preventive: During transport, protect food
from dust and from any other type of
contamination
B
Unidentified
-
Contamination by foreign objects (hair,
sand, dust ) as a result of incorrect
hygiene practices
P
Improper cold storage temperature(T >
50C) for more than 2h results in
bacterial spore germination of
pathogenic species and /or
multiplication of any number of
surviving pathogenic viable cell count
to unacceptable level
B
Hazard Analysis
Probability Severity
Control: Verifying compliance with good
hygiene practices
Preventive: Compliance with good
hygiene practices pertinent to transport and
delivery of food:
Adequately clean vehicles between loads
Properly protect food during transportation
Compliance with good personal hygiene
practices.
Protect the product from direct contact
with customers and environmental
contamination
Control: Verifying compliance with good
hygiene practices during transport
Preventive: During transport, protect food
from dust and from any other type of
contamination
Control: Verifying compliance with good
hygiene practices
Preventive: Maintain storage temperature
<50C
Control: Chilled foods held at > 50C for <2
hours should either be used immediately,
restored to a temperature of ≤50Cor
discarded as appropriate after risk
assessment.
Risk
Level
3
2
6
3
2
6
-
-
-
3
2
6
4
3
12
Justification: Salmonella ,
Staphylococcus aureus,
Escherichia coli and Listeria
doesn’t form spores.
Growth temperature for all
vegetative cells range from 5 to
45°C with an optimum growth -
No
36
Raw Material/
Food Contact
Material/Process
Step
Potential Hazard
Category
(B/C/P)
Control and preventative Measures
Hazard Analysis
Probability Severity
Chilled food held at >5 °C for between 2
and 4 hours, should be used immediately or
discarded.
Chilled food held at >5 °C for >4 hours,
should be discarded.
Risk
Level
-temperature of 35 – 37°C.
Given likely occurrence of
reported incidents of breakdowns
or faulty operation of the walk-in
chiller over the past year, whichresulted in products liable to be
disposed on safety grounds, the
probability rated at 4 to cover the
degree of uncertainty.
Severity depends on how soon the
deviation is detected and
corrected to bring back things
under control, which has a chance
of going unnoticed before product
quality/safety compromised. The
higher the time food being
exposed to temperature deviation,
the higher the viable cell count,
so is the severity.
Pineapple has low water activity
following osmotic dehydration,
and it doesn’t support microbial
growth afterwards though, owing
to distribution of ingredients in
different parts of the cake water
activity varies accordingly.
Given product characteristics,
pineapple Gateau requires
refrigeration to assure quality and
safety.
No
36
Raw Material/
Food Contact
Material/Process
Step
Chill Storage in
outlets
Chill Storage in
outlets
Potential Hazard
Microbial cross-contamination as a
result of incorrect hygiene practices:
(Salmonella, Staphylococcus aureus
and Escherichia coli, Listeria)
Category
(B/C/P)
Control and preventative Measures
B
Preventive: Compliance with good
hygiene practices
Protect the product from direct contact with
customers and environmental
contamination
Unidentified
C
Contamination by foreign objects (hair,
sand, dust ) as a result of incorrect
hygiene practices
P
Hazard Analysis
Probability Severity
Control: Verifying compliance with good
hygiene practices
Preventive: Protect the product from direct
contact with customers, outlet employees
and environmental contamination
Control: Verifying compliance with good
hygiene practices
Risk
Level
3
2
6
-
-
-
3
2
6
ISO 22000:2018. Decision tree for the selection and categorization of OPRPs and CCPs.
HACCP Plan-Identification of Critical Control Points(CCPs) and Operational Prerequisite Programs (OPRPs)
B-Biological, C-Chemical, P-Physical
Process
Step
Significant hazard
identified in the hazard
analysis
Q1
Does the
process/nonprocess step
have a
significant
food safety
hazard and /
or probability
of failure of
its
functioning?
If Yes move
to Q2
If No this step
is a PRP
Receiving
water
Dry
cleaning/w
et cleaning
and
sanitizing
eggs
Flour
sieving
Skin
removal of
pineapples
and cutting
into pieces
Beating
sugar and
eggs in the
dough
mixer
Q2
Does this
step
specifically
designed and
capable to
prevent or
reduce the
likely
occurrence
of hazard(s)
to an
acceptable
level?
Q3
Could
contaminatio
n or failure
of identified
hazard(s)
occur in
excess of
acceptable
levels or
could this
increase to
unacceptable
levels?
Q4
Will a
subsequent
step prevent
or reduce the
likely
occurrence
of hazard(s)
to an
acceptable
level?
If Yes move
to Q5
If No move
to Q3
If No not a
CCP/OPRP
If No move
to Q5
If Yes not a
CCP/OPRP
Q5
Does the
measurable
critical/contr
ol measures,
or
observation
criteria
available?
If Yes move
to Q6
If No
Modify
process/
product and
move to Q2
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Introduction of pathogenic
bacteria of public health
concern from the use of
equipment and utensils
with contaminated food
contact surfaces
E.g. Dough mixer
Yes
Yes
Yes
If Yes
move to Q7
Yes
If No
Modify
process/
product and
move to Q2
Yes
Yes
Yes
If Yes move
to Q4
Presence of pathogens of
public health significance
in unacceptable levels
Pathogenic salmonella
likely to present on
contaminated egg shells
surviving the cleaning/
sanitizing steps causing a
risk of contamination of
the egg interior during
subsequent stages.
Not screening extraneous
matter and insect parts
Physical contamination of
pineapples with metal
fragments likely to detach
from metal blade
Q6
Does
monitoring
feasible
with
measurable
critical/
control
limits, or
observable
action
criteria?
Q7
Does it a
process step
or nonprocess
step?
If a Process
step move
to Q8
Q8
Does it a
single
control
measure or
part of a
combination
of control
measures
(CCM)?
If a Nonprocess
step move
to Q11
If the
answer is
Single move
to Q9
If the
answer is
CCM move
to Q11
Q9
Does it
enable
timely
correction
at a
failure?
If Yes
CCP or
OPRP
If No
Modify
process/
product
and move
to Q6
Q 10
If YES
Are there
critical
limits
If No
STOP :
OPRP
If YES
STOP:
CCP
Non
Process
-
-
Yes
OPRP 1
Yes
Process
Single
Yes
No
OPRP-2
Yes
NonProcess
`
`
Q11
Does it
enable
control of
process or
product at
a failure?
If
YesOPR
P
If No
Modify
process/
product
and move
to Q2
Yes
OPRP
No
Yes
Yes
HACCP Plan-Identification of Critical Control Points(CCPs) and Operational Prerequisite Programs (OPRPs)
Process
Significant
hazard
B-Biological,
C-Chemical,
Step
identified in the hazard
analysis
Mixing
in the
dough
mixer
Putting
into
molds
Baking
Q1
P-Physical
Q2
Does this
step
specifically
designed and
capable to
prevent or
reduce the
likely
occurrence
of hazard(s)
to an
acceptable
level?
Q3
Could
contamination
or failure of
identified
hazard(s)
occur in
excess of
acceptable
levels or
could this
increase to
unacceptable
levels?
Q4
Will a
subsequent
step prevent
or reduce the
likely
occurrence
of hazard(s)
to an
acceptable
level?
If Yes move
to Q2
If No this
step is a
PRP
If Yes move
to Q5
If No move
to Q3
If No not a
CCP/OPRP
If No move
to Q5
Physical contamination
of the batter with metal
fragments likely to
detach from spiral
mixer of the dough
mixer whilst being
mixed
Microbial
contamination as a
result of incorrect
hygiene practices:
(Salmonella,Staphyloco
ccus aureus
and Escherichia coli)
Yes
No
Yes
No
Yes
Yes
Microbial survival and
multiplication:
Yes
Yes
Yes
No
(Salmonella, Yersinia,,
Shigella Norovirus,Sta
phylococcus aureus,
Listeria monocytogenes
Escherichia coli
O157:H7, Micrococcus
and Bacillus)
Does the
process/nonprocess step
have a
significant
food safety
hazard and /
or
probability
of failure of
its
functioning?
If Yes move
to Q4
Yes
If Yes not a
CCP/OPRP
No
Q5
Does the
measurable
critical/contr
ol measures,
or
observation
criteria
available?
If a Process
step move
to Q8
Q8
Does it a
single
control
measure or
part of a
combination
of control
measures
(CCM)?
If a Nonprocess
step move
to Q11
If the
answer is
Single move
to Q9
Yes
If No
Modify
process/
product and
move to Q2
Yes
Process
If the
answer is
CCM move
to Q11
Sin
Yes
Yes
Process
Sin
If Yes move
to Q6
If No
Modify
process/
product and
move to Q2
Q6
Does
monitoring
feasible with
measurable
critical/
control
limits, or
observable
action
criteria?
If Yes move
to Q7
Q7
Does it a
process step
or nonprocess
step?
Q9
Does it
enable
timely
correction
at a failure?
If Yes
CCP or
OPRP
Move to
Q10
Q 10
If YES
Are there
critical
limits
If No
STOP :
OPRP
If YES
STOP:
CCP
If No
Modify
process/
product and
move toQ6
Yes
No
OPRP-3
Yes
Yes
CCP-1
Q11
Does it
enable
control of
process or
product at
a failure?
If
YesOPR
P
If No
Modify
process/
product
and move
to Q2
Process
Step
Cutting
(Removi
ng top
and
bottom
layers),
And
Topping
a 2nd
cake
layer
Chill
Storage
Significant hazard
identified in the hazard
analysis
Introduction of
pathogenic organisms
resulting from human
hand contact:
Fecal viruses:
Fecal Bacteria:
Fecal worms
AND
Cross contamination
with pathogenic
microbes from
contaminated
surfaces(Salmonella,
Staphylococcus aureu
sand Escherichia coli)
Improper cold storage
temperature (T > 50C)
for more than 2h results
in bacterial spore
germination of
pathogenic species and
/or multiplication of any
number of surviving
pathogenic viable cell
count to unacceptable
level
Q1
Does the
process/nonprocess step
have a
significant
food safety
hazard and /
or
probability
of failure of
its
functioning?
Q2
Does this
step
specifically
designed and
capable to
prevent or
reduce the
likely
occurrence
of hazard(s)
to an
acceptable
level?
Q3
Could
contamination
or failure of
identified
hazard(s)
occur in
excess of
acceptable
levels or
could this
increase to
unacceptable
levels?
Q4
Will a
subsequent
step prevent
or reduce the
likely
occurrence
of hazard(s)
to an
acceptable
level?
If Yes move
to Q2
If No this
step is a
PRP
If Yes move
to Q5
If No move
to Q3
If No not a
CCP/OPRP
If No move
to Q5
Yes
No
Yes
Yes
If Yes move
to Q4
Yes
Yes
If Yes not a
CCP/OPRP
Q5
Does the
measurable
critical/contr
ol measures,
or
observation
criteria
available?
If Yes move
to Q6
If No
Modify
process/
product and
move to Q2
Q6
Does
monitoring
feasible with
measurable
critical/
control
limits, or
observable
action
criteria?
If Yes move
to Q7
No
Yes
If No
Modify
process/
product and
move to Q2
Yes
No
Yes
Yes
Q7
Does it a
process step
or nonprocess
step?
If a Process
step move
to Q8
Q8
Does it a
single
control
measure or
part of a
combination
of control
measures
(CCM)?
If a Nonprocess
step move
to Q11
If the
answer is
Single move
to Q9
Process
If the
answer is
CCM move
to Q11
CCM
Non-process
Q9
Does it
enable
timely
correction
at a failure?
If Yes
CCP or
OPRP
Move to
Q10
Q 10
If YES
Are there
critical
limits
If No
STOP :
OPRP
If YES
STOP:
CCP
If No
Modify
process/
product and
move toQ6
Yes
Q11
Does it
enable
control of
process or
product at
a failure?
If
YesOPR
P
If No
Modify
process/
product
and move
to Q2
No
OPRP-4
Yes
OPRP-5
HACCP Plan-Identification of Critical Control Points (CCPs) and Operational Prerequisite Programs (OPRPs)
Process
Significant
hazard
B-Biological,
C-Chemical,
Step
identified in the hazard
analysis
Metal
detecting
Chill
Storage
in outlets
Metal contamination
not detecting
Improper cold storage
temperature (T > 50C)
for more than 2h results
in bacterial spore
germination of
pathogenic species and
/or multiplication of any
number of surviving
pathogenic viable cell
count to unacceptable
level
Q1
P-Physical
Q2
Does this
step
specifically
designed and
capable to
prevent or
reduce the
likely
occurrence
of hazard(s)
to an
acceptable
level?
Q3
Could
contamination
or failure of
identified
hazard(s)
occur in
excess of
acceptable
levels or
could this
increase to
unacceptable
levels?
Q4
Will a
subsequent
step prevent
or reduce the
likely
occurrence
of hazard(s)
to an
acceptable
level?
If Yes move
to Q2
If No this
step is a
PRP
If Yes move
to Q5
If No move
to Q3
If No not a
CCP/OPRP
If No move
to Q5
Yes
Yes
Yes
Yes
Does the
process/nonprocess step
have a
significant
food safety
hazard and /
or
probability
of failure of
its
functioning?
If Yes move
to Q4
Yes
Yes
If Yes not a
CCP/OPRP
Q5
Does the
measurable
critical/contr
ol measures,
or
observation
criteria
available?
If Yes move
to Q6
If No
Modify
process/
product and
move to Q2
Q6
Does
monitoring
feasible with
measurable
critical/
control
limits, or
observable
action
criteria?
If Yes move
to Q7
No
Yes
If No
Modify
process/
product and
move to Q2
Yes
No
Yes
Yes
Q7
Does it a
process step
or nonprocess
step?
If a Process
step move
to Q8
Q8
Does it a
single
control
measure or
part of a
combination
of control
measures
(CCM)?
If a Nonprocess
step move
to Q11
If the
answer is
Single move
to Q9
If the
answer is
CCM move
to Q11
Non –
process
Non-process
Q9
Does it
enable
timely
correction
at a failure?
If Yes
CCP or
OPRP
Move to
Q10
If No
Modify
process/
product and
move toQ6
Q 10
If YES
Are there
critical
limits
If No
STOP :
OPRP
If YES
STOP:
CCP
Q11
Does it
enable
control of
process or
product at
a failure?
If
YesOPR
P
If No
Modify
process/
product
and move
to Q2
Yes
OPRP-6
Yes
OPRP-7
Establishing Measurable or Observable Action Criteria, monitoring practices, corrective actions and verifications for OPRPs
Step
(1)
Receiving
water
Significant
Hazard
Control Measure
Presence of
pathogens of
public health
significance in
unacceptable
levels
For municipal
water: Carry out onsite
micro checks and
obtain Certificate
of Analysis of
local sampleWater Authority
For dug well/ tube
well water:
Chlorination
Measurable
or observable
Action
Criteria
Chlorine level
after 30 min of
contact time
with water
maintained at:
0.5 ppm at
minimum or
2 ppm at
maximum or
within the range
in between.
Monitoring
Actions to implement
What
How
Where
When
Who
Corrections
Corrective Actions
Residual/
free
chlorine
level
Free
Chlorine
test kit
Water tap
Daily, at
the
beginning
of the
operation.
QAA
Correction: Add
more chlorine to
water using inhouse chlorine
dosing system if
free chlorine level
measures below
0.6 ppm when
checked by
Chlorine test kit.
Wait 30 min of
contact time
before checking
and approving for
use as processing
water.
Corrective Action:
 Root cause
analysis
 In case of
municipal water,
contact the water
authority
 Preventive
maintenancewater
disinfection/
purification
system.
 Provision of
adequate
resources to
address cause of
non-compliances
 Audit to
determine and
implement action
needed in order
to prevent
recurrence.
 In cause of
incompetency, by
providing regular
training and
evaluation, and
assign people
based on
competency.
 Assign
responsibility
Document all actions
taken and define
responsibilities.
(Water pH: 6.5- 8.5
Disinfectant
concentration: 0.52mg/L of residual
chlorine level.
Contact time: 30 min
for residual chlorine
level of 0.5 ppm
Water temperature:
180C to 370C)
Record: Daily Water chlorine record
Responsibilities
and authorities
Monitoring –
Maintenance
technician
Correction
and Corrective
Actions – Quality
Assurance Manager
Establishing Measurable or Observable Action Criteria, monitoring practices, corrective actions and verifications for OPRPs
Step
Flour
sieving
Significant
Hazard
Not screening
extraneous
matter and
insect parts
Control
Measure
Sieving
Measurable or
observable
Action Criteria
Pore (mesh)
size 2 by 2 mm
Monitoring
Actions to implement
What
How
Where
When
Integrity of
the flour
sifter
Visual
observation
Cake room
1x per hour
Who
QAA
Correction
Re-sieve
Corrective
Action
Replace the
sieve Correct
the cause to
prevent
recurrence
Record: Flour sifter integrity Record
Skin
removal of
pineapples
and cutting
into pieces
Mixing in
the dough
mixer
When there
is no
mechanical
means of
detection:
e.g. metal
detectors
Physical
contamination
of pineapples
with metal
fragments
likely to
detach from
metal blade
Physical
contamination
of the batter
with metal
fragments
likely to
detach from
spiral mixer
of the dough
mixer whilst
being mixed
Check the
integrity of the
knife blades
after
performing
skin removal
and cutting on
each lot of
pineapples
comprises with
5-10 fruits
No integrity
defect
Check the
integrity
of the mixer
spiral after
each
mixing cycle
No integrity
defect
Knife
blades
Visual
observation
Pineapple
cutting
section
After every
skin removal
and cutting
secession
performed per
lot comprises
with 5 -10
fruits
QAA
Every
kneading
Cycle
QAA
Record: Knife blade integrity record
Mixer
spiral
Visual
observation
Dough
mixing
section
Record: Spiral Integrity record
Correction:
Location and
removal of scrap
metal;
(If the pieces of
metal are
not located, the
entire batch of
product should be
discarded,
placed in proper
place, properly
identified as a not
compliant product)
Correction:
Location and
removal of scrap
metal;
(If the pieces of
metal are
not located, the
entire batch
of product should
be discarded,
placed in proper
place, properly
identified as
a not compliant
product)
Corrective
Action:
Replacement
of the knives
Responsibility
and authority
Monitoring –
Employee
performing
the sieving
Correction
and Corrective
Actions – QAM
Monitoring –
Employee
performing
the sieving
Correction
and Corrective
Actions – QAM
Corrective
Action:
Replacement
of the kneader
spiral
Monitoring –
Employee
making
the kneading
Correction
and Corrective
Actions – QAM
Establishing Measurable or Observable Action Criteria, monitoring practices, corrective actions and verifications for OPRPs
Step
Significant
Hazard
Control
Measure
Measurable or
observable Action
Criteria
Cutting
(Removing
top and
bottom
layers),
Introduction of
pathogenic
organisms
resulting from
human hand
contact:
Fecal viruses:
Fecal
Bacteria:
Fecal worms
Complianc
e with good
personal
hygiene
practices
Strict adherence to
Proper hand washing
and sanitizing
practices:
And
Topping a
2nd cake
layer
5 steps, 20 seconds
minimum hand
washing time,
application of 70 %
alcohol.
Adherence to gloves
policy
Monitoring
Actions to implement
What
How
Where
When
Hand
washing
procedure
Visual
inspection
Hand
washing
station
Daily
Who
Quality
supervisor
Record: Personal Hygiene Log
Criteria in
gloves
policy
Visual
inspection
Bakery
Daily
Quality
supervisor
Record: Personal Hygiene Log
Analyze colony counts
(cfu) on the surface
using Hand SWAB
testing:
APC
:< 50
Coliform SPP. : None
E coli : None
Listeria: None
ATP Monitoring:
RLU 10 or less
Correction
Rewashing
hands
CFU
Plate Count
Technique
Palms of
hands
Quarterly
An
accredited
laboratory
Record: SWAB test report
RLU
ATP
Luminometer
Record; Luminometer record
Palms of
hands
Weekly
Quality
Supervisor
Rewashing
hands and
hygienically
wearing a new
pair.
Put on hold the
product/ batch
affected by
unhygienic
handling whilst
hygienic
quality/safety
being
investigated.
Re –cleaning
hands, Put on
hold the
product/ batch
affected by
unhygienic
handling whilst
hygienic
quality/safety
being
investigated.
Corrective Action
Providing Food
Safety/ Hygiene
training, training
effectiveness
evaluation,
Provision of
adequate resources
Employee vetting
practices
Responsibility
and authority
Monitoring:
Quality
Supervisor
Correction
and Corrective
Actions – QAM
Providing Food
Safety/ Hygiene
training, training
effectiveness
evaluation,
Provision of
adequate resources
Employee vetting
practices
Monitoring:
Quality
Supervisor
Providing Food
Safety/ Hygiene
training, training
effectiveness
evaluation,
Provision of
adequate resources,
Employee vetting
practices, revision
of the effectiveness
of cleaning
chemicals and
procedures, increase
monitoring
frequency
Monitoring:
Quality
Supervisor
Correction
and Corrective
Actions – QAM
Correction
and Corrective
Actions – QAM
Establishing Measurable or Observable Action Criteria, monitoring practices, corrective actions and verifications for OPRPs
Step
Cutting
(Removing
top and
bottom
layers),
And
Topping a
2nd cake
layer
Chill
Storage
Significant
Hazard
Cross
contamination
with pathogenic
microbes from
contaminated
surfaces(Salmon
ella,
Staphylococcus
aureusand
Escherichia
coli)
Improper cold
storage
temperature (T >
50C) for more
than 2h results
in bacterial
spore
germination of
pathogenic
species and /or
multiplication of
any number of
surviving
pathogenic
viable cell
count to
unacceptable
level
Control Measure
Keep facilities,
equipment and
utensils for the
operation properly
sanitized.
Perform the task
quickly,
hygienically and
without
interruptions.
Compliance with
GHP.
Maintain storage
temperature (air
temperature) at or
below 4 0C so that
at the food interior
is reached at least a
temperature of 5 °
C
Measurable or
observable
Action
Criteria
Adherence to
cleaning
schedule
Monitoring
Actions to implement
What
How
Where
When
Cleaning
and
sanitizing
Visual
observation
Cleaning
location /
Wash-up
area
Weekly
Who
Quality
Supervisor
Air
temperature at
or below 4 0C
Internal
temp.
Digital
probe food
thermometer
Dispatch
walk-inchiller
Corrections
Corrective Actions
Re-cleaning and
sanitizing
Providing Food
Safety/ Hygiene
training, training
effectiveness
evaluation,
Provision of
adequate resources
Employee vetting
practices
Monitoring:
Quality
Supervisor
Correct the cause to
prevent recurrence
Preventive
Maintenance, cool
room calibration,
Adjust monitoring
frequency based on
reliability, limit
freezer opening
times, installing
PVC strip curtains
to minimize cold
escape, blast
freezing products
prior to cold
storage, avoid
overstocking and
store below what is
recommended, store
properly to
minimize cold
currents reaching
containers/products,
use perforated
storage containers in
place of solid
containers which
blocks air current
reaching
Monitoring:
Quality
Supervisor
Put on hold the
product/ batch
affected by
contaminated food
contact surfaces
whilst hygienic
quality/safety
being investigated.
Record: Cleaning/ Sanitizing Record
Weekly
Quality
Supervisor
Chilled foods held
at > 50C for <2
hours to either be
used immediately,
restored to a
temperature of
≤50Cor discarded
as appropriate after
risk assessment.
Chilled food held
at >5 °C for
between 2 and 4
hours, to be used
immediately or
discarded.
Chilled food held
at >5 °C for >4
hours, to be
discarded.
Record: Cool Room Temperature Log
081 57 28 862
Responsibility
and authority
Correction
and Corrective
Actions – QAM
Correction:
QAM
Corrective
Action: QAM,
Maintenance
Engineer
Step
Metal
detecting
Significant
Hazard
Metal
contamination
not detecting
Control
Measure
Metal detector
must detect 2.0
mm ferrous,
3.0 mm nonferrous, and 3.5
mm stainless
steel test
samples when
the test
samples are
passed through
the detector
with the
product. The
metal detector
must reject the
product.
Measurable or
observable
Action
Criteria
Minimum
detectable
limit2.0 mm
ferrous, 3.0
mm nonferrous, and
3.5 mm
stainless steel
Monitoring
Actions to implement
What
How
Where
When
Equipment
check
(Metal
detectability)
1. Test the metal detector
by passing a sample piece
of metal through the
detector to ensure that it is
operating effectively and
able to detect metal present
in the product.
Dispatch
Check
before
starting
operations
each day
AND
Check every
four hours
during
operation;
AND
Check at the
end of
operations
each day;
AND
Check
whenever
there is an
equipment
malfunction
that could
increase the
likelihood
that metal
could be
introduced
into the food
2. Check metal samples
of 2.0 mm ferrous, 3.0 mm
non-ferrous, and 3.5 mm
stainless steel, one at a
time. Each check must
include all three sample
tests.
3. Sample into the middle
of the product and then pass
the product package, if
available, through the metal
detector. A properly
operating metal detector
must detect the metal
sample in the product.
1. Each time a metal
contaminant is detected, the
metal detector belt must
retract and the rejected
product must drop into the
rejection box.
Record the metal sample
(i.e., the metal detector is
operating correctly) or not
acceptable (“X”) (i.e., the
metal detector is not
operating correctly) on the
“Daily Metal Detector
Check Record,” including
the date, the time, and
initials.
Record: Record of equipment inspections.
Who
Corrections
Equipment A. When the
metal detector
operator
Or
fails to detect a
metal test
sample:
production 1. Immediately
supervisor halt all steps in
or
A member
of the
quality
control
staff
Or,
a member
of the
maintenan
ce or
engineerin
g staff
or
Any other
person
who has
an
understand
ing of the
operation
of the
equipment
.
which rotating
metal blades
and/or sharp
metal cutting
edges involved
until the issue
rectified.
2. Unless the
issue is rectified,
visually check the
equipment for
broken or missing
parts.
e.g. check
integrity of the
mixer spiral after
each mixing cycle
B. Destroy all
product produced
since the previous
satisfactory
equipment
check;.
Or
Divert all product
produced since
the previous
satisfactory
equipment check
to a non-food use.
CorrectiveAc
tions
Metal
detector
validation
assisted by
the
manufacturer
Annual
calibration of
the metal
detector by
the
manufacturer
and
verification of
the calibration
report by a
qualified
individual
Correct the
cause to
prevent
recurrence
Responsibility
and authority
Monitoring:P
roduction
supervisor
Correction
and
Corrective
Action:QAM
Establishing Measurable or Observable Action Criteria, monitoring practices, corrective actions and verifications for OPRPs
Step
Significant
Hazard
Control
Measure
Measurable or
observable
Action Criteria
Metal
detecting
Metal
inclusion
Metal
detecting
No detectable
metal fragments
are in the
product
passing the
through the
metal detector
Monitoring
What
The
Product for
the
presence
of metal
fragments
How
Electronic
metal
detector
Where
Dispatch
Record: Metal detector operation log
Actions to implement
When
Continuous
Who
Monitoring is
performed by
the equipment
itself. A check
should be made
at least once per
day to ensure
that the device is
operating or is
in place. This
may be
performed by
the equipment
operator, a
production
supervisor, a
member of
the quality
control staff, a
member of the
maintenance or
engineering
staff, or any
other person
who has an
understanding of
the operation
of the
equipment.
Corrections
Correction:
If the product is
processed without
metal detection,
hold it for metal
detection.
Correct operating
procedures to ensure
that the product is
not processed
without metal
detection.
Rework to remove
metal fragments
from any product
rejected by the
metal detector.
OR
Destroy;
OR
• Divert to non-food
use
Identify the source
of the metal found
in the product and
fix the damaged
equipment.
Corrective Actions
Attempt to locate and
correct the source of the
fragments found in
product by the metal
detector or separated
from the product stream
by the magnets, screens,
or other devices
AND
Make adjustments to the
materials, equipment,
and/or process, as
needed, to prevent future
introduction of metal
fragments
Responsibility
and authority
Monitoring:
Production
supervisor
Or
Equipment
operator
Or
a member of
the
maintenance
or
engineering
staff
Or
A member
of the QC
team
Correction
and CA:
QAM
Establishing Measurable or Observable Action Criteria, monitoring practices, corrective actions and verifications for OPRPs
Step
Chill
Storage
Significant
Hazard
Improper cold
storage
temperature (T >
50C) for more
than 2h results
in bacterial
spore
germination of
pathogenic
species and /or
multiplication of
any number of
surviving
pathogenic
viable cell
count to
unacceptable
level
Control Measure
Maintain storage
temperature (air
temperature) at or
below 4 0C so that
at the food interior
is reached at least a
temperature of 5
°C
Measurable or
observable
Action
Criteria
Air
temperature at
or below 4 0C
Monitoring
Actions to implement
What
How
Where
When
Internal
temp.
Digital
probe food
thermometer
Dispatch
walk-inchiller
Weekly
Who
Quality
Supervisor
Record: Product internal temperature log
Air temp.
Temperature
indicator
Upright
display
chiller or
cake
cabinet
Record: Cool Room Temperature Log
Daily,
once in
every 4
hrs.
Outlet
employees
Corrections
Corrective Actions
Chilled foods held
at > 50C for <2
hours to either be
used immediately,
restored to a
temperature of
≤50Cor discarded
as appropriate after
risk assessment.
Correct the cause to
prevent recurrence
Preventive
Maintenance, cool
room calibration,
Adjust monitoring
frequency based on
reliability, limit
freezer opening
times, installing
PVC strip curtains
to minimize cold
escape, blast
freezing products
prior to cold
storage, avoid
overstocking and
store below what is
recommended, store
properly to
minimize cold
currents reaching
containers/products,
use perforated
storage containers in
place of solid
containers which
blocks air current
reaching
Chilled food held
at >5 °C for
between 2 and 4
hours, to be used
immediately or
discarded.
Chilled food held
at >5 °C for >4
hours, to be
discarded.
Responsibility
and authority
Monitoring:
Outlet
employees
Correction:
QAM
Corrective
Action: QAM,
Maintenance
Engineer
Hazard Control Plan - Identification of Critical Control Points (CCPs)
Step
Baking
Significant
Hazard
Biological:
Microbial
multiplication
(Salmonella,
Staphylococcs
aureus
and Escherichia
coli)
Control Measure
Compliance with
good personal
hygiene practices.
Meet binomial time/
temperature set (10–
12 minutes at 200–
220ºC) for the
process so that at the
interior is reached at
least a temperature of
70 ° C
The goal is to reach
inside the product
temperature at or
above 70 ° C.
Measurable
Critical limits
The internal
temperature of
the product must
be at least 70°C
for a minimum
of 1 minute.
Monitoring
What
How
Binomial
time /temp,
internal time
/temp of the
product
Clock ovens /
Penetration
Thermometer.
Record: Baking log
Where
Bakery
oven
Frequency
Weekly
Correction
Corrective
Action
Responsibility
and authority
Correction:
Extend or shorten
the cooking time
to achieve the
desired end
product and that
inside the product
is achieved a
temperature
above 70°C.If the
product is not
fitfor human
consumption,
must be rejected,
put in place, duly
identified as
nonconforming
product.
Correction
Action:
Reset the
binomial
time
/temperature
Monitoring:
Oven operator
or employee
responsible for
baking
Who
Responsible
employee/
QAM
Correction:
Ex. Pastry
Chef / QAM
Corrective
Action: QAM,
Maintenance
Engineer
Process Step
(CCP/OPRP) What
(1)
Receiving water
Verification Activities
Weekly verification of monitoring &
corrective action records.
Who
Recordkeeping Activities
Name of the record
Manager,
supervisor, or
trained
designee.
Trained
auditor with
technical
expertise who
is not directly
involved in
the operation.
FST
Daily water chlorine check record
Water chlorination log
Quarterly analyze training related records
to ascertain that people are well trained,
competent and skilled to perform their
assigned duties.
FST
Training records
Training effectiveness evaluation
record
Competency evaluation record
Correction Action Record
Check Chlorine test kit for accuracy and
damage and to ensure that it is operational
before putting it into operation; perform
these same checks daily, at the beginning of
operations.
A trained
designee
Review water quality analysis records
FST
Water microbiology test reports
Water chemical and physical
parameters analysis reports
Review of deviation reports
Review of past validation reports
Assessment of corrective action
effectiveness
Review of linkages between the Hazard
Control plan and PRP programmes
Review control measures for their
continued suitability
FST
FST
FST
Deviation reports
Validation reports
Food Safety Meeting minutes
FST
Hazard Control Plan review records.
FST
HACCP Plan Review and
Amendment Records
Conduct periodic internal audits to assess
the extent of being compliant with
requirements as in the ISO/TS 220021:2009 standard and SLS 873 Part 1:2015,
which outlines specific requirements for
processing water.
Reassess water purification and sanitation
processes and procedures- annually by
HACCP team.
Validation
1.
Internal Audit Reports
Nonconformity records
2.
Food Safety meeting minutes
Corrective action records
3.
4.
5.
6.
Intentionally contaminate a sample of processing
water dechlorinated by adding a known amount of
Sodium thiosulfate with a sample of polluted water
drawn from a source known to harborage pathogens
of public health concern and allow incubating at 37
0
C for 48 hrs.
Calculate and add the amount of chlorine required to
achieve 0.5 ppm of residual chlorine after a contact
time of 20 min with water at water temperature
between 18 0C to 37 0C and pH at 6.5- 8.5.
Check the residual chlorine level with chlorine test
Kit after a 20 min period of chlorination.
Further chlorinate if the level is below 0.6 ppm until
the level reaches at or above 0.6 as indicated on the
test kit after keeping a further 20min contact period
with water.
Dechlorinate the sample after a 20 min has passed
since chlorination and get it analyzed by an
accredited laboratory for the following
microbiological parameters.
Parameter
Total Plate Count @36±2 0C for 48h
Total Plate Count @22±2 0C for 48h
Total Coliform
Faecal coliforms
Faecal streptococci
Sulfate reducing bacteria
Escherichia coli
Max acceptable
limit
10/ml
100/ml
None
None
None
None
None
Process Step
(CCP/OPRP) What
Flour sieving
Skin removal of
pineapples and
cutting into pieces
Cont’d on the
next page
Verification Activities
Who
Recordkeeping Activities
Name of the record
Validation
Flour sifter integrity Record
Worst case:
Intentionally contaminate about 500 g of
wheat flour with a known amount (100 or
more)of a sterile, non-porous, non-soluble
material made of an inert material, in the
correct sizes (the hazard size range)that can
be detected or removed in a flour sifter and
try to recover them out the other side with
flour sifter.
Just count them, after all flour is run through
the sifter.
Weekly verification of monitoring &
corrective action records.
Quarterly analyze training related records
to ascertain that people are well trained,
competent and skilled to perform their
assigned duties.
Review of deviation reports
Manager, supervisor, or
trained designee.
FST
FST
Training records
Training effectiveness evaluation record
Competency evaluation record
Correction Action Record
Deviation reports
Review of past validation reports
FST
Validation reports
Assessment of corrective action
effectiveness
Review of linkages between the Hazard
Control plan and PRP programmes
Review control measures for their
continued suitability
FST
Food Safety Meeting minutes
FST
Hazard Control Plan review records.
FST
HACCP Plan Review and Amendment
Records
Review monitoring, corrective action, and
verification records within 1 week of
preparation
Perform ongoing review of HACCP Plan in
response to deviations and/or System and
product Modification
Periodically evaluate the Checkers’ ability
to detect changes in knife blade’s integrity
due to missing parts.
Conduct biannual internal audits to assess
whether specified requirements have been
fulfilled.
A trained designee
Knife Integrity Check Record
Corrective Action Log
FST
Document Review log
FST
Employee calibration records
Quarterly analyze training related records
to ascertain that people are well trained,
competent and skilled to perform their
assigned duties.
Periodically evaluate practical effectiveness
of training provided.
Interviewing employees
Review of deviation reports
If 100% of the contaminant is detected and
recovered, the process is validated.
Frequency: Biannually
Mixer Spiral Inspection Process:
Intentionally damage the cutting edge of a
knife so that a metal fragment with the size
of 2mm is lost from the metal blade and
check knife-integrity- checkers’ capability of
detecting it as a deformity upon integrity
check.
Frequency: Biannually
Trained auditor with
technical expertise who
is not directly involved
in the operation.
FST
Internal Audit Reports
Nonconformity records
FST
Training effectiveness evaluation record
QAM
Employee audit records.
FST
Deviation reports
Training records
Competency evaluation record
Correction Action Record
Process Step
(CCP/OPRP) What
Cont’d from the
previous page
Skin removal of
pineapples and
cutting into pieces
Cutting
(Removing top
and bottom
layers),
And
Topping a 2nd
cake layer
Verification Activities
Who
Recordkeeping Activities
Name of the record
Review of past validation reports
FST
Validation reports
Assessment of corrective action
effectiveness
Review of linkages between the Hazard
Control plan and PRP programmes
Review control measures for their
continued suitability
Review monitoring, corrective action, and
verification records within 1 week of
preparation
Conduct periodic internal audits to assess
the extent of being compliant with GHPs.
FST
Food Safety Meeting minutes
FST
Hazard Control Plan review records.
FST
HACCP Plan Review and Amendment
Records
Personal Hygiene Log
Corrective Action Log
Reassess hand hygiene practices - annually
by HACCP team.
QAM
Trained auditor with
technical expertise who
is not directly involved
in the operation.
FST
Internal Audit Reports
Nonconformity records
Evidence of process
assessments/amendments
Corrective Action Log
Quarterly analyze training related records
to ascertain that people are well trained,
competent and skilled to perform their
assigned duties.
Quarterly evaluate practical effectiveness of
training provided.
Interviewing employees to assess their
knowledge about GHPs
Review of deviation reports
FST
Evidence of continual improvements to
further stricken in-process controls
Training records
Competency evaluation record
Correction Action Record
FST
Training effectiveness evaluation record
QAM
Employee audit records.
FST
Deviation reports
Review of past validation reports
FST
Validation reports
Assessment of corrective action
effectiveness
Review of linkages between the Hazard
Control plan and PRP programmes
Review control measures for their
continued suitability
FST
Food Safety Meeting minutes
FST
Hazard Control Plan review records.
FST
HACCP Plan Review and Amendment
Records
Validation
Worst Cause:
Obtain 2 hand SWABs from palms of a food
handler, of which the first sample before
washing hands and the other after following
5 step procedure of hand washing.
Investigate APC on both samples using Agar
plate Count technique
Repeat the test for at least 5 randomly
selected employees and evaluate the test
results
Or,
Perform ATP SWAB on palms on both
mentioned occasions and analyze the
samples using a Lumibnometer
Repeat the test for at least 5 randomly
selected employees and evaluate the test
results
Frequency: Biannually
Process Step
(CCP/OPRP) What
Chill Storage
Verification Activities
Who
Recordkeeping Activities
Name of the record
Thermometer calibrated weekly, or as needed, by QAM
QAM
Thermometer calibration log
Monitoring and corrective action records reviewed on a
weekly basis, or as needed, by QAM
Signed and dated HACCP plan reviewed and modified at
least annually or as needed by QAM
QAM
Corrective Action Log
Leave a bottle of water to stand in the unit
overnight to achieve the equilibrium with internal
unit temperature and get water temperature daily as
a measure of the actual minimum temperature a
food can get in the cool room/ refrigeration unit.
Monthly calibrate refrigerator unit/cool room
thermometers internally using water/ice method or
against a reference thermometer.
Check probe food thermometers for accuracy and
damage and to ensure that it is operational before
putting it into operation; perform these same checks
daily, at the beginning of operations; and calibrate
it once per year
Monthly verification of repair and maintenance
records
A trained
designee
Water temperature record-cool
room/refrigerator
Kitchen
technician
Refrigerator unit/cool room
thermometer calibration log
(Internal)
Reference Probe food
thermometer calibration log
(External)
Daily verification of monitoring & corrective
action records.
Auditing of cold storage process to verify
conformity with specifications pertinent to cold
storage/ Internal Auditing
Reassess cold storage process - annually by
HACCP team.
Regular and/ or random verification of the whole
cold storage process on site where it is performed.
Validation
Scientific literature citation of validation
studies:
Paper Reference:
Low-Temperature Critical Limits –
Click HERE for a copy of the paper.
A trained
designee
Manager,
supervisor, or
trained designee.
Manager,
supervisor, or
trained designee.
Trained auditor
who is not
directly involved
in the operation.
Food Safety
Team
Maintenance and Repair Record
Refrigerator unit/cool room
temperature log
Corrective Action Log
Internal Food temperature logcold storage
Internal Audit Report
Verification Records
“The Tompkin paper includes scientific
justification for setting a cooler temperature
at 44.6ºF or below for safe storage of raw or
cooked meat and poultry. It also contains
information on how to set critical limits and
what to do if there's a deviation.”
Or;
Method (Worst Case):
Aseptically collect 2 samples of Pineapple
Gateux from a single cake weighing each 75
g;
Blast freeze/quick freeze one sample and
quick chill /blast chill the other sample
before storing at 4 0C in a refrigerator set to
maintain at which temperature without
subjecting to temperature fluctuations
throughout the storage period.
Submit the 1st sample immediately to an
accredited laboratory to microbiologically
analyze for APC.
Analyze the 2nd sample same way after
storing 3- 7 days at 4 0C
APC count on the 2nd sample should be
below 104or less than two times the APC
value tested for the 1st sample to validate the
step
Process Step
(CCP/OPRP) What
Metal Detecting
Verification Activities
At the end of each shift, review the “Daily
Metal Detector Check Record” to ensure that it
has been properly completed.
Validation
Who
Recordkeeping Activities
Name of the record
A trained designee
Daily Metal Detector Check Record
Metal detecting process:
Insert the metal sample into the middle of the
product and then pass the product through a
properly operating metal detector. If the
control measures are valid metal
contaminant is detected, the metal detector
belt retracted and the rejected product is
dropped into the rejection box.
Once per week, ensure that the monitoring of
the metal detector follows the written
monitoring procedure.
If non-conformance is found during the
verification procedure, investigate the cause
of the non-conformance and take necessary
corrective actions to prevent reoccurrence.
Record all observations (e.g., whether or not
the detector is operating effectively, nonconformances, and corrective actions taken)
on the “Daily Metal Detector Check Record,”
including the date, the time, and initials.
Perform ongoing review of HACCP Plan in
response to deviations and/or System and
product Modification
Conduct biannual internal audits to assess
whether specified requirements have been
fulfilled.
Quarterly analyze training related records to
ascertain that people are well trained,
competent and skilled to perform their assigned
duties.
Interviewing employees
Scientific literature citations:
Ministry of Health, B. C. (n.d.). SLICED
WHOLE WHEAT BREAD SAFETY PLAN.
Retrieved from www2.gov.bc.ca:
https://www2.gov.bc.ca/assets/gov/health/ke
eping-bc-healthy-safe/food-safetysecurity/sliced_whole_wheat_bread.pdf?bcg
ovtm=CSMLS
FST
Document Review log
Trained auditor with
technical expertise
who is not directly
involved in the
operation.
FST
Internal Audit Reports
Nonconformity records
QAM
Training records
Training effectiveness evaluation record
Competency evaluation record
Correction Action Record
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 and PRP programmes
Review control measures for their continued
FST
Hazard Control Plan review records.
FST
HACCP Plan Review and Amendment
suitability
Process Step
(CCP/OPRP) What
Baking
Records
Verification Activities
Who
Daily verification of monitoring & corrective action
records.
Once per week, ensure that the monitoring of the
baking process follows the written monitoring
procedure.
If non-conformance is found during the verification
procedure, investigate the cause of the nonconformance and take necessary corrective actions to
prevent reoccurrence.
Check penetration thermometer and/or oven
thermometer for accuracy and damage and to ensure
that it is operational before putting it into operation;
perform these same checks daily, at the beginning of
operations; and calibrate it once per year
Annually, perform heat distribution test on ovens to
ensure that binomial time/temperature can be
achieved everywhere in the oven.
If deviations reveal that heat is not uniformly
distributed and under-processing could occur on
certain locations, take necessary corrective actions
and prevent recurrence.
Conduct periodic internal audits on baking process to
ascertain whether it in compliant with specific food
safety requirements.
Monthly verification of repair and maintenance
records for ovens.
Perform ongoing review of HACCP Plan in response
to deviations and/or System and product
Modification
Reassess baking process - annually by HACCP team.
Monthly evaluate competency, awareness and
training of monitoring, measuring and calibrating
persons to ensure that human error accounting for
Recordkeeping Activities
Name of the record
Validation
Baking Log
Corrective Action Log
Worst Case
Aseptically collect about 75 g of baked
bread/bun sample and get it analyzed by
an accredited laboratory for the presence/
survival of the following microbial
parameters and verify that the test results
conform to the specified limits shown
against each parameter
Oven thermometer calibration Record
Food Safety Team
Heat Distribution Test Report
Corrective Action Log
Total microorganisms (300C):≤105UFC/g
Enterobacter iaceaespp: ≤ 10² UFC/g
Staphylococcus aureus: ≤ 10² UFC/g
Salmonella spp: Absence in 25g
Listeria monocytogenes: Absence in 25g
Fungi (Molds) and Yeasts: ≤ 10² UFC/g
Units of 30 gr. and 48 gr.
Frequency: Biannual
Trained auditor
who is not directly
involved in the
operation.
Manager,
supervisor, or
trained designee.
FST
Internal Audit Reports
Maintenance and Repair Record
Preventive Maintenance Record
Document Review log
Food Safety Team
Food Safety Team
Training need evaluation record
Competency evaluation record
Correction Action Record
likely deviations are corrected and corrective actions
taken upon.
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