Generic Hazard Analysis
and
Critical Control Points
(HACCP)
Plan for the
Canadian Brewing Industry
A Project of
Brewers Association of Canada
HACCP Working Group
Revision Date: November 2009
www.brewers.ca
Table of Contents
Introduction.............................................................................................................5
HACCP Principle 1 - Hazard Identification.............................................................9
HACCP Principle 2 - Critical Control Points..........................................................10
HACCP Principle 3 - Critical Limits.......................................................................11
HACCP Principle 4 - Establish Monitoring Procedures........................................11
HACCP Principle 5 - Establish Deviation Procedures..........................................13
HACCP Principle 6 - Establish Verification Procedures.......................................14
HACCP Principle 7 - Establish Record Keeping/Documentation.........................15
BAC Generic HACCP Program.............................................................................17
Form 1: Product/Process Description..................................................................19
Form 2: List of Product Ingredients and Incoming Materials...............................23
Form 3: Process Flow Diagram...........................................................................27
Form 4: Schematic Diagram................................................................................41
Form 5: Hazard Identification Biological Hazards................................................45
Form 6: Hazard Identification Chemical Hazards................................................57
Form 7: Hazard Identification Physical Hazards..................................................69
Form 8: Critical Control Points.............................................................................81
Form 3A: Process Flow Diagram with CCPs.....................................................127
Form 5A: Biological Hazards Control & CCPs...................................................141
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Table of Contents (Continued)
Form 6A: Chemical Hazards Control & CCPs...................................................153
Form 7A: Physical Hazards Controls & CCPs...................................................167
Form 9: Hazards not Controlled by Brewery.....................................................181
Form 10: HACCP Plan.......................................................................................185
HACCP Plan Appendices....................................................................................193
Appendix 1- Form 3 - Information used for Flowcharts......................................195
Appendix 2- Form 8 – Critical Control Points.....................................................213
Appendix 3 - Form 10 - Additions for Low Alcohol Beer.....................................217
Appendix 4 – Diagrams for Hazard Identification & CCP Decision Tree............221
Appendix 5 – BAC Glass Inclusion Reference...................................................225
Appendix 6 – Blank Forms 1 - 10.......................................................................229
Appendix 7 – Reference Literature.....................................................................243
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Introduction
HACCP (Hazard Analysis Critical Control Point) systems are required under
proposed Health Canada’s Good Manufacturing Practices Regulations for Food.
Specifically, manufacturers must develop procedures to ensure products
manufactured do not pose a health risk.
The HACCP program is a world-wide recognized systematic and preventative
approach that addresses biological, chemical and physical hazards through
anticipation and prevention, rather than by finished production inspection.
This document is a working guide to preparing a customized program of hazard
analysis and identification of critical control points (CCP) for brewers, as an aid to
consistent compliance and inspection by the Canadian Food Inspection Agency
(CFIA). This document is not a customized model per se. Each brewer using this
working guide is responsible for producing his or her own customized model.
Prior to the development and implementation of a HACCP program,
establishments must have developed, documented and implemented programs
to control factors that may not be directly related to manufacturing controls but
support the HACCP plans and the Good Manufacturing Practices (GMP). These
programs are called Pre-requisite programs. These are discussed in detail in
another document (see BAC- Generic Pre-requisite Programs).
There are 12 basic steps to implementing a HACCP program. They are:
1.
Assemble the HACCP team;
2.
Describe the product;
3.
Identify intended uses;
4.
Construct process Flow Diagram and Plant Schematic;
5.
Verify on site the Flow Diagram and Plant Schematic;
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Introduction (Continued)
6.
List hazards associated with each step (Principle 1);
7.
Determine Critical Control Points (Principle 2);
8.
Establish Critical Limits (Principle 3);
9.
Establish Monitoring Procedures (Principle 4);
10. Establish Deviation Procedures (Principle 5);
11. Establish Verification Procedures (Principle 6); and
12. Establish record keeping/documentation for Principles one through six
(Principle 7).
This manual deals in detail with steps 1 through 8, which include Principles 1
through 3 of HACCP system elements. It also discusses in general terms the
follow-up requirements that make up steps 9 through 12.
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Instructions for Companies
It is suggested that the user of this document becomes acquainted with the BAC
– Food Safety Toolkit Introduction document before attempting to proceed with
applying the recommendations herein.
There are also other BAC guidance documents that are to be used along with
this BAC - Generic HACCP Plan model. They are:

BAC/HACCP Plan Workbook; and

BAC/HACCP Plan Glossary.
Pre-requisite programs should be established before attempting to implement the
HACCP program.
Each company will determine the appropriate internal procedures to follow to
ensure that the programs are implemented as described and are effective.
Reminder - This document is not a customized model per se. Each brewery using
this working guide is responsible for producing its own customized HACCP
program.
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HACCP Working Group Members
The BAC HACCP Working Group was established under the direction of the
Product Integrity Committee of the Brewers Association of Canada.
These Pre-requisite Programs have been developed by the Brewers Association
of Canada (BAC) with a Technical Committee comprised of industry members,
government
representatives
and
food
safety
consultants.
The
BAC
acknowledges the committee members for their outstanding contribution to the
BAC/HACCP project.
We also extend our appreciation and gratitude to Agriculture and AgriFood Canada and the Canadian Food Inspection Agency for their financial
and technical support of this project.
Mr. B. Andrews
Molson Canada
Ms. E. Bounsall
Brasserie McAuslan
Ms. S. Buttenham
Sleeman Breweries Ltd.
Ms. M. Dewar
Brewers Association of Canada
Dr. T. Dowhanick
Labatt Breweries of Canada
Ms. A. Fuller
Great Western Brewing Company
Mr. L Harford
Brewers Association of Canada
Mr. M. Ligas
Magnotta Brewery
Mr. G. Muise
Pump House Brewery
Mr. R. Savage
Molson Canada
Mr. A. Kassianenko
Canadian Food Inspection Agency
Mr. G. Sundeen
Canadian Food Inspection Agency
Mr. F. Schreurs
Guelph Food Technology Centre
Mr. P. Medeirois
Guelph Food Technology Centre
Mr. K. McMillan
Guelph Food Technology Centre
Ms. A. Brown
Guelph Food Technology Centre
Ms. M. Harris-Bailey
Guelph Food Technology Centre
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HACCP Principle 1 - Hazard Identification
Principle 1: Conduct a hazard analysis.

A product safety hazard is any biological, chemical, or physical
property that may cause beer to be unsafe for human consumption.

Breweries determine the product safety hazards and identify the
preventive measures the plant can apply to control these hazards.
On the basis of available information for each of the ingredients used in beer and
for each of the process steps in brewing, potential biological, physical and
chemical hazards are identified.
Information sources include published
databases, scientific literature, company records, external and internal audits etc.
In addition to identifying potential hazards, Forms 5, 6 and 7 are used to identify
the control points.
Diagrams for Hazards Identification and CCP Decision Tree
Critical Control Points for breweries are determined using the HACCP Decision
Tree. The Decision Tree was first developed by a Codex Alimentarius working
group on HACCP in June 1991. This Decision Tree has been slightly modified to
include a prescreening question and preliminary instructions.
Pre-screening question = Determine if (hazard) fully controlled by Pre-requisite
Programs. If ‘yes’, indicate “Pre-requisite Program(s)” and proceed to the next
identified hazard. If ‘no’, proceed to Question 1. (See Appendix)
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HACCP Principle 2 - Critical Control Points
Principle 2: Identify critical control points.
A critical control point (CCP) is a point, step, or procedure in a food process at
which control can be applied and, as a result, a food safety hazard can be
prevented, eliminated, or reduced to an acceptable level.
Using the Decision Tree, Form 8 is completed. The last column is where Critical
Control Points are identified. CCP’s are labelled numerically with a category
qualifier for Biological, Physical and Chemical (B, P or C) hazard and expected
outcome of the control measure (elimination of risk(e), prevention (p), or
minimize or reduce (r)). In this model , the Critical Control Points in breweries were identified
as follows:
Step
CCP #
Empty Bottle Inspection
CCP1-P
Empty Bottle Inspection/ Residual Liquid Detector
CCP1-C
Filling (Auto-Flush Only)
CCP2-P
Internal Cleaning (Manual)
CCP3-C
Hazards identified on Forms 5, 6 and 7 are either controlled at some point in the
brewing process or cannot be controlled by the facility. Form 9 is intended to
identify control measures that do not take place in the brewery but are controlled
elsewhere. No such hazards were identified in the analysis of breweries.
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HACCP Principle 3 - Critical Limits
Principle 3: Establish critical limits for each critical control point.

A critical limit is the maximum or minimum value to which a
physical, biological, or chemical hazard must be controlled at a
critical control point to prevent, eliminate, or reduce to an
acceptable level.
For each Critical Control Point, critical limits were established. These are values
which separate acceptability from unacceptability. They are intended to meet
government regulations, industry standards or other scientific data.
HACCP Principle 4 - Establish Monitoring Procedures
Principle 4: Establish critical control point monitoring requirements.
Monitoring is the act of conducting a planned sequence of observations or
measurements of control parameters to assess whether a CCP is under control.

Monitoring activities are necessary to ensure that the process is
under control at each critical control point. Each monitoring
procedure and its frequency will be listed in the HACCP plan.
At each CCP, the monitoring requirements and the means to ensure that the CCP
remains within the critical limits are specified. Monitoring procedures generally
relate to on-line processes and are usually by observation or by measurement.
The frequency of testing, who is responsible for carrying out the testing, and the
testing procedures must also be specified. The monitoring specifications are
written on Form 10 for each CCP.
Each brewery will develop its own
specifications, where required.
Monitoring tracks the system's operation and allows for action to be taken in the
event of a loss of control or where there is a trend toward the loss of control. It
provides information to a brewery on a timely basis, allowing for decisions on the
acceptability of the lot at a particular stage in the process. Monitoring procedures
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HACCP Principle 4 - Establish Monitoring Procedures (Continued)
performed in the establishment during operation will result in written
documentation that will serve as an accurate record of the operating conditions.
If any of the critical limits is out of control as determined by the monitoring
procedures, the CCP will be out of control. Lack of control at a CCP is defined as
being a critical defect or a deviation. Deviations will result in the production of a
hazardous or unsafe product Therefore, adequate and effective monitoring
procedures are essential due to the serious consequences arising from
deviations. Most monitoring procedures for CCPs must be rapid because they
relate to on-line processes and there is not sufficient time for lengthy analytical
testing. Physical and chemical measurements or visual observations are
preferred because they can be done rapidly. All monitoring equipment must be
properly calibrated for accuracy. Examples of some physical and chemical
measurements taken to monitor the critical limits are: temperature, time and pH.
There are many ways to monitor critical control points. Monitoring can be done
on a continuous or batch basis. The reliability of continuous monitoring (100 % is
preferred where feasible). The established monitoring frequency must be
sufficient to substantiate that the hazard is under control. Responsibility for
monitoring is clearly identified and individuals monitoring the CCPs must be
trained in the testing procedure and must fully understand the purpose and
importance of monitoring. The individual must have ready access to the
monitoring activity and must be unbiased in monitoring and reporting. Finally the
individual must accurately report the monitoring activity.
All operational records and documents that are associated with CCP monitoring
must be properly completed and signed by the person doing the monitoring and
verified/signed by a responsible official of the company.
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HACCP Principle 5 - Establish Deviation Procedures
Principle 5: Establish corrective actions.

These are actions to be taken when monitoring indicates a
deviation from an established critical limit. The final rule requires a
plant's HACCP plan to identify the corrective actions to be taken if a
critical limit is not met. Corrective actions are intended to ensure
that no product injurious to health or otherwise adulterated as a
result of the deviation enters commerce.
A deviation is defined as failure to meet the specified critical limits. Deviation
procedures are pre-determined and document the set of corrective actions that
are implemented when a deviation occurs.
All deviations must be corrected by taking appropriate corrective action(s) to
control the non-compliant product and to correct the cause of non-compliance.
The corrective action(s) taken must be recorded and filed.
A deviation procedure must describe the acceptable corrective action(s) for a
deviation. The diversity of possible deviations at each CCP means that more than
one corrective action may be necessary at each CCP. The corrective action(s)
must correct the cause of the deviation and must control the actual or potential
hazard resulting from the deviation. Product control includes proper identification,
and handling of the affected lots. The deviation procedures at each CCP are
written on Form 10. These procedures will be developed by each brewery in
accordance with the brewery’s requirements.
Corrective actions are prescribed and formalized so that employees responsible
for critical control point monitoring understand and are able to perform the
appropriate corrective action(s) in the event of a deviation.
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HACCP Principle 5 - Establish Deviation Procedures (Continued)
When a deviation occurs, it will most likely be noticed during the routine
monitoring of a CCP. A deviation results when the pre-determined critical limit for
a CCP is out of compliance. If the proper corrective action is not taken the
deviation may result in an unacceptable health risk.
HACCP Principle 6 - Establish Verification Procedures
Principle 6: Establish procedures for verifying the HACCP system is working as
intended.

Validation ensures that the plans do what they were designed to do;
that is, they are successful in ensuring the production of safe
product. Plants will be required to validate their own HACCP plans.

Verification ensures the HACCP plan is adequate, that is, working
as intended. Verification procedures may include such activities as
review of HACCP plans, CCP records, critical limits and analytical
data
Verification activities are methods, procedures and tests used to determine if the
HACCP plans for that establishment are valid and are operating properly.
Verification activities are generally involved and may include analytical testing. In
carrying out the verification activities, the establishment may find that some
hazards were overlooked or they may discover new or unexpected hazards. In
this case, the plan needs to be modified appropriately. The verification
procedures at each CCP are written on Form 10 by each brewery in accordance
with the brewery requirements. Both the establishment and the CFIA will have a
role in verifying HACCP plan compliance and will carry out activities to verify that
the HACCP plan is operating properly. Verification activities differ from monitoring
activities. Results from verification activities are not intended to make decisions
on the acceptability of lots of product. Verification activities involve for example,
analytical testing or auditing of the monitoring procedures, product sampling,
audits of monitoring and verification records.
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HACCP Principle 7 - Establish Record Keeping/ Documentation
Principle 7: Establish record keeping procedures.

The HACCP program requires that all plants maintain certain
documents, including its hazard analysis and written HACCP plan,
and records documenting the monitoring of critical control points,
critical limits, verification activities, and the handling of critical limit
deviations.
The HACCP records are defined as the record keeping that is done at each CCP
and that contain the information required to ensure that the HACCP plan is
followed.
Records are essential in determining the compliance of the establishment in
following the agreed-upon HACCP plan. The HACCP records differ from the
records that are kept to ensure compliance to the pre-requisite program
requirements. The required HACCP records to be kept at each CCP are written
on Form 10 by each brewery in accordance with the brewery requirements.
Monitoring results are documented together with any deviations and corrective
action taken. Failure to document the control of a CCP would be a critical
departure from the HACCP plan. Verification activities are also to be recorded.
Records must specify who recorded the information and must indicate who
reviewed and signed off the information.
A record may be in any form (processing chart, written record, computerized
record) and show the historical record of the process, the monitoring, the
deviations and the corrective actions (including disposition of product) that
occurred at the identified CCP. The information contained in the records is used
to establish the product's processing profile that would be used if there are any
subsequent problems. Accurate records allow for trace back of the actual
manufacturing conditions which will aid in troubleshooting if a problem arises.
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HACCP Principle 7 - Establish Record Keeping/ Documentation
(Continued)
The importance of records to the HACCP program must be emphasized. The
records are an important tool that is
used to ensure that the establishment is
following the agreed upon HACCP plan. It will be imperative that the
establishment maintain up-to-date, properly filed, and accurate records.
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BAC GENERIC HACCP
PROGRAM
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FORM 1:
PRODUCT/PROCESS
DESCRIPTION
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HACCP Plan - Form 1
Page 1 of 1
Title: Form 1 – Product Description
Completed By: BAC TC
Approved By: BAC TC
BAC Generic
Date:
Date:
Process/Product Name: BEER
1. Product Name(s)
Beer, Ale, Stout, Malt Liquor
 As defined in the Food and Drug Regulations B.02.130 to
B.02.132.

3
3. How it is to be used

Consumer product - Alcoholic beverage
4. Packaging





Glass bottles
Lined aluminum bottles
Lined cans
Stainless steel kegs
Plastic bottles (PET etc.)
5. Shelf Life
Shelf Life Information required.
6. Where it will be sold

2. Important Product
Characteristics
(aw, pH, PRESERVATIVES..)

7. Labelling Instructions



8. Special Distribution
Control
Government sales provisions apply - licensed retailers, hotels
etc.
On premise and off premise
Food and Drug Regulations (i.e. alcohol content labelling)
Consumer Packaging and Labelling Legislative/Regulatory
requirements
Claims allowed by Health Canada (i.e. energy value)
Inspection done on third party carriers and carriers dedicated to
food
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FORM 2:
LIST OF PRODUCT
INGREDIENTS AND
INCOMING MATERIALS
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HACCP Plan - Form 2
Page 1 of 1
BAC Generic
Title: Form 2 List of Product Ingredients and Incoming Materials
Completed By: BAC TC
Date:
Approved By: BAC TC
Date:
Product Name: BEER
LIQUID INGREDIENTS
DRY INGREDIENTS
(allowable)
PRIMARY PACKAGING
MATERIALS

Potable water

Barley malt B C P

New Glass P
- City Water B C P

Wheat malt B C P

Used glass B C P
- Well/ Surface Water B C P

Hops BC P

Lined aluminum cans P
- Purchased Water B C

Cereal grain e.g. wheat
(non-malted), corn, oats,
rice B C P

Lined aluminum bottles P

New stainless steel kegs P

Used stainless steel kegs None

Plastic bottles e.g. PET None

Crowns , Closures and Can
Ends None
OTHER INGREDIENTS (allowable)
OTHER INGREDIENTS
(allowable)
OTHER INGREDIENTS
(allowable)

Caramel C P

Preservatives C

Yeast B C

Dextrin C P


Food enzymes C
- Ascorbic Acid, Calcium
Ascorbate, Potassium
Metabisulphite, Sodium
Metabisulphite
Carbohydrate matter, e.g.
sucrose, syrup Honey

Salt C P

Hop oil C P

Hop extract C P

Carbon dioxide C
- Amylase, Glucoamylase,
Glucanase, Papain,
Pentosanase, Protease

Stabilizing agents C
- Calcium Alginate,
Carrageenan, Propylene
Glycol Alginate

Water preparation
agents C
- Ammonium Phosphate,
dibasic, Calcium Chloride,
Calcium Hydroxide,
Calcium Sulphate, Citric
Acid, Lactic Acid,
Magnesium Sulphate,
Phosphoric Acid,
Sulphuric Acid

Yeast foods C
- Manganese Sulphate,
Phosphoric Acid, Zinc
Sulphate, Ammonium
Persulphate (brewers’ yeast)

Processing aids B C
- Irish Moss Seaweed;
Activated Carbon;
Magnesium Silicate;
Cellulose; China Clay;
Diatomaceous Earth; Gelatin;
Silica Gel;
Polyvinylpolypyrrolidone;
Wood Shavings derived from
oak, beech, hazelnut or
cherry wood;
Dimethylpolysiloxane (wort),
Hydrogen Peroxide (mash);
- Purchased CO2
- Regenerated CO2

Liquid wheat extract C P

Nitrogen/ Oxygen/ Compressed
Air C
B/ C/ P = Biological (B) or Chemical (C) or Physical (P) hazard(s) identified.
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FORM 3:
PROCESS FLOW DIAGRAM
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HACCP Plan - Form 3
BAC GENERIC HACCP PLAN FORM 3
Approved By: BAC HACCP Technical Committee
Approval Date:
Total # of Pages Including Key = 12
Page 1 of 12
KEY
Box with no fill = Process Step
Blue Filled Box = Input
Yellow Filled Box = Output
Dotted Line = Optional Step
Red Filled Circle = Last step in process
Open-ended Box = Chemical/ Material used
that is not an ingredient or processing aid
that does not contact the product directly .
B
Biological Hazard identified at this step
C
Chemical Hazard identified at this step
P
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Physical Hazard identified at this step
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HACCP Plan - Form 3
MASTER FLOWCHART OF
MAJOR PROCESS STEPS (PS) FOR MAKING BEER (Page 2 of 12)
FULL TANKER
(Step T6) B C
RECEIVING
(PS1) B C P
STORAGE & HANDLING
(Step PS2) B C P
Water & Dry
Ingredients
Yeast,
Processing
Aids
FULL TANKER
UNLOADING
(Step T7) B C
BREWING
(Step PS3) C
MILLING/ MASHING/ LAUTERING
KETTLE/ WHIRLPOOL/ COOLING
FERMENTATION
(Step PS4) C
Processing
Aids, CO2
AGING
(Step PS5) C
CLARIFICATION/ FILTERING
BRIGHT BEER STORAGE
(Step PS6) C
Bottles, Cans, Kegs,
Crowns, Tankers
New
Bottles
Prep
PS8 (NB)
CP
Returned
Bottles
Prep
PS8 (RB)
BCP
BRIGHT BEER
PROCESSING
(Step PS7) C
PACKAGING
(Step PS8)
BOTTLING
Step PS8 (BT) C P
CANNING
Step PS8 (C) B C
KEGGING
Step PS8 (K) C
TANKERING
Step PS8 (T) B C
- Washing
- Inspection
- Filling
- Flushing
- Rinsing
- Filling
- Packing
- Cleaning
- Filling
- Palletizing
- Filling
WAREHOUSING/ SHIPPING
(Step PS9)
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HACCP Plan - Form 3
PS3 - BREWING (Page 3 of 12)
RECEIVING
(Step B1) B C P
Storage
(Step B2) B C P
Milling
(Step B3) C
Cereal Cooker
(Step B4)
Mashing
(Step B5)
Lautering
(Step B6)
Holding Tank
(Step B7)
Kettle
(Step B8)
Whirlpool
(Step B9)
Oxygen
Wort Cooling
(Step B10)
Next Process - PS4
Fermentation
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HACCP Plan - Form 3
PS4 - FERMENTATION (Page 4 of 12)
COLD WORT
Oxygen/ Sterile
Air
WORT OXYGENATION/
WORT AERATION
(Step F1 )
Yeast Propagation
(Step Y1)
Yeast Storage
(Step Y2)
Acid Washing
(Step Y3)
YEAST
FERMENTATION
(Step F2)
CO2
Cooling
(Step F3) C
Yeast
Removal
GREEN BEER
(Step F4)
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Next Process - PS5 -Aging/
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Clarification/ Filtration
HACCP Plan - Form 3
PS5 - AGING/ CLARIFICATION/ FILTRATION (Page 5 of 12)
GREEN BEER
COOLING
(Step A1) C
Buffer tank
(Step A2)
Centrifuge
(Step A3)
Processing aids,
Stabilizers,
CO2, Preservatives
Yeast,
By-products
Buffer tank
(Step A4)
CO2
Cooling tank
(Step A5) C
CO2, Hops
Aging Tank
(Step A6) C
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives
Caramel & other
ingredients,
Processing aids,
Stabilizers, CO2,
Preservatives
Beer,
Spent Hops, CO2
Secondary Storage
(Step A7) C
CO2, Spent
Yeast
Surge/ Buffer Tank
(Step A8) C
Filtration
(Step A9) C
CO2
CO2, Spent
Yeast
Deaerated water,
CO2, Nitrogen
Bright Beer Storage
(Step A10 = PS6) C
CO2
Next Process - PS7 Bright BeerProcessing
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HACCP Plan - Form 3
PS7 (BBP) - BRIGHT BEER PROCESSING
PS7 (SF)
STERILE FILTRATION
CO2
(Page 6 of 12)
PS7 (P)
FLASH PASTEURIZATION
Bright Beer Tank
(Step SF1) C
Bright Beer Tank
(Step FP1) C
Filtration
(Step SF2) C
Flash Pasteurization
(Step FP2) C
Sterile Beer Tank
(Step SF3)
Pasteurized Beer Tank
(Step FP3)
Next Process - PS8 -Packaging
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Next Process - PS8 -Packaging
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HACCP Plan - Form 3
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HACCP Plan - Form 3
Process Step 8
PS8 (RB) - RETURNED BOTTLES PREP
(Page 7 of 12)
Receiving/ Storage
(Step RB1) P
Caustic
Hydro Jet Sprays
(Step RB8) B C P
De-Palletizing
(Step RB2) P
De-Casing & Inspection
(Steps RB3-4) P
Post Soak
(Step RB9 C P
Bottle Wash Loading
(Step RB5) P
External Flush
(Step RB10) P
Pre-Rinse
(Step RB6) P
Water,
Chemicals &
Steam
External Rinse
(Step RB11) P
Soak Tanks (caustic)
(Step RB7) C P
Water
Interior Rinse
(Steps RB12) C P
Water
FINAL RINSE
(Step RB13) C P
Next: (PS8- BT) Bottling
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3
Process Step 8
PS8 (NB) - NEW BOTTLES PREP
(Page 8 of 12)
Receiving
(Step NB1) P
Preliminary Inspection
(Step NB2) P
Storage
(Step NB3-6) P
Inspection
(Step NB7) P
RINSE
(Steps NB8-9) C P
Next: (PS8- BT) Bottling
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3
Process Step 8
PS8 (BT) - BOTTLING (Page 9 of 12)
BOTTLES - See
Returned Bottles Prep
& New Bottle Prep
Air
Empty Bottle Inspection
Drying
(Step BT11)
(Steps BT1) C P
Water
Down Bottle Filler In-Feed Control
(Steps BT2) P
Label & Code
(Steps BT12-13)
Bright Beer,
CO2, Compressed Air
Water
Filling
(Steps BT3-5) C P
CO2,
Glass
Filled Bottle Inspection
(Step BT14)
Crowns, Compressed Air
Water
Crowning
(Step BT6 ) C P
Water
Bottle Flush (External)
(Steps BT7-8)
Steam
& Chemicals
Pasteurize
(Step BT9)
Foam Inspection/ Candling
(Step BT10) P
Packing & Sealing
(Steps BT15-18)
Secondary Code & Full Case
Inspection
(Steps BT19-20)
Palletize
(Step BT21)
Storage
(Step BT22)
Live Load
SHIPPING
(Step BT23)
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3
Process Step 8
PS8 (K) - KEGGING (Page 10 of 12)
KEGS
Receiving
(Step K1)
Racking
(Step K7)
Storage, Handling,
De-palletizing
(Steps K2-3)
Internal Cleaning
Manual
(Steps K8-12) C
Internal Cleaning
Automated
(Steps K8-12) C
Filling (Step K18) C
Barnes Neck Wash &
Sanitize
(Step K19-21)
External Inspection
(Step K4 )
Sterilize & Hold
(Step K13)
Dust Cap Applied
(Steps K22)
Purge to Empty &
Counter Pressure
(Steps K14-15)
Air Dry
(Step K23)
Barnes Neck Sanitize &
Inspect
(Step K16-17)
Code
(Step K24)
External Cleaning
(Steps K5-6)
Weigh & Palletize
(Steps K25-26)
Storage
(Step K27)
Live Load
SHIPPING
(Step K28)
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3
Process Step 8
PS8 (C) - CANNING (Page 11 of 12)
CANS
Drying (Steps C16-17)
Receiving
(Step C1)
Coding
(Step C6)
Storage & Handling
(Step C2) B C
Fill Height Inspection
(Step C18)
Rinser
(Step C7) C
Depalletizing/ Pallet ID
(Steps C3-4 )
Inspection
(Step C5)
Divert to Packers
(Steps C19)
Bright
Beer,
CO2
Filling
(Steps C8- 10)
CO2
Hi Cone Machine
(Step C20)
Can Ends
Water
Seaming
(Steps C11-13) C
External Flush
(Step C14)
Pastuerizer
(Step C15)
Case Packers
(Steps C21)
Inspection
(Step C22)
Tray Machine & Code
(Steps C23-24)
Palletize
(Step C25)
Storage
(Step C26)
Live Load
SHIPPING
(Step C27)
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3
Process Step 8
PS8 (T) - TANKERING (Page 12 of 12)
Empty Tanker
(Step T1) C
Caustic, Water,
Acid
CO2
Tanker Washing
(Step T2) C
Tanker Purge
(Step T3) C
CO2
Bright Beer,
CO2
Tanker Filling
(Step T4) B C
Tanker Shipping
(Step T5)
Full Tanker Receiving
(Step T6) B C
FULL TANKER UNLOADING
(Step T7) B C
BAC Generic HACCP Model
Revision Date: November 2009
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FORM 4:
SCHEMATIC DIAGRAM
BAC Generic HACCP Model
Revision Date: November 2009
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BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 4
Page 1 of 1
BAC Generic
Title: Form 4 – Schematic Diagram
Completed By: BAC TC
Approved By: BAC TC
Date:
Date:
Note: Each brewery must be individually assessed at the time of implementation to ensure identified
hazards have been addressed.
Schematic Diagram
TO BE COMPLETED –
BAC Generic HACCP Model
Revision Date: November 2009
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BAC Generic HACCP Model
Revision Date: November 2009
Page 49 of 252
FORM 5:
HAZARD IDENTIFICATION
BIOLOGICAL HAZARDS
BAC Generic HACCP Model
Revision Date: November 2009
Page 50 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 51 of 252
HACCP Plan - Form 5
BAC Generic
Title: Form 5 – Hazard Identification - Biological Hazards
Completed By: BAC TC
Date:
Approved By: BAC TC
Date:
List all biological hazards
related to ingredients,
incoming material,
processing, product flow,
etc.
Identified biological
hazards (Bacteria,
parasites, viruses,
etc.)
Controlled at:
INGREDIENTS
LIQUID INGREDIENTS
City Water
Coliform, E. Coli
Purchased Water
Coliform, E. Coli
Well/ Lake/ Surface/ Water
Coliform, E. Coli,
Parasites
DRY INGREDIENTS
Barley malt
Micro (fecal
contamination from birds,
mice)
Wheat (malted/ non-malted),
Micro (fecal
contamination from birds,
mice)
Cereal Grain, e.g. corn, oats,
rice
Micro (fecal
contamination from birds,
mice)
Hops
Fecal contamination
(E. coli)
OTHER INGREDIENTS
Yeast
Cross contaminated e.g.
Salmonella
Carbohydrate Matter
(e.g. sucrose, syrup,
honey)
Clostridium
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 5
OTHER INGREDIENTS (Continued)
Yeast
Cross contaminated e.g.
Salmonella
Carbohydrate Matter
(e.g. sucrose, syrup,
honey)
Clostridium
Salt
None identified
Hop Oil
None identified
Hop Extract
None identified
Nitrogen/ Oxygen/
Compressed Air
Purchased CO2
None Identified
Regenerated CO2
None identified
Liquid Wheat Extract
None identified
Caramel
None identified
Dextrin
None Identified
Food Enzymes
None identified
Stabilizing Agents
None identified
Water preparation agents
None identified
Preservatives
None Identified
Yeast Foods
None Identified
Processing aids
Examples – Gelatin, Irish
Moss, Wood Shavings
Fecal contamination (e.g.
Gelatin, Irish Moss)
PRIMARY PACKAGING MATERIAL
New glass
None identified
Used glass
Bacteria
Lined aluminum cans and
bottles
None identified
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 5
New Kegs
None identified
PRIMARY PACKAGING MATERIAL (Continued)
Used Kegs
None identified
Plastic Bottles, e.g. PET
None Identified
Crowns
None identified
Closures & Can Ends
None Identified
PROCESS STEPS
PS1- RECEIVING
Micro contamination from
receiving open containers
(e.g. bird droppings).
PS2- STORAGE/ HANDLING
Mold growth from
improper storage
conditions
Insect or pest infestation
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
None identified
B4 - Cereal Cooker
None identified
B5 - Mashing (Mash Mixer,
Mash Cooker)
None identified
B6 - Lautering (Lauter Tun,
Mash Filter removal of spent
grains
None identified
B7 – Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified
B10 - Wort Cooling (Heat
Exchanger)
None identified
PS4 -FERMENTATION
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 5
Cold Wort (from B10)
None identified
PROCESS STEPS (Continued)
F1 Wort Oxygenation/ Wort
Aeration
None identified
F2 - Fermentation
None identified
F3 - Cooling
None identified
F4 - Green Beer
None identified
PS4 – SUB-PROCESS YEAST
PREPARATION
Y1 – Propagation
None identified
Y2 – Storage
None identified
Y3 – Acid Washing
None identified
PS5 - AGING/ CLARIFICATION/
FILTRATION
A1 - Cooling
None identified
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
None identified
A6 - Aging Tank
None identified
A7 - Secondary Storage
None identified
A8 - Surge/ buffer Tank
None identified
A9 – Filtration
None identified
A10 – Bright Beer Storage
(See PS6 below)
PS6 – BRIGHT BEER STORAGE
None identified
PS7 BRIGHT BEER PROCESSING
PS7 (SF) – Sterile Filtration
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 5
SF1 - Bright Beer Tank
None identified
PROCESS STEPS (Continued)
SF2 - Filtration
None identified
SF3 - Sterile Beer Tank
None identified
PS7(FP) – Flash Pasteurization
FP1 - Bright Beer Tank
None identified
FP2 - Pasteurization
None identified
FP3 - Pasteurized Beer Tank
None identified
PS8 RB –
RETURNED BOTTLES PREP
(FLOAT GLASSWARE PREP)
RB1 - Receiving/ Storage
None identified
RB2 - De-palletizing
None identified
RB3- RB4 - De-casing &
Inspection (visual)
None identified
RB5 - Bottle Wash Loading
None identified
RB6 - Pre-rinse sprays
None identified
RB7 - Soak Tanks With Caustic
None identified
RB8 - Hydro Jet Sprays
Spray malfunction and
debris is left in bottle (e.g.
pathogenic Clostridium,
Listeria, Hepatitis (A/B/C)
RB9- Post-Soak
None identified
RB10 - External Flush
None identified
RB11 - Ext. Rinse
None identified
RB12 - Interior Rinse
None identified
RB13 - Final Rinse
None identified
PS8 NB NEW BOTTLES (GLASSWARE)
PREP
NB1- NB2 - Receiving &
Preliminary Inspection
BAC Generic HACCP Model
Revision Date: November 2009
None identified
Page 56 of 252
HACCP Plan - Form 5
NB3 – NB 6 Storage (Pallet
Prep, De-palletize)
None identified
PROCESS STEPS (Continued)
NB7 – Inspection (Human,
visual)
None identified
NB8 - Bottle Loading,
None identified
NB9 - Bulk Glass Rinser
None identified
PS8 BT - BOTTLING
BT1
Empty Bottle Inspection
(Human or Machine inspection)
None identified
BT2 – Down Bottle Filler In-Feed
Control
None identified
BT3 – BT5 Filling (Purges ,
Filling, Fobbing)
None identified
BT6 - Crowning
None identified
BT7 – BT 8 Bottle Flush (Full
Bottle Wash - external)
None identified
BT9 –
Pasteurize
None identified
BT10 - Foam Inspection &/or
Candling
None identified
BT11 – Drying (Bottle Drying
and Air Knives)
None identified
BT12 – BT13 Labelling, Coding
None identified
BT14 – Filled Bottle Inspection
None identified
BT15 – BT18 Packing & Sealing
(Divert to packers, Carton, Case
Pack, Sealing)
None identified
BT19 – BT20 Secondary Code & None identified
Inspection (Secondary
Packaging, Code/Inspection)
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 5
BT21 –
Palletize
None identified
PROCESS STEPS (Continued)
BT22 - Storage (or Live Load)
None identified
BT23 - Shipping
None identified
PS8 (K) - KEGGING
K1 - Receiving (See PS1)
None identified
K2 – K3 Storage & Handling ,
De-palletizing (See PS2)
None identified
K4 - External Inspection
None identified
K5 – K6 External Cleaning (Ext
Wash/Inspection)
None identified
K7 –
Racking
None identified
K8 – K12 Internal Cleaning
(Purge, Flush, Wash, Purge,
Rinse)
None identified
K13 - Sterilize & Hold
None identified
K14 – K 15 Purge to Empty &
Counter pressure
None identified
K 16 - K17 Barnes Neck Sanitize None identified
& Inspect
K18 - Filling
None identified
K19 – K 21 Barnes Neck, Wash
& Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product Code Applied
None identified
K25 – K 26 Weigh (In-line
weighing) & Palletize
None identified
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 5
K27 - Storage
None identified
K28 - Shipping
None identified
PROCESS STEPS (Continued)
PS8 (C) - CANNING
C1 - Receiving
None identified
C2 - Storage & Handling
Bacterial contamination
from leaking roof or pipes
C3 – C 4 De-palletize / Pallet ID
(Collect & Timestamp Can Pallet
ID, De-palletize)
None identified
C5 - Online visual inspection
None identified
C6 - Primary code applied
None identified
C7 - Bulk in-line rinser
None identified
C8 – C 10 Filling (preevacuation & beer fill)
None identified
C11 – C13 Seaming
None identified
C14 - External Can Flush
None identified
C15 –
Pasteurizer
None identified
C16 – C17 Drying
None identified
C18 - Fill Height Inspection
None identified
C19 - Divert to Packers
None identified
C20 - Hi-Cone Machine
None identified
C21 - Case Packers
None identified
C22 – Inspection (Human,
visual) Inspection
None identified
C23 – C24 Tray Machine &
Code
None identified
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 5
C25 –
Palletize
None identified
C26 - Storage (or Live Load)
None identified
PROCESS STEPS (Continued)
C27 –
Shipping
None identified
PS8 T TANKERING
T1 - Empty Tanker (Receiving)
None identified
T2 - Tanker Washing/ Rinsing
None identified
T3 - Tanker Purging
None identified
T4 - Tanker Filling/ Loading
Insect or pest infestation
of hoses
T5 – Tanker Shipping
None identified
T6 – T7 Full Tanker Receiving &
Unloading
Insect or pest infestation
of hoses
BAC Generic HACCP Model
Revision Date: November 2009
Page 60 of 252
HACCP Plan - Form 5
Date:
BAC Generic HACCP Model
Revision Date: November 2009
Approved by:
Page 61 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 62 of 252
FORM 6:
HAZARD IDENTIFICATION
CHEMICAL HAZARDS
BAC Generic HACCP Model
Revision Date: November 2009
Page 63 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 64 of 252
HACCP Plan - Form 6
BAC Generic
Title: Form 6 – Hazard Identification - Chemical Hazards
Completed By: BAC TC
Date:
Approved By: BAC TC
Date:
List all chemical hazards related
to ingredients, incoming
material, processing, product
flow, etc.
Identified chemical hazards
Controlled at:
INGREDIENTS
LIQUID INGREDIENTS
City Water
Pesticides, Heavy metals
Purchased Water
Cleaning chemicals, cross
contamination from previous
load
Well/ Lake/ Surface/ Water
Pesticides, Heavy metals
DRY INGREDIENTS
Barley malt
Pesticides, Mycotoxins,
Allergen (cross-contamination
from carrier), NDMA
Wheat (malted/ non-malted),
Pesticides, Mycotoxins,
Allergen, NDMA
Cereal Grain, e.g. corn, oats,
rice
Pesticides, Mycotoxins,
Allergen (cross-contamination
from carrier), NDMA
Hops
Pesticides, Mycotoxins
OTHER INGREDIENTS
Yeast
Heavy Metals, cleaning
chemicals (used in tankers)
Carbohydrate Matter
(e.g. sucrose, syrup,
honey)
Antibiotic residue, heavy
metal (honey)
Salt
Non-food grade
Hop Oil
Residual solvents, Non-food
grade
BAC Generic HACCP Model
Revision Date: November 2009
Page 65 of 252
HACCP Plan - Form 6
OTHER INGREDIENTS (Continued)
Hop Extract
Residual solvents, Non-food
grade
Nitrogen/ Oxygen/
Compressed Air
Purchased CO2
Chemical non-volatile gases,
Non-food grade
Regenerated CO2
Contamination from oil (from
the compressor)
Liquid Wheat Extract
Allergen
Caramel
Non-food grade
Dextrin
Non-food grade
Food Enzymes
Non-food grade
Stabilizing Agents
Heavy metals, Non-food
grade
Water preparation agents
Heavy metals, Non-food
grade
Preservatives
Allergens (Sulphites), Nonfood grade
Yeast Foods
Heavy metals, Non-food
grade
Processing aids
Examples – Gelatin, Irish
Moss, Wood Shavings
Heavy metals, Non-food
grade
PRIMARY PACKAGING MATERIAL
New glass
None identified
Used glass
Lubricants, mycotoxins
Lined aluminum cans and
bottles
None identified
New Kegs
None identified
Used Kegs
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 66 of 252
HACCP Plan - Form 6
PRIMARY PACKAGING MATERIAL (Continued)
Plastic Bottles, e.g. PET
None identified
Crowns
None identified
Closures & Can Ends
None identified
PROCESS STEPS
PS1- RECEIVING
Chemical – Contamination
from truck (damage, leaks,
odors)
PS2- STORAGE/ HANDLING
Chemical - Crosscontamination from allergens
(e.g. wheat)
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
Chemical – Allergen crosscontamination (e.g. from
residues in the mill)
B4 - Cereal Cooker
None identified
B5 - Mashing (Mash Mixer,
Mash Cooker)
None identified
B6 - Lautering (Lauter Tun,
Mash Filter removal of spent
grains
None identified
B7 – Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified
B10 - Wort Cooling (Heat
Exchanger)
None identified
PS4 -FERMENTATION
Cold Wort (from B10)
None identified
F1 Wort Oxygenation/ Wort
Aeration
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 67 of 252
HACCP Plan - Form 6
PRIMARY PACKAGING MATERIAL (Continued)
F2 - Fermentation
None identified
F3 - Cooling
Coolant leak
F4 - Green Beer
None identified
PS4 – SUB-PROCESS YEAST
PREPARATION
Y1 – Propagation
None identified
Y2 – Storage
None identified
Y3 – Acid Washing
None identified
PS5 - AGING/ CLARIFICATION/
FILTRATION
A1 - Cooling
Coolant leak
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
Coolant leak
A6 - Aging Tank
Coolant leak
A7 - Secondary Storage
Coolant leak
Sulphites as an allergen
A8 - Surge/ buffer Tank
Sulphites as an allergen
A9 – Filtration
Sulphites as an allergen
A10 – Bright Beer Storage
(See PS6 below)
PS6 – BRIGHT BEER STORAGE
Coolant leak
Sulphites as an allergen
Cleaning chemicals
PS7 BRIGHT BEER
PROCESSING
PS7 (SF) – Sterile Filtration
SF1 - Bright Beer Tank
BAC Generic HACCP Model
Revision Date: November 2009
Coolant leak
Sulphites as an allergen
Cleaning chemicals
Page 68 of 252
HACCP Plan - Form 6
PRIMARY PACKAGING MATERIAL (Continued)
SF2 - Filtration
Sulphites as an allergen
SF3 - Sterile Beer Tank
None identified
PS7(FP) – Flash Pasteurization
FP1 - Bright Beer Tank
Coolant leak
Sulphites as an allergen
Cleaning chemicals
FP2 - Pasteurization
Contamination from coolant
FP3 - Pasteurized Beer Tank
None identified
PS8 RB –
RETURNED BOTTLES PREP
(FLOAT GLASSWARE PREP)
RB1 - Receiving/ Storage
None identified
RB2 - De-palletizing
None identified
RB3- RB4 - De-casing &
Inspection (visual)
None identified
RB5 - Bottle Wash Loading
None identified
RB6 - Pre-rinse sprays
None identified
RB7 - Soak Tanks With
Caustic
Too concentrated, too low, no
caustic, wrong chemical
Bottle unable to drain
RB8 - Hydro Jet Sprays
Bottle unable to drain
RB9- Post-Soak
Bottle unable to drain
RB10 - External Flush
None identified
RB11 - Ext. Rinse
None identified
RB12 - Interior Rinse
Spray malfunction
Bottle plugged unable to drain
RB13 - Final Rinse
Bottle unable to drain
PS8 NB NEW BOTTLES (GLASSWARE)
PREP
BAC Generic HACCP Model
Revision Date: November 2009
Page 69 of 252
HACCP Plan - Form 6
PRIMARY PACKAGING MATERIAL (Continued)
NB1- NB2 - Receiving &
Preliminary Inspection
None identified
NB3 – NB 6 Storage (Pallet
Prep, De-palletize)
None identified
NB7 – Inspection (Human,
visual)
None identified
NB8 - Bottle Loading,
None identified
NB9 - Bulk Glass Rinser
Contaminated air, sanitizing
spray
PS8 BT - BOTTLING
BT1
Empty Bottle Inspection
(Human or Machine
inspection)
MACHINE:
Failure of the system to detect
residual liquid and caustic
BT2 – Down Bottle Filler InFeed Control
None identified
BT3 – BT5 Filling (Purges ,
Filling, Fobbing)
CIP chemicals in bottle
BT6 - Crowning
Lubricants
BT7 – BT 8 Bottle Flush (Full
Bottle Wash - external)
None identified
BT9 –
Pasteurize
None identified
BT10 - Foam Inspection &/ or
Candling
None identified
BT11 – Drying (Bottle Drying
and Air Knives)
None identified
BT12 – BT13 Labelling,
Coding
Product not coded or not
correctly coded
BT14 – Filled Bottle Inspection
None identified
BAC Generic HACCP Model
Revision Date: November 2009
HUMAN:
Failure of personnel to detect
residual liquid
Page 70 of 252
HACCP Plan - Form 6
PRIMARY PACKAGING MATERIAL (Continued)
BT15 – BT18 Packing &
Sealing
(Divert to packers, Carton,
Case Pack, Sealing)
None identified
BT19 – BT20 Secondary Code
& Inspection (Secondary
Packaging, Code/Inspection)
Product not coded or not
correctly coded
BT21 –
Palletize
None identified
BT22 - Storage (or Live Load)
None identified
BT23 - Shipping
None identified
PS8 (K) - KEGGING
K1 - Receiving (See PS1)
None identified
K2 – K3 Storage & Handling ,
De-palletizing (See PS2)
None identified
K4 - External Inspection
None identified
K5 – K6 External Cleaning
(Ext Wash/Inspection)
Old codes not effectively
removed
K7 –
Racking
None identified
K8 – K12 Internal Cleaning
(Purge, Flush, Wash, Purge,
Rinse)
Automated
Cleaning solution not
effectively removed.
Manual
Cleaning solution not
effectively removed.
K13 - Sterilize & Hold
None identified
K14 – K 15 Purge to Empty &
Counter pressure
None identified
K 16 - K17 Barnes Neck
Sanitize & Inspect
None identified
K18 - Filling
CIP solution
BAC Generic HACCP Model
Revision Date: November 2009
Page 71 of 252
HACCP Plan - Form 6
PRIMARY PACKAGING MATERIAL (Continued)
K19 – K 21 Barnes Neck,
Wash & Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product Code Applied
Incorrect or missing code
K25 – K 26 Weigh (In-line
weighing) & Palletize
None identified
K27 - Storage
None identified
K28 - Shipping
None identified
PS8 (C) - CANNING
C1 - Receiving
None identified
C2 - Storage & Handling
Contamination from leaking
roof or pipes
C3 – C 4 De-palletize / Pallet
ID
(Collect & Timestamp Can
Pallet ID, De-palletize)
Incorrect or missing code on
pallet
C5 - Online visual inspection
None identified
C6 - Primary code applied
Incorrect or missing code –
C7 - Bulk in-line rinser
Chemicals from compressed
air or water
C8 – C 10 Filling (preevacuation & beer fill)
None identified
C11 – C13 Seaming
Chemicals, Lubricants
C14 - External Can Flush
None identified
C15 –
Pasteurizer
None identified
C16 – C17 Drying
None identified
C18 - Fill Height Inspection
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 72 of 252
HACCP Plan - Form 6
PRIMARY PACKAGING MATERIAL (Continued)
C19 - Divert to Packers
None identified
C20 - Hi-Cone Machine
None identified
C21 - Case Packers
None identified
C22 – Inspection (Human,
visual) Inspection
None identified
C23 – C24 Tray Machine &
Code
Incorrect or missing code
C25 –
Palletize
None identified
C26 - Storage (or Live Load)
None identified
C27 –
Shipping
None identified
PS8 T TANKERING
T1 - Empty Tanker (Receiving)
Cleaning chemicals and/ or
sanitizer
T2 - Tanker Washing/ Rinsing
Cleaning chemicals and/ or
sanitizer
T3 - Tanker Purging
Contaminated CO2
T4 - Tanker Filling/ Loading
Cross contamination from
using hose on non-food
material
T5 – Tanker Shipping
None identified
T6 – T7 Full Tanker Receiving
& Unloading
Cross contamination with
chemicals from the supplier
Cross contamination from
using hose on non-food
material
Date:
BAC Generic HACCP Model
Revision Date: November 2009
Approved by:
Page 73 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 74 of 252
FORM 7:
HAZARD IDENTIFICATION
PHYSICAL HAZARDS
BAC Generic HACCP Model
Revision Date: November 2009
Page 75 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 76 of 252
BAC Generic
Title: Form 7 – Hazard Identification - Physical Hazards
Completed By: BAC TC
Date:
Approved By: BAC TC
Date:
List all physical
hazards related to
ingredients, incoming
material, processing,
product flow, etc.
Identified physical
hazards
Controlled at:
INGREDIENTS
LIQUID INGREDIENTS
City Water
Silt
Purchased Water
None identified
Well/ Lake/ Surface/ Water
Silt
DRY INGREDIENTS
Barley malt
Glass, Metal
Wheat (malted/ nonmalted),
Glass, Metal
Cereal Grain, e.g. corn,
oats, rice
Glass, Metal
Hops
Insects, metal
OTHER INGREDIENTS
Yeast
None identified
Carbohydrate Matter
(e.g. sucrose,
syrup, honey)
None identified
Salt
Rocks
Hop Oil
Plastic
Hop Extract
Plastic
Nitrogen/ Oxygen/
Compressed Air
Purchased CO2
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 77 of 252
OTHER INGREDIENTS (Continued)
Regenerated CO2
None identified
Liquid Wheat Extract
Plastic (from packaging)
Caramel
Plastic (from container)
Dextrin
Plastic (from container)
Food Enzymes
None identified
Stabilizing Agents
None identified
Water preparation agents
None identified
Preservatives
None identified
Yeast Foods
None identified
Processing aids
Examples – Gelatin, Irish
Moss, Wood Shavings
None identified
PRIMARY PACKAGING MATERIAL
New glass
Critical Glass Defects , Glass
Used glass
Critical Glass Defects , Dirt,
Dust, Glass, Syringes, Medical
Patches
Lined aluminum cans
and bottles
Metal Shavings
New Kegs
Metal Shavings
Used Kegs
None identified
Plastic Bottles, e.g. PET
None identified
Crowns
None identified
Closures & Can Ends
None identified
PROCESS STEPS
PS1- RECEIVING
BAC Generic HACCP Model
Revision Date: November 2009
Pests in hoses used for
transferring material, Bulk
Receiving
Page 78 of 252
PROCESS STEPS (Continued)
PS2- STORAGE/ HANDLING
Insect or pest infestation
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
None identified
B4 - Cereal Cooker
None identified
B5 - Mashing (Mash Mixer,
Mash Cooker)
None identified
B6 - Lautering (Lauter Tun,
Mash Filter removal of
spent grains
None identified
B7 – Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified
B10 - Wort Cooling (Heat
Exchanger)
None identified
PS4 -FERMENTATION
Cold Wort (from B10)
None identified
F1 Wort Oxygenation/ Wort
Aeration
None identified
F2 - Fermentation
None identified
F3 - Cooling
F4 - Green Beer
None identified
PS4 – SUB-PROCESS
YEAST PREPARATION
Y1 – Propagation
None identified
Y2 – Storage
None identified
PROCESS STEPS (Continued)
BAC Generic HACCP Model
Revision Date: November 2009
Page 79 of 252
Y3 – Acid Washing
None identified
PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
None identified
A6 - Aging Tank
None identified
A7 - Secondary Storage
None identified
A8 - Surge/ buffer Tank
None identified
A9 – Filtration
None identified
A10 – Bright Beer Storage
None identified
PS6 – BRIGHT BEER
STORAGE
None identified
PS7 BRIGHT BEER
PROCESSING
PS7 (SF) – Sterile
Filtration
SF1 - Bright Beer Tank
None identified
SF2 - Filtration
None identified
SF3 - Sterile Beer Tank
None identified
PS7(FP) – Flash
Pasteurization
FP1 - Bright Beer Tank
None identified
FP2 - Pasteurization
None identified
FP3 - Pasteurized Beer Tank
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 80 of 252
PROCESS STEPS (Continued)
PS8 RB –
RETURNED BOTTLES PREP
(FLOAT GLASSWARE PREP)
RB1 - Receiving/ Storage
Damage to bottles
RB2 - De-palletizing
Damage to bottles
RB3- RB4 - De-casing &
Inspection (visual)
Damage to bottles
RB5 - Bottle Wash Loading
Damage to bottles
RB6 - Pre-rinse sprays
Damage to bottles (e.g.
Temperature shock due to
storage)
RB7 - Soak Tanks With
Caustic
Damage to bottles
RB8 - Hydro Jet Sprays
Damage to bottles
Bottle contains foreign object
(spray malfunction)
Bottle contains foreign object
(plugged but sprays cannot clear
object)
RB9- Post-Soak
Damage to bottles (e.g.
Temperature shock)
Bottle plugged
RB10 - External Flush
Damage to bottles (e.g.
Temperature shock)
RB11 - Ext. Rinse
Damage to bottles
(e.g. Temperature shock)
RB12 - Interior Rinse
Damage to bottles
Bottle contains foreign object
(spray malfunction)
Bottle contains foreign object
(plugged but sprays cannot clear
object)
BAC Generic HACCP Model
Revision Date: November 2009
Page 81 of 252
PROCESS STEPS (Continued)
RB13 - Final Rinse
Damage to bottles
Bottle contains foreign object
(spray malfunction)
Bottle contains foreign object
(plugged but sprays cannot clear
object)
PS8 NB NEW BOTTLES
(GLASSWARE) PREP
NB1- NB2 - Receiving &
Preliminary Inspection
Damage to bottles
NB3 – NB 6 Storage (Pallet
Prep, De-palletize)
Damage to bottles
NB7 – Inspection (Human,
visual)
Missed critical glass defects
NB8 - Bottle Loading,
Damage to bottles
NB9 - Bulk Glass Rinser
Spray malfunction
(e.g. plugged sprays)
PS8 BT - BOTTLING
BT1
Empty Bottle Inspection
(Human or Machine
inspection)
MACHINE:
Failure of the system to detect
foreign matter, glass defects,
bottle damage
HUMAN:
Failure of personnel to detect
foreign matter, glass defects,
glass damage
BT2 – Down Bottle Filler InFeed Control
Glass inclusions from breakage
of down bottle at filler in-feed
BT3 – BT5 Filling (Purges ,
Filling, Fobbing)
Chipping of bottles (e.g. from
filling equipment), glass
inclusion
Auto-Flush
Burst bottle leading to glass
inclusion
Manual Flush
Burst bottle leading to glass
inclusion
BAC Generic HACCP Model
Revision Date: November 2009
Page 82 of 252
PROCESS STEPS (Continued)
BT6 - Crowning
Bottle finish damage
(leading to glass inclusions)
BT7 – BT 8 Bottle Flush
(Full Bottle Wash - external)
None identified
BT9 –
Pasteurize
None identified
BT10 - Foam Inspection
&/or Candling
HUMAN:
Physical – Failure to detect
foreign matter (including glass)
MACHINE:
Physical – Failure to detect
foreign matter (including glass)
BT11 – Drying (Bottle
Drying and Air Knives)
None identified
BT12 – BT13 Labelling,
Coding
Product not coded or not
correctly coded
BT14 – Filled Bottle
Inspection
None identified
BT15 – BT18 Packing &
Sealing
None identified
(Divert to packers, Carton,
Case Pack, Sealing)
BT19 – BT20 Secondary
Code & Inspection
(Secondary Packaging,
Code/Inspection)
Product not coded, or not
correctly coded
BT21 –
Palletize
None identified
BT22 - Storage (or Live
Load)
None identified
BT23 - Shipping
None identified
PS8 (K) - KEGGING
K1 - Receiving (See PS1)
BAC Generic HACCP Model
Revision Date: November 2009
None identified
Page 83 of 252
PROCESS STEPS (Continued)
K2 – K3 Storage & Handling
, De-palletizing (See PS2)
None identified
K4 - External Inspection
None identified
K5 – K6 External Cleaning
(Ext Wash/Inspection)
Old codes not effectively
removed
K7 –
Racking
None identified
K8 – K12 Internal Cleaning
(Purge, Flush, Wash,
Purge, Rinse)
None identified
K13 - Sterilize & Hold
None identified
K14 – K 15 Purge to Empty
& Counter pressure
None identified
K 16 - K17 Barnes Neck
Sanitize & Inspect
None identified
K18 - Filling
None identified
K19 – K 21 Barnes Neck,
Wash & Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product Code Applied
Incorrect or missing code
K25 – K 26 Weigh (In-line
weighing) & Palletize
None identified
K27 - Storage
None identified
K28 - Shipping
None identified
PS8 (C) - CANNING
C1 - Receiving
None identified
C2 - Storage & Handling
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 84 of 252
PROCESS STEPS (Continued)
C3 – C 4 De-palletize /
Pallet ID
(Collect & Timestamp Can
Pallet ID, De-palletize)
Incorrect or missing code on
pallet
C5 - Online visual
inspection
None identified
C6 – Primary code applied
Incorrect or missing code –
C7 - Bulk in-line rinser
None identified
C8 – C 10 Filling (preevacuation & beer fill)
None identified
C11 – C13 Seaming
None identified
C14 - External Can Flush
None identified
C15 –
Pasteurizer
None identified
C16 – C17 Drying
None identified
C18 - Fill Height Inspection
None identified
C19 - Divert to Packers
None identified
C20 - Hi-Cone Machine
None identified
C21 - Case Packers
None identified
C22 – Inspection (Human,
visual) Inspection
None identified
C23 – C24 Tray Machine &
Code
Incorrect or missing code
C25 –
Palletize
None identified
C26 - Storage (or Live
Load)
None identified
C27 –
Shipping
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 85 of 252
PROCESS STEPS (Continued)
PS8 T TANKERING
T1 - Empty Tanker
(Receiving)
None identified
T2 - Tanker Washing/
Rinsing
None identified
T3 - Tanker Purging
None identified
T4 - Tanker Filling/ Loading
None identified
T5 – Tanker Shipping
None identified
T6 – T7 Full Tanker
Receiving & Unloading
None identified
Date:
BAC Generic HACCP Model
Revision Date: November 2009
Approved by:
Page 86 of 252
FORM 8:
CRITICAL CONTROL
POINTS
BAC Generic HACCP Model
Revision Date: November 2009
Page 87 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 88 of 252
Critical Control Points - Form 8
BAC Generic
Incoming
material/ process
step/ hazards on
schematic
diagram
Title: Form 8 – Critical Control Points
Completed By: BAC TC
Approved By: BAC TC
Category
and
identified
hazard.
Determine if fully controlled by
Pre-requisite program.
*If “yes” = indicate “Pre-requisite
Program” and proceed to next
identified hazard.
*If “no” = proceed to question1 (Q1).
Date:
Date:
Q1. Could a
control
measure(s)
be used by
the operator
at any
process
step?
If NO = not a
CCP +
identification
on how this
hazard will be
controlled
before and
after the
process
+ proceed to
the next
identified
hazard
If YES =
description +
next question
(Q2)
BAC Generic HACCP Model
Revision Date: November 2009
Q2. Is it
likely that
contaminati
on with the
identified
hazard
could
occur in
excess of
the
acceptable
level or
could
increase to
an
unacceptab
le level?
Q3. Is this
process
step
specificall
y
designed
to
eliminate/
reduce
the likely
occurrenc
e of the
identified
hazard to
an
acceptabl
e level?
If NO = not
a CCP +
proceed to
the next
identified
hazard
If NO =
next
question
(Q4)
If YES =
next
question
(Q3)
Page 89 of 252
If YES =
CCP + go
to last
column
Q4. Will a
subsequen
t step
eliminate
the
identified
hazard or
reduce
likely
occurrenc
e to an
acceptable
level?
CCP
Number
+ proceed
to next
identified
hazard
If NO = CCP + go to last
column
If YES =
not a CCP
+ identify
subsequent
step +
proceed to
the next
identified
hazard
Critical Control Points - Form 8
INGREDIENTS
LIQUID INGREDIENTS
WATER
City Water
Biological Coliform, E.
Coli
PP – Premises, Water Quality (BAC
A4.1) – All Hazards
Chemical Pesticides,
Heavy metals
Physical –
Silt
Purchased Water
Biological Coliform, E.
Coli
Chemical –
Cleaning
chemicals,
cross
contamination
from previous
load
Well/ Lake/
Surface/ Water
Biological Coliform, E.
Coli, Parasites
PP – Premises, Water Quality
(BAC A4.1)
PP - Transportation Receiving &
Storage (BAC B1.1)
- COA/ Supplier Audits
PP – Premises, Water Quality
(BAC A4.1)
Chemical Pesticides,
Heavy metals
Physical –
Silt
BAC Generic HACCP Model
Revision Date: November 2009
Page 90 of 252
Critical Control Points - Form 8
DRY INGREDIENTS
Barley malt
Biological –
Micro (faecal
contamination
from birds,
mice)
Chemical –
Pesticides,
Mycotoxins,
Allergen
(crosscontamination
from carrier),
NDMA
PP - Transportation Receiving &
Storage (BAC B1.1)
- COA from supplier
PP - Transportation Receiving &
Storage (BAC B1.1)
- COA / Letter of Guarantee
PP - Transportation Receiving &
Storage (BAC B1.1) - Receiving
Inspection (screens, magnets)
Physical –
Glass, Metal
BAC Generic HACCP Model
Revision Date: November 2009
Page 91 of 252
Critical Control Points - Form 8
Wheat (malted/
nonmalt
ed),
Biological –
Micro (faecal
contamination
from birds,
mice)
Chemical –
Pesticides,
Mycotoxins,
Allergen,
NDMA
Physical –
Glass, Metal
PP - Transportation Receiving &
Storage (BAC B1.1)
+ COA from supplier
PP - Transportation Receiving &
Storage (BAC B1.1)
+ COA / Letter of Guarantee,
Allergen Management Program
PP - Transportation Receiving &
Storage (BAC B1.1)
+ Receiving Inspection (screens,
magnets)
Cereal Grain,
e.g.
corn
,
oats,
rice
Biological –
Micro (faecal
contamination
from birds,
mice)
Chemical –
Pesticides,
Mycotoxins,
Allergen
(crosscontamination
from carrier),
NDMA
Physical –
Glass, Metal
BAC Generic HACCP Model
Revision Date: November 2009
PP - Transportation Receiving &
Storage (BAC B1.1)
+ COA from supplier
PP - Transportation Receiving &
Storage (BAC B1.1)
+ COA / Letter of Guarantee,
Allergen Management Program
PP - Transportation Receiving &
Storage (BAC B1.1)
+ Receiving Inspection (screens,
magnets)
Page 92 of 252
Critical Control Points - Form 8
Hops
Biological –
Faecal
contamination
(E. coli)
PP - Transportation Receiving &
Storage (BAC B1.1)
Chemical –
Pesticides,
Mycotoxins
PP – Transportation, Receiving &
Storage (BAC B1.1)
Physical –
Insects, metal
+ COA
+ COA
PP - Transportation Receiving &
Storage (BAC B1.1)
+ COA, Inspection
OTHER INGREDIENTS
Yeast
Biological –
Cross
contaminated
e.g.
Salmonella
Chemical –
Heavy Metals,
cleaning
chemicals
(used in
tankers)
PP – Transportation, Receiving &
Storage (BAC B1.1)
Physical –
None
identified
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
+ COA, Wash Tickets
BAC Generic HACCP Model
Revision Date: November 2009
Page 93 of 252
Critical Control Points - Form 8
Carbohydrate
Matt
er
(e.g. sucrose,
syru
p,
hone
y)
Biological –
Clostridium
Chemical –
Antibiotic
residue,
heavy metal
(honey)
PP – Transportation, Receiving &
Storage (BAC B1.1)
Physical –
None
identified
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
+ COA
Salt
Biological –
None
identified
Chemical –
Non-food
grade
Yes –
Screens,
filters,
inspection
No
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
(Partially Controlled)
Physical –
Rocks
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ Inspection
BAC Generic HACCP Model
Revision Date: November 2009
Page 94 of 252
Critical Control Points - Form 8
Hop Oil
Biological –
None
identified
Chemical –
Residual
solvents, Nonfood grade
+ PP – Transportation, Receiving &
Storage (BAC B1.1)
Physical –
Plastic
PP – Transportation, Receiving &
Storage (BAC B1.1)
COA
+ COA, Inspection
Hop Extract
Biological –
None
identified
Chemical –
Residual
solvents, Nonfood grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
Physical –
Plastic
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
+ COA, Inspection
BAC Generic HACCP Model
Revision Date: November 2009
Page 95 of 252
Critical Control Points - Form 8
Nitrogen/
Oxygen/
Compressed Air
Biological –
None
Identified
Purchased CO2
Chemical –
Chemical nonvolatile gases,
Non-food
grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA, QC Testing
Physical –
None
identified
Regenerated
CO2
Chemical Contamination
from oil (from
the
compressor)
BAC Generic HACCP Model
Revision Date: November 2009
PP - Equipment (BAC C1.2)
Page 96 of 252
Critical Control Points - Form 8
Liquid
Extract
Wheat
Biological –
None
identified
Chemical –
Allergen
Allergen Management Program
Physical –
Plastic (from
packaging)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Caramel
Biological –
None
identified
Chemical –
Non-food
grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Physical –
Plastic (from
container)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
BAC Generic HACCP Model
Revision Date: November 2009
Page 97 of 252
Critical Control Points - Form 8
Dextrin
Biological –
None
identified
Chemical –
Non-food
grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Physical –
Plastic (from
container)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Food Enzymes
Biological –
None
identified
Chemical –
Non-food
grade
Physical –
None
identified
BAC Generic HACCP Model
Revision Date: November 2009
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Page 98 of 252
Critical Control Points - Form 8
Stabilizing
Agents
Biological –
None
identified
Chemical –
Heavy metals,
Non-food
grade + COA
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Physical –
None
identified
Water
preparation
agents
Biological –
None
identified
Chemical –
Heavy metals,
Non-food
grade + COA
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Physical –
None
identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 99 of 252
Critical Control Points - Form 8
Preservatives
Biological –
None
identified
Chemical –
Allergens
(Sulphites),
Non-food
grade
Physical –
None
identified
Yeast Foods
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA,
Allergen Management Program
Biological –
None
identified
Chemical –
Heavy metals,
Non-food
grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA,
Physical –
None
identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 100 of 252
Critical Control Points - Form 8
Processing aids
Examples
–
Gelatin,
Irish
Moss,
Wood
Shavings
Biological –
Faecal
contamination
(e.g. Gelatin,
Irish Moss)
Chemical –
Heavy metals,
Non-food
grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
Physical –
None
identified
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
+ COA
PRIMARY PACKAGING MATERIAL
New glass
Q1
Q2
Q3
Q4
Yes – Bottle
Rinse
Yes
No
YesEmpty
Bottle
Inspection
BiologicalNone
identified
Chemical –
None
identified
Physical Critical Glass
Defects ,
Glass
(Partially Controlled)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+COA, Inspection
BAC Generic HACCP Model
Revision Date: November 2009
Page 101 of 252
Critical Control Points - Form 8
Used glass
BiologicalBacteria
Yes –
Pasteurization
No
No (no
pathogens
known to
survive in
final product
due to
properties of
beer, e.g.
low pH,
alcohol
content see
Form 1)
Yes
Chemical –
Lubricants,
mycotoxins
(Partially Controlled)
PP – Transportation, Receiving &
Storage (BAC B1.1)
Yes – Bottle
Rinse
Yes
No
+ Inspection,
Yes –
Empty
Bottle
Inspection/
RLD
Physical Critical Glass
Defects , Dirt,
Dust, Glass,
Syringes,
Medical
Patches,
BAC Generic HACCP Model
Revision Date: November 2009
No
Yes – Bottle
Wash
Page 102 of 252
No
Yes –
Empty
Bottle
Inspection
Critical Control Points - Form 8
Lined aluminum
cans and bottles
Biological –
None
identified
Chemical –
None
identified
Physical –
(Partially Controlled)
Metal
Shavings
PP – Transportation, Receiving &
Storage (BAC B1.1)
Yes – Rinse
No
Yes - Rinse
No
+COA
New Kegs
Biological –
None
identified
Chemical –
None
identified
Physical –
Metal
Shavings
BAC Generic HACCP Model
Revision Date: November 2009
(Partially Controlled)
Rinse
Page 103 of 252
Critical Control Points - Form 8
Used Kegs
Biological –
None
identified
Chemical –
None
identified
Physical –
None
identified
Plastic Bottles,
e.g. PET
Biological –
None
identified
Chemical –
None
identified
Physical –
None
identified
Crowns
Biological –
None
identified
Chemical –
None
identified
Physical –
None
identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 104 of 252
Critical Control Points - Form 8
Closures & Can
Ends
Biological –
None
identified
Chemical –
None
identified
Physical –
None
identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 105 of 252
Critical Control Points - Form 8
PROCESS STEPS
PS1- RECEIVING
Biological –
Micro
contamination
from receiving
open
containers (e.g.
bird droppings).
PP – Premises (BAC A1.1 & BAC
A2.1)
Chemical –
Contamination
from truck
(damage,
leaks, odors)
PP – Transportation, Receiving &
Storage (BAC B1.1)
Physical –
Pests in hoses
used for
transferring
material, Bulk
Receiving
PP - Pest Control (BAC E2.1)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ Seal Integrity
PP - Pest Control (BAC E2.1)
PP – Personnel (BAC D1.2)
+ Training
BAC Generic HACCP Model
Revision Date: November 2009
Page 106 of 252
Critical Control Points - Form 8
PS2- STORAGE/
HANDLING
Biological Mold growth
from improper
storage
conditions
PP - Premises (BAC A2.1)
Chemical Crosscontamination
from allergens
(e.g. wheat)
Allergen Management Program
Physical &
Biological Insect or pest
infestation
PP - Pest Control (BAC E2.1)
PP - Sanitation (BAC E1.1)
PS3 - BREWING
B1 - Receiving
(See PS1
above)
B2 - Storage
(See PS2
above)
B3 - Milling
Chemical –
Allergen crosscontamination
(e.g. from
residues in the
mill)
B4 - Cereal
Cooker
PP - Sanitation (BAC E1.1)
Allergen Management Program
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 107 of 252
Critical Control Points - Form 8
B5 - Mashing
(Mash Mixer,
Mash Cooker)
None identified
B6 - Lautering
(Lauter Tun, Mash
Filter removal of
spent grains
None identified
B7 – Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified
B10 - Wort
Cooling (Heat
Exchanger)
None identified
PS4
-FERMENTATION
Cold Wort (from
B10)
None identified
F1 Wort
Oxygenation/
Wort Aeration
None identified
F2 - Fermentation
None identified
F3 - Cooling
Chemical Coolant leak
F4 - Green Beer
None identified
BAC Generic HACCP Model
Revision Date: November 2009
PP – Equipment (BAC C1.2)
Page 108 of 252
Critical Control Points - Form 8
PS4 – SUBPROCESS
YEAST
PREPARATION
Y1 – Propagation
None identified
Y2 – Storage
None identified
Y3 – Acid
Washing
None identified
PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling
Chemical Coolant leak
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
Chemical Coolant leak
PP – Equipment (BAC C1.2)
A6 - Aging Tank
Chemical Coolant leak
PP – Equipment (BAC C1.2)
BAC Generic HACCP Model
Revision Date: November 2009
PP – Equipment (BAC C1.2)
Page 109 of 252
Critical Control Points - Form 8
A7 - Secondary
Storage
Chemical Coolant leak
PP – Equipment (BAC C1.2)
Sulphites as an
allergen
Allergen Management Program
A8 - Surge/ buffer
Tank
Chemical Sulphites as an
allergen
Allergen Management Program
A9 – Filtration
Chemical Sulphites as an
allergen
Allergen Management Program
A10 – Bright Beer
Storage
(See PS6
below)
PS6 – BRIGHT
BEER STORAGE
Chemical –
PP – Equipment (BAC C1.2)
Coolant leak
Allergen Management Program
Sulphites as an
allergen
PP - Sanitation (BAC E1.1)
Cleaning
chemicals
PS7 BRIGHT
BEER
PROCESSING
PS7 (SF) –
Sterile Filtration
BAC Generic HACCP Model
Revision Date: November 2009
Page 110 of 252
Critical Control Points - Form 8
SF1 - Bright Beer
Tank
Chemical –
Coolant leak
PP – Equipment (BAC C1.2)
Sulphites as an
allergen
Allergen Management Program
Cleaning
chemicals
PP - Sanitation (BAC E1.1)
SF2 - Filtration
Sulphites as an
allergen
Allergen Management Program
SF3 - Sterile Beer
Tank
None identified
PS7(FP) – Flash
Pasteurization
FP1 - Bright Beer
Tank
Chemical –
PP – Equipment (BAC C1.2)
Coolant leak
Sulphites as an
allergen
Allergen Management Program
Cleaning
chemicals
PP - Sanitation (BAC E1.1)
BAC Generic HACCP Model
Revision Date: November 2009
Page 111 of 252
Critical Control Points - Form 8
FP2 Pasteurization
Chemical –
PP – Equipment (BAC C1.2)
Contamination
from coolant
FP3 - Pasteurized
Beer Tank
None identified
PS8 RB –
RETURNED
BOTTLES PREP
(FLOAT
GLASSWARE
PREP)
RB1 - Receiving/
Storage
Physical Damage to
bottles
PP – Transportation, Receiving &
Storage (BAC B1.1)
PP – Personnel (BAC D1.2)
Training
RB2 - Depalletizing
Physical Damage to
bottles
PP – Equipment (BAC C1.2)
PP – Transportation, Receiving &
Storage (BAC B1.1)
PP – Personnel (BAC D1.2)
Training
BAC Generic HACCP Model
Revision Date: November 2009
Page 112 of 252
Critical Control Points - Form 8
RB3- RB4 - Decasing &
Inspection (visual)
Physical Damage to
bottles
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
RB5 - Bottle
Wash Loading
Physical Damage to
bottles
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
RB6 - Pre-rinse
sprays
RB7 - Soak Tanks
With Caustic
Physical Damage to
bottles (e.g.
Temperature
shock due to
storage)
PP – Equipment (BAC C1.2)
Physical Damage to
bottles
PP – Equipment (BAC C1.2)
Chemical –
Too
concentrated,
too low, no
caustic, wrong
chemical
PP – Equipment (BAC C1.2)
Chemical Bottle unable to
drain
Training
BAC Generic HACCP Model
Revision Date: November 2009
PP – Transportation, Receiving &
Storage (BAC B1.1)
PP – Transportation, Receiving &
Storage (BAC B1.1)
PP – Personnel (BAC D1.2)
No
Yes (EBI/
RLD)
Yes
Page 113 of 252
No
Yes(EBI/
RLD)
Critical Control Points - Form 8
RB8 - Hydro Jet
Sprays
Biological –
Spray
malfunction
and debris is
left in bottle
(e.g.
pathogenic
Clostridium,
Listeria,
Hepatitis
(A/B/C)
(Partially Controlled)
PP – Equipment (BAC C1.2)
Physical Damage to
bottles,
Physical Bottle contains
foreign object
(spray
malfunction)
Physical –
Bottle contains
foreign object
(plugged but
sprays cannot
clear object)
Chemical –
Bottle unable to
drain
No
Yes (EBI)
(Partially Controlled)
PP – Equipment (BAC C1.2)
Yes
No
Yes (EBI)
Yes
No
Yes (EBI)
Yes
No
Yes (EBI/
RLD)
Yes (EBI)
PP – Equipment (BAC C1.2)
No
No
BAC Generic HACCP Model
Revision Date: November 2009
Yes – (no
pathogens
known to
survive in final
product –
properties of
beer, e.g. low
pH, alcohol
content see
Form 1)
Yes (EBI/
RLD)
Page 114 of 252
Critical Control Points - Form 8
RB9- Post-Soak
Physical Damage to
bottles (e.g.
Temperature
shock),
Physical Bottle plugged
Chemical –
Bottle unable to
drain
(Partially Controlled)
Yes (EBI)
Yes
No
Yes (EBI)
Yes (EBI)
Yes
No
Yes (EBI)
Yes (EBI/
RLD)
Yes
No
Yes (EBI/
RLD)
Yes (EBI)
Yes
No
Yes (EBI)
Yes (EBI)
Yes
No
Yes (EBI)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
No
No
RB10 - External
Flush
RB11 - Ext. Rinse
Physical Damage to
bottles (e.g.
Temperature
shock)
(Partially Controlled)
Physical Damage to
bottles
(e.g.
Temperature
shock)
(Partially Controlled)
BAC Generic HACCP Model
Revision Date: November 2009
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
Page 115 of 252
Critical Control Points - Form 8
RB12 - Interior
Rinse
Physical Damage to
bottles
(Partially Controlled)
Yes (EBI)
Yes
No
Yes (EBI)
No
Yes (EBI)
Yes
No
Yes (EBI)
PP – Equipment (BAC C1.2)
Yes (EBI/
RLD)
Yes
No
Yes (EBI/
RLD)
PP – Equipment (BAC C1.2)
Physical Bottle contains
foreign object
(spray
malfunction)
Physical –
Bottle contains
foreign object
(plugged but
sprays cannot
clear object)
Chemical –
Spray
malfunction
Chemical Bottle plugged
unable to drain
PP – Equipment (BAC C1.2)
No
BAC Generic HACCP Model
Revision Date: November 2009
Page 116 of 252
Critical Control Points - Form 8
RB13 - Final
Rinse
Physical Damage to
bottles,
Physical Bottle contains
foreign object
(spray
malfunction)
Physical –
Bottle contains
foreign object
(plugged but
sprays cannot
clear object)
(Partially Controlled)
Yes (EBI)
Yes
No
Yes (EBI)
No
Yes (EBI)
Yes
No
Yes (EBI)
No
Yes (EBI/
RLD)
Yes
No
Yes (EBI/
RLD)
PP – Equipment (BAC C1.2)
PP – Equipment (BAC C1.2)
Chemical –
Bottle unable to
drain
PS8 NB NEW BOTTLES
(GLASSWARE)
PREP
NB1- NB2 Receiving &
Preliminary
Inspection
Physical Damage to
bottles
BAC Generic HACCP Model
Revision Date: November 2009
PP – Transportation, Receiving &
Storage (BAC B1.1)
PP – Personnel (BAC D1.2)
Training
Page 117 of 252
Critical Control Points - Form 8
NB3 – NB 6
Storage (Pallet
Prep, Depalletize)
Physical Damage to
bottles
PP – Equipment (BAC C1.2)
NB7 – Inspection
(Human, visual)
Physical –
Missed critical
glass defects
(Partially Controlled)
Physical
Damage
bottles
PP – Equipment (BAC C1.2)
NB8 Loading,
Bottle
PP – Personnel (BAC D1.2)
Training
–
to
Yes (EBI)
Yes
PP – Personnel (BAC D1.2)
Training
PP – Personnel (BAC D1.2)
Training
NB9 - Bulk Glass
Rinser
Physical –
PP – Equipment (BAC C1.2)
Spray
malfunction
(e.g. plugged
sprays)
Chemical
–
Contaminated
air, sanitizing
spray
PP – Equipment (BAC C1.2)
PP – Personnel
Training
(BAC
D1.2)
PS8 BT BOTTLING
BAC Generic HACCP Model
Revision Date: November 2009
Page 118 of 252
No
Yes (EBI)
Critical Control Points - Form 8
BT1
MACHINE:
MACHINE:
Empty Bottle
Inspection
Physical Failure of the
system to
detect foreign
matter, glass
defects, bottle
damage
(Partially Controlled)
Human or
Machine
inspection (EBI/
RLD)
Yes (EBI)
Yes
Yes
CCP1-P
Yes (EBI/
RLD)
Yes
Yes
CCP1-C
Yes (EBI)
Yes
Yes
CCP1-P
Yes (EBI
Yes
Yes
CCP1-C
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
Chemical Failure of the
system to
detect residual
liquid and
caustic
HUMAN:
Physical Failure of
personnel to
detect foreign
matter, glass
defects, glass
damage
Chemical Failure of
personnel to
detect residual
liquid
(Partially Controlled)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
HUMAN:
(Partially Controlled)
PP – Personnel (BAC D1.2)
Training, SOP (personnel rotation)
(Partially Controlled)
PP – Personnel (BAC D1.2)
Training
, SOP (personnel rotation)
BAC Generic HACCP Model
Revision Date: November 2009
Page 119 of 252
Critical Control Points - Form 8
BT2 – Down
Bottle Filler InFeed Control
Physical –
Glass
inclusions from
breakage of
down bottle at
filler in-feed
BAC Generic HACCP Model
Revision Date: November 2009
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Page 120 of 252
Critical Control Points - Form 8
BT3 – BT5 Filling
(Purges , Filling,
Fobbing)
Physical –
Chipping of
bottles (e.g.
from filling
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
equipment),
glass inclusion
Auto-Flush:
Physical –
Burst bottle
leading to glass
inclusion
Auto-Flush:
Yes (SOP
Burst Bottle
Detection
System/ Filler
Flush/ Auto
Flush)
Yes
(Partially Controlled)
PP – Equipment (BAC C1.2)
Manual Flush:
Physical –
Burst bottle
leading to glass
inclusion
PP – Personnel (BAC D1.2)
Training
PP – Transportation, Receiving &
Storage (BAC B1.1)
Yes (SOP on
Burst Bottle
Monitoring
and Reject &
Flush)
Manual Flush:
BAC Generic HACCP Model
Revision Date: November 2009
Page 121 of 252
Yes
CCP2-P
Critical Control Points - Form 8
BT3 – BT5 Filling
(Purges , Filling,
Fobbing)
(Continued)
(Partially Controlled)
Yes
No
Yes
(Foam
Inspectio
n&/or
Candling)
Yes
No
Yes
(Foam
Inspectio
n
&/or
Candling)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
Chemical –
CIP chemicals
in bottle
PP – Transportation, Receiving &
Storage (BAC B1.1)
PP - Sanitation (BAC E1.1)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
BT6 - Crowning
Physical
–
Bottle
finish
damage
(leading
to
glass
inclusions)
Chemical
Lubricants
(Partially Controlled)
Yes
(SOP,
Foam
Inspection
&/or Candling)
PP – Equipment (BAC C1.2)
PP – Personnel
Training
(BAC
D1.2)
–
PP – Equipment (BAC C1.2)
BAC Generic HACCP Model
Revision Date: November 2009
Page 122 of 252
Critical Control Points - Form 8
BT7 – BT 8 Bottle
Flush (Full Bottle
Wash - external)
None identified
BT9
–
Pasteurize
None identified
BT10 - Foam
Inspection &/or
Candling (Human)
Physical –
Failure to
detect foreign
matter
(including
glass)
Note: Automated
Foam Inspection
is not within the
scope of this
generic model.
BT11 – Drying
(Bottle Drying and
Air Knives)
None identified
BT12 – BT13
Labelling, Coding
Product not
coded or not
correctly coded
BT14 – Filled
Bottle Inspection
None identified
BT15 – BT18
Packing & Sealing
(Divert to packers,
Carton, Case
Pack, Sealing)
None identified
BAC Generic HACCP Model
Revision Date: November 2009
PP – Personnel (BAC D1.2)
Training
Yes (increase
number of
inspectors)
No
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
Page 123 of 252
Critical Control Points - Form 8
BT19 – BT20
Secondary Code
& Inspection
(Secondary
Packaging,
Code/Inspection)
Product not
coded, or not
correctly coded
BT21 –
Palletize
None identified
BT22 - Storage
(or Live Load)
None identified
BT23 - Shipping
None identified
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PS8 (K) KEGGING
K1 - Receiving
(See PS1)
None identified
K2 – K3 Storage
& Handling , Depalletizing (See
PS2)
None identified
K4 - External
Inspection
None identified
K5 – K6 External
Cleaning (Ext
Wash/Inspection)
Old codes not
effectively
removed
K7 –
Racking
None identified
BAC Generic HACCP Model
Revision Date: November 2009
PP - Recall (BAC F1.2)
Page 124 of 252
Critical Control Points - Form 8
K8 – K12 Internal
Cleaning (Purge,
Flush, Wash,
Purge, Rinse)
Automated
Automated
Chemical –
Cleaning
solution not
effectively
removed.
PP - Sanitation (BAC E1.1)
Manual:
Chemical –
Cleaning
solution not
effectively
removed.
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
No
Yes
Manual:
(Partially Controlled)
PP - Sanitation (BAC E1.1)
PP – Personnel (BAC D1.2)
Training
K13 - Sterilize &
Hold
None identified
K14 – K 15 Purge
to Empty &
Counter pressure
None identified
K 16 - K17
Barnes Neck
Sanitize & Inspect
BAC Generic HACCP Model
Revision Date: November 2009
Page 125 of 252
Yes
Yes
CCP3-C
Critical Control Points - Form 8
K18 - Filling
Chemical –
CIP solution
PP - Sanitation (BAC E1.1)
PP – Personnel (BAC D1.2)
Training
PP – Equipment (BAC C1.2)
K19 – K 21
Barnes Neck,
Wash & Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product
Code Applied
Incorrect or
missing code
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
K25 – K 26 Weigh
(In-line weighing)
& Palletize
None identified
K27 - Storage
None identified
K28 - Shipping
None identified
PS8 (C) CANNING
C1 - Receiving
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 126 of 252
Critical Control Points - Form 8
C2 - Storage &
Handling
Biological –
Bacterial
contamination
from leaking
roof or pipes
PP – Premises (BAC A1.1 & BAC
A2.1)
Chemical Contamination
from leaking
roof or pipes
PP – Premises (BAC A1.1 & BAC
A2.1)
C3 – C 4 Depalletize / Pallet
ID
(Collect &
Timestamp Can
Pallet ID, Depalletize)
Incorrect or
missing code
on pallet
PP - Recall (BAC F1.2)
C5 - Online visual
inspection
None identified
C6 - Primary code
applied
Incorrect or
missing code –
PP – Personnel (BAC D1.2)
Training
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
C7 - Bulk in-line
rinser
Chemical –
Chemicals from
compressed air
or water
BAC Generic HACCP Model
Revision Date: November 2009
PP – Premises (BAC A4.1)
PP – Equipment (BAC C1.2)
Page 127 of 252
Critical Control Points - Form 8
C8 – C 10 Filling
(pre-evacuation &
beer fill)
None identified
C11 – C13
Seaming
Chemical –
Chemicals,
Lubricants
C14 - External
Can Flush
None identified
C15 –
Pasteurizer
None identified
C16 – C17 Drying
None identified
C18 - Fill Height
Inspection
None identified
C19 - Divert to
Packers
None identified
C20 - Hi-Cone
Machine
None identified
C21 - Case
Packers
None identified
C22 – Inspection
(Human, visual)
Inspection
None identified
BAC Generic HACCP Model
Revision Date: November 2009
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
Page 128 of 252
Critical Control Points - Form 8
C23 – C24 Tray
Machine & Code
Incorrect or
missing code
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
C25 –
Palletize
None identified
C26 - Storage (or
Live Load)
None identified
C27 –
Shipping
None identified
PS8
T
TANKERING
T1 - Empty
Tanker
(Receiving)
Chemical –
Cleaning
chemicals and/
or sanitizer
PP – Transportation, Receiving &
Storage (BAC B1.1)
COA, Wash Ticket,
PP – Personnel (BAC D1.2)
Training
T2 - Tanker
Washing/ Rinsing
Chemical –
Cleaning
chemicals and/
or sanitizer
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
PP - Sanitation (BAC E1.1)
BAC Generic HACCP Model
Revision Date: November 2009
Page 129 of 252
Critical Control Points - Form 8
T3 - Tanker
Purging
Chemical –
Contaminated
CO2
For Regenerated CO2 – PP –
Equipment (BAC C1.2)
PP – Personnel (BAC D1.2)
Training
For Purchased CO2 - PP –
Transportation, Receiving &
Storage (BAC B1.1)
COA
T4 - Tanker
Filling/ Loading
T5 – Tanker
Shipping
Biological –
Insect or pest
infestation of
hoses
No
Chemical –
Cross
contamination
from using
hose on nonfood material
PP – Personnel (BAC D1.2)
Training
Yes – (no
pathogens
known to
survive in final
product due to
the properties
of beer, e.g.
low pH, see
Form 1)
No
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 130 of 252
Critical Control Points - Form 8
T6 – T7 Full
Tanker Receiving
& Unloading
Biological –
Insect or pest
infestation of
hoses
No
Chemical –
Cross
contamination
with chemicals
from the
supplier
PP – Transportation, Receiving &
Storage (BAC B1.1)
Chemical –
Cross
contamination
from using
hose on nonfood material
PP – Personnel (BAC D1.2)
Training
Date:
BAC Generic HACCP Model
Revision Date: November 2009
Yes – (no
pathogens
known to
survive in final
product due to
the properties
of beer, e.g.
low pH,
alcohol
content see
Form 1)
No
+ COA
Approved by:
Page 131 of 252
Critical Control Points - Form 8
BAC Generic HACCP Model
Revision Date: November 2009
Page 132 of 252
Critical Control Points - Form 8
FORM 3A:
PROCESS FLOW DIAGRAM
WITH CCPS
BAC Generic HACCP Model
Revision Date: November 2009
Page 133 of 252
Critical Control Points - Form 8
BAC Generic HACCP Model
Revision Date: November 2009
Page 134 of 252
HACCP Plan - Form 3A
BAC GENERIC HACCP PLAN FORM 3a
Approved By: BAC HACCP Technical Committee
Approval Date:
Total # of Pages Including Key = 12
Page 1 of 12
KEY
Box with no fill = Process Step
Blue Filled Box = Input
Yellow Filled Box = Output
Dotted Line = Optional Step
Red Filled Circle = Last step in process
Open-ended Box = Chemical/ Material used
that is not an ingredient or processing aid
that does not contact the product directly .
CCP
BAC Generic HACCP Model
Revision Date: November 2009
Critical Control Point
Page 135 of 252
HACCP Plan - Form 3A
MASTER FLOWCHART OF
MAJOR PROCESS STEPS (PS) FOR MAKING BEER (Page 2 of 12)
FULL TANKER
(Step T6)
RECEIVING
(PS1)
STORAGE & HANDLING
(Step PS2)
Water & Dry
Ingredients
Yeast,
Processing
Aids
FULL TANKER
UNLOADING
(Step T7)
BREWING
(Step PS3)
MILLING/ MASHING/ LAUTERING
KETTLE/ WHIRLPOOL/ COOLING
FERMENTATION
(Step PS4)
Processing
Aids, CO2
AGING
(Step PS5)
CLARIFICATION/ FILTERING
BRIGHT BEER STORAGE
(Step PS6)
Bottles, Cans, Kegs,
Crowns, Tankers
New
Bottles
Prep
PS8 (NB)
Returned
Bottles
Prep
PS8 (RB)
BRIGHT BEER
PROCESSING
(Step PS7)
PACKAGING
(Step PS8)
BOTTLING
Step PS8 (BT)
CCP1-C,P
CCP2-P
- Washing
- Inspection
- Filling
- Flushing
CANNING
Step PS8 (C)
KEGGING
Step PS8 (K)
CCP3-C
- Rinsing
- Filling
- Packing
- Cleaning
- Filling
- Palletizing
TANKERING
Step PS8 (T)
- Filling
WAREHOUSING/ SHIPPING
(Step PS9)
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3A
PS3 - BREWING (Page 3 of 12)
RECEIVING
(Step B1)
Storage
(Step B2)
Milling
(Step B3)
Cereal Cooker
(Step B4)
Mashing
(Step B5)
Lautering
(Step B6)
Holding Tank
(Step B7)
Kettle
(Step B8)
Whirlpool
(Step B9)
Oxygen
Wort Cooling
(Step B10)
Next Process - PS4
Fermentation
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3A
PS4 - FERMENTATION (Page 4 of 12)
COLD WORT
Oxygen/ Sterile
Air
WORT OXYGENATION/
WORT AERATION
(Step F1 )
Yeast Propagation
(Step Y1)
Yeast Storage
(Step Y2)
Acid Washing
(Step Y3)
YEAST
FERMENTATION
(Step F2)
CO2
Cooling
(Step F3)
Yeast
Removal
GREEN BEER
(Step F4)
Next Process - PS5 -Aging/
Clarification/ Filtration
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3A
PS5 - AGING/ CLARIFICATION/ FILTRATION (Page 5 of 12)
GREEN BEER
COOLING
(Step A1)
Buffer tank
(Step A2)
Centrifuge
(Step A3)
Processing aids,
Stabilizers,
CO2, Preservatives
Yeast,
By-products
Buffer tank
(Step A4)
CO2
Cooling tank
(Step A5)
CO2, Hops
Aging Tank
(Step A6)
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives
Beer,
Spent Hops, CO2
Secondary Storage
(Step A7)
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives
CO2, Spent
Yeast
Surge/ Buffer Tank
(Step A8)
Caramel & other
ingredients,
Processing aids,
Stabilizers, CO2,
Preservatives
Filtration
(Step A9)
CO2
CO2, Spent
Yeast
Deaerated water,
CO2, Nitrogen
Bright Beer Storage
(Step A10 = PS6)
CO2
Next Process - PS7 Bright BeerProcessing
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3A
PS7 (BBP) - BRIGHT BEER PROCESSING
PS7 (SF)
STERILE FILTRATION
CO2
(Page 6 of 12)
PS7 (P)
FLASH PASTEURIZATION
Bright Beer Tank
(Step SF1)
Bright Beer Tank
(Step FP1)
Filtration
(Step SF2)
Flash Pasteurization
(Step FP2)
Sterile Beer Tank
(Step SF3)
Pasteurized Beer Tank
(Step FP3)
Next Process - PS8 -Packaging
BAC Generic HACCP Model
Revision Date: November 2009
Next Process - PS8 -Packaging
Page 140 of 252
HACCP Plan - Form 3A
Process Step 8
PS8 (RB) - RETURNED BOTTLES PREP (Page 7 of 12)
Receiving/ Storage
(Step RB1)
Caustic
Hydro Jet Sprays
(Step RB8)
De-Palletizing
(Step RB2)
De-Casing & Inspection
(Steps RB3-4)
Post Soak
(Step RB9)
Bottle Wash Loading
(Step RB5)
External Flush
(Step RB10)
Pre-Rinse
(Step RB6)
Water,
Chemicals &
Steam
External Rinse
(Step RB11)
Soak Tanks (caustic)
(Step RB7)
Water
Interior Rinse
(Steps RB12)
Water
FINAL RINSE
(Step RB13)
Next: (PS8- BT) Bottling
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3A
Process Step 8
PS8 (NB) - NEW BOTTLES PREP (Page 8 of 12)
Receiving
(Step NB1)
Preliminary Inspection
(Step NB2)
Storage
(Step NB3-6)
Inspection
(Step NB7)
RINSE
(Steps NB8-9)
Next: (PS8- BT) Bottling
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3A
Process Step 8
PS8 (BT) - BOTTLING (Page 9 of 12)
BOTTLES - See
Returned Bottles Prep
& New Bottle Prep
Air
Empty Bottle Inspection
Drying
(Step BT11)
(Steps BT1)
Water
CCP1-C, P
Down Bottle Filler In-Feed Control
(Steps BT2)
Label & Code
(Steps BT12-13)
Bright Beer,
CO2, Compressed Air
Filling
(Steps BT3-5)
Water
CCP2-P
CO2,
Glass
Filled Bottle Inspection
(Step BT14)
Crowns, Compressed Air
Water
Crowning
(Step BT6 )
Water
Bottle Flush (External)
(Steps BT7-8)
Steam
& Chemicals
Pasteurize
(Step BT9)
Foam Inspection/ Candling
(Step BT10)
Packing & Sealing
(Steps BT15-18)
Secondary Code & Full Case
Inspection
(Steps BT19-20)
Palletize
(Step BT21)
Storage
(Step BT22)
Live Load
SHIPPING
(Step BT23)
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3A
Process Step 8
PS8 (K) - KEGGING (Page 10 of 12)
KEGS
Receiving
(Step K1)
Racking
(Step K7)
Storage, Handling,
De-palletizing
(Steps K2-3)
Internal Cleaning
Manual
(Steps K8-12)
CCP3-C
Internal Cleaning
Automated
(Steps K8-12)
Filling (Step K18)
Barnes Neck Wash &
Sanitize
(Step K19-21)
External Inspection
(Step K4 )
Sterilize & Hold
(Step K13)
Dust Cap Applied
(Steps K22)
Purge to Empty &
Counter Pressure
(Steps K14-15)
Air Dry
(Step K23)
Barnes Neck Sanitize &
Inspect
(Step K16-17)
Code
(Step K24)
External Cleaning
(Steps K5-6)
Weigh & Palletize
(Steps K25-26)
Storage
(Step K27)
Live Load
SHIPPING
(Step K28)
BAC Generic HACCP Model
Revision Date: November 2009
Page 144 of 252
HACCP Plan - Form 3A
Process Step 8
PS8 (C) - CANNING (Page 11 of 12)
CANS
Drying (Steps C16-17)
Receiving
(Step C1)
Coding
(Step C6)
Storage & Handling
(Step C2)
Fill Height Inspection
(Step C18)
Rinser
(Step C7)
Depalletizing/ Pallet ID
(Steps C3-4 )
Inspection
(Step C5)
Divert to Packers
(Steps C19)
Bright
Beer,
CO2
Filling
(Steps C8- 10)
CO2
Hi Cone Machine
(Step C20)
Can Ends
Water
Seaming
(Steps C11-13)
External Flush
(Step C14)
Pastuerizer
(Step C15)
Case Packers
(Steps C21)
Inspection
(Step C22)
Tray Machine & Code
(Steps C23-24)
Palletize
(Step C25)
Storage
(Step C26)
Live Load
SHIPPING
(Step C27)
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 3A
Process Step 8
PS8 (T) - TANKERING (Page 12 of 12)
Empty Tanker
(Step T1)
Caustic, Water,
Acid
CO2
Tanker Washing
(Step T2)
Tanker Purge
(Step T3)
CO2
Bright Beer,
CO2
Tanker Filling
(Step T4)
Tanker Shipping
(Step T5)
Full Tanker Receiving
(Step T6)
FULL TANKER UNLOADING
(Step T7)
Date: _______________ Approved by: ________________________________
BAC Generic HACCP Model
Revision Date: November 2009
Page 146 of 252
FORM 5A:
BIOLOGICAL HAZARDS
CONTROL & CCPS
BAC Generic HACCP Model
Revision Date: November 2009
Page 147 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 148 of 252
HACCP Plan - Form 5A
BAC Generic
Title: Form 5A – Hazard Identification - Biological Hazards
Control & CCPs
Completed By: BAC TC
Date:
Approved By: BAC TC
Date:
Note – No CCPs were identified for biological hazards in Beer.
List all biological hazards related
to ingredients, incoming material,
processing, product flow, etc.
Identified biological
hazards (Bacteria,
parasites, viruses, etc.)
Controlled at:
City Water
Coliform, E. Coli
PP – Premises, Water Quality
(BAC A4.1)
Purchased Water
Coliform, E. Coli
PP – Premises, Water Quality
(BAC A4.1)
Well/ Lake/ Surface/ Water
Coliform, E. Coli,
Parasites
PP – Premises, Water Quality
(BAC A4.1)
Micro (fecal
contamination from birds,
mice)
PP - Transportation
Receiving & Storage (BAC
B1.1)
INGREDIENTS
LIQUID INGREDIENTS
DRY INGREDIENTS
Barley malt
- COA from supplier
Wheat (malted/ non-malted),
Micro (fecal
contamination from birds,
mice)
PP - Transportation
Receiving & Storage (BAC
B1.1)
+ COA from supplier
Cereal Grain, e.g. corn, oats,
rice
Micro (fecal
contamination from birds,
mice)
PP - Transportation
Receiving & Storage (BAC
B1.1)
+ COA from supplier
Hops
Fecal contamination (E.
coli)
PP - Transportation
Receiving & Storage (BAC
B1.1)
+ COA
BAC Generic HACCP Model
Revision Date: November 2009
Page 149 of 252
HACCP Plan - Form 5A
OTHER INGREDIENTS
Yeast
Cross contaminated e.g.
Salmonella
PP – Transportation,
Receiving & Storage (BAC
B1.1)
+ COA
Carbohydrate Matter
(e.g. sucrose, syrup,
honey)
Clostridium
PP – Transportation,
Receiving & Storage (BAC
B1.1)
+ COA
Salt
None identified
Hop Oil
None identified
+ PP – Transportation,
Receiving & Storage (BAC
B1.1)
+COA
Hop Extract
None identified
Nitrogen/ Oxygen/
Compressed Air
Purchased CO2
None Identified
Regenerated CO2
None identified
Liquid Wheat Extract
None identified
Caramel
None identified
Dextrin
None Identified
Food Enzymes
None identified
Stabilizing Agents
None identified
Water preparation agents
None identified
Preservatives
None Identified
Yeast Foods
None Identified
Processing aids
Examples – Gelatin, Irish
Moss, Wood Shavings
Fecal contamination (e.g.
Gelatin, Irish Moss)
PP – Transportation,
Receiving & Storage (BAC
B1.1)
+ COA
BAC Generic HACCP Model
Revision Date: November 2009
Page 150 of 252
HACCP Plan - Form 5A
PRIMARY PACKAGING MATERIAL
New glass
None identified
Used glass
Bacteria
Lined aluminum cans and
bottles
None identified
New Kegs
None identified
Used Kegs
None identified
Plastic Bottles, e.g. PET
None Identified
Crowns
None identified
Closures & Can Ends
None Identified
No pathogens known to survive
in final product due to
properties of beer, e.g. low pH,
alcohol content see Form 1
PROCESS STEPS
PS1- RECEIVING
Micro contamination from
receiving open containers
(e.g. bird droppings).
PP – Premises (BAC A1.1 &
BAC A2.1)
PP - Pest Control (BAC E2.1)
PS2- STORAGE/ HANDLING
Mold growth from
improper storage
conditions
PP - Premises (BAC A2.1)
Insect or pest infestation
PP - Pest Control (BAC E2.1)
PP - Sanitation (BAC E1.1)
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
None identified
B4 - Cereal Cooker
None identified
B5 - Mashing (Mash Mixer,
Mash Cooker)
None identified
B6 - Lautering (Lauter Tun,
Mash Filter removal of spent
grains
None identified
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 5A
PROCESS STEPS (Continued)
B7 – Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified
B10 - Wort Cooling (Heat
Exchanger)
None identified
PS4 -FERMENTATION
Cold Wort (from B10)
None identified
F1 Wort Oxygenation/ Wort
Aeration
None identified
F2 - Fermentation
None identified
F3 - Cooling
None identified
F4 - Green Beer
None identified
PS4 – SUB-PROCESS YEAST
PREPARATION
Y1 – Propagation
None identified
Y2 – Storage
None identified
Y3 – Acid Washing
None identified
PS5 - AGING/ CLARIFICATION/
FILTRATION
A1 - Cooling
None identified
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
None identified
A6 - Aging Tank
None identified
A7 - Secondary Storage
None identified
PROCESS STEPS (Continued)
BAC Generic HACCP Model
Revision Date: November 2009
Page 152 of 252
HACCP Plan - Form 5A
A8 - Surge/ buffer Tank
None identified
A9 – Filtration
None identified
A10 – Bright Beer Storage
(See PS6 below)
PS6 – BRIGHT BEER STORAGE
None identified
PS7 BRIGHT BEER PROCESSING
PS7 (SF) – Sterile Filtration
SF1 - Bright Beer Tank
None identified
SF2 - Filtration
None identified
SF3 - Sterile Beer Tank
None identified
PS7(FP) – Flash Pasteurization
FP1 - Bright Beer Tank
None identified
FP2 - Pasteurization
None identified
FP3 - Pasteurized Beer Tank
None identified
PS8 RB –
RETURNED BOTTLES PREP
(FLOAT GLASSWARE PREP)
RB1 - Receiving/ Storage
None identified
RB2 - De-palletizing
None identified
RB3- RB4 - De-casing &
Inspection (visual)
None identified
RB5 - Bottle Wash Loading
None identified
RB6 - Pre-rinse sprays
None identified
RB7 - Soak Tanks With Caustic
None identified
RB8 - Hydro Jet Sprays
Spray malfunction and
debris is left in bottle (e.g.
pathogenic Clostridium,
Listeria, Hepatitis (A/B/C)
(Partially Controlled)
PP – Equipment (BAC C1.2)
Also, no pathogens known to
survive in final product –
properties of beer, e.g. low pH,
alcohol content see Form 1.
PROCESS STEPS (Continued)
BAC Generic HACCP Model
Revision Date: November 2009
Page 153 of 252
HACCP Plan - Form 5A
RB9- Post-Soak
None identified
RB10 - External Flush
None identified
RB11 - Ext. Rinse
None identified
RB12 - Interior Rinse
None identified
RB13 - Final Rinse
None identified
PS8 NB NEW BOTTLES (GLASSWARE)
PREP
NB1- NB2 - Receiving &
Preliminary Inspection
None identified
NB3 – NB 6 Storage (Pallet
Prep, De-palletize)
None identified
NB7 – Inspection (Human,
visual)
None identified
NB8 - Bottle Loading,
None identified
NB9 - Bulk Glass Rinser
None identified
PS8 BT - BOTTLING
BT1
Empty Bottle Inspection
(Human or Machine inspection)
None identified
BT2 – Down Bottle Filler In-Feed
Control
None identified
BT3 – BT5 Filling (Purges ,
Filling, Fobbing)
None identified
BT6 - Crowning
None identified
BT7 – BT 8 Bottle Flush (Full
Bottle Wash - external)
None identified
BT9 –
Pasteurize
None identified
BT10 - Foam Inspection &/or
Candling
None identified
PROCESS STEPS (Continued)
BAC Generic HACCP Model
Revision Date: November 2009
Page 154 of 252
HACCP Plan - Form 5A
BT11 – Drying (Bottle Drying
and Air Knives)
None identified
BT12 – BT13 Labelling, Coding
None identified
BT14 – Filled Bottle Inspection
None identified
BT15 – BT18 Packing & Sealing
(Divert to packers, Carton, Case
Pack, Sealing)
None identified
BT19 – BT20 Secondary Code & None identified
Inspection (Secondary
Packaging, Code/Inspection)
BT21 –
Palletize
None identified
BT22 - Storage (or Live Load)
None identified
BT23 - Shipping
None identified
PS8 (K) - KEGGING
K1 - Receiving (See PS1)
None identified
K2 – K3 Storage & Handling ,
De-palletizing (See PS2)
None identified
K4 - External Inspection
None identified
K5 – K6 External Cleaning (Ext
Wash/Inspection)
None identified
K7 –
Racking
None identified
K8 – K12 Internal Cleaning
(Purge, Flush, Wash, Purge,
Rinse)
None identified
K13 - Sterilize & Hold
None identified
K14 – K 15 Purge to Empty &
Counter pressure
None identified
K 16 - K17 Barnes Neck Sanitize None identified
& Inspect
PROCESS STEPS (Continued)
BAC Generic HACCP Model
Revision Date: November 2009
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HACCP Plan - Form 5A
K18 - Filling
None identified
K19 – K 21 Barnes Neck, Wash
& Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product Code Applied
None identified
K25 – K 26 Weigh (In-line
weighing) & Palletize
None identified
K27 - Storage
None identified
K28 - Shipping
None identified
PS8 (C) - CANNING
C1 - Receiving
None identified
C2 - Storage & Handling
Bacterial contamination
from leaking roof or pipes
C3 – C 4 De-palletize / Pallet ID
(Collect & Timestamp Can Pallet
ID, De-palletize)
None identified
C5 - Online visual inspection
None identified
C6 - Primary code applied
None identified
C7 - Bulk in-line rinser
None identified
C8 – C 10 Filling (preevacuation & beer fill)
None identified
C11 – C13 Seaming
None identified
C14 - External Can Flush
None identified
C15 –
Pasteurizer
None identified
C16 – C17 Drying
None identified
C18 - Fill Height Inspection
None identified
PP – Premises (BAC A1.1 &
BAC A2.1)
PROCESS STEPS (Continued)
BAC Generic HACCP Model
Revision Date: November 2009
Page 156 of 252
HACCP Plan - Form 5A
C19 - Divert to Packers
None identified
C20 - Hi-Cone Machine
None identified
C21 - Case Packers
None identified
C22 – Inspection (Human,
visual) Inspection
None identified
C23 – C24 Tray Machine &
Code
None identified
C25 –
Palletize
None identified
C26 - Storage (or Live Load)
None identified
C27 –
Shipping
None identified
PS8 T TANKERING
T1 - Empty Tanker (Receiving)
None identified
T2 - Tanker Washing/ Rinsing
None identified
T3 - Tanker Purging
None identified
T4 - Tanker Filling/ Loading
Insect or pest infestation
of hoses
T5 – Tanker Shipping
None identified
T6 – T7 Full Tanker Receiving &
Unloading
Insect or pest infestation
of hoses
Date:
Approved by:
BAC Generic HACCP Model
Revision Date: November 2009
No pathogens known to survive
in final product due to
properties of beer, e.g. low pH,
alcohol content see Form 1
No pathogens known to survive
in final product due to
properties of beer, e.g. low pH,
alcohol content see Form 1
Page 157 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 158 of 252
FORM 6A:
CHEMICAL HAZARDS
CONTROL & CCPS
BAC Generic HACCP Model
Revision Date: November 2009
Page 159 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 160 of 252
HACCP Plan - Form 6A
BAC Generic
List all chemical
hazards related to
ingredients,
incoming
material,
processing,
product flow, etc.
Title: Form 6A
Hazard Identification - Chemical Hazards Control & CCPs
Completed By: BAC TC
Date:
Approved By: BAC TC
Date:
Identified chemical hazards
Controlled at:
INGREDIENTS
LIQUID INGREDIENTS
City Water
Pesticides, Heavy metals
PP – Premises, Water Quality (BAC
A4.1)
Purchased Water
Cleaning chemicals, cross
contamination from previous load
PP - Transportation Receiving &
Storage (BAC B1.1)
- COA/ Supplier Audits
Well/ Lake/
Surface/ Water
Pesticides, Heavy metals
PP – Premises, Water Quality (BAC
A4.1)
Barley malt
Pesticides, Mycotoxins, Allergen
(cross-contamination from carrier),
NDMA
PP - Transportation Receiving &
Storage (BAC B1.1)- COA / Letter of
Guarantee
Wheat (malted/
nonmalte
d),
Pesticides, Mycotoxins, Allergen,
NDMA
PP - Transportation Receiving &
Storage (BAC B1.1)
DRY INGREDIENTS
+ COA / Letter of Guarantee,
Allergen Management Program
Cereal Grain,
e.g.
corn,
oats,
rice
Pesticides, Mycotoxins, Allergen
(cross-contamination from carrier),
NDMA
Hops
Pesticides, Mycotoxins
PP - Transportation Receiving &
Storage (BAC B1.1)
+ COA / Letter of Guarantee,
Allergen Management Program
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
BAC Generic HACCP Model
Revision Date: November 2009
Page 161 of 252
HACCP Plan - Form 6A
OTHER INGREDIENTS (Continued)
Yeast
Heavy Metals, cleaning chemicals
(used in tankers)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA, Wash Tickets
Carbohydrate
Matte
r
(e.g.
sucro
se,
syrup,
honey
)
Antibiotic residue, heavy metal
(honey)
Salt
Non-food grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Hop Oil
Residual solvents, Non-food grade
+ PP – Transportation, Receiving &
Storage (BAC B1.1)
COA
Hop Extract
Residual solvents, Non-food grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Nitrogen/
Oxygen/
Compressed Air
Chemical non-volatile gases, Nonfood grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA, QC Testing
Purchased CO2
Regenerated
CO2
Contamination from oil (from the
compressor)
PP - Equipment (BAC C1.2)
Liquid Wheat
Extract
Allergen
Allergen Management Program
Caramel
Non-food grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Dextrin
Non-food grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
BAC Generic HACCP Model
Revision Date: November 2009
Page 162 of 252
HACCP Plan - Form 6A
Food Enzymes
Non-food grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
OTHER INGREDIENTS (Continued)
Stabilizing
Agents
Heavy metals, Non-food grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Water
preparation
agents
Heavy metals, Non-food grade
Preservatives
Allergens (Sulphites), Non-food
grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA,
Allergen Management Program
Yeast Foods
Heavy metals, Non-food grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Processing aids
Examples –
Gelatin, Irish
Moss, Wood
Shavings
Heavy metals, Non-food grade
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
PRIMARY PACKAGING MATERIAL
New glass
None identified
Used glass
Lubricants, mycotoxins
PP – Transportation, Receiving &
Storage (BAC B1.1) (Partially
Controlled)
+ Inspection,
+ EBI (Empty Bottle Inspection) /
RLD(Residual Liquid Detector)
Lined aluminum cans
and bottles
None identified
New Kegs
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 163 of 252
HACCP Plan - Form 6A
Used Kegs
None identified
Plastic Bottles, e.g. PET
None identified
PRIMARY PACKAGING MATERIAL (Continued)
Crowns
None identified
Closures & Can Ends
None identified
PROCESS STEPS
PS1- RECEIVING
Chemical – Contamination
from truck (damage, leaks,
odors)
PP – Transportation, Receiving &
Storage (BAC B1.1)
PS2- STORAGE/
HANDLING
Chemical - Crosscontamination from
allergens (e.g. wheat)
Allergen Management Program
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
Chemical – Allergen crosscontamination (e.g. from
residues in the mill)
B4 - Cereal Cooker
None identified
B5 - Mashing (Mash Mixer,
Mash Cooker)
None identified
B6 - Lautering (Lauter
Tun, Mash Filter removal
of spent grains
None identified
B7 – Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified
B10 - Wort Cooling (Heat
Exchanger)
None identified
PP - Sanitation (BAC E1.1)
Allergen Management Program
PS4 -FERMENTATION
Cold Wort (from B10)
BAC Generic HACCP Model
Revision Date: November 2009
None identified
Page 164 of 252
HACCP Plan - Form 6A
F1 Wort Oxygenation/
Wort Aeration
None identified
PROCESS STEPS
F2 - Fermentation
None identified
F3 - Cooling
Coolant leak
F4 - Green Beer
None identified
PP – Equipment (BAC C1.2)
PS4 – SUB-PROCESS
YEAST PREPARATION
Y1 – Propagation
None identified
Y2 – Storage
None identified
Y3 – Acid Washing
None identified
PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling
Coolant leak
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
Coolant leak
PP – Equipment (BAC C1.2)
A6 - Aging Tank
Coolant leak
PP – Equipment (BAC C1.2)
A7 - Secondary Storage
Coolant leak
PP – Equipment (BAC C1.2)
Sulphites as an allergen
Allergen Management Program
A8 - Surge/ buffer Tank
Sulphites as an allergen
Allergen Management Program
A9 – Filtration
Sulphites as an allergen
Allergen Management Program
A10 – Bright Beer Storage
(See PS6 below)
PS6 – BRIGHT BEER
STORAGE
Coolant leak
PP – Equipment (BAC C1.2)
Sulphites as an allergen
Allergen Management Program
Cleaning chemicals
PP - Sanitation (BAC E1.1)
BAC Generic HACCP Model
Revision Date: November 2009
PP – Equipment (BAC C1.2)
Page 165 of 252
HACCP Plan - Form 6A
PS7 BRIGHT BEER
PROCESSING
PROCESS STEPS (Continued)
PS7 (SF) – Sterile
Filtration
SF1 - Bright Beer Tank
Coolant leak
PP – Equipment (BAC C1.2)
Sulphites as an allergen
Allergen Management Program
Cleaning chemicals
PP - Sanitation (BAC E1.1)
SF2 - Filtration
Sulphites as an allergen
Allergen Management Program
SF3 - Sterile Beer Tank
None identified
PS7(FP) – Flash
Pasteurization
FP1 - Bright Beer Tank
Coolant leak
PP – Equipment (BAC C1.2)
Sulphites as an allergen
Allergen Management Program
Cleaning chemicals
PP - Sanitation (BAC E1.1)
FP2 - Pasteurization
Contamination from coolant
PP – Equipment (BAC C1.2)
FP3 - Pasteurized Beer Tank
None identified
PS8 RB –
RETURNED BOTTLES
PREP (FLOAT
GLASSWARE PREP)
RB1 - Receiving/ Storage
None identified
RB2 - De-palletizing
None identified
RB3- RB4 - De-casing &
Inspection (visual)
None identified
RB5 - Bottle Wash
Loading
None identified
RB6 - Pre-rinse sprays
None identified
RB7 - Soak Tanks With
Caustic
Too concentrated, too low,
no caustic, wrong chemical
Bottle unable to drain
BAC Generic HACCP Model
Revision Date: November 2009
PP – Equipment (BAC C1.2)
PP – Transportation, Receiving &
Storage (BAC B1.1)
Page 166 of 252
HACCP Plan - Form 6A
PP – Personnel (BAC D1.2) Training
PROCESS STEPS (Continued)
RB8 - Hydro Jet Sprays
Bottle unable to drain
EBI (Empty Bottle
Inspection)/RLD(Residual Liquid
Detector)
RB9- Post-Soak
Bottle unable to drain
EBI/RLD
RB10 - External Flush
None identified
RB11 - Ext. Rinse
None identified
RB12 - Interior Rinse
Spray malfunction
PP – Equipment (BAC C1.2)
Bottle plugged unable to
drain
EBI/ RLD
Bottle unable to drain
EBI/ RLD
RB13 - Final Rinse
PS8 NB NEW BOTTLES
(GLASSWARE) PREP
NB1- NB2 - Receiving &
Preliminary Inspection
None identified
NB3 – NB 6 Storage
(Pallet Prep, De-palletize)
None identified
NB7 – Inspection (Human,
visual)
None identified
NB8 - Bottle Loading,
None identified
NB9 - Bulk Glass Rinser
Contaminated air, sanitizing
spray
PP – Equipment (BAC C1.2)
MACHINE:
Failure of the system to
detect residual liquid and
caustic
MACHINE:
(Partially Controlled)
PP – Personnel (BAC D1.2) Training
PS8 BT - BOTTLING
BT1
Empty Bottle Inspection
(Human or Machine
inspection)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
CCP1-C
HUMAN:
Failure of personnel to
detect residual liquid
HUMAN:
(Partially Controlled)
PP – Personnel (BAC D1.2) Training
SOP (personnel rotation)
BAC Generic HACCP Model
Revision Date: November 2009
Page 167 of 252
HACCP Plan - Form 6A
CCP1-C
PROCESS STEPS (Continued)
BT2 – Down Bottle Filler
In-Feed Control
None identified
BT3 – BT5 Filling
(Purges , Filling, Fobbing)
CIP chemicals in bottle
PP - Sanitation (BAC E1.1)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
BT6 - Crowning
Lubricants
BT7 – BT 8 Bottle Flush
(Full Bottle Wash external)
None identified
BT9 –
Pasteurize
None identified
BT10 - Foam Inspection
&/or Candling
None identified
BT11 – Drying (Bottle
Drying and Air Knives)
None identified
BT12 – BT13 Labelling,
Coding
Product not coded or not
correctly coded
BT14 – Filled Bottle
Inspection
None identified
BT15 – BT18 Packing &
Sealing
None identified
PP – Equipment (BAC C1.2)
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
(Divert to packers, Carton,
Case Pack, Sealing)
BT19 – BT20 Secondary
Code & Inspection
(Secondary Packaging,
Code/Inspection)
Product not coded or not
correctly coded
BT21 –
Palletize
None identified
BT22 - Storage (or Live
Load)
None identified
BAC Generic HACCP Model
Revision Date: November 2009
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
Page 168 of 252
HACCP Plan - Form 6A
BT23 - Shipping
None identified
PROCESS STEPS (Continued)
PS8 (K) - KEGGING
K1 - Receiving (See PS1)
None identified
K2 – K3 Storage &
Handling , De-palletizing
(See PS2)
None identified
K4 - External Inspection
None identified
K5 – K6 External
Cleaning (Ext
Wash/Inspection)
Old codes not effectively
removed
K7 –
Racking
None identified
K8 – K12 Internal
Cleaning (Purge, Flush,
Wash, Purge, Rinse)
Automated
Automated
Cleaning solution not
effectively removed.
PP - Sanitation (BAC E1.1)
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
Manual
Manual
Cleaning solution not
effectively removed.
(Partially Controlled)
PP - Sanitation (BAC E1.1)
PP – Personnel (BAC D1.2) Training
CCP3-C
K13 - Sterilize & Hold
None identified
K14 – K 15 Purge to
Empty & Counter pressure
None identified
K 16 - K17 Barnes Neck
Sanitize & Inspect
None identified
K18 - Filling
CIP solution
PP - Sanitation (BAC E1.1)
PP – Personnel (BAC D1.2) Training
BAC Generic HACCP Model
Revision Date: November 2009
Page 169 of 252
HACCP Plan - Form 6A
PP – Equipment (BAC C1.2)
PROCESS STEPS (Continued)
K19 – K 21 Barnes Neck,
Wash & Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product Code
Applied
Incorrect or missing code
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
K25 – K 26 Weigh (In-line
weighing) & Palletize
None identified
K27 - Storage
None identified
K28 - Shipping
None identified
PS8 (C) - CANNING
C1 - Receiving
None identified
C2 - Storage & Handling
Contamination from leaking
roof or pipes
PP – Premises (BAC A1.1 & BAC A2.1)
C3 – C 4 De-palletize /
Pallet ID
(Collect & Timestamp Can
Pallet ID, De-palletize)
Incorrect or missing code
on pallet
PP - Recall (BAC F1.2)
C5 - Online visual
inspection
None identified
C6 - Primary code applied
Incorrect or missing code –
PP – Personnel (BAC D1.2) Training
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
C7 - Bulk in-line rinser
Chemicals from
compressed air or water
C8 – C 10 Filling (preevacuation & beer fill)
None identified
C11 – C13 Seaming
Chemicals, Lubricants
BAC Generic HACCP Model
Revision Date: November 2009
PP – Premises (BAC A1.1 & BAC A2.1)
PP – Equipment (BAC C1.2)
PP – Equipment (BAC C1.2)
Page 170 of 252
HACCP Plan - Form 6A
PP – Personnel (BAC D1.2) Training
PROCESS STEPS (Continued)
C14 - External Can Flush
None identified
C15 –
Pasteurizer
None identified
C16 – C17 Drying
None identified
C18 - Fill Height
Inspection
None identified
C19 - Divert to Packers
None identified
C20 - Hi-Cone Machine
None identified
C21 - Case Packers
None identified
C22 – Inspection (Human,
visual) Inspection
None identified
C23 – C24 Tray Machine
& Code
Incorrect or missing code
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
C25 –
Palletize
None identified
C26 – Storage
(or Live Load)
None identified
C27 –
Shipping
None identified
PS8 T TANKERING
T1 - Empty Tanker
(Receiving)
Cleaning chemicals and/ or
sanitizer
PP – Transportation, Receiving &
Storage (BAC B1.1)
COA, Wash Ticket,
PP – Personnel (BAC D1.2) Training
T2 - Tanker Washing/
Rinsing
BAC Generic HACCP Model
Revision Date: November 2009
Cleaning chemicals and/ or
sanitizer
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
Page 171 of 252
HACCP Plan - Form 6A
PP - Sanitation (BAC E1.1)
PROCESS STEPS (Continued)
T3 - Tanker Purging
Contaminated CO2
For Regenerated CO2 – PP – Equipment
(BAC C1.2)
PP – Personnel (BAC D1.2) Training
For Purchased CO2 - PP –
Transportation, Receiving & Storage
(BAC B1.1)
COA
T4 - Tanker Filling/
Loading
Cross contamination from
using hose on non-food
material
T5 – Tanker Shipping
None identified
T6 – T7 Full Tanker
Receiving & Unloading
Cross contamination with
chemicals from the supplier
PP – Transportation, Receiving &
Storage (BAC B1.1)
Cross contamination from
using hose on non-food
material
+ COA
Date:
BAC Generic HACCP Model
Revision Date: November 2009
PP – Personnel (BAC D1.2) Training
PP – Personnel (BAC D1.2) Training
Approved by:
Page 172 of 252
FORM 7A:
PHYSICAL HAZARDS
CONTROLS & CCPS
BAC Generic HACCP Model
Revision Date: November 2009
Page 173 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 174 of 252
HACCP Plan - Form 7A
BAC Generic
Title: Form 7A –
Hazard Identification - Physical Hazards Control & CCPs
Completed By: BAC TC
Date:
Approved By: BAC TC
Date:
List all physical hazards
related to ingredients,
incoming material,
processing, product flow,
etc.
Identified physical
hazards
Controlled at:
City Water
Silt
PP – Premises, Water Quality (BAC
A4.1)
Purchased Water
None identified
Well/ Lake/ Surface/ Water
Silt
PP – Premises, Water Quality (BAC
A4.1)
Barley malt
Glass, Metal
PP - Transportation Receiving &
Storage (BAC B1.1) - Receiving
Inspection (screens, magnets)
Wheat (malted/ nonmalted),
Glass, Metal
PP - Transportation Receiving &
Storage (BAC B1.1)
INGREDIENTS
LIQUID INGREDIENTS
DRY INGREDIENTS
+ Receiving Inspection (screens,
magnets)
Cereal Grain, e.g. corn,
oats, rice
Glass, Metal
PP - Transportation Receiving &
Storage (BAC B1.1)
+ Receiving Inspection (screens,
magnets)
Hops
Insects, metal
PP - Transportation Receiving &
Storage (BAC B1.1)
+ COA, Inspection
BAC Generic HACCP Model
Revision Date: November 2009
Page 175 of 252
HACCP Plan - Form 7A
OTHER INGREDIENTS
Yeast
None identified
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA, Wash Tickets
Carbohydrate Matter
(e.g. sucrose,
syrup, honey)
None identified
Salt
Rocks
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
(Partially Controlled)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ Inspection
Hop Oil
Plastic
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA, Inspection
Hop Extract
Plastic
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA, Inspection
Nitrogen/ Oxygen/
Compressed Air
Purchased CO2
None identified
Regenerated CO2
None identified
Liquid Wheat Extract
Plastic (from packaging)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Caramel
Plastic (from container)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Dextrin
Plastic (from container)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ COA
Food Enzymes
BAC Generic HACCP Model
Revision Date: November 2009
None identified
Page 176 of 252
HACCP Plan - Form 7A
OTHER INGREDIENTS (Continued)
Stabilizing Agents
None identified
Water preparation agents
None identified
Preservatives
None identified
Yeast Foods
None identified
Processing aids
Examples – Gelatin, Irish
Moss, Wood Shavings
None identified
PRIMARY PACKAGING MATERIAL
New glass
Critical Glass Defects ,
Glass
(Partially Controlled)
PP – Transportation, Receiving &
Storage (BAC B1.1)
+COA, Inspection
+ EBI (Empty Bottle Inspection)
Used glass
Lined aluminum cans and
bottles
Critical Glass Defects , Dirt,
Dust, Glass, Syringes,
Medical Patches,
+ Bottle Wash
Metal Shavings
(Partially Controlled) PP –
Transportation, Receiving & Storage
(BAC B1.1)
+ EBI (Empty Bottle Inspection)
+COA
+ Rinse
New Kegs
Metal Shavings
(Partially Controlled)
Rinse
Used Kegs
None identified
Plastic Bottles, e.g. PET
None identified
Crowns
None identified
Closures & Can Ends
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 177 of 252
HACCP Plan - Form 7A
PROCESS STEPS
PS1- RECEIVING
PS2- STORAGE/
HANDLING
Pests in hoses used for
transferring material, Bulk
Receiving
PP – Personnel (BAC D1.2)
Insect or pest infestation
PP - Pest Control (BAC E2.1)
+ Training
PS3 - BREWING
B1 - Receiving
(See PS1 above)
B2 - Storage
(See PS2 above)
B3 - Milling
None identified
B4 - Cereal Cooker
None identified
B5 - Mashing (Mash Mixer,
Mash Cooker)
None identified
B6 - Lautering (Lauter
Tun, Mash Filter removal
of spent grains
None identified
B7 – Holding Tank
None identified
B8 - Kettle
None identified
B9 Whirlpool
None identified
B10 - Wort Cooling (Heat
Exchanger)
None identified
PS4 -FERMENTATION
Cold Wort (from B10)
None identified
F1 Wort Oxygenation/
Wort Aeration
None identified
F2 - Fermentation
None identified
F3 - Cooling
F4 - Green Beer
None identified
PS4 – SUB-PROCESS
YEAST PREPARATION
BAC Generic HACCP Model
Revision Date: November 2009
Page 178 of 252
HACCP Plan - Form 7A
PROCESS STEPS (Continued)
Y1 – Propagation
None identified
Y2 – Storage
None identified
Y3 – Acid Washing
None identified
PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling
A2 - Buffer tank
None identified
A3 - Centrifuge
None identified
A4 - Buffer tank
None identified
A5 - Cooling tank
None identified
A6 - Aging Tank
None identified
A7 - Secondary Storage
None identified
A8 - Surge/ buffer Tank
None identified
A9 – Filtration
None identified
A10 – Bright Beer Storage
None identified
PS6 – BRIGHT BEER
STORAGE
None identified
PS7 BRIGHT BEER
PROCESSING
PS7 (SF) – Sterile
Filtration
SF1 - Bright Beer Tank
None identified
SF2 - Filtration
None identified
SF3 - Sterile Beer Tank
None identified
PS7(FP) – Flash
Pasteurization
FP1 - Bright Beer Tank
BAC Generic HACCP Model
Revision Date: November 2009
None identified
Page 179 of 252
HACCP Plan - Form 7A
PROCESS STEPS (Continued)
FP2 - Pasteurization
None identified
FP3 - Pasteurized Beer Tank
None identified
PS8 RB –
RETURNED BOTTLES
PREP (FLOAT
GLASSWARE PREP)
RB1 - Receiving/ Storage
Damage to bottles
PP – Transportation, Receiving &
Storage (BAC B1.1)
PP – Personnel (BAC D1.2) Training
RB2 - De-palletizing
Damage to bottles
PP – Equipment (BAC C1.2)
PP – Transportation, Receiving &
Storage (BAC B1.1)
PP – Personnel (BAC D1.2) Training
RB3- RB4 - De-casing &
Inspection (visual)
Damage to bottles
RB5 - Bottle Wash
Loading
Damage to bottles
RB6 - Pre-rinse sprays
Damage to bottles (e.g.
Temperature shock due to
storage)
PP – Equipment (BAC C1.2)
RB7 - Soak Tanks With
Caustic
Damage to bottles
PP – Equipment (BAC C1.2)
RB8 - Hydro Jet Sprays
Damage to bottles,
(Partially Controlled)
Bottle contains foreign object
(spray malfunction)
PP – Equipment (BAC C1.2)
Bottle contains foreign object
(plugged but sprays cannot
clear object)
PP – Equipment (BAC C1.2)
Damage to bottles (e.g.
Temperature shock),
(Partially Controlled)
RB9- Post-Soak
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
Bottle plugged
PP – Transportation, Receiving &
Storage (BAC B1.1)
+EBI
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
+EBI
BAC Generic HACCP Model
Revision Date: November 2009
Page 180 of 252
HACCP Plan - Form 7A
PROCESS STEPS (Continued)
RB10 - External Flush
Damage to bottles (e.g.
Temperature shock)
(Partially Controlled)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
+EBI
RB11 - Ext. Rinse
Damage to bottles
PP – Equipment (BAC C1.2)
(e.g. Temperature shock)
PP – Personnel (BAC D1.2) Training
+EBI
RB12 - Interior Rinse
Damage to bottles
PP – Equipment (BAC C1.2)
Bottle contains foreign object
(spray malfunction)
PP – Equipment (BAC C1.2)
+EBI
Bottle contains foreign object
(plugged but sprays cannot
clear object)
RB13 - Final Rinse
Damage to bottles,
PP – Equipment (BAC C1.2)
Bottle contains foreign object
(spray malfunction)
PP – Equipment (BAC C1.2)
+EBI
Bottle contains foreign object
(plugged but sprays cannot
clear object)
PS8 NB NEW BOTTLES
(GLASSWARE) PREP
NB1- NB2 - Receiving &
Preliminary Inspection
Damage to bottles
PP – Transportation, Receiving &
Storage (BAC B1.1)
PP – Personnel (BAC D1.2) Training
NB3 – NB 6 Storage
(Pallet Prep, De-palletize)
Damage to bottles
NB7 – Inspection (Human,
visual)
Missed critical glass defects
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
(Partially Controlled)
PP – Personnel (BAC D1.2) Training
+EBI
BAC Generic HACCP Model
Revision Date: November 2009
Page 181 of 252
HACCP Plan - Form 7A
PROCESS STEPS (Continued)
NB8 - Bottle Loading,
Damage to bottles
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
NB9 - Bulk Glass Rinser
Spray malfunction (e.g.
plugged sprays)
PP – Equipment (BAC C1.2)
MACHINE:
Failure of the system to
detect foreign matter, glass
defects, bottle damage
MACHINE:
(Partially Controlled)
PS8 BT - BOTTLING
BT1
Empty Bottle Inspection
(Human or Machine
inspection)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
CCP1-P
HUMAN:
Failure of personnel to detect
foreign matter, glass defects,
glass damage
HUMAN:
(Partially Controlled)
PP – Personnel (BAC D1.2) Training,
SOP (personnel rotation)
CCP1-P
BT2 – Down Bottle Filler
In-Feed Control
Glass inclusions from
breakage of down bottle at
filler in-feed
PP – Equipment (BAC C1.2)
BT3 – BT5 Filling
(Purges , Filling, Fobbing)
Chipping of bottles (e.g. from
filling equipment), glass
inclusion
PP – Equipment (BAC C1.2)
Auto-Flush
Auto-Flush
Burst bottle leading to glass
inclusion
(Partially Controlled)
PP – Personnel (BAC D1.2)
PP – Personnel (BAC D1.2) Training
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
PP – Transportation, Receiving &
Storage (BAC B1.1)
CCP2-P
Manual Flush
Manual Flush
Burst bottle leading to glass
inclusion
(Partially Controlled)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
PP – Transportation, Receiving &
Storage (BAC B1.1)
+ Foam Inspection
BAC Generic HACCP Model
Revision Date: November 2009
Page 182 of 252
HACCP Plan - Form 7A
PROCESS STEPS (Continued)
BT6 - Crowning
Bottle finish damage
(leading to glass
inclusions)
(Partially Controlled)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
+ Foam Inspection/ Candling
BT7 – BT 8 Bottle Flush
(Full Bottle Wash external)
None identified
BT9 –
Pasteurize
None identified
BT10 - Foam Inspection
&/or Candling
HUMAN
T11 – Drying (Bottle
Drying and Air Knives)
None identified
BT12 – BT13 Labelling,
Coding
Product not coded or not
correctly coded
BT14 – Filled Bottle
Inspection
None identified
BT15 – BT18 Packing &
Sealing
(Divert to packers, Carton,
Case Pack, Sealing)
None identified
BT19 – BT20 Secondary
Code & Inspection
(Secondary Packaging,
Code/Inspection)
Product not coded, or not
correctly coded
BT21 –
Palletize
None identified
BT22 - Storage (or Live
Load)
None identified
BT23 - Shipping
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Physical – Failure to detect
foreign matter (including
glass)
PP – Personnel (BAC D1.2) Training
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
Page 183 of 252
HACCP Plan - Form 7A
PROCESS STEPS (Continued)
PS8 (K) - KEGGING
K1 - Receiving (See PS1)
None identified
K2 – K3 Storage &
Handling , De-palletizing
(See PS2)
None identified
K4 - External Inspection
None identified
K5 – K6 External
Cleaning (Ext
Wash/Inspection)
Old codes not effectively
removed
K7 –
Racking
None identified
K8 – K12 Internal
Cleaning (Purge, Flush,
Wash, Purge, Rinse)
None identified
K13 - Sterilize & Hold
None identified
K14 – K 15 Purge to
Empty & Counter pressure
None identified
K 16 - K17 Barnes Neck
Sanitize & Inspect
None identified
K18 - Filling
None identified
K19 – K 21 Barnes Neck,
Wash & Sanitize
None identified
K22 - Dust Cap
None identified
K23 - Air Dry
None identified
K24 - Product Code
Applied
Incorrect or missing code
PP - Recall (BAC F1.2)
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
K25 – K 26 Weigh (In-line
weighing) & Palletize
None identified
K27 - Storage
None identified
BAC Generic HACCP Model
Revision Date: November 2009
Page 184 of 252
HACCP Plan - Form 7A
PROCESS STEPS (Continued)
K28 - Shipping
None identified
PS8 (C) - CANNING
C1 - Receiving
None identified
C2 - Storage & Handling
None identified
C3 – C 4 De-palletize /
Pallet ID
(Collect & Timestamp Can
Pallet ID, De-palletize)
Incorrect or missing code on
pallet
C5 - Online visual
inspection
None identified
C6 - Primary code applied
Incorrect or missing code –
PP - Recall (BAC F1.2)
PP – Personnel (BAC D1.2) Training
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
C7 - Bulk in-line rinser
None identified
C8 – C 10 Filling (preevacuation & beer fill)
None identified
C11 – C13 Seaming
None identified
C14 - External Can Flush
None identified
C15 –
Pasteurizer
None identified
C16 – C17 Drying
None identified
C18 - Fill Height
Inspection
None identified
C19 - Divert to Packers
None identified
C20 - Hi-Cone Machine
None identified
C21 - Case Packers
None identified
C22 – Inspection (Human,
visual) Inspection
None identified
PROCESS STEPS (Continued)
BAC Generic HACCP Model
Revision Date: November 2009
Page 185 of 252
HACCP Plan - Form 7A
C23 – C24 Tray Machine
& Code
Incorrect or missing code
PP - Recall (BAC F1.2)
PP – Equipment (BAC C1.2)
PP – Personnel (BAC D1.2) Training
C25 –
Palletize
None identified
C26 - Storage (or Live
Load)
None identified
C27 –
Shipping
None identified
PS8 T TANKERING
T1 - Empty Tanker
(Receiving)
None identified
T2 - Tanker Washing/
Rinsing
None identified
T3 - Tanker Purging
None identified
T4 - Tanker Filling/
Loading
None identified
T5 – Tanker Shipping
None identified
T6 – T7 Full Tanker
Receiving & Unloading
None identified
Date:
BAC Generic HACCP Model
Revision Date: November 2009
Approved by:
Page 186 of 252
FORM 9:
HAZARDS NOT CONTROLLED
BY BREWERY
BAC Generic HACCP Model
Revision Date: November 2009
Page 187 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 188 of 252
HACCP Plan - Form 9
BAC Generic
Title: Form 9 – Hazards not Controlled by Brewery
Completed By: BAC TC
Date:
Approved By: BAC TC
Date:
Hazards not controlled by Brewery
Hazards (B = Biological, C=Chemical, P= Physical)
Indicate the way the Hazard could be
Addressed (Cooking Instructions,
Public Education, Use Before Date,
etc.)
Hazard Descriptions
BAC Generic HACCP Model
Revision Date: November 2009
Page 189 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 190 of 252
FORM 10:
HACCP PLAN
BAC Generic HACCP Model
Revision Date: November 2009
Page 191 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 192 of 252
HACCP Plan - Form 10
PRODUCT
Process
Steps
Empty Bottle
Inspection- EBI
(Step BT1)
NAME:
CCP/
Hazard
Number
CCP1-P
Hazard
Description
Critical
Limits
Monitoring
procedures
Deviation
Procedures
Verification
Procedures
HACCP
Records
Physical Failure of the
system to
detect foreign
matter, glass
defects, bottle
damage
EBI test
bottle failure
Who – Packaging
Operator/ QA
personnel
If the CCP test fails,
the line is stopped by
Packaging Operator/
QA. Manager/
Supervisor is
notified.
Pre-start
check
completed on
system by
electricians.
EBI Test Bottle
Monitoring
Records
(i.e. 100%
test bottle
rejection)
Frequency – At start
up, hourly and at end
of shift
Refer to SOP
describing EBI testing.
The Packaging
Operator or QA
personnel signs and
dates the EBI Test
Bottle Monitoring
Form.
BAC Generic HACCP Model
Revision Date: November 2009
BEER
Hold product from
last successful test
100% inspection of
product since last
successful test is
done (accept/ reject
product).
Repair/ fix equipment
and verify.
Page 193 of 252
Line
Supervisor
reviews
records after
each shift or
daily and
signs & dates
records.
Monthly QA
record
review.
Corrective
Action Records
Verification
Records
Product Hold &
Inspection
Records
Product
Destruction
Records
HACCP Plan - Form 10
Process
Steps
Empty Bottle
Inspection
/Residual Liquid
Detector
CCP/
Hazard
Number
CCP1-C
EBI/RLD
Hazard
Description
Critical
Limits
Monitoring
procedures
Deviation
Procedures
Verification
Procedures
HACCP
Records
Chemical Failure of the
system to
detect residual
liquid and
caustic
RLD test
bottle failure
Who – Packaging
Operator/ QA
personnel
If the CCP test fails,
the line is stopped by
Packaging Operator/
QA. Manager/
Supervisor is notified.
Pre-start
check
completed on
system by
electricians.
RLD Test Bottle
Monitoring
Records
Hold product from
last successful test
Line
Supervisor
reviews
records after
each shift or
daily and
signs & dates
records.
(i.e. 100%
test bottle
rejection)
Frequency – At startup, hourly and at end
of shift
(Step BT1)
Refer to SOP
describing RLD
testing.
Product is discarded.
The Packaging
Operator or QA
personnel signs and
dates the RLD Test
Bottle Monitoring
Form.
BAC Generic HACCP Model
Revision Date: November 2009
Page 194 of 252
Monthly QA
record
review.
Corrective
Action Records
Verification
Records
Product
Destruction
Records
HACCP Plan - Form 10
Process
Steps
CCP/
Hazard
Number
Filling
CCP2-P
(Auto-Flush
Only)
(Steps BT 3BT5)
Hazard
Description
Critical
Limits
Monitoring
procedures
Deviation
Procedures
Verification
Procedures
HACCP
Records
Physical –
Burst bottle
leading to
glass inclusion
100%
functioning
auto-flush
(That is, the
flushing
spray is on,
short fill
cycle, reject
pattern to
specification).
Who – Packaging
Operator
If:
Line
Supervisor
reviews
records after
each shift or
daily and
signs & dates
records.
Auto-Flush
Monitoring
Records
Frequency–
Hourly test and at end
of production ; bottle
burst
Refer to SOP Autoflush Monitoring
Procedure
Document on AutoFlush Monitoring
Form. Sign and date.
- System failed hourly
test
or
- Bottle burst and
system did not catch it
The Operator will:
- Shut off line
- Run suspect bottles to
reject
- Flush filler
- Hold product from last
successful check
- Re-inspect 100% of
product since last
successful check
(accept / reject
product).
BAC Generic HACCP Model
Revision Date: November 2009
Page 195 of 252
Monthly QA
record
review.
Annual
validation of
auto-flush.
Corrective
Action Records
Verification
Records
Annual Autoflush Validation
Records
Product Hold &
Inspection
Records
HACCP Plan - Form 10
Process
Steps
Internal
Cleaning
(Manual)
CCP/
Hazard
Number
CCP3-C
(Steps K8 – K12)
Hazard
Description
Critical
Limits
Monitoring
procedures
Deviation
Procedures
Verification
Procedures
HACCP
Records
Chemical –
Cleaning
solution not
effectively
removed.
Rinse water
visible in
sight glass of
test keg.
Who - Kegging
Operator
If the CCP fails:
QA personnel
will perform a
sodium check
on the test
keg from the
start of each
production
run.
Keg Cleaning
Records
Sodium in the
test keg
sample must
meet the
Canadian
Drinking
Water
Guidelines of
<200mg/L of
sodium.
Verification
Reports
No
detectable
caustic carryover based
on
phenolphthal
ein check.
Frequency – Start up,
*every 24 kegs and at
the completion of
kegging operation
Perform a visual check
for rinse water and
phenolphthalein check
for caustic carry over
Refer to SOP for
details.
Note: Frequency of
‘every 24 Kegs’ is for
example purposes
only. Frequency
should be determined
based off current
operations (i.e. rate
and number of bottles
produce)
BAC Generic HACCP Model
Revision Date: November 2009
The Kegging Operator
notifies the Line
Supervisor and
describes the failure.
If the rinse water is not
visible through the sight
glass and/or the
phenolphthalein check
is positive for caustic
(turns pink), the
Kegging Operator
performs 2 additional
test keg runs and if
either of the re-test fails
a CCP failure has
occurred. If both re-test
passes, production may
resume.
Production may resume
when the problem has
been corrected and
confirmed by 2
consecutive test keg
runs.
Page 196 of 252
The
Supervisor
verifies the
keg rinse
reports daily.
Analytical
Results
Corrective
Action Report
CCP Monthly
Audit
CCP Training
Records
HACCP Plan - Form 10
Process
Steps
Internal
Cleaning
(Manual)
CCP/
Hazard
Number
Hazard
Description
Critical
Limits
Monitoring
procedures
CCP3-C
(Steps K8 – K12)
Deviation
Procedures
Verification
Procedures
If the CCP failure
occurs during
production, production
is stopped and all kegs
are put on hold back to
the last good check.
QA performs
a CCP audit
on a monthly
basis.
All held product is 100%
discarded.
Deviations and
Corrective Actions are
recorded on the
Corrective Action
Report by the
Supervisor.
Date:
BAC Generic HACCP Model
Revision Date: November 2009
Approved by:
Page 197 of 252
HACCP
Records
BAC Generic HACCP Model
Revision Date: November 2009
Page 198 of 252
HACCP PLAN
APPENDICES
BAC Generic HACCP Model
Revision Date: November 2009
Page 199 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 200 of 252
APPENDIX 1
FORM 3
INFORMATION USED FOR
FLOWCHARTS
BAC Generic HACCP Model
Revision Date: November 2009
Page 201 of 252
BAC Generic HACCP Model
Revision Date: November 2009
Page 202 of 252
Information Used to Create Flowcharts
Major Process Steps (Ps) for Making Beer
INPUT
PROCESS STEP/ ID
Dry Ingredients
PS1
Receiving
PS2
Storage & Handling
Barley Malt, Wheat Malt,
Cereal Grains, Water, Water
Preparation Agents, Hops,
Other ingredients
PS3
Brewing - Milling
- Mashing
- Lautering
- Kettle
- Whirlpool
- Cooling
Spent grains (byproduct), Hot Water,
Trub, Wort, Cold
Water
Other
Ingredients( processing
aids), Yeast
PS4
Fermentation
Yeast, Pitching Yeast
Other
Ingredients( processing
aids)
PS5
Aging
Beer, CO2
(collection, waste)
- Clarification
- Filtration
OUTPUT
Bulk Beer
CO2
Packaging Materials,
PS6
Bright Beer Storage
PS7
Bright Beer Processing
PS8
Packaging
PS9
Warehousing/Shipping
Bright Beer
New Bottles (NB), Returned
Bottles (RB), Kegs, Tankers,
Cans
BAC Generic HACCP Model
Revision Date: November 2009
Page 203 of 252
Information Used to Create Flowcharts
Ps3 - Brewing
INPUT
PROCESS STEP/ ID
Liquid/ Dry/ Bulk
Compressed Air
B1
Receiving (See PS1)
B2
Storage (See PS2)
Barley Malt, Wheat Malt
B3
Milling
Malt Dust, Grist
Cereal, Prepared
Brewing Water, Steam
B4
Cereal Cooker
Cooked Cereal
Prepared Brewing
Water,Steam, Grist
B5
Mashing (Mash Mixer, Mash
Cooker)
Mash
Sparge water, Steam
B6
Lautering (Lauter Tun, Mash
Filter removal of spent grains
Spent Grains, Sweet
Water
B7
Holding Tank
B8
Kettle
B9
Whirlpool/ Centrifuge/ Hot Wort
Tank
B10
Wort Cooling (Heat Exchanger)
Hops, Hop oil, other
ingredients (eg. syrup),
Steam
Oxygen
OUTPUT
Cooled Wort
Next process - PS4 Fermentation
BAC Generic HACCP Model
Revision Date: November 2009
Page 204 of 252
Information Used to Create Flowcharts
Ps4 - Fermentation
INPUT
PROCESS STEP/ ID
OUTPUTS
Oxygen or sterile air,
F1
Wort
Oxygenation/
Wort Aeration
Aerated/ Oxygenated Wort
Cooled aerated wort, Dry Hop,
Pitching yeast (See PS3 –
Brewing)
F2
Fermentation
CO2
(Cooling Step)
F3
Cooling
Yeast
F4
Green Beer
Green Beer,
Cold Wort
Next Process – PS5 Aging (Primary Storage)
Sub-Process - Yeast Preparation
INPUT
PROCESS STEP/ ID
OUTPUTS
Yeast Source, New Culture
Y1
Propagation
Pitching Yeast
Pitching Yeast
(Cooling Step)
Y2
Storage
Waste Yeast
Acids, Phosphoric, Sulphuric
Y3
Acid Washing
Pitching Yeast
Waste Yeast
Oxygenated Wort, Aerated Wort,
Nutrients
Next Process – F2 Fermentation
BAC Generic HACCP Model
Revision Date: November 2009
Page 205 of 252
Information Used to Create Flowcharts
Ps5 - Aging/Clarification/Filtration
INPUT
PROCESS STEP/ ID
Green Beer (See
PS4 - Fermentation)
A1
Cooling
A2
Buffer Tank
A3
Centrifuge
Yeast/ Spent Waste
(by-product)
A4
Buffer tank
CO2
A5
Cooling
CO2, Hops
A6
Aging Tank
Beer, Spent Hops,
CO2
De-aerated Water,
Processing Aids,
Stabilizers, CO2
A7
Secondary Storage
Spent Yeast, CO2
A8
Surge/ buffer Tank
CO2
A9
DE Pre-filter/ Filter Trap/ Sheet
Filter/ Membrane Filter/ PVPP
Filter
Spent DE, Spent
Yeast, Spent Hops,
CO2,
A10
Bright Beer Storage
Bright Beer, O2
Processing Aids,
Stabilizers, CO2
OUTPUTS
Preservatives
Preservatives
De-aeration Water,
Processing Aids,
Stabilizers, CO2
Preservatives
Caramel and other
ingredients,
Processing Aids,
Stabilizers, CO2,
Nitrogen
Preservatives
CO2, De-aerated
Water, Nitrogen
Next Process – PS7 Bright Beer Processing
BAC Generic HACCP Model
Revision Date: November 2009
Page 206 of 252
Information Used to Create Flowcharts
Ps7 - Bright Beer Processing
A – Sterile Filtration
INPUT
PROCESS STEP/ ID
OUTPUTS
Filter Preparation
(Membrane Filters, Candle
Filters, Integrity Test, Re-chill)
SF1
Bright Beer
Tank
Effluent
SF2
Sterile
Filtration
Sterile Beer
SF3
Sterile Beer
Tank
CIP Chemicals, Steam, Water,
Coolant, Sterile Gases
Bright Beer, CO2
Next Process – PS8 Packaging
B – Flash Pasteurization
INPUT
PROCESS STEP/ ID OUTPUTS
Bright Beer
FP1
Flash
Pasteurized Beer
pasteurization
Steam , hot water, coolant,
CO2
Effluent
FP2
Pasteurized
Beer Tank
Next Process – PS8 Packaging
BAC Generic HACCP Model
Revision Date: November 2009
Page 207 of 252
Information Used to Create Flowcharts
Packaging Processes - Ps8 (RB)
Returned Bottles Prep (Float Glassware Prep)
INPUT
PROCESS STEP/ ID
OUTPUT
Returned (Float) Glassware
RB1
Receiving/ Storage
RB2
De-palletizing
Pallets, Straps, Film,
Twine
RB3
De-casing
Foreign materials,
Scrap cartons, Scrap
Partitions, Damaged
Broken Glass,
crowns
RB4
Human (Visual)
Inspection
Foreign materials,
Scrap cartons, Scrap
Partitions, Damaged
Broken Glass,
crowns
RB5
Bottle Wash Loading
Waste beer, debris
First Post Soak
RB6
Pre-rinse sprays
Straws, butts, waste
water
Steam, water, chemicals
RB7
Soak Tanks With
Caustic
Label pulp, Caustic
(Sodium Hydroxide),
Plastic
Caustic Solution
RB8
Hydro Jet Sprays
Receive Ext Flush
RB9
Post-Soak
Recovered post soak
(effluent)
Recovered External/
Internal
RB10
External Flush
Recovered external
flush
Recovered Final Rinse
RB11
External and internal
Rinse
Recovered external
rinse, label pulp
carryover
Potable Water
RB12
Interior Final Rinse
Recovered final rinse
Potable Water
RB13
External Final Rinse
Recovered final rinse
Washed Glassware
Next Process – PS8 BT - Bottling
BAC Generic HACCP Model
Revision Date: November 2009
Page 208 of 252
Information Used to Create Flowcharts
Packaging Processes - Ps8 (NB)
New Bottles (Glassware) Prep
INPUT
PROCESS STEP/ ID
New Glassware
NB1
Receiving
NB2
Preliminary Inspection
NB3
Storage
NB4
Collect the Manufacturing Pallet
tags
NB5
Pallet prep
Straps, film
NB6
De-palletize
Top frame, tier sheet,
pallets
NB7
Visual Inspection
Rejects, damaged
glassware
NB8
Bottle Loading
NB9
Bulk Glass Rinser
Potable Water,
Compressed Air
OUTPUT
Reject loads and
pallets
Rinsed glassware
Rinse Water effluent
Next Process – PS8 BT - Bottling
BAC Generic HACCP Model
Revision Date: November 2009
Page 209 of 252
Information Used to Create Flowcharts
Packaging Processes - Ps8 (BT)
Bottling
INPUT
PROCESS STEP/ ID
OUTPUT
Washed and Finished
Glass, (New or Float)
BT1
Empty Bottle Inspection
Rejects, Finished
Water and Lube
BT2
Down bottle filler in-feed
control
Rejects
BT3
Purges & Evacuation &
Positive Pressure
Glass, debris,
shards
Compressed Air,
Conveyor Lubricant,
Conveyor Flush Water,
CO2, Compressed Air,
Potable Water, Lube
Water
CO2, Counter pressure
bowl, Bright Beer, Hot
Pressurized Water, Filter
Pressurized Water
CO2
BT4
Filling
Bottle breakage,
CO2
BT5
Fobbing
Beer foam overflow
Packaging Materials,
Crowns, Compressed air,
City Water flush,
Lubricants
BT6
Crowning
Damaged crowns,
water effluent, bottle
breakage, spilled
beer
City Water Flush
BT7
Crowner Flush (external)
Water and beer
effluent
City Water
BT8
Filled Bottle wash external
Rejects
Water, Steam, Chemicals
BT9
Pasteurize
Effluent, broken
glass
BT10
Foam Inspection/ Candling
Inspection
Rejects
BAC Generic HACCP Model
Revision Date: November 2009
Page 210 of 252
Information Used to Create Flowcharts
Packaging Processes - Ps8 (BT) (Continued)
Bottling (Continued)
INPUT
PROCESS STEP/ ID
Ambient air blower
BT11
Bottle Drying and Air
Knives
Packaging material,
adhesive, compressed air
BT12
Labelling
Bottle breakage,
labels, adhesive,
beer
Packaging material (ink)
BT13
Primary Packaging, Coding
Inks, Cleaning
Solutions
BT14
Filled Bottle Inspection
Rejects
BT15
Divert to packers
BT16
Carton Forming
Rejects, damaged
BT17
Case Packing
Bottle breakage,
beer, damage
Packaging Material Adhesive
BT18
Case Sealing
Bottle breakage,
beer, damage
Packaging Material – Ink
BT19
Secondary Packaging
Code
Inks, Cleaning
Solutions
BT20
Full Case Inspection
Rejects
Pallets, Tier sheets, trays,
straps, shrink wrap, pallet
ID
BT21
Palletize
Finished Goods
Finished Goods
BT22
Storage (or Live Load)
BT23
Shipping
Packaging material,
cartons, adhesive,
partitions (inserts)
BAC Generic HACCP Model
Revision Date: November 2009
OUTPUT
Page 211 of 252
Information Used to Create Flowcharts
Packaging Processes - Ps8 (K)
Kegging
INPUT
PROCESS STEP/ ID
Keg Float, Keg Caps,
Bright Beer
K1
Receiving (See PS1)
K2
Storage & Handling (See PS2)
K3
De-palletizing (See PS2)
K4
External Inspection
Rejected Kegs
K5
Ext Wash
Dust caps,
labels, effluent
K6
Post Wash Inspection
Temporary
storage
Kegs Temperature
Storage
K7
Racking
Compressed Air
K8
Purge to Empty
Waste beer,
rejected kegs
Potable Water
K9
Flush
Rinsings
Acid Steam & Sodium
Hydroxide
K10
Wash
Drain or recover
Compressed Air
K11
Purge to empty
Residual CIP
solution
Heated Water
K12
Rinse
Rinsings to drain
Steam
K13
Sterilize & Hold
CO2
K14
Purge to Empty
Residual Water,
CO2
CO2
K15
Counter Pressure
CO2
Steam
K16
Barnes Neck Sanitize
Fill
K17
Inspect
Rejected Keg
Water & Detergents
BAC Generic HACCP Model
Revision Date: November 2009
OUTPUT
Page 212 of 252
Information Used to Create Flowcharts
Packaging Processes - Ps8 (K) (Continued)
Kegging (Continued)
INPUT
PROCESS STEP/ ID
OUTPUT
Bright Beer, Clean Kegs
from storage
K18
Filling
Waste Beer
Steam
K19
Sterilize Barnes Neck
Condensate
Chlorinated Water
K20
Final Rinse Dome
Chlorinated
water to drain
Sanitation chemicals
K21
Chemical Sanitize Barnes Neck
Packaging Material
K22
Dust Cap
Plant air
K23
Air Dry
Packaging Material
K24
Product Code Applied
K25
In-line weighing
K26
Palletize
K27
Storage or Live Load
K28
Shipping
BAC Generic HACCP Model
Revision Date: November 2009
Full goods
storage
Page 213 of 252
Information Used to Create Flowcharts
Packaging Processes - Ps8 (C)
Canning
INPUT
PROCESS STEP/ ID
OUTPUT
Cans, Can ends, Bright
Beer (from Ps7)
C1
Receiving
Damaged Cans
C2
Storage & Handling
C3
Collect & Timestamp Can
Pallet ID
Straps (to scrap/
recycle)
C4
De-palletize to mass
conveyor
Pallet, frame (top),
tier sheet
C5
Online visual inspection
Non-conforming
cans (rejects)
Packaging Material (ink)
C6
Primary code applied
Ink
Treated water filtered
C7
Bulk in-line rinser
Rinse water 1(Bulk
Rinse discharge
water)
CO2 & Bright beer
C8
Filling (pre-evacuation &
beer fill)
Open filled cans
Open filled cans & CO2
C9
Bubble breakers
CO2
CO2
C10
Under Cover Gassing
CO2
Can ends
C11
Collect manufacturing lot
detail for ends
Paper sleeves to
baler
Continuous lubrication
C12
Double seaming
Excess/ surplus
lube, Beer
C13
Filler valve monitor
Reject cans
C14
External Can Flush
Water to sewer
Rinse water (Bulk Rinse
discharge water)
1
Output from one step may be used as input to another step (indicated by bolded print)
BAC Generic HACCP Model
Revision Date: November 2009
Page 214 of 252
Information Used to Create Flowcharts
Packaging Processes - Ps8 (C) (Continued)
Canning (Continued)
INPUT
PROCESS STEP/ ID
OUTPUT
Heating, City Water, Water
Treatment
C15
Pasteurizer
Second cooling
water to drain
Ambient Air
C16
Pre-Blower Station
Compressed Air, Ambient
Air
C17
Final Dryer Station
C18
Fill Height Inspection
Reject cans
C19
Divert to Packers
Finished Cans
Open Format 6’s & 8’s, HiCone Web, Finished
Cans
C20
Hi-Cone Machine
Closed format 12’s & 24’s,
cartons, Finished Cans
C21
Case Packers
C22
Visual Inspection
Rejects, cans, Hicone, cartons
Trays, Hot Melt
C23
Tray Machine
Reject Trays
Packaging Material (ink)
C24
Secondary Code applied
Ink
Pallets & Stretch film
C25
Transfer to Palletizer
Finished Pallets
Finished Pallets
C26
Storage (or Live Load)
C27
Shipping
BAC Generic HACCP Model
Revision Date: November 2009
Page 215 of 252
Information Used to Create Flowcharts
Ps8 (T)
Tankering
INPUT
PROCESS STEPS/ ID
T1
Empty Tanker
Caustic Water, Acid
T2
Tanker Washing
City Water, CO2
T3
Tanker Purging
Bright Beer, Clean
Tanker
T4
Tanker Filling
T5
Tanker Shipping
T6
Full Tanker Receiving
T7
Full Tanker Unloading
BAC Generic HACCP Model
Revision Date: November 2009
OUTPUT
Clean Tanker, CO2
Page 216 of 252
Information Used to Create Flowcharts
Other Sub-Process - Co2
(No Flowchart)
INPUT
PROCESS STEP/ ID
Collected CO2
CO1
Increase Pressure (Booster)
CO2
Scrubbers (remove water soluble
compounds)
CO3
Carbon Filters - Deodorizer
CO4
Carbon Filters – Dust Filters
CO5
Compressor
CO6
Dryers
Moisture
CO7
Particulate Filter
Particulate Material
CO8
CO2 Condensers
CO9
Liquid Storage
CO10
Vaporization
CO11
High Pressure Carbon Filters
CO12
Particulate Filters
CO2 Purchase
BAC Generic HACCP Model
Revision Date: November 2009
OUTPUTS
Water soluble
compounds
Particulate Material
CO2, Particulate
Material
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Information Used to Create Flowcharts
Other Sub-Process - Water Processing
(No Flowchart)
INPUT
PROCESS STEPS
OUTPUTS
Water Source – City, Well,
Purchased
W2 Purification:
Purified Water
(2)
Purified Water (2)
W3 Storage
Acids, Salts, Steam
W4 Brewing Water Preparation, pH
adjustments, Salts addition
Mash Water
W5 De-aeration, Cooling, Carbonation
Line Packing or
Push Water
Purified Water
CO2
Reverse Osmosis, UV, Ozonation,
Chlorination, Filtration (Sand, DE,
Activated carbon, multimedia)
Sparge Water
Dilution Water for
High Gravity
CO2
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APPENDIX 2
FORM 8
CRITICAL COTNROL
POINTS
(LOW ALCOHOL BEER)
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HACCP Plan - Appendix 2
Form 8 – Critical Control Points for Low Alcohol Beer
BAC Generic
Incoming
material/ process
step/ hazards on
schematic
diagram
Title: Form 8 – Critical Control Points (Low Alcohol Beer)
Completed By: BAC TC
Approved By: BAC TC
Category
and
identified
hazard.
Determine if fully controlled by
Pre-requisite program.
*If “yes” = indicate “Pre-requisite
Program” and proceed to next
identified hazard.
*If “no” = proceed to question1 (Q1).
Q1. Could a
control
measure(s)
be used by
the operator
at any
process
step?
If NO = not a
CCP +
identification
on how this
hazard will be
controlled
before and
after the
process
+ proceed to
the next
identified
hazard
If YES =
description +
next question
(Q2)
BAC Generic HACCP Model
Revision Date: November 2009
Date:
Date:
Q2. Is it
likely that
contaminati
on with the
identified
hazard
could
occur in
excess of
the
acceptable
level or
could
increase to
an
unacceptab
le level?
Q3. Is this
process
step
specificall
y
designed
to
eliminate/
reduce
the likely
occurrenc
e of the
identified
hazard to
an
acceptabl
e level?
If NO = not
a CCP +
proceed to
the next
identified
hazard
If NO =
next
question
(Q4)
If YES =
next
question
(Q3)
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If YES =
CCP + go
to last
column
Q4. Will a
subsequen
t step
eliminate
the
identified
hazard or
reduce
likely
occurrenc
e to an
acceptable
level?
CCP
Number
+ proceed
to next
identified
hazard
If NO = CCP + go to last
column
If YES =
not a CCP
+ identify
subsequent
step +
proceed to
the next
identified
hazard
HACCP Plan - Appendix 2
Form 8 – Critical Control Points for Low Alcohol Beer
Process Step (For Low Alcohol Beer Only)
PS3 - AGING/
CLARIFICATION/
FILTRATION
A10 – Bright
Beer Storage
Biological –
Inadequate
pH
adjustment
to control
Clostridia
growth
downstream
No
Yes
Yes
Chemical –
None
identified
Physical –
None
identified
Date:
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Yes
CCP4-B
APPENDIX 3
FORM 10
ADDITIONS FOR
LOW ALCOHOL BEER
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HACCP Plan - Appendix 3
Form 10 - Additions for Low Alcohol Beer
LOW ALCOHOL BEER ONLY
PRODUCT NAME:
Process
Steps
CCP/Hazar
d Number
Hazard
Description
Critical
Limits
Monitoring
procedures
Deviation
Procedures
Verification
Procedures
HACCP
Records
Bright Beer
Storage (Step
A10)
CCP4-B
Inadequate pH
adjustment to
control
Clostridia
growth
downstream
pH <4.5
pH analysis of
wort in kettle by
QA
pH must be less
than 4.4 at kettle
wort sample in
kettle
pH analysis performed on each kettle
wort cooler sample & result reviewed
by QA manager or designate (if
greater than pH 4.5 will reprocess and
recheck)
Lab
reports
(Note: This
is an
arbitrary
number.
CCP
numbering
will depend
on the
number of
CCPs
found in
individual
breweries
CCPs)
- If pH greater than
or equal to 4.4
will add additional
acid to kettle &
recheck.
- If pH greater than
or equal to 4.4
QA manager (or
designate)
notified and a
deviation report
must be
completed
pH analysis performed on each BBT &
result reviewed by QA manager or
designate (if greater than pH 4.5 will
reprocess and recheck)
pH analysis performed on each filler
start up sample & result reviewed by
QA manager or designate (if greater
than pH 4.5 will dump product)
Calibration of pH meter & control
checks of 5 samples prior to run.
After each production the QA Manager
or designate verifies the calibration
records for BBT approvals.
QA Manager conducts yearly audit of
lab analyses.
Date:
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Calibratio
n records
Audit
records
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APPENDIX 4
DIAGRAMS FOR
HAZARD IDENTIFICATION &
CCP DECISION TREE
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Diagrams for Hazard Identification and CCP Decision Tree
Critical Control Points for breweries were determined using the HACCP Decision
Tree. The Decision Tree was first developed by a Codex Alimentarius working
group on HACCP in June 1991.
4.1 Hazard Determination
These questions are to be answered for each potential hazard at each step:
Is the presence of a potential hazard in the
line or the environment probable?
Is the presence of a potential
hazard in raw material
probable?
YES
NO
NO
YES
No Hazard*
YES
Is an unacceptable level,
survival, persistence or
increase at this step
probable?
NO
Is an unacceptable
contamination at this step
probable?
NO
YES
No Hazard*
YES
Is reduction, if any at a
further step adequate?
NO
HAZARD
* Not a hazard to be controlled at this step.
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4.2 CCP Decision Tree
Pre-screening question –
Determine if (hazard) fully controlled by Pre-requisite programs. If ‘yes’,
indicate “Pre-requisite Program(s)” and proceed to the next identified
hazard. If ‘no’, proceed to Question 1 below.
Q1
Could a control measure(s) be used by the operator at any process step?
No C.M. exists
C.M.(S) exists
Not a CCP. Identify how this hazard will
be controlled before or after the process
and proceed to next identified hazard.
Q2
Is it likely that contamination with the identified hazard could occur in excess of
the acceptable level or could increase to an unacceptable level?
No
Yes
Not a CCP. Proceed to next
identified hazard.
Q3
Is this process step specifically designed to eliminate or reduce the likely
occurance of this identified hazard to an acceptable level?
No
Q4
Yes = CCP
Will a subsequent step eliminate the identified hazard or reduce its likely
occurance to an acceptable level?
Yes
No = CCP
Not a CCP. Proceed to next identified hazard.
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APPENDIX 5
BAC GLASS INCLUSION
REFERENCE
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BAC Glass Inclusion Reference
The Critical Control Points for the brewing industry have been identified through
analysis as described in preceding sections.
In 1988, a BAC Glass Integrity Task Force developed a manual entitled Good
Manufacturing Practice on the Prevention of Glass Inclusion in Finished Product.
As its name implies, it was intended to ensure that product entering the market
contained no glass contaminants. The GMP was updated 1998 to deal with
changes in the industry and technology in the last 10 years.
The GMP deals specifically with:
Environmental Controls
 Preventive Measures
 Regular Maintenance Checks
Prewash Bottle Handling
 Preventive Measures
 Corrective Measures
Bottle Washing
 Preventive Measures
Bottle Conveying Systems
 Preventive Measures
 Corrective Actions
Washed Bottle Inspection
 Inspection Methods
 Maintenance Measures
 Corrective Measures
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BAC Glass Inclusion Reference (Continued)
Filling and Crowning Operations
 Corrective Measures for Glass Inclusions
 Continual Incident Levels
Filled Bottle Inspections
 Uncrowned, Improperly Crowned and Low-Filled Bottles
 Foam-Picking
 Candling
 Filtration
 Reaction to Inclusions
Verification and Monitoring for GMP
 Written Procedures
 Setup and Maintenance Checklists
 Production Records
 Quality Checklists
 Consumer Incidents Correlation
This document will be helpful in developing individual brewery HACCP Programs.
Copies of the manual may be obtained by contacting:
Brewers Association of Canada
100 Queen Street, Suite 650
Ottawa, Ontario K1P 1J9
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Telephone: (613) 232-9601 Fax: (613) 232-2283
E-mail: office@brewers.ca
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APPENDIX 6
BLANK FORMS 1 - 10
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PRODUCT DESCRIPTION
FORM 1
PROCESS/PRODUCT TYPE NAME:
1. Product Name(s)
2. Important Product Characteristics
(Aw, Ph, Preservatives,...)
3. How it is to be Used
4. Packaging
5. Shelf Life
6. Where it will be Sold
7. Labelling Instructions
8. Special Distribution Control
Date:
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LIST OF PRODUCT INGREDIENTS
AND INCOMING MATERIALS
FORM 2
PRODUCT NAME:
Date:
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PROCESS FLOW DIAGRAM
FORM 3
PRODUCT NAME(S):
Date:
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PLANT SCHEMATIC
FORM 4
PRODUCT NAME(S):
Date:
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HAZARDS IDENTIFICATION
FORM 5
PRODUCT NAME(S)
List all biological hazards related to ingredients, incoming material, processing, product
flow, etc.
IDENTIFIED BIOLOGICAL HAZARDS
CONTROLLED AT
(Bacteria, Parasites, Viruses...)
Date:
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Revision Date: November 2009
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HAZARDS IDENTIFICATION
FORM 6
PRODUCT NAME(S)
List all chemical hazards related to ingredients, incoming material, processing, product
flow, etc.
IDENTIFIED CHEMICAL HAZARDS
Date:
BAC Generic HACCP Model
Revision Date: November 2009
CONTROLLED AT
Approved by:
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HAZARDS IDENTIFICATION
FORM 7
PRODUCT NAME(S)
List all physical hazards related to ingredients, incoming material, processing, product
flow, etc.
IDENTIFIED PHYSICAL HAZARDS
Date:
BAC Generic HACCP Model
Revision Date: November 2009
CONTROLLED AT
Approved by:
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CCP DETERMINATION
FORM 8
Process Step/
Incoming Material
Category and
identified Hazard
Fully controlled by
Pre-requisite
program?
*If yes indicate and
proceed to next
identified hazard
*If no proceed to
(Q1)
Date:
BAC Generic HACCP Model
Revision Date: November 2009
Q1. Could a control
measure(s) be
used at any
process step?
*If no = not CCP.
Identify how this
hazard will be
controlled before
and after the
process and proceed
to next identified
hazard.
*If yes = describe
and proceed to (Q2)
Q2. Is it likely that
contamination with
the identified
hazard could occur
in excess of the
acceptable level or
could increase to
an unacceptable
level?
Q3. Is this process
step specifically
designed to
eliminate/reduce
the likely
occurrence of the
identified hazard to
an acceptable
level?
Q4. Will a
subsequent step
eliminate the
hazard or reduce
its likely
occurrence to an
acceptable level?
CCP Number
*If no = CCP. Go to
last column
*If no = not CCP.
Proceed to next
identified hazard
*If yes = proceed to
(Q3)
*If no = proceed to
(Q4)
*If yes = CCP. Go to
last column
Approved by:
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*If yes = not a CCP.
Identify subsequent
step and proceed to
the next identified
hazard
*Proceed to the next
identified hazard
APPENDIX 7
REFERENCE LITERATURE
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References
Procedures to Implement the Hazard Analysis Critical Control Point System.
International Association of Milk, Food and Environmental Sanitarians, Inc. Ames, Iowa.
1991
Micro-organisms in foods, Book 4. Application of the hazard analysis critical control
point (HACCP) system to ensure microbiological safety and quality. The International
Commission on Microbiological Specifications for Foods (ICMSF). Blackwell Scientific
Publications. Oxford. 1988.
Food Safety Enhancement Program. Volumes 1 - 4. Agriculture Canada. 1993-7.
A Simple Guide to Understanding and Applying The Hazard Analysis Critical Control
Point Concept. 2nd edition. international Life Sciences Institute. 1997
CFIA Generic HACCP Plan Models
http://www.inspection.gc.ca/english/fssa/polstrat/haccp/manue/ch2sec3-45e.shtml#2.4
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