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 BAC Generic HACCP Model Revision Date: November 2009 Page 3 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Page 4 of 245 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; BAC Generic HACCP Model Revision Date: November 2009 Page 5 of 245 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. BAC Generic HACCP Model Revision Date: November 2009 Page 6 of 245 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. BAC Generic HACCP Model Revision Date: November 2009 Page 7 of 245 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 Agri-Food 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 BAC Generic HACCP Model Revision Date: November 2009 Page 8 of 245 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) BAC Generic HACCP Model Revision Date: November 2009 Page 9 of 245 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. BAC Generic HACCP Model Revision Date: November 2009 Page 10 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Page 11 of 245 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. BAC Generic HACCP Model Revision Date: November 2009 Page 12 of 245 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. BAC Generic HACCP Model Revision Date: November 2009 Page 13 of 245 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. BAC Generic HACCP Model Revision Date: November 2009 Page 14 of 245 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. BAC Generic HACCP Model Revision Date: November 2009 Page 15 of 245 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. BAC Generic HACCP Model Revision Date: November 2009 Page 16 of 245 BAC GENERIC HACCP PROGRAM BAC Generic HACCP Model Revision Date: November 2009 Page 17 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 18 of 245 FORM 1: PRODUCT/PROCESS DESCRIPTION BAC Generic HACCP Model Revision Date: November 2009 Page 19 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 20 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Page 21 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 22 of 245 FORM 2: LIST OF PRODUCT INGREDIENTS AND INCOMING MATERIALS BAC Generic HACCP Model Revision Date: November 2009 Page 23 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 24 of 245 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. BAC Generic HACCP Model Revision Date: November 2009 Page 25 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 26 of 245 FORM 3: PROCESS FLOW DIAGRAM BAC Generic HACCP Model Revision Date: November 2009 Page 27 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 28 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Physical Hazard identified at this step Page 29 of 245 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 - Washing - Inspection - Filling - Flushing - Rinsing - Filling - Packing - Cleaning - Filling - Palletizing TANKERING Step PS8 (T) B C - Filling WAREHOUSING/ SHIPPING (Step PS9) BAC Generic HACCP Model Revision Date: November 2009 Page 30 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Page 31 of 245 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) Next Process - PS5 -Aging/ Clarification/ Filtration BAC Generic HACCP Model Revision Date: November 2009 Page 32 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Page 33 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Next Process - PS8 -Packaging Page 34 of 245 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 Page 35 of 245 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 Page 36 of 245 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 Page 37 of 245 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 Page 38 of 245 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 Seaming (Steps C11-13) C Water 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 Page 39 of 245 HACCP Plan - Form 3 Process Step 8 PS8 (T) - TANKERING (Page 12 of 12) Empty Tanker (Step T1) C Caustic, Water, Acid Tanker Washing (Step T2) C CO2 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 Page 40 of 245 FORM 4: SCHEMATIC DIAGRAM BAC Generic HACCP Model Revision Date: November 2009 Page 41 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 42 of 245 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 Page 43 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 44 of 245 FORM 5: HAZARD IDENTIFICATION BIOLOGICAL HAZARDS BAC Generic HACCP Model Revision Date: November 2009 Page 45 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 46 of 245 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 Page 47 of 245 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 New Kegs None identified BAC Generic HACCP Model Revision Date: November 2009 Page 48 of 245 HACCP Plan - Form 5 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 Cold Wort (from B10) BAC Generic HACCP Model Revision Date: November 2009 None identified Page 49 of 245 HACCP Plan - Form 5 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 SF1 - Bright Beer Tank BAC Generic HACCP Model Revision Date: November 2009 None identified Page 50 of 245 HACCP Plan - Form 5 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 None identified NB3 – NB 6 Storage (Pallet Prep, De-palletize) None identified BAC Generic HACCP Model Revision Date: November 2009 Page 51 of 245 HACCP Plan - Form 5 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 & Inspection (Secondary Packaging, Code/Inspection) None identified BT21 – Palletize None identified BAC Generic HACCP Model Revision Date: November 2009 Page 52 of 245 HACCP Plan - Form 5 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 K27 - Storage None identified K28 - Shipping None identified BAC Generic HACCP Model Revision Date: November 2009 Page 53 of 245 HACCP Plan - Form 5 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 C25 – Palletize None identified C26 - Storage (or Live Load) None identified BAC Generic HACCP Model Revision Date: November 2009 Page 54 of 245 HACCP Plan - Form 5 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 Date: BAC Generic HACCP Model Revision Date: November 2009 Approved by: Page 55 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 56 of 245 FORM 6: HAZARD IDENTIFICATION CHEMICAL HAZARDS BAC Generic HACCP Model Revision Date: November 2009 Page 57 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 58 of 245 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 59 of 245 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 60 of 245 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 61 of 245 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 62 of 245 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 63 of 245 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 64 of 245 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 65 of 245 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 66 of 245 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 67 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 68 of 245 FORM 7: HAZARD IDENTIFICATION PHYSICAL HAZARDS BAC Generic HACCP Model Revision Date: November 2009 Page 69 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 70 of 245 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 71 of 245 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 72 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Page 73 of 245 PROCESS STEPS (Continued) 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 74 of 245 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 75 of 245 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 76 of 245 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 77 of 245 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 78 of 245 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 79 of 245 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 80 of 245 FORM 8: CRITICAL CONTROL POINTS BAC Generic HACCP Model Revision Date: November 2009 Page 81 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 82 of 245 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 specifical ly designed to eliminate/ reduce the likely occurren ce 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 83 of 245 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 84 of 245 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 85 of 245 Critical Control Points - Form 8 Wheat (malted/ non-malted), 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 86 of 245 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 87 of 245 Critical Control Points - Form 8 Carbohydrate Matter Biological – Clostridium (e.g. sucrose, syrup, honey) 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 88 of 245 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 89 of 245 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 90 of 245 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 91 of 245 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 92 of 245 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 93 of 245 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 94 of 245 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 95 of 245 Critical Control Points - Form 8 Used glass Yes – Pasteurization BiologicalBacteria 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 96 of 245 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 97 of 245 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 98 of 245 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 99 of 245 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 100 of 245 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 101 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 PP – Equipment (BAC C1.2) Page 102 of 245 Critical Control Points - Form 8 F4 - Green Beer None identified PS4 – SUBPROCESS YEAST PREPARATION Y1 – Propagation None identified Y2 – Storage None identified Y3 – Acid Washing None identified PS5 - AGING/ CLARIFICATION/ FILTRATION PP – Equipment (BAC C1.2) 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 Page 103 of 245 Critical Control Points - Form 8 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) A7 - Secondary Storage Cleaning chemicals PS7 BRIGHT BEER PROCESSING PS7 (SF) – Sterile Filtration BAC Generic HACCP Model Revision Date: November 2009 Page 104 of 245 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 105 of 245 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 106 of 245 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 107 of 245 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 108 of 245 Critical Control Points - Form 8 RB9- Post-Soak Physical Damage to bottles (e.g. Temperature shock), (Partially Controlled) 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 Physical Bottle plugged Chemical – Bottle unable to drain Yes (EBI) 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 109 of 245 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 110 of 245 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 111 of 245 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) NB8 Loading, Bottle Physical Damage bottles PP – Personnel (BAC D1.2) Training – to Yes (EBI) Yes PP – Personnel (BAC D1.2) Training PP – Equipment (BAC C1.2) 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 112 of 245 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 113 of 245 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 114 of 245 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) PP – Personnel (BAC D1.2) Training Manual Flush: Physical – Burst bottle leading to glass inclusion 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 115 of 245 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 116 of 245 Critical Control Points - Form 8 BT7 – BT 8 Bottle Flush (Full Bottle Wash - external) None identified – None identified BT9 Pasteurize BT10 - Foam Inspection &/or Candling (Human) Note: Automated Foam Inspection is not within the scope of this generic model. 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 (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 117 of 245 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 118 of 245 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) PP – Equipment (BAC C1.2) PP – Personnel (BAC D1.2) Training Manual: Chemical – Cleaning solution not effectively removed. 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 119 of 245 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 120 of 245 Critical Control Points - Form 8 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 – C2 - Storage & Handling 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 121 of 245 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 122 of 245 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 123 of 245 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 124 of 245 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 125 of 245 Critical Control Points - Form 8 BAC Generic HACCP Model Revision Date: November 2009 Page 126 of 245 Critical Control Points - Form 8 FORM 3A: PROCESS FLOW DIAGRAM WITH CCPS BAC Generic HACCP Model Revision Date: November 2009 Page 127 of 245 Critical Control Points - Form 8 BAC Generic HACCP Model Revision Date: November 2009 Page 128 of 245 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 129 of 245 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 Page 130 of 245 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 Page 131 of 245 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 Page 132 of 245 HACCP Plan - Form 3A PS5 - AGING/ CLARIFICATION/ FILTRATION (Page 5 of 12) COOLING GREEN BEER (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 Page 133 of 245 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 134 of 245 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 Page 135 of 245 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 Page 136 of 245 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 Page 137 of 245 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 138 of 245 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 Seaming (Steps C11-13) Water 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 Page 139 of 245 HACCP Plan - Form 3A Process Step 8 PS8 (T) - TANKERING (Page 12 of 12) Empty Tanker (Step T1) Caustic, Water, Acid Tanker Washing (Step T2) CO2 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 140 of 245 FORM 5A: BIOLOGICAL HAZARDS CONTROL & CCPS BAC Generic HACCP Model Revision Date: November 2009 Page 141 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 142 of 245 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 143 of 245 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 144 of 245 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 Page 145 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Page 146 of 245 HACCP Plan - Form 5A PROCESS STEPS (Continued) 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. BAC Generic HACCP Model Revision Date: November 2009 Page 147 of 245 HACCP Plan - Form 5A PROCESS STEPS (Continued) 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 BAC Generic HACCP Model Revision Date: November 2009 Page 148 of 245 HACCP Plan - Form 5A PROCESS STEPS (Continued) 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 & Inspection (Secondary Packaging, Code/Inspection) None identified 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 BAC Generic HACCP Model Revision Date: November 2009 Page 149 of 245 HACCP Plan - Form 5A PROCESS STEPS (Continued) 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 BAC Generic HACCP Model Revision Date: November 2009 PP – Premises (BAC A1.1 & BAC A2.1) Page 150 of 245 HACCP Plan - Form 5A PROCESS STEPS (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 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: 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 Approved by: Page 151 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 152 of 245 FORM 6A: CHEMICAL HAZARDS CONTROL & CCPS BAC Generic HACCP Model Revision Date: November 2009 Page 153 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 154 of 245 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 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/ non-malted), Pesticides, Mycotoxins, Allergen, NDMA PP - Transportation Receiving & Storage (BAC B1.1) Well/ Lake/ Surface/ Water DRY INGREDIENTS + COA / Letter of Guarantee, Allergen Management Program Cereal Grain, e.g. corn, oats, rice Pesticides, Mycotoxins, Allergen (cross-contamination from carrier), NDMA PP - Transportation Receiving & Storage (BAC B1.1) + COA / Letter of Guarantee, Allergen Management Program Hops Pesticides, Mycotoxins PP – Transportation, Receiving & Storage (BAC B1.1) + COA BAC Generic HACCP Model Revision Date: November 2009 Page 155 of 245 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 Matter (e.g. sucrose, 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 Food Enzymes Non-food grade PP – Transportation, Receiving & Storage (BAC B1.1) + COA BAC Generic HACCP Model Revision Date: November 2009 Page 156 of 245 HACCP Plan - Form 6A 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 Used Kegs None identified Plastic Bottles, e.g. PET None identified BAC Generic HACCP Model Revision Date: November 2009 Page 157 of 245 HACCP Plan - Form 6A 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) None identified F1 Wort Oxygenation/ Wort Aeration None identified BAC Generic HACCP Model Revision Date: November 2009 Page 158 of 245 HACCP Plan - Form 6A 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 PP – Equipment (BAC C1.2) 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) PS7 BRIGHT BEER PROCESSING BAC Generic HACCP Model Revision Date: November 2009 Page 159 of 245 HACCP Plan - Form 6A PROCESS STEPS (Continued) PS7 (SF) – Sterile Filtration 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 SF1 - Bright Beer Tank PS7(FP) – Flash Pasteurization 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 FP1 - Bright Beer Tank 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 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 160 of 245 HACCP Plan - Form 6A 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: HUMAN: (Partially Controlled) Failure of personnel to detect residual liquid PP – Personnel (BAC D1.2) Training SOP (personnel rotation) CCP1-C BAC Generic HACCP Model Revision Date: November 2009 Page 161 of 245 HACCP Plan - Form 6A 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 BT23 - Shipping None identified BAC Generic HACCP Model Revision Date: November 2009 PP - Recall (BAC F1.2) PP – Equipment (BAC C1.2) Page 162 of 245 HACCP Plan - Form 6A 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 PP – Equipment (BAC C1.2) BAC Generic HACCP Model Revision Date: November 2009 Page 163 of 245 HACCP Plan - Form 6A 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 PP – Premises (BAC A1.1 & BAC A2.1) PP – Equipment (BAC C1.2) PP – Equipment (BAC C1.2) PP – Personnel (BAC D1.2) Training BAC Generic HACCP Model Revision Date: November 2009 Page 164 of 245 HACCP Plan - Form 6A 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 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 165 of 245 HACCP Plan - Form 6A 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 PP – Personnel (BAC D1.2) Training 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 Approved by: Page 166 of 245 FORM 7A: PHYSICAL HAZARDS CONTROLS & CCPS BAC Generic HACCP Model Revision Date: November 2009 Page 167 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 168 of 245 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 169 of 245 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 PP – Transportation, Receiving & Storage (BAC B1.1) + COA Salt Rocks (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 170 of 245 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 171 of 245 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 172 of 245 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 173 of 245 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 PP – Equipment (BAC C1.2) 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 – 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 174 of 245 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 175 of 245 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 176 of 245 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 177 of 245 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 178 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Page 179 of 245 HACCP Plan - Form 7A PROCESS STEPS (Continued) 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 180 of 245 FORM 9: HAZARDS NOT CONTROLLED BY BREWERY BAC Generic HACCP Model Revision Date: November 2009 Page 181 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 182 of 245 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 183 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 184 of 245 FORM 10: HACCP PLAN BAC Generic HACCP Model Revision Date: November 2009 Page 185 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 186 of 245 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 187 of 245 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 188 of 245 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 - System failed hourly test Frequency– Hourly test and at end of production ; bottle burst Refer to SOP Autoflush Monitoring Procedure Document on AutoFlush Monitoring Form. Sign and date. 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 189 of 245 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 190 of 245 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 191 of 245 HACCP Records BAC Generic HACCP Model Revision Date: November 2009 Page 192 of 245 HACCP PLAN APPENDICES BAC Generic HACCP Model Revision Date: November 2009 Page 193 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 194 of 245 APPENDIX 1 FORM 3 INFORMATION USED FOR FLOWCHARTS BAC Generic HACCP Model Revision Date: November 2009 Page 195 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 196 of 245 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 CO2 Packaging Materials, PS6 Bright Beer Storage PS7 Bright Beer Processing PS8 Packaging PS9 Warehousing/Shipping OUTPUT Bulk Beer Bright Beer New Bottles (NB), Returned Bottles (RB), Kegs, Tankers, Cans BAC Generic HACCP Model Revision Date: November 2009 Page 197 of 245 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 198 of 245 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 199 of 245 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 200 of 245 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 201 of 245 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 202 of 245 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 203 of 245 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 204 of 245 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 205 of 245 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 206 of 245 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 207 of 245 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 208 of 245 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, Hi- C20 Cone Web, Finished Cans 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 209 of 245 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 210 of 245 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 Page 211 of 245 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) Reverse Osmosis, UV, Ozonation, Chlorination, Filtration (Sand, DE, Activated carbon, multimedia) Purified Water (2) W3 Storage Acids, Salts, Steam W4 Brewing Water Preparation, pH adjustments, Salts addition Purified Water CO2 Mash Water Sparge Water W5 De-aeration, Cooling, Carbonation Line Packing or Push Water Dilution Water for High Gravity CO2 BAC Generic HACCP Model Revision Date: November 2009 Page 212 of 245 APPENDIX 2 FORM 8 CRITICAL COTNROL POINTS (LOW ALCOHOL BEER) BAC Generic HACCP Model Revision Date: November 2009 Page 213 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 214 of 245 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 specifical ly designed to eliminate/ reduce the likely occurren ce 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 215 of 245 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: BAC Generic HACCP Model Revision Date: November 2009 Approved by: Page 216 of 245 Yes CCP4-B APPENDIX 3 FORM 10 ADDITIONS FOR LOW ALCOHOL BEER BAC Generic HACCP Model Revision Date: November 2009 Page 217 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 218 of 245 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: BAC Generic HACCP Model Revision Date: November 2009 Approved by: Page 219 of 245 Calibratio n records Audit records BAC Generic HACCP Model Revision Date: November 2009 Page 220 of 245 APPENDIX 4 DIAGRAMS FOR HAZARD IDENTIFICATION & CCP DECISION TREE BAC Generic HACCP Model Revision Date: November 2009 Page 221 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 222 of 245 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? NO YES NO YES No Hazard* Is an unacceptable level, survival, persistence or increase at this step probable? YES 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. BAC Generic HACCP Model Revision Date: November 2009 Page 223 of 245 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. BAC Generic HACCP Model Revision Date: November 2009 Page 224 of 245 APPENDIX 5 BAC GLASS INCLUSION REFERENCE BAC Generic HACCP Model Revision Date: November 2009 Page 225 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 226 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Page 227 of 245 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 Telephone: (613) 232-9601 Fax: (613) 232-2283 E-mail: office@brewers.ca BAC Generic HACCP Model Revision Date: November 2009 Page 228 of 245 APPENDIX 6 BLANK FORMS 1 - 10 BAC Generic HACCP Model Revision Date: November 2009 Page 229 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 230 of 245 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: BAC Generic HACCP Model Revision Date: November 2009 Approved by: Page 231 of 245 LIST OF PRODUCT INGREDIENTS AND INCOMING MATERIALS FORM 2 PRODUCT NAME: Date: BAC Generic HACCP Model Revision Date: November 2009 Approved by: Page 232 of 245 PROCESS FLOW DIAGRAM FORM 3 PRODUCT NAME(S): Date: BAC Generic HACCP Model Revision Date: November 2009 Approved by: Page 233 of 245 PLANT SCHEMATIC FORM 4 PRODUCT NAME(S): Date: BAC Generic HACCP Model Revision Date: November 2009 Approved by: Page 234 of 245 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: BAC Generic HACCP Model Revision Date: November 2009 Approved by: Page 235 of 245 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: Page 236 of 245 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: Page 237 of 245 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: Page 239 of 245 *If yes = not a CCP. Identify subsequent step and proceed to the next identified hazard *Proceed to the next identified hazard HAZARDS NOT CONTROLLED BY OPERATOR FORM 9 PRODUCT NAME(S) List here any biological, chemical and physical hazards which are not controlled by the Operator. INDICATE THE WAY THE HAZARD COULD BE ADDRESSED (COOKING INSTRUCTIONS PUBLIC EDUCATION, USE BEFORE DATE,..). HAZARDS Date: BAC Generic HACCP Model Revision Date: November 2009 Approved by: Page 240 of 245 HACCP PLAN FORM 10 PRODUCT NAME: Process Steps CCP/Hazard Number Date: BAC Generic HACCP Model Revision Date: November 2009 Hazard Description Critical Limits Monitoring Procedures Approved by: Page 241 of 245 Deviation Procedures Verification Procedures HACCP Records BAC Generic HACCP Model Revision Date: November 2009 Page 242 of 245 APPENDIX 7 REFERENCE LITERATURE BAC Generic HACCP Model Revision Date: November 2009 Page 243 of 245 BAC Generic HACCP Model Revision Date: November 2009 Page 244 of 245 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 BAC Generic HACCP Model Revision Date: November 2009 Page 245 of 245