HACCP Plan With Flow Chart-1

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TIRUPATI FOOD INDUSTRIES, SONIPAT

RAI INDUSTRIAL AREA, SONIPAT

DOCUMENT NUMBER
TFI/HACCP/01

DOCUMENT NAME
HACCP PLAN FOR PULSES PRODUCT
(Based on Requirements of ISO 22000:2005)

15/07/2011 1.00
DATE VERSION

Prepared By :______________________

Approved By :______________________

Date of Approval :______________________


TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCT
Document Number TFI/HACCP/01 Date of Issue 15-05-2010
Version 1.00 Page 2 of 23

TABLE OF CONTENTS

1. PRODUCT DESCRIPTION ................................................................................................................................. 3


2. FLOW CHART ...................................................................................................................................................... 5
3. HAZARD ANALYSIS ........................................................................................................................................... 7
4. SELECTION AND ASSESSMENT OF CONTROL MEASURES ................................................................... 9
5. CCP PLAN.............................................................................................................................................................20
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCT
Document Number TFI/HACCP/01 Date of Issue 15-05-2010
Version 1.00 Page 3 of 23

1. PRODUCT DESCRIPTION
Product Characteristics-

Product name Pulses

General product
Specifications (appearance As per the Finished Product Specifications
etc.)

Specific product
Specifications (chemical,
As per the Finished Product Specifications
microbiological and physical
characteristics)

Processing Technique Cleaning of all kind of pulses.


 Pulses are packed in 1 Kg, 5 Kg,10Kg, 25Kg& 50Kg- Jute bags/
Final Packaging pouches/HDPE Bags and as per buyer’s specification, with polythene
Liners.
Storage at Ambient Temperature.
Storage and Shelf life
For own brands, declared as per legal legislation of the importing country
Domestic:
1. 25 Kg Bag: Name of Manufacturer & Brand, Product Name, Nt. Weight,
Packing Month, Max. Retail Price, Batch No., Vegetarian Logo.
Labeling instructions 2. 10 kg Bag: Name of Manufacturer & Brand, Product Name, Nt. Weight,
Packing Month, Max. Retail Price, Batch No., Vegetarian Logo.
3. 5 Kg Bag: Name of Manufacturer & Brand, Product Name, Nt. Weight, Packing
Month, Max. Retail Price, Batch No., Vegetarian Logo.

Potential mishandling of the


 Usage of the product after the prescribed shelf life.
product

Intended Use

Where it will be sold Domestic Markets

Who will consume Consumer


Additional preparation As desired by Customer depending on recipe
methods before
consumption
Ultimate day of use
especially after breaking the Last day of the Shelf Life
package

Sensitive consumers NA

Intended for High – Risk


NA
Population
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 4 of 23

2. FLOW CHART
PM and Other Consumables

Receiving of Packing
Materials/ consumables

Sampling

Kept on hold Rejection & Send


QC Checked for Decision back to supplier

Accepted

Unloading of PM
and consumables

Storage of PM
in PM Stores Storage of Chemicals at separate
designated place in Store
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 5 of 23

Flow Chart for RM Receiving. Approval and Storage

Receiving of raw CCP 1


Pulses

Sampling

Kept on hold for Rejected and Sent


QC Check back to Supplier
Decision

Unloading of Pulses

CCP
Fumigation OPRP 1

OPRP
Automatic
Cleaning

Magnetic Separator
OPRP 2

Feeding tank

Final magnet CCP 2

Packing

Final inspection and testing

Dispatch
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 6 of 23

3. HAZARD ANALYSIS
The Food Safety Team followed the methodology explained below to conduct the Hazard Analysis:

 Identification of distinct process steps for each product cluster based on the flow diagrams.
 For each process step:
 Identification of all potential hazards associated with that process step.
 Classification of hazard based on type (whether physical, biological or chemical) and category (into which part of
the PRP does this hazard fall).
 A description of the hazard.
 The likely occurrence of the identified hazard, evaluated quantitatively, in terms of high, medium or low likelihood
of occurrence, as follows:

Corresponding Number to be entered into


Level the Hazard Identification and Hazard
Probability of Occurrence of Identified Hazard
Assessment Worksheet
Very high chances of occurrence HIGH 10
Moderate chances of occurrence MEDIUM 5
Marginal chances of occurrence LOW 3

 The severity of the hazard’s adverse health effects, evaluated quantitatively, in terms of critical, major or minor
impact severity, as follows:

Corresponding Number to be entered into the


Level Hazard Identification and Risk Analysis
Severity of hazard in case of occurrence
Worksheet
Will definitely result into unsafe product CRITICAL 10
Most Likely to result into unsafe product SERIOUS 8
May result into unsafe product MAJOR 5
Will not result in unsafe product MINOR 3

The risk rating, in quantitative terms (arrived at by multiplying the probability of occurrence of identified hazard with
the severity of hazard in case of occurrence), and the classification of the control measures based on the risk rating.
If the multiplication of Probability x Severity (Risk) is more than 25, then Control Measure is required to control the
identified hazard. If risk is < 25, then the routine PRPs are sufficient to control the hazard.

Severity of Impact
Probability Of Occurrence
CRITICAL (10) SERIOUS (8) MAJOR(5) MINOR (3)
HIGH (10) 100 80 50 30

MEDIUM (5) 50 40 25 15

LOW (3) 30 24 15 9
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 7 of 23

An explanation / justification for the risk rating arrived at, together with the general control measures in place for that
risk.
A risk level of below 25 is generally considered as permissible and can be controlled by Regular PRPs. While
conducting the HACCP Analysis, practical experiences, experimental data, professional literature, etc, have been
taken into account.
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 8 of 23

4. SELECTION AND ASSESSMENT OF CONTROL MEASURES

For all the steps, where risk level is higher than 25, it is considered that these hazards can’t be controlled by R-PRPs
and combinations of control measures are selected based on the hazard analysis, which are capable of preventing,
eliminating or reducing food safety hazards to defined acceptable levels.
The control measures selected are categorized as to whether they need to be managed through operational PRP (s) or
by the HACCP plan.
The selection and categorization of control measure is carried out using a logical approach that includes assessment
with regard to the following:
- Effect on identified food safety hazard (A)
- Feasibility / Frequency of Monitoring (B)
- Place within the system (C)
- Likelihood of failure (D)
- Severity in case of failure (E)
- Is measure specifically designed? (F)
- Synergistic effects (G)
The method and parameters used for the categorization of control measure is described in the below table:
Effect on Identified Food Safety Hazard ( A )
1 Reduction
2 Elimination / Prevention
Feasibility / Frequency of Monitoring (B)
1 Satisfactory
2 Not Satisfactory
Place within the system (C)
1 Further Steps available for Control
2 Last step- no further stages
Probability of Failure of Control Measure (D)
1 Lower Chances
2 Higher Chances
Consequence in case of failure of control measure (E)
1 Lower
2 Higher
Is control measures specifically designed? (F)
1 No
2 Yes
Synergistic Effects (G)
1 No effect on performance of other Control measures
2 Yes, effects other Control measures

Total Score= (A + B + C + D + E + G) X F
If the total score is < 8: then the Control Measure is PRP, if the Score is between 8 – 11: then the Control Measure is
Operational PRP, if Score is 12 or more, Control Measure is HACCP Plan or CCP
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 9 of 23

ASSESSMENT OF CONTROL MEASURES

Controlled
SEVERITY

by R-PRP
Identify Potential

RATING
Ingredient /

RISK
LHO
Hazards introduced,

SCORE
Is
Processing Control Measures
controlled or enhanced A B C D E F G CTG- CM
Step
at this step

PACKING MATERIAL AND OTHER CONSUMABLES


(P) Chances of physical 3 3 9  Vehicle inspection at the time of
contamination by the receiving
material like dust, dirt,  Material is purchases from approved
metal, glass, stone, vendors. YES
coming with the packing
 Vendor has been instructed to follow
material.
hygiene and sanitation as per
company rules.
(C) Chances of Chemical 3 5 15  Purchase of all the material from
contamination from inks approved vendor.
used in printing of PM (jute  Vehicle inspection at the time of
bags), granules used in receiving.
preparation of laminates
Receiving of  Food grade packing material
and inks used in printing
Packing certificate is received from vendor.
on laminates and from
material and  All the lubricants/cleaning chemicals
vehicle during transit due
consumables are of appropriate grade and the
to previously loaded/ partly
load chemical. MSDS is available for all the
YES
chemicals.
(C) Chances of Chemical
contamination from  All the chemicals used for treatment
lubricants, cleaning are FDA compliant and the MSDS of
chemicals of improper the chemical used for treatment is
specifications. available.
(C ) Chances of chemical
contamination from the
chemicals used for
treatment of pallets.
( B )NA
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 10 of 23

ASSESSMENT OF CONTROL MEASURES

Controlled
SEVERITY

by R-PRP
Identify Potential

RATING
Ingredient /

RISK
LHO
Hazards introduced,

SCORE
Is
Processing Control Measures
controlled or enhanced A B C D E F G CTG- CM
Step
at this step

(P) Chances of physical 3 5 15  Post sampling & inspection, material


contamination if post is covered properly.
Sampling sampling & inspection, PM YES
 Training to all on Goods laboratory
QA/QC are left loose. Practices is done.
inspection
(C ) & ( B )NA

(P) & (B)NA

Material on
hold for (C) Chances of cross 3 3 9  Materials are kept segregated in
management contamination due proper condition (like good product)
decision materials on hold if gets with proper labeling before returning YES
approved and not stored to supplier (if finally rejected).
properly.
Rejection & (P) , (C ) & ( B )NA
sent back to
supplier
(P) & (C ) NA

Unloading of ( B ) Chances of 3 3 9  SSOP for Personal hygiene is


Packing microbiological implemented.
material and contamination due to  All the packaging materials are
consumables improper hand hygiene of accepted with Outer cover which is YES
the handler removed from the packing material
when before entering the process
area.
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 11 of 23

ASSESSMENT OF CONTROL MEASURES

Controlled
SEVERITY

by R-PRP
Identify Potential

RATING
Ingredient /

RISK
LHO
Hazards introduced,

SCORE
Is
Processing Control Measures
controlled or enhanced A B C D E F G CTG- CM
Step
at this step

 Plant is maintained in good


Storage of (P) Physical contamination condition.
packing in store like paint flakes, 3 3 9 YES
 Regular inspection is done.
material in PM dust, dirt etc.
Store,  GSP is followed.
Storage of (C) Chances of chemical  Chemical are stored at segregated
Pallet. contamination placed in 3 5 15 places in proper lock and key YES
Storage of the store. condition.
chemical in  Pest control system is in place.
(B) Biological
Chemical
Storage Area contamination like spider, 3 5 15  Regular cleaning & inspection is YES
lizard, weevils. done.
FOR RM RECEIVING, APPROVAL AND STORAGE
(P) Chances of physical 3 3 9  Purchase of material from approved
contamination of Pulses by vendor.
the material like dust, dirt,  Vehicle inspection at the time of
metal, glass, stone, NO 2 1 2 1 2 2 1 18 CCP 1
receiving
poisonous seed, Rodent
 Further pre-cleaning step will remove
hair & excreta.
the impurities.
Receiving of (C) Chances of Chemical 3 5 15  Purchase of material from approved
Raw pulses contamination from field vendor.
like (Pesticide residues,  Vehicle inspection at the time of
heavy metal content, receiving.
mycototoxins) and from NO
 Testing of finished product from
vehicle during transit due
External laboratory for heavy metals,
to previously load/ partly
Pesticide residue, mycotoxins once
load chemical.
in a year as documented in
Inspection and Test Plan
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 12 of 23

ASSESSMENT OF CONTROL MEASURES

Controlled
SEVERITY

by R-PRP
Identify Potential

RATING
Ingredient /

RISK
LHO
Hazards introduced,

SCORE
Is
Processing Control Measures
controlled or enhanced A B C D E F G CTG- CM
Step
at this step

(B) Chances of microbial 3 5 15  Material purchase from approved


contamination (Fungal vendor.
(Aspergillus flavus) &  Most of the purchase are done in
infestation (insect, larvae, company provided bags
weevils, ant)
 Infested material is not accepted. NO
(B) Chances of microbial
 In case of infested Pulses is
contamination due to dirty/
accepted as per the defined
damaged gunny bags
permitted level, fumigation is done
used for packaging of
before use.
Pulses.
( P) Chance of metallic 3 5 15  Sampling scoop is cleaned before
contamination from use and maintaining in good
Sampling scoop particles condition and replaced as and when
& Foreign matter required.
contamination in open  Training to all on Goods laboratory
bags. Practices is done. YES
Sampling  Further Step magnet in line to control
QA/QC, metallic contamination.
inspection  Post sampling bags are
appropriately closed from sampling
point.
(C) Chances of chemical 3 3 9  Clean & dry scoop is used.
contamination due to un  GLP follow up YES
cleaned or improperly
cleaned scoop
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 13 of 23

ASSESSMENT OF CONTROL MEASURES

Controlled
SEVERITY

by R-PRP
Identify Potential

RATING
Ingredient /

RISK
LHO
Hazards introduced,

SCORE
Is
Processing Control Measures
controlled or enhanced A B C D E F G CTG- CM
Step
at this step

(B) Chances of microbial 3 3 9  Clean & dry scoop is used.


contamination due to un  GLP follow up YES
clean or improperly
cleaned scoop
(P) NA
(C) Chances of cross 3 3 9  Materials are kept segregated in
contamination due proper condition (like good product)
materials on hold if gets with proper labeling before returning YES
approved and not stored to supplier (if finally rejected).
Material on properly.
hold for
management (B) Chances of cross 5 3 15  Materials are kept segregated
decision contamination due and well protected with proper
materials on hold due to labeling.
YES
weevils or other micro  Hold material is not unloaded
organisms cross till the management decision.
contamination
Rejection & (P), (C ) & (B ) NA
sent back to
supplier
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 14 of 23

ASSESSMENT OF CONTROL MEASURES

Controlled
SEVERITY

by R-PRP
Identify Potential

RATING
Ingredient /

RISK
LHO
Hazards introduced,

SCORE
Is
Processing Control Measures
controlled or enhanced A B C D E F G CTG- CM
Step
at this step

(P)Chances of physical 3 5 15  All the area are cleaned as per the


contamination of Pulses documented procedure and records
due to improper handling for the cleaning
like metal from unloading  Hooks are maintained in good
hooks used by un loader. condition.
Contamination from dirty  Cloth on handle is changed YES
cloth on handle of regularly.
unloading hook
 Further Steps like cleaning, and
Chances of Physical magnet will take care
Unloading of contamination form un
Pulses cleaned Area
(C) NA
(B) Chance of cross 3 3 9  SSOP for Personal Hygiene is
contamination from documented and implemented.
infested material &  Daily personal hygiene is checked.
improper personal hygiene YES
 Infested material is not unloaded and
practices of unloading
if unloaded after appropriate
labour.
approval, will be fumigated
immediately.
 Control of fumigation operation
by approved external agency,
(B)-Chances of biological
contamination due to live  Monitoring of dozes and
Fumigation 5 5 25 exposure period is monitoring YES 2 1 2 1 2 1 2 10 OPRP 1
weevils due to inadequate
storage condition. stack-wise as per
validated/documented
procedure.
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 15 of 23

ASSESSMENT OF CONTROL MEASURES

Controlled
SEVERITY

by R-PRP
Identify Potential

RATING
Ingredient /

RISK
LHO
Hazards introduced,

SCORE
Is
Processing Control Measures
controlled or enhanced A B C D E F G CTG- CM
Step
at this step

Control of fumigation operation by


approved external agency,
(C)-Chances of the Regular Monitoring of dozes and
5 5 25 YES 2 1 2 1 2 1 2 10
residues of fumigant exposure period is monitoring stack-
wise as per validated/documented
procedure
(P)-NA

(B)-NA

(C)-NA

Cleaning Regular inspection and preventive


maintenance schedule of the classifier,
(P)-chances of foreign further stages will reduce the chances
matter due to improper 3 5 15 of addition in the product. YES
functioning of Cleaner
Sampling of Pre Cleaner Output at
hourly at Once in 4 hour frequency
(P) Chances of metallic 3 10 30  Cleaning of magnet at is done before
contamination eg. Ferrous and after the process & record is
chips adhering to magnet, maintained Magnet cleaning record. NO 2 1 1 1 1 1 2 8 OPRP 2
Dust, dirt due to improper
Magnetic or delay cleaning.
Separator (C ) NA

(B)-NA
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 16 of 23

ASSESSMENT OF CONTROL MEASURES

Controlled
SEVERITY

by R-PRP
Identify Potential

RATING
Ingredient /

RISK
LHO
Hazards introduced,

SCORE
Is
Processing Control Measures
controlled or enhanced A B C D E F G CTG- CM
Step
at this step

(P) Chances of Physical 3 5 15  SSOP for Personal hygiene is


contamination due to implemented.
knives use for bag  Further Steps like magnet will take YES
opening, Paint flakes ,Hair care of metallic contamination.
of person at feeding end.
Feeding tank (B) Chances of Microbial 3 3 09  Use of sanitizer
contamination from the  Medical checkup & training
person working at intake YES
 Daily personal hygiene check. SSOP
hopper.
for personal Hygiene
(C) NA
(P) Chances of metallic 3 10 30  Cleaning of magnet at is done before
contamination e.g Ferrous and after the process & record is
chips adhering to magnet, maintained Magnet cleaning record. NO 2 1 2 1 2 2 1 18 CCP 2
Dust, dirt due to improper  Calibration of magnet is done.
Final Magnet or delay cleaning.
 No further step in this line
(C ) NA
(B)-NA
(P)- Chances of metallic 3 8 24 All the machines undergo preventive YES
Manual/ contamination from the maintenance as per schedule.
Automatic machine while packing.
Packing Further Steps of inspection and testing
will take care.
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 17 of 23

ASSESSMENT OF CONTROL MEASURES

Controlled
SEVERITY

by R-PRP
Identify Potential

RATING
Ingredient /

RISK
LHO
Hazards introduced,

SCORE
Is
Processing Control Measures
controlled or enhanced A B C D E F G CTG- CM
Step
at this step

(C)- Chances of chemical 3 5 15  SSOP for Personal hygiene is YES


contamination from worker documented and Implemented.
hands or due to lubricants  All the lubricants used at Food
from moving parts of the Grade Grease Points if of Food
machine. Grade.
 Training is imparts to maintenance
team on lubrication.
(B)- Chances of microbial 3 8 24 SSOP for Personal hygiene is
contamination from dirty implemented.
hands of worker/ sccop SSOP for cleaning and Sanitation is
involved in manual packing Implemented.
B-Chances of Microbial
Cross Contamination  SSOP for cross contamination
3 3 9 Yes
during inspection prevent the microbial contamination.
procedure.
Inspection --
C-None --- --- ---
and Testing -
P-Chances of
contamination from dust,  Immediate closing of the bags after
3 3 9
dirt & other foreign sampling and inspection.
material.
(P) Physical contamination
like dust ,dirt from unclean 3 5 15 Vehicle inspection system is in place YES
Dispatch vehicle
( C ) & ( B ) NA
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 18 of 23

HAZARD ANALYSIS FROM OUT SOURCED ACTIVITY


( P )Contamination from YES
3 3 9  Pest agency checks the system.
dead insects or flies.
( C )Chemical  Pest spray is done only in out side. YES
Pest Control contamination from 3 5 15  Training has been given to pest
Agency pesticides control personnel.
(B)Microbial contamination  Pest agency personnel has been YES
from personnel conducting 3 5 15 instructed to follow the hygiene rules
pest control activity. of the organization.
Calibration
Agencies/ Product quality may be
Consultancy affected if calibration or  Calibration is done from NABL
3 3 9 YES
services/ calibrating equipment is mal accredited laboratory
Consultancy functioning.
services
Product quality may be
affected if testing
equipment is mal
External  Calibration is done from NABL
functioning. like equipment 3 3 9 YES
testing accredited laboratory
is not competent to detect
laboratories the heavy metals,
pesticides
(P)Physical contamination
 Transporter has been instructed to
like dust, dirt or foreign
clean the vehicle prior to bring for
matter contamination in 3 3 9 YES
loading.
product due to unclean
 Vehicle inspection system is in place.
Transporters vehicle.
(C )Chemical contamination
like diesel or other  Vehicle inspection system is in place
3 3 9 YES
objectionable material to ensure no chemical contamination..
already present in vehicle.
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 19 of 23

(B )Birds or other pest


contamination due to  Transporter has been advised to
3 5 15 YES
improper covering or cover the vehicle properly.
protection of the material.
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 20 of 23

5. CCP Plan

CCP Name Receiving of Pulses CCP 1

Correction and Corrective Actions, preventive


Limits Monitoring procedures Verification Procedure
action

What: Vehicle checklists On Product: What: Vehicle checklists


How: Physically check What: Checking of vehicle How: visual
When: Every vehicle Who: Concerned Supervisor/ QC Department
No Physical When: Once in a Day
Contamination Where: On the gate Recorded By: Production Supervisor
Where: Laboratory
Who: QC Supervisor Corrective action: Call the transporter has
been instructed to clean the vehicle for Who: QA Head
Record Name: Vehicle
loading. Record Name: Vehicle checklists
checklists
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 21 of 23

CCP Name Final Magnet Seperator CCP 2

Limits Monitoring of CCP Corrections / Corrective Actions Verification

If Magnet Found heavily contaminated


Correction:
On Product:
What: Reprocessing of material What: Magnet cleaning
What: Magnet cleaning
Who: Director Works/ Miller
Record Name: NC Register How: Visual
How: With cloth & Brush
CL/AL/TL =No Recorded By: Production Supervisor
metallic On Equipment: When: Once in Shift
When: Shift Wise
contamination What: Cleaning of Magnet
in product Where: Lab
Where: At Magnets Who: Concerned Supervisor
Record Name: NC Register
Recorded By: Production Supervisor Who: In Charge QA/QC
Who: Plant Operator
Corrective action
Identify the cause of nonconformity correct Record Name: Magnet cleaning Report
Record Name: Magnet cleaning Report
cause of detected nonconformity to prevent
further occurrence, retrain the employee or
improve the frequency of the magnet cleaning
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 22 of 23

OPRP-1 FUMIGATION CCP Name: Doses of Fumigants

Limits Corrections / Corrective Action, Preventive


Monitoring of OPRP Verification
Action

What: Fumigant dozes, exposure time What: Fumigant dozes, exposure time
How: Visual Inspection How: Visual Inspection
No physical On Product;
When: Every Stack When: Once in a day
contamination What: Re-fumigation
Where: Store Where: Store
Who: QC Supervisor
Who: QC Supervisor Who: QA Incharge
Record Name: Record Name:
Fumigation Monitoring Records Fumigation Monitoring Records
TIRUPATI FOOD INDUSTRIES PVT. LTD, SONIPAT
Document Name HACCP PLAN FOR PULSES PRODUCTS
Document Number TFI/HACCP/01 Date of Issue 15-05-2011
Version 1.00 Page 23 of 23

OPRP -2 Magnetic Separator OPRP Name: Magnetic Separator

Correction and Corrective Actions,


Limits Monitoring procedures Verification
preventive action

If Magnet Found heavily contaminated


Correction:
On Product:
What: Magnet cleaning What: Reprocessing of material What: Magnet cleaning
Who: Director Works/ Miller
How: With cloth & Brush Record Name: NC Register How: Visual
CL/AL/TL =No Recorded By: Production Supervisor
metallic When: Hourly On Equipment: When: Once in Shift
contamination in What: Cleaning of Magnet
product Where: At Magnets Where: Lab
Who: Concerned Supervisor
Record Name: NC Register
Who: Plant Operator Recorded By: Production Supervisor Who: In Charge QA/QC
Corrective action
Record Name: Magnet cleaning Identify the cause of nonconformity correct Record Name: Magnet cleaning Report
Report cause of detected nonconformity to prevent
further occurrence, retrain the employee or
improve the frequency of the magnet cleaning

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