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HACCP Plan With Flow Chart-1
HACCP Plan With Flow Chart-1
HACCP Plan With Flow Chart-1
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 :______________________
TABLE OF CONTENTS
1. PRODUCT DESCRIPTION
Product Characteristics-
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)
Intended Use
Sensitive consumers NA
2. FLOW CHART
PM and Other Consumables
Receiving of Packing
Materials/ consumables
Sampling
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
Sampling
Unloading of Pulses
CCP
Fumigation OPRP 1
OPRP
Automatic
Cleaning
Magnetic Separator
OPRP 2
Feeding tank
Packing
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:
The severity of the hazard’s adverse health effects, evaluated quantitatively, in terms of critical, major or minor
impact severity, as follows:
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
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
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
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
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
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
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
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
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
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)-NA
(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
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
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
5. CCP Plan
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