Doc. No.: PI/MR/26. REV.

NO:00
FOOD SAFETY/ HACCP/ FOOD DEFENSE TEAM SELECTION CRITERIA
Effective Date: December, 09 Next Review Date: December-10
S. Team Designation Qualification Experience Required Training Required
No. Required
01 Team Leader/ M.R. Graduate Production activity : 5 Years At least 1) Hazard Identification
Admn. Activity: 1 Year 2) Hazard Analysis
Knowledge of HACCP/ Food 3) HACCP Plan
Defence: 1 Year 4) Risk Assessment for Food Defense
5) Setting the critical limits
6) Method of monitoring the control limits
7) Communication Skills
8) all Policy Understandings
9) GMP Guidelines
10) Knowledge of performing the internal audits
11) Broken Glass control procedure.
12) Understanding all requirements of ISO-22000
02 Team Members Minimum 10+2 Concerned Department: Min. 2 years 1) Hazard Identification
Knowledge of HACCP and Food 2) Hazard Analysis
Defense: min. 3 Months 3) HACCP Plan
4) Risk Assessment for Food Defense
5) Understanding all requirements of ISO-22000

Prepared By: Food Safety Team Member Approved By: Food Safety Team Leader
 Doc. No.: PI/MR/25.REV.NO:00
HACCP/ FOOD DEFENCE TEAM CHART
Date: December, 09 Next Review Date:
December-10
S. Name of Department Team Actual Actual Actual Trainings Any Action Plan
No. Person Designatio Qualification Experience Deficiencies (if Reqd.)
n
01 S.S.Tomar Plant Head Team M. Sc 24 Years  Hazard Identification & Analysis No
Leader (chemistry)  Risk Assessment for Food safety Deficiency
 Method of monitoring the control Found
limits
 Communication Skills
 Quality & Safety Policy Decision
 GMP Guidelines
 Conduction of internal audits
 Concept & implementation of
ISO-22000
 Hazard Identification No
02 Ramesh A.G.M Team B. Sc 18 Years  Hazard Analysis Deficiency
Sonania (Starch Member  HACCP Plan Found
Derivatives)  Risk Assessment for Food
Defense
 Understanding quality standards.
 Understanding quality standards No
03 Rakesh Gaur Manager-HR Team MBA (HR) 8 Years  Qualification criteria for Deficiency
Member employees. Found
 Impart quality & food safety
training at all levels
 Understanding of HACCP plan.
 Understanding of HACCP plan. No
 Vendor assessment & Rating Deficiency
04 M. L. Sharma  Quality Purchase Found
Manager- Team B. Sc 21 Years  Understanding all requirements
Purchase Member for food safety.

 Quality System Auditor No

05 Narendra Gupta Manager -QA Team M.Sc (TQM) 8 Years  Conduction of internal Audit Deficiency
Member  Risk Assessment for Food Found
Defense
 Understanding all quality
standards.
06 Tarun Sharma Asst. Manager – Team B.Tech 9 Years  Concept & implementation of No
Production Member (Chemical) ISO-22000 Deficiency
 Hazard Identification Found
 Hazard Analysis
 HACCP Plan
 Risk Assessment for Food
Defense
 Understanding all requirements
07 Sameer Suhail Dy. Manger- R & Team B. Tech 8 Years  Concept & implementation of No
D Member (Dairy) ISO-22000 Deficiency
 Hazard Identification Found
 Hazard Analysis
 HACCP Plan
 Risk Assessment for Food
Defense
 Understanding all Requirement
08 Sunil Bansal Microbiologist) Team M. Sc 4 Years  Concept & implementation of No
Member (Microbiology) ISO-22000 Deficiency
 Hazard Identification Found
 Hazard Analysis
 HACCP Plan
 Risk Assessment for Food
Defense
 Understanding all Requirement

Prepared By: Food Safety Team Member Approved By: Food Safety Team Leader
 Doc. No.: PI/MR/35, REV.NO:00

Product characteristic for raw material and for the final product
Raw materials, Ingredients and product contact materials.
Raw Material: Wheat Flour Portable Enzyme Hydrochloric Acid Filtration Aid Packing Material Packing Material
Water Inner (Primary) Outer (Secondary)
Biological, chemical and Absence of Ph : 6.50 – 7.00 Specific Gravity: 1.15- Strength : 30% Sodium Meta Bisulphite LDPE Food grade bags Polypropylene HDPE
physical characteristic; foreign particles, Hardness, ppm 1.25 Colour: Whit Liquor of size 22 x 44” & laminated bags of Size
Free from lumps. ≤ 300 pH: 5-6.7 Absence of sediments thickness 225 ± 5 gauge 20 x 40”.
TDS , ppm
≤ 500
Form Liquid /Solid/ Powder Solid Liquid Liquid Liquid Solid Solid Solid
Method of production; At ambient At ambient At refrigeration At ambient temperature At ambient temperature At ambient temperature At ambient temperature
Packaging & delivery temperature in temperature in Temperature. (5-10 in acid tank. in bags. in form of bundles. in form of bundles.
methods wheat flour silo water tank. °C)
Storage condition and shelf
life;
Food safety related Free from foreign Free from Free from Extraneous Free from Extraneous Free from Extraneous Free from Extraneous Free from Extraneous
acceptance criteria or particles. Extraneous matters matters matters matters and odour. matters and odour.
specification of purchased matters
materials and ingredients
appropriate to their intended
use.
(See SOP’s & SSOP’s, flow charts & HACCP plans provided )
Characteristics of end products
The characteristic of end products are described in documents to the extent needed to conduct the hazard analysis (see 7.4), including information on the following as appropriate:
1. Product name or similar identification: Malto Dextrin Powder
2. Composition:
i. Moisture content %, max : 4.50
ii. Dextrose Equivalent (DE). : As per customer requirement
iii. Ash content %, max. : 0.4%
iv. SPC cfu/g, max. : 3000
v. Yeast & Mould cfu/g max. : 50
vi. Coliform/ 0.1g : Nil
vii. E.coli/g : Absent

3. Intended use, shelf life and storage condition, packaging: Used in Bakery products, animal feed products, rich formulation & other Industrial usage. Best before 12 months from date of packing. 25
Kgs PP Bags
4. Method(s) of distribution: Through Truck Transportation and covered from all sides.
5. Is the product hazardous to any group: No

Prepared By: Food Safety Team Member Approved By: Food Safety Team Leader
 Doc. No.: PI/MR/20.REV.NO:00
HAZARD ANALYSIS
STEP/ INPUT: PRODUCTION ACTIVITIES
HAVE YOU CONSIDERED ALL POTENTIAL HAZARDS- YES Date: 01st Dec, 09
Step Step Name Hazard Cause Li Sev TR S/ Control Measures Q1 Q2 Q3 Q4 CCP/CP Reason for
No k N /CQP/QP decision
2 Slurry Microbial Left over residue in the D 3 17 N Clean tank Y N Y Y PRP
Storage tank periodically, Ensure no
Tank residue of the product
& chemicals remains.
4 Jet Cooker Microbial and Initial Microbial Load of D 3 17 N Maintain Jet Cooking Y N Y Y OPRP-1
Enzymatic the Product & Enzyme temp: 105-115 o C
Dosing.
7 Dextrinizati Microbial Left over residue in the D 3 17 N Clean tank Y N Y Y PRP
on Columns tank. periodically, Ensure no
residue of the product
& chemicals remains.
9 Sacharieatio Chemical HCL of 32% strength C 3 13 S Continuous ph Y N Y Y OPRP-2
n Tank dosing. monitoring during
HCL dosing. Adjust ph
to: 4.8-6.
11 Filtration Physical Initial Physical C 3 13 S The entire product Y N Y Y PRP
impurities in the should pass through
product. filter cloth with 2
micron pore size.
Periodic washing of
the filter cloth.
14 Ion Chemical Chemicals such as HCL C 2 13 S The entire product Y N Y Y PRP
Exchange and Filter aid used in the should pass through
unit. process. Ion exchange to
convert anion to cat
ion.
 Doc. No.: PI/MR/20.REV.NO:00
HAZARD ANALYSIS
STEP/ INPUT: PRODUCTION ACTIVITIES
HAVE YOU CONSIDERED ALL POTENTIAL HAZARDS- YES Date: 01st Dec, 09
Step Step Name Hazard Cause Li Sev TR S/ Control Measures Q1 Q2 Q3 Q4 CCP/CP Reason for
No k N /CQP/QP decision
15 Evaporation Microbial Left over residue in the D 3 17 N Clean tank Y N - - PRP
Unit tank. periodically, Ensure no
residue of the product
& chemicals remains.
18 Air heater Physical and Initial Physical and C 3 13 S Clean the Air filter Y N Y N CCP-1
Microbial Microbial load in the air. periodically and
heating of inlet air
temp: 190 to 200 °C.
19 Drying Microbial & Initial Microbial Load of A 3 6 S Maintain Outlet temp Y N Y Y PRP
Physical the Product. – 95-112 o C.
21 Packing Physical Foreign particles in the A 3 6 S Verification of vibro Y N Y N CCP-2
product. screen intactness.

Prepared By: Food Safety Team Member Approved By: Food Safety Team Leader
 Doc. No.: PI/MR/23.REV.NO:00
HACCP PLAN (FOR PRODUCTION)
STEP HAZARD. CCP/ CRITICAL MONITORING CORRECTIVE VERIFICATION RECORDS
NO. CQP No LIMITS ACTIONS METHOD
What Where How Frequency Who
19 Microbial & CCP-1 Drying Inlet Temp PLC Digital Once/ hr Supervisor Stop Feed& PI/PM/12 PI/MR/24-
Physical temp: 190- room display recycle A
200° C products until it
attain an
optimum temp.
21 Physical CCP-2 Vibro Screen Sieve Vibro Visual Every Supervisor Stop feed for its PI/PM/12 PI/MR/24-
(0.25 mm) Intactness Screen Shift repair/ replace B
with new one.

Prepared By: Food Safety Team Member Approved By: Food Safety Team Leader
 Doc. No.: PI/MR/21.REV.NO:00
SIGNIFICANCE IDENTIFICATION CHART FOR FOOD SAFETY
SEV: SEVERITY (CONSEQUENCES): Lik: Likelihood of Occurrence (Frequency)
1: Serious Sickness cause to the death of Consumer A: Occur at once in the day for that job
2: Consumer is hospitalized for treatment B: Occur at once in a weak.
3: Consumer is ill and take the medicine for treatment C: Occur at Once in Month
4: Not Significant D: Once in while
E: Practically Impossible
HAZARD SIGNIFICANCE MATRIX
FREQUENCY A B C D E
CONSEQUENCE
1 1 2 4 7 11
2 3 5 8 12 16
3 6 9 13 17 20
4 10 14 18 21 23

SIGNIFICANCE IDENTIFICATION CHART FOR FOOD QUALITY

SEV: SEVERITY (CONSEQUENCES): Lik: Likelihood of Occurrence (Frequency)

1: Immediate and Final Cessation of business A: Common repeating occurrence

2: Product Recall B: Known to occur/ it has happened
3: Rejection of delivery by the customer C: Could be occurring
4: Warning advice of non-conformance (Complaints) D: Not expected to occur
5: Not of Commercial Significance E: Practically Impossible
HAZARD SIGNIFICANCE MATRIX
FREQUENCY A B C D E
CONSEQUENCE
1 1 2 4 7 11
2 3 5 8 12 16
3 6 9 13 17 20
4 10 14 18 21 23
5 15 19 22 24 25
Significant Hazards are those whose rating is below and equal to 16 marks.
 Doc. No.: PI/MR/22.REV.NO:00

Questioning Technique for deciding the CCP/CQP for any potential Hazard:
 Doc. No.: PI/MR/36.REV.NO:00
VERIFICATION PLAN
Management has ensured a proper verification system for HACCP system, which enables the organization to determine whether the HACCP system is followed in
accordance with the documented plan and ensure that a safe product is delivered to the customers.

Activity Frequency Records RESPONSIBILITY

2. Verify Flow Diagram
3. Review Identified Hazards
4. Risk Assessment
Yearly Process Flow Diagram-FOOD SAFETY SYSTEM Manual FOOD SAFETY SYSTEM
Team
Yearly HACCP Hazard Analysis FOOD SAFETY SYSTEM
FOOD SAFETY SYSTEM Manual Team
Yearly HACCP Hazard Analysis FOOD SAFETY SYSTEM
FOOD SAFETY SYSTEM Manual Team

5. Review appropriateness of Yearly CCP Determination FOOD SAFETY SYSTEM

CCPs FOOD SAFETY SYSTEM Manual Team
6. CCP Records Monthly Critical Control Limits Team Leader/MR

4. Monitoring Records Three months Process & Supply Records Team Leader

8. Records of Corrective Bi-Yearly CA/PA Record Team Leader

Action/PA

9.Cleaning 3 monthly Cleaning records as per schedule Team Leader

10. GMPs/PRPs Team Leader

- Personal Hygiene F Monthly & half Personnel Hygiene ,Health check up
yearly
- Preventive maintenance Half Yearly Maintenance Records
- Supplier evaluation Yearly Vendor Rating Records
- Calibration Record Half Yearly Calibration Records
- Waste disposal Half yearly Waste record
- Cleaning Status 3 monthly Cleaning status record
- Pest Control 3 Monthly Pest Control contract, effectiveness check
 Doc. No.: PI/MR/37.REV.NO:00
VALIDATION PLAN FOR CCP
Step CCP Significant Hazard Related CCP Validation Criteria
No. No.
19 CCP-01 Drying temperature Drying Inlet temp: 190- On the basis of past experience/ complaints from customers and in house
220° C study, if the temperature is not in between this ratio then the desired
microbial and water activity in final product is not achieved.
21 CCP-02 Foreign Contamination Vibro Screen On the basis of past experience that presence of any foreign material in the
(Physical) (0.25 mm) product effect on the end product and finally contaminate the product

Prepared By: Food Safety Team Member Approved By: Food Safety Team Leader
 Doc. No.: PI/MR/14.REV.NO:00
RISK ASSESSMENT PROGRAM
Process Activity Potential Product Cause Effect Containment/ Immediate Corrective Action Responsible
Security Risk Method Person
Storage of Handling Material get damage due As no proper Damage product Rectify the existing system of Providing the Production
Material and Storage to not proper handling handling and may cause the handling as through stackers and complete training manager
of Material and storage system storage, material wastage of material proper racks arrangement for the and proper
get damage storage of material infrastructure to
avoid such problem
in future.
Production During the Material get damage As no access Effect on the 1) Proper Identity Card provide Security Person
processing during production by control system Product Security to any person who so ever enter checks the ID Proof
of material any unauthorized is there, this in the production, Laboratory of the entire person
employee/ visitor/ problem may and in store area who so ever went in
contractor enter in the occur 2) For the Visitor and for the that dept.
production Floor contractors, the Do and Do not Also check, for the
shall be made and implemented visitor/ contractor to
also. follow the Do and
Do not’s.
During the Product or sample of the As no access Effect on the 1) Proper Identity Card provide Security Person
…do…. processing product get pilferage control system Product Security to any person who so ever enter checks the ID Proof
of material during the processing by is there, this in the production, Laboratory of the entire person
any unauthorized problem may and in store area. who so ever went in
employee/ visitor/ occur 2) For the Visitor and for the that dept.
contractor enter in the contractors, the Do and Do not Also check, for the
production Floor shall be made and implemented visitor/ contractor to
also. follow the Do and
Do not’s.
During the The Pilferage of As the window/ Effect on the 1) Check for all the Outside Trained all the Production
…do… Transferring Material through throw door can be Product Security doors and gates, windows, roof production Manager
of Material it from the Window, or easily open by openings, and vent openings are supervisor to check
from one from any Open Door in any body, so secured with locks at all times. on the daily basis and
station to the Production/ Store this problem can 2) Check for the Main door, the inform to the
another Area occur door is of self closing nature. production manager
for necessary actions

Prepared By: Production Manager Approved By MD

 Doc. No.: PI/MR/14
RISK ASSESSMENT PROGRAM
Process Activity Potential Product Cause Effect Containment/ Immediate Corrective Action Responsible
Security Risk Method Person
While Pilferage may be As no control over Effect on the Check all the vehicle who so Make a policy that
Receiving of unloading/ due to transferring any vehicle of Product Security ever for the security checks by no private vehicle of
material/ Loading of that material in employee and of the the security Incharge any employee and of
Dispatching material from some unauthorized visitor, this may visitor allowed inside
of Material the carrier. vehicle within the happens the vehicle also the
company of any unloaded cargo is
employee and of again checked by the
visitor. security Incharge for
complete unloading.
While Pilferage may be As no control over Effect on the Check by the security Incharge Ensure the proper
Receiving of transferring due to transferring the security of the Product Security on the routine basis around the fencing around the
material/ the material in that material as building, this may building after every one hour building.
Dispatching the production some areas where happen Ensure that security
of Material floor the material can Incharge checks all
throw outside the corners of
building for proper
During the While Good Material get As no specific place/ Contamination Providing the proper labels for Providing the Production
Processing temporary contaminated during method to identify effects to the the identification of material. training to the Manager
storage of the mixing with the the rework/ rejected Product damage concerned supervisor
material in reworked/ rejected material in the about the use of label
processing during the production floor of In-process, rework
processing , rejected material
During the While storage Remaining raw As no proper Contamination Proper Storage System for the Check the properness Production
Processing of balance material get method/ means to effects to the storage of remaining raw of the method of Supervisor
material of contaminated store any remaining Product damage material after and during any storage through
any batch in because of poor raw material so this batch. covering the
the production storage effects the problem may occur remaining material
line surrounding material and also labeled them
for its identification

Prepared By: Production Manager Approved By MD