Olam Agro India Private Limited, Marupalli Document Name: HACCP PlanDocument Number: MGT-002-REQ-005

Total CCPs -1

Record on-site verification on flow-diagram - 05/08/2017

Processing Significant Control of Contractual Food

Utility WIP with weighment CCPs Recycle Waste/Byproduct
steps Hazards significant Hazards Work place handlers

Cashew Processing

Cyclone Other
Dust and Light P5 Impurities
Impurities

RCN Pre
Cleaner
P4

Dust & Pre

RCN <18mm Cleaned
size RCN

P1 QC Warehouse QC Supercalibr Vertical

Check Storage ator RCN >18mm Elevator Sizer
Receipt Check
Q1 P2 P3 size P6 P7
RCN Q2

24-26mm +26mm
18-20mm 20-22mm 22-24mm RCN
-18mm RCN
RCN RCN RCN
RCN

Conveyor 1 to
Mechanical
Shelling
P10A
Cooker 1 Cooker 2
P8A P8B
Steam from
Conveyor 2 to Boiler U1
Mechanical
Shelling
P10B
QC
Check Cooling Till Cooked
Q3 Ambient RCN
P9
Conveyor 3 to
Mechanical
Shelling
Shelling P10C
Machines
P11

Conveyor
P12

QC
Check
Q4 QC
Check
Q5 Kernels

Siever
P13

ShelledW
holes

Inspection QC
Meyer
Check
sorter conveyor
Q6
P14A P15B
R1 Shelled
Pieces
Air clasifier
P14B Shooter Cyclone
R2 P18
P15A

R3
Kernels
Siever
P16 Kernels
R2, R3
Sizer
P19

Air Classifier R1
P17

Shell

R1 R2 R3 Kernels

Manual
Shelling
P20

Shelled Shelled Shell

Wholes Pieces

Borma
P21

Borma Borma
Wholes Pieces

Humidification
P22

Transfer to QC
Peeling Check Q7
P23

Peeling SKGL-1 Peeling Vietnam Peeling Vietnam Peeling Vietnam Peeling Vietnam Peeling SKGL-2
P31 m/c feedHopper1 m/c feedHopper2 m/c feed Hopper3 m/c feed Hopper4 P24E
P24A P24B P24C P24D

Elevator 1 Elevator 2 Elevator 3 Elevator 4 Elevator 5

Elevator 1
P25A P25B P25C P25D P25E
P32

A5
A1 A2 A3 A4
2nd pass peeling

Rev04 DOI: 05/08/2017

Olam Agro India Private Limited, Marupalli Document Name: HACCP PlanDocument Number: MGT-002-REQ-005

A1 A2 A3 A4 A5 Wholes

Large
Rocket QC
Pieces
Peeler1,2,3,4,5 Check
P26 Q09

Small Large
Pieces Pieces
Air from WW 1 RC1
Compressor
U2
Air Peeler Husk
1,2,3,4,5 Meyer
P27 P29
2nd
Accept Manual
Wholes Segregation
P30A Recycle
Accept
Meyer Pieces Pieces
QC Wholes P29
Check
Q8 Final
Large meyer Manual
Pieces reject Segregation
One more pass Recycle P30B
Whole *
Super Calibrator Small
1,2,3,4,5,6 Pieces
P28 Small
Husk Winnowing Pieces
Graded Butts Rotten Shell
Husk+Pie P29A Pieces
ces
Husk

RC2
WW 1
WW 2 SW SSW PUK PP/AT Butts Rottens Uncut Shell

Grading Grading Grading Grading

Machine 1 Machine 2 Machine 3 Machine 4 Not OK
P33A Not OK QC Small
P33B P33C P33D QC Check
RC4 Pieces
Check RC3 Q11
Q15
OK
OK

Destoner Feed
Graded Recycle Collection In Hopper RC5
Whole Whole * Crates P35
P34B

Elevator
QC Not OK P36
Check RC7
Q10

OK Cyclone Destoner
Stones
P37B P37A

Collection In
Crates
P34A Inspection
Conveyor Foreign
P38 Matter

Transfer to IR
RC8 area/Fumigation
P47 Collection In
Crates
P39
Collection In
Stacking in Crates
Crates / SS bins P46
P48
QC Not OK
Check RC6
Fumigation only Q12
for Powder
P49
OK
QC
Check Not OK
Aeration RC9
P49A Q14

IR2+ Cooling Dicer Feed

IR1 + Cooling IR3+ Cooling
Conveyor Hopper
Conveyor Conveyor P40
P50A P50B
P50C

Cold room Accept Recycle

P51 Pieces Pieces
Elevator
RC10 P41

Not OK
Material Transfer
to packing OK
P52 Buhler QC Multi Grade Galaxy Dice or
RC11 P45 Check Separator siever Size
Q13 P44 P43 P42

QC Not OK Not OK QC
Check RC12 Check
Q16a Q16b

OK OK Air from
Compressor
U3

Feed Hopper Feed Hopper

P53A RC13 P53B

Elevator Elevator
P54A P54B

Vibratory Sieve Vibratory Sieve

P55A P55B

Magnet A1 Magnet B1
P56A P56B

Aspirator A1 Aspirator B1
P57A P57B

Inspection Inspection
Conveyor Conveyor
P58A P58B

Magnet A2 Magnet B2
P59A P59B

Aspirator A2 Aspirator B2
P60A P60B

CCP 1a
CCP 1b
Online Metal Air from Online Metal
Detection Compressor Detection CCP 1a and 1b Hazards Controls:-
P61A U4 P61B Chances of metal Monitoring Frequency -
contamination 1. At the start up of Production after a shut down for sanitation
2. At the restart of production after significant unplanned down
RC14 time events of 24 hours or more
3 Once in two Hours
Elevator Elevator 4. At Start up, after grade change,
P62A P62B 5.After repair/Maintenance/Adjustment to detection
equipment(Sensitivity)
6.At the end of each shift if production will not continue into
next shift with 1.0 mm Fe, 1.2 mm Non - Ferrous & 1.8 mm
Stainless steel test pieces & two time passes of each test
piece.
Air from
Hopper with Compressor Hopper with
Weighment U5 Weighment
Rev04 DOI: 05/08/2017 P63A P63B
 next shift with 1.0 mm Fe, 1.2 mm Non - Ferrous & 1.8 mm
Stainless steel test pieces & two time passes of each test
piece.
Olam Agro India Private Limited, Marupalli Document Name: HACCP PlanDocument Number: MGT-002-REQ-005
Air from
Hopper with Compressor Hopper with
Weighment U5 Weighment
P63A P63B Dispatch Vehicle
arrival Vehicle
Dispatch
P72
arrival
P72

Rev04 DOI: 05/08/2017

 Hopper with Hopper with
Olam Agro India Private Limited, Marupalli Weighment Weighment Document Name: HACCP PlanDocument Number: MGT-002-REQ-005
P63A P63B Dispatch Vehicle
arrival Vehicle
Dispatch
Dispatch
P72
arrival Vehicle
arrival Vehicle
Dispatch
P72
P72
arrival
QC Not OK Not OK QC P72
Check RC15 Check
Q17a Q17b

OK OK

Pouch Forming Pouches, Molds Pouch Forming

P64A and Sleeves P64B
U6

Filled Pouch Filled Pouch

Elevator Elevator
P65A P65B

Settler Settler
P66A P66B

B1 B2

B1 B2

Dispatch Vehicle Vehicle Not OK Corrective Action Not OK

arrival Inspection Taken Reject
P72 Q19 P74

Roller Roller
P67A P67B
OK
OK
Vacumm packing Air from Vacumm packing
Compressor
with CO2 flushing with CO2 flushing RC18
U7
P68A P68B
6
CO2 from
cylinder Not OK
U8

OK
Labelling and Cartons stacking 24 Hours FG Warehouse Dispatch
Cartoning on pallets Release P71 P73
P69 P70 Q18

Labels, Cartons
and BOPP tape Damaged Pouches,
U9 damaged Cartons

Rev04 DOI: 05/08/2017

 Olam Agro India Private Limited, Marupalli
Document Name: HACCP PlanDocument Number: MGT-002-REQ-004

PROCESS STEP DESCRIPTION

Process Step
M#, L# or Details and Technical Data
P#
Description

RCN is received by trucks and is stored in the warehouse originwise and is

P1 RCN Receipt
coded. No of bags is recorded and the total bags are tagged as per origin code.

RCN is stored safely inside the warehouse to prevent from external factors such
P2 RCN Storage
as rain and dust.

This elevator is used to lift the RCN from the feeding point to the next stage in
P3 Vertical elevator a steady input to prevent accumulation of material in the next stage (Pre-
Cleaner)

This stage is to remove any physical contamination like dust, paper and any
P4 Pre- Cleaner
other unacceptable physical contamination.

This is a negative pressure which sucks the physical contamination which is

P5 Cyclone
mixed with the RCN to outside of the cleaning centre.
This is used to convey the Pre-cleaned RCN from pre- cleaner equipment to the
P6 Conveyer
next stage (Elevator)
This elevator is used to lift the RCN from the feeding point to the next stage in
P7 Vertical elevator
a steady input to prevent accumulation of material in the next stage (Sizer)

P8 RCN Sizer Sizer is used to seggregate identical pieces based on size

Cooker is used to steam boil the RCN to enable it for cutting easily. Steam of
P9a/ P9b Cooker about 4- 5 Kg is passed into the steam jacket of the cooker and the steam inturn
cooks the RCN , It makes the hard shell soft and breakable.

RCN that is discharged from the cooker will be at high temperature which is
P10 Cooling till ambient suitable for the next stage of processing. It will be cooled naturally for 24
Hours. Bags will be kept size wise and cooled.

P11a/ This conveyer is used to carry cooked and cooled RCN from cooking section to
Conveyer to mechanical shelling
P11b/ P11c Shelling section

Shelling machines are mechanical way of cutting the shell and extracting the
P12 Shelling machines nut. This is done by a cutter and splitter arrangement where the nut is paased
through the machine and is cut.
Conveyer is used to convey the cut shells and the kernel to the next stage
P13 Conveyer
( Seiver)

P14 Siever The cut RCN is passed through a seive and the nut is seived out from the shell.

The cyclone is used to suck the light weighted shells from the line and to carry
P15 Cyclone
it outside for bagging.

The rollers are used to convey the uncut / partially cut RCN from the top of the
sieve to the next conveyer where the RCN is carried forward to the next step.
P16 Rollers
The uncut RCN is named as R1,R2,R3 based on the type of cutting where R1 -
Shell with Pieces / R2- Shell with wholes and R3- Uncut

Shooter is an arrangement with a hard metal plate where the R2 type of RCN is
P17 Shooter made to hit the plate in this process the wholes would be extracted from the
shell and sieved out.
P18 Siever The sievers are used to separate the kernels which comes out of the shooter.

P19 Rollers These rollers are used to seggregate the Shells based on size/ Cut

Rev00 DOI: 02/01/2016

 Olam Agro India Private Limited, Marupalli
Document Name: HACCP PlanDocument Number: MGT-002-REQ-004

PROCESS STEP DESCRIPTION

Process Step
M#, L# or Details and Technical Data
P#
Description
Super calibrators are used to separate the kernels based on size. Its has a rollers
P20 Super Calibrator with perforations which allows the whole kernel to travels through it whereas
the pieces will fall in between the perforations
Manual shelling as the name implies is done manually by person who personelly
P21 Manual Shelling cuts the RCN with the aid of a cutting machine and seggregating the kernels
from the shell.

Borma is a roasting process where the kernels are heated to remove the "TESTA"
which is the skin of the kernel. Steam is passed through a series of tube like in a
P22 Borma heat exchanger the heat generated in the tube are passed to the kernels with
the help of a fan. The max temp is 80 deg. and is the retention time is 480 min
(8 hours)

The heated kernels post 8 hours will be removed from the borma chamber and
introduced into the humidification chamber where cool is passed for a period of
P23 Humidification
8 hours to cool the RCN. This immediate cooling of the kernels will facilitate
the easy removal of the testa.

The kernels are stored on plates which is inturn arrayed into trolleys and then
P24a/ subjected to the borma and humidifucation process. The trolleys post
Transfer to Peeling section
P24b/P24c humidification will be moved to the peeling section for the next process
(Peeling)

P25a/ The trolleys which are moved into the peeling section is being emptied into the
Peeling Feed Hopper
P25b/P25c peeling machine feed hopper

Rev00 DOI: 02/01/2016

Nestlé GI-31.202-2 9/27/2011

HAZARD IDENTIFICATION and DESCRIPTION

Justification
Location of potential hazard Hazard description Hazard assessment
Hazard assesment
Indicate the step (e.g. raw material, Describe clearly and specifically the hazards that are "reasonably expected" to occur at each step: Class (M = Microbiological, P = Q1: Based on the hazard description, likelihood of occurrence
logistics or process) at which the Physical, C = Chemical, A = Allergens, N = Nutritional over- or underdosing), agent, size, origin, nature, etc. (before applying the control measure) and severity of health
hazard may be introduced. effects, does this hazard need to be controlled, i.e. is it a Provide supporting data/references
significant hazard?
Significant
H# Hazard Class Origin or source of the Nature of the Acceptable level in end product Likelihood of Severity of hazard?
hazard (e.g. where and hazard (e.g. occurrence adverse health (Yes/No) For non significant hazards, document how it is managed e.g. by
how it can be introduced presence, ability effect For significant a PRP, through a specification or Major Allergen Declaration
M #, L# or into the product or its to grow, survive,
Step (description) hazard, select (MAD).
P# environment) formation of source (legal, and categorize
toxins or toxic level control
spec, study)
chemicals, measure(s) on
migration of WS F.
chemicals)
Foreign body common
crop, supplier Foreign body
(Wooden splints, threads, Likely Can cause
M1 Semolina H1 stones, polybags strips,
P line,Storage & Presence should be GI - 31.715
(1/month) illness
4C Yes Rotary Sieve of 2 mm is in place
transport condition <2mm
personel object, insects)

Foreign body
Foreign Body Metal Pieces( Supplier line,Storage Likely Can cause
M1 Semolina H2 P Presence should be GI-31.726 4C Yes Rotary Sieve of 2 mm is in place with magnets
Fe & Non Fe) & transport condition (1/month) illness
<2mm

Supplier QA is in place ( Supplier audit reports).

Pest Infestation (Weevils & Could occur can cause
M1 Semolina H3 P Supplier & factory Presence Absent FSSAI 3D No Integrated Pest management is in place both at supplier
Beetles) (1/6month) inconvience
& factory. Daily monitoring checks & records are in place.

Pathogen CP-51.010 & Could occur Can cause

M1 Semolina H4 M Supplier Presence Absent
MI- 51.014 (1/6month) illness
3B Yes
Contamination(Salmonella)

Heavy metals As per RM Almost of no Contaminants monitoring of RM in place as per RM

M1 Semolina H8 C Supplier Presence
QMS
FSSAI Unlikely
significance
1E No
QMS. Result was ok (reference - Heavy metals reports.)
(As,Pb,Sn,Hg,Cu,Zn & Cd)

One sample was analyzed by MOGA, result was found to

As per RM Almost of no
M1 Semolina H9 Pesticides Residues C Supplier Presence
QMS
FSSAI Unlikely
significance
1E No be lower than the LOQ. More monitoring to be done next
year.

Mycotoxins ( Aflatoxins
As per RM Almost of no Mycotoxins monitoring of RM in place as per RM QMS.
M1 Semolina H10 B+G,Ocratoxin, Vomitoxin, C Supplier Presence
QMS
FSSAI,Nestle Unlikely
significance
1E No
Result was ok
Zearalenone)

NOTs (Agaric acid, Saffrole, As per RM Almost of no NOTs monitoring of RM in place as per RM QMS. Result
M1 Semolina H11 C Supplier Presence
QMS
FSSAI Unlikely
significance
1E No
was ok (reference - Heavy metals reports.)
Hydrocyanic)
Gluten is Can lead to
M1 Semolina H8 Gluten A Supplier Presence contituent of MI.51.014 1/Day serious 5B Yes Semolina is declared as ingredient on pack.
wheat flour illness

Biological comtamination with Almost of no PRP. Supplier Quality assurance in place.

M1 Semolina H13 C GMO contamination Presence Absent Nestle Unlikely 1E No
GMO significance PRP. GMO certificate from supplier is in place.

Supplier decleration no Melanine in RM. COA with every

As per RM Almost of no consignment.
M1 Semolina H17 Melamine & Cyanuric acid C Supplier Presence NRC Unlikely 1E No
QMS significance Add as per p-QMS from R&D.
Monitoring as per factory RM Qms.
As per RM Almost of no
M1 Semolina H18 T2HT2 C Supplier Presence NRC Unlikely 1E No
QMS significance

Pathogen Chlorination of Drinking water done and is monitored by

CP-51.010 & Can cause technicians for required norms.
M3 DM Water H4 Contamination(Salmonella, M Borewell Presence Absent
MI- 51.014
Rare
illness
2C No
Monitoring of Drinking Water samples in place acc. to
Bacillus cereus) regulatory requirement.

Contaminants monitoring of Drinking water in place as

Heavy metals As per Utiliity Almost of no
M3 DM Water H8 C Borewell Presence
QMS
FSSAI Unlikely
significance
1E No per Utility QMS. Result was ok (reference - Heavy metals
(As,Pb,Sn,Hg,Cu,Zn & Cd) reports.)

Factory, Product/Line HACCP study N° WS E - page 7

Nestlé GI-31.202-2 9/27/2011

Justification
Location of potential hazard Hazard description Hazard assessment
Hazard assesment
Indicate the step (e.g. raw material, Describe clearly and specifically the hazards that are "reasonably expected" to occur at each step: Class (M = Microbiological, P = Q1: Based on the hazard description, likelihood of occurrence
logistics or process) at which the Physical, C = Chemical, A = Allergens, N = Nutritional over- or underdosing), agent, size, origin, nature, etc. (before applying the control measure) and severity of health
hazard may be introduced. effects, does this hazard need to be controlled, i.e. is it a Provide supporting data/references
significant hazard?
Significant
H# Hazard Class Origin or source of theNature of the Acceptable level in end product Likelihood of Severity of hazard?
hazard (e.g. where and hazard (e.g. occurrence adverse health (Yes/No) For non significant hazards, document how it is managed e.g. by
how it can be introduced
presence, ability effect For significant a PRP, through a specification or Major Allergen Declaration
M #, L# or into the product or its
to grow, survive,
Step (description) hazard, select (MAD).
P# environment) formation of and categorize
toxins or toxic control Chiiled Water HACCP in place.
Pathogen Contamination chemicals, measure(s) on Chlorination of drinking water (used in Chiller) is done.
Through cross CP-51.010 & Can cause
M4 Chilled Water H4 (Salmonella, Bacillus M
contamination in PHE
Presence
migration of Absent
MI- 51.014
Rare
illness
2B YesF.
WS Pressure of Chilled Water to be lesser than the pressure
cereus) chemicals) of drinking water so that there's no cross contamination
inside PHE.

As per water
Pathogen Improper cleaning of pathogen CP-51.010 & Can cause Cleaning of dosing & buffer tank is in place.
M5 DM Water H4 M
buffer tank
Presence
monitoring MI- 51.014
Unlikely
illness
1B No
Pathogen monitoring in place for Drinking water.
Contamination(Salmonella)
plan

Foreign Body common Could occur Almost no Past history is ok, Filters cleaning & maintainence is in
M7 Compressed Air H1 P Torn Filters Presence Absent GI - 31.715
(1/6month) significance
3E No
place
(Dust/Dirt)

Pathogen Improper pore Should be CP-51.010 & Can cause Compressed air passing through EU 4 filters.
M7 Compressed Air H4 M
size/Torn Filters
Presence
absent MI- 51.014
Unlikely
illness
1B No
Considered Compressed air HACCP.
Contamination(Salmonella)

Compressed air passing throught EU 4/5 filters.

In addition to the above, dessicant dryers (SMS 30/30 or
Improper Cleaning &
Should be Can cause SB 30/30) helps in remoing moisture.
M7 Compressed Air H14 Non food grade oil particles C Maintenance - Presence
absent
Nestle Unlikely
illness
1C No
DD 500/520 for degreasing and dust removal.
Torn/Damaged filters
Near to KHS filling machine, 15 µ filter is provided to curb
moisture & oil contamination.

Temp inside drier is Set point+/-2˚C & processing time is

Due to contaminated Should be Likely(1/ Almost no 2.5 hrs.
M9 Atmospheric Air H4 Bacterial contamination M
Air
Contamination
absent
MI- 51.014
month) significance
4E No
If temp +/- 2˚C of set point , alarm indication in control
room PC.
Temp inside drier is Set point+/-2˚C & processing time is
Due to contaminated Should be Likely(1/ Almost no 2.5 hrs.
M11 Hot Air H4 Bacterial contamination M
Air
Contamination
absent
MI- 51.014
month) significance
4E No
If temp +/- 2˚C of set point , alarm indication in control
room PC.
Due to contaminated Should be Can cause Atmospheric air passing through EU 3 filters.
M12 Chilled Air H4 Bacterial contamination M
Air
Contamination
absent
MI- 51.014 Unlikely
illness
1C No

Foreign body common

Foreign body
(Wooden splints, threads, Can cause Basic PRP's in place to avoid contamination.
M13 Pasta Bits H1 stones, polybags strips,
P Process Line Presence should be GI - 31.715 Unlikely
illness
1C No
Critical Areas like Acrylic/Polycarbonate are checked as
<2mm
personel object, insects) OPRP in every shift in Foreign Body Checklist.

Various loose parts in line are checked through OPRP in

Foreign body
Foreign Body Metal Pieces( Likely Can cause Foreign Body Checklist.
M13 Pasta Bits H2 P Process Line Presence should be GI-31.726
(1/month) illness
4C No
Further during filling, the pasta bits are passed through
Fe & Non Fe) <2mm
MD before filling.

Pest Infestation (Weevils & Could occur can cause Integrated Pest management is in place at factory.
M13 Pasta Bits H3 P During Storage Presence Absent FSSAI
(1/6month) inconvience
3D No
Daily monitoring checks & records are in place.
Beetles)
Storage of Pasta bits will be in a conditioned room.

Pathogen Pasta Bits are released basis Moisture norms of 10-11%.

Can lead to
Should be CP-51.010 & Only released pasta bits are kept for storage. Moisture %
M13 Pasta Bits H4 Contamination(Salmonella, M During Storage Growth
absent MI- 51.014
Unlikely serious 1C No
of 10 - 11% is a limiting factory for growth of pathogenic
Bacillus cereus) illness
micro organisms.
Each consignment samples taken & send to QA lab,
Could occur Almost no Performed Sniff test consignment & consignment release
M14 Laminates H12 Print Ink C Supplier Presence No off smell Nestle
(1/6month) significance
3E No
after sniff test result.
Sniff test prformed on line for every new roll

Factory, Product/Line HACCP study N° WS E - page 8

Nestlé GI-31.202-2 9/27/2011

Justification
Location of potential hazard Hazard description Hazard assessment
Hazard assesment
Indicate the step (e.g. raw material, Describe clearly and specifically the hazards that are "reasonably expected" to occur at each step: Class (M = Microbiological, P = Q1: Based on the hazard description, likelihood of occurrence
logistics or process) at which the Physical, C = Chemical, A = Allergens, N = Nutritional over- or underdosing), agent, size, origin, nature, etc. (before applying the control measure) and severity of health
hazard may be introduced. effects, does this hazard need to be controlled, i.e. is it a Provide supporting data/references
significant hazard?
Significant
H# Hazard Class Origin or source of the Nature of the Acceptable level in end product Likelihood of Severity of hazard?
hazard (e.g. where and hazard (e.g. occurrence adverse health (Yes/No) For non significant hazards, document how it is managed e.g. by
how it can be introduced presence, ability effect For significant a PRP, through a specification or Major Allergen Declaration
M #, L# or into the product or its to grow, survive,
Step (description) hazard, select (MAD).
P# C Supplier
environment) Presence
formation of Unlikely Can cause
Heavy metals, Should be and categorize Supplier QA is in place.
M14 Laminate H8 toxins or toxic Nestle (Once in 2 illness 1C No
control
(Pb.Cd,Hg,Cu) chemicals,
absent years) Monitoring per year as per QMS is in place.
measure(s) on
migration of WS F.
C Supplier Presence
chemicals) Unlikely Can cause
Residual solvent,Poly Should be (Once in 2 illness Supplier QA is in place.
M14 Laminate H15,16 absent
Nestle 1C No
Monitoring per year as per QMS is in place.
aromatic amines years)

Foreign Body common Each consignment samples taken & condition of tranport
( Dust/Dirt ,Threads, Foreign body Unlikely & material checked as per RM/PM receipt handlinfg
Almost no
M14 Laminates H1 polybags strips,gasket P Supplier Presence should be GI - 31.715 (Once in 2
significance
1E No format.
chips, wooden splints, glass <2mm years) Outer carton covering remove on the line & visual
etc) inspection by line technician before use.

Foreign Body common

( Dust/Dirt ,Threads, Visual check by technicians of cleanliness & seal
Foreign body
During tranportation & Can cause integrity.
M15 T.M Sachet H1 polybags strips,gasket P
storage
Presence should be GI - 31.715 Rare(1/Year)
illness
2C No
If found any deviation reclean sachets & discard if seal if
chips, wooden splints, glass <2mm
not proper.
etc)
Foreign Body common
( Dust/Dirt ,Threads, Foreign body Unlikely
Almost no Secondary packaging,Each consignment checked for
M16 Shipper H1 polybags strips,gasket P Supplier Presence should be GI - 31.715 (Once in 2
significance
1E No
foreign body as per RM/PM receipt handling procedure
chips, wooden splints, glass <2mm years)
etc)

Supplier Quality Assurance is in place.

Foreign Body common Visual inspection by tipping person during tipping.
( Dust/Dirt ,Threads, Foreign Body boxes are present in each process area.
Foreign body
polybags strips,gasket Supplier & During can cause There might be chances to get this hazard due to
P2 Tipping H1 P Presence should be GI - 31.715 Rare 2C No
chips, wooden splints, glass operation illness improper handling by tipping person.
<2mm
etc) Rotary Sieve 2mm, Magent & Metal detector before filling
are the subsequent steps.

Supplier Quality Assurance is in place.

Visual inspection by tipping person during tipping.
Foreign Body boxes are present in each process area.
Foreign Body Metal Pieces( Knives & similar materials: to be controlled quantity
Foreign body
Supplier & During can cause numbering, usable place etc.
P2 Tipping H2 Fe & Non Fe)/ metal P
operation
Presence should be GI-31.726 Rare
illness
2C No
There might be chances to get this hazard due to
shavings/ nuts & bolts <2mm
improper handling by tipping person.
Rotary Sieve 2mm, Magent & Metal detector before filling
are the subsequent steps.

Line cleaning procedure & checklist is in place.

M&I is in place to check the misalignment.
Foreign body There might be chances to get this hazard due to
Can cause
P3a Screw Conveyor H2 Foreign Body Metal shaving P Due to misalignment Presence should be GI-31.726 Unlikely
illness
1C No improper handling at operator level, in this case screw
<2mm will trip due overload.
Rotary Sieve 2mm, Magent & Metal detector before filling
are the subsequent steps

Monitoring of magnetic trap per shfit is in place.

Foreign Body Metal Pieces( Cleaning checklist is in place
Overloading of Foreign body
can cause There might be chances to get this hazard down the line
P4 Magnetic Trap H2 Fe & Non Fe)/ metal P magnetic trap with fe Presence should be GI-31.726 Rare
illness
2C Yes
due to lack of monitoring & material have excess metal
shavings/ nuts & bolts particles <2mm
particles.
Metal detector before filling as subsequent step.

Factory, Product/Line HACCP study N° WS E - page 9

Nestlé GI-31.202-2 9/27/2011

Justification
Location of potential hazard Hazard description Hazard assessment
Hazard assesment
Indicate the step (e.g. raw material, Describe clearly and specifically the hazards that are "reasonably expected" to occur at each step: Class (M = Microbiological, P = Q1: Based on the hazard description, likelihood of occurrence
logistics or process) at which the Physical, C = Chemical, A = Allergens, N = Nutritional over- or underdosing), agent, size, origin, nature, etc. (before applying the control measure) and severity of health
hazard may be introduced. effects, does this hazard need to be controlled, i.e. is it a Provide supporting data/references
significant hazard?
Significant
H# Hazard Class Origin or source of the Nature of the Acceptable level in end product Likelihood of Severity of hazard?
hazard (e.g. where and hazard (e.g. occurrence adverse health (Yes/No) For non significant hazards, document how it is managed e.g. by
how it can be introduced presence, ability effect For significant a PRP, through a specification or Major Allergen Declaration
M #, L# or into the product or its to grow, survive,
Step (description) hazard, select (MAD).
P# environment) formation of and categorize Monitoring of Rotary Sieve (2mm) intactness per shfit is
Foreign Body common toxins or toxic control in place.
chemicals, measure(s) on
( Dust/Dirt ,Threads, Foreign body Cleaning checklist is in place
Rotary Sieve migration of can cause WS F.
P5
(2mm)
H1 polybags strips,gasket P Damaged sieve Presence
chemicals) should be GI - 31.715 Rare
illness
2C Yes There might be chances to get this hazard down the line
chips, wooden splints, glass <2mm due to lack in monitoring.
etc) Die protector sieve (C-F-C : 2 no. of 1.5mm & 1 no. of
0.5mm) is subsequent step.

Monitoring of Rotary Sieve (2mm) intactness per shfit is

in place. Cleaning checklist is in place
Foreign body
Rotary Sieve can cause There might be chances to get this hazard down the line
P5
(2mm)
H2 Foreign Body Metal shaving P Damaged sieve Presence should be GI-31.726 Rare
illness
2C Yes
due to lack in monitoring.
<2mm
Die protector sieve (C-F-C : 2 no. of 1.5mm & 1 no. of
0.5mm) is subsequent step.

Foreign body Unlikely Past history is ok.

Foreign Body common Almost no
P8 Jet Filters H1 P Damaged filter Presence should be GI - 31.715 (Once in 2 1E No Cleaning checklist is in place. Check in every M & I.
(Threads of bag filters) significance
<2mm years) Vacuum suction stops if filter got damaged.
Nut & bolt of air
Foreign body PRP. Check in every M & I in process technician
Foreign Body Metal -Nut & purging pipes, Due to can cause
P10 Batch Hooper H2 P Presence should be GI-31.726/ Rare 2C No Cleaning checklist is in place
bolt of air purging pipes mishandling during illness
<2mm
M& I

Supplier QA in Place
Foreign body Integrated Pest management is in place both at supplier
Pest Infestation (Weevils & can cause
P10 Batch Hooper H3 P From Raw material Ability to grow should be GI-31.726 Rare 2C No & factory. Daily monitoring checks & records are in place.
Beetles) illness
<2mm Batch hopper & bag filter are checked on M&I

Line cleaning procedure & checklist is in place.

M&I is in place to check the misalignment.
There might be chances to get this hazard due to
Foreign body
Can cause improper handling at operator level, in this case screw
P12 Screw Conveyor H2 Foreign Body Metal shaving P Due to misalignment Presence should be GI-31.726 Unlikely
illness
1C No
will trip due overload.
<2mm
Die protector sieve (C-F-C : 2 no. of 1.5mm & 1 no. of
0.5mm) &metal detector before filling aresubsequent
step

PRP. Yearly leak test of plate heat exchanger.

Plate heat Due to chiled water Can cause
P17
exchanger
H4 Bacterial contamination M Presence Absent MI- 51.014 Unlikely
illness
1C No Chilled Water pressure to be less than the drinking water
leakage pressure to avoid cross contamniation.

Due to insufficient
Pathogen Growth & Can lead to Proper flushing of the remaining dough using 100 bar
cleaned equipment, Max.
P18 Polymatic Mixer H4 contamination(Staph. M development of
1000cfu/g
CP 50.010 Once / month serious 4B Yes pressure.Poly matic mixture to be cleaned fully if the
not applied toxin illness production is stopped for more than 72 hrs
Aureus)
personal hygiene

Foreign body
Foreign bodies metal -metal Misalignment of pin can cause Mixer screws can not run in miss aligned conditions.
P18 Polymatic Mixer H2 P Presence should be GI-31.726 Rare 2C No
shavings screw of mixer illness Kneeder will trip due to overload.
<2mm
Water leakage from Almost no
P18 Polymatic Mixer H4 Bacterial contamination M
jacket
Presence Absent MI- 51.014 Very unlikely
significance
1E No

Dosing water Hose & noozle is checked & cleaned

can cause before startup.
P18 Polymatic Mixer H4 Mold growth M water dosing pipe Growth Absent CP 50.010 Rare
illness
2C No
Before starting pump will run for 3min to check the
uniform flow rate.
PRP. Food Grade certificate
Foreign body
Damage of water can cause PRP. Pipe is checked & cleaned before startup
P18 Polymatic Mixer H1 Foreign Body common P
dosing pipe
Presence should be GI-31.726 Rare
illness
2C No
Before starting pump will run for 3 min to check the
<2mm
uniform flow rate.

Factory, Product/Line HACCP study N° WS E - page 10

Nestlé GI-31.202-2 9/27/2011

Justification
Location of potential hazard Hazard description Hazard assessment
Hazard assesment
Indicate the step (e.g. raw material, Describe clearly and specifically the hazards that are "reasonably expected" to occur at each step: Class (M = Microbiological, P = Q1: Based on the hazard description, likelihood of occurrence
logistics or process) at which the Physical, C = Chemical, A = Allergens, N = Nutritional over- or underdosing), agent, size, origin, nature, etc. (before applying the control measure) and severity of health
hazard may be introduced. effects, does this hazard need to be controlled, i.e. is it a Provide supporting data/references
significant hazard?
Significant
H# Hazard Class Origin or source of the Nature of the Acceptable level in end product Likelihood of Severity of hazard?
hazard (e.g. where and hazard (e.g. occurrence adverse health (Yes/No) For non significant hazards, document how it is managed e.g. by
how it can be introduced presence, ability effect For significant a PRP, through a specification or Major Allergen Declaration
M #, L# or into the product or its to grow, survive,
Step (description) hazard, select (MAD).
P# environment) of formation of Foreign body
Foreign bodies metal Misalignment can cause and categorize
P23 Screw Press H2 P Presence
toxins or toxic should be GI-31.726 Rare 2C No
control Press Screw can not run in miss aligned conditions.
shavings screw conveyor illness
chemicals, <2mm measure(s) on
migration of WS F.
chemicals)
Due to insufficient
Growth & Can lead to Proper flushing of the remaining dough using 100 bar
Pathogen contamination cleaned equipment, Max.
P18 Polymatic Mixer H4 M development of
1000cfu/g
CP 50.010 Once / month serious 4B Yes pressure.Poly matic mixture to be cleaned fully if the
(Staph. Aureus) not applied toxin illness production is stopped for more than 72 hrs
personal hygiene

Foreign Body common

(Dust/Dirt, Threads,
Die Protector Could occur can cause MD is in subsequent step.Validated with Brass test
P24
Seive
H1 polybags strips, gasket P Damaged sieve Presence Absent GI - 31.715
(1/6month) illness
3C Yes
piece.Checking before start up is in place.
chips, wooden splints, glass
etc)
Foreign Body common
(Dust/Dirt ,Threads, Foreign body
can cause Monitoring is done during start up.
P25 Die H1 polybags strips,gasket P Damage of inserts Presence should be GI - 31.715 Rare
illness
2C No
Change inserts basis condition.
chips, wooden splints, glass <2mm
etc)
Foreign body
Due to damage Could occur can cause Monitoring is done during shift start, part of foreign body
P29 Cutter H1 Foreign Body common P Presence should be GI - 31.715
(1/6month) illness
3C Yes
checklist.
cutter <2mm
PCB hooper for Foreign body
Due to broken can cause Hopper is made of Poly carbonate sheet of more than 5
P30 feeding pasta to H1 Foreign body common P Presence should be GI - 31.715 Rare 2C No
equipment illness mm . Managed through CP.
predryer <2mm

Foreign body
Due to broken can cause PRP. Check during M & I
P32 Shaking pre drying H2 Foreign bodies P Presence should be GI-31.726 Rare 2C No
equipment (sieve) illness Rec. Cleaning checklist is in place
<2mm

survival due
Bacterial
survival of the pathogenic to in-sufficient CP-51.010 & can cause PRP.Continous Monitoring of temp & humidity
P32 Shaking pre drying H6
bacteria
M contamination of Absent
MI- 51.014
Rare
illness
2C No
Drying is the subsequent step.
heat
the raw material
treatment

Foreign body
Bristles in bucket can cause PRP. Check during M& I .
P33 Bucket elevetor H1 Foreign body common -bristles P Presence should be GI-31.726 Rare 2C Yes
conveyor illness FB checklist is in place
<2mm
Due to damage of Foreign body
Foreign body common - can cause PRP. Check during M& I .
P33 Bucket elevetor H2
polycarbonate
P polycarbonate Presence should be GI-31.726 Rare
illness
2C No
FB checklist is in place
windows <2mm
Foreign body
Foreign Body common (Teflon Ware & Tare Due to Can cause PRP. Check during M& I .
P33 Bucket elevetor H1 P Due to damage should be GI - 31.715 Unlikely 1C No
guides) moving elevetors illness FB checklist is in place
<2mm

Bacterial survival due to

survival of the pathogenic CP-51.010 & Could occur can cause Continous monitoring of Dryer temperature is in
P34 Drying H6 M contamination of the in-sufficient Absent 3C Yes
bacteria MI- 51.014 (1/6month) illness place.
raw material heat treatment

Foreign body
Due to broken can cause PRP. Check during M & I
P34 Drying H2 Foreign bodies P Presence should be GI-31.726 Rare 2C No
equipment (sieve) illness Cleaning chechlist is in place
<2mm
No past history (Acc to supplier)
Foreign body
Due to broken Can cause Metal detector before filling
P34 Drying H2 Foreign bodies P Presence should be GI-31.726 Unlikely 1C No
equipment (belt) illness PRP. Check during M& I .
<2mm
FB checklist is in place

Factory, Product/Line HACCP study N° WS E - page 11

Nestlé GI-31.202-2 9/27/2011

Justification
Location of potential hazard Hazard description Hazard assessment
Hazard assesment
Indicate the step (e.g. raw material, Describe clearly and specifically the hazards that are "reasonably expected" to occur at each step: Class (M = Microbiological, P = Q1: Based on the hazard description, likelihood of occurrence
logistics or process) at which the Physical, C = Chemical, A = Allergens, N = Nutritional over- or underdosing), agent, size, origin, nature, etc. (before applying the control measure) and severity of health
hazard may be introduced. effects, does this hazard need to be controlled, i.e. is it a Provide supporting data/references
significant hazard?
Significant
H# Hazard Class Origin or source of the Nature of the Acceptable level in end product Likelihood of Severity of hazard?
hazard (e.g. where and hazard (e.g. occurrence adverse health (Yes/No) For non significant hazards, document how it is managed e.g. by
how it can be introduced presence, ability effect For significant a PRP, through a specification or Major Allergen Declaration
M #, L# or into the product or its to grow, survive,
Step (description) hazard, select (MAD).
P# environment) formation of Belt cleaning before start up
and categorize
Due insufficient toxins or toxic CP-51.010 & Can cause control Line sampling after cooler as per Pathogen monitoring
P35 Cooling H4 Pathogenic contamintion M cleaning of cooler Presence
chemicals, Absent Unlikely 1C No on
measure(s)
MI- 51.014 illness plan -2814-FQA-DOC-57.02. Plan prepared as per
belts migration of WS F. reference document - CP -51.010.
chemicals)
Due to damage of Foreign body
can cause There is no vibration there.PCB sheet is more then 4 mm
P37, Belt Conveyor H2 FBC (Polycarbonate ) P polycarbonate Presence should be < GI - 31.715 Rare
illness
2C No
thick.
windows 2mm

Ware & Tare Due to

moving elevetors/Due Foreign body
Foreign Body common (Teflon Can cause PRP. Check during M& I .
P38 Bucket elevetor H1 P to damage of Due to damage should be GI - 31.715 Unlikely 1C No
guides, Polycarbonate) illness Cleaning checklist is in place
polycarbonate <2mm
windows

PRP. IBCs are closed always when they are not in

operation.
Due to improper can cause Outside cleaning of IBC before filling.
P42 IBC storage H4 Bacterial contamination M Presence Absent MI- 51.014 Rare 2C No
cleaning illness Pasta bits IBC filling log sheet
Line sampling of IBC as per Pathogen Monitoring Plan.

Due to damage of Foreign body

Foreign Body common Could occur can cause
P45 Vibro feeder H1
(Polycarbonate )
P polycarbonate Presence should be < GI - 31.715
(1/6month) illness
3C Yes
windows 2mm
Due to damage of Foreign body
Foreign Body common can cause PRP. Check during M& I .
P46 Z - Bucket elevetor H1
(Polycarbonate )
P polycarbonate Presence should be GI - 31.715 Rare
illness
2C No
Cleaning checklist is in place
windows <2mm
Foreign body
Foreign Body common (Teflon Ware & Tare Due to Can cause PRP. Check during M& I .
P46 Z - Bucket elevetor H1 P Due to damage should be GI - 31.715 Unlikely 1C No
guides) moving elevetors illness Cleaning checklist is in place
<2mm
Due to damage of Foreign body
Foreign Body common Could occur can cause
P47 Cross feeder H1
(Polycarbonate )
P polycarbonate Presence should be < GI - 31.715
(1/6month) illness
3C No It is made of poly carbonate and is min 4 mm thick
windows 2mm
Foreign body
Foreign Body common Could occur can cause
P48 Dispersion Feeder H1 P Due to Ware & Tare Presence should be < GI - 31.715 3C Yes
(Bancollan Sheet) (1/6month) illness
2mm
Foreign body
Foreign Body common Could occur can cause
P49 Stopper H1 P Due to Ware & Tare Presence should be < GI - 31.715 3C Yes
(Bancollan Sheet) (1/6month) illness
2mm

P 44 - P Allergens due to product Mix Should not Could occur can cause
Filling H7 A Product Mix up Presence CP 51.013 3C No Change over checkkist is in place
54 up occur (1/6month) illness

Foreign body can lead to

Foreign Body Metal Pieces( Due to malfuctioning
P54 Metal detector H2 P Presence should be < GI-31.726 1/day serious Yes
Fe & Non Fe) of metal detector
2mm illness
Foreign body
Diverting timming Foreign Body Metal Pieces( From machine due to Could occur can cause
P55 H2 P Presence should be < GI-31.726 3C Yes
Hopper Fe & Non Fe), Nuts & Bolts movement (1/6month) illness
2mm
Foreign body
Can cause
P63 Air purging H14 Non food grade oil particles P from compressed air Presence should be GI-31.726 Rare
illness
2C No Refer Compressed Air HACCP study
<2mm
due to moist Can cause
P63 Air purging H4 Micro contamination M
compressed air
Presence Absent MI- 51.014 Rare
illness
2C No Refer Compressed Air HACCP study
Foreign body
TM Dispenser Can cause
P65
Conveyor
HI Foreign Body Lug P Due to Ware & Tare Presence should be GI - 31.715 Rare
illness
2C No Checked every 30 mins and recorded in Log sheet.
<2mm

Factory, Product/Line HACCP study N° WS E - page 12

Nestlé GI-31.202-2 9/27/2011

Justification
Location of potential hazard Hazard description Hazard assessment
Hazard assesment
Indicate the step (e.g. raw material, Describe clearly and specifically the hazards that are "reasonably expected" to occur at each step: Class (M = Microbiological, P = Q1: Based on the hazard description, likelihood of occurrence
logistics or process) at which the Physical, C = Chemical, A = Allergens, N = Nutritional over- or underdosing), agent, size, origin, nature, etc. (before applying the control measure) and severity of health
hazard may be introduced. effects, does this hazard need to be controlled, i.e. is it a Provide supporting data/references
significant hazard?
Significant
H# Hazard Class Origin or source of the Nature of the Acceptable level in end product Likelihood of Severity of hazard?
hazard (e.g. where and hazard (e.g. occurrence adverse health (Yes/No) For non significant hazards, document how it is managed e.g. by
how it can be introduced presence, ability effect For significant a PRP, through a specification or Major Allergen Declaration
M #, L# or into the product or its to grow, survive,
Step (description) hazard, select (MAD).
P# environment) formation of
Foreign body and categorize
Foreign Body Metal Pieces( From machine due to toxins or toxic Could occur can cause control
P66 Filler Pocket H2 P Presence
chemicals, should be < GI-31.726 3C Yes
Fe & Non Fe), Nuts & Bolts movement (1/6month) illness measure(s) on
migration of 2mm WS F.
chemicals)
Foreign body common (Teflon Foreign body
From filler pocket due Could occur can cause
P66 Filler Pocket H1 of Filler pocket), springs, P Presence should be < GI - 31.715 3C Yes
to movement (1/6month) illness
surclips etc 2mm

Foreign Body Visual check by operator during Cut open. Specific color
common( Threads, Foreign body coding crates are in place to handle the rework.
Can cause
M 17 Rework H1 polybags strips,gasket P From Cut open Presence should be GI - 31.715 Rare
illness
2C No Rework bags are sent for milling. Rework again will be
chips, wooden splints, glass <2mm passed through sieves & MD before being filled as
& Cleaning tool bristles) finished product.

Foreign body
Can cause
P67 Clips for laminate H1 Clip (metal / plastic) P Due to Ware & Tare Presence should be GI - 31.715 Rare
illness
2C No Checked every 30 mins and recorded in Log sheet.
<2mm

Factory, Product/Line HACCP study N° WS E - page 13