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 PLAN EXAMPLES
FOODIE FRED
123 Example Street
Food City, IL 60618

Preventive Controls Plan

Nuts - Pressed Energy Bar
March 22, 2021

FOODIE FRED

Plan Information
Process Flow Diagram
Procedures
Hazard Analysis Worksheet
PC Plan Summary
Ingredients
Equipment
SOPs
 General Plan Information
Plan Name: Nuts - Pressed Energy Bar
Description: This product is a ready to eat energy bar packed in a pouch for on-the-go eating. The low water activity makes the product
shelf stable. Processing involves dry mixing and forming with no process lethality step. Water activity ≤0.65 Ingredients: Corn
syrup, blanched/slivered almonds, crisped rice, dried cranberries, canola oil, pan release agent (soy lecithin), vitamin and
mineral pre-blend.
Intended Use: Ready-to-eat bars
Intended End Users: General consumption
Packaging Type: Metalized polyethylene film, individual retail package with label
Sold At:
Sold As:
Spl Distribution Controls: Ambient, not to exceed 90°F
Spl Handling Controls: None
Labeling Instructions: None
Storage Conditions: Ambient, not to exceed 90°F
Package Fill Data:
Processing Description:

Product Properties & Characteristics

Water Activity pH Level Viscosity Shelf life Density

</= 0.65 One year

Safety Team
Name Position Type of Training # Training Docs Preventive Control Qualified?

John Doe Floor Supervisor 0

Jane Doe Plant Manager 0

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123 Example Street Food City, IL 60618
 Process Flow Diagram

Receive ingredients Receive Ingredients Crisp

Hazard Control Receive Ingredients dried Hazard Control
Almonds Hazard Control Rice
cranberries
PC PC

Receive Ingredients Pan

Hazard Store ingredients Receive Ingredients Corn Hazard Control
release agent.
syrup, Canola oil.

Hazard Measure ingredients Control

PC

Hazard Mix and Warm Syrup Control

PC

Hazard Cool Syrup (120 to 130ºF) Control Hazard Mix Dry Ingredients Control
PC PC

Spray Pans [pan release Hazard Blend Ingredients Control

Hazard Control
spray] PC
PC

Hazard Form/Press Control

PC

Hazard Setting Control

PC

Hazard Cutting Control Hazard Receiving Packaging Control

PC PC

Hazard Metal Detection Control Hazard Rework Control

Storing Packaging
PC PC

Hazard Wrap, Case Control

PC

Store, Ship

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123 Example Street Food City, IL 60618
 Procedures: Nuts - Pressed Energy Bar

Receive ingredients Almonds:

Corn syrup – Received in 5 gallon plastic containers Canola oil – Received in 5 gallon plastic containers Almonds, blanched and slivered – Received in 20 lb. bags.
Specifications require blanching after shelling and sorting for defects and mold. Prior to blanching, shelled almonds are treated with propylene oxide (PPO) to
achieve the minimum 4-log reduction of Salmonella required for California almonds in North America. Screening and testing for aflatoxin is also conducted.
Quarterly, Certificates of Analysis (COA) for Salmonella, Enterobacteriaceae and aflatoxin conformance to specifications accompany shipments. Crisped rice –
Received in 22 lb. bag-in-box. Ingredients include rice flour, corn flour, sugar and salt. Dried cranberries – Received in 25 lb. cases. Ingredients include cranberries,
sugar and sunflower oil. Packaged in the same facility as peanuts, tree nuts, soy, and milk products. Vitamin/ mineral pre-blend – Vitamins (A, B-mix, C, E) and
minerals (Ca, Mg, K, Zn) received in 1 lb. plastic sealed bags, with 10 bags in a box. Certificates of analysis accompany each shipment, confirming levels of vitamins
and minerals. Pan release agent – contains soy lecithin – received in spray cans

Receiving Packaging:
Corrugated shippers and pre-printed metalized film are received in bulk at the factory. Specifications require food grade material for metalized film. Suppliers
provide a Certificate of Conformance that packaging materials and inks meet food safety and regulatory requirements. Appropriate allergen label information is
included in the specification and reviews are conducted for each receipt, including listing almonds and soy lecithin on the ingredient statement, followed by
“Contains Almond, Soy” and “May Contain” peanuts, tree nuts and milk on the precautionary statement.

Spray Pans [pan release spray]:

Pans that have been cleaned and dried are sprayed by hand with a processing aid containing soy lecithin.

Receive Ingredients dried cranberries:

Receive Ingredients Crisp Rice:

Receive Ingredients Corn syrup, Canola oil.:

Receive Ingredients Pan release agent.:

Storing Packaging:
Cartons and trays are stored in the dry storage room adjacent to the packaging area. Unused trays are covered during storage between uses. Plastic wrap is stored
in sealed containers to protect from contamination. Packaging is used First-In-First-Out.

Store ingredients:
All ingredients are stored in the dry storage room (temperature kept below 75°F) in the ingredient area, arranged by ingredient code number. All containers are
sealed to avoid cross-contact and cross-contamination during storage. Ingredients that contain allergens are labelled and stored in specific locations with like
allergenic ingredients.

Measure ingredients:
Ingredients are measured and staged in a dedicated room. The hygiene level of the room is consistent with the requirements of exposed product manufacturing
areas. Allergenic materials are weighed on dedicated equipment into dedicated containers using color coded tools dedicated to the allergen. Employees change
smocks and gloves before and after handling an allergenic material.

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123 Example Street Food City, IL 60618
 Mix Dry Ingredients:
Dry ingredients: almonds, crisped rice, dried cranberries, vitamin/mineral pre blend Almonds, crisped rice, dried cranberries, and the vitamin/mineral pre-blend are
added to a mixer and blended for 30 minutes to ensure even distribution.

Mix and Warm Syrup:

Corn syrup and canola oil are added to a jacketed mixer and warmed to 195 to 205°F and blended for 20 minutes to ensure even distribution. Warming facilitates
more uniform blending and is not intended to be a kill step in these low water activity ingredients.

Cool Syrup (120 to 130ºF):

The syrup is cooled to 120-130°F and held in the mixer until needed.

Blend Ingredients:
Mixed dry ingredients are gradually added to the syrup mixer. Rework is added at this step.

Form/Press:
The blended mass is dispensed onto pans. The mixture is formed and pressed with rollers to ensure consistent spreading and density.

Setting:
Pans are moved to setting area where they are cooled to ambient temperature around 70°F.

Cutting:
Sheets are cut mechanically in two successive cutting operations, vertically and horizontally (rotary blade, reciprocal blade).

Metal Detection:
Cut bars are passed through a calibrated metal detector on the conveyor. Bars that are kicked off during this operation are passed through a more sensitive metal
detector. Rejected bars are inspected and sent to waste. The performance of the metal detector is verified once an hour using metal detectable wands containing 1.5
mm ferrous and 2.0 mm stainless steel.

Rework:
Rework may be generated from the mixing operation, blending operation or after cutting of sheets. Rework is collected in clean and dry containers, which are
labelled with the product name, relevant allergens, and date rework was generated. Allowable rework use is calculated based upon the composition of the rework.
Rework is used according to a rework/allergen matrix to ensure that no undeclared allergens are introduced into products. Potential rework material is discarded
approximately monthly to break the rework “chain,” which simplifies traceability.

Wrap, Case:
The identity of wrapping material is confirmed for each batch placed on the line to ensure that it is the correct material and contains relevant allergen declaration
information. Trays containing cut bars are flipped onto wrappers and bars are individually heat sealed and cut. Lot information is printed onto each sealed package.
Bars are transferred by hand into cases, with 24 bars/case. Product and lot information is printed on each case. Cases are transferred by hand to pallets, which are
sealed in plastic.

Store, Ship:
Pallets are transferred by fork lift to the warehouse where they are stored under ambient condition at < 70% RH until shipping.

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123 Example Street Food City, IL 60618
 Hazard Analysis Worksheet
Process Step / PC Identify potential Is this hazard Justify your decision What preventive Is this step a
hazards introduced, significant? for column 3 measures can be Preventive Control?
controlled or enhanced (Yes / No) applied to prevent (Yes / No)
at this step (1) the significant
(B) Biological hazards?
(C) Chemical

(P) Physical

(A) Allergen

Receive ingredients B - Salmonella spp. Yes Untreated almonds have a Type: Supplier Yes PC #1
Almonds history of Salmonella
Measures: Approved
issues
supplier 3rd party audit
and quarterly testing by
supplier

C - Aflatoxin Yes Almonds have a history of Type: Supplier

potential contamination
Measures: Quarterly
with aflatoxin
testing by supplier

A - Undeclared allergens: No Almonds are tree nuts Type: Prerequisite

Undeclared allergens - that are a recognized food Program (SOP)
Incorrect label, allergen
SOPs: Prevent Allergen
Undeclared allergens -
Cross Contamination,
cross-contact
Verification of Allergen
labelling

Measures: Allergen
control – Label review and
allergen cross contact
prevention

P - Foreign Material No Pieces are removed at

supplier during sorting,
including optical sorter.

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123 Example Street Food City, IL 60618
 Consumer complaint data
do not indicate an issue

Receiving Packaging A - Undeclared allergens - Yes Printing errors have Type: Allergen Yes PC #2
Incorrect label occurred and a correct
Measures: Allergen
allergen statement is
control – Verify allergen
essential for safety.
labeling
Packaging line operators
check the label number
but not necessarily the
allergen information.

B - None

C - None

P - None

Spray Pans [pan release B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #3
spray] possible if environment
Measures: Sanitation
and employee practices
control – Zoning,
not managed at
maintaining dry
appropriate hygiene level.
environment

A - Undeclared allergens - Yes Materials containing Type: Allergen

cross-contact allergens other than those
Measures: Proper
on the label are handled in
cleaning between
the same environment.
allergens. Use of
dedicated tools, run order
of allergenic materials

C - None

P - None

Receive Ingredients dried B - Salmonella spp. No Process to manufacture No

cranberries cranberries has sufficient
lethality. If present,

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123 Example Street Food City, IL 60618
 Salmonella levels will
decrease during storage

A - Undeclared allergens - Yes Cranberries are not a food Type: Prerequisite

Incorrect label allergen, but ingredient
has precautionary labeling
for other food allergens
handled at supplier facility
Program (SOP)
SOPs: Verification of
Allergen labelling
Measures: Allergen
control – Subsequent
allergen labeling

C - None

P - None

Receive Ingredients Crisp B - Salmonella spp. Yes A few cereal outbreaks Type: Supplier Yes PC #4
Rice have occurred, but not
Measures: Approved
with this specific type of
supplier 3rd party audit
process. Warrants
supplier program at a
reduced level of concern.

C - None

P - None

Receive Ingredients Corn B - None No

syrup, Canola oil.
C - None

P - None

Receive Ingredients Pan A - Undeclared allergens - No Soy is a recognized food Type: Prerequisite No
release agent. Incorrect label allergen. All products use Program (SOP)
this processing aid, so
SOPs: Verification of
cross contact is not
Allergen labelling
relevant.

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123 Example Street Food City, IL 60618
 Measures: Allergen
control – Subsequent
allergen labeling

B - None

C - None

P - None

Storing Packaging B - None No

C - None

P - None

Store ingredients A - Undeclared allergens - No Ingredients with allergens No

cross-contact are stored in the
warehouse in segregated
areas and in sealed
containers, easily
managed by general
controls.

B - None

C - None

P - None

Measure ingredients B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #5
possible if measuring
Measures: Sanitation
environment not
controls Zoning, dry
managed at appropriate
environment
hygiene level.

C - None

P - None

Mix Dry Ingredients B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #6
possible if environment

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123 Example Street Food City, IL 60618
 and employee practices Measures: Sanitation
not managed at controls – Zoning ,
appropriate hygiene level. maintaining dry
environment

A - Undeclared allergens - Yes Materials containing Type: Allergen

cross-contact allergens other than those
Measures: Allergen
on the label are handled in
controls – Proper cleaning
the same environment.
between allergens. Use of
dedicated tools, run order
of allergenic materials

P - Metal Yes Metal on metal contact Type: Prerequisite

occurs in equipment Program (SOP)

SOPs: Metal Detection

Measures: Subsequent
metal detection

C - None

Mix and Warm Syrup B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #7
possible if environment
Measures: Sanitation
and employee practices
control Zoning,
not managed at
maintaining dry
appropriate hygiene level.
environment

C - None

P - None

Cool Syrup (120 to 130ºF) B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #8
possible if environment
Measures: Sanitation
and employee practices
control Zoning,
not managed at
maintaining dry
appropriate hygiene level.
environment

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123 Example Street Food City, IL 60618
 C - None

P - None

Blend Ingredients B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #9
possible if environment
Measures: Sanitation
and employee practices
control Zoning,
not managed at
maintaining dry
appropriate hygiene level.
environment

A - Undeclared allergens - Yes Materials containing Type: Allergen

cross-contact allergens other than those
Measures: Allergen
on the label are handled in
controls – Proper cleaning
the same environment.
between allergens. Use of
dedicated tools, run order
of allergenic materials

P - Metal Yes Poorly maintained or Type: Other

improperly operated
Measures: Other control
mixer could generate
– Preventive maintenance
foreign bodies. Preventive
maintenance reduces
occurrence

C - None

Form/Press B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #10
possible if environment
Measures: Zoning,
and employee practices
maintaining a dry
not managed
environment

P - Metal No Poorly maintained or Type: Other

improperly use pressing
Measures: Subsequent
equipment could generate
metal detection
metal fragments.
Preventive maintenance
reduces occurrence

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123 Example Street Food City, IL 60618
 C - None

Setting B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #11
possible if environment
Measures: Zoning,
and employee practices
maintaining a dry
not managed at
environment
appropriate hygiene level.

A - Undeclared allergens - Yes Materials containing Type: Allergen

cross-contact allergens other than those
Measures: Proper
on the label are handled in
cleaning between
the same environment.
allergens. Use of
dedicated tools, run order
of allergenic materials

C - None

P - None

Cutting B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #12
possible if environment
Measures: Zoning,
and employee practices
maintaining a dry
not managed
environment

A - Undeclared allergens - Yes Materials containing Type: Allergen

cross-contact allergens other than those
Measures: Proper
on the label are handled in
cleaning between
the same environment.
allergens. Use of
dedicated tools, run order
of allergenic materials

P - Metal No Poorly maintained or Type: Other

improperly used cutting
Measures: Subsequent
equipment could generate
metal detection
metal fragments.

C - None

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123 Example Street Food City, IL 60618
 Metal Detection P - Metal Yes Metal may be present Type: Process Yes PC #13
from previous operations
Measures: Metal detector

B - None

C - None

Rework B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #14
possible if processing
Measures: Zoning,
environment and
maintaining dry
employee practices not
environment and
managed at appropriate
equipment, proper drying
hygiene level.
after allergen changeover

A - Undeclared allergens - Yes Materials containing Type: Allergen

cross-contact allergens other than those
Measures: Use of
on the label are handled in
dedicated storage
the same environment.
containers, rework use
matrix run order of
allergenic materials,
proper cleaning of tools
and equipment between
allergens, GMP

C - None

P - None

Wrap, Case B - Salmonella spp. Yes Cross contamination Type: Sanitation Yes PC #15
possible if processing
Measures: Zoning,
environment and
maintaining dry
employee practices not
environment and
managed at appropriate
equipment, proper drying
hygiene level.
after allergen changeover

A - Undeclared allergens - Yes The product contains Type: Allergen

Incorrect label almonds and soy which

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123 Example Street Food City, IL 60618
 are food allergens. The Measures: Verification
wrapper has the labeling appropriate label used

C - None

P - None

Store, Ship B - None No

C - None

P - None

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123 Example Street Food City, IL 60618
 PC Plan Summary
Preventive Significant Hazards Critical Monitor Corrective Actions Verification Records
Control Limits What How Frequency Who

PC #1: B - Salmonella spp. Propylene Incoming For each Every batch Technician, A copy of a See
Propylene oxide
Receive oxide goods/ingre shipment QA 3rd party appendix:
treatment required for
ingredients treatment dients received, Manager audit is Batch
California almonds in
Almonds required for the requested Records
North America achieves a
California incoming from the Log,
minimum 4-log reduction
almonds in goods supplier Corrective
of Salmonella
North technician annually. Action Log,
America verifies that The audit Raw
achieves a the material date, Material
minimum 4- is from the auditor and
log approved qualification Receiving
reduction of supplier s, audit
Salmonella location procedures
using the and audit
Bill of results are
Lading, reviewed by
documents our Quality
the check in Assurance
the Manager.
incoming Follow up
goods log with the
and files the supplier
Bill of takes place,
Lading. as
necessary,
to verify
that any
corrective
actions
mentioned
in the
report have
been
completed,

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 with
records
maintained
for this
activity.
Salmonella
not
detected in
5 u 25g
samples per
lot

C - Aflatoxin Sorting to Incoming 3rd party Every batch Technician/ A copy of a See
For each shipment
remove goods/ingre audit of QA 3rd party appendix:
received, the incoming
moldy nuts dients approved Manager audit is Batch
goods technician verifies
that may supplier requested Records
that the material is from
contain and from the Log,
the approved supplier
aflatoxin quarterly supplier Corrective
location using the Bill of
certificates annually. Action Log,
Lading, documents the
of analysis The audit Raw
check in the incoming
(COA) date, Material
goods log and files the Bill
auditor and
of Lading.
qualification Receiving
s, audit
procedures
and audit
results are
reviewed by
our Quality
Assurance
Manager.
Follow up
with the
supplier
takes place,
as
necessary,
to verify

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 that any
corrective
actions
mentioned
in the
report have
been
completed,
with
records
maintained
for this
activity.

PC #2: A - Undeclared allergens - Product Ingredient Visual exam Each receipt Label QA See
If label is incorrect, reject
Receiving Incorrect label label listing and of wrapper before specialist manager or appendix:
labels and return to
Packaging declares allergen label to release to designee Allergen
supplier or destroy.
allergens declaration match production reviews and Label Check
Identify root cause and
present in matches product initials Record Log,
conduct training as
the formula product formula per records Corrective
needed or discuss with
and has SOP 14 264 within 7 Action Log
supplier how to prevent
precautiona working
recurrence
ry labeling days and
from results with
ingredients past results
to identify
any trends

PC #3: B - Salmonella spp. The Production Environmen Weekly Sanitation A See

Rework is covered and
Spray Pans ingredient area tal manager Salmonella appendix:
stored in a room adjacent
[pan release measureme monitoring environmen Corrective
to the processing area,
spray] nt room tal Action Log,
and maintained at the
and monitoring Equipment
same hygiene level as the
processing program is Cleaning
processing area (See SOP
areas are in place to Log,
15-789 – Rework
maintained verify that Monthly
Procedures).
at a higher controls are
hygiene sufficient to

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 level than prevent the Sanitation
receiving, presence Control
storage, and Record
and harborage
shipping of
areas, as Salmonella
specified in in the
SOP 15-123 environmen
– High t and
Hygiene equipment.
Sanitation The
Procedures. program
As specified includes an
in SOP 15- evaluation
456 – of
Employee Enterobacte
Hygiene in riaceae
High levels as
Hygiene additional
Areas, verification
employees that
must put on conditions
smocks that do not exist
do not have that could
pockets, lead to the
change into presence
factory and
shoes, put harborage
on of
protective Salmonella.
equipment Enterobacte
(hair net, riaceae
beard net), environmen
and wash tal
their hands monitoring
before occurs
entering weekly and
ingredient Salmonella
measureme

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 nt and monitoring
production occurs
areas. monthly.

A - Undeclared allergens - No residual Application Procedures After Sanitation Hygiene See

Reclean line
cross-contact allergenic of effective as outlined products Manager audit; ATP appendix:
material cleaning; in Allergen containing swabs Allergen
from visual Change allergenic Label Check
previous inspection Over materials Record Log,
production prior to Procedures not in this Corrective
start up – SOP 14 recipe are Action Log,
456 handled on Equipment
the line Cleaning
Log

PC #4: B - Salmonella spp. The crisping Incoming 3rd party Every batch QA A copy of a See
For each shipment
Receive process ingredients audit of Manager 3rd party appendix:
received, the incoming
Ingredients provides approved audit is Batch
goods technician verifies
Crisp Rice sufficient supplier requested Records
that the material is from
heat to kill from the Log,
the approved supplier
Salmonella. supplier Corrective
location using the Bill of
Zoning and annually. Action Log,
Lading, documents the
dry cleaning The audit Raw
check in the incoming
used to date, Material
goods log and files the Bill
prevent auditor and
of Lading.
recontamin qualification Receiving
ation. s, audit
procedures
and audit
results are
reviewed by
our Quality
Assurance
Manager.
Follow up
with the
supplier
takes place,

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 as
necessary,
to verify
that any
corrective
actions
mentioned
in the
report have
been
completed,
with
records
maintained
for this
activity.

PC #5: B - Salmonella spp. The Storage Environmen Every QA A See

As specified in SOP 15-456
Measure warehouse room/ tal Month supervisor Salmonella appendix:
– Employee Hygiene in
ingredients and loading Ingredient monitoring environmen Allergen
High Hygiene Areas,
areas are measureme tal Label Check
employees must put on
dry cleaned. nt room monitoring Record Log,
smocks that do not have
Ingredient program is Corrective
pockets, change into
measureme in place to Action Log,
factory shoes, put on
nt room, verify that Monthly
protective equipment
production controls are Sanitation
(hair net, beard net), and
areas, and sufficient to Control
wash their hands before
rework prevent the Record
entering ingredient
storage presence
measurement and
rooms are and
production areas. Rework
maintained harborage
is covered and stored in a
dry during of
room adjacent to the
production. Salmonella
processing area, and
Lines and in the
maintained at the same
equipment environmen
hygiene level as the
are wet t and
processing area (See SOP
cleaned and equipment.
15-789 – Rework
sanitized The
Procedures).

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 when program
changing includes an
over from a evaluation
product of
containing a Enterobacte
different riaceae
allergen. levels as
Equipment additional
is verification
completely that
dried prior conditions
to do not exist
production. that could
See these lead to the
Standard presence
Operating and
Procedures harborage
for details: of
SOP 16-454 Salmonella.
– Dry Enterobacte
Cleaning riaceae
environmen
tal
monitoring
occurs
weekly and
Salmonella
monitoring
occurs
monthly.
SOP 15-282:
Environmen
tal
Monitoring
Verification
Procedures

PC #6: Mix B - Salmonella spp. The Production Environmen Every QA A See

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123 Example Street Food City, IL 60618
 Dry warehouse area tal Batch/ Supervisor The ingredient Salmonella appendix:
Ingredients and loading monitoring Monthly measurement room and environmen Batch
areas are processing areas are tal Records
dry cleaned. maintained at a higher monitoring Log,
Ingredient hygiene level than program is Corrective
measureme receiving, storage, and in place to Action Log,
nt room, shipping areas, as verify that Equipment
production specified in SOP 15-123 – controls are Cleaning
areas and High Hygiene Sanitation sufficient to Log,
rework Procedures. As specified prevent the Monthly
storage in SOP 15-456 – Employee presence Sanitation
rooms are Hygiene in High Hygiene and Control
maintained Areas, employees must harborage Record
dry during put on smocks that do not of
production. have pockets, change into Salmonella
Lines and factory shoes, put on in the
equipment protective equipment environmen
are wet (hair net, beard net), and t and
cleaned and wash their hands before equipment.
sanitized entering ingredient The
when measurement and program
changing production areas. Rework includes an
over from a is covered and stored in a evaluation
product room adjacent to the of
containing a processing area, and Enterobacte
different maintained at the same riaceae
allergen. hygiene level as the levels as
Equipment processing area (See SOP additional
is 15-789 – Rework verification
completely Procedures). that
dried prior conditions
to do not exist
production. that could
See these lead to the
Standard presence
Operating and
Procedures harborage
for details: of
Salmonella.

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 SOP 16-454 Enterobacte
– Dry riaceae
Cleaning environmen
tal
monitoring
occurs
weekly and
Salmonella
monitoring
occurs
monthly.
SOP 15-282:
Environmen
tal
Monitoring
Verification
Procedures

A - Undeclared allergens - No residual Application Procedures After Sanitation Hygiene See

Reclean line
cross-contact allergenic of effective as outlined products Manager audit; ATP appendix:
material cleaning; in Allergen containing swabs Corrective
from the visual an Change allergenic Action Log,
previous inspection Over materials Equipment
production prior to Procedures not in this Cleaning
start up – SOP 14 recipe are Log,
456 handled on Monthly
the line Sanitation
Control
Record

PC #7: Mix B - Salmonella spp. Zoning and Processing Environmen Every batch QA A See
The warehouse and
and Warm Related area tal Supervisor Salmonella appendix:
loading areas are dry
Syrup GMP monitoring environmen Batch
cleaned. Ingredient
Controls. tal Records
measurement room,
The monitoring Log,
production areas, and
ingredient program is Corrective
rework storage rooms are
measureme in place to Action Log,
maintained dry during
nt room verify that Equipment
production. Lines and

PLAN EXAMPLES
03/22/2021 Page: 22
123 Example Street Food City, IL 60618
 and equipment are wet controls are Cleaning
processing cleaned and sanitized sufficient to Log,
areas are when changing over from prevent the Monthly
maintained a product containing a presence Sanitation
at a higher different allergen. and Control
hygiene Equipment is completely harborage Record
level than dried prior to production. of
receiving, See these Standard Salmonella
storage, Operating Procedures for in the
and details: SOP 16-455 – environmen
shipping Controlled Wet Cleaning t and
areas, as equipment.
specified in The
SOP 15-123 program
– High includes an
Hygiene evaluation
Sanitation of
Procedures. Enterobacte
As specified riaceae
in SOP 15- levels as
456 – additional
Employee verification
Hygiene in that
High conditions
Hygiene do not exist
Areas, that could
employees lead to the
must put on presence
smocks that and
do not have harborage
pockets, of
change into Salmonella.
factory Enterobacte
shoes, put riaceae
on environmen
protective tal
equipment monitoring
(hair net, occurs
beard net), weekly and

PLAN EXAMPLES
03/22/2021 Page: 23
123 Example Street Food City, IL 60618
 and wash Salmonella
their hands monitoring
before occurs
entering monthly.
ingredient SOP 15-282:
measureme Environmen
nt and tal
production Monitoring
areas. Verification
Rework is Procedures,
covered and SOP 15-283
stored in a Environmen
room tal
adjacent to Monitoring
the for Special
processing Circumstan
area, and ces
maintained
at the same
hygiene
level as the
processing
area (See
SOP 15-789
– Rework
Procedures)
.

PC #8: Cool B - Salmonella spp. The Production Environmen Every QA A See

The warehouse and
Syrup (120 ingredient area tal Month Supervisor Salmonella appendix:
loading areas are dry
to 130ºF) measureme monitoring environmen Batch
cleaned. Ingredient
nt room tal Records
measurement room,
and monitoring Log,
production areas, and
processing program is Corrective
rework storage rooms are
areas are in place to Action Log,
maintained dry during
maintained verify that Monthly
production. Lines and
at a higher controls are
equipment are wet
hygiene sufficient to
cleaned and sanitized

PLAN EXAMPLES
03/22/2021 Page: 24
123 Example Street Food City, IL 60618
 level than when changing over from prevent the Sanitation
receiving, a product containing a presence Control
storage, different allergen. and Record
and Equipment is completely harborage
shipping dried prior to production. of
areas, as See these Standard Salmonella
specified in Operating Procedures for in the
SOP 15-123 details:  SOP 16-454 – Dry environmen
– High Cleaning t and
Hygiene equipment.
Sanitation The
Procedures. program
As specified includes an
in SOP 15- evaluation
456 – of
Employee Enterobacte
Hygiene in riaceae
High levels as
Hygiene additional
Areas, verification
employees that
must put on conditions
smocks that do not exist
do not have that could
pockets, lead to the
change into presence
factory and
shoes, put harborage
on of
protective Salmonella.
equipment Enterobacte
(hair net, riaceae
beard net), environmen
and wash tal
their hands monitoring
before occurs
entering weekly and
ingredient Salmonella
measureme monitoring

PLAN EXAMPLES
03/22/2021 Page: 25
123 Example Street Food City, IL 60618
 nt and occurs
production monthly.
areas. SOP 15-282:
Rework is Environmen
covered and tal
stored in a Monitoring
room Verification
adjacent to Procedures
the
processing
area, and
maintained
at the same
hygiene
level as the
processing
area (See
SOP 15-789
– Rework
Procedures)
.

PC #9: B - Salmonella spp. The Equipment Environmen Every shift Sanitation A See
Rework is covered and
Blend ingredient before and tal Manager Salmonella appendix:
stored in a room adjacent
Ingredients measureme after monitoring environmen Corrective
to the processing area,
nt room production tal Action Log,
and maintained at the
and monitoring Equipment
same hygiene level as the
processing program is Cleaning
processing area (See SOP
areas are in place to Log,
15-789 – Rework
maintained verify that Monthly
Procedures).
at a higher controls are Sanitation
hygiene sufficient to Control
level than prevent the Record
receiving, presence
storage, and
and harborage
shipping of
areas, as Salmonella

PLAN EXAMPLES
03/22/2021 Page: 26
123 Example Street Food City, IL 60618
 specified in in the
SOP 15-123 environmen
– High t and
Hygiene equipment.
Sanitation The
Procedures. program
includes an
evaluation
of
Enterobacte
riaceae
levels as
additional
verification
that
conditions
do not exist
that could
lead to the
presence
and
harborage
of
Salmonella.
Enterobacte
riaceae
environmen
tal
monitoring
occurs
weekly and
Salmonella
monitoring
occurs
monthly.

A - Undeclared allergens - No residual Application Procedures After Sanitation Hygiene See

Reclean line
cross-contact allergenic of effective as outlined products manager audit; ATP appendix:

PLAN EXAMPLES
03/22/2021 Page: 27
123 Example Street Food City, IL 60618
 material cleaning; in Allergen containing swabs Corrective
from the visual Change allergenic Action Log,
previous inspection Over materials Equipment
production prior to Procedures not in this Cleaning
start up – SOP 14 recipe are Log,
456 handled on Monthly
the line Sanitation
Control
Record

PC #10: B - Salmonella spp. The Processing Environmen Lines and Sanitation A See
Rework is covered and
Form/Press ingredient areas tal equipment manager Salmonella appendix:
stored in a room adjacent
measureme monitoring are wet environmen Corrective
to the processing area,
nt room cleaned and tal Action Log,
and maintained at the
and sanitized monitoring Monthly
same hygiene level as the
processing when program is Sanitation
processing area (See SOP
areas are changing in place to Control
15-789 – Rework
maintained over from a verify that Record
Procedures).
at a higher product controls are
hygiene containing a sufficient to
level than different prevent the
receiving, allergen. presence
storage, Equipment and
and is harborage
shipping completely of
areas, as dried prior Salmonella
specified in to in the
SOP 15-123 production. environmen
– High t and
Hygiene equipment.
Sanitation The
Procedures. program
includes an
evaluation
of
Enterobacte
riaceae
levels as

PLAN EXAMPLES
03/22/2021 Page: 28
123 Example Street Food City, IL 60618
 additional
verification
that
conditions
do not exist
that could
lead to the
presence
and
harborage
of
Salmonella.
Enterobacte
riaceae
environmen
tal
monitoring
occurs
weekly and
Salmonella
monitoring
occurs
monthly.

PC #11: B - Salmonella spp. The Production Environmen Lines and Sanitation A See
Rework is covered and
Setting ingredient area tal equipment Manager Salmonella appendix:
stored in a room adjacent
measureme Monitoring are wet environmen Corrective
to the processing area,
nt room cleaned and tal Action Log,
and maintained at the
and sanitized monitoring Monthly
same hygiene level as the
processing when program is Sanitation
processing area (See SOP
areas are changing in place to Control
15-789 – Rework
maintained over from a verify that Record
Procedures).
at a higher product controls are
hygiene containing a sufficient to
level than different prevent the
receiving, allergen. presence
storage, Equipment and
and is harborage

PLAN EXAMPLES
03/22/2021 Page: 29
123 Example Street Food City, IL 60618
 shipping completely of
areas, as dried prior Salmonella
specified in to in the
SOP 15-123 production. environmen
– High t and
Hygiene equipment.
Sanitation The
Procedures. program
As specified includes an
in SOP 15- evaluation
456 – of
Employee Enterobacte
Hygiene in riaceae
High levels as
Hygiene additional
Areas, verification
employees that
must put on conditions
smocks that do not exist
do not have that could
pockets, lead to the
change into presence
factory and
shoes, put harborage
on of
protective Salmonella.
equipment Enterobacte
(hair net, riaceae
beard net), environmen
and wash tal
their hands monitoring
before occurs
entering weekly and
ingredient Salmonella
measureme monitoring
nt and occurs
production monthly.
areas.

PLAN EXAMPLES
03/22/2021 Page: 30
123 Example Street Food City, IL 60618
 A - Undeclared allergens - No residual No residual Procedures After Sanitation Hygiene See
Reclean line
cross-contact allergenic allergenic as outlined products manager audit; ATP appendix:
material material in Allergen containing swabs Corrective
from the from the Change allergenic Action Log,
previous previous Over materials Monthly
production production Procedures not in this Sanitation
– SOP 14 recipe are Control
456 handled on Record
the line

PC #12: B - Salmonella spp. The Production Environmen measureme Sanitation A See

Rework is covered and
Cutting ingredient area tal nt room, Manager Salmonella appendix:
stored in a room adjacent
measureme Monitoring production environmen Corrective
to the processing area,
nt room areas and tal Action Log,
and maintained at the
and rework monitoring Monthly
same hygiene level as the
processing storage program is Sanitation
processing area (See SOP
areas are rooms are in place to Control
15-789 – Rework
maintained maintained verify that Record
Procedures).
at a higher dry during controls are
hygiene production. sufficient to
level than Lines and prevent the
receiving, equipment presence
storage, are wet and
and cleaned and harborage
shipping sanitized of
areas, as when Salmonella
specified in changing in the
SOP 15-123 over from a environmen
– High product t and
Hygiene containing a equipment.
Sanitation different The
Procedures. allergen. program
As specified Equipment includes an
in SOP 15- is evaluation
456 – completely of
Employee dried prior Enterobacte
Hygiene in to riaceae
High production. levels as

PLAN EXAMPLES
03/22/2021 Page: 31
123 Example Street Food City, IL 60618
 Hygiene additional
Areas, verification
employees that
must put on conditions
smocks that do not exist
do not have that could
pockets, lead to the
change into presence
factory and
shoes, put harborage
on of
protective Salmonella.
equipment Enterobacte
(hair net, riaceae
beard net), environmen
and wash tal
their hands monitoring
before occurs
entering weekly and
ingredient Salmonella
measureme monitoring
nt and occurs
production monthly.
areas.

A - Undeclared allergens - No residual Application Procedures After Sanitation Hygiene See

Reclean line
cross-contact allergenic of effective as outlined products manager audit; ATP appendix:
material cleaning; in Allergen containing swabs Corrective
from the visual Change allergenic Action Log,
previous inspection Over materials Monthly
production prior to Procedures not in this Sanitation
start up – SOP 14 recipe are Control
456 handled on Record
the line

PC #13: P - Metal No metal All the Visual Beginning, Trained Review See
Correct operating procedures to
Metal fragment products Examinatio Middle and production metal appendix:
ensure that the product is not
Detection that would pass n that the End of Shift employee detector Metal
processed without metal

PLAN EXAMPLES
03/22/2021 Page: 32
123 Example Street Food City, IL 60618
 cause injury through a detector is or when detection. If metal is found in the logs and Detection
or choking metal working. product is product, segregate the product, corrective Log
are in the detector. Examine the rejected. inspect the lot and identify the action logs
product Kick out product source of the metal found and fix within 7
passing products that is the damaged equipment. working
through the that have rejected by days.
metal the the
detector presence of detector.
metal
fragments

PC #14: B - Salmonella spp. The Production Environmen Lines and Sanitation A See
Rework is covered and
Rework ingredient area tal equipment manager Salmonella appendix:
stored in a room adjacent
measureme monitoring are wet environmen Corrective
to the processing area,
nt room cleaned and tal Action Log,
and maintained at the
and sanitized monitoring Monthly
same hygiene level as the
processing when program is Sanitation
processing area (See SOP
areas are changing in place to Control
15-789 – Rework
maintained over from a verify that Record
Procedures).
at a higher product controls are
hygiene containing a sufficient to
level than different prevent the
receiving, allergen. presence
storage, Equipment and
and is harborage
shipping completely of
areas, as dried prior Salmonella
specified in to in the
SOP 15-123 production. environmen
– High t and
Hygiene equipment.
Sanitation The
Procedures. program
As specified includes an
in SOP 15- evaluation
456 – of
Employee Enterobacte
Hygiene in riaceae

PLAN EXAMPLES
03/22/2021 Page: 33
123 Example Street Food City, IL 60618
 High levels as
Hygiene additional
Areas, verification
employees that
must put on conditions
smocks that do not exist
do not have that could
pockets, lead to the
change into presence
factory and
shoes, put harborage
on of
protective Salmonella.
equipment Enterobacte
(hair net, riaceae
beard net), environmen
and wash tal
their hands monitoring
before occurs
entering weekly and
ingredient Salmonella
measureme monitoring
nt and occurs
production monthly.
areas.

A - Undeclared allergens - No residual Application Procedures After Sanitation Hygiene See

Reclean line
cross-contact allergenic of effective as outlined products Manager audit; ATP appendix:
material cleaning; in Allergen containing swabs Corrective
from the visual Change allergenic Action Log,
previous inspection over materials Monthly
production prior to Procedures not in this Sanitation
start up – SOP 14 recipe are Control
456 handled on Record
the line

PC #15: B - Salmonella spp. The Production Environmen End of the Trained A See
Wrap, Case ingredient area tal shift production Salmonella appendix:

PLAN EXAMPLES
03/22/2021 Page: 34
123 Example Street Food City, IL 60618
 measureme monitoring employee Rework is covered and environmen Corrective
nt room stored in a room adjacent tal Action Log,
and to the processing area, monitoring Monthly
processing and maintained at the program is Sanitation
areas are same hygiene level as the in place to Control
maintained processing area (See SOP verify that Record
at a higher 15-789 – Rework controls are
hygiene Procedures). sufficient to
level than prevent the
receiving, presence
storage, and
and harborage
shipping of
areas, as Salmonella
specified in in the
SOP 15-123 environmen
– High t and
Hygiene equipment.
Sanitation The
Procedures. program
As specified includes an
in SOP 15- evaluation
456 – of
Employee Enterobacte
Hygiene in riaceae
High levels as
Hygiene additional
Areas, verification
employees that
must put on conditions
smocks that do not exist
do not have that could
pockets, lead to the
change into presence
factory and
shoes, put harborage
on of
protective Salmonella.
equipment Enterobacte

PLAN EXAMPLES
03/22/2021 Page: 35
123 Example Street Food City, IL 60618
 (hair net, riaceae
beard net), environmen
and wash tal
their hands monitoring
before occurs
entering weekly and
ingredient Salmonella
measureme monitoring
nt and occurs
production monthly.
areas.

A - Undeclared allergens - Label Confirm Visual Beginning Line QA See

If the label is incorrect,
Incorrect label number that inspection and end of Operator, manager or appendix:
segregate product,
matches a packaging of the run and QA designee Allergen
inspect back to the last
product used wrapper when label Manager reviews Label Check
good check, relabel or
matches stock to stock is initials Record Log,
destroy; identify the root
the product match the changed records Corrective
cause and
number product within 7 Action Log
conduct training as
number working
needed to prevent a
days and
recurrence
compares
results with
past results
to identify
any trends

PLAN EXAMPLES
03/22/2021 Page: 36
123 Example Street Food City, IL 60618
 Ingredients & Suppliers

Ingredient Name: Corn Syrup

Description:

ProcessSteps:

Step
Name Description

Receive Corn syrup – Received in 5 gallon plastic containers Canola oil – Received in 5 gallon plastic containers Almonds, blanched and slivered – Received in 20
ingredients lb. bags. Specifications require blanching after shelling and sorting for defects and mold. Prior to blanching, shelled almonds are treated with
Almonds propylene oxide (PPO) to achieve the minimum 4-log reduction of Salmonella required for California almonds in North America. Screening and testing
for aflatoxin is also conducted. Quarterly, Certificates of Analysis (COA) for Salmonella, Enterobacteriaceae and aflatoxin conformance to specifications
accompany shipments. Crisped rice – Received in 22 lb. bag-in-box. Ingredients include rice flour, corn flour, sugar and salt. Dried cranberries –
Received in 25 lb. cases. Ingredients include cranberries, sugar and sunflower oil. Packaged in the same facility as peanuts, tree nuts, soy, and milk
products. Vitamin/ mineral pre-blend – Vitamins (A, B-mix, C, E) and minerals (Ca, Mg, K, Zn) received in 1 lb. plastic sealed bags, with 10 bags in a box.
Certificates of analysis accompany each shipment, confirming levels of vitamins and minerals. Pan release agent – contains soy lecithin – received in
spray cans

Store All ingredients are stored in the dry storage room (temperature kept below 75°F) in the ingredient area, arranged by ingredient code number. All
ingredients containers are sealed to avoid cross-contact and cross-contamination during storage. Ingredients that contain allergens are labelled and stored in
specific locations with like allergenic ingredients.

Measure Ingredients are measured and staged in a dedicated room. The hygiene level of the room is consistent with the requirements of exposed product
ingredients manufacturing areas. Allergenic materials are weighed on dedicated equipment into dedicated containers using color coded tools dedicated to the
allergen. Employees change smocks and gloves before and after handling an allergenic material.

Blend Mixed dry ingredients are gradually added to the syrup mixer. Rework is added at this step.
Ingredients

Cool Syrup The syrup is cooled to 120-130°F and held in the mixer until needed.
(120 to
130ºF)

PLAN EXAMPLES
03/22/2021 Page: 37
123 Example Street Food City, IL 60618
 Step
Name Description

Mix and Corn syrup and canola oil are added to a jacketed mixer and warmed to 195 to 205°F and blended for 20 minutes to ensure even distribution. Warming
Warm facilitates more uniform blending and is not intended to be a kill step in these low water activity ingredients.
Syrup

Suppliers:

Ingredient Name: Canola Oil

Description:

ProcessSteps:

Step
Name Description

Receive Corn syrup – Received in 5 gallon plastic containers Canola oil – Received in 5 gallon plastic containers Almonds, blanched and slivered – Received in 20
ingredients lb. bags. Specifications require blanching after shelling and sorting for defects and mold. Prior to blanching, shelled almonds are treated with
Almonds propylene oxide (PPO) to achieve the minimum 4-log reduction of Salmonella required for California almonds in North America. Screening and testing
for aflatoxin is also conducted. Quarterly, Certificates of Analysis (COA) for Salmonella, Enterobacteriaceae and aflatoxin conformance to specifications
accompany shipments. Crisped rice – Received in 22 lb. bag-in-box. Ingredients include rice flour, corn flour, sugar and salt. Dried cranberries –
Received in 25 lb. cases. Ingredients include cranberries, sugar and sunflower oil. Packaged in the same facility as peanuts, tree nuts, soy, and milk
products. Vitamin/ mineral pre-blend – Vitamins (A, B-mix, C, E) and minerals (Ca, Mg, K, Zn) received in 1 lb. plastic sealed bags, with 10 bags in a box.
Certificates of analysis accompany each shipment, confirming levels of vitamins and minerals. Pan release agent – contains soy lecithin – received in
spray cans

Store All ingredients are stored in the dry storage room (temperature kept below 75°F) in the ingredient area, arranged by ingredient code number. All
ingredients containers are sealed to avoid cross-contact and cross-contamination during storage. Ingredients that contain allergens are labelled and stored in
specific locations with like allergenic ingredients.

Measure Ingredients are measured and staged in a dedicated room. The hygiene level of the room is consistent with the requirements of exposed product
ingredients manufacturing areas. Allergenic materials are weighed on dedicated equipment into dedicated containers using color coded tools dedicated to the
allergen. Employees change smocks and gloves before and after handling an allergenic material.

PLAN EXAMPLES
03/22/2021 Page: 38
123 Example Street Food City, IL 60618
 Step
Name Description

Blend Mixed dry ingredients are gradually added to the syrup mixer. Rework is added at this step.
Ingredients

Suppliers:

Ingredient Name: Vitamin/Mineral Pre-blend

Description:

ProcessSteps:

Step
Name Description

Receive Corn syrup – Received in 5 gallon plastic containers Canola oil – Received in 5 gallon plastic containers Almonds, blanched and slivered – Received in 20
ingredients lb. bags. Specifications require blanching after shelling and sorting for defects and mold. Prior to blanching, shelled almonds are treated with
Almonds propylene oxide (PPO) to achieve the minimum 4-log reduction of Salmonella required for California almonds in North America. Screening and testing
for aflatoxin is also conducted. Quarterly, Certificates of Analysis (COA) for Salmonella, Enterobacteriaceae and aflatoxin conformance to specifications
accompany shipments. Crisped rice – Received in 22 lb. bag-in-box. Ingredients include rice flour, corn flour, sugar and salt. Dried cranberries –
Received in 25 lb. cases. Ingredients include cranberries, sugar and sunflower oil. Packaged in the same facility as peanuts, tree nuts, soy, and milk
products. Vitamin/ mineral pre-blend – Vitamins (A, B-mix, C, E) and minerals (Ca, Mg, K, Zn) received in 1 lb. plastic sealed bags, with 10 bags in a box.
Certificates of analysis accompany each shipment, confirming levels of vitamins and minerals. Pan release agent – contains soy lecithin – received in
spray cans

Store All ingredients are stored in the dry storage room (temperature kept below 75°F) in the ingredient area, arranged by ingredient code number. All
ingredients containers are sealed to avoid cross-contact and cross-contamination during storage. Ingredients that contain allergens are labelled and stored in
specific locations with like allergenic ingredients.

Measure Ingredients are measured and staged in a dedicated room. The hygiene level of the room is consistent with the requirements of exposed product
ingredients manufacturing areas. Allergenic materials are weighed on dedicated equipment into dedicated containers using color coded tools dedicated to the
allergen. Employees change smocks and gloves before and after handling an allergenic material.

Mix Dry Dry ingredients: almonds, crisped rice, dried cranberries, vitamin/mineral pre blend Almonds, crisped rice, dried cranberries, and the vitamin/mineral
Ingredients pre-blend are added to a mixer and blended for 30 minutes to ensure even distribution.

PLAN EXAMPLES
03/22/2021 Page: 39
123 Example Street Food City, IL 60618
 Step
Name Description

Blend Mixed dry ingredients are gradually added to the syrup mixer. Rework is added at this step.
Ingredients

Suppliers:

Ingredient Name: Pan release oil

Description: The pan release oil contains soybean oil, soy lecithin and natural flavor

ProcessSteps:

Step
Name Description

Receive Corn syrup – Received in 5 gallon plastic containers Canola oil – Received in 5 gallon plastic containers Almonds, blanched and slivered – Received in 20
ingredients lb. bags. Specifications require blanching after shelling and sorting for defects and mold. Prior to blanching, shelled almonds are treated with
Almonds propylene oxide (PPO) to achieve the minimum 4-log reduction of Salmonella required for California almonds in North America. Screening and testing
for aflatoxin is also conducted. Quarterly, Certificates of Analysis (COA) for Salmonella, Enterobacteriaceae and aflatoxin conformance to specifications
accompany shipments. Crisped rice – Received in 22 lb. bag-in-box. Ingredients include rice flour, corn flour, sugar and salt. Dried cranberries –
Received in 25 lb. cases. Ingredients include cranberries, sugar and sunflower oil. Packaged in the same facility as peanuts, tree nuts, soy, and milk
products. Vitamin/ mineral pre-blend – Vitamins (A, B-mix, C, E) and minerals (Ca, Mg, K, Zn) received in 1 lb. plastic sealed bags, with 10 bags in a box.
Certificates of analysis accompany each shipment, confirming levels of vitamins and minerals. Pan release agent – contains soy lecithin – received in
spray cans

Store All ingredients are stored in the dry storage room (temperature kept below 75°F) in the ingredient area, arranged by ingredient code number. All
ingredients containers are sealed to avoid cross-contact and cross-contamination during storage. Ingredients that contain allergens are labelled and stored in
specific locations with like allergenic ingredients.

Measure Ingredients are measured and staged in a dedicated room. The hygiene level of the room is consistent with the requirements of exposed product
ingredients manufacturing areas. Allergenic materials are weighed on dedicated equipment into dedicated containers using color coded tools dedicated to the
allergen. Employees change smocks and gloves before and after handling an allergenic material.

Blend Mixed dry ingredients are gradually added to the syrup mixer. Rework is added at this step.
Ingredients

PLAN EXAMPLES
03/22/2021 Page: 40
123 Example Street Food City, IL 60618
 Suppliers:

Ingredient Name: Dried Cranberries

Description:

ProcessSteps:

Step
Name Description

Receive Corn syrup – Received in 5 gallon plastic containers Canola oil – Received in 5 gallon plastic containers Almonds, blanched and slivered – Received in 20
ingredients lb. bags. Specifications require blanching after shelling and sorting for defects and mold. Prior to blanching, shelled almonds are treated with
Almonds propylene oxide (PPO) to achieve the minimum 4-log reduction of Salmonella required for California almonds in North America. Screening and testing
for aflatoxin is also conducted. Quarterly, Certificates of Analysis (COA) for Salmonella, Enterobacteriaceae and aflatoxin conformance to specifications
accompany shipments. Crisped rice – Received in 22 lb. bag-in-box. Ingredients include rice flour, corn flour, sugar and salt. Dried cranberries –
Received in 25 lb. cases. Ingredients include cranberries, sugar and sunflower oil. Packaged in the same facility as peanuts, tree nuts, soy, and milk
products. Vitamin/ mineral pre-blend – Vitamins (A, B-mix, C, E) and minerals (Ca, Mg, K, Zn) received in 1 lb. plastic sealed bags, with 10 bags in a box.
Certificates of analysis accompany each shipment, confirming levels of vitamins and minerals. Pan release agent – contains soy lecithin – received in
spray cans

Store All ingredients are stored in the dry storage room (temperature kept below 75°F) in the ingredient area, arranged by ingredient code number. All
ingredients containers are sealed to avoid cross-contact and cross-contamination during storage. Ingredients that contain allergens are labelled and stored in
specific locations with like allergenic ingredients.

Measure Ingredients are measured and staged in a dedicated room. The hygiene level of the room is consistent with the requirements of exposed product
ingredients manufacturing areas. Allergenic materials are weighed on dedicated equipment into dedicated containers using color coded tools dedicated to the
allergen. Employees change smocks and gloves before and after handling an allergenic material.

Mix Dry Dry ingredients: almonds, crisped rice, dried cranberries, vitamin/mineral pre blend Almonds, crisped rice, dried cranberries, and the vitamin/mineral
Ingredients pre-blend are added to a mixer and blended for 30 minutes to ensure even distribution.

Blend Mixed dry ingredients are gradually added to the syrup mixer. Rework is added at this step.
Ingredients

Suppliers:

PLAN EXAMPLES
03/22/2021 Page: 41
123 Example Street Food City, IL 60618
 Ingredient Name: Slivered Almonds

Description:

ProcessSteps:

Step
Name Description

Receive Corn syrup – Received in 5 gallon plastic containers Canola oil – Received in 5 gallon plastic containers Almonds, blanched and slivered – Received in 20
ingredients lb. bags. Specifications require blanching after shelling and sorting for defects and mold. Prior to blanching, shelled almonds are treated with
Almonds propylene oxide (PPO) to achieve the minimum 4-log reduction of Salmonella required for California almonds in North America. Screening and testing
for aflatoxin is also conducted. Quarterly, Certificates of Analysis (COA) for Salmonella, Enterobacteriaceae and aflatoxin conformance to specifications
accompany shipments. Crisped rice – Received in 22 lb. bag-in-box. Ingredients include rice flour, corn flour, sugar and salt. Dried cranberries –
Received in 25 lb. cases. Ingredients include cranberries, sugar and sunflower oil. Packaged in the same facility as peanuts, tree nuts, soy, and milk
products. Vitamin/ mineral pre-blend – Vitamins (A, B-mix, C, E) and minerals (Ca, Mg, K, Zn) received in 1 lb. plastic sealed bags, with 10 bags in a box.
Certificates of analysis accompany each shipment, confirming levels of vitamins and minerals. Pan release agent – contains soy lecithin – received in
spray cans

Store All ingredients are stored in the dry storage room (temperature kept below 75°F) in the ingredient area, arranged by ingredient code number. All
ingredients containers are sealed to avoid cross-contact and cross-contamination during storage. Ingredients that contain allergens are labelled and stored in
specific locations with like allergenic ingredients.

Measure Ingredients are measured and staged in a dedicated room. The hygiene level of the room is consistent with the requirements of exposed product
ingredients manufacturing areas. Allergenic materials are weighed on dedicated equipment into dedicated containers using color coded tools dedicated to the
allergen. Employees change smocks and gloves before and after handling an allergenic material.

Mix Dry Dry ingredients: almonds, crisped rice, dried cranberries, vitamin/mineral pre blend Almonds, crisped rice, dried cranberries, and the vitamin/mineral
Ingredients pre-blend are added to a mixer and blended for 30 minutes to ensure even distribution.

Blend Mixed dry ingredients are gradually added to the syrup mixer. Rework is added at this step.
Ingredients

Suppliers:

Ingredient Name: Crisped Rice

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 Description:

ProcessSteps:

Step
Name Description

Receive Corn syrup – Received in 5 gallon plastic containers Canola oil – Received in 5 gallon plastic containers Almonds, blanched and slivered – Received in 20
ingredients lb. bags. Specifications require blanching after shelling and sorting for defects and mold. Prior to blanching, shelled almonds are treated with
Almonds propylene oxide (PPO) to achieve the minimum 4-log reduction of Salmonella required for California almonds in North America. Screening and testing
for aflatoxin is also conducted. Quarterly, Certificates of Analysis (COA) for Salmonella, Enterobacteriaceae and aflatoxin conformance to specifications
accompany shipments. Crisped rice – Received in 22 lb. bag-in-box. Ingredients include rice flour, corn flour, sugar and salt. Dried cranberries –
Received in 25 lb. cases. Ingredients include cranberries, sugar and sunflower oil. Packaged in the same facility as peanuts, tree nuts, soy, and milk
products. Vitamin/ mineral pre-blend – Vitamins (A, B-mix, C, E) and minerals (Ca, Mg, K, Zn) received in 1 lb. plastic sealed bags, with 10 bags in a box.
Certificates of analysis accompany each shipment, confirming levels of vitamins and minerals. Pan release agent – contains soy lecithin – received in
spray cans

Store All ingredients are stored in the dry storage room (temperature kept below 75°F) in the ingredient area, arranged by ingredient code number. All
ingredients containers are sealed to avoid cross-contact and cross-contamination during storage. Ingredients that contain allergens are labelled and stored in
specific locations with like allergenic ingredients.

Measure Ingredients are measured and staged in a dedicated room. The hygiene level of the room is consistent with the requirements of exposed product
ingredients manufacturing areas. Allergenic materials are weighed on dedicated equipment into dedicated containers using color coded tools dedicated to the
allergen. Employees change smocks and gloves before and after handling an allergenic material.

Mix Dry Dry ingredients: almonds, crisped rice, dried cranberries, vitamin/mineral pre blend Almonds, crisped rice, dried cranberries, and the vitamin/mineral
Ingredients pre-blend are added to a mixer and blended for 30 minutes to ensure even distribution.

Blend Mixed dry ingredients are gradually added to the syrup mixer. Rework is added at this step.
Ingredients

Suppliers:

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 Equipment
Equipment Name: Sample Equipment
Make: Sample
Model: Sample
Serial Number:
Description:
ProcessSteps:

Step
Name Description

Measure Ingredients are measured and staged in a dedicated room. The hygiene level of the room is consistent with the requirements of exposed product
ingredients manufacturing areas. Allergenic materials are weighed on dedicated equipment into dedicated containers using color coded tools dedicated to the
allergen. Employees change smocks and gloves before and after handling an allergenic material.

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 SOP and Policy Report
A list of a facility's Standard Operating Procedures and Policies

Summary List of SOPs and Policies

Prevent Allergen Cross Contamination: Verification that allergen containing material is kept separate from non-allergen materials

Verification of Allergen labelling: Monitor accuracy of labels for allergens.

Metal Detection: Testing to detect metal pieces with a magnet

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 Prevent Allergen Cross Contamination

Scope/Introduction: Verification that allergen containing material is kept separate from non-allergen materials

Responsible for Implementation: Supervisor

Frequency: Upon receiving raw materials and anytime materials are brought in or out of cooler.

Last Updated By: Your Name

Last Updated On: December 1st 2020, 5:45:50 am

Instructions

Verification that allergen containing material is kept separate from non-allergen materials. Before and after production runs, there is monitoring for where
materials are being stored. Refer to SOP "Preventing Cross Contamination during Storage & Preparation".

Corrective Action

1. The Allergens are to be immediately removed from a non-allergen area and be kept with other like allergen products. 
2. Production on HOLD until verification that there has been no cross-contamination of allergen material with non-allergen material.

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 Verification of Allergen labelling

Scope/Introduction: Monitor accuracy of labels for allergens.

Responsible for Implementation: Supervisor

Frequency: Start of labelling being printed for production run

Last Updated By: Virat Joshi

Last Updated On: December 1st 2020, 9:41:38 pm

Instructions

Monitor accuracy of labels. If label does not contain accurate statement, it cannot be used. Refer to the Allergen Program. Refer to SOP "Preventing Cross
Contamination During Storage and Preparation".

Corrective Action

Production is halted until accurate labels are available.

PLAN EXAMPLES
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123 Example Street Food City, IL 60618
 Metal Detection

Scope/Introduction: Testing to detect metal pieces with a magnet

Responsible for Implementation: Trained production employee

Frequency: Before, during and after operation

Last Updated By:

Last Updated On: March 1st 2021, 4:35:56 pm

Instructions

1. Subject the product to metal detection devices

2. Conduct regular inspections of at-risk equipment for signs of metal contamination.

PLAN EXAMPLES
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