The Food Safety Plan H.A.C.C.P

Terms of reference:

This linear HACCP plan covers the manufacture of an apple yogurt product, packaged in a pot.

It will start at raw materials intake through to dispatch of processing plant.

The HACCP plan will cover final product safety and will look at the following hazards:

Physical Glass and hard brittle plastic

Metal

Chemical Pesticide residues in fruit

Chemical residues associated with the packaging materials

Chemical residues associated with cleaning

Biological Unwanted bacteria yogurt, raw milk and fruit.

The company has in place a number of effective prerequisite programs including:

Cleaning and Sanitising

Pest Control

Personal Hygiene Requirements

Staff Training

The company complies with the following acts of legislation

Regulation (EC) No 178/2002 of the European Parliament and of the Council

Regulation (EC) No 852/2004 of the European Parliament and of the Council

And the following codes of practice/guidelines documents were used in developing this

HACCP plan:

Campden BRI HACCP: A Practical Guide (Fourth edition). Guideline No 42

British Retail Consortium Global Standard for Food Safety (Issue 6)

Department of Health Guidelines for the Safe Production of Heat Preserved Foods

Institute of Food Science and Technology Food & Drink Good Manufacturing Practice, A

Guide to its Responsible Management.

Codex Alimentarius Food Hygien Basic Texts (Third Edition)

1.1 The HACCP food safety team

1.1.1

The HACCP plan is developed and managed by Fab Foods multi-disciplinary food safety team

which includes those responsible for quality/technical, production operations, engineering and

other relevant functions.

The team leader has an in-depth knowledge of HACCP and is able to demonstrate competence

and experience.

The team members have specific knowledge of HACCP and relevant knowledge of product,

process and associated hazards.

In the event of the company not having appropriate in-house knowledge, external expertise will

used, but day-to-day management of the food safety system remains the responsibility of the

company.

HACCP Team Member Responsibility

Quality Assurance Carries out systematic measurements,

comparison with BRC standard, monitoring

of processes and an aims to prevent error.

Quality Control Reviews the quality of all factors involved in

production with focus on process outputs.

Production Specialist contribute details of what actually happens

on the production line

throughout all shift patterns

Engineer Provides information on the operating

characteristics of the process

equipment under study and the hygienic

design of equipment and buildings

Microbiologist Understands the microbiological hazards and

risks associated with the product.

Others Including; specialist equipment operators,

hygiene manager, ingredient and packaging

buyers, distribution manager, maintenance

and calibration operators.

External HACCP Members If knowledge is not available in-company,

consultation with an eternal resource will be

carried out.

Table 1: Breakdown of Fab Foods HACCP Team and Responsibilities.

All persons are trained in HACCP and repeat the training annually.

Below is a table showing how Fab Foods operates an organised structure of the HACCP team.

Table 2: Fab Foods operation of an organised structure of the HACCP team.

1.2 Prerequisite programmes

1.2.1

Fab Foods has established and maintains environmental and operational programmes necessary

to keep an environment suitable to produce safe and legal food products

Prerequisite programmes include:

Cleaning and Sanitising

Pest Control

Personal Hygiene Requirements

Staff Training

Process

Step

Hazard

Prevention

Control

Limits

Monitor

Method

Monitor

Frequency

Record

Sheet

Person

Responsi

ble

Corrective

action

Validation

ENVIRONMENTAL HYGIENE

Environ

mental

Hygiene

Presence

of listeria/ Salmonell

a

Environm

ent swabs

Listeria/sa

lmonella

absent

ISO

approved

methods

Weekly

monthly/

Quarterly

Pathogen

file

QC

Manager

Full investigati

on, re

clean and re swab

area

Weekly

review of pathogen

file by QC

HYGIENIC HANDLING OF INGREDIENTS

* Milk,

* Starter

Cultures (S.thermo

philus&

L.burglarious)

* Fruit

(diced apples)

*Stabiliser

(pectin) * Flavour

Enhancers

Presence

of pathogeni

c

microorganisms

Pathogen

screening

Below pathogen

limits

SOP Testing

procedure

for investigati

on of

pathogens

Weekly

Pathogen

screening monitorin

g sheet

QC

Manager

In case of pathogen

presence

immediate rejection

of

product.

Presence

of pathogeni

c

microorganisms

CLEANING, MAINTENANCE & PERSONNEL HYGIENE AT PRIMARY PRODUCTION

Cleaning,

Maintena

nce &

Personnel

Hygiene

at

Primary

Productio

n

Physical /Micro

contamina

tion

Cleaning

procedures

Clean

areas,

swab enterobact

eria

PREMISES

Design,

layout,

Internal

Structure

s &

Fittings

Physical /Micro

contamina

tion

Food grade

walls and

equipment

Clean &

undamaged

Visual and

Hygiene and

housekeep

ing audits

Ongoing.

Hygiene

and Housekee

ping

Audits

Technical

Action log

created.

Actions

monitored continuou

sly

Internal and

external

audits

EQUIPMENT

Food

Control

&

Monitori

ng

Equipme

nt

Physical

/Micro

contamination

Audit/Visual

Inspection

Clean &

undamage

d

Visual and Hygiene

and

housekeeping audits

Ongoing.

Hygiene and

Housekee

ping Audits

QC

manager

Hygiene and

household

records created.

Continuou

s monitorin

g.

Internal

and

external audits

Containe

rs For

Waste &

Inedible

Substanc

es

Physical

/Micro

contamina

tion

Clean

colour coded

waste

containers

Correct

colour, clean and

undamage

d

Visual and

Hygiene and

housekeep

ing audits

Clean

daily

Hygiene

and Housekee

ping

Audits

Productio

n

Monitorin

g log

created.

Daily monitorin

g of waste

containers

FACILITIES

Water

Storage

Legionella

contamination

Legionella

testing Absent

External company

sample

and test

All areas at least

twice

annually

Water

storage records

Quality

Control Officer

Investigate if

legionella

found in water, risk

access

product

Legionella

file

Personal

Hygiene/c

aptive

clothing

Physical

/Micro contamina

tion

Hand

washing/captive

clothing

Correct

hand

washing procedure

s and

change of clothing in

productio

n areas

Visual hand

swabs,

and Hygiene

and

housekeeping audits

On-

going/qua

rterly

Hygiene records

All

Employee

s

Report deviations

to

supervisor/manager

Action log

Temperat

ure

Control

Product

contamination

Temperature

monitorin

g

Temperature

specificati

ons

Calibrated

thermometers

As per

schedules

Temperat

ure Records

QC

manager

Report deviations

to QC

manager

Weekly audit of

temperatu

re records

CLEANING MANAGEMENT

Cleaning

Program

mes

Contamin

ation due to

ineffective hygiene

procedure

Spray with

acidic

solution after clean

on filler inside

surfaces

Surface

hygiene tests

Surface

hygiene tests

After each

cleaning cycle

Cleaning logs

Productio

n operators

Do not

proceed

with productio

n until

satisfactory hygiene

has been achieved

Weekly review of

cleaning

logs.

Internal/external

audits

Cleaning

Program

mes

Contamination due

to

ineffective hygiene

procedure

CIP and

hand

cleaning

procedure

s

Cleaning

carried out to correct

time,

temperature and

sanitizer

strength

Visual

inspection

s, sanitizer

checks

and

swabbing regimes

As per

cleaning

scheduled/

frequencie

s

Cleaning

logs

Operators/

Team

leaders/Technical

Do not

proceed

with productio

n until

satisfactory plant

hygiene

has been achieved.

Weekly

review of cleaning

logs.

Internal/e

xternal

audits

PEST CONTROL SYSTEMS

Pest

Control

Microbiol

ogical,

Physical or

chemical

risks associated

with pests.

Pestguard

Plus contract in

place with

Rentokil

All

evidence of pest

activity

reported and

controlled.

Pest

Control

Technician

Pest control

technician

-monthly visits

Rentokil

File reports.

Technical

Manager

All pest

control actions &

corrective

actions taken

reported

to technical

manager.

Rentokil

report.

WASTE MANAGEMENT

Waste

Managem

ent

Rubbish

provides environme

nt for pest

harborage.

Rubbish cleared on

a regular

and routine

basis.

All rubbish to

be

removed.

Hygiene &

Housekee

ping Audit schedule

in place.

Once per month

Waste

transportat

ion

documentation

Any

reports of visual

sightings

of waste/deb

ris in the

production area or

surroundi

ng areas.

Waste

coordinati

ng officer

Action log created

and issued

to Technical

Manager

Waste

documentation file.

PERSONAL CLEANLINESS

Hygiene

Policy

Non-

compliance with

general

hygiene practises

Fully

document

ed

Hygiene

Code of

Practice compiled

from Customer

Codes of

Practice and Good

Manufact

uring Practices.

100%

complianc

e by all site

personnel.

Hygiene

& Housekee

ping Audit

schedule in place.

Quarterly

Hygiene records

Technical Manager

Action log

created and issued

to General Manager

Hygiene and

Housekee

ping audit

Personnel

hand swabbing

regime in

place for productio

n area.

Monthly

Hygiene

records

Technical

manager

Re swab

and if

positive discuss

hygiene

policy with the

operator

Hygiene

and

Housekeeping audit

Visitors

Visitors not aware

of the site

hygiene requireme

nts.

Unfit/unwell visitors

enter site.

Rules for Visitors

Procedure

in place. Sign in at

reception.

Sign in agreement

to follow

company rules

while on

site.

No unfit

visitors

allowed in high risk

areas of

factory.

Hygiene

rules

Each

visitor.

Visitors

Book

Reception

ist

Vistors

must meet

the correct safety

citeria to

be allowed

access to

the premise

Annual

audit of

visitor records

Table 3: Fab Foods Prerequisite Process.

Cleaning and Sanitising

The order of operation for cleaning/sanitizing of food product contact surfaces is

Rinse

Clean

Rinse

Sanitize.

The company uses a number of types of cleaning.

Mechanical Cleaning. Often referred to as clean-in-place (CIP). Requires no disassembly or

partial disassembly.

Clean-out-of-Place (COP). Can be partially disassembled and cleaned in specialized COP

pressure tanks.

Manual Cleaning. Requires total disassembly for cleaning and inspection.

Following cleaning, sanitization is completed, types include;

Thermal Sanitization involving the use of hot water or steam for a specified temperature and

contact time.

Chemical Sanitization involving the use of an approved chemical sanitizer at a specified

concentration and contact time.

Cleaning and Sanitization is carried out to remove unwanted matter on food-contact surface,

referred to as Food Soil.

Detergents and cleaning compounds are composed of mixtures of ingredients that interact with

soils in several ways: Physically active ingredients alter physical characteristics such as

solubility or colloidal stability. Chemically active ingredients modify soil components to make

them more soluble and, thus, easier to remove. Example of cleaning agents used are Alkaline

Builders, Acid Builders, Water Conditioners, Oxidizing Agents, and Enzyme-based detergents.

The below table is used when selecting cleaning agent to use.

Surface Deposit Cleaning Solubility

Sugar Water soluble

Fat Alkali soluble

Protein Alkali soluble

Starch Water soluble, Alkali soluble

Monovalent Salts Water soluble; Acid soluble

Table 4: Surface Deposit vs. the Cleaning Solubility

Examples of sanitizers include; Chlorine, Iodophors, Quarternary ammonium compounds,

Acid anionic, Fatty Acid, Peroxyacetic acid

The below table can be used when selecting cleaning agent to use

Chlorine

Iodophors

Quarternary

ammonium

compounds

Acid anionic

Fatty

Acid

Peroxyacetic

acid

Corrosive Corrosive Slightly

corrosive

Noncorrosive Slightly

corrosive

Slightly

corrosive

Slightly

corrosive

Irritating to skin Irritating Not

irritating

Not irritating Slightly

irritating

Slightly

irritating

Not irritating

Effective at

neutral pH

Yes Depends

on type

In most cases No No Yes

Effective at acid

pH

Yes, but

unstable

Yes

In some

cases

Yes, below

3.0-3.5

Yes,

below 3.5-

4.0

Yes

Effective at

alkaline pH

Yes, but

less than

at neutral

pH

No

In most cases

No

No

Less

effective

Affected by

organic material

Yes Moderately Moderately Moderately Partically Partially

Affected by

water hardness

No Slightly Yes Slightly Slightly Slightly

Residual

antimicrobial

activity

None

Moderate

Yes

Yes

Yes

None

Cost Low High Moderate Moderate Moderate Moderate

Incompatibilities

Acid

solutions,

phenols,

amines

Highly

alkaline

detergents

Anionic

wetting

agents,

soaps, and

acids

Cationic

surfactants

and alkaline

detergents

Cationic

surfactants

and

alkaline

detergents

Reducing

agents, metal

ions, strong

alkalies

Stability of use

solution

Dissipates

rapidly

Dissipates

slowly

Stable Stable Stable Dissipates

slowly

Maximum level

permitted by

FDA without

rinse

200ppm

25ppm

200ppm

Varied

Varied

100-200ppm

Water

temperature

sensitivity

None

High

Moderate

Moderate

Moderate None

Foam level None Low Moderate Low/Moderate Low None

Phosphate None High None High Moderate None

Soil load

tolerance

None Low High Low Low Low

Table 5: Comparison of the Chemical and Physical Properties in commonly used Sanitizers

It is important that the clean, sanitized equipment and surfaces drain dry and are stored dry so

as to prevent bacteria growth. Necessary equipment must also be cleaned and stored in a clean,

sanitary manner.

Cleaning/sanitizing procedures are evaluated for adequacy through evaluation and inspection

procedures. Adherence to prescribed written procedures (inspection, swab testing, direct

observation of personnel) are continuously monitored, and records maintained to evaluate long-

term compliance.

(Schmidt, 2000)

All areas regarding Cleaning and Sanitizing must be documented and signed in appropriate

specification sheets.

Pest Control

Pest Control is carried out to eliminate the entry of insects and rodents into the food processing

premises.

Pests include: Rodents (Rats, Squirrels, Mice etc.) Cockroaches, Flies, Ant, Birds and other

vertebrates.

Control of Pests in done by an outside service provided by Rentokil. (Hazel House, Millennium

Park, Naas, Co Kildare, 1890 333 888).

Poisoned Bait, Traps, Electrical Discharge system, Repellents, Pitfall traps and Sticky insect

traps are among the controls put in place by Rentokil.

In addition to this:

The exterior of the premises is well-maintained by designated maintenance staff, lawns

are mowed once a week and any debris which could be a possible nesting place for

rodents/insects are removed. Evidence of pests such as dropping are examined for.

The interior and exterior of processing plant is inspected twice weekly to ensure that no

pests have begun to congregate.

Pest control is included on the factory daily schedule.

Drains onsite are fitted with rodent traps.

All entrances to the factory are effectively concealed from pests when closed.

In the event that a pest is found on the premises immediate action must be taken.

Incident should be immediately reported to supervisor. Product recall may be necessary.

All areas regarding Pest Control must be documented and signed in appropriate

specification sheets.

Personal Hygiene Requirements / Staff Training

The below house rules are in place as well and in conjunction with H.A.C.C.P. Staff are

trained upon entry and annually by an official body which comply with the FSAIs Guide to

Food Safety Training Level 1 and Level 2.

Prerequisite Control Measure

All staff in contact with food items must

confirm they are free of disease before they

are employed.

Require new staff members to complete a

questionnaire about their medical situation

and/or arrange for them to be tested for

infectious diseases.

All staff in contact with food items must

wear protective clothing.

Clean white cotton/polyester overalls or

coats for all staff in contact with

unpackaged food are provided and dry

cleaned.

Staff are prohibited staff who are

experiencing vomiting or diarrhoea or have

infected wounds on their hands or lower

arms from handling unpackaged food items.

If a person has these symptoms either send

them home until they are better or move

them to an area when they do not handle

unpackaged food items. Provide adhesive

medical dressings for staff to put over any

wounds, cuts or abrasions on hands or lower

arms

Ensure that staff put on disposable hair nets,

and beard nets (where applicable) before

putting on their protective clothing.

It is company policy to arrange for staff to

be inducted and trained to do this.

Use gloves that are fit for purpose.

Glove sizes are available to take into

account the different sized hands/ The

gloves should be tight fitting but not so tight

as to be uncomfortable. Disposable gloves

have are designed for use with food. For

tasks such as cleaning or pest control use

rubber, non-disposable, thick gloves.

Staff must remove protective clothing

before going to the toilet.

The facility is designed so staff must outer

layer of protective clothing - prior to going

to the toilet. This will include installing

hooks on which to hang the clothes coming

off.

Provide facilities for staff to store outdoor

clothes and personal effects.

Install lockable cabinets in the changing

facility.

Staff must to wash hands regularly

especially after bathroom, food or smoke

breaks; after handling waste or uncooked

food items and after sneezing or touching

their faces.

Signs are placed in bathrooms and in

entrances to the processing areas

reminding people to wash their hands

Eating, drinking or chewing of gum in food

processing areas is prohibited.

It is policy that eating, drinking or chewing

of gum in food processing areas is

prohibited. A canteen is provided for such

activities.

Staff should not sneeze over food items.

Staff are trained to turn away and sneeze

into the crook of their arm or into hands

over their face. Afterwards they should

blow their nose with tissues & wash their

hands

Wearing of any jewellery in food

processing areas is prohibited. This

includes watches, ring, earrings, necklaces

bracelets and hairpieces.

All staff must sign a declaration saying they

will abide by this policy.

Visitors are asked to remove jewellery.

Signs to doorways leading into processing

areas remind people they should remove

jewellery.

Table 6: Personal Hygiene Requirements / Staff Training & Control Measures.

1.3 Description of the product

1.3.1

The scope of each HACCP plan, includes the products and processes covered, including

Composition, e.g. raw materials, ingredients, allergens, recipe

Origin of ingredients

Physical or chemical properties that impact food safety, e.g. pH, aw

Treatment and processing, e.g. cooking, cooling

Packaging system, e.g. modified atmosphere, vacuum

Storage and distribution conditions, e.g. chilled, ambient

Target safe shelf life under prescribed storage and usage conditions

Instructions for use, and potential for known customer misuse, e.g. storage, preparation.

Process/Product type: Yogurt

Product name: Absolutely Apple

Composition:

Skim milk, skim milk powder, apple fruit,

preservatives, bacterial cultures (

Important product characteristics aw, pH, preservatives, processing

How it is to be used: Direct consumption

Packaging: Plastic cup and foil sealed

Shelf life: 2 weeks

Where it will be sold: Retailers

Labelling instructions: Within legal limits, as per BRC standards.

Special storage and distribution control: Refrigerated at < 5C

Table 7: Product Description

1.3.2

Fab Foods ensures that the HACCP plan is based on comprehensive information sources, which

are referenced and available on request. It uses:

the latest scientific literatures

historical & known hazards associated with specific food products relevant codes of

practice

recognized guidelines

food safety legislation relevant for the production and sale of products

customer requirements.

1.4 Identified intended use

1.4.1

The intended use of the product by the customer is described, defining the consume target

groups, including the suitability of the product for vulnerable groups of the population (e.g.

infants, elderly, allergy sufferers).

1.5 Construction a process flow diagram

1.5.1

The prepared flow diagram covers each product, product category or process. This sets out all

aspects of the food process operation within the HACCP scope, from raw material receipt

through to processing, storage and distribution. It contains the following:

plan of premises and equipment layout

raw materials including introduction of utilities & other contact materials, e.g water,

packaging

sequence and interaction of all process steps

outsourced processes and subcontracted work

process parameters

potential for process delay

rework and recycling

low/high-care/high-risk area segregation

finished products, intermediate/semi-processed products, by-products and waste.

Path ofMilk

CCP 1

Divert of Product where applicable

2. Mixing Hopper

12. Holding of yogurt in

holding tanks

21. Cold Storage,

Unit Operations

Milk storage Silo

When the milk is received after passing quality testing. The milk is pumped from the tanker to

the milk storage silos. Here the milk should be stored at

Pasteurisation

Milk which is still at 4C is pumped from the balance tank into the regeneration section of the

plate heat exchanger, where it is heated. The plate heat exchanger contains a series of stainless

steel plates stacked together with spaces in between them. The spaces are the forming chambers

which hold the milk as it passes through.

The milk will increase from 4C to 72C for effective pasteurisation. This is held for 15 seconds

and then chilled again to 4C.

In the regeneration section the heat of the pasteurised milk is used to warm up the cold milk.

Therefore the outgoing hot milk is the heating medium for the cold raw milk. The cold milk is

the cooling medium for the hot milk, as it is used to cool down the hot milk from 72C to 4C.

This all takes place in the plate heat exchanger where counter current flow is the most effective

way of heat exchange. When the cold milk meets the oncoming hot milk, and is heated up, it

is then passed through the holding tube which is long enough to last at least 15 seconds. Here

the milk is being pasteurised. It flows to the regeneration section where it warms up the cool

milk coming in and then off to the cooling section which is the final section.

The divert valve on the processing unit is used for diversion of any liquid that may be under

the pasteurisation temperature. In this case if its under 72C the milk is brought back to the

regeneration section and pasteurised again.

Pasteurisation is a thermal processing technique whereby milk is exposed to a

time / temperature combination of 72C for 15 seconds. This will make the product safe for

human consumption. Pasteurisation does not affect chemical, physical or organoleptic

characteristics of the milk. The primary function of pasteurisation is a food safety function.

However, as well as destroying pathogenic bacteria, pasteurisation will also destroy spoilage

bacteria and denature enzymes. This has the effect of extending the shelf-life of milk, both

chemically and microbiologically. Therefore pasteurisation is a critical control point in the

process.

A Phosphastase test must be carried out to show pasteurisation was effective.(

Raw milk contains acid and alkaline phosphatases. These enzymes catalyse the hydrolysis of

certain phosphate esters. The thermal stability of alkaline phosphatase (AP) in milk is slightly

higher than that of Microbacterium tuberculosis. AP is inactivated by heating milk to 72C and

holding for 15seconds. Inactivation of AP ensures the destruction of Microbacterium

tuberculosis. Adequately pasteurised milk will be phosphate negative.

Homogenisation

Homogenisation process allows two immiscible liquids to become mixed. This is achieved by

turning one of the liquids into a state consisting of extremely small particles distributed

uniformly throughout the other liquid.

When the milk is fed through the homogeniser, the workhead generates high shear rates. The

milk is forced through a small passage at high velocity. The disruption of the fat globules is

due to turbulence and cavitation.

While milk is forced through, the large fat globules are broken down into smaller ones.

Resulting in a size of 2-5 microns. This results in a stable emulsion, better mouth feel of the

product, reduced sensitivity to lipid oxidation.

Deaeration

Deaeration is the removal of oxygen and other dissolved gassed in the product. This is to

prevent/avoid undesirable changes in the final end product. Not only free air can be removed

but also mechanical air. Deaeration of a product can result in an oxygen level of

Cutting of yogurt pH

These bacteria form a symbiotic starter culture to ferment milk. By creating the starter culture

it increases the production of lactic acid in the fermentation process.

Streptococcus thermophilus starts to grow first dropping the milks pH from 6.6 to 5.0, and

produces carbon dioxide and lactic acid. These products stimulate Lactobacillus bulgaricus to

grow and further drop the pH to 4.2. The sugar found in milk is lactose, when the starter culture

is added to milk it breaks the lactose into glucose. After the sugar glucose is formed it. Then it

is fermented into lactic acid by the microorganisms.

The lactic acid decreases the pH of the milk and causes the casein, protein found in milk,

molecules to denature and stick together. The milk then curdles to produce yogurt

Filtration

Filtration of yogurt can remove the excess whey from fermentation process and gasses which

were produced form the starter cultures. This improves quality and shelf life of the product.

Filtration membrane used in this process is 0.5mm.

Yogurt Holding Tanks

After filtration the yogurt is cooled and then passed into yogurt holding tanks. The tanks here

keep the yogurt at the right temperature under atmospheric pressure. The yogurt is gently

agitated to keep the yogurt mixed with no whey separation and to keep a good consistency for

the product.

Metal Detection

Metal detection is a very important procedure in the manufacturing process. The yogurt is

frequently checked using a pipeline metal detector prior to final processing and final packaging.

The product is normally pumped through a non-metallic pipeline which passes through the

detector. Removal of contaminated product is achieved through the use of automated reject

valves which divert the product flow out of the process. Any high viscosity products that are

being produced which have the potential to solidify in the pipeline, there are heated pipelines

and valves are used, to limit pipe blockages. This will remove all contaminated substances

from the product, resulting in a high quality and safe product.

Blast Chilling

Blast chillers/freezers rapidly chill foods from a temperature of 140C to 40C in less than two

hours. As for yogurt, this will be even less. Blast chillers are ideal for chilling foods quickly

that are made on a daily basis. Blast chillers and freezers have powerful fans that create a fast

even air flow that is very cold. It uses a high-powered refrigeration system to blast the cold air

laterally over the product at high speed, extracting heat at an optimum rate, whilst maintaining

food quality. After the chill or freeze cycle is complete, the equipment switches into Hold mode

to keep the food at the required temperature.

Traying/Packaging

After the yogurt has been chilled, it is then ready to be put into yogurt pots. These are single

yogurt pots chosen for this product. The machine used here is the Automatic Rotary Type Cup

Filling & Sealing Machine SP-2502.

Cups fall into the holders on the machine, there are two stacks of yogurt cups, were two falls

each time into the individual holders. These are then passed along to the dust and blow suction

system. This takes away any access particles away from the cup. It passes on to a UV sterilizer,

this kills all microbes that may be present in the cups which could have got contaminated during

storage. It provides a sterile environment for the yoghurt. It moves on to the piston filler where

the cup fills up with the chilled yogurt from the blast chillier.

The amount of yogurt is poured out is calibrated on the machine.

The cups are ready to be sealed, they are flushed with nitrogen, and the oxygen is reduced so

that a longer shelf life can be obtained from the product. The yogurt cup is then sealed, brought

to the out feed system of the machine where a lever comes down and sucks the yogurt filled

cups out on to the vender belt to the labelling machine.

The yogurt cups pass though the labelling machine, where is puts on a sleeve around the yogurt

cup, stating all the requirements, such as yogurt name and nutritional information. A label is

also stuck on the lid of the yogurt stating the best before date.

Cold storage/Dispatch

The yogurts are taken of the labelling line and are stored at 4C in trays/ boxes in cold storage

rooms. These are now ready to be picked up by the truckers through dispatch. A physical test

is done before any of the yogurts are dispatched. The Yogurt is now sold to consumers.

1.6 Verification of flow diagram

1.6.1

The HACCP food safety team verifies the accuracy of the flow diagrams by on-site audit and

challenge at least annually. Daily and seasonal variations are considered and evaluated.

Records of verified flow diagrams are maintained.

1.7 List all potential hazards associated with each process step, conduct a

hazard analysis and consider any measures to control identified hazards

1.7.1

The HACCP food safety team identifies and records all the potential hazards that are

reasonably expected to occur at each step in relation to product, process and facilities.

This includes hazards present in raw materials, those introduced during the process or surviving

the process steps, and allergen risks. It also takes account of the preceding and following steps

in the process chain.

Fab Foods uses Risk Analysis to establish Hazards and uses it in conjunction with Food

Standards such as Food Safety Requirements, HACCP, Good Manufacturing & Hygiene

Practices and Total Quality Management to put an effective Food Management programme in

place.

Table 8: Risk Analysis in conjunction with Food Standards such as Food Safety

Requirements, HACCP, Good Manufacturing & Hygiene Practices and Total Quality

Management.

1.7.2

The HACCP food safety team conducts a hazard analysis to identify hazards which need to be

prevented, eliminated or reduced to acceptable levels. Consideration are given to the following:

likely occurrence of hazard

severity of the effects on consumer safety

vulnerability of those exposed

survival and multiplication of micro-organisms of specific concern to the product

presence or production of toxins, chemicals or foreign bodies

contamination of raw materials, intermediate/semi-processed or finished product.

Where elimination of the hazard is not practical, justification for acceptable levels of the hazard

in the finished product shall be determined and documented.

1.7.3

The HACCP food safety team considers the control measures necessary to prevent or eliminate

a food safety hazard or reduce it to an acceptable level. Where the control is achieved through

existing prerequisite programmes, this is stated and the adequacy of the programme to control

the hazard is validated.

Step

Process step

Hazards

Control

measures

Critical

limits

Monitoring

procedure Corrective

action

1(a)

Raw Milk

(Receive Milk)

Presence of

micro-

organisms

Microbiologi

cal analysis.

Keep records

for each

tanker route

Bactoscan

results

Raw milk

procedure

Reject milk if

not to

microbiologic

al limits

1(b)

Raw milk

(Release tests)

Antibiotics

Foreign

material

Rosa test

Kundrat test

ATK test

In-line filter.

Inspect

tanker before

offloading.

Quality of

gaskets

Negative

No damage

gaskets

Raw milk

procedure

Raw milk

procedure

Reject milk

Follow up

Daily tanker

inspections

1(c)

Raw milk

(Cooling)

Microbial

Temperature

Milk

Cooled to <

3oC

Cold chain

procedure

Maintenance

of ice banks

1(d)

Raw milk (Silo

relase)

Microbial

Chemical

risk

Temperature

and time

Cleaning

Milk to be

kept at

minimum

of 3oC

Within

parameters

Cold chain

procedure

GMP

Maintenance

of silos

Quarterly

check by

supplier of

chemicals

2(a)

Cream

separation

Chemical

risk

Cleaning

Within

parameters

GMP

SOCP

Quarterly

check by

supplier of

chemicals

3(a)

Homogenisatio

n

Chemical

risk

Cleaning

Within

parameters

GMP

SOCP

Quarterly

check by

supplier of

chemicals

4(a) Pasteurisation Microbial Temperature

and time

Temperatur

e and time

GMP WI

GLP

Re-pasteurise

4(b)

Pasteurisation

(Transfer of

milk to holding

tank)

Microbial

Cleaning

Wash not

more than

24 h before

Visual on

PC display

Wash

5

Loading milk

for mixing

Microbial

Cleaning

Wash not

more than

24 h before

Visual on

PC display

Wash

6

Powder mixing

Physical

foreign

material

Production

and process

control

Wash not

more than

24 h before

Visual on

PC display

Wash

7

T105 to storage

tank

Microbial

Cleaning

Wash not

more than

24 h before

Visual on

PC display

Wash

8

Pasteurisation

and

homogenisation

process

Microbial

Time and

temperature

Pasteurisati

on Temperature

& time

Temperatur

e and

recorder

and visual

on PC

display

Empty

pasteuriser

and repeat

washing and

sanitisation

9

Cooling down

to maturation

temperature and

ferment

addition

Microbial

Temperature

Temperature

Temperatur

e and

recorder

and visual

on PC

display

Too high: can

be cooled

with ice

water; too

low; stop the

process

10

Maturation and

breaking of

curd

Microbial

Cleaning

Wash not

more than

24 h before

Visual on

PC display

Wash

11

Cooling down,

smoothing with

filter and

transfer to

storage tank

Microbial

Cleaning

Wash 1

hour before

Visual on

PC display

Wash

12

Addition of

sterile apple

fruit pieces

Microbial

Cleaning

Wash 24 h

before

Visual on

PC display

Wash

13 Packing Microbial Cleaning Wash 24 h

before

Visual on

PC display

Wash

14

Storage

Microbial

Lab test

< 4C 24 h

Viscosity

Coliform

Count

Visual on PC

display

15

Dispatch

Microbial

Temperature

< 4C

Pre-cool

temperatur

e

Visual on PC

display

1.8 Determination of the critical control points (CCP)

1.8.1 For each hazard that requires control, control points are reviewed to identify those that

are critical. CCPs are those control points which are required in order to prevent or eliminate a

food safety hazard or reduce it to an acceptable level. If a hazard is identified at a step where

control is necessary for safety but the control does not exist, the product or process shall be

modified at that step, or at an earlier or later step, to provide a control measure.

Fab Foods implements a system by which critical points can be identified.

Table 9: Decision Tree used by company to establish Critical Control Points.

Simplified Decision Tree

YES NO

NO YES

CCP Not CCP Not CCP

Ref: Advised by the Chartered Institute of Environmental Health (C.I.E.H) U.K.

Q2. Is there a later step at which this

hazard is or can be controlled? (Under

your control)

Would a loss of control at this point result in a realistic risk of illness or

injury?

Results of Decision Tree for CCP Determination

Step Process step Hazards Control measures Control point

1(a) Raw Milk

(Receive Milk)

Presence of micro-

organisms

Microbiological analysis.

Keep records for each tanker

route

CP

1(b) Raw milk

(Release tests)

Antibiotics

Foreign material

Rosa test Kundrat test ATK test

In-line filter. Inspect tanker

before offloading. Quality of

gaskets

CCP

CCP

1(c) Raw milk

(Cooling)

Microbial Temperature CP

1(d) Raw milk (Silo

relase)

Microbial

Chemical risk

Temperature and time

Cleaning

CP

GMP

2(a) Cream

separation

Chemical risk Cleaning GMP

3(a) Homogenisatio

n

Chemical risk Cleaning GMP

4(a) Pasteurisation Microbial Temperature and time CCP

4(b) Pasteurisation

(Transfer of

milk to holding

tank)

Microbial Cleaning GMP

5 Loading milk

for mixing

Microbial Cleaning GMP

6 Powder mixing Physical foreign

material

Production and process control GMP

7 T105 to storage

tank

Microbial Cleaning GMP

8 Pasteurisation

and

homogenisation

process

Microbial Time and temperature CCP

9 Cooling down

to maturation

temperature and

ferment

addition

Microbial Temperature CCP

10 Maturation and

breaking of

curd

Microbial Cleaning GMP

11 Cooling down,

smoothing with

filter and

transfer to

storage tank

Microbial Cleaning GMP

12 Addition of

sterile apple

fruit pieces

Microbial Cleaning GMP

13 Packing Microbial Cleaning GMP

14 Storage Microbial Lab test CP

15 Dispatch Microbial Temperature CP

Fab Foods recognises the below as Critical Control Points in the production of the

product.

1. The presence of antibiotics, and foreign material in raw milk,

2. Effective pasteurisation and homogenisation,

3. Maintaining the correct fermentation Temperatures

1.9 Establishment critical limits for each CCP

1.9.1

For each CCP, the appropriate critical limits are defined in order to identify clearly whether the

process is in or out of control. Critical limits include:

measurable wherever possible, e.g. time, temperature, pH

supported by clear guidance or examples where measures are subjective, e.g.

photographs.

1.9.2

The HACCP food safety team validate each CCP. Documented evidence show that the control

measures selected and critical limits identified are capable of consistently controlling the

hazard to the specified acceptable level.

1.10 Establishment of a monitoring system for each CCP

1.10.1

A monitoring procedure is established for each CCP to ensure compliance with critical limits.

The monitoring system is able to detect loss of control of CCPs and wherever possible provides

information in time for corrective action to be taken. Means of monitoring include:

online measurement

offline measurement

continuous measurement, e.g. thermographs, pH meters etc.

where discontinuous measurement is used, the system ensures that the sample taken is

representative of the batch of product.

1.10.2

Records associated with the monitoring of each CCP include the date, time and result of

measurement and are signed by the person responsible for the monitoring and verified, as

appropriate, by an authorised person. Where records are in electronic form there is evidence

that records have been checked and verified.

1.11 Establishment a corrective action plan

1.11.1

The HACCP food safety team specifies and documents the corrective action to be taken when

monitored results indicate a failure to meet a control limit, or when monitored results indicate

a trend towards loss of control. This includes the action to be taken by nominated personnel

with regard to any products that have been manufactured during the period when the process

was out of control.

1.12 Establishment of verification procedures

1.12.1

Procedures of verification are established to confirm that the HACCP plan, including controls

managed by prerequisite programmes, are effective. Examples of verification activities

include:

internal audits

review of records where acceptable limits have been exceeded

review of complaints by enforcement authorities or customers

review of incidents of product withdrawal or recall.

Results of verification are recorded and communicated to the HACCP food safety team.

Critical Control Points Management

Critical

Control

Point

(CCP)

Significan

t

Hazard

Critical

Limits for

each

preventat

ive

measure

Monitoring

Correcti

ve

actions

Records

Verificati

on

What How Frequenc

y

Who

Presence of

Antibiotics

in raw milk

Allergic

reactions to

residues,

Development of

resistant

strains of bacteria,

Removes

starter

cultures

See Table 11 Below

Presence

of

antibiotics

Mainly

Beta-Lactam

DSM

Delvo-Test

&

Charm Test

On each

batch of milk in all

tankers,

silos, cream

vats,

fermentation tanks.

On site micro lab.

Reject &

Dispose, inform

Farm

Liaison Officer

and the

Dep.t of Agricult

ure

Corrective

action log.

Antibiotic testing log.

Milk &

Yogurts quality

log.

For each

batch

processed the QA

superviso

r will review

each log

Presence of

foreign

material in

raw milk

Can cause

physical,

biological and/or

chemical

adverse effects.

Foreign material

must be

absent in milk.

Presence

of

Foreign Matter

ISO

5538:200

4 Milk -

Inspectio

n by attributes

On each batch of

milk in all

tankers, silos,

cream

vats, fermentati

on tanks.

On site

micro lab.

Remove

or Reject &

Dispose,

inform Farm

Liaison

Officer and the

Dep.t of

Agriculture

Corrective

action log. Antibiotic

testing log.

Milk & Yogurts

quality

log.

For each

batch

processed the QA

superviso

r will review

each log

HTST

Pasteurisat

ion

If not carried out

correctly,

harmful

spoilage

m/org can grow

72C for

20

seconds

TVC

Table 11: Comparison of the EU maximum residue limits (EEC Regulation 2377/90 and

amendments) with the sensitivities of the microbial inhibition assays for the detection of

antibiotics in milk.

1.13 HACCP Plan Overview

Step Process step Hazards Control

measures

Control

point Critical

limits

Monitoring

procedure

s

Corrective

action

1(a)

Raw Milk

(Receive Milk)

Presence of

micro-

organisms

Microbiologi

cal analysis.

Keep records

for each

tanker route

CP

Bactoscan

results

Raw milk

procedure

Reject milk if

not to

microbiologic

al limits

1(b)

Raw milk

(Release tests)

Antibiotics

Foreign

material

Rosa test

Kundrat test

ATK test

In-line filter.

Inspect

tanker before

offloading.

Quality of

gaskets

CCP

CCP

Negative

No damage

gaskets

Raw milk

procedure

Raw milk

procedure

Reject milk

Follow up

Daily tanker

inspections

1(c)

Raw milk

(Cooling)

Microbial

Temperature

CP

Milk

Cooled to <

3oC

Cold chain

procedure

Maintenance

of ice banks

1(d)

Raw milk (Silo

relase)

Microbial

Chemical

risk

Temperature

and time

Cleaning

CP

GMP

Milk to be

kept at

minimum

of 3oC

Within

parameters

Cold chain

procedure

GMP

Maintenance

of silos

Quarterly

check by

supplier of

chemicals

2(a)

Cream

separation

Chemical

risk

Cleaning

GMP

Within

parameters

GMP

SOCP

Quarterly

check by

supplier of

chemicals

3(a)

Homogenisatio

n

Chemical

risk

Cleaning

GMP

Within

parameters

GMP

SOCP

Quarterly

check by

supplier of

chemicals

4(a) Pasteurisation Microbial Temperature

and time

CCP Temperatur

e and time

GMP WI

GLP

Re-pasteurise

4(b)

Pasteurisation

(Transfer of

milk to holding

tank)

Microbial

Cleaning

GMP

Wash not

more than

24 h before

Visual on

PC display

Wash

5

Loading milk

for mixing

Microbial

Cleaning

GMP

Wash not

more than

24 h before

Visual on

PC display

Wash

6

Powder mixing

Physical

foreign

material

Production

and process

control

GMP

Wash not

more than

24 h before

Visual on

PC display

Wash

7

T105 to storage

tank

Microbial

Cleaning

GMP

Wash not

more than

24 h before

Visual on

PC display

Wash

8

Pasteurisation

and

homogenisation

process

Microbial

Time and

temperature

CCP

Pasteurisati

on Temperature

& time

Temperatur

e &

recorder &

visual on

PC display

Empty

pasteuriser

and repeat

washing and

sanitisation

9

Cooling down

to maturation

temperature and

ferment

addition

Microbial

Temperature

CCP

Temperature

Temperatur

e and

recorder

and visual

on PC

display

Too high: can

be cooled

with ice

water; too

low; stop the

process

10

Maturation and

breaking of

curd

Microbial

Cleaning

GMP

Wash not

more than

24 h before

Visual on

PC display

Wash

11

Cooling down,

smoothing with

filter and

transfer to

storage tank

Microbial

Cleaning

GMP

Wash 1

hour before

Visual on

PC display

Wash

12

Addition of

sterile apple

fruit pieces

Microbial

Cleaning

GMP

Wash 24 h

before

Visual on

PC display

Wash

13 Packing Microbial Cleaning GMP Wash 24 h

before

Visual on

PC display

Wash

14

Storage

Microbial

Lab test

CP

< 4C 24 h

Viscosity

Coliform

Count

Visual on PC

display

15

Dispatch

Microbial

Temperature

CP

< 4C

Pre-cool

temperatur

e

Visual on PC

display

Table 12: HACCP Plan Overview (where CP = Control Point, CCP = Critical Control

Point, GMP = Good Manufacturing Practice, SOCP = Standard Operating Cleaning

Procedure)

1.14 HACCP documentation and record keeping

1.14.1

Documentation and record keeping are sufficient to enable the company to verify that the

HACCP controls, including controls managed by prerequisite programmes, are in place and

maintained.

Doc &

Record

Ingredients Product safety Processing Packaging Storage and

distribution

Deviations

and

corrective

actions

Supplier certification -

documenting

compliance

with

processors specifications

along with

Certificates of

Analysis

Data and

records to

establish the

efficacy of

barriers in

maintaining

product safety

Records

from all

monitored

CCPs

Records

indicating

compliance

with

specifications

of packaging

materials

Temperature

records

Indicating

approved

revisions and

changes in

ingredients,

formulations,

processing,

packaging

and

distribution

control

Processor

audit records

verifying

supplier

compliance

Data and

records

establishing the

safe shelf life

of the product,

as age of

product can

affect safety

Records

verifying

the

continued

adequacy

of the

process

Records

indicating

compliance

with sealing

specifications

Records

showing that

no product is

shipped after

shelf life date

Storage

temperature

records for all

ingredients

Documentation

of the

adequacy

of the

processing

procedures

from a

knowledgeable

process

authority

Storage temperature

records for

temperature

sensitive

ingredients

Table 13: Documentation and Record keeping of the HACCP standard.

Documents used to control HACCP:

Sample documents and records from I.S. 340:2007

1.15 Review of the HACCP plan

1.15.1

The HACCP food safety team reviews the HACCP plan and prerequisite programmes annually

and prior to any changes which may affect product safety. Changes can include

change in raw materials or supplier of raw materials

change in ingredients/recipe

change in processing conditions or equipment

change in packaging, storage or distribution conditions

change in consumer use

emergence of a new risk, for example adulteration of an ingredient

developments in scientific information associated with ingredients, process or product.

Appropriate changes resulting from the review shall be incorporated into the HACCP plan

and/or prerequisite programmes, fully documented and validation recorded.