Procedure for HACCP Plan

8/9/2019 Procedure for HACCP Plan

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Organization: SPRINTECH

Doc. Title: HACCP Plan Procedure

Document Code: STP/ISP-0 Rev#:00

INTEGRATED SYSTEM PROCEDURE

HACCP PLA

(CLAUSE 7.. of ISO 22000:2005)

Name Designation Signature Date

Prepared by: Mr. Mujtaba ISO Coordinator

e!ie"ed by: Mr. Waqa MR

Appro!ed by: Mr. Muja!id "li MD

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DOCUMENT HISTORY

#$%&

DAT#PA'#&

S#CTI(N DC& NAT)# (* A+#ND+#NT

"ll c!ange made in t!e document are noti$ed in t!e Document %itor&. 'or detail o(

amendment) *leae re(er to relevant DCR +Doc. C!ange Requet,.

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,% Purpose

T!e *ur*oe o( t!i *rocedure i to identi(& *oible (ood a(et& !azard and

control in *lace to ma-e ure t!e (ood a(et& !azard are eliminated or controlled

to enure acce*table level.

% Scope

T!i *rocedure a**lie to all activitie at identi$ed CC

.% esponsibilities

Management Re*reentative and 'ood Sa(et& Team /eader i re*onible

(or

0, T!e im*lementation o( t!i *rocedure

1, Monitoring o( t!e %"CC *eronnel de*uted at CC

2, 3eri$cation and igning o( %"CC record.

% Procedure

%, #stablising a HACCP Team

S*rintec! ac-aging !a etabli!ed a %"CC team made u* o( *eo*le

(rom a 4ide range o( dici*line a given in "**endi5 I. T!e team

include:0. " team leader to convene t!e grou* and to direct t!e 4or- o( t!e

team enuring t!at t!e %"CC conce*t i *ro*erl& a**lied.

1. Member 4it! major role in *roduction o( t!e (ood *ac-aging

material) eac! 4it! an undertanding o( *articular (ood a(et&

!azard and aociated ri-.

% Describing a product

" (ull decri*tion o( t!e *roduct 4it! relevant a(et& in(ormation i

*re*ared a

given in "**endi5 II. "lo in(ormation regarding !o4 t!e *roduct i to

be

*ac-aged) tored and tran*orted i alo conidered toget!er 4it!

(act

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regarding it6 !el( li(e and recommended torage tem*erature.

/abelling

in(ormation i alo included.

T!i in(ormation 4ill ait t!e %"CC team to identi(& 6real6 !azard

aociated

4it! t!e *roce.

%.Describing a product1s intended use

T!e %"CC team alo de$ne t!e normal or e5*ected ue o( t!e *roduct

b& t!e

cutomer and t!e conumer (or 4!ic! t!e *roduct i intended. T!i

in(ormation i

recorded on t!e ame (orm o( *roduct decri*tion) ee "**endi5 II.

%Construction o2 *lo" Diagram ( Description of Manufacturing

process)

"ll t!e te* involved in t!e *roce (rom receiving t!e ra4 material to

*lacing

t!e end *roduct t!roug! *re*aration) *roceing ) *ac-aging ) torage

and

ditribution i *reented in a detailed 7o4 diagram.

"(ter t!e 7o4 diagram !a been made) a multidici*linar& team 4ill

con$rm it

on8ite during o*erating !our. "n& oberved deviation 4ill reult in an

amendment o( t!e original 7o4 diagram to ma-e it accurate.

%3 Identi4cation and Analysis o2 Ha5ard6s7T!e %"CC team ne5t conduct a !azard anal&i to identi(& (or t!e

%"CC *lan

4!ic! !azard are o( uc! a nature t!at t!eir elimination or reduction to

acce*table

level i eential to t!e *roduction o( a a(e (ood *ac-aging.

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'ood a(et& !azard (or %"CC *lan !ave been clai$ed into t!ree t&*e

o( !azard:

,% 8iological % Cemical .% Pysical

In conducting t!e !azard anal&i) t!e (ollo4ing !ould be conidered:

a. t!e li-el& occurrence o( !azard and everit& o( t!eir advere !ealt!

e9ect

b. t!e qualitative andor quantitative evaluation o( t!e *reence o(

!azard

c. urvival or multi*lication o( *at!ogenic micro8organim and

unacce*table generation o( c!emical in intermediate *roduct) $nal

*roduct) *roduction line or line environment

d. *roduction or *eritence in (ood o( to5in or ot!er undeirable

*roduct o( microbial metabolim) c!emical or *!&ical agent or

allergen

e. contamination +or recontamination, o( a biological +micro8organim)

*araite,) c!emical or *!&ical nature o( ra4 material) intermediate

*roduct

or $nal *roduct.

Once a (ood a(et& !azard !a been identi$ed) t!en a**ro*riate control

meaure are ta-en into conideration. T!ee are an& action or activit& t!at

can be ued to control t!e identi$ed !azard) uc! t!at it i *revented)

eliminated) or reduced to an acce*table level.

%9 Identi4cation o2 Critical Control Points 6CCPs7

T!e identi$cation o( a critical *oint (or t!e control o( a !azard i done

b& t!e %"CC

team ) according to t!eir judgment ) e5*erience and -no4ledge o( t!e

*roce.

;ac! *roce te* identi$ed in t!e 7o4 diagram i conidered in equence.

T!e team 4ill determine 4!et!er t!e !azard can occur at t!i te*) and i( o

4!et!er control meaure e5it. I( t!e !azard can be controlled adequatel&)

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and i not bet controlled at anot!er te*) and i eential (or (ood a(et&)

t!en t!i te* i a CC (or t!e *eci$ed !azard.

T!e identi$cation o( critical control *oint !a t4o conequence (or t!e

%"CC team

4!ic! !ould t!en:

,% ;nure t!at a**ro*riate control meaure are e9ectivel& deigned and

im*lemented.

% ;tabli! and im*lement a monitoring &tem at eac! critical *oint.

roduction !ould ceae until control meaure are available and a CC i

introduced.

% Critical ;imits at Critical Control Points

;ac! control meaure aociated 4it! a critical control *oint 4ill give rie to

t!e

*eci$cation o( critical limit. Critical limit corre*ond to t!e e5treme

value acce*table 4it! regard to *roduct a(et&. T!e& e*arate

acce*tabilit& (rom unacce*tabilit&. T!e& are et (or obervable or

meaurable *arameter 4!ic! can demontrate t!at t!e critical *oint i

under control. It !ould be baed on ubtantiated evidence t!at t!e c!oen

value 4ill reult in *roce control.

%< +onitoring Procedures at Critical Control Points

Monitoring i t!e mec!anim (or con$rming t!at critical limit at eac! CC

are being

met. " (requenc& o( obervation or meaurement 4!ic! *rovide reliable

in(ormation i etabli!ed.

T!e *rocedure decribe t!e met!od) t!e (requenc& o( obervation or

meaurement

and t!e recording *rocedure and identi(& eac! critical *oint:

a. 4!o i to *er(orm monitoring and c!ec-ing)

b. 4!en monitoring and c!ec-ing i *er(ormed)

c. !o4 monitoring and c!ec-ing i *er(ormed.

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Record aociated 4it! monitoring CC mut be igned b& t!e 'ood

Sa(et& Team /eader doing t!e monitoring and t!e record are veri$ed b&

Management Re*reentative o( t!e com*an&.

%= Correcti!e Actions

'or eac! critical control *oint corrective action i *lanned in advance b&

t!e

%"CC team) o t!at t!e& can be ta-en 4it!out !eitation 4!en monitoring

indicate

a deviation (rom t!e critical limit.

Suc! corrective action 4ill include:

< Identi$cation o( t!e *eron+, re*onible (or t!e im*lementation o( t!e

corrective action)

< Decri*tion o( mean and action required to correct t!e oberved

deviation)

< "ction to be ta-en 4it! regard to *roduct t!at !ave been manu(actured

during t!e

*eriod 4!en t!e *roce 4a out o( control)

< Written record o( meaure ta-en indicating all relevant in(ormation +(ore5am*le:

date) time) t&*e o( action) actor and ubequent veri$cation c!ec-,.

Monitoring 4ill indicate t!at *reventive meaure +c!ec-ing equi*ment)

c!ec-ing t!e

*eron !andling t!e (ood *ac-aging material) c!ec-ing t!e e=cac& o(

*reviou

corrective meaure) etc., !ould !ave to be ta-en i( corrective action (or

t!e ame

*rocedure !ave to be ta-en re*eatedl&.

%,0 $eri4cation Procedures

T!e %"CC team !ould *eci(& t!e met!od and *rocedure to be ued (or

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determining i( t!e %"CC *lan i 4or-ing correctl&. Met!od (or veri$cation

ma&

include in *articular random am*ling and anal&i) rein(orced anal&i or

tet

at elected critical *oint) inteni$ed anal&i o( intermediate or $nal

*roduct)

urve& on actual condition during torage.

T!e (requenc& o( veri$cation !ould be u=cient to con$rm t!at %"CC

*lan i

4or-ing e9ectivel&. T!e (requenc& o( veri$cation !all de*end on t!e

c!aracteritico( t!e buine ) t!e monitoring (requenc&) t!e accuracie o( t!e

em*lo&ee) t!e

number o( deviation detected over time and t!e !azard involved.

3eri$cation *rocedure include:

< "udit o( %"CC and it record)

< In*ection o( o*eration)

< Con$rmation t!at CC are -e*t under control)

< 3alidation o( critical limit)

< Revie4 o( deviation and *roduct di*oition> corrective action ta-en

4it! regard to t!e *roduct.

T!e (requenc& o( veri$cation 4ill greatl& in7uence t!e amount o( rec!ec- or

recall

required in cae a deviation e5ceeding t!e critical limit !a been detected.

3eri$cation

!all com*rie all o( t!e (ollo4ing element) but not necearil& all at t!e

ame time:

< C!ec- on t!e correctne o( t!e record and anal&i o( deviation

< C!ec- on t!e *eron monitoring *roceing) torage andor tran*ort

activitie

< !&ical c!ec- on t!e *roce being monitored

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< Calibration o( intrument ued (or monitoring.

3eri$cation i carried out b& Management Re*reentative omeone ot!er

t!an t!e *eron 4!o i re*onible (or *er(orming t!e monitoring and

corrective action.

W!ere *oible) validation activitie !ould include action to con$rm t!e

e=cac& o( all element o( t!e %"CC *lan. In cae o( c!ange) it i necear&

to

revie4 t!e &tem) to enure t!at it i or 4ill be till valid.

;5am*le o( c!ange include:

< c!ange in ra4 material or in *roduct) *roceing condition +(actor& la&out

andenvironment) *roce equi*ment) cleaning and diin(ection *rogram,)

< c!ange in *ac-aging) torage or ditribution condition)

< c!ange in conumer ue)

< recei*t o( an& in(ormation on a ne4 !azard aociated 4it! t!e *roduct.

W!ere necear&) uc! a revie4 mut reult in t!e amendment o( t!e

*rocedure laid

do4n. T!e c!ange !ould be (ull& incor*orated into t!e documentation and

record-ee*ing &tem in order to enure t!at accurate u*8to8date

in(ormation i available.

%,, Documentation and ecord >eeping

%"CC *rocedure !ould be documented. Documentation and record

-ee*ing !ould be a**ro*riate to t!e nature and ize o( t!e o*eration and

u=cient to ait t!e buine to veri(& t!at t!e %"CC control are in

*lace and being maintained. Document and record !ould be -e*t (or a

u=cient time to allo4 t!e com*etent aut!orit& to audit t!e %"CC &tem.

Document !ould be igned b& Management Re*reentative o( t!e

com*an&.

Documentation e5am*le are:

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< %azard anal&i>

< CC determination>

< Critical limit determination>

< Modi$cation to t!e %"CC &tem.

Record e5am*le are:

< CC monitoring activitie>

< Deviation and aociated corrective action>

< 3eri$cation activitie.

%, Training

T!e Management re*reentative and (ood a(et& team leader !all ma-e

ure t!at all

*eronnel are a4are o( t!e !azard identi$ed +i( an&,) t!e critical *oint in

t!e

*roduction) torage) tran*ort andor ditribution *roce and t!e corrective

meaure) t!e *reventive meaure and documentation *rocedure

a**licable in

t!e o*eration o( t!e com*an&.

%, elated Documents

%"CC Mater lan

%"CC lan 3alidationReaement C!ec-lit

Corrective ? reventive "ction 'orm

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Figure 1. CCP Decision Tree- Flow Diagram

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Figure 2. Manufacturing Process Flow Diagram

Appendix I: Establishing a HACCP ea!

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HACCP Team

*acility Name : S*rintec! ac-aging Date :Se*tember 12 ) 1@0A

Team +ember PositionHACCP Team

oleSignatur

e

S&ed Mujtaba "li roduction Member"dvior

Waqa %aanManagement

Re*reentative"dvior

Bman S!au-at ".M roduction Member

air ilalInc!arge E"

roduct Sa(et& Team /eader

Imran "meerrinting

Su*erviorMember

Tariq %uain/aminationSu*ervior

Member

Ir(an S!ei-!/aminationSu*ervior

Member

F!alid ImtiazSlitting

Su*erviorMember

Mu!ammad %uain

ag Ma-ing

Su*ervior Member

Waqa GunaidSleeve Ma-ing

Su*erviorMember

Haveed F!alidWare!oue

Inc!argeMember

Hadeem "!madDi*atc!"itant

Member

Fa!i( Me!moodMaintenance

;ngineerMember

S&ed Eaim Raza

urc!ae

;5ecutive Member

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Appendix II: P"#d$%t &es%"ipti#n '#"!at

P"#d$%t &es%"ipti#n ( Intended )se*e%ti#n: &ate:

P"#d$%t Categ#"+ ,a!e

P"#d$%t des%"ipti#n:

-i#l#gi%al. Che!i%al and Ph+si%al

Cha"a%te"isti%s

Intended *hel/ i/e ( *t#"age C#nditi#ns

Pa%aging e$i"e!ents

abeling e$i"e!ents

eth#d #/ &ist"ib$ti#n

Intended )se

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Appendix III: HACCP alidati#neassess!ent Che%list

HACCP $alidation/eassessment Ceclistlant Hame : roduct Date Conducted :

Conducted b& :

$alidation Type

Initial Validation ( within 12 months of implementation)

Validation (Reassessment) due to changes in the raw materials or source of raw materials , product formulation ,

processing method or system , including computer and their softwares, packaging , finished product distriution

systems or the intended use or the intended consumers of the finished product or type of consumer complaints!

"nnual Validation (Reassessment ) of the #"$$P Plan including #a%ard "nalysis

#pi% E* ,I/ E*

&es%"ibe

'##d *a/et+

I!pli%ati#n;

A"e !#di/i%ati#ns t# the HACCP

s+ste! "e$i"ed;

1


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.ew or emerging ha%ards

Regulatory "gency

recommendation e!g!,

guidance

"ny confirmed food

safety consumer

complaints

3< E=al$ate ade$a%+ #/ CCP>s. %"iti%al li!its. !#nit#"ing. %#""e%ti=e a%ti#n. CCP =e"i/i%ati#n. and "e%#"d eeping

p"#%ed$"es< e=ie? %$""ent CCP %$!entati#n

/o the $$Ps control the

ha%ards'

"re the $PP criticallimits ade+uate'

/o monitoring methods

and fre+uencydemonstrate control'

/o correcti-e actionsproperly address

affected product'

/oes -alidation include

re-iew of consumercomplaints'

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Appendix I: HACCP Plan eassess!ent Change '#"!

HACCP Plan eassessment Cange *orm

*acility Name:

Person6s7esponsible:

HACCP Plan Name/Number and

/uring the reassessment of this plan, the person(s) responsile listed ao-e hasha-e determined that

$hanges, "dditions, or /eletions were needed! 0hose changes are documented elow! "lso attached is

information used to support modification(s) of this plan!

Cec (ne CHAN'# ADDITI(N D#;#TI(N

Bat speci4cally "ere Canged / Added / Deleted

By "as it Canged / Added / Deleted

Bat is te basis 2or te Cange / Addition / Deletion

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a" +aterial Ha5ard Analysis


, . 3 9

;ist eac ra"material/ingredient in teprocess

Does tis material/ ingredientINT(D)C# apotential 2oodsa2ety a5ardBat is itC C!emical !&ical iological

Is tis a5ardC(NT(;;#D by aPre-reuisiteProgram orprocess stepI( ;S) indenti(& t!e*rogram or *roce. I( a*re8requiite *rogram or*roce i identi$ed) donot com*lete Column A8J and go to ne5t *rocete*. I( HO) go to columnA.

Is tis a5ard#;I+INAT#D by asubseuentprocess stepI( ;S) t!i te* i HOT aCC. Indenti(& t!eubequent *roce te*in Column K and *roceedto t!e ne5t *roce te*.I( t!e !azard ieliminated at t!i te*)enter HO and go tocolumn J and aign CC#.

Identi2y te lastprocess step tat"ill eliminate tepotential a5ard%

Assign a CCP &"en te ans"erin Column & isN(%(otherwise lea-e lank)

'ilm +;T ) 3C )O) %D;) %T/)O) C) /D; )H/OH ; ,

C Ho

e L 'oreignMaterial

e L ReceivingIn*ection

Ho

"d!eive+!ot melt) rein )

lamination,

C Ho

e L 'oreignMaterial


e 8 In(etation e L ReceivingIn*ection

In- and c!emical

C e L lant C!emicale L C!emical Control

lan

Ho

Ho

a*er ) leac! oard+variou t&*e andgrade,

C Ho

e L 'oreignMaterial


e 8 Moulde L ReceivingIn*ection

ac-ing Material C Ho

Ho

e L 'oreignMaterial ?


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In(etation

Process Ha5ard Analysis


, . 3 9;ist eac ra"material/ingredient in teprocess

Do tis material /ingredientINT(D)C# apotential 2oodsa2ety a5ardBat is itC C!emical !&ical iological

Is tis a5ardC(NT(;;#D by aPre-reuisiteProgram orprocess stepI( ;S) indenti(& t!e*rogram or *roce. I( a*re8requiite *rogram or*roce i identi$ed) donot com*lete Column A8J and go to ne5t *rocete*. I( HO) go to columnA.

Is tis a5ard#;I+INAT#D by asubseuentprocess stepI( ;S) t!i te* i HOT aCC. Indenti(& t!eubequent *roce te*in Column K and *roceedto t!e ne5t *roce te*.I( t!e !azard ieliminated at t!i te*)enter HO and go tocolumn J and aign CC#.

Identi2y te lastprocess step tat"ill eliminate tepotential a5ard%

Assign a CCP &"en te ans"erin Column & isN(%(otherwise lea-e lank)

Receiving In*ection

C Ho

e L 'oreignMaterial


e 8 In(etatione L Receiving

In*ection

Ware!ouing

C Ho

e L 'oreignMaterial


e 8 In(etatione L Receiving

In*ection

rinting

Ce L IncorrectDeign

e L /ine Clearance

e L Deign c!ec-litHo

.o 3ine $learance

$$P41 Ho

Ho

/aminationSolventle

C e Ho .o 3ine $learance

$$P42 Ho

e L Contamination in(etation

e L eronal %&giene ?%oue-ee*ing *rogram

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/amination Solventae

C e Ho .o 3ine $learance

$$P45 Ho



SlittingC Ho

Ho

Ho

ag Ma-ing

C Ho .o Visual Inspection

$$P46 Ho



Sleeve ? Tube Ma-ing

C Ho

Ho



ac-aging

Ce L Incorrect*alletizing +allergen,

Ho .o Visual Inspection and

pallet control $$P47 Ho



Ware!ouing

C Ho

Ho

e L Contamination In(etation


Di*atc!S!i**ing

C Ho

Ho

e L Contamination in(etation e L eronal %&giene ?%oue-ee*ing *rogram

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HACCP +aster Plan


HACCP Plan 2or +ulti-layer *leEible Pacaging +aterials

CPPNumber

Signi4cantHa5ard

Critical;imit

+onitoring Correcti!eAction

$eri4cation

ecord6s7Bat Ho" *reuency Bo

$$P413ine

$learance

Printed materials

from pre-ious 8os

ha-e not een fully

cleared!

.o materials

from other

8os allowed

in area!

Printing

procedure

perator

remo-es all

materials from

pre-ious order

efore new 8o

starts up!

*ach

work orderperator

perator

remo-es

materials per

critical limits

and re4

inspects line!

Verified y

operator or

other co4

worker

Production

Records

$$P423ine

$learance

3aminated materials

from pre-ious 8os

ha-e not een fully

cleared!

.o materials

from other

8os allowed

in area!

3amination

procedure

perator

remo-es all

materials from

pre-ious order

efore new 8ostarts up!

*ach

work orderperator

perator

remo-es

materials per

critical limits

and re4inspects line!

Verified y

operator or

other co4

worker

Production

Records

$$P453ine

$learance

3aminated materials

from pre-ious 8os

ha-e not een fully

cleared!

.o materials

from other

8os allowed

in area!

3amination

procedure

perator

remo-es all

materials from

pre-ious order

efore new 8o

starts up!

*ach

work orderperator

perator

remo-es

materials per

critical limits

and re4

inspects line!

Verified y

operator or

other co4

worker

Production

Records

$$P46

VisualInspection

Incorrect uniti%ing or

palleti%ing due to

inad-ertent mi9ing of

ags results in

allergen risk due to

mi9ed product types

.o mi9ing of

ags!Visual

Inspection

:ork

instructions for

operators

helpers

*ach

cartonperator

perator

remo-es

materials per

critical limits!

Verified y

operator or

other co4

worker

Production

Records

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$$P47Visual

Inspection; Pallet$ontrol

Incorrect uniti%ing or

palleti%ing due to

inad-ertent mi9ing of

ags results in mi9ed

product types

.o mi9ing of

ags!Visual

Inspection

coupled with

pallet

segregation!

:ork

instructions for

operators

helpers

*-ery

palletperator


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