Page 1
Registration and approval of the study
MANAGEMENT SHEET
Page A
Recording and filing of supporting
LIST OF SUPPORTING
information
DOCUMENTS
Page B
PROCESS FLOW Helps to understand the process
DESCRIPTION
Page E
With help of the decision tree the control
CONTROL MEASURE
measures are categorized to CCP, OPRP
SELECTION AND
or Modification
CATEGORIZATION
Page F
Evidence that the control measure can
VALIDATION OF CONTROL
achieve the targeted limits
MEASURES
Page G
MODIFICATION(S) AND List of modifications with all details
FOLLOW-UP
MANAGEMENT SHEET
Complete the first section (below) at the start of the HACCP study
Description of scope of study (e.g. module (start and end point) or products included)
Scope of study is covered line of steam generation that is used for process (direct contact to the product)
Page 1 - 2
PRODUCT DESCRIPTIONS
Characteristics of product
Name (product(s), product group(s), line)
Steam (HP & LP)
Materials
Raw materials / Ingredients (or attach list with
-
RM numbers)
High risk ingredient(s) (e.g. allergens, microbial
-
risks, foreign body source)
Packaging materials
-
Rework
-
Other
-
Use by Consumers
Intended use
-
Page 2 - 3
Flow Diagram
Flow
Critical Limits /
(Page C)
CCP No Diagram
Hazard
Code
Hazard Targets Monitoring Corrections
OPRP No Code Step Control measure(s)
description (or Limits if How, frequency, who? Responsibilities
(as in
applicable)
Page 5)
A1 Soft Water Chemical 1x/ shift by boiler operator as
CP CON
Contamination
Total Hardness < 1 ppm
describe in analysis procedure
Boiler Operator
A4 NALCO 22310
Chemical 1x/ shift by boiler operator as
CP CON
Contamination TDS Max. 2000 uS/cm describe in analysis procedure Boiler Operator
A5 Condensate
A6 Culinary Steam Chemical
CP CON
Contamination Aspect Clear 1x/shift by boiler operator, visual Boiler Operator
A5 Condensate
Chemical 1x/ shift by boiler operator as
CP A6 Culinary Steam CON
Contamination
Hardness Max. 1 ppm.
describe in analysis procedure
Boiler Operator
A5 Condensate
A6 Culinary Steam Chemical 1x/ shift by boiler operator as
CP CON
Contamination pH 5.0 7.0 describe in analysis procedure
Boiler Operator
A5 Condensate
A6 Culinary Steam Chemical 1x/ shift by boiler operator as
CP CON
Contamination Conductivity Max. 15 uS/cm describe in analysis procedure
Boiler Operator
Page 4 - 6
CP PLAN INCLUDING OPRPs
Verification
Corrective actions
Records (details in
Responsibilities
Page 5)
Boiler Water
Softener Regeneration
LogBook
Boiler Water
Adjust dosing pump 22310
LogBook
Boiler Water
Softener Regeneration
LogBook
Adjust alkalinity booster Boiler Water
dosing pump LogBook
Boiler Water
Softener Regeneration
LogBook
Boiler Water
Softener Regeneration
LogBook
Boiler Water
Adjust LP Steam
LogBook
Boiler Water
Adjust 2811 dosing pump
LogBook
Boiler Water
Blowdown boiler water
LogBook
Boiler Water
Drain condensate
LogBook
Boiler Water
Softener Regeneration
LogBook
Boiler Water
Drain condensate
LogBook
Boiler Water
Drain condensate
LogBook
Page 4 - 7
VERIFICATION PLAN
Verification activity Verification procedure Frequency Responsible Records
(e.g of CCP monitoring or OPRP functioning, (e.g. methods or procedures to use, observations to be (how often is the task to be (who is responsible for (which records should be used)
corrective actions) made or measurements to be taken, actions if there is performed) the task)
a deviation or follow-up)
Water Report
Follow standard analysis procedure.
Total Hardness analysis in soft water 1x/shift Boiler Operator In case deviation: out of norm water
In case deviation: softener regeneration
report
Water Report
Aspect monitoring in boiler feed water Visual monitoring 1x/shift Boiler Operator In case deviation: out of norm water
report
Water Report
Follow standard analysis procedure.
Hardness analysis in feed water 1x/shift Boiler Operator In case deviation: out of norm water
In case deviation: softener regeneration
report
Water Report
Follow standard analysis procedure.
pH monitoring in feed water 1x/shift Boiler Operator In case deviation: out of norm water
In case deviation: adjust dosing pump
report
Water Report
Follow standard analysis procedure.
P-Alkalinity monitoring in feed water 1x/shift Boiler Operator In case deviation: out of norm water
In case deviation: softener regeneration
report
Water Report
Follow standard analysis procedure.
M-Alkalinity monitoring in feed water 1x/shift Boiler Operator In case deviation: out of norm water
In case deviation: softener regeneration
report
Water Report
Visual monitoring in temperature gauge
Temperature monitoring in feed water 1x/shift Boiler Operator In case deviation: out of norm water
In case of deviation: adjust LP Steam control valve
report
Water Report
Follow standard analysis procedure.
Sulfit monitoring in boiler water 1x/shift Boiler Operator In case deviation: out of norm water
In case deviation: adjust dosing pump
report
Water Report
Follow standard analysis procedure.
TDS monitoring in boiler water 1x/shift Boiler Operator In case deviation: out of norm water
In case deviation: blowdown boiler water
report
Water Report
Follow standard analysis procedure.
pH monitoring in boiler water 1x/shift Boiler Operator In case deviation: out of norm water
In case deviation: adjust dosing pump
report
Water Report
Visual monitoring
Aspect monitoring in condensate return 1x/shift Boiler Operator In case deviation: out of norm water
In case of deviation: drain condensate
report
Page 5 - 8
Water Report
Follow standard analysis procedure.
Hardness monitoring in condensate return 1x/shift Boiler Operator In case deviation: out of norm water
In case of deviation: softener regeneration
report
Water Report
Follow standard analysis procedure.
pH monitoring in condensate return 1x/shift Boiler Operator In case deviation: out of norm water
In case of deviation: drain condensate
report
Water Report
Follow standard analysis procedure.
Conductivity monitoring in condensate return 1x/shift Boiler Operator In case deviation: out of norm water
In case of deviation: drain condensate
report
Page 5 - 9
LIST OF SUPPORTING DOCUMENTS
Document
No Description: Title, Date of issue
number
3 ISO -
10
11
12
13
14
Page A - 10
Page A - 11
LIST OF SUPPORTING DOCUMENTS
Author / Company / Organisation Filing location
Page A - 12
Page A - 13
PROCESS FLOW DESCRIPTION (Optional)
Process Step
Flow Diagram
Code
(as in
Description
Page 5)
A1 Soft Water
A2 NALCO 2811
A3 NALCO 2584
A3 NALCO 8507
A4 NALCO 22310
A5 Steam Condensate
A6 Culinary Steam
B2 Drum Nalco
B3 Loos Boiler
B4 Maxitherm Boiler
C1 Condensate Tank
C2 Manual Tipping
C3 Dosing Pump
C4 Strainer
C5 Pump 1,2
C6 Steam
C7 Strainer/Steam Trap
C8 Steam Purifier
C9 Desuperheater
Page B - page 14
ESS FLOW DESCRIPTION (Optional)
Soft Water Means Water with Total Hardness Content < 1ppm
Alkalinity Adjuster
Alkalinity Adjuster
(Polymer) as Antiscalant
2 m3 condensate tank
Page B - page 15
HAZARDOUS AGENT CODES AND CLASSIFICATION
Code Hazard Class Hazardous Agent Description
Page C - 16
Page C - 17
Severity of health
effect
Can cause
A
fatality
Can lead to
B
serious illness
Can cause
C
illness
Can cause
D
inconvenience
Almost of no
E
significance
1 2 3 4 5
Unlikely Rare Could Likely Frequent
occur
(<1/2 (1 / year) (1/6 month) (1 / month) (1 / week)
years)
Likelihood of occurrence
HAZARD IDENTIFICATION and DESCRIPTION
Justification
Location of potential hazard Hazard description Hazard assessment
for selection of Hazards and Assesment
Indicate the step (e.g. raw Describe clearly and specifically the hazards that are "reasonably expected" to occur at each step: Class (M, Q1: Based on the hazard description, likelihood of Provide supporting data/references on likelihood of occurrence, information on
material, processing or P, C or A), agent, size, origin, nature, etc. occurrence (before applying the control measure) severity of health effects and acceptabel level in end product.
distribution) at which the hazard and severity of health effects, does this hazard
may be introduced. needs to be controlled, i.e. is it a significant hazard?
Step (description) Hazard Class Origin or source of the Nature of the hazard Acceptable level in Likelihood of Severity of Significant hazard? For each hazard, document why it is or why it is not likely to occur or causing
Flow
Hazard Code
hazard (e.g. where and (e.g. precense, ability end product occurrence adverse health (Yes/No) adverse health effects. For non significant hazards document if it is manged e.g.
Diagra
(Page C)
how it can be to grow, survive, effect For significant hazard, by a PRP, through a specification or Major Allergen Declaration (MAD).
m Code introduced into the formation of toxins or select and categorize Make sure that all haz
(as in product or its toxic chemicals, control measure(s) on
Page environment) migration of Page E.
5) chemicals)
4 A YES 4A
Frequent:
Almost In every week, we found the residual hardness in feed water is out of
norm
Counter Measure:
Periodical checking & Softener Regeneration or membrane replacement. In
case needed, do boiler chemical cleaning
4 A YES 4A
Frequent:
Almost In every week, we found the residual hardness in feed water is out of
norm
Counter Measure:
Periodical checking & Adjust LP Steam control valve to accelerate the
evaporation of residual sulfit
1 C NO 1C
Unlikely:
Maximum daily usage possible: 1.09 ppm
Feed water 64000L/shift
Chemical Dosing pump 7 L/hr, dilution 20 x
A3 NALCO 2584 CON
Contamination
C Raw Material Presence 2 mg/m3
NSF Certified, G5 Standard for direct contact with food
3A YES
1 C NO
Unlikely:
Maximum daily usage possible: 1.09 ppm
Feed water 64000L/shift
Chemical Dosing pump 7 L/hr, dilution 20 x
A3 NALCO 8507 CON C Raw Material Presence 2 mg/m3
Contamination NSF Certified, G5 Standard for direct contact with food
4 E NO
Likely:
May occure 1 times/month
Chemical
A4 NALCO 22310 CON C Raw Material Presence 93 ppm Almost no significance:
Contamination
Maximum daily usage possible: 2 ppm
When doesnt dilute: 103 ppm --> 6000 uS/cm. (Won't happen)
NSF Certified, G6 Standard for steam with direct contact with food
A5 Condensate 4 D YES
Likely:
May occure 1 times/month
Counter Measure:
Periodical checking of conductivity and drain condensate if out of norm
Page D - 19
B1 4 C NO 4C
Likely:
occurred weekly
Chemical
as desicribe in TM
Feed Water Tank CON Contamination C Raw Material Presence
203-11.1 Can cause inconvinience:
5A YES
(silica, alkalinity, ph)
Chemical contamination will generate odor and since the steam is culinary
steam, may affect the product aroma
B3 1 D NO
Unlikely:
No particles Never happen in the last 2 year
Foreign bodies rusty and particel
Loos Boiler FBG P Contamination >2mm, no sharp
General weld from pipe
particles Can cause inconvinience:
foreing bodies will cause blockage in another strainer
B3 1 C NO
Unlikely:
Never happen in the last 2 year
Chemical
Loos Boiler CON C occurrence of priming Contamination Not presence
Contamination Can cause ilness:
During extraordinary priming, boiler water may be carried over to culinary
steam which contact to product and will cause ingestion problem
B4 1 D NO 1D
Unlikely:
No particles Never happen in the last 2 year
Foreign bodies rusty and particel
Maxitherm Boiler FBG
General
P
weld from pipe
Contamination >2mm, no sharp 3B YES
particles Can cause inconvinience:
foreing bodies will cause blockage in another strainer
B4 1 C NO 1C
Unlikely:
Never happen in the last 2 year
Chemical
Maxitherm Boiler CON
Contamination
C occurrence of priming Contamination Not presence
Can cause ilness:
4B YES
During extraordinary priming, boiler water may be carried over to culinary
steam which contact to product and will cause ingestion problem
C1 1 D NO 1D
Unlikely:
No particles Never happen in the last 2 year
Foreign bodies rusty and particel
Condensate Tank FBG
General
P
weld from pipe
Presence >2mm, no sharp 5B YES
particles Can cause inconvinience:
foreing bodies will cause blockage in another strainer
C2 1 D NO 1D
Unlikely:
No particles Never happen in the last 2 year
Foreign bodies dust and plastic
Manual Tipping FBG
General
P
during handling
Presence >2mm, no sharp 1C NO
particles Can cause inconvinience:
foreing bodies will cause blockage in another strainer
C3 1 C NO 1C
Unlikely:
Never happen in the last 2 year
Chemical
Dosing Pump CON
Contamination
C Over dosing Presence Not presence Can cause ilness: 2C NO
If there is extraordinary problem in dosing pump, the limit flow my be reach
and chemical contamination in case of priming may lead to product
contamination.
C4 1 D NO 1D
Unlikely:
No particles Never happen in the last 2 year
Foreign bodies unproper function of
Strainer FBG
General
P
strainer
Contamination >2mm, no sharp 3C YES
particles Can cause inconvinience:
foreing bodies will cause blockage in another strainer
C5 1 D NO 1D
Unlikely:
No particles Never happen in the last 2 year
Foreign bodies unproper function of
Pump 1,2 CON
General
P
strainer
Contamination >2mm, no sharp 4C YES
particles Can cause inconvinience:
foreing bodies will cause blockage in another strainer (steam stariner)
C6 1 D NO 1D
Unlikely:
Never happen in the last 2 year
No particles
Foreign bodies rusty and particel
Steam FBG
General
P
weld from pipe
Presence >2mm, no sharp
Can cause inconvinience: 2D NO
particles
foreing bodies will settled in the bottom of the pipe, will no carry over to steam
flow
C7 1 D NO 1D
Unlikely:
Never happen in the last 2 year
No particles
Foreign bodies unproper function of
Strainer/Steam Trap FBG
General
P
strainer
Contamination >2mm, no sharp
Can cause inconvinience:
3D NO
particles
foreing bodies will settled in the bottom of the pipe, will no carry over to steam
flow
Page D - 20
C8 No particles 1 D NO 1D
Foreign bodies unproper function of Install standard steam purifier (based on Nestle standard)
Steam Purifier FBG
General
P
steam purifier
Contamination >2mm, no sharp
* Covered in Manufacturing HACCP 4D YES
particles
4E NO
5E YES
Page D - 21
CONTROL MEASURE SELECTION and CATEGORIZATION
Flow
Hazard Code
(Page C)
Diagram
Code Step Hazard Description of control measures Q1 Q2 Q3 Q4 Q5 CCP / OPRP
(as in
Page 5)
A1 Soft Water
Chemical
CON crosscheck measurement as listed in. Yes No Yes yes no OPRP
Contamination
A2 NALCO 2811
Chemical
CON Sulfit analysis in boiler water as listed in Yes No Yes yes no OPRP
Contamination
A5 Condensate
Chemical
CON Conductivity measurement Yes No Yes yes no OPRP
Contamination
Page E - 22
A6 Culinary
Steam
Chemical
CON crosscheck measurement as listed in Yes No Yes yes no OPRP
Contamination
B1 Feed Water
Tank
Chemical
CON crosscheck measurement as listed in. Yes No Yes yes no OPRP
Contamination
Page E - 23
RE SELECTION and CATEGORIZATION
Q2: Will a subsequent processing step, including expected use by consumer, guarantee the removal of this Significant Hazard, or its reduction to
an acceptable level? YES: Identify and name subsequent step. NO: Go to Q3.
Q3: Are control measures or practices in place at this step, and do they exclude, reduce or maintain this Significant Hazard to/at an acceptable level?
YES: Go to Q4. NO: Modify the process or product and go to Q1.
Q4: Is it possible to establish critical limits for the control measure at this step?
YES: Go to Q5. NO: This hazard is managed by an OPRP.
Q5: Is it possible to monitor the control measure in such a way that corrective actions can be taken immediately when there is a loss of control?
YES: This hazard is managed by the HACCP-plan (CCP). NO: This hazard is managed by an OPRP.
Justification Provide supporting evidence that that slelected control measure(s) and target/critical limits will
adequately control the hazard.
Page E - 24
Q1: Yes , see Page D
Q2: No:
Q3: Yes
Q4: Yes
Q5: No,periodical checking as per limit standard in.
Page E - 25
VALIDATION OF CONTROL MEASURES
The HACCP team has to provide, or ask for, evidence that selected control measures are capable of achieving the intended control for identified hazards.
The HACCP Team Leader shall provide answers to the following questions:
- Have potential hazards been correctly identified as significant or not?
- Are applied control measures capable of reducing the significant hazards to acceptable level?
- Are Critical limits correct and appropriate?
- Will the Corrections restore products safety control?
Hazardous agent Step Significant? EVIDENCE, that necessary prerequisite programs prevent this potential hazard Assessment Control Critical Limits Corrections
from becoming significant are in place measure
Page F -26
Condensate
*Include Culinary steam
Periodical checking of condensate aspects as approved..
condensate Yes
*Steam sampling under (what document/ manual/ iso standard/ boiler manual)
MFG QMS
Max. 15
X Conductivity Drain
Chemical Contamination uS/cm
Page F -27
MODIFICATION(s) AND FOLLOW-UP
Step Hazard description Modification Provisional Control Measure(s)
No Description Hazard Agent Modifi- Recommended modification and confirmation of Limit date Immediate measures to be applied while
Code cation Center of Excellence for action. modifications are not yet implemented.
No
Page G - 28