HACCP Example - Courtesy of Fletchers Bakery, Sheffield HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (1-4) - STAYFRESH BREAD

September 2004 Process Step

1.0 Flour intake 1.1

Hazard
Foreign bodies in final product

Control Measures
Approved supplier & compliance with specification sieve line,4&6mm mesh Pest Control Contract & hygiene schedule Purchase from approved, audited supplier

CCP
1

Critical Limits
Sieve integrity Sieve contact no damage

Monitoring Procedure
Certificate of analysis with every delivery. Daily check of integrity Annual clean and monthly inspections. Certificate of analysis, random challenge testing. Certificate of analysis, random challenge testing.

Corrective Action
Reject out of specification deliveries. Follow sieve procedure Engs. Pest control to advise Reject out of specification deliveries. Inform QA and supplier. Water board inform of contamination, stop use of suspect water. Recall suspect product Reject out of specification deliveries. Inform QA and supplier. Reject out of specification deliveries. Inform QA and supplier. Reject out of specification deliveries. Inform QA and supplier. Q.A. to advise on required action Repeat wash cycle.

Responsible Personnel
Q.A. Stores Personnel. Engineers

1.2

Infestation in silos

1.3

Survival of microorganisms

Activity in traps, other evidence eg, droppings, beetles Compliance with specification

Pest controller/Hygiene QA, production, stores

2.0

Water intake

2.1 Survival of microorganisms, chlorine overdose, foreign matter

Routine microbiological checks, Water authority. (water haccp referenced)

Compliance with specification

Water authority, production, CRISIS MGT team

3.0

Salt

3.1

Foreign bodies in final product. Survival of microorganisms Foreign bodies in final product. Survival of microorganisms, rancidity Microbiological,

Approved supplier & compliance with specification sieve in line, 4mm mesh. Approved supplier & compliance with specification.

Sieve integrity Compliance with specification

4.0

Vegetable Fat

4.1

Compliance with specification

5.0

Yeast Intake

5.1

Approved supplier compliance with spec. Temp. check on delivery. Temperature check on storage vessel, daily.

Maintain temperature below 4C Max 8 Limited time Temperature control

Certificate of analysis with every delivery. random challenge testing. Certificate of analysis with every delivery. Random challenge testing. Stock rotation. Certificate of conformity each delivery. Temperature checks recorded. Operator to complete cleaning record start/end time. +ve release on cleaning procedure Certificate of conformity each del. Certificate of conformity each del.

Q.A. Stores , production

Q.A. Stores , production

Q.A. Stores Personnel

5.2

QA/Stores Personnel

5.3

Taints from poor tank cleaning

Tank cleaned weekly, by member of QADept.

Wash programme pH7 ( neutral)

QA Technologist

6.0

Bread Improver

6.1

7.0

Potassium Sorbate

8.0

Sorbate solution

8.1

Foreign bodies in final product. Survival of micro-organisms Foreign bodies in final product. Survival of microorganisms Incorrect solution strength.

Purchase from approved, audited supplier. Sieve specification met Purchase from approved, audited supplier

Sieve integrity Compliance with specification Compliance with specification

Reject out of spec. deliveries. Inform QA and supplier. Reject out of spec. deliveries. Inform QA and supplier. Do not use re weigh adjust weight accordingly

QA/Stores Production - QA/Stores Production

Monitored on plant

11

Bread 1800g/10 litres water

Weights taken. 1/4ly verification for legislation

Production

HACCP Example - Courtesy of Fletchers Bakery, Sheffield

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (2-4) STAYFRESH BREAD September 2004 Process Step 9.0 Bag Flour 9.1 Hazard Foreign bodies in final product. Survival of microorganisms Foreign bodies in final product. Survival of microorganisms Micro growth on machine Infestation Control Measures Sieved at stage 17. Purchased from approved, audited supplier Purchased from approved, audited supplier CCP 8 Critical Limits Sieve integrity Compliance with specification Compliance with specification Monitoring Procedure Certificate of conformity each del. Random challenge tests for micro Certificate of conformity each del. Random challenge tests for micro Routine testing on water schedule Regular housekeeping checks and control of spillages See Step 1.2 Corrective Action Reject out of spec. deliveries. Inform Qa and supplier Reject out of spec. deliveries. Inform Qa and supplier reclean Clean and report if evidence found Responsible Personnel Stores/QA Production

10.0

Vinegar

10.1

Stores/QA Production

11.0 12.0

Ice Making Machine Ambient Storage

Cleaning and water Good storage

No evidence of growth No evidence of infestation

Plant and Hygiene DeptStores

13.0

Bulk Storage

13.1

Infestation in silos

See Step 1.2

See Step 1.2

See Step 1.2

Hygiene / Pest control Co Stores Q.A. Personnel

14.0

Chilled Storage

14.1

Ingredient deterioration

Maintain temp <4 C

Temperature control >8 C Action

15.0 16.0

Chilled Bulk Storage Packaging Store

15.1 16.1

Ingredient deterioration Foreign body hazards ( wood/ infestation)

See step 5.2 Purchased packaging from approved, audited supplier, shroud it and store appropriately. Sieve checks, metal detection step Document codes and follow recipe Dough temps checked. Dough weights checked Regular checks on integrity Regular checks on integrity Proper storage- off floor, upside down/covered

2 -

See step 5.2 All food contact items covered. No findings of foreign matter Sieve mesh size & integrity step Correct codes and recipe No fibres near food contact area. - No fibres near food contact area. Free from dirt

Temperatures checked daily and on 24hour alarmed system See step 5.2 Regular housekeeping checks and control of packagingSieve checked before & after use QA Audit, Foreman checks ( hourly) Calibrated probe Calibrated scale Daily checks Daily checks routine use

Check ingredient temp. reject out of spec. ingredients. See step 5.2 Clean and report if evidence found

See step 5.2 Stores

17.0 18.0

Sieve dry ingredients Weigh Station

17.1 18.1

19.0 20.0 21.0 22.0 23.0 24.0

Mixer Divider First mould rounder Intermediate proof Final Mould Baking Tin Storage

Foreign bodies in final product. Wrong recipe amounts, lack of ingredient trace codes No perceived hazard No perceived hazard Fibres on belts No perceived hazard Fibres on belts Dirt from incorrect storage

1 12

Replace sieve Hold incorrect product -

Production Engineering/QA Prodn/QA

Prodn/QA Prodn/QA

Remove fibres or replace belt Remove fibres or replace belt clean tins/ ensure blower is working

- Production Engineering - Production Engineering Prodn/ engineering

HACCP Example - Courtesy of Fletchers Bakery, Sheffield

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (3-4) STAYFRESH BREAD September 2004 Process Step Hazard Control Measures CCP Critical Limits Monitoring Procedure Check tin blower is on and working Weekly clean Corrective Action Responsible Personnel Prodn

25.0

Dough into tins

Foreign bodies in final product. Product debris from structure No perceived hazard No perceived hazard Under baking - survival of pathogenic organisms. No perceived hazard No perceived hazard Microbial spoilage Microbial spoilage

26.0

Prover

Tins air-jet blown to remove any foreign bodies, online vacuum system. Regular cleaning of structure

Hygiene

27.0 28.0 29.0

Addition of lids. Lid storage Baking

Correct heating process 3

Ex-oven temp > 94C

Product temp check 2 hourly with cal. Temp probe. QA 3 x daily + hr production Internal temp. taken 2 hourly. Every product type. Process , cooler on. Inspect sensitivity 1 per hr. during production Detectors challenged hourly.

Reject under baked product. Hand spray Adjust sprayer Report fault to Engs. Document quantity, temp & date code. Quarantine unscreeded prd return through detector Stop using machine Check blades entact, if broken blade is found isolate & destroy bread back to last good check. Call engineer to rectify fault. Recall product incorrectly coded, amend code Quarantine unscreeded prd return through detector

Production Q.A. Production QA, Engrs. Production Engineers

30.0 31.0 32.0 33.0

Removal of lids. Remove bread from tins. Potassium Sorbate Sprayer Cooler controlled condition

5g of 15.2% solution Correct temperature at packing

11 4

Min 4g Max 6 g Ex cooler temp <34 C

34.0

Metal detection

34.1

Metal in final product.

100% effective

35.0

Slicer

35.1

Metal in final product

Blade break detector on slicers

Detection 3.5mm Fe, 4.5mm Non Fe. 6.35mm SS Broken blade detectors operational

Production Q.A. Production Engineers Q.A.

36.0 37.0

Bag Machine Thurne tag BBE code

No perceived hazard Lack of traceability

Thurne tag checks for codingstart and end of run

12

Correct code

Daily and changeover checks

Prodn/ QA

38.0

Metal Detection

38.1

Metal in final product

100% effective

Detection 3.00mm Fe / 4.00mm Nfe 6.35mm SS

Inspect sensitivity 1 per hr. during production

Production Q.A.

39.0

Finished Prod. Wt. Control Basket

18.1

Non compliance to average weight procedure

Dirty baskets

15 minute average weight checks

Operator Inspection

13

Target 800g, T1 and T2 procedure inoperation

-

Bread Average weight procedure

-

Remedial action procedure

Inform - Supplier

Prodn/QA

40.0

Logistics Production Q.A.

HACCP Example - Courtesy of Fletchers Bakery, Sheffield

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (4-4) Process Step Hazard STAYFRESH BREAD September 2004 Control Measures CCP Critical Limits Monitoring Procedure Despatch trailer check Corrective Action Responsible Personnel Despatch -

41.0 42.0 43.0 44.0

Stack Ambient storage Load onto ambient vehicle Deliver customer ambient

No perceived hazard No perceived hazard Dirty vehicles No perceived hazard.

Vehicle check prior to loading -

Free from foreign matter, taints -

Do not load/ clean trailor -

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (4-4) Process Step Hazard

FROZEN BREAD September 2004 Control Measures CCP Critical Limits Monitoring Procedure
24 hour freezer alarm,

Corrective Action

Responsible Personnel
Engineers/ Production.

40.0

Freezer

Temperature out of spec, product defrosts

Freezer checks, 24 hour surveillance on freezer

-8 Deg C

QA Hold product and check for quality

41.0 42.0 43.0 44.0

BOX Seal and code Palletise Frozen storage

No perceived hazard Lack of traceability No perceived hazard Temperature out of spec

Box code checks hourly Vehicle check prior to loading -

12 -

Correct BB and julienne code Free from foreign matter, taints -

Hourly checks and QA audit Despatch trailer check -

Stop Do not load/ clean trailor -

Despatch -

Doc Title: Food Safety HACCP Stayfresh bread Originated by: Doc Ref: QA/haccp/bread/full haccp/stayfresh (and frozen) bread

Authorised by:

Date :Sept 2004 Revision : 3 Page 4 of 4