New Haccp Manual DD 02 Feb 17 (1) Bijali

1
INDEX
Sr. No Document No. Description Page

1. ANNEXTURE A Company Profile 3
2. ANNEXTURE B Quality and Safety Policy 4
3. ANNEXTURE C Visitor Policy 6
4. ANNEXTURE D Food Safety Team 8
5. ANNEXTURE E Letter of Appointment of HACCP Team Leader 9
6. ANNEXTURE F Letter of Appointment of HACCP Team 10
7. HSP0-1 HACCP Scope 11
8. Product Description & Intended Use 14
9. Assemble HACCP Team 15
10. Flow Chart 16
11. Verification of Flow Chart 17
12. Hazard Analysis & Identification of CCP 18
13. HACCP Plan 44
14. Critical Limits Validation Record 48
15. HSP-02 Good Manufacturing Practice 49
16. HSP-03 Standard Sanitation Operation 59
17. HSP-04 Standard Operation Procedure 76
18. HSP-05 Product Recall 81
19. HSP-06 Product Recall Flow Chart 84
20. HSP-07 Raw & Product Water Specifications 86
2
Company Profile
BIJANI Water is the owner of a water bottling plant in Al-Jurf Industrial

Area 1, Ajman. The factory was founded in 2014 and was revitalized later,
in early 2017, with the help of new management and fresh investment.
To this date, we have the biggest production capacity in the area, with up
to 24,000 PET Bottles per Hour and strive to become the most efficient
water bottling factory in the region.
The company specializes in bottled water under the highest quality

standards, using the best materials available. The water passes rigorous
inspections and quality tests from both, private and government
structures, on a regular basis.
We are in partnership with a select number of domestic and international

water brands, bottling water under their private labels. In addition, we
have a selection of sizes available under our own brand - 250ml, 500ml &
1,500ml PET bottles, however, we are also interested in expanding to
330ml and 5-gallon bottles.
3
QUALITY AND SAFETY POLICY
We are committed:
 To supply safe and good quality drinking water to all our consumers.
 To maintain hygienic processing and handling of Product in the
factory and deliveries to the consumers.
 To Satisfy the needs and expectations of our stock holders including
consumers, investors, employees and other interested parties
 To provide a clean, safe and healthy working environment to our
employers.
 To comply with national and International standards related to
bottling drinking water.
 To work towards HACCP certification and fallow HACCP manual
diligently.
4
QUALITY POLICY
BIJANI's guiding philosophy - "A Heritage of Quality" finds

expression at all levels of BDW's activities. Quality in its
manufacturing technology, Quality in its relations with its
employees, customers and excellence in the Quality of its
products.
Our goal is to deliver the highest quality drinking water to

consumers meet their daily micronutrients, hydration needs,&
maintain health values by assuring their performance, Consistency,
Safety, and Values. This commitment is rooted in our corporate
values and is essential to our continued growth and success. We
will meet our comprehensive "Global Food Safety Standards" in
the design, manufacturing, and distribution of our products as well
as meet or exceed all government requirements and consumer
expectations worldwide. We will maintain these high-quality
standards as we design and manufacture our products by the most
efficient means possible to ensure they are affordable to the
greatest number of consumers throughout the world.
Our commitment to quality is 'The Spirit of Excellence'
5
VISITOR POLICY
BIJANI WATER commitment to quality and food safety is to

develop standards and practices that reflect our role as the quality
leader in the specialty Bottled Water industry. It is everyone’s
responsibility to ensure that all products that leave our plant meet
the highest quality and safety standards.
Hair nets, Mouth mask, Beard & Moustache nets.

Visitors are to wear mouth mask, hair nets. Hair nets are to be
worn in a manner that effectively restrains all hair. This includes
moustaches, goatees and any other facial hair.
Shoes.
Shoes must cover by covers the entire foot (no open toe, high heel
and / or slippery shoes or sandals).
Visitor Hygiene
 Do not enter the production area unless guided by a ARDW’s

employee.
 Jewelry is prohibited in the production and warehouse areas.
 No cell phones or cameras are allowed.
 No food, drink or open container of any kind is allowed in the
production or warehouse areas.
 No glass is allowed in the production and warehouse areas.
 No smoking and/or chewing tobacco is allowed in the
building.
6
 For your safety, visitors can only wear flat, closed-toe shoes
in the production and warehouse areas.
 Do not touch any equipment, buttons, etc. unless instructed

to do so. Participants need to be very careful and be aware
that floors can be slippery, equipment can be hot, piping and
fixtures may be a head level.
Wear appropriate clean clothing.
No overly loose or dragging articles that may be caught in
machinery
Those with illnesses that may be spread through foods should
not enter the plant. Symptoms that
Should be considered a risk include
Intestinal illness with repeated severe Diarrhea, strong
nausea, vomiting, high fever, chills, jaundice, hepatitis
Prepared By Approved By
Mr.Ravinder Singh Mr.Rashid
(Quality Control & microbiologist) (General Manager)
7
Food Safety Team
Sr.No Name Designation & FSMS related experience /

Department Responsibilities
1. Responsible for Cross checking of
Mr. Rashid General Manager Every Section, Auditing and
verification.
2. Mr. Ravinder Singh Quality Control & HACCP Team Leader, Responsible
microbiologist for Implementation of Food Safety
Raw, Record CCP & CP Limits.
3. Mr. M Nishad Accountant Responsible for Storage of Finished
Goods and Raw Material.
Responsible for FIFO & LIFO and
maintain the hygiene of Store.
4. Cleaning and maintenance of

machinery.
sanitization of filling machines and
Mr.Vyshak Krishna Operator plant
Maintenance and recovery of any
fault during the production.
Maintains the production record.
5. The backwash of Filters and RO
Membrane.
Operate the Water Purification
Process.
Mr. Mahesh Gopi Operator
Check the Level of Ozone and
Mineralization.
Cleaning and sanitization of RO
unit.
6. Responsible for Checking of Bottle
Vineesh K Operator
during Blowing and Filling.
8
Letter of Appointment of HACCP Team Leader
Date: 01/09/17
This is to certify that Mr Ravinder Singh has been appointed as the Food
Safety Team Leader for Bijani Drinking Water Purification Food Safety
System.
He shall be responsible for:
 Review and finalization of the Food Safety documents and all
amendments.
 Review and finalization of the flow charts, their hazard analysis and
determination of CCP.
 Ensuring the conduction of Food Safety verification and validation of
critical limits and Pre-requisite program.
 Ensuring that the Food Safety system is operating and maintained as
per the requirements of Bijani Drinking Water Purification as per the
FSMS standards.
General Manager
Bijani Drinking Water Purification
9
Letter of Appointment of HACCP Team
Date: 01/09/17
The following members are appointed as Members of the Food Safety Team of
Role in Food Safety

S. No. Name Designation & Department
Team
Cross Check &
1 Mr. Rashid General Manager
Verification
Mr Ravinder Singh Quality Control &
2 Team Leader
Microbiologist
3 Account Production Control
Mr M Nishad
4 Mr.Vyshak Krishna Operator Maintenance
5 Mr. Mahesh Gopi Operator Sanitization
6. Vineesh K Operator Bottle Test & Check
Bijani Drinking Water Purification.

All members shall be responsible for:-
 Making of the flow charts, their hazard analysis and determination of CCP,
conduction of HACCP Verification and Validation.
 Ensuring that the HACCP system is operating and maintained in
Bijani Drinking Water Purification as per the Food Safety standards.
 Providing adequate guidance and training to all for carrying out their duties in the
reception and storage areas, processing areas, stores and all other sections as per Al
Ramzi Drinking Water Purification approved HACCP Plans, procedures, and operating
methods.
 Effective implementation and monitoring of cleaning schedule and strict personnel
hygiene measures in the factory.
General Manager
Bijani Drinking Water Purification
10
HACCP SCOPE
11
QUALITY CONTROL
BIJANI DRINKING
WATER HACCP Manual
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
HACCP SCOPE Issue Date 01.09.17
HACCP SCOPE
The scope of the present HACCP Plan covers the manufacturing and
distribution of Bottled Minerals Water in the premises of UAE & Gulf
Countries.
The entire production is manufactured and dispatched from the premises
AL-Jurf, Ajman Factory. The manufacturing unit works for two shifts in a day
and consisting of 20 employees.
The company‘s HACCP system is build upon the firm foundation of current
Food safety programs such as Good Manufacturing Practices and Sanitation
Standard Operation Procedures.
The HACCP Program undertaken by the company is consistent with the

principles and guidelines laid down by the FAO/WHO Codex Alimentarius
Commission 2003 & ICMSF
The present study identifies and analyzes the Food Safety Hazards
associated with the manufacturing of the Bottled Water according to the
food safety plan from the receipt of the raw materials till the time the
finished goods are delivered to the customer. The present system also
details and elaborates on:
o Identifying the levels of risk of each hazard) Biological, Chemical and

Physical) and determines its significance at every stage of process
flow.
o Determining the Critical Control Points, establishing Critical Limit.
o Monitoring each of the established CCP.
o Take Corrective actions in case of non-conformance and its
implementation.
o Implementation support of the system & procedures.
12
o Record Keeping and Documentation system.
o Review and Auditing of established Plan.
o Review of HACCP Plan in response to any changes or modifications,
which could alter hazard and risk profile.
o Review all aspects of HACCP to confirm performance against
Objective
FOOD SAFETY OBJECTIVES
The food safety objective associated with this product is:
To ensure that the bottled water for drinking purposes contains no micro-
organisms pathogenic for humans and meets guideline values for Physic-
Chemical constituents so that there is no significant risk to the consumer.
13
QUALITY CONTROL
BIJANI DRINKING
WATER HACCP Manual
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
PRODUCT DESCRIPTION
Issue Date 01.09.17
PRODUCT DESCRIPTION
Our product is mainly 4 types of PET Bottle Packaging 1.5 L,500 ml,330 ml,
250 ml. We accept our supply water only from qualified and recognized
companies and the supplied water is made subject to various testing
measures before acceptance of each consignment.
Our processing of water includes but not limited to pre-filtration of 5

microns, post filtration of 1 micron and 0.2 micron filtration for Bottled
water, multimedia and carbon filtration, microbial removal by Ozone. The
processed water is periodically tested for quality at our own in-house
laboratory.
A thorough chemical and microbiological analysis of our product is done on

a weekly basis by the Department of Food and Health, Ajman Municipality.
INTENDED USE
For all consumer groups including infants, Immuno-compromised etc.

The consumer practice: Water can be consumed on its own, to make
beverages, hot soup or for all cooking purposes.
14
QUALITY CONTROL
BIJANI DRINKING
WATER HACCP Manual
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
PRODUCT DESCRIPTION
Issue Date 01.09.17
ASSEMBLE HACCP TEAM
 The team should be multidisciplinary

 Include people who are familiar with the actual operations.
 Have the required knowledge and authority to implement changes.
 Team members include:
Sr.No NAME OF PERSON DESIGNATION QUALIFICATION

1. Mr. RAVINDER SINGH Q.C Control & B.TECH(Food
Microbiologist Engineering & Tech)
2. Mr. MOHAMMED NISHAD Accountant B.A
3. Mr. RASHID General Manager GRADUATE
4. Mr. Vyshak Krishna Supervisor Diploma in ME
5. Mr. Mahesh Gopi Operator 12 Standard
6. Mr. Nasir Operator 12 Standard
15
QUALITY CONTROL
BIJANI DRINKING
WATER HACCP Manual
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
PRODUCT DESCRIPTION
Issue Date 01.09.17
FLOW CHART
Flow diagram should cover all steps in the operation. When applying HACCP to a
given operation, consideration should be given to steps preceding and following
the specified operation
16
QUALITY CONTROL
BIJANI WATER HACCP Manual
ARDW-HSP-01
Doc No. :
Issue No. : 00
Revision : 00
VERIFICATION OF FLOW DIAGRAM Issue Date 25.08.17
17
VERIFICATION OF FLOW DIAGRAM
On site confirmation of flow diagram: The HACCP team should confirm the
processing operation against the flow diagram during all stages and hours
of operation and amend the flow diagram where appropriate.
The flow diagram given is checked verified on line by:
17
HAZARD ANALYSIS & IDENTIFICATION
OF CP & CCP
18
QUALITY CONTROL
BIJANI DRINKING
WATER HACCP Manual
BDW-HSP-01
Doc No. :
Issue No. : 02
HAZARDS ANALYSIS & IDENTIFICATIION Revision : 01
Issue Date 01.09.17
OF CP AND CCP POINTS
STEP: HAZARD ANALYSIS
Principle 1: The HACCP team should list all hazards that may be reasonably expected
to occur at each step of processing. Conduct a hazard analysis to identify for the
HACCP plan, which hazards are of such nature that their elimination or reduction to
acceptable levels is essential to the production of a safe food.
The HACCP team must consider what control measures if any, exist which can be
applied for each hazard. More than one control measure may be required to control
a specific hazard(s) and more than one hazard may be controlled by a specific
control measure.
Principle 2: The determination of CCP in the HACCP system can be facilitated by the
application of a decision tree, which indicates a logic reasoning approach.
Application of a decision tree should be flexible and should be used for guidance
when determining CCPs.
 Does a preventive measure exist at this step or subsequent steps in the

process flow for the identified hazard? If yes
 Does this step eliminate or reduce the likely occurrence of significant hazard
to an acceptable level? If yes – CCP, If No
 Could contamination with an identified hazard or hazards occur in excess of
acceptable level or could this increase to the unacceptable level? If yes,
 Will a subsequent step eliminate the identified hazard or the likely occurrence
to an acceptable level? If No –CCP
19
QUALITY CONTROL
BIJANI DRINKING WATER HACCP Manual
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
HAZARD ANALYSIS WORKSHEET Issue Date 01.09.17
Principle 1 Principle 2
Step Hazard Cause Control Q1 Q2 Q3 Q4 Q1 Explanation
Biological Contamination Approved Y N Y Y Y Further step
Hazard with pathogenic Supplier will
microorganisms eliminate
the
identified
hazard
Chemical Contamination Approved Y N N - Y Identified
1). Receipt of Raw water
Hazard with inorganic, Supplier hazard will

organic (Lab Certificate) not increase
constituents, etc to an
unacceptabl
e levels
Physical Presence of Approved Y N Y Y Y Further step
Hazard foreign bodies. Suppliers will
eliminate
the
identified
Hazard
20
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological Contamination Controlled by N Y N - CP Identified
Hazard with pathogenic SSOP Refer: hazard will
microorganisms HSP 03 not increase
to an
unacceptable
levels
2). Transportation in Tanker
Chemical Contamination Controlled by Y N N - CP Identified

Hazard from sanitizer SSOP Refer: hazard will
residues HSP 03 not increase
to an
unacceptable
levels
Physical Presence of Controlled by Y N N - CP Identified
Hazard foreign bodies. SSOP Refer: hazard will
HSP 03 not increase
to an
unacceptable
levels
21
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological No Chance of ----- ---- ---- ---- ---- ---- ----
Hazard Contamination
3). Pumping
Chemical No Chance of ----- ---- ---- ---- ---- ---- ----

Physical No Chance of ----- ---- ---- ---- ---- ---- ----
22
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological Contamination Controlled by Y N Y ---- CP Identified
Hazard with pathogenic SSOP & SOP hazard will
microorganisms Refer: HSP 03 not increase
&04 to an
unacceptable
4). Pre-filtration Bag Filter
levels
Chemical Contamination
Hazard from sanitizer ------ ---- ---- ---- ---- ---- ----
Chemicals
Physical Presence of Controlled by Y N Y ---- CP Identified
Hazard foreign bodies. SSOP & SOP hazard will
Refer: HSP 03 not increase
&04 to an
unacceptable
levels
23
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological Contamination Controlled by Y N Y ---- CP Identified
SSOP Refer:
Hazard with pathogenic hazard will
HSP 03
microorganisms not increase
Cleaning of
to an
Tank time to
time unacceptable
levels
5). Storage in Raw Water Tanks
Chemical None Controlled by Identified

SSOP Refer:
Hazard Y N Y ---- CP hazard will
HSP 03
Cleaning of not increase
Tank time to
to an
time
unacceptable
levels
Physical Presence of Controlled by Y N N ---- CP Identified
SSOP Refer:
Hazard foreign bodies. hazard will
HSP 03
Cleaning of not increase
Tank time to
to an
time
unacceptable
levels
24
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological No Chance of ----- ---- ---- ---- ---- ---- ----
6). Pumping
Chemical No Chance of ----- ---- ---- ---- ---- ---- ----

Physical No Chance of ----- ---- ---- ---- ---- ---- ----
25
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological Contamination Controlled by Y N N ---- CP Identified
Hazard with SSOP & SOP hazard will
&04 to an
7). Multimedia Sand Filtration
unacceptable
levels
Chemical None Identified
Hazard ------ ---- ---- ---- ---- ---- ----
Physical Turbidity Controlled by Y N N ---- CP Identified
Hazard SSOP & SOP hazard will
&04
to an
unacceptable
levels
26
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological Contamination Controlled Y N N ---- CP Identified
Hazard with by SSOP & hazard will
microorganisms SOP not increase
Refer: HSP to an
03 &04 unacceptable
levels
Chemical Retention of Regular
Hazard Chlorine and maintenance Y Y Y N CCP1 As there is
Organic , Back no
8). Carbon Filter
constituents in washing, subsequent

the water due to chlorine next step to
inactivation of checking in eliminate the
the carbon the product identified
Ref: hazard
BDW-QC-05
BDW-QC-06
Physical Contamination Controlled Y N N ---- CP Identified

Hazard with foreign by SSOP hazard will
bodies. Refer: HSP not increase
03 to an
unacceptable
levels
27
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Hazard with SSOP & SOP hazard will
&04 to an
unacceptable
levels
Chemical Contaminated Monitor the Identified
Hazard with Dry carbon Conductivity Y N Y --- CP hazard will
and Trapping of of the not increase
9). Micron Filtration
Calcium and process to an

magnesium water, unacceptable
particles. Regular levels
Change.
Ref:
BDW-QC-04
Physical Contamination Controlled by Y N N ---- CP Identified
Hazard with foreign SSOP hazard will
bodies. Refer: HSP 03 not increase
to an
unacceptable
levels
28
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Hazard with pathogenic SSOP Refer: hazard will
microorganisms. HSP 03 not increase
to an
unacceptable
10). Reverse Osmosis (Demineralization)
level.
Chemical Contamination Controlled by Identified
Hazard from sanitizer SSOP Refer: Y N Y ---- CP hazard will
residue during HSP 03 not increase
membrane to an
cleaning unacceptable
level.
Hazard foreign bodies. SSOP Refer: hazard will
HSP 03 not increase
to an
unacceptable
level.
29
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Hazard with SSOP & hazard will
microorganisms. Supplier not increase
approval. to an
Refer: HSP 03 unacceptable
& 04 levels
Chemical Excess quantity Control of As there is no

11). Minerals Addition
Hazard of Minerals in minerals Y N Y --- CCP subsequent

water. preparation -2 next step to
& addition. eliminate the
Checking of identified
Conductivity, hazard
TDS,pH in
every batch
Hazard with mineral SOP & SSOP hazard will
slots. Refer: HSP 03 not increase
& 04 to an
unacceptable
levels
30
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological No chance of ----- ---- ---- ---- ---- ---- ----
Hazard contamination
12). Mixing
Chemical No chance of ----- ---- ---- ---- ---- ---- ----

Physical No chance of ----- ---- ---- ---- ---- ---- ----
31
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological Contamination Controlled by Y Y N ---- CCP As there is no
Hazard with Dosing of -3 subsequent
microorganisms Ozone gas to next step to
such as bacterial an eliminate the
Count. acceptable identified
level 0.25 hazard
PPM
13). Ozone disinfection

Hazard from sanitizer SSOP Refer: Y N N ---- CP hazard will
residue. HSP 03 not increase
to an
unacceptable
level.
Hazard with foreign SOP & SSOP hazard will
bodies. Refer: HSP 03 not increase
& 04 to an
unacceptable
level.
32
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological No chance of ----- ---- ---- ---- ---- ---- ----
14). Product Tank Storage
Chemical No chance of ----- ---- ---- ---- ---- ---- ----

Physical No chance of ----- ---- ---- ---- ---- ---- ----
33
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Hazard with Pathogenic SOP & SSOP hazard will
organisms. Refer: HSP not increase
03 & 04 to an
unacceptable
level.
15).Ultra Filtration 0.2 micron

Hazard with sanitizer SOP & SSOP Y N N ---- CP hazard will
chemicals. Refer: HSP 03 not increase
& 04 to an
unacceptable
level.
Hazard foreign bodies. SOP & SSOP hazard will
& 04 to an
unacceptable
level.
34
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Step Hazard Cause Control Q1 Q2 Q3 Q4 Q1 Explanatio
n
Biological Contamination Controlled by Y N Y Y CP Further
Hazard from Air HPC Air step will
moisture Purification eliminate
and Drying the
system hazard.
Chemical Contamination Controlled by Further

16). Blow bottles
Hazard from chemicals Machine Y N Y Y CP step will

like lubrication Cleaning. eliminate
oil. the
identified
hazard.
Physical Contamination Controlled by Y N Y Y CP Further
Hazard due to damage or Machine step will
deshape of PET Cleaning. eliminate
bottle. the
identified
hazard
35
QUALITY CONTROL
BIJANI DRINKING
WATER HACCP Manual
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological Not Chance, we ----------- N N N N --- -----------
Hazard use Ozone
Treated Water.
18). Final rinsing with product water.
Chemical Improper ----------------- Identified

Hazard Cleaning may Y N Y N CP hazard will
result in the not increase
presence of oil or to an
air smell from unacceptable
blow. level.
Physical Improper Controlled by Y N Y Y CP Identified
Hazard cleaning may SOP & SSOP hazard will
result in the Refer: HSP 03 not increase
presence of & 04 to an
foreign bodies in unacceptable
bottles. level.
36
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
HAZARD ANALYSIS WORKSHEET
Biological Contamination of Controlled by Y N Y Y CP Identified
Hazard microorganisms SOP & SSOP hazard will
from the filler. (Effective not increase
cleaning step
to an
for RB)
unacceptable
Refer: HSO 03
level.
& 04
19). Filling
Chemical Improper rinsing Controlled by Identified

Hazard may result in the SOP& SSOP Y N Y Y CP hazard will
retention of Refer: HSP 03 not increase
& 04
chemicals inside to an
the bottle unacceptable
level.
Physical Improper cleaning Controlled by Y N Y Y CP Identified hazard
Hazard may result in the SOP & SSOP will not increase
presence of foreign Refer: HSP 03 & to an
bodies in bottles. 04 unacceptable
level.
37
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological Dirty or dusty Controlled by Y N N ---- CP Identified
Hazard cartons may SOP & SSOP hazard will
contaminate the Refer: HSO not increase
product during 03 & 04 to an
storage, unacceptable
20) Capping
transportation & level

tipping
Chemical ---- ---- ---- ---- ---- ---- ----
Hazard None identified
Physical ---- ---- ---- ---- ---- ---- ---- ----
Hazard
38
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Step Hazard Cause Control Q1 Q2 Q3 Q4 Q1 Explanati
on
Biological ---- ---- ---- ---- ---- ---- ----
21). Coding
Chemical ---- ---- ---- ---- ---- ---- ----

Physical . ---- ---- ---- ---- ---- ---- ----
39
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological ---- ---- ---- ---- ---- ---- ----
22). Inspection
Chemical ---- ---- ---- ---- ---- ---- ----

Physical . ---- ---- ---- ---- ---- ---- ----
40
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological ---- ---- ---- ---- ---- ---- ----
23). Labeling & Packing
Chemical ---- ---- ---- ---- ---- ---- ----

Physical . ---- ---- ---- ---- ---- ---- ----
41
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological ---- ---- ---- ---- ---- ---- ----
24). Packaging & Storing
Chemical ---- ---- ---- ---- ---- ---- ----

Physical . ---- ---- ---- ---- ---- ---- ----
42
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
Biological ---- ---- ---- ---- ---- ---- ----
25). Loading
Chemical ---- ---- ---- ---- ---- ---- ----

Physical . ---- ---- ---- ---- ---- ---- ----
43
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
ESTABLISH HACCP PLAN Issue Date 01.09.17
ESTABLISH HACCP PLAN
1. Establish critical limits for each CCP (Principle 3)

Critical limits are criterion that must be for each preventive measure associated with a CCP.
It represents the boundaries that are used to ensure that an operation produces safe
products. It must be specified and validated if possible for each Critical Control Point.
2. Establish a monitoring system for each CCP (Principle 4)

Monitoring is the scheduled measurement or observation of a CCP relative to its critical
limits. The monitoring procedures must be able to detect loss control at the CCP. Further
monitoring should ideally provide this information in time to make adjustments to ensure
control of the process to prevent violating the critical limits. Where possible, process
adjustment should be made when monitoring results indicate a trend towards a loss of
control at a CCP. The adjustments should be taken before a deviation occurs. A designated
person with knowledge and authority to carry out corrective actions when indicated must
evaluate data derived from monitoring.
3. Establishment corrective actions (Principle 5)

The cause of the deviation, take action to prevent recurrence and follow up with monitoring
and reassessment to ensure that the action taken is effective. Specific corrective actions
must be developed for each CCP in the HACCP system.
4. Establishment of verification procedures (Principle 6)

Establish procedures for verification, verification and auditing methods, procedures
and tests, including random sampling and analysis that can be used to determine if the
HACCP system is working correctly. The frequency of verification should be sufficient to
confirm that the HACCP system is working effectively.
5. Establishment of documentation and record keeping (Principle 7)

Efficient and accurate record keeping is essential to the application of an HACCP
system. Records provide evidence that the HACCP system is working, provide tracking
system, and help to identify problems, evidence of compliance to critical limits and
evidence of corrective action
44
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
HACCP PLAN Issue Date 01.09.17
 Product description: Bottled Pure Drinking Water

 Method of Distribution and Storage: Dry Storage
 Intend use: Consumed without any treatment
(1) (2) (3) (8) (9) (10)

Principal 4
Critical Significant Principal 3 Principal Principal Principal 7
control Hazards Monitoring 5 6
point Critical (4) (5) (6) (7) Correctiv Records Verificatio
Limits for e Actions n
each What How Frequ Who
preventiv ency
e measure
CCP 1 Chemical Chlorine Check Visually Every Qualit Back Daily Verificatio
A.CARBON Retention in final the , 4 hrs. y Washing, Analytical n of Daily
FILTER of chlorine, product is taste, sensor, Contro Reproces Report, analytical
odor, color nil. Taste odor, by ller sing CCP report by
producing and odor color compar Discard, Monitori HACCP
substance should be and ator Change ng team
& organic acceptabl chlorine and Carbon files leader,
constituent e, no color level in photo Media Calibratio
s in the producing process meter n Record,
water due substance water HACCP
to in review
activation record,
Training
record
45
(1) (2) (3) Principal 4 (8) (9) (10)
Principal Monitoring Principal 5 Principal 6 Principal 7

3 Corrective
(4) (5) (6) (7)
Critical Significan Critical Actions Records
control t Hazards Limits for Verification
point each What How Frequ Who
preventiv ency
e
measure
CCP 2 Chemical TDS >100 Check By TDS Start Quality Adjust the Adjust the Verification
Mineraliz s and the total meter up & Controll flow rate flow rate of Daily
ation Excess of <130, dissolve After er of dosing of dosing Analysis
minerals d solids Every Pumps Pumps Report
chemical Correct in 2 hrs. and and after every
s (Mg, preparati product prepare prepare week.
Ca,K,Na on ratio water proper proper Calibrate
etc.) will of conc. conc. the TDS
result in minerals Minerals Minerals meter
disorder solution solution internally
ness of after every
bones month and
and teeth externally
in every
year
46
(1) (2) (3) Principal 4 (8) (9) (10)
Principal 3 Monitoring Principal 5 Principal Principal 7

Critical 6
(4) (5) (6) (7)
Critical Significant Limits for Corrective Verificatio
contro Hazards each Actions Records n
l point preventiv What How Freque Who
e measure ncy
CCP 3 Pathogeni Residual Test By DPD Start Quality Retain Daily Microbiol
Ozoniz c ozone ozone method up, Controll affected analytical ogy report
ation microorga level is level in on Photo After er product, report
nisms 0.1-0.5 the Meter every 4 Shutdown Verificatio
maybe ppm product hrs, water n of Daily
present if water Quality supply for analytical
the ozone Visual Controll filling, test report by
level is Working Visual observati er for CCP HACCP
very low. condition checkin on Every 4 microbiol Monitori team
(Health of ozone g of the hrs. ogical ng files leader,
and safety generator workin analysis, Calibratio
threat g Adjust the n record,
from conditi machine HACCP
excessive No on of valves, review
Ozonizatio detectable the Reprocess records
n.) ozone in ozone ing, Training
the air. generat Rejection records
or increase.
47
QUALITY CONTROL
BDW-HSP-01
Doc No. :
Issue No. : 02
Revision : 01
CRITICAL LIMITS & VALIDATION RECORD Issue Date 01.09.17
Step/Input Critical Limits Justification Details

Chlorine in the final product 0.2-0.4 As per UAE Standards for Bottled
Carbon Filter ppm Drinking Water
Total Hardness <200 ppm As per UAE Standards for Bottled

mineralization(RO) Chloride 150 ppm Drinking Water
Sodium 100 ppm
Residual level 0.2 to 0.4 ppm As per UAE Standards for Bottled
Ozonization No detectable ozone in the air Drinking Water Company’s practical
experience
48
Good Manufacturing Practices (GMP
49
QUALITY CONTROL
BDW-HSP-02
Doc No. :
Issue No. : 02
Revision : 01
GOOD MANUFACTURING PRACTICE Issue Date 01.09.17
BIJANI Drinking Water Purification, is having a well written Good Manufacturing

Practices prepared and followed in accordance with the applicable sections of the
International Codes of Practice – General Principles of Food Hygiene (CAC/RCP 1- 1969,
Rev 3 (1997), in accordance with the International Code of Practice for the Collecting,
Processing and Marketing of Natural Mineral Waters (CAC/RCP 33-1985) and the standards
prescribed by the local Government on the bottled drinking water.
Being a supplier of the drinking water to the public, the primary aim is to ensure the
safety of the water by adopting the following:
1. Pre-requisite Programs including GMP and SSOP

2. System assessment to determine whether the water supply chain can deliver water of a
quality that meets identified targets.
3. Monitoring of the control measures in the supply chain, which are of importance in
securing water safety.
4. HACCP Plans documenting the system assessment and monitoring, describing, actions to
be taken during normal operations or incident conditions.
The objective is to ensure good drinking water bottling and supply practice by:
 Prevention of contamination of raw water.
 The reduction and removal of contamination through treatment process to meet
the water quality targets/specification.
 Prevention of contamination during storage, bottling, distribution and handling of
bottled drinking water.
This is achieved by:
 Development of an understanding of the Food/ Water Safety System
 Identification of potential sources of contamination, and how they can be
controlled.
 Validation of control measures employed to control hazards.
 Implementing a system for monitoring the control measures within the
Management System and initiating timely corrective actions to ensure that water
is consistently supplied.
 Verification of system and product
50
QUALITY CONTROL
BDW-HSP-02
Doc No. :
Issue No. : 02
Revision : 01
RAW WATER AND PROCESSING FACILITIES Issue Date 01.09.17
1. Protective Measures for collection and transportation of raw water

The raw water is received from DUBAL and transported in a 5,000- gallon capacity tanker to
the company. The tanker is keep clean as per the cleaning schedule.
The raw water is checked for every tanker for assessing the chemical and physical qualities
of water. Microbiological quality is assessed as per the Inspection Test Plan. The pipes,
pumps coming into contact with water or used for its collection and storage are made of
stainless steel and PVC to guarantee that the water will not get contaminated.
2. Design and Facilities
2.1 Location
The factory is located in area which is free from objectionable odors, smoke, dust or other
contaminants and is free from flooding.
2.2 Buildings and Facilities
2.2.1 Type of Construction

Factory building is constructed to provide enough space for RM-FM, Mechanical Section,
Filling, Labeling, Packaging and Storing. Ceiling and floor tiles are maintained and replace if
necessary. Plant is designed in such a way to allow easy handling of raw materials and
finished products. Separate halls/rooms are provided for storing raw materials including
empty cartons, caps, Label, PET, chemicals spare parts, etc.
2.3 Disposition of Holding Facilities
2.3.1: Adequate working space provided to allow for satisfactory performance of all
operations.
2.3.2: The plant designed to permit easy and adequate cleaning and to facilitate proper
supervision of good drinking water bottling and supply practices and hygiene.
2.3.3: The buildings and facilities designed to provide separation by partition, location and
other effective means between those operations, which may cause cross-contamination.
51
2.4 Processing Plant
2.4.1 Floors: Painted and waterproof, non-absorbent, washable, non-slip and non-toxic
materials, and easy to clean and disinfect. Floors slope sufficiently for liquids to drain on
trapped outlets.
2.4.2 Walls: Waterproof, non-absorbent, washable and non-toxic materials, and easy to
clean and disinfect.
2.4.3 Ceilings: Designed and constructed, and finished as to prevent the accumulation of dirt
and minimize condensation, mould development and flaking, and easy to clean.
2.4.4 Doors: Have smooth, non-absorbent surfaces and all doors are self –closing and close
fitting.
2.4.5 Prevent Contamination: In water treatment and filling area, all overhead structures
and fittings are installed in such a manner as to avoid contamination directly or indirectly to
the water by condensation and drip, mould development and flaking. They should be easy to
clean.
2.4.6 Use of Wood: The use of wood is minimized to allow easy cleaning and disinfections
and all new installations are monitored to avoid wooden parts/fittings.
52
QUALITY CONTROL
BDW-HSP-02
Doc No. :
Issue No. : 02
Revision : 01
HYGIENE FACILITIES AND CONTROL Issue Date 01.09.17
3. Hygienic Facilities
3.1: Waste Disposal: Plant has an efficient waste disposal system which is maintained in
good order and repaired immediately. All effluent lines (including sewer systems) were large
enough to carry peak loads and constructed to avoid contamination of potable water
supplies.
3.2: Changing Facilities and Toilets: Adequate, suitable and conveniently located changing
facilities and toilets provided in the factory. Toilets designed to ensure hygienic removal of
waste matter. These are well lighted, ventilated and not opened directly in to drinking water
handling areas. Hand washing facilities, a suitable hand –cleaning preparation, and with
suitable hygienic means of drying hands, provided adjacent to toilets and in such position
that the employee must pass them when returning to the processing area. Notices are
posted directing personnel to wash their hands after using the toilet.
3.3: Hand washing facilities: Adequate and conveniently located facilities for hand washing
and drying provided wherever the process demands. Facilities for hand disinfections also
provided.
3.4: Lighting: Adequate lighting is provided throughout the factory. Light bulbs and fixtures
suspended over are of safety type and protected to prevent contamination in case of
breakage.
3.5: Ventilation: Adequate ventilation provided to prevent excessive heat, steam

condensation and to remove contaminated air. Ventilation openings provided with
protective enclosure of non- corrodible material.
4. Hygiene Control Program
A permanent cleaning and disinfections schedule prepared to ensure that all areas are
appropriately cleaned and that critical areas, equipment and material are designated for
special attention. Duties for cleaning of factory are assigned to the operator. He is well
trained in cleaning techniques and responsible for the entire program as per the schedule.
This cleaning activity is cross checked by Quality Controller every day before the production
53
starts. All the staff has the thorough understanding of the significance of contamination and
the hazards involved. Refer SSOP.
54
QUALITY CONTROL
BDW-HSP-02
Doc No. :
Issue No. : 02
Revision : 01
PEST CONTROL & STORAGE OF CHEMICALS Issue Date 01.09.17
5. Pest Control
An effective and continuous program for the control of pests is maintained. The company
has a contract with outside Pest Control Agency for carrying out the pest control activities.
Factory and surrounding areas are regularly examined for evidence of infestation.
Eradication measures are instituted near the entrance to control pests. Control measures
involving treatment with chemical, physical, or biological agents undertaken by or under
direct supervision of personnel who have a thorough understanding of the potential hazards
to health resulting from the use of these agents. Refer SSOP
6. Storage of Hazardous Substances

Pesticides or other substances which may represent a hazard to health are suitably labeled
with a warning about their toxicity and use. They are stored in locked rooms or cabinets
used only for that purpose and dispensed and handled only by authorized and properly
trained personnel or by persons under strict supervision of trained personnel.
55
QUALITY CONTROL
BDW-HSP-02
Doc No. :
Issue No. : 02
Revision : 01
GHP & HEALTH Issue Date 01.09.17
7. Personnel Hygiene and Health Requirements
7.1 Hygiene Training: Adequate in house training is given to all staff in hygienic handling
of water and in personal hygiene so that they understand the precautions necessary to
prevent contamination of water. The key people (HACCP Team) including the supervisory
level staff attended HACCP training.
7.2 Medical Examination: The staff have a medical examination prior to employment by
the official agency having jurisdiction, acting on medical advice, considers that this
necessary. All employees have a valid health card can be renew in time.
7.3 Communicable Diseases: The management has taken care to ensure that no person,
while known or suspected to be suffering from, or a carrier of a disease likely to be
transmitted through food or while affected with infected wounds, skin infections, sores or
diarrhea is permitted to work in any drinking water handling area, in any capacity in which
there is any likelihood of such a person directly or indirectly contaminating water with
pathogenic micro-organisms.
7.4 Washing of Hands: Hands always washed before commencing work, immediately
after using the toilet, after handling contaminated material and whenever else necessary.
After handling any material, which might be capable of transmitting disease, hands are
washed and disinfected immediately. Notices requiring hand washing displayed. We have an
adequate supervision to ensure compliance with this requirement.
7.5 Personal Cleanliness: Every person engaged in a drinking water processing area
maintain a high degree of personal cleanliness while on duty, and wear suitable protective
clothing including head covering and footwear, all of which are cleanable.
7.6 Personal Behavior: Any behavior, which could result in contamination of water such
as eating, smoking, chewing (e.g. gum, sticks, betel nuts, etc.) or unhygienic practices such
as spitting, are prohibited in the plant. The access of people in the plant is controlled to
prevent transfer of hazards from people.
56
Supervision:- Responsibility for ensuring compliance by all personnel with all above
requirements specifically allocated to competent supervisory personnel
57
QUALITY CONTROL
BDW-HSP-02
Doc No. :
Issue No. : 02
Revision : 01
HYGIENIC PROCESSING Issue Date 01.09.17
8. Factory: Hygienic Processing Requirements
8.1 Raw Water Requirements: To ensure a good and stable quality of water, the
following criteria monitored regularly:
 Odor, taste and appearance of the water.
 Chemical parameters including the conductance & ph of water.
 The microbiological parameters like Total Coliform, E. coli, etc.
8.2 Treatment: The treatment includes filtration, minerals addition, RO Purification and
disinfections by ozone. Technically competent personnel are involved in the treatment of
drinking water.
Treatment and necessary controls are in such as a way as to protect against contamination
or development of a public health hazard and against deterioration within the limits of good
commercial practice.
8.3 Chemicals and Ingredients: All chemicals used in the factory are purchased from
approved reputable suppliers with a Material Safety Data Sheet.
8.4 Processing and Production Records: the control measures in the process are monitored
in a timely manner to prevent the supply of any potentially unsafe water. Permanent, legible
and dated records of pertinent processing and production details keep concerning each
day’s production. These records retained for the period of two years. Monitoring programs
are reviewed periodically, and altered where necessary. The operational limits are set to
define the operational effectiveness of the activity, with sufficient frequency to reveal any
failures in a timely fashion and to implement corrective actions in response to the deviation
from limits.
8.5 Storage and transport of the end product: The end product is stored and transported
under each condition as well preclude contamination with and/ or proliferation of
microorganisms and protect against deteriorations of the product. During storage, periodic
inspection of the end product taken to ensure that only drinking water, which is fit for
human consumption, with a residual Ozone level is dispatched and that end product
specification should be complied with. The dispatched area, the vehicles for the
58
transportation of water and the tankers also follow the disinfections schedule to prevent the
chances of contamination
8.6 Sampling and Laboratory controlled procedure:

The inspection and test plane is maintained by Quality assurance staff intended as guide
line for testing the water at the sources in a critical control points and finish products.
Bottled Drinking water should contain no parasite, Pathogenic microorganisms and should
meet the criteria of W.H.O drinking water quality, IBWA standards and U.A.E standards for
bottled drinking water
59
Standard Sanitation Operation
Procedure
60
QUALITY CONTROL
BDW-HSP-03
Doc No. :
Issue No. : 02
RAW WATER SANITIZATION Revision : 01
Issue Date 01.09.17
This SSOP describes how the company meets certain hygiene and sanitation precaution
policies and practices. This also describes how the plant sanitary operation will be monitored
and corrective actions are made to ensure that the prescribed conditions and practices are
met. The monitoring frequency has been described depending on the requirement and the
level of risk.
1. Protection of Raw Water
1.1 Goal: The water supply shell be from an approve sources and it should be protected and
operated to get a safe and sanitary quality product water.
1.2 Procedure
1.2.1 The raw water is received from DUBAL and the supplier ensures the portability of the
water.
1.2.2 The raw water is pre-filtered to remove the microorganisms and turbidity. The filter
will be replaced every month by the plant engineer.
1.2.3 The raw water is store in main tank have capacity 40000 gallons which are made of
GRP Steel. The tanks are of self-drainage type, sealed and leak free.
1.2.4 The storage and pumping facilities are clean and maintained by the regular
maintenance program. The tanks are cleaned by outside contractor approved by Ajman
Municipality after every six months. The tanks are kept open for twelve hours prior to
cleaning for releasing all the hazards gases.
1.2.5 For the cleaning of the tanks are practiced by the contractor
 Close the inlet/outlet valves of the tanks.
 Rub the floor and walls with sanitized cloth or brush.
 Use detergent (Surfactant)
 Rinse it with Raw water
 Sanitized with Peroxide solution or 20 ppm free Chlorine solution.
 Final Rinse with product water.
61
The pipe lines connecting the raw water line and the processing line are made of food
grade PVC, which will not contaminate the contact water and are protected against
mechanical damage.
1.3 Monitoring
1.3.1 A sample of raw water is subjected to Physio-Chemical analysis daily and for
microbiological analysis every month. Results are recorded in microbiological Analysis
report.
1.3.2 The quality controller supervises the tank cleaning.
1.4 Corrective Actions:

1.4.1 If the raw water is very turbid or not clean, the water will not be supplied for
production and hold the lot for inspection. Production will resume only when water meets
the quality standards prescribe for the raw water.
1.4.2 If sampling indicate the presence fecal coliforms or coliforms in more than 5% of
sample, the plant will stop the production the safety is assured. The quality assurance
department will ensure the safety of the held product by re sampling and testing.
62
QUALITY CONTROL
BDW-HSP-03
Doc No. :
Issue No. : 02
GENERAL CLEANING Revision : 01
Issue Date 01.09.17
2. Conditions and Cleanliness of food contact Surfaces
2.1 Goal: All utensils and surface of equipment’s that come in to contact with drinking
water during processing are clean and sanitized with effective cleaning and sanitizing
procedures.
2.2 Procedure
2.2.1 Bottled drinking water contact surfaces are adequately cleanable. All equipment’s
and utensils are made of PVC/ Stainless Steel. Equipment’s and utensils are subjected to
thorough cleaning operations in the following frequencies.
1) Sanitize before the day’s operations begin.
2) Cleaned at the end of the day’s operations.
63
CLEANING SCHEDULE
Area Responsibility Description of cleaning Frequency

1. Pre- filtration Quality Controller The filtration bucket is changed, internal wall After every
Assembly of the filter is cleaned and sanitize months
2. Raw water & Quality Controller For the cleaning of the tanks are practiced by After every 6
Product water the contractor months
tanks Close the inlet/outlet valves of the tanks.
Rub the floor and walls with sanitized cloth
or brush.
Use detergent (Surfactant)
Rinse it with Raw water
Sanitized with Pero Solution or 20 ppm free
Chlorine solution.
Final Rinse with product water.
3. Rapid sand Filter Quality Controller Rapid sand filter is back washed with raw After 2 Days
water before starting the production at least
30 min after every week
Plant Manager Filter Media change After every 1

years
4. Carbon Filter Quality Controller Carbon filter is back washed with raw water Daily & Weekly
at least 15 Min before starting the
production and at least 30 min after every
week
Plant Manager After every 2

Filter Media change years
5. Minerals Tanks Quality Controller Clean and sanitize with Ozonated Water Every 2 months
6. Reverse osmosis Factory Manager (General Automatic Back wash, Daily

unit Manager) Cleaning of membranes, yearly
Filter change, services and Maintenance 15 days
64
7. Ozone Factory Manager (General The ozone tank and ozone contact reservoir
Generator Manager) are cleaned with ozonated water. Daily
The media for air filter is changed.
Services & maintenance. After 3 months
Monthly
8. Filter and Factory Manager (General The filters are cleaned from inside and
product water Manager) outside with cloths/brush by using detergent
lines to remove dirt, grease. Anticalin is used to
clean the scales from internal surfaces. Then
sanitized with 0.1% Peroxide solution. Finally Daily
rinse with product water.
Product pipelines are sanitized with
Ozonated Water.
9.RB washing Operator All the cleaned bottles are again sniffed and
inside the machine inspected before feeding into the
washer/filler machine. All doubtful bottles
will be returned back for cleaning. Washing
in the machine comprises of 3 steps: Daily
Rinsing with P3-Oxonia (0.4%)solution at a
temperature 50-60 oC. Final rinsing with
product water at normal temperature.
Bottles are thoroughly washed from outside
and inside with high jet pressure.
10.Bottle washing Operator All new bottles are first inspected visually for As required
smell, presence of plastic pieces and damage.
Then these bottles are directly fed into the
washer/filler for washing & filling.
65
11. Caps and cap Quality Controller Only good caps produce under hygienic Daily
bucket conditions are only accepted. Cap buckets
are cleaned and sanitized with food grade
detergent, antibacterial solution and
ozonated water. Then the caps are
transferred to the bowl of filler for capping
with the help of bucket.
12. Cap Head & Operator Drain off the product water that remains Daily
Product water inside the tank after production. Before
reservoir cleaning starting the production, this tank will be filled
with product water and passed through lines.
Clean with food grade detergent and sanitize
with ozonated water.
Monthly
13.Production area, Quality Controller Removal of dirt, dust, etc by a clean brush.
Washing area Wet the area with rejected product water
and apply a detergent. Washed with rejected
product water then sanitize by antibacterial Daily
reagent. Finally leave it for dry naturally.
14. Loading, Quality controller Remover the dirt and dust with the broom
unloading Area and clean with rejected product water.
Daily
15. Storage Area Quality controller Removal of dirt, dust, etc by a clean brush.
Wet the area with rejected product water
and apply a detergent. Wash with rejected Daily
product water then sanitize by antibacterial
reagent. Finally leave it to dry naturally.
16. Wash basins, Quality controller Washbasins are cleaned with detergent,
toilets etc. sanitize with antibacterial reagent and check
soap dispensers, tissue rolls etc. toilets are Daily
cleaned, floor mats are washed and dry.
17.Doors, windows, Quality controller Removal of dust, washing with detergent and
ceilings, exhaust finally sanitize with antibacterial reagent Weekly
fans, air curtain,
etc……
66
2.3 Monitoring: The cleaning is done by relevant responsible workers and
monitored/inspected by quality controller who records his findings in the daily cleaning
records.
2.3.1 To assess the efficiency of the cleaning operations, the quality controller checks the
entire area for the cleaning daily and records the findings in sanitation assessment report.
2.3.2 To assess the degree of cleanliness, swab analysis is taken by the quality controller
every night and records is findings in the swab testing report.
2.4 Corrective Actions
2.4. Food contact surfaces that are not adequately cleanable are repaired or replaced.
Food contact surfaces that are not cleaned are re-cleaned. If the results for swab analysis
are not satisfactory, instructions are given to the staff for effective cleaning.
67
QUALITY CONTROL
BDW-HSP-03
Doc No. :
Issue No. : 02
GHP Revision : 01
Issue Date 01.09.17
3. Personnel Hygiene
3.1 Goal : Good personal hygiene protects the water against contamination. All persons
engaged in the processing operation should maintain very high degree of personal hygiene
to ensure the safety of the drinking water.
3.2 Procedure
3.2.1 Smoking is strictly prohibited to all the staff in the company.

3.2.2 Operators are instructed to wash the hands thoroughly with sanitizer and water and
dried with tissue paper. They are instructed to wash their hands before starting their work,
immediately after visiting the toilet and after handling contaminated material. In addition,
all employees are required to use head cover and safety shoes. The supervisor observes all
employees for their practices at the entrances, during process and at each absence from
duty stations.
3.2.3 The company issues 2 pairs of uniforms and a pair of boots to all workers every year.
It is the responsibility of the worker to wash the uniforms and makes it clean and tidy.
Employees are not allowed to use personal gear in place of this item.
3.2.4 Personal with communicable diseases or infected wounds are not allowed inside
factory areas where contamination to drinking water, contact surfaces or packaging
materials can occur. Personnel are instructed to report health conditions to the supervisor.
3.2.5 All personnel working in the plant shall: -

 Wear clean garments
 Have a high standard of personal cleanliness and grooming?
 Wash hands before start the work and after every absence from processing area
 Wear caps.
 Keep hair and beard clean
 Bath or shower daily.
 Keep finger nails short and clean
 Store clothing and personal belongings outside the process areas
 Avoid habits such as smoking, chewing, coughing etc within the processing area.
Hand Washing:
68
How to wash hands:
 Use warm water
 Use non-perfumed sanitizer
 Sanitize the hands thoroughly and make sure that all parts are cleaned.
 Clean the finger tips and thumbs.
 Dry with clean paper towel to dry the hands.
 Dispose of the paper towels in a cover dustbin
 When wash the hands:
 After putting on protective clothing and before starting the work.
 Before entering.
 After visiting Toilets.
 After drinking/eating/smoking.
 After blowing the nose, coughing or sneezing.
 After handling dirty equipment, walls, floor etc.
 After carrying out cleaning duties.
3.2.6 Production operators, workers and maintenance personnel are getting training
programs on personal hygiene and food handling techniques by Quality controller and
outside trainers. The quality controller is assigned to assure compliance of the hygiene
practices.
3.2.7 Visitors to processing or handling area should, wear protective clothing and adhere
to the personal hygiene requirements.
3.3 Monitoring
3.3.1 The quality controller maintains all employees for cleanliness of outer garments at
the time of entry. Observations will be recorded daily staff monitoring / hygiene report.
3.4 Corrective Action

3.4.1 Re-train the staff on personal hygiene and solution. Workers correct definition in hair
restraint use gloves use, hand washing, personal belonging storage, eating and drinking in
plant.
69
QUALITY CONTROL
BDW-HSP-03
Doc No. :
Issue No. : 02
PEST CONTROL Revision : 01
Issue Date 01.09.17
4. Pest control
4.1 Goal : No pests are in any area of the bottling plant.
4.2 Procedure
4.2.1 An effective pest, insects, birds and rodent control program has adopted by the
company. The company has a contact with outside pest control agency. They visit the
company in every month or they will be informed if anybody finds any pests inside and
around the facility. They insect the interior of the plant and premises with
4.2.2 Appropriate chemicals. After completion, they issue a certificate for completion of
work.
4.2.3 Good hygiene practices followed to avoid creating an environment conducive to

pests.
4.2.4 Factory building always kept in good repair and condition to prevent pest access
and to eliminate potential breeding sites.
4.2.5 The material safety data sheets for the pest control chemicals are kept on file. Only
those pesticides, which are approved by Dubai Municipality is used. Signs for rodent
droppings. Run ways, grease marks, burrows, nest and gnawed scraps of food are checked
daily.
4.2.6 Plant grounds and interior areas are kept free of litter, waste and other conditions
that might attract pests.
4.2.7 All water tanks are provided with tight covers preventing breeding or flies and
mosquitoes.
70
4.3 Monitoring
4.3.1 The details of pest control are entered in the pest control file and the Quality
Controller reviews reports of pest treatment. Plant overall conditions are inspected and
the readings noted on the daily sanitation assessment record.
4.4.1 The pest control agency is notified of any pest problem and treats it pest treatments
are frequent if problems are identified.
71
QUALITY CONTROL
BDW-HSP-03
Doc No. :
Issue No. : 02
MAINTENANCE Revision : 01
Issue Date 01.09.17
5. Maintenance:
5.1 Goal: For effective sanitation controls, proper maintenance of the company is
essential.
5.2 Procedure:
5.1.2 The facility has skilled and trained maintenance of all machinery in pumping,
treatment, storing and delivery of water to tankers.
5.1.3 The building and surroundings are maintained in good condition to facilitate easy
cleaning. Maintenance is done as per the schedule.
5.1.4 Regular maintenance program exists with outside contracts for the facility’s
ventilation system, which ensures adequate ventilation, air flow and air pressure that
prevents or inhibits the formation of condensate in the processing and storage areas.
5.1.5 Paint and other hazardous items are not allowed while production resumes. These
items are used only in a maintenance day. All chemicals used in the factory possess
material safety data sheet.
5.1.6 Maintenance is as per the procedure for maintenance.
5.3 Monitoring:
5.3.1 The plant manager/ operator is responsible for doing the routine maintenance for all
the machineries. The details are recorded in the maintenance records. The break down
maintenance details is usually attached with the plant maintenance
5.4 Corrective Actions:
5.4.1 in case of any break down, the plant manager /plant operator is the responsible
persons to fine out the failure and necessary corrective action are taken. Production will
resume after rectifying the problem with the machineries. In out of control situation,
outside people or the machine manufactures are hired for doing maintenance.
72
QUALITY CONTROL
BDW-HSP-03
Doc No. :
Issue No. : 02
WATER CONTACT SURFACES Revision : 01
Issue Date 01.09.17
6: THE SAFTEY OF THE WATER THAT COMES INTO DIRECT CONTACT WITH FOOD
CONTACT SURFACE
6.1 Goal
6.1.1 Water that comes into direct contact with food contact surfaces is derived from a
safe and sanitary source or is treated to make it safe.
6.2 Procedure:
6.2.1 The operation water used in the plant is from the same raw water. The raw water is
used for all operation including cleaning, back washing, employee sanitation purposes, etc.
The floors are clean with rejected product water.
6.3 Monitoring procedure
6.3.1 The plant manager/quality controller monitors the plumbing lines daily and the
samples of the operation water.
6.4.1 If the operation water fails to meet the standards of the product water, the plumbing
lines to operation water and if it needs any rectification, will be done by the maintenance
department.
73
QUALITY CONTROL
BDW-HSP-03
Doc No. :
Issue No. : 02
LABELLING AND STORAGE OF CHEMICALS Revision : 01
Issue Date 01.09.17
7: LABELING AND STORAGE OF CHEMICALS AND TOXIC COMPOUNDS.
7.1 Goal: Food, food contact surfaces and food packing materials shall be protected from
adulteration with lubricants, fuel, pesticides, cleaning compounds, sanitizing agents, or
other chemical or physical contaminants
7.2 Procedure
7.2.1 All cleaning compounds and sanitizing agents used by the company is clearly
identified by labeling and stored away from the process area from any other lubricants or
chemicals.
7.2.2 Anti-scalants, disinfectants, and other additives {if any} are stored in a separate area
free from contamination.
7.2.3 The operator store and properly label all non-food grade lubricants within the
maintenance area.
7.3 Monitoring
7.3.1 Invoices are checked at receiving before chemicals are stored in the chemical storage
area. The operator inspects the processing area daily before operation begins for possible
contamination. The quality controller records the condition of labeling in the sanitation
assessment record.
7.4.1 Unapproved chemicals are returned and improperly stored chemicals are moved to
the correct storage area.
74
QUALITY CONTROL
BDW-HSP-03
Doc No. :
Issue No. : 02
HAND WASHING AND TOILET CLEANING Revision : 01
Issue Date 01.09.17
8: HAND WASHING AND TOILET FACILITIES.
8.1 Goal
8.1.1 Adequate readily accessible hand washing and toilet facilities that provide proper
sewage disposal shall be available and maintained in a sanitary conditions and good repair.
8.2 Procedure
8.2.1 Adequate numbers of toilets are provided for the workers near the entrance. The
doors are of self-closing types and maintenance department keeps toilet facilities operable
and in good repair. Enough hand washing facility is provided near the plant.
8.3 Monitoring
8.3.1 The toilets and wash basins are clean at least once every day and all the
employees are advised to keep it clean. The condition of the restrooms will be
inspected daily by the quality controller and results are recorded in the sanitation
assessment report.
8.4.1 The quality controller initiates the cleaning of toilet facility and correction of any
potentially contaminating condition. Repairs are made as needed
75
STANDARD OPERATION PROCEDURE
76
QUALITY CONTROL
BDW-HSP-04
Doc No. :
Issue No. : 02
STANDARD OPERAION PROCEDURE Revision : 01
Issue Date 01.09.17
STANDARD OPERATION PROCEDURE
Aim: Written SOPs are made available to the key personal so that the personnel engaged
in the production follow effective process operations.
The process carried out by the company shall be broadly classified as:
 Bottling of drinking water in following PET bottles:

250mL
330mL
500mL
1.5 L
The standard operation procedure adopted throughout the process chain is detailed in this
chapter.
11.1 RECEIPT OF PACKING MATERIALS AND LABELS:

The material for packing including PET Preform, Cartons, Caps, Labels are purchased as per
company’s section and requirements. At the time of receipt each lot is inspected for
quality and correctness of printing by the section supervisor and quality controller. The
material is followed by material safety data sheet. The accepted lot is entered in the
computer as well as stock register for packing. The packing material stored away from wall
and floor, protected from birds, rodents, insects, extraneous matters and dust.
The packing material from different types is stacked separately so that they can be easily
identified and taken. The area is kept dust free, dry and well lighted. The quality controller
assesses cleanliness of packing material room and details record in the daily cleaning
report. Through proper maintenance and effective ventilation control, the mould attack in
the area is prevented. No other chemicals such as lubricants, fuels, pesticides, cleaning
compounds are kept near to the packing area so that adulteration with these compounds
is totally eliminated.
77
11.2 TRANSPORTATION OF RAW WATER:
Raw water is received from DUBAL through Water Transport Tankers.
11.3 PRE FILTARION

The raw water is pre- filtered to remove sand and other course particles. Pre- filtration
assembly contains a porous bucket, which entrapped the macro-particles and removes the
turbidity of raw water.
11.4 CHLORINATION
After Pre-filtration, Chlorination is done to kill the Germs and Bacteria
11.5 RAW WATER STORAGE:
After filtration, raw water is stored in raw water tank have capacity of 40K gallon.
Sanitation is done as per SSOP. Testing include Microbiology test for coli forms & E coli,
Chemical Testing for TDS, Conductivity, Hardness, pH, Chlorine and Physical parameter.
11.6 PRESSURIZING PUMP (Low Pressure):

This sustains the pressure through the pipes.
11.7 MULTIMEDIA SAND FILTER:

It is connected with carbon series. Sand filtration is the process of removing micro particles
from the water. This is made up of sand particles of different granule size which are
arranged in layers in such a way that the largest particle size is stacked on top of the next
granular size bed. RSF will completely eliminate the turbidity from the raw water. Further,
these trapped suspended particles in the mixed bed are removed from the filter through
the backwash process, which involves the flushing the sand media with water in the
opposite direction flow. Back washing and media change is as per SSOP. The various
aspects of its functioning and regular quality checks that are carried out are recorded.
Turbidity is checked after every 4 Hrs and the results are recorded in the control point
monitoring file and daily analytical report.
11.8 CARBON FILTER & PRE FILTER:

It removes the smell, bad taste, chlorine, organic components and color producing
substance present in the water. The chlorine content of water is checked after every after
every 4 Hrs and the results are recorded in CCP monitoring file.
78
11.9 REVERSE OSOMOSIS:
It is used to remove all physical, chemical and microbiological components of water. The
principle involves forcing the filtered mineral water through a semi permeable membrane
at high pressure. The dissolved minerals are collected by the residual reject water and are
drained. This also entraps un-dissolved materials like colloids and microorganisms. The
filter will get replace when it is blocked and membrane becomes inactive. The machine is
maintained as per SSOP.
11.10 MINERALIZATION:
After RO Purification Process 99.5% of dissolved solids separate from water.

Mineralization is the Process addition of Micro nutrients in water which is necessary
for biological process in human Body.
11.11 OZONATION:
Water is passed through ozone contact column to get a residual limit of 0.10-0.40 mg/l.
Samples are analyzed to check the residual limit of ozone and also microbiological
parameters and the results are recorded in the microbiological analysis report & CCP file.
11.12 PRODUCT WATER STORAGE:

After mixing the so-called product water is stored in product tanks for ready release to
bottling plant.
11.13 POST FILTRATION:

Even the last traces of all microorganisms and small particle are filtered through finest
filters of 0.2µ. The filters are regularly replaced as per the maintenance schedule.
11.14 FILLING:
Filler is sterilized prior to filling. Swab test are conducted to test the effectiveness of
cleaning. Depending on type of packing the water is filled to the required amount. Start up
manual volume checks to fine tune filling process and the monitoring is recorded in the
CCP monitoring file.
11.15 CAPPING:
The sanitized caps are transferred to the hopper and the fully automatic bottling line will
automatically seal the bottle. The caps are tested by swab method to analyze the hygienic
condition of manufacture, packing and transportation and the results are recorded in the
Swab Analysis report.
79
11.16 CODING AND LEBELING:
The production and expiry dates are printed on each cap with indelible ink and manually
insert the sleeves.
11.17 PACKAGING & STORAGE:

All production is stored at the on-site warehouse; palletized to ensure that potential
damage is minimized, and are labeled clearly for correct stock rotation. The final bottled
water is analyzed for chemical parameter for Quality Check. After the storage of three
days, the final product will be checked for biological & physio–chemical analysis and the
results are recorded in the daily analytical report.
11.18 LOADING AND TANSPORTATION:

All Carton Pallets are loaded into the vehicle manually and transportation in clean vehicle
for distribution.
80
PRODUCT RECALL PROCEDURE
81
QUALITY CONTROL
BDW-HSP-04
Doc No. :
Issue No. : 02
PRODUCT RECALL Revision : 01
Issue Date 01.09.17
1 Process
1.1 Product identification and tractability

The procedure ensures the traceability of the product to the raw material. The time of
packing is also printed on each bottle e.g.
P: 01/01/17(Date of Production)
E: 31/12/17(Date of Expiry)
Numbers of bottle packed on that date for a batch will be traced from the production
register and from the details of the raw martial can be traced back. Thus, product recall
can be limited to specific code/batch.
During the online process control or in the finale inspection stage any deviation/ defects, if
notice, can easily be traced back to the raw material stage and also to the responsible
person so that timely corrective action/ recalls could be effected.
1.2 The Recall Team
Water purification has formed a recall team (HACCP team and people from sales
department), which initiates the means to prepared in advance how to handle products
emergencies.
The HACCP Team Leader has been assigned as the recall Coordinator to prepare for and
coordinates all activities related to recalls or withdrawals. Marketing and sales department
are responsible in getting the product out of the market place. They must be able to
identify customers and to pinpoint the location and quality of suspected product.
1.3 Health Hazard Evaluation and Classification

If a recall is to be made, the HACCP team will classify the recall. Once notified of a product
defect, the team will evaluate its potential seriousness. Based on the determination, the
team assigns a recall a classification (Class 1, Class 2, or Class 3) to indicate the relative
degree of health hazard of the product being recalled or considered for recall.
82
1.4 Recall Coordination Outline
1) Institute a log showing date and time of events and action taken.
2) Correlate and evaluate known information on the extent and nature of the problem.
3) Discontinue distribution of affected product code(S).
4) Notified (in this odor): comply officials; trade associations; regulatory agency, if
required; and suppliers, as necessary.
5) Decide whether to recall or make further investigation.
6) Determine area and level of distribution of product code(s).
7) Continue investigation of nature, extent, cause and remedy of problem as necessary.
Look at processing, processing, packaging, warehouse spoilage, customer complaint
records, and sanitation records.
8) Reexamine recall decision, if necessary.
9) Notify and instruct company staff.
10) Determine disposition of recalled product.
11) Prepare and issue, with Municipality concurrence, recall requests in form of includes
necessary instructions.
12) Prepare and issue news releases as necessary, preferably with concurrence of
regulatory agency.
13) Maintain records of recall progress.
14) Report recall progress to company officials and Municipality
15) Complete effectiveness and final report.
83
QUALITY CONTROL
BDW-HCP-05
Doc No. :
Issue No. : 02
Revision : 01
PRODUCT RECALL FLOW CHART Issue Date 01.09.17
FLOW CHART
84
85
QUALITY CONTROL
BDW-HSP-06
Doc No. :
Issue No. : 02
Revision : 01
RAW WATER SPECIFICATIONS Issue Date 01.09.17
RAW WATER SPECIFICATION
Sr No. PARAMETER MEASURING UNIT VALUE RANGE

1. pH @ 25 0C - 7.0 – 8.0
2. Conductivity µs/cm 200-400

@25 0C
3. Total Dissolved solids @25 0C mg/l 110-200
4. Total Hardness as CaCo3 mg/l 50-80
5. Calcium mg/l 40-80

as CaCo3
6. Magnesium mg/l 04-10

as CaCo3
7. Chloride mg/l 15-35
8. Total & free chlorine mg/l 0.1-0.5
9. Sulfate mg/l 20-60
10. Trace metals mg/l Nil
86
QUALITY CONTROL
BDW-HSP-06
Doc No. :
Issue No. : 02
Revision : 01
BOTTLED WATER SPECIFICATIONS Issue Date 01.09.17
Sr No. PARAMETER MEASURING UNIT VALUE RANGE

0
1. pH @ 25 C - 7.0 – 7.7
2. Conductivity µs/cm 220-250

@25 0C
3. Total Dissolved solids @25 0C mg/l 110-120
4. Total Hardness as CaCo3 mg/l 62-68
5. Calcium mg/l 15-18

as CaCo3
6. Magnesium mg/l 08-10

as CaCo3
7. Chloride mg/l 23-25
8. Total & free chlorine mg/l 0.0
9. Sulfate mg/l 20-25
10. Trace metals mg/l Nil
11. Potassium mg/l 11-12
12. Sodium mg/l 4
13. Bicarbonates mg/l 27-30
87
88
89

New Haccp Manual DD 02 Feb 17 (1) Bijali

Uploaded by

Copyright:

Available Formats

New Haccp Manual DD 02 Feb 17 (1) Bijali

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

New Haccp Manual DD 02 Feb 17 (1) Bijali

Uploaded by

Copyright:

Available Formats

What is the company profile of BIJANI Water?

What is the company profile of BIJANI Water?

What is the Quality and Safety Policy of BIJANI Water?

What is the Quality and Safety Policy of BIJANI Water?

1

Sr. No Document No. Description Page

2. ANNEXTURE B Quality and Safety Policy 4

3. ANNEXTURE C Visitor Policy 6

4. ANNEXTURE D Food Safety Team 8

5. ANNEXTURE E Letter of Appointment of HACCP Team Leader 9

6. ANNEXTURE F Letter of Appointment of HACCP Team 10

7. HSP0-1 HACCP Scope 11

8. Product Description & Intended Use 14

9. Assemble HACCP Team 15

10. Flow Chart 16

11. Verification of Flow Chart 17

12. Hazard Analysis & Identification of CCP 18

13. HACCP Plan 44

14. Critical Limits Validation Record 48

15. HSP-02 Good Manufacturing Practice 49

16. HSP-03 Standard Sanitation Operation 59

17. HSP-04 Standard Operation Procedure 76

18. HSP-05 Product Recall 81

19. HSP-06 Product Recall Flow Chart 84

20. HSP-07 Raw & Product Water Specifications 86

BIJANI Water is the owner of a water bottling plant in Al-Jurf Industrial

The company specializes in bottled water under the highest quality

We are in partnership with a select number of domestic and international

 To maintain hygienic processing and handling of Product in the

factory and deliveries to the consumers.

 To Satisfy the needs and expectations of our stock holders including

consumers, investors, employees and other interested parties

 To provide a clean, safe and healthy working environment to our

 To comply with national and International standards related to

bottling drinking water.

 To work towards HACCP certification and fallow HACCP manual

BIJANI's guiding philosophy - "A Heritage of Quality" finds

Our goal is to deliver the highest quality drinking water to

BIJANI WATER commitment to quality and food safety is to

Hair nets, Mouth mask, Beard & Moustache nets.

 Do not enter the production area unless guided by a ARDW’s

 Do not touch any equipment, buttons, etc. unless instructed

Sr.No Name Designation & FSMS related experience /

4. Cleaning and maintenance of

Role in Food Safety

5 Mr. Mahesh Gopi Operator Sanitization

6. Vineesh K Operator Bottle Test & Check

Bijani Drinking Water Purification.

The HACCP Program undertaken by the company is consistent with the

o Identifying the levels of risk of each hazard) Biological, Chemical and

FOOD SAFETY OBJECTIVES

The food safety objective associated with this product is:

Our processing of water includes but not limited to pre-filtration of 5

A thorough chemical and microbiological analysis of our product is done on

For all consumer groups including infants, Immuno-compromised etc.

ASSEMBLE HACCP TEAM

 The team should be multidisciplinary

Sr.No NAME OF PERSON DESIGNATION QUALIFICATION