Chapter 3 HACCP Workbook Template
Chapter 3 HACCP Workbook Template
Chapter 3 HACCP Workbook Template
Complete the section below at the start of the hazard control plan/HACCP study.
HACCP study no: Version No: HACCP study scope
HACCP/ CGP/001 0 Factory Sri Vyjayanthi Labs Pvt. Ltd
HACCP study details Check as appropriate Plant/line Second line
New HACCP study new Brand --
Scheduled review every one year Product name Calcium Glycerophosphate
when ever changes are
Unscheduled review done through CCF then Product code CGP
HACCP will be reviewed
Date study started -- FSMS reference
Description of scope of study (for example, module, start and end point, or products included)
The scope of the study is to ensure
The scope of the study is to ensure the Hazard identifictaion and its control
Scheduled or unscheduled review: main changes/reasons/causes
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HACCP team members
Name Responsibility/role/expertise Department/company
N.Santha Rao Production executive Production
M.Seeta Rama Raju-PD Production incharge Production
K.V.SubbaRaju-QC Quality control incharge Quality control
Key processing steps (such as drying, heat treatments, freezing) washing, drying, milling, seiveing, and blending
Other --
Instructions for use by consumers (including use or storage after opening) Storage At room tempearture
Distribution/storage/description
Distribution instructions (ambient, chilled, frozen, and so on) ---
Storage instructions (ambient, chilled, frozen, and so on) At room temperature
Shelf life conditions 5 years shelf life
Other ---
Use by consumers
Intended use For food industry
Target group of users and special consumer considerations (for example,
Infants
infants, the elderly)
Reasonably expected mishandling and misuse ---
Composition
High-risk ingredients No High risk ingredients are present
Epichlorohydrin is a key raw material liquid form.
Key chemical, biological, and physical characteristics
Check the specific gravity with the help of Hydrometer by Production chemist and record the result.
2 Spec.Gravity: ________ (1.05 to 1.07) and Cool the Reaction mass to 30°C to 35°C. PRP
Charge Tri sodium phosphate in to the reactor. Raise the temperature of Reaction mass to 80°C to 90°C.
3 Add water slowly at 80°C to 90°C and stir the reaction mass 15 minutes. PRP
Check the specific gravity with the help of Hydrometer by Production chemist and record the result.
4 Specific Gravity: ______(1.27 to 1.28) PRP
Maintain the temperature 100°C to 105°C for 2.0 to 5.0 hrs to attain the required specific gravity, Check
the specific gravity with the help of Hydrometer by Production chemist and record the result.
5 Specific Gravity: _______1.30 to 1.31) PRP
Unload the Reaction mass in to Nutch Filter and filter the reaction mass.Slowly reduce the Specific gravity
6 to attain 1.18 - 1.20 by adding water. PRP
Add Hydrated Lime to the reaction mass. Heat to boil the filtered mass to 100°C to 105°C.
7 Send sample to QC Phosphates: ______ Limit: Should be absent PRP
Transfer SGP solution from HDPE tank/ SS tank to Reactor. Discard the bottom settled salt material.
Adjust pH to 6.5 to 7.5 with Hydrochloric Acid.Send sample to QC for analysis
8 Result: _________ PRP
Take Calcium Chloride solution of gravity 1.20 to1.22 into Receiver
9 Take filtered SGP solution as into SS Receiver PRP
Transfer the Calcium chloride solution from receiver through the 0.50µ Filter and 0.45μ filter into the
10 reactor.Add the SGP solution under stirring from receiver through the 0.50µFilter and 0.45μ filter into the OPRP
reactor.
Check the Buchner’s filter and ensure that it is clean and ready. Unload the Reaction mass from Reactor
11 into SS Buckner. PRP
Wash the cake with 50% to 55% methanol through 0.2µ filter.Send sample to QC for Chlorides: Chlorides
12 PRP
Dry the cake by applying vacuum. Unload the wet cake material in to SS tanks
13 PRP
Ensure the Drier is cleaned and ready for drying. Load the material into the Tray drier
Dry the material at 105ºC to 110ºC for 16 to 20 hrs. (The drying temperature monitored from room
14 temperature to 110 ºC) Send sample to QC for LOD .LOD: _________ (NMT 12%) CCP
Check the integrity of Miller mesh.Charge the material in to the Miller slowly and Complete the milling of
15 the entire batch.Weigh the material. PRP
Check the integrity of sifter mesh.Ensure the sifter is cleaned and ready for sieving. Charge the material in
16 to the Sifter slowly and Complete the Sieving of the entire batch OPRP
17 Send sample to QC for complete analysis.Once it complies the material will be subjected ti blending. PRP
After complete of blending the sample to be anlysed as per the custeomer required specifcation, which
18 may include physical, chemical, metal and pathogen contaminants testing. PRP
Before packing the blended material will be passed through the Metal detctor in order to ensure the
19 material is free form metal contaminants. OPRP
Authorization Authorization
Name Position/responsibilities on the team Signature Date The document should be approved on-site after the flow diagram check is completed.
WS 4 Hazard Identification
Work Sheet 4: Hazard Identification and Description
Location of potential hazard Hazard description Hazard assessment Justification of hazard selection and assessment
Indicate the step (for example, raw material, processing, or distribution) at which the hazard Q1: Based on the hazard description, the likelihood of occurrence (before applying the control measure), and the severity of health effects, Provide supporting data / references on the likelihood of occurrence, information on the severity of the health effects, and the acceptable level in the
Describe clearly and specifically the hazards that are reasonably expected to occur at each step: class (B, P, C, or A), agent, size, origin, nature, and so on
may be introduced does this hazard need to be controlled, that is, is it a significant hazard? end product
Hazard class: For each hazard, document why it is or why it is not likely to occur or cause adverse health effects.
Significant hazard? (yes/no)
B = biological For a nonsignificant hazard, document if it is managed, for example, by a PRP, through a specification or major allergen declaration.
Origin/source of the hazard (for example, where and how it may be introduced into the Nature of the hazard (for example, presence, ability to grow and survive, the formation of toxins Likelihood of
Step no: Step (description) C = chemical Hazardous agent description Hazard no. Acceptable level in the end product Severity of adverse health effect For significant hazard, select and categorize control measure(s) on work sheet 5 Make sure that all hazards likely to occur are considered.
product or the product environment) or toxic chemicals, the migration of chemicals) occurrence
P = physical Justify why a certain hazard has been disregarded.
A = allergen
Check the integrity of sifter mesh.Ensure the sifter is The maganetic particles
If any extraneous material and maganetic mixup with
cleaned and ready for sieving. Charge the material in may pass through if the If The extraneous material mix it should not be present in
16 P = physical 3 product it can be controlled by using sifter with magnetic It is not toxin it comes under extrnaeous material contaminant. Rare OPRP
to the Sifter slowly and Complete the Sieving of the magnetic rods are not up with material to be seived. the product
rods.
entire batch present in the sifter
Severity of health
effect
Significant
Can lead to serious illness 4
(controlled by OPRPs or CCPs)
Insignificant
Can cause inconvenience 2
(controlled by PRPs)
Almost no significance 1
Score 1 2 3 4 5
Very
Rare Could occur Likely Frequent
frequent
(1/year) (1/6 months) (1/month) (1/week)
(1/day)
Likelihood of occurrence
Note: The hazard assessment table helps separate significant from nonsignificant hazards and to document the decision.
WS 5 Control Measures
Work Sheet 5: Control Measure Selection and Categorization
Step and hazard Control measures Categorization of control measures in OPRPs and CCPs (answer questions Q1 to Q5 as necessary)
Select and describe a control measure or Q1: Based on the likelihood of occurrence (before applying the control measure) and the severity of adverse health effects (WS 4), is this hazard significant (needs to be controlled)? YES: This is a significant hazard. Go to Q2. NO: This is not a significant hazard.
combination of control measures capable of
Transfer the hazards considered significant in the hazard assessment in work sheet 4 to this work sheet (5).
preventing, eliminating, or reducing the hazard to an
acceptable level. Q2: Will a subsequent processing step, including expected use by consumers, guarantee the removal of this significant hazard, or its reduction to an acceptable level? YES: Identify and name the 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.
Document the rationale for the selection, for
example, the effectiveness of applied control 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 and action criteria.
measures alone or in combination against identified
hazards (refer to documents if possible). Q5: Is it possible to monitor or observe the control measure in such a way that corrections can be made immediately if there is a loss of control? YES: This hazard is managed by the hazard control–HACCP
plan (CCP). NO: This hazard is managed by an OPRP and action criteria.
Decision justification: provide supporting evidence that the selected control measure(s) and target/critical limits or action
Step no. Step description Hazard no. Hazardous agent description Description of control measures Q1 Q2 Q3 Q4 Q5 CCP, OPRP, or process modification
criteria will adequately control the hazard.
Ensure the Drier is cleaned and ready for drying. Load the
material into the Tray drier
If the material not properly dried it
Dry the material at 105ºC to 110ºC for 16 to 20 hrs. (The The adequate temprature is to be Based on LOD content result in the material. We can use the material for further usage.so this
14 3 won't complies the required CCP
drying temperature monitored from room temperature to maintained to meet required LOD step is concerned has more critical control point.
specification
110 ºC) Send sample to QC for LOD .LOD: _________
(NMT 12%)
Check the integrity of sifter mesh.Ensure the sifter is The material before blending it is pass
The maganetic particles may pass
cleaned and ready for sieving. Charge the material in to through the sifter and also before The cleaning of the magnetic rods and sifter to be done for evey batch in order to checkany
16 4 through if the magnetic rods are not OPRP
the Sifter slowly and Complete the Sieving of the entire performing the acrivity ensure the foreign material present or not.
present in the sifter
batch sifter magnetic rods cleaned or not.
The hazard control/HACCP team must provide or ask for evidence that selected control measures are capable of achieving the intended control over the hazards identified
The hazard control–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 levels?
· Are the critical limits correct and appropriate?
· Will the corrections restore product safety control?
CCP no. or
Step Hazardous agent description Control measure Justification for the selection of control measures Checking control measure effectiveness Critical limits (for CCP only) Justification for the selection of critical limits Corrections
OPRP no.
WS 7 Hazard Control Plan
Work Sheet 7: Hazard Control Plan
CCP no. or
Verification activity Verification procedure Frequency Person responsible Records
OPRP no.
WS 9 Modifications
Work Sheet 9: Modification(s) and Follow-Up
Recommended
modification and
Step no. Step description Hazard no. Hazardous agent description Modification no. confirmation of Limit date
transfer for
action
Provisional control measure(s)
WS 10 Meeting Summary
Work Sheet 10: Hazard Control Plan–HACCP Meeting Summary