ab1 haccp plan bread 1

HACCP Example - Courtesy of Fletchers Bakery, Sheffield
HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (1-4) - STAYFRESH BREAD September 2004

Process Step Hazard Control Measures CCP Critical Limits Monitoring Corrective Responsible

1.0 Flour intake Procedure Action Personnel

2.0 Water intake 1.1 Foreign bodies in final Approved supplier & 1 Sieve integrity Certificate of Reject out of Q.A. Stores
3.0 Salt Sieve contact no analysis with every specification Personnel.
4.0 Vegetable Fat product compliance with damage delivery. deliveries. Engineers
5.0 Yeast Intake Daily check of Follow sieve
specification sieve integrity procedure Engs.
6.0 Bread Improver
7.0 Potassium Sorbate line,4&6mm mesh
8.0 Sorbate solution
1.2 Infestation in silos Pest Control Contract & Activity in traps, other Annual clean and Pest control to Pest
hygiene schedule evidence eg, monthly inspections. advise controller/Hygiene
droppings, beetles

1.3 Survival of micro- Purchase from approved, 8 Compliance with Certificate of Reject out of QA, production,

organisms audited supplier specification analysis, random specification stores

challenge testing. deliveries. Inform
QA and supplier.

2.1 Routine microbiological 8 Compliance with Certificate of Water board inform Water authority,

Survival of micro- checks, Water authority. specification analysis, random of contamination, production, CRISIS
organisms, chlorine (water haccp referenced) challenge testing. stop use of suspect MGT team
overdose, foreign matter water. Recall suspect
product

3.1 Foreign bodies in final Approved supplier & 8 Sieve integrity Certificate of Reject out of Q.A. Stores ,
Compliance with analysis with every specification production
product. compliance with specification delivery. deliveries. Inform
random challenge QA and supplier.
Survival of micro- specification sieve in line, testing.

organisms 4mm mesh.

4.1 Foreign bodies in final Approved supplier & 8 Compliance with Certificate of Reject out of Q.A. Stores ,

product. compliance with specification analysis with every specification production
Survival of micro- specification. delivery. Random deliveries. Inform
organisms, rancidity challenge testing. QA and supplier.

Stock rotation.

5.1 Microbiological, Approved supplier 8 Maintain temperature Certificate of Reject out of Q.A. Stores
compliance with spec. Temp. below 4C Max 8 conformity each specification Personnel
check on delivery. Limited time delivery. deliveries. Inform
QA and supplier.

5.2 Temperature check on 2 Temperature control Temperature checks Q.A. to advise on QA/Stores Personnel

storage vessel, daily. recorded. required action

5.3 Taints from poor tank Tank cleaned weekly, by Wash programme pH7 Operator to complete Repeat wash cycle. QA Technologist
cleaning member of QADept.
( neutral) cleaning record

start/end time. +ve

release on cleaning

procedure

6.1 Foreign bodies in final Purchase from approved, 8 Sieve integrity Certificate of Reject out of spec. QA/Stores

product. Survival of audited supplier. Compliance with conformity each del. deliveries. Inform Production

micro-organisms Sieve specification met specification QA and supplier.

Foreign bodies in final Purchase from approved, 8 Compliance with Certificate of Reject out of spec. - QA/Stores
product. audited supplier
specification conformity each del. deliveries. Inform Production

Survival of micro- QA and supplier.

organisms

8.1 Incorrect solution Monitored on plant 11 Bread 1800g/10 litres Weights taken. Do not use re weigh Production

strength. water 1/4ly verification for adjust weight

legislation accordingly

HACCP Example - Courtesy of Fletchers Bakery, Sheffield
HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (2-4) STAYFRESH BREAD September 2004

Process Step Hazard Control Measures CCP Critical Limits Monitoring Corrective Action Responsible
Procedure Personnel
9.0 Bag Flour 9.1 Foreign bodies in Sieved at stage 17. 8 Sieve integrity Reject out of spec. Stores/QA
Purchased from approved, Compliance with Certificate of deliveries. Inform Production
final product. audited supplier specification conformity each del. Qa and supplier
Random challenge Stores/QA
Survival of micro- tests for micro Reject out of spec. Production
deliveries. Inform
organisms Certificate of Qa and supplier Plant and
conformity each del. Hygiene Dept-
10.0 Vinegar 10.1 Foreign bodies in Purchased from approved, 8 Compliance with Random challenge reclean
audited supplier specification Stores
final product. tests for micro Clean and report if
evidence found Hygiene / Pest
Survival of micro- Routine testing on control Co
water schedule See Step 1.2
organisms
Regular
11.0 Ice Making Machine Micro growth on Cleaning and water - No evidence of housekeeping
Good storage growth checks and control
machine of spillages
- No evidence of
12.0 Ambient Storage Infestation infestation See Step 1.2

13.0 Bulk Storage 13.1 Infestation in silos See Step 1.2 See Step 1.2

14.0 Chilled Storage 14.1 Ingredient Maintain temp <4 C 2 Temperature control Temperatures Check ingredient Stores Q.A.
deterioration
>8 C Action checked daily and temp. reject out of Personnel

on 24hour alarmed spec. ingredients.
system

15.0 Chilled Bulk Storage 15.1 Ingredient See step 5.2 2 See step 5.2 See step 5.2 See step 5.2 See step 5.2

deterioration

16.0 Packaging Store 16.1 Foreign body hazards Purchased packaging from - All food contact Regular Clean and report if Stores
( wood/ infestation) approved, audited supplier, items covered. No housekeeping evidence found
shroud it and store findings of foreign checks and control
appropriately. of packaging-
matter

17.0 Sieve dry ingredients 17.1 Foreign bodies in Sieve checks, metal 1 Sieve mesh size & Sieve checked Replace sieve Production
final product. detection step Engineering/QA
integrity step before & after use

18.0 Weigh Station 18.1 Wrong recipe Document codes and 12 Correct codes and QA Audit, Foreman Hold incorrect Prodn/QA

amounts, lack of follow recipe recipe checks ( hourly) product
ingredient trace codes

19.0 Mixer No perceived hazard Dough temps checked. - - Calibrated probe - Prodn/QA

20.0 Divider No perceived hazard Dough weights checked - - Calibrated scale Prodn/QA

21.0 First mould rounder Fibres on belts Regular checks on - No fibres near food Daily checks Remove fibres or - Production
22.0 Intermediate proof No perceived hazard integrity contact area. - replace belt Engineering

- -- - -

23.0 Final Mould Fibres on belts Regular checks on - - No fibres near Daily checks Remove fibres or - Production
24.0 Baking Tin Storage routine use replace belt Engineering
Dirt from incorrect integrity food contact area.
storage clean tins/ ensure Prodn/
Proper storage- off floor, - Free from dirt blower is working engineering

upside down/covered

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 Corrective Action Responsible
- Procedure Personnel
-
25.0 Dough into tins Foreign bodies in final Tins air-jet blown to remove - Check tin blower is on - Prodn
product. any foreign bodies, online - and working
26.0 Prover vacuum system. Hygiene
Product debris from Weekly clean -
27.0 Addition of lids. structure Regular cleaning of structure
28.0 Lid storage
29.0 Baking No perceived hazard -- - - --

30.0 Removal of lids. No perceived hazard -- - - --
31.0 Remove bread from tins.
32.0 Potassium Sorbate Under baking - survival Correct heating process 3 Ex-oven temp > 94C Product temp check 2 Reject under baked Production
of pathogenic organisms. - hourly with cal. Temp product. Q.A.
Sprayer probe.
33.0 Cooler controlled No perceived hazard -- - -
-
condition
No perceived hazard -- - - --

Microbial spoilage 5g of 15.2% solution 11 Min 4g QA 3 x daily Hand spray Adjust Production
Max 6 g + ½ hr production sprayer QA, Engrs.
Microbial spoilage Correct temperature at 4 Ex cooler temp Report fault to Engs.
packing <34 C Internal temp. taken 2 Document quantity, Production
hourly. Every product temp & date code. Engineers
34.0 Metal detection 34.1 Metal in final product. 100% effective 6 Detection 3.5mm Fe, type. Process , cooler
4.5mm Non Fe. on. Quarantine Production
35.0 Slicer 35.1 Metal in final product Blade break detector on slicers 6.35mm SS unscreeded prd return Q.A.
Broken blade detectors Inspect sensitivity 1 through detector Production
operational per hr. during Stop using machine Engineers
production Check blades entact, Q.A.
if broken blade is
Detectors challenged found isolate & -
hourly. destroy bread back to
last good check. Call
36.0 Bag Machine - No perceived hazard - - -- engineer to rectify
37.0 Thurne tag BBE code Lack of traceability 12 fault.
Thurne tag checks for coding-
start and end of run -

Correct code Daily and changeover Recall product Prodn/ QA
checks incorrectly coded,

amend code

38.0 Metal Detection 38.1 Metal in final product 100% effective 6 Detection 3.00mm Fe / Inspect sensitivity 1 Quarantine Production
4.00mm Nfe per hr. during unscreeded prd return Q.A.
39.0 Finished Prod. Wt. 18.1 Non compliance to 15 minute average weight 13 6.35mm SS production through detector
Control average weight checks - Prodn/QA
procedure Target 800g, T1 and Bread Average Remedial action
Operator Inspection T2 procedure weight procedure procedure
Dirty baskets inoperation
40.0 Basket - Inform - Supplier Logistics
- Production Q.A.

HACCP Example - Courtesy of Fletchers Bakery, Sheffield

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (4-4) STAYFRESH BREAD September 2004

Process Step Hazard Control Measures CCP Critical Limits Monitoring Corrective Action Responsible
Procedure Personnel

41.0 Stack No perceived hazard - -- - --

42.0 Ambient storage No perceived hazard - -- - --

43.0 Load onto ambient Dirty vehicles Vehicle check prior to - Free from foreign Despatch trailer Do not load/ clean Despatch
vehicle No perceived hazard. loading trailor -
matter, taints check
44.0 Deliver customer - -
ambient -- -

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (4-4) FROZEN BREAD September 2004

Process Step Hazard Control Measures CCP Critical Limits Monitoring Corrective Action Responsible
Procedure Personnel

40.0 Freezer Temperature out of spec, Freezer checks, 24 hour 5 -8 Deg C 24 hour freezer alarm, QA Hold product and Engineers/
41.0 BOX
product defrosts surveillance on freezer check for quality Production.

No perceived hazard - -- - --

42.0 Seal and code Lack of traceability Box code checks hourly 12 Correct BB and Hourly checks and Stop -
43.0 Palletise Despatch
44.0 Frozen storage julienne code QA audit
-
No perceived hazard Vehicle check prior to - Free from foreign Despatch trailer Do not load/ clean

loading matter, taints check trailor

Temperature out of - -- - -

spec

Doc Title: Food Safety HACCP – Stayfresh bread Authorised by: Date :Sept 2004
Originated by: Revision : 3
Doc Ref: QA/haccp/bread/full haccp/stayfresh (and frozen) Page 4 of 4
bread