Bakery Haccp plan

modern bakries group
modern bakries groupquality control section Head at modern Bakries group em modern bakries group
••
HACCP PLAN FOR BAKED FOODS Department of Food Science and Technology Faculty of Agricultural Technology Bogor Agricultural University 2009
Langkah 1 : Establish the HACCP team Name Expertise/Position Position in the team Dewi Food Tech. & HACCP specialist/ Coordinator QA Mgr. Rahman Engineering/Production Mgr. Member Putri Microbiology/QC Mgr. Member Surya Chemistry/Warehouse Mgr. Member
Step 2 : Product Description • Name of product • Composition • Product characteristics • Methods of processing • Methods of preservation • Primary packaging • Conditions of storage • Method of distribution • Shelflife • Specific labelling • Instruction on the label : cream-filled bread : Susu skim, kultur BAL, glukosa : Susu kental, asam, pH 4.3 : pasteurisasi, fermentasi : fermentasi : cup Polyethylene : Suhu 4oC : Dalam truk beropendingin : 3 minggu : - : -
Step 3 : Identification of the Product’s Intended Use • Name of product • Intended use • Target consumer : Cream-filled bread : Directly consumed : General public
Step 4 : Establish Process Flow Diagram Process flow diagram for the bread : Weigh all ingredients (sugar, salt, skim milk, shortening, egg, wheat flour, yeast, cold water) Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-300C) Divide the dough and weigh 900 gram each Fermentation 2 (27-300 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
Step 4 : Establish Process Flow Diagram Process flow diagram for the cream : Weigh all the ingredients (jelly mallow, butter, shortening) Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
Step 5 : On-site Confirmation of Flow Diagram : Bread Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving (egg, water) Dry storage at room temperature (25-300 C) Storage at 5-150 C Weigh all ingredients Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-300C) Divide the dough and weigh 900 gram each Fermentation 2 (27-300 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
Step 5 : On-site Confirmation of Flow Diagram : Cream Receiving (jelly mallow, butter, shortening) Dry storage at room temperature (25-300 C) Weigh all the ingredients Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving of egg Storage of egg Weighing of all ingredients Mixing of sugar, salt, skim milk B B B P B P P Contaminated yeast (by spoilage or pathogenic m.o.) Insects Presence of pathogenic bacteria Eggshell (cracked/broken eggs) Growth of pathogenic bacteria Insect bone pieces Insect bone pieces, personal items
Process Step Potential Hazard(s) B/C/P Description of Hazard Adding egg and shortening Adding wheat flour, yeast and cold water Blending Rounding the dough Fermentation 1 Dividing the dough Fermentation 2 B P B P B P B B B B Contamination of pathogenic bacteria Eggshell Contamination of spoilage or pathogenic bacteria (from yeast and water) Insect bone pieces Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) B/C/P Description of Hazard Spreading with egg Baking Cooling Filling with cream Packaging Storage B B B B B B Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o. Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) B/C/P Description of Hazard Receiving jelly mallow, butter, shortening Storage Weighing all ingredients Mixing Beating Storage - B C - P P B - Contamination of spoilage m.o. Decomposition of chemical compound - Personal item Personal item Growth of spoilage m.o. Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Preventive or Control Measures Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) B Contaminated yeast (by spoilage or pathogenic m.o.) Quality assurance (certificate of analysis) from supplier Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) P Insects Proper storage conditions (dry, clean), sealed packaging of the ingredients. Receiving of egg, water B Presence of pathogenic bacteria Certificate of analysis from egg supplier, acceptable water source P Eggshell (cracked/broken eggs) Inspection of incoming eggs Storage of egg B Growth of pathogenic bacteria Refrigerated storage (5-15 0 C), Label expired date. Weighing of all ingredients P Insect bone pieces, personal items Inspection of the ingredients, SOP for production area (no personal items are wore) Mixing of sugar, salt, skim milk P Insect bone pieces, personal items Inspection of the ingredients, SOP for production area (no personal items are wore) Adding egg and shortening P Eggshell Inspection of the ingredients (cracked eggs) Adding wheat flour, yeast and cold water P Insect bone pieces Filtering of wheat flour Blending B Contamination of spoilage m.o. from the air SSOP P Personal item SOP for production area (no personal items are wore) Rounding the dough B Contamination of spoilage & pathogenic m.o. from the air & worker SSOP
Process Step Potential Hazard(s) Description of Hazard Preventive or Control MeasuresB/C/P Fermentation 1 B Contamination of spoilage m.o. from the air SSOP Dividing the dough B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Fermentation 2 B Contamination of spoilage m.o. from the air SSOP Spreading with egg B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Baking B Survival of spoilage m.o. Correct time and temperature Cooling B Contamination of spoilage m.o. from the air SSOP Filling with cream B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Packaging B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Storage B Contamination of spoilage molds Proper storage condition (dry, clean), expired date must be stated on the label Receiving jelly mallow, butter, shortening - Storage B Contamination of spoilage m.o. Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients Weighing all ingredients Mixing P Personal item SSOP Beating P Personal item SSOP Storage B Growth of spoilage m.o. Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight) Principle 1 : Hazard Analysis HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps (cont.) Name of Product : Cream-filled Bread
Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Severity Significant hazard (Y/N) Preventive or Control Measures Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg, water Storage of egg Weighing of all ingredients B P B P B P Contaminated yeast (by spoilage/ pathogenic m.o.) Insects Presence of pathogenic bacteria Eggshell (Cracked / broken eggs) Growth of pathogenic bacteria Insect bone pieces, personal items l h m h l l M M M M L M N Y N Y N N Quality assurance (certificate of analysis) from supplier Proper storage conditions (dry, clean), sealed packaging of the ingredients. Certificate of analysis from egg supplier, acceptable water source Inspection of incoming eggs Refrigerated storage (5-150 C), Label expired date. Inspection of the ingredients, SOP for production area (no personal items are wore)
Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Mixing of sugar, salt, skim milk Adding egg and shortening Adding wheat flour, yeast and cold water Blending Rounding the dough Fermentation 1 P P P B P B B Insect bone pieces, personal items Eggshell Insect bone pieces Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air l m m m m l l M M M L M L L N N N N N N N Inspection of the ingredients, SOP for production area (no personal items are wore) Inspection of the ingredients (cracked eggs) Filtering of wheat flour SSOP SOP for production area (no personal items are wore) SSOP SSOP Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging of bread Storage and distribution B B B B B B B B Contamination of spoilage and pathogenic m.o. from the air, weigh- scale, and worker Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o. Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds m l m l m m m m L L H H M H H M N N Y N N Y Y N SSOP SSOP SSOP Correct time and temperature SSOP SSOP SSOP Proper storage condition (dry, clean), expired date must be stated on the label Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Receiving jelly mallow, butter, shortening Storage of jelly mallow, butter, shortening Weighing all ingredients Mixing Beating Storage of cream - B C - P P B - Contamination of spoilage m.o. Decomposition of chemical compound - Personal item Personal item Growth of spoilage m.o. - m m - l l m - H H - M M H - Y Y - N N Y - Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients - SSOP SSOP Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight) Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
Principle 2 : Establishment of Critical Control Point CCP HACCP Plan Worksheet 2A : Establishment of CCP in Ingredients Name of Product : Cream-filled Bread Ingredient Potential Hazard (s) P1 P2 P3 CCP? Sugar B P Y Y Y Y N N N N Wheat flour B P Y Y Y Y N N N N Yeast B Y Y N N Egg B C P Y Y Y Y N N N - - N Y Y Water B Y Y N N
Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Potential Hazard(s) P1 P2 P3 P4 P5 CCP? Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Storage of egg Weighing of all ingredients Mixing of sugar, salt, skim milk Adding egg and shortening Adding wheat flour, yeast and Cold water Blending B P B P B P P P P B P N Y N Y N N N N N N N - Y - Y - - - - - - - - N - N - - - - - - - - Y - Y - - - - - - - - N - N - - - - - - - N CCP N CCP N N N N N N N
Process Step Potential Hazard(s) P1 P2 P3 P4 P5 CCP? Rounding the dough Fermentation 1 Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging Storage and distribution of bread B B B B B B B B B B N N N N Y N N Y Y N - - - - Y - - Y Y - - - - - N - - N N - - - - - Y - - Y Y - - - - - Y - - N N - N N N N N N N CCP CCP N Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread
Process Step Potential Hazard(s) P1 P2 P3 P4 P5 CCP? Storage of jelly mallow, butter, shortening Mixing Beating Storage of cream B C P P B Y Y N N Y Y Y - - Y N N - - N Y Y - - Y N N - - N CCP CCP - - CCP Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread
Principle 3: Establishment of Critical Limits HACCP Plan Worksheet 3 : Establishment of Critical Limits Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20-250 C Holding Time <10 min, T=20-250 C Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date
Principle 4: Establishment of Monitoring Procedures HACCP Plan Worksheet 4 : Establishment of Monitoring Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures What How Where Who Freq. Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90=92 Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20-250 C Holding Time <10 min, T=20-250 C Antibiotic residue on CoA Cracked/broken eggs Rh Storage time SSOP application Cracked/broken eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temp. Receiving site Receiving site Storage room / warehouse Receiving site Production area Production area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Area personnel Area personnel Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temp., check label Measure temp. check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day
Principle 5: Establishment of Corrective Actions HACCP Plan Worksheet 5 : Establishment of Corrective Actions (1) Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions What How Where Who Frequency Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure Rh,check storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperatur e Check/ measure time and temperatur e Receiving site Receiving site Storage room / warehouse Receiving site Production area Production area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Area personnel Area personnel Every receiving Every receiving Every day Every Receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr.
Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions What How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature, check label Measure temperature, check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Principle 5: Establishment of Corrective Actions HACCP Plan Worksheet 5 : Establishment of Corrective Actions (1) Name of Product : Cream-filled Bread
Principle 6: Establishment of Verification Procedures HACCP Plan Worksheet 6 : Establishment of Verification Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification ActivitiesWhat How Where Who Frequen cy Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/bro ken eggs Rh Storage time SSOP application Cracked/bro ken eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehou se mngr. Receiving personnel Productio n superviso r Productio n superviso r Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh- meter Inspection of insects contamination every 1 month Customer complaint Microb.analysisof products Microb. Analysis of products
Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification ActivitiesWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature, check label Measure temperature, check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day 1. Disposition of non- complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non- complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Principle 6: Establishment of Verification Procedures HACCP Plan Worksheet 6 : Establishment of Verification Procedures (cont.) Name of Product : Cream-filled Bread
Principle 7: Establishment of Record-keeping Procedures HACCP Plan Worksheet 7 : Establishment of Record-keeping Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification Activities RecordsWhat How Where Who Frequenc y Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Production supervisor Production supervisor Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh-meter Inspection of insects contamination every 1 month Customer complaint Microb. analysis of products Microb. Analysis of products Receiving log Warehouse log, Rh operation document, Rh calibration documents, Insects inspection document Receiving log Production log, microb. analysis document Production log, microbiological analysis document
Ingredient / Process Step CCP No. CL Monitoring Procedures Corrective Actions Verificatio n Activities RecordsWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature , check label Measure temperature , check label Wareho use Wareho use Warehous e mngr. Warehous e mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Warehouse log, microb. Analysis document Warehouse log, microb. Analysis document Principle 7: Establishment of Record-keeping Procedures HACCP Plan Worksheet 7 : Establishment of Record-keeping Procedures (cont.) Name of Product : Cream-filled Bread
HACCP Plan Cream-Filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification Activities RecordsWhat How Where Who Frequenc y Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Production supervisor Production supervisor Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh-meter Inspection of insects contamination every 1 month Customer complaint Microb. analysis of products Microb. Analysis of products Receiving log Warehouse log, Rh operation document, Rh calibration documents, Insects inspection document Receiving log Production log, microb. analysis document Production log, microbiological analysis document
Ingredient / Process Step CCP No. CL Monitoring Procedures Corrective Actions Verificatio n Activities RecordsWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature , check label Measure temperature , check label Wareho use Wareho use Warehous e mngr. Warehous e mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Warehouse log, microb. Analysis document Warehouse log, microb. Analysis document HACCP Plan (cont.) Cream-Filled Bread
1 de 32

Bakery Haccp plan

••
Baixar para ler offline
Alimentos

QUALITY MANAGEMENT OF BAKERY PRODUCTS

modern bakries group
modern bakries groupquality control section Head at modern Bakries group em modern bakries group

Recomendados

Haccp of milk pasteurizationHaccp of milk pasteurization
Haccp of milk pasteurizationumairahmad76
12.3K visualizações•14 slides
Haccp final planHaccp final plan
Haccp final planPiumali Suraweera
7.4K visualizações•81 slides
Haccp plan in chocolateHaccp plan in chocolate
Haccp plan in chocolatesafeena p a
28.3K visualizações•20 slides
HACCP PresentationHACCP Presentation
HACCP PresentationRAGHAVENDRA ADIGA
173.2K visualizações•25 slides
The haccp system and applicationThe haccp system and application
The haccp system and applicationNik Ronaidi
15.6K visualizações•48 slides
Introduction to HACCPIntroduction to HACCP
Introduction to HACCPAsian Food Regulation Information Service
20.7K visualizações•29 slides

Mais conteúdo relacionado

Mais procurados

FOOD QUALITY CONTROLFOOD QUALITY CONTROL
FOOD QUALITY CONTROLMariya Raju
60.1K visualizações•49 slides
What is FSSC 22000What is FSSC 22000
What is FSSC 22000Eng. A.karam Al Malkawi
13.4K visualizações•46 slides

Mais procurados(20)

FOOD QUALITY CONTROLFOOD QUALITY CONTROL
FOOD QUALITY CONTROL
Mariya Raju•60.1K visualizações
HACCP PLAN FOR FRUIT JUICE INDUSTRY[000157]HACCP PLAN FOR FRUIT JUICE INDUSTRY[000157]
HACCP PLAN FOR FRUIT JUICE INDUSTRY[000157]
Ajna Alavudeen•45.7K visualizações
Iso 22000 food safety management systemIso 22000 food safety management system
Iso 22000 food safety management system
Naveen Kumar•21.6K visualizações
What is FSSC 22000What is FSSC 22000
What is FSSC 22000
Eng. A.karam Al Malkawi•13.4K visualizações
ISO 22000 - Food Safety Management System and HACCP ImplementationISO 22000 - Food Safety Management System and HACCP Implementation
ISO 22000 - Food Safety Management System and HACCP Implementation
SobanManzoor1•1.4K visualizações
Good Manufacturing Practices in Food ProcessingGood Manufacturing Practices in Food Processing
Good Manufacturing Practices in Food Processing
Piumali Suraweera•44.9K visualizações
Haccp milk industry(pasteurization) Haccp milk industry(pasteurization)
Haccp milk industry(pasteurization)
geethuvavachi•26.7K visualizações
BAKERY AND CONFECTIONERY TECHNOLOGY notesBAKERY AND CONFECTIONERY TECHNOLOGY notes
BAKERY AND CONFECTIONERY TECHNOLOGY notes
Mohit Jindal•22.4K visualizações
Food Safety Management Systems (FSMS) Food Safety Management Systems (FSMS)
Food Safety Management Systems (FSMS)
SukhveerSingh31•21.8K visualizações
Principles of food sanitationPrinciples of food sanitation
Principles of food sanitation
Akmal Hafiz•24K visualizações
Critical Control Point (CCP): www.chefqtrainer.blogspot.comCritical Control Point (CCP): www.chefqtrainer.blogspot.com
Critical Control Point (CCP): www.chefqtrainer.blogspot.com
Culinary Training Program•8.7K visualizações
ICE CREAM HACCP GUIDLINESICE CREAM HACCP GUIDLINES
ICE CREAM HACCP GUIDLINES
Eng. A.karam Al Malkawi•37.1K visualizações
HACCP Plan for Pineapple Jam Manufacturing Plant HACCP Plan for Pineapple Jam Manufacturing Plant
HACCP Plan for Pineapple Jam Manufacturing Plant
MuhammadSaqibJaved6•6.9K visualizações
Personal Hygiene in Food ProductionPersonal Hygiene in Food Production
Personal Hygiene in Food Production
FAO•59.5K visualizações
Tab 2 haccp team (example)Tab 2 haccp team (example)
Tab 2 haccp team (example)
Yousef Abuazza•1.9K visualizações
Sensory Evaluation Lab ReportSensory Evaluation Lab Report
Sensory Evaluation Lab Report
Charityn Fernandez•22.9K visualizações
Sensory evaluation of food productsSensory evaluation of food products
Sensory evaluation of food products
Dr. Nataraj Durgannavar•127.6K visualizações
HACCP PRESENTATIONHACCP PRESENTATION
HACCP PRESENTATION
Pallavi B S (Food Technologist)•4.9K visualizações
Food Safety TrainingFood Safety Training
Food Safety Training
Hamilton County Public Health•14.1K visualizações
Food Safety Risk Analysis - Part 1Food Safety Risk Analysis - Part 1
Food Safety Risk Analysis - Part 1
safefood360•22.7K visualizações

Similar a Bakery Haccp plan

Food Packaging of Dairy ProductsFood Packaging of Dairy Products
Food Packaging of Dairy ProductsIlyana Causing
7.2K visualizações•38 slides
Report cnv sdasua07042021Report cnv sdasua07042021
Report cnv sdasua07042021Mia Lê
38 visualizações•53 slides
Extrusion pptExtrusion ppt
Extrusion pptCheshtaMamgain
611 visualizações•29 slides

Similar a Bakery Haccp plan(20)

Milk thermal treatmentMilk thermal treatment
Milk thermal treatment
Faculty of Veterinary Medicine ,Benha university•863 visualizações
Microbiology of food productsMicrobiology of food products
Microbiology of food products
subhananthini jeyamurugan•171 visualizações
Food Packaging of Dairy ProductsFood Packaging of Dairy Products
Food Packaging of Dairy Products
Ilyana Causing•7.2K visualizações
Milk & milk products (alfahad farwa)Milk & milk products (alfahad farwa)
Milk & milk products (alfahad farwa)
AlfahadFarwa•124 visualizações
Report cnv sdasua07042021Report cnv sdasua07042021
Report cnv sdasua07042021
Mia Lê•38 visualizações
Extrusion pptExtrusion ppt
Extrusion ppt
CheshtaMamgain•611 visualizações
Ways to help reduce Wastage in the Dairy Food ChainWays to help reduce Wastage in the Dairy Food Chain
Ways to help reduce Wastage in the Dairy Food Chain
African Dairy Conference and Exhibition•1.2K visualizações
Monika Jadacka presentationMonika Jadacka presentation
Monika Jadacka presentation
Monika Jadacka•441 visualizações
HK Measures to Reduce the Risk of Listeria Monocytogenes in RTE Food_2016HK Measures to Reduce the Risk of Listeria Monocytogenes in RTE Food_2016
HK Measures to Reduce the Risk of Listeria Monocytogenes in RTE Food_2016
Asian Food Regulation Information Service•624 visualizações
Food safety plan hot dogs Food safety plan hot dogs
Food safety plan hot dogs
Goutham Matta•4.4K visualizações
Cultivation Technology of White Oyster MushroomCultivation Technology of White Oyster Mushroom
Cultivation Technology of White Oyster Mushroom
Bureau of Agricultural Research•11.5K visualizações
BF power point za 23KHT i SDW i CTBF power point za 23KHT i SDW i CT
BF power point za 23KHT i SDW i CT
Julijana Savic-Dineva•273 visualizações
Round board vellon cheeseRound board vellon cheese
Round board vellon cheese
Oscar Herrera•321 visualizações
Pasteurization(suraj)Pasteurization(suraj)
Pasteurization(suraj)
BARKATULLA UNIVERSITY, BHOPAL•872 visualizações
session8 chapter6 quality system.pptxsession8 chapter6 quality system.pptx
session8 chapter6 quality system.pptx
RatipornChomrit•5 visualizações
Concentrated milks technology and faultsConcentrated milks technology and faults
Concentrated milks technology and faults
Faculty of Veterinary Medicine ,Benha university•1.3K visualizações
QCQC
QC
Lucy Melikyan•148 visualizações
Elderflower ice cream development presentationElderflower ice cream development presentation
Elderflower ice cream development presentation
Boykie Mackay•2 visualizações
Elderflower Ice Cream Development PresentationElderflower Ice Cream Development Presentation
Elderflower Ice Cream Development Presentation
Boykie Mackay•3.2K visualizações
Quality management of bakery productsQuality management of bakery products
Quality management of bakery products
modern bakries group•3.3K visualizações

Mais de modern bakries group

Bread fualtBread fualt
Bread fualtmodern bakries group
2.6K visualizações•5 slides
Food sensory evaluationFood sensory evaluation
Food sensory evaluationmodern bakries group
1.1K visualizações•1 slide
Cake faultsCake faults
Cake faultsmodern bakries group
6K visualizações•5 slides
Cake faults Cake faults
Cake faults modern bakries group
741 visualizações•1 slide

Mais de modern bakries group(20)

Bread fualtBread fualt
Bread fualt
modern bakries group•2.6K visualizações
Bread problems &amp;solutionsBread problems &amp;solutions
Bread problems &amp;solutions
modern bakries group•3.1K visualizações
Food sensory evaluationFood sensory evaluation
Food sensory evaluation
modern bakries group•1.1K visualizações
Sensory evaluation of breadSensory evaluation of bread
Sensory evaluation of bread
modern bakries group•3.3K visualizações
Cake faultsCake faults
Cake faults
modern bakries group•6K visualizações
Cake faults Cake faults
Cake faults
modern bakries group•741 visualizações
Haccp audite Haccp audite
Haccp audite
modern bakries group•894 visualizações
Haccp training level 2 Haccp training level 2
Haccp training level 2
modern bakries group•963 visualizações
Haccp manualHaccp manual
Haccp manual
modern bakries group•743 visualizações
Food quality and safety systems a training manual onFood quality and safety systems a training manual on
Food quality and safety systems a training manual on
modern bakries group•737 visualizações
Haccp trainingHaccp training
Haccp training
modern bakries group•611 visualizações
Haccp training Haccp training
Haccp training
modern bakries group•804 visualizações
HACCP & GMP trainingHACCP & GMP training
HACCP & GMP training
modern bakries group•4.8K visualizações
Jam HACCP PlanJam HACCP Plan
Jam HACCP Plan
modern bakries group•7.7K visualizações
Flour improvers.Flour improvers.
Flour improvers.
modern bakries group•3.1K visualizações
Haccp case studyHaccp case study
Haccp case study
modern bakries group•3.8K visualizações
Haccp case studyHaccp case study
Haccp case study
modern bakries group•1.4K visualizações
Implementation of Hazard Analysis Critical Control Points (HACCP) Implementation of Hazard Analysis Critical Control Points (HACCP)
Implementation of Hazard Analysis Critical Control Points (HACCP)
modern bakries group•841 visualizações
Haccp system Haccp system
Haccp system
modern bakries group•843 visualizações
Introduction haccpIntroduction haccp
Introduction haccp
modern bakries group•4.9K visualizações

Último

yod dinner-min.pdfyod dinner-min.pdf
yod dinner-min.pdfyaredabera7
27 visualizações•18 slides
KETO DIETKETO DIET
KETO DIETyourfavourited
5 visualizações•2 slides
yod Lunch.pdfyod Lunch.pdf
yod Lunch.pdfyaredabera7
15 visualizações•22 slides
COFFEE UPDATED.COFFEE UPDATED.
COFFEE UPDATED.SUBHRANSHU SAHANI
49 visualizações•92 slides
work experience.pptxwork experience.pptx
work experience.pptxchloemeadows2000
8 visualizações•47 slides

Último(20)

health benefits of pistachioshealth benefits of pistachios
health benefits of pistachios
californiapistachios•14 visualizações
yod dinner-min.pdfyod dinner-min.pdf
yod dinner-min.pdf
yaredabera7•27 visualizações
KETO DIETKETO DIET
KETO DIET
yourfavourited•5 visualizações
yod Lunch.pdfyod Lunch.pdf
yod Lunch.pdf
yaredabera7•15 visualizações
COFFEE UPDATED.COFFEE UPDATED.
COFFEE UPDATED.
SUBHRANSHU SAHANI•49 visualizações
work experience.pptxwork experience.pptx
work experience.pptx
chloemeadows2000•8 visualizações
History of the Coffee Maker.pdfHistory of the Coffee Maker.pdf
History of the Coffee Maker.pdf
David G.•7 visualizações
yod pdf.pdfyod pdf.pdf
yod pdf.pdf
yaredabera7•20 visualizações
yod Diner.pdfyod Diner.pdf
yod Diner.pdf
yaredabera7•9 visualizações
yod new.pdfyod new.pdf
yod new.pdf
yaredabera7•13 visualizações
FOOD TRUCK CRAVIN.pptxFOOD TRUCK CRAVIN.pptx
FOOD TRUCK CRAVIN.pptx
keerthidigits•6 visualizações
yod Lunchh_compressed.pdfyod Lunchh_compressed.pdf
yod Lunchh_compressed.pdf
yaredabera7•15 visualizações
yod dinnn_compressed.pdfyod dinnn_compressed.pdf
yod dinnn_compressed.pdf
yaredabera7•15 visualizações
chakhleindore (1).pdfchakhleindore (1).pdf
chakhleindore (1).pdf
prithviraj711716•7 visualizações
SAKTHI MASALA (1).pptxSAKTHI MASALA (1).pptx
SAKTHI MASALA (1).pptx
DineshkumarGovindara5•12 visualizações
NESTLE Powerpoint.pptxNESTLE Powerpoint.pptx
NESTLE Powerpoint.pptx
anu1251•7 visualizações
CAP& MAPCAP& MAP
CAP& MAP
kasidharth09•5 visualizações
yod lunch_compressed.pdfyod lunch_compressed.pdf
yod lunch_compressed.pdf
yaredabera7•25 visualizações
A ppt on Arsenic Contamination in the food chain: A threat to food security a...A ppt on Arsenic Contamination in the food chain: A threat to food security a...
A ppt on Arsenic Contamination in the food chain: A threat to food security a...
pallabig2312•8 visualizações
tropitradings.pdftropitradings.pdf
tropitradings.pdf
adthameswilume•7 visualizações

Bakery Haccp plan

  • 1. HACCP PLAN FOR BAKED FOODS Department of Food Science and Technology Faculty of Agricultural Technology Bogor Agricultural University 2009
  • 2. Langkah 1 : Establish the HACCP team Name Expertise/Position Position in the team Dewi Food Tech. & HACCP specialist/ Coordinator QA Mgr. Rahman Engineering/Production Mgr. Member Putri Microbiology/QC Mgr. Member Surya Chemistry/Warehouse Mgr. Member
  • 3. Step 2 : Product Description • Name of product • Composition • Product characteristics • Methods of processing • Methods of preservation • Primary packaging • Conditions of storage • Method of distribution • Shelflife • Specific labelling • Instruction on the label : cream-filled bread : Susu skim, kultur BAL, glukosa : Susu kental, asam, pH 4.3 : pasteurisasi, fermentasi : fermentasi : cup Polyethylene : Suhu 4oC : Dalam truk beropendingin : 3 minggu : - : -
  • 4. Step 3 : Identification of the Product’s Intended Use • Name of product • Intended use • Target consumer : Cream-filled bread : Directly consumed : General public
  • 5. Step 4 : Establish Process Flow Diagram Process flow diagram for the bread : Weigh all ingredients (sugar, salt, skim milk, shortening, egg, wheat flour, yeast, cold water) Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-300C) Divide the dough and weigh 900 gram each Fermentation 2 (27-300 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
  • 6. Step 4 : Establish Process Flow Diagram Process flow diagram for the cream : Weigh all the ingredients (jelly mallow, butter, shortening) Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
  • 7. Step 5 : On-site Confirmation of Flow Diagram : Bread Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving (egg, water) Dry storage at room temperature (25-300 C) Storage at 5-150 C Weigh all ingredients Mixing (sugar, salt and skim milk) Add shortening and egg Blending (into creamed mixture) Add wheat flour, yeast, and cold water Blending (into non-sticky dough) Round the dough Fermentation 1 (15 minutes at 27-300C) Divide the dough and weigh 900 gram each Fermentation 2 (27-300 C) Spread dough surface with beaten-egg Baking (10-15 minutes at 1800C) Cooling at room temperature (25-300C) Filling with cream Packaging (PET bag/pouch) Storage and distribution at room temperature (25-300C) for a maximum 3-5 days
  • 8. Step 5 : On-site Confirmation of Flow Diagram : Cream Receiving (jelly mallow, butter, shortening) Dry storage at room temperature (25-300 C) Weigh all the ingredients Mix all the ingredients Beating (medium speed, 20 minutes) Storage (refrigerated)
  • 9. Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving of egg Storage of egg Weighing of all ingredients Mixing of sugar, salt, skim milk B B B P B P P Contaminated yeast (by spoilage or pathogenic m.o.) Insects Presence of pathogenic bacteria Eggshell (cracked/broken eggs) Growth of pathogenic bacteria Insect bone pieces Insect bone pieces, personal items
  • 10. Process Step Potential Hazard(s) B/C/P Description of Hazard Adding egg and shortening Adding wheat flour, yeast and cold water Blending Rounding the dough Fermentation 1 Dividing the dough Fermentation 2 B P B P B P B B B B Contamination of pathogenic bacteria Eggshell Contamination of spoilage or pathogenic bacteria (from yeast and water) Insect bone pieces Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 11. Process Step Potential Hazard(s) B/C/P Description of Hazard Spreading with egg Baking Cooling Filling with cream Packaging Storage B B B B B B Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o. Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 12. Process Step Potential Hazard(s) B/C/P Description of Hazard Receiving jelly mallow, butter, shortening Storage Weighing all ingredients Mixing Beating Storage - B C - P P B - Contamination of spoilage m.o. Decomposition of chemical compound - Personal item Personal item Growth of spoilage m.o. Principle 1 : Hazard Analysis HACCP Plan Worksheet 1A2: Identification of Hazard at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 13. Principle 1 : Hazard Analysis HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Preventive or Control Measures Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) B Contaminated yeast (by spoilage or pathogenic m.o.) Quality assurance (certificate of analysis) from supplier Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) P Insects Proper storage conditions (dry, clean), sealed packaging of the ingredients. Receiving of egg, water B Presence of pathogenic bacteria Certificate of analysis from egg supplier, acceptable water source P Eggshell (cracked/broken eggs) Inspection of incoming eggs Storage of egg B Growth of pathogenic bacteria Refrigerated storage (5-15 0 C), Label expired date. Weighing of all ingredients P Insect bone pieces, personal items Inspection of the ingredients, SOP for production area (no personal items are wore) Mixing of sugar, salt, skim milk P Insect bone pieces, personal items Inspection of the ingredients, SOP for production area (no personal items are wore) Adding egg and shortening P Eggshell Inspection of the ingredients (cracked eggs) Adding wheat flour, yeast and cold water P Insect bone pieces Filtering of wheat flour Blending B Contamination of spoilage m.o. from the air SSOP P Personal item SOP for production area (no personal items are wore) Rounding the dough B Contamination of spoilage & pathogenic m.o. from the air & worker SSOP
  • 14. Process Step Potential Hazard(s) Description of Hazard Preventive or Control MeasuresB/C/P Fermentation 1 B Contamination of spoilage m.o. from the air SSOP Dividing the dough B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Fermentation 2 B Contamination of spoilage m.o. from the air SSOP Spreading with egg B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Baking B Survival of spoilage m.o. Correct time and temperature Cooling B Contamination of spoilage m.o. from the air SSOP Filling with cream B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Packaging B Contamination of spoilage and pathogenic m.o. from the air and worker SSOP Storage B Contamination of spoilage molds Proper storage condition (dry, clean), expired date must be stated on the label Receiving jelly mallow, butter, shortening - Storage B Contamination of spoilage m.o. Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients Weighing all ingredients Mixing P Personal item SSOP Beating P Personal item SSOP Storage B Growth of spoilage m.o. Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight) Principle 1 : Hazard Analysis HACCP Plan Worksheet 1B2: Identification of Preventive or Control Measures at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 15. Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps Name of Product : Cream-filled Bread Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Severity Significant hazard (Y/N) Preventive or Control Measures Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast) Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg, water Storage of egg Weighing of all ingredients B P B P B P Contaminated yeast (by spoilage/ pathogenic m.o.) Insects Presence of pathogenic bacteria Eggshell (Cracked / broken eggs) Growth of pathogenic bacteria Insect bone pieces, personal items l h m h l l M M M M L M N Y N Y N N Quality assurance (certificate of analysis) from supplier Proper storage conditions (dry, clean), sealed packaging of the ingredients. Certificate of analysis from egg supplier, acceptable water source Inspection of incoming eggs Refrigerated storage (5-150 C), Label expired date. Inspection of the ingredients, SOP for production area (no personal items are wore)
  • 16. Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Mixing of sugar, salt, skim milk Adding egg and shortening Adding wheat flour, yeast and cold water Blending Rounding the dough Fermentation 1 P P P B P B B Insect bone pieces, personal items Eggshell Insect bone pieces Contamination of spoilage m.o. from the air Personal item Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage m.o. from the air l m m m m l l M M M L M L L N N N N N N N Inspection of the ingredients, SOP for production area (no personal items are wore) Inspection of the ingredients (cracked eggs) Filtering of wheat flour SSOP SOP for production area (no personal items are wore) SSOP SSOP Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 17. Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging of bread Storage and distribution B B B B B B B B Contamination of spoilage and pathogenic m.o. from the air, weigh- scale, and worker Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Survival of spoilage m.o. Contamination of spoilage m.o. from the air Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage and pathogenic m.o. from the air and worker Contamination of spoilage molds m l m l m m m m L L H H M H H M N N Y N N Y Y N SSOP SSOP SSOP Correct time and temperature SSOP SSOP SSOP Proper storage condition (dry, clean), expired date must be stated on the label Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 18. Process Step Potential Hazard(s) B/C/P Description of Hazard Reasonably likely to occur Seve- rity Significant hazard (Y/N) Preventive or Control Measures Receiving jelly mallow, butter, shortening Storage of jelly mallow, butter, shortening Weighing all ingredients Mixing Beating Storage of cream - B C - P P B - Contamination of spoilage m.o. Decomposition of chemical compound - Personal item Personal item Growth of spoilage m.o. - m m - l l m - H H - M M H - Y Y - N N Y - Proper storage condition (refrigerated, no direct exposure to sunlight), discard any expired ingredients - SSOP SSOP Cream should be packaged with label stating the expired date, proper storage condition (refrigerated, no direct exposure to sunlight) Principle 1 : Hazard Analysis HACCP Plan Worksheet 1C2: Determination of Hazards Significance at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 19. Principle 2 : Establishment of Critical Control Point CCP HACCP Plan Worksheet 2A : Establishment of CCP in Ingredients Name of Product : Cream-filled Bread Ingredient Potential Hazard (s) P1 P2 P3 CCP? Sugar B P Y Y Y Y N N N N Wheat flour B P Y Y Y Y N N N N Yeast B Y Y N N Egg B C P Y Y Y Y N N N - - N Y Y Water B Y Y N N
  • 20. Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread Process Step Potential Hazard(s) P1 P2 P3 P4 P5 CCP? Receiving (sugar, salt, skim milk, shortening, wheat flour, yeast Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Storage of egg Weighing of all ingredients Mixing of sugar, salt, skim milk Adding egg and shortening Adding wheat flour, yeast and Cold water Blending B P B P B P P P P B P N Y N Y N N N N N N N - Y - Y - - - - - - - - N - N - - - - - - - - Y - Y - - - - - - - - N - N - - - - - - - N CCP N CCP N N N N N N N
  • 21. Process Step Potential Hazard(s) P1 P2 P3 P4 P5 CCP? Rounding the dough Fermentation 1 Dividing the dough Fermentation 2 Spreading with egg Baking Cooling Filling with cream Packaging Storage and distribution of bread B B B B B B B B B B N N N N Y N N Y Y N - - - - Y - - Y Y - - - - - N - - N N - - - - - Y - - Y Y - - - - - Y - - N N - N N N N N N N CCP CCP N Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 22. Process Step Potential Hazard(s) P1 P2 P3 P4 P5 CCP? Storage of jelly mallow, butter, shortening Mixing Beating Storage of cream B C P P B Y Y N N Y Y Y - - Y N N - - N Y Y - - Y N N - - N CCP CCP - - CCP Principle 2 : Establishment of Critical Control Point (CCP) HACCP Plan Worksheet 2B : Establishment of CCP at Process Steps (cont.) Name of Product : Cream-filled Bread
  • 23. Principle 3: Establishment of Critical Limits HACCP Plan Worksheet 3 : Establishment of Critical Limits Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20-250 C Holding Time <10 min, T=20-250 C Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date
  • 24. Principle 4: Establishment of Monitoring Procedures HACCP Plan Worksheet 4 : Establishment of Monitoring Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures What How Where Who Freq. Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90=92 Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20-250 C Holding Time <10 min, T=20-250 C Antibiotic residue on CoA Cracked/broken eggs Rh Storage time SSOP application Cracked/broken eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temp. Receiving site Receiving site Storage room / warehouse Receiving site Production area Production area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Area personnel Area personnel Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temp., check label Measure temp. check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day
  • 25. Principle 5: Establishment of Corrective Actions HACCP Plan Worksheet 5 : Establishment of Corrective Actions (1) Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions What How Where Who Frequency Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = Time < 1 month SSOP = applied Cracked/broken egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure Rh,check storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperatur e Check/ measure time and temperatur e Receiving site Receiving site Storage room / warehouse Receiving site Production area Production area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Area personnel Area personnel Every receiving Every receiving Every day Every Receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr.
  • 26. Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions What How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature, check label Measure temperature, check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Principle 5: Establishment of Corrective Actions HACCP Plan Worksheet 5 : Establishment of Corrective Actions (1) Name of Product : Cream-filled Bread
  • 27. Principle 6: Establishment of Verification Procedures HACCP Plan Worksheet 6 : Establishment of Verification Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification ActivitiesWhat How Where Who Frequen cy Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/bro ken eggs Rh Storage time SSOP application Cracked/bro ken eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehou se mngr. Receiving personnel Productio n superviso r Productio n superviso r Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh- meter Inspection of insects contamination every 1 month Customer complaint Microb.analysisof products Microb. Analysis of products
  • 28. Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification ActivitiesWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature, check label Measure temperature, check label Warehouse Warehouse Warehouse mngr. Warehouse mngr. Every day Every day 1. Disposition of non- complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non- complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Principle 6: Establishment of Verification Procedures HACCP Plan Worksheet 6 : Establishment of Verification Procedures (cont.) Name of Product : Cream-filled Bread
  • 29. Principle 7: Establishment of Record-keeping Procedures HACCP Plan Worksheet 7 : Establishment of Record-keeping Procedures Name of Product : Cream-filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification Activities RecordsWhat How Where Who Frequenc y Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Production supervisor Production supervisor Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh-meter Inspection of insects contamination every 1 month Customer complaint Microb. analysis of products Microb. Analysis of products Receiving log Warehouse log, Rh operation document, Rh calibration documents, Insects inspection document Receiving log Production log, microb. analysis document Production log, microbiological analysis document
  • 30. Ingredient / Process Step CCP No. CL Monitoring Procedures Corrective Actions Verificatio n Activities RecordsWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature , check label Measure temperature , check label Wareho use Wareho use Warehous e mngr. Warehous e mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Warehouse log, microb. Analysis document Warehouse log, microb. Analysis document Principle 7: Establishment of Record-keeping Procedures HACCP Plan Worksheet 7 : Establishment of Record-keeping Procedures (cont.) Name of Product : Cream-filled Bread
  • 31. HACCP Plan Cream-Filled Bread Ingredient/ Process Step CCP No. CL Monitoring Procedures Corrective Actions Verification Activities RecordsWhat How Where Who Frequenc y Egg Storage (sugar, salt, skim milk, shortening, wheat flour, yeast) Receiving egg Filling with cream Packaging of bread 1 (C) 2 (P) 3 (P) 4 (P) 5 (B) 6 (B) Antibiotic residue = 0 Cracked / broken egg = 0 Rh = 90-92% Time < 1 month SSOP = applied Cracked/broke n egg = 0 Holding Time <10 min, T=20- 250 C Holding Time <10 min, T=20- 250 C Antibiotic residue on CoA Cracked/broke n eggs Rh Storage time SSOP application Cracked/broke n eggs Time and temperature Time and temperature Check the CoA Inspection of incoming eggs Measure the Rh Check the storage time Check the application of SSOP Inspection of incoming eggs Check/ measure time and temperature Check/ measure time and temperature Receiving site Receiving site Storage room / warehous e Receiving site Productio n area Productio n area Receiving personnel Receiving personnel Warehouse mngr. Receiving personnel Production supervisor Production supervisor Every receiving Every receiving Every day Every receiving Time : every 10 minutes T : Every 6 hours Time : Every 10 minutes T : Every 6 hours 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of contaminated ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to warehouse mngr. 1. Rejection of non-complying ingredient 2. Write a report to warehouse mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record 4. Write a report to QA mngr. Analysis of antibiotic residue every 1 year Calibration of Rh-meter Inspection of insects contamination every 1 month Customer complaint Microb. analysis of products Microb. Analysis of products Receiving log Warehouse log, Rh operation document, Rh calibration documents, Insects inspection document Receiving log Production log, microb. analysis document Production log, microbiological analysis document
  • 32. Ingredient / Process Step CCP No. CL Monitoring Procedures Corrective Actions Verificatio n Activities RecordsWhat How Where Who Frequency Storage of jelly mallow, butter, shortening Storage of cream 7 (B) 8 (C) 9 (B) T = 5-150 C, label expired date T = 5-150 C, label expired date Temperature, label of the ingredients Temperature, label of cream Measure temperature , check label Measure temperature , check label Wareho use Wareho use Warehous e mngr. Warehous e mngr. Every day Every day 1. Disposition of non-complying ingredients 2. Correct the cause to prevent recurrences 3. Maintain record 1. Disposition of non-complying products 2. Correct the cause to prevent recurrences 3. Maintain record Microb. Analysis of ingredients Microb. Analysis of cream Warehouse log, microb. Analysis document Warehouse log, microb. Analysis document HACCP Plan (cont.) Cream-Filled Bread