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HACCP Plan Procedure
Document Code:
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STP/ISP-0
INTEGRATED SYSTEM PROCEDURE
HACCP PLAN
(CLAUSE 7.. of ISO 22000:2005)
Name
Designation
Prepared by:
Mr. Mujtaba
ISO Coordinator
Reviewed by:
Mr. Waqas
MR
Approved by:
Mr. Mujahid Ali
MD
Page 1 of 25
Signature
Date
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HACCP Plan Procedure
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DOCUMENT HISTORY
REV.
#
DATE
PAGE
#
SECTION
DCR#
NATURE OF AMENDMENT
* All changes made in the document are notified in the Document History. For details of
amendments, please refer to relevant DCR (Doc. Change Request).
Page 2 of 25
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1. Purpose
The purpose of this procedure is to identify possible food safety hazards and
controls in place to make sure the food safety hazards are eliminated or controlled
to ensure acceptable levels.
2. Scope
This procedure applies to all activities at identified CCPs
3. Responsibilities
Management Representative and Food Safety Team Leader is responsible
for
1) The implementation of this procedure
2) Monitoring of the HACCP personnel deputed at CCPs
3) Verification and signing of HACCP records.
4. Procedure
4.1
Establishing a HACCP Team
Sprintech Packaging has established a HACCP team made up of people
from a wide range of disciplines as given in Appendix I. The team
includes:
1. A team leader to convene the group and to direct the work of the
team ensuring that the HACCP concept is properly applied.
2. Members with major role in production of the food packaging
material, each with an understanding of particular food safety
hazards and associated risks.
4.2
Describing a product
A full description of the product with relevant safety information is
prepared as
given in Appendix II. Also information regarding how the product is to
be
packaged, stored and transported is also considered together with
facts
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regarding it's shelf life and recommended storage temperatures.
Labelling
information is also included.
This information will assist the HACCP team to identify 'real' hazards
associated
with the process.
4.3 Describing a products intended use
The HACCP team also defines the normal or expected use of the product
by the
customer and the consumer for which the product is intended. This
information is
recorded on the same form of product description, see Appendix II.
4.4 Construction of Flow Diagram ( Description of Manufacturing
process)
All the steps involved in the process from receiving the raw materials to
placing
the end product through preparation, processing , packaging , storage
and
distribution is presented in a detailed flow diagram.
After the flow diagram has been made, a multidisciplinary team will
confirm it
on-site during operating hours. Any observed deviation will result in an
amendment of the original flow diagram to make it accurate.
4.5
Identification and Analysis of Hazard(s)
The HACCP team next conducts a hazard analysis to identify for the
HACCP plan
which hazards are of such a nature that their elimination or reduction to
acceptable
levels is essential to the production of a safe food packaging.
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Food safety hazards for HACCP plan have been classified into three types
of hazards:
1. Biological
2. Chemical
3. Physical
In conducting the hazard analysis, the following should be considered:
a. the likely occurrence of hazards and severity of their adverse health
effects
b. the qualitative and/or quantitative evaluation of the presence of
hazards
c. survival or multiplication of pathogenic micro-organisms and
unacceptable generation of chemicals in intermediate products, final
products, production line or line environment
d. production or persistence in foods of toxins or other undesirable
products of microbial metabolism, chemicals or physical agents or
allergens
e. contamination (or recontamination) of a biological (micro-organisms,
parasites), chemical or physical nature of raw materials, intermediate
products
or final products.
Once a food safety hazard has been identified, then appropriate control
measures are taken into consideration. These are any action or activity that
can be used to control the identified hazard, such that it is prevented,
eliminated, or reduced to an acceptable level.
4.6
Identification of Critical Control Points (CCPs)
The identification of a critical point for the control of a hazard is done
by the HACCP
team , according to their judgment , experience and knowledge of the
process.
Each process step identified in the flow diagram is considered in sequence.
The team will determine whether the hazard can occur at this step, and if so
whether control measures exist. If the hazard can be controlled adequately,
Page 5 of 25
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and is not best controlled at another step, and is essential for food safety,
then this step is a CCP for the specified hazard.
The identification of critical control points has two consequences for the
HACCP team
which should then:
1. Ensure that appropriate control measures are effectively designed and
implemented.
2. Establish and implement a monitoring system at each critical point.
Production should cease until control measures are available and a CCP is
introduced.
4.7
Critical Limits at Critical Control Points
Each control measure associated with a critical control point will give rise to
the
specification of critical limits. Critical limits correspond to the extreme
values acceptable with regard to product safety. They separate
acceptability from unacceptability. They are set for observable or
measurable parameters which can demonstrate that the critical point is
under control. It should be based on substantiated evidence that the chosen
values will result in process control.
4.8
Monitoring Procedures at Critical Control Points
Monitoring is the mechanism for confirming that critical limits at each CCP
are being
met. A frequency of observations or measurements which provides reliable
information is established.
The procedure describes the methods, the frequency of observations or
measurements
and the recording procedure and identify each critical point:
a. who is to perform monitoring and checking,
b. when monitoring and checking is performed,
c. how monitoring and checking is performed.
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Records associated with monitoring CCPs must be signed by the Food
Safety Team Leader doing the monitoring and the records are verified by
Management Representative of the company.
4.9
Corrective Actions
For each critical control point corrective actions is planned in advance by
the
HACCP team, so that they can be taken without hesitation when monitoring
indicates
a deviation from the critical limit.
Such corrective action will include:
Identification of the person(s) responsible for the implementation of the
corrective action,
Description of means and action required to correct the observed
deviation,
Action to be taken with regard to products that have been manufactured
during the
period when the process was out of control,
Written record of measures taken indicating all relevant information (for
example:
date, time, type of action, actor and subsequent verification check).
Monitoring will indicate that preventive measures (checking equipment,
checking the
person handling the food packaging material, checking the efficacy of
previous
corrective measures, etc.) should have to be taken if corrective actions for
the same
procedure have to be taken repeatedly.
4.10 Verification Procedures
The HACCP team should specify the methods and procedures to be used for
Page 7 of 25
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determining if the HACCP plan is working correctly. Methods for verification
may
include in particular random sampling and analysis, reinforced analysis or
tests
at selected critical points, intensified analysis of intermediate or final
products,
surveys on actual condition during storage.
The frequency of verification should be sufficient to confirm that HACCP
plan is
working effectively. The frequency of verification shall depend on the
characteristics
of the business , the monitoring frequency, the accuracies of the
employees, the
number of deviations detected over time and the hazards involved.
Verification procedures include:
Audits of HACCP and its records,
Inspection of operations,
Confirmation that CCPs are kept under control,
Validation of critical limits,
Review of deviations and product dispositions; corrective actions taken
with regard to the product.
The frequency of verification will greatly influence the amount of recheck or
recall
required in case a deviation exceeding the critical limits has been detected.
Verification
shall comprise all of the following elements, but not necessarily all at the
same time:
Check on the correctness of the records and analysis of deviations
Check on the person monitoring processing, storage and/or transport
activities
Physical check on the process being monitored
Page 8 of 25
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Calibration of instruments used for monitoring.
Verification is carried out by Management Representative someone other
than the person who is responsible for performing the monitoring and
corrective actions.
Where possible, validation activities should include actions to confirm the
efficacy of all elements of the HACCP plan. In case of change, it is necessary
to
review the system, to ensure that it is or will be still valid.
Examples of change include:
change in raw material or in product, processing conditions (factory layout
and
environment, process equipment, cleaning and disinfection program),
change in packaging, storage or distribution conditions,
change in consumer use,
receipt of any information on a new hazard associated with the product.
Where necessary, such a review must result in the amendment of the
procedures laid
down. The changes should be fully incorporated into the documentation and
recordkeeping system in order to ensure that accurate up-to-date
information is available.
4.11 Documentation and Record Keeping
HACCP procedures should be documented. Documentation and record
keeping should be appropriate to the nature and size of the operation and
sufficient to assist the business to verify that the HACCP controls are in
place and being maintained. Documents and records should be kept for a
sufficient time to allow the competent authority to audit the HACCP system.
Documents should be signed by Management Representative of the
company.
Documentation examples are:
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Hazard analysis;
CCP determination;
Critical limit determination;
Modifications to the HACCP system.
Record examples are:
CCP monitoring activities;
Deviations and associated corrective actions;
Verification activities.
4.12 Training
The Management representative and food safety team leader shall make
sure that all
personnel are aware of the hazards identified (if any), the critical points in
the
production, storage, transport and/or distribution process and the corrective
measures, the preventive measures and documentation procedures
applicable in
the operations of the company.
4.1 Related Documents
HACCP Master Plan
HACCP Plan Validation/Reassessment Checklist
Corrective & Preventive Action Form
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Figure 1. CCP Decision Tree- Flow Diagram
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Figure 2. Manufacturing Process Flow Diagram
Appendix I: Establishing a HACCP Team
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HACCP Team
Facility Name : Sprintech Packaging
Date : September 23 , 2014
Team Member
Position
HACCP Team
Role
Syed Mujtaba Ali
Production
Member/Advisor
Waqas Hassan
Management
Representative
Advisor
Usman Shaukat
A.M Production
Member
Yasir Bilal
Incharge QA/
Product Safety
Team Leader
Imran Ameer
Printing
Supervisor
Member
Tariq Hussain
Lamination
Supervisor
Member
Irfan Sheikh
Lamination
Supervisor
Member
Khalid Imtiaz
Slitting
Supervisor
Member
Muhammad Hussain
Bag Making
Supervisor
Member
Waqas Junaid
Sleeve Making
Supervisor
Member
Naveed Khalid
Warehouse
Incharge
Member
Nadeem Ahmad
Dispatch
Assistant
Member
Kashif Mehmood
Maintenance
Engineer
Member
Syed Qasim Raza
Purchase
Executive
Member
Page 14 of 25
Signatur
e
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STP/ISP-0
HACCP Objective
Facility Name : Sprintech
Date : September 23 ,
Packaging
2014
The purpose of the facility HACCP Team is to ensure safe
products for our customers and their consumers. The HACCP
Team will evaluate raw materials and processes to determine
Critical Control Points. Critical Control Points will be monitored
as will other points and processes. The team will provide
documented training for the facility. The facility HACCP Plan will
be re - assessed at least annually. Facility management will
provide adequate resources for the implementation and
maintenance of the HACCP Program.
Sign-off and Approval
Position
Name
Production
Syed Mujtaba Ali
Management
Representative
Waqas Hassan
A.M Production
Usman Shaukat
Incharge QA/ Product
Safety
Yasir Bilal
Printing Supervisor
Imran Ameer
Lamination Supervisor
Tariq Hussain
Lamination Supervisor
Irfan Sheikh
Slitting Supervisor
Khalid Imtiaz
Bag Making Supervisor
Muhammad
Hussain
Sleeve Making
Supervisor
Waqas Junaid
Warehouse Incharge
Naveed Khalid
Dispatch Assistant
Nadeem Ahmad
Maintenance Engineer
Kashif Mehmood
Purchase Executive
Syed Qasim Raza
Page 15 of 25
Signature
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Doc. Title:
Document Code:
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STP/ISP-0
Appendix II: Product Description Format
Product Description & Intended Use
Section:
Date:
Product Category Name
Product description:
Biological, Chemical and Physical
Characteristics
Intended Shelf Life & Storage Conditions
Packaging Requirements
Labeling Requirements
Method of Distribution
Intended Use
Page 16 of 25
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Appendix III: HACCP Validation/Reassessment Checklist
HACCP Validation/Reassessment Checklist
Plant Name :
Product
Date Conducted :
Conducted by
Validation Type
Initial Validation ( within 12 months of implementation)
Validation (Reassessment) due to changes in the raw materials or source of raw materials , product formulation ,
processing method or system , including computer and their softwares, packaging , finished product distribution
systems or the intended use or the intended consumers of the finished product or type of consumer complaints.
Annual Validation (Reassessment ) of the HACCP Plan including Hazard Analysis
Topic
YES
NO
If YES
Describe
Food Safety
Implication?
1.Evaluate product and process
Product description
changed, e.g.; intended
use, consumer?
Formula changed?
Ingredients / Packaging
changed?
Any new product
consumption or storage
methods?
Any new suppliers?
Process flow changed?
Equipment / software
changed?
Finished product
distribution changed?
Other , e.g.; production
volume increased
2. Evaluate product / process history
Repeat CCP deviations?
Any recent industry recalls
of similar product since
last annual
Page 17 of 25
Are modifications to the HACCP
system required?
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New or emerging hazards
STP/ISP-0
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Regulatory Agency
recommendation e.g.,
guidance
Any confirmed food
safety consumer
complaints
3. Evaluate adequacy of CCPs, critical limits, monitoring, corrective action, CCP verification, and record keeping
procedures. Review current CCP Documentation
Do the CCPs control the
hazards?
Are the CPP critical
limits adequate?
Do monitoring methods
and frequency
demonstrate control?
Do corrective actions
properly address
affected product?
Does validation include
review of consumer
complaints?
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Appendix IV: HACCP Plan Reassessment Change Form
HACCP Plan Reassessment Change Form
Person(s)
Responsibl
e:
Facility Name
:
HACCP Plan Name/Number and
Date :
During the reassessment of this plan, the person(s) responsible listed above has/have determined that
Changes, Additions, or Deletions were needed. Those changes are documented below. Also attached is
information used to support modification(s) of this plan.
Check One
CHANGE
ADDITION
What specifically were Changed / Added / Deleted?
Why was it Changed / Added / Deleted?
What is the basis for the Change / Addition / Deletion?
Page 19 of 25
DELETION
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Raw Material Hazard Analysis
Facility Name : Sprintech Packaging
1
List each raw
material/
ingredient in the
process
Does this material
/ ingredient
INTRODUCE a
potential food
safety hazard?
What is it?
Is this hazard
CONTROLLED by a
Pre-requisite
Program or
process step?
C =Chemical
P = Physical
B = Biological
Films (PET , PVC ,
BOPP, HDPE, HTL
,OPP, CPP, LDPE ,
NYLON PE )
Adhesives
(hot melt, resins ,
lamination)
Ink and chemicals
Paper , Bleach Board
(various types and
grades)
Packing Materials
Date : September 23 , 2014
No
Yes Foreign
Material
No
No
Yes Foreign
Material
P
B
Yes - Infestation
Yes Plant Chemical
No
No
No
Yes Foreign
Material
Yes - Moulds
No
P
B
No
Yes Foreign
Materials &
If YES, indentify the
program or process. If a
pre-requisite program or
process is identified, do
not complete Columns 46 and go to next process
step. If NO, go to column
4.
Is this hazard
ELIMINATED by a
subsequent
process step?
If YES, this step is NOT a
CCP. Indentify the
subsequent process step
in Column 5 and proceed
to the next process step.
If the hazard is
eliminated at this step,
enter NO and go to
column 6 and assign CCP
#.
Yes Receiving
Inspections
Yes Receiving
Inspections
Yes Receiving
Inspections
Yes Chemical Control
Plan
Yes Receiving
Inspections
Yes Receiving
Inspections
Yes Receiving
Inspections
Page 20 of 25
5
Identify the last
process step that
will eliminate the
potential hazard.
6
Assign a CCP #
when the answer
in Column #4 is
NO.
(otherwise leave blank)
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Infestation
Process Hazard Analysis
Facility Name : Sprintech Packaging
1
List each raw
material/
ingredient in the
process
2
Do this material /
ingredient
INTRODUCE a
potential food
safety hazard?
What is it?
C =Chemical
P = Physical
B = Biological
Receiving Inspections
Warehousing
Yes - Infestation
No
Yes Foreign
Material
Is this hazard
CONTROLLED by a
Pre-requisite
Program or
process step?
If YES, indentify the
program or process. If a
pre-requisite program or
process is identified, do
not complete Columns 46 and go to next process
step. If NO, go to column
4.
Identify the last
process step that
will eliminate the
potential hazard.
If YES, this step is NOT a
CCP. Indentify the
subsequent process step
in Column 5 and proceed
to the next process step.
If the hazard is
eliminated at this step,
enter NO and go to
column 6 and assign CCP
#.
6
Assign a CCP #
when the answer
in Column #4 is
NO.
(otherwise leave blank)
Yes Receiving
Inspections
Yes Receiving
Inspections
Yes - Infestation
P
B
No
Yes
No
No
Yes Contamination /
infestation
Yes Personal Hygiene &
Housekeeping programs
Is this hazard
ELIMINATED by a
subsequent
process step?
Yes Receiving
Inspections
Yes Receiving
Inspections
Yes Incorrect
Design
Yes Line Clearance
No
Lamination
Solventless
No
Yes Foreign
Material
Printing
Date : September 23 , 2014
Yes Design checklist
No
No
No
Line Clearance
CCP-1
Page 21 of 25
Line Clearance
CCP-2
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Lamination Solvent
Base
Slitting
Bag Making
Yes
No
Yes Contamination /
infestation
No
No
No
No
No
Yes Contamination /
infestation
No
B
C
Sleeve & Tube Making
P
B
C
Packaging
P
B
C
Warehousing
P
B
C
Dispatch/Shipping
P
B
No
Yes Contamination /
infestation
Yes Incorrect
palletizing (allergen)
No
Yes Contamination /
infestation
No
No
Yes Contamination /
Infestation
No
No
Yes Contamination /
infestation
STP/ISP-0
No
No
Rev#: 00
Line Clearance
CCP-3
Yes Personal Hygiene &
Housekeeping programs
No
Visual Inspection
CCP-4
Yes Personal Hygiene &
Housekeeping programs
Yes Personal Hygiene &
Housekeeping programs
No
No
Yes Personal Hygiene &
Housekeeping programs
Yes Personal Hygiene &
Housekeeping programs
Yes Personal Hygiene &
Housekeeping programs
Page 22 of 25
Visual Inspection and
pallet control
CCP-5
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HACCP Master Plan
Facility Name : Sprintech Packaging
Date : September 23 , 2014
HACCP Plan for Multi-layer Flexible Packaging Materials
CPP
Number
CCP-1
Line
Clearance
CCP-2
Line
Clearance
CCP-3
Line
Clearance
CCP-4
Visual
Inspection
Significant
Hazard
Critical
Limit
Printed materials
from previous jobs
have not been fully
cleared.
No materials
from other
jobs allowed
in area.
Laminated materials
from previous jobs
have not been fully
cleared.
No materials
from other
jobs allowed
in area.
Laminated materials
from previous jobs
have not been fully
cleared.
No materials
from other
jobs allowed
in area.
Incorrect unitizing or
palletizing due to
inadvertent mixing of
bags results in
allergen risk due to
mixed product types
No mixing of
bags.
Monitoring
What
How
Printing
procedure
Operator
removes all
materials from
previous order
before new job
starts up.
Lamination
procedure
Operator
removes all
materials from
previous order
before new job
starts up.
Lamination
procedure
Operator
removes all
materials from
previous order
before new job
starts up.
Visual
Inspection
Frequency
Each
work order
Each
work order
Each
work order
Work
instructions for
operators /
helpers
Page 23 of 25
Each
carton
Who
Corrective
Action
Verificatio
n
Record(s)
Verified by
operator or
other coworker
Production
Records
Operator
Operator
removes
materials per
critical limits
and reinspects line.
Operator
Operator
removes
materials per
critical limits
and reinspects line.
Verified by
operator or
other coworker
Production
Records
Operator
Operator
removes
materials per
critical limits
and reinspects line.
Verified by
operator or
other coworker
Production
Records
Operator
removes
materials per
critical limits.
Verified by
operator or
other coworker
Production
Records
Operator
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Visual
Inspection
& Pallet
Control
Incorrect unitizing or
palletizing due to
inadvertent mixing of
bags results in mixed
product types
No mixing of
bags.
Visual
Inspection
coupled with
pallet
segregation.
HACCP Plan Procedure
Rev#: 00
STP/ISP-0
Work
instructions for
operators/
helpers
Page 24 of 25
Every
pallet
Operator
Segregate
affected
pallets.
Verified by
operator or
other coworker
Production
Records
Organization:
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Doc. Title:
Document Code:
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STP/ISP-0
Page 25 of 25
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