HACCP Example - Courtesy of Fletchers Bakery, Sheffield

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (1-4) - STAYFRESH BREAD September 2004
Process Step
1.0

2.0

Flour intake

Water intake

Hazard

Control Measures

CCP

Critical Limits

Monitoring
Procedure

Corrective
Action

Responsible
Personnel

1.1

Foreign bodies in final

product

Approved supplier &

compliance with
specification sieve
line,4&6mm mesh

Sieve integrity
Sieve contact no
damage

Infestation in silos

Pest Control Contract &

hygiene schedule

Reject out of
specification
deliveries.
Follow sieve
procedure Engs.
Pest control to
advise

Q.A. Stores
Personnel.
Engineers

1.2

Certificate of
analysis with every
delivery.
Daily check of
integrity
Annual clean and
monthly inspections.

1.3

Survival of microorganisms

Purchase from approved,

audited supplier

Certificate of
analysis, random
challenge testing.

QA, production,
stores

Routine microbiological
checks, Water authority.
(water haccp referenced)

Compliance with
specification

Certificate of
analysis, random
challenge testing.

Sieve integrity
Compliance with
specification

Certificate of
analysis with every
delivery.
random challenge
testing.
Certificate of
analysis with every
delivery. Random
challenge testing.
Stock rotation.
Certificate of
conformity each
delivery.

Reject out of
specification
deliveries. Inform
QA and supplier.
Water board inform
of contamination,
stop use of suspect
water. Recall suspect
product
Reject out of
specification
deliveries. Inform
QA and supplier.
Reject out of
specification
deliveries. Inform
QA and supplier.

Q.A. Stores ,
production

Reject out of
specification
deliveries. Inform
QA and supplier.
Q.A. to advise on
required action

Q.A. Stores
Personnel

Repeat wash cycle.

QA Technologist

Reject out of spec.

deliveries. Inform
QA and supplier.
Reject out of spec.
deliveries. Inform
QA and supplier.

QA/Stores
Production

Do not use re weigh

adjust weight
accordingly

Production

2.1
Survival of microorganisms, chlorine
overdose, foreign matter

Activity in traps, other

evidence eg,
droppings, beetles
Compliance with
specification

3.0

Salt

3.1

Foreign bodies in final

product.
Survival of microorganisms

Approved supplier &

compliance with
specification sieve in line,
4mm mesh.

4.0

Vegetable Fat

4.1

Foreign bodies in final

product.
Survival of microorganisms, rancidity

Approved supplier &

compliance with
specification.

5.0

Yeast Intake

5.1

Microbiological,

Approved supplier
compliance with spec. Temp.
check on delivery.

Maintain temperature
below 4C Max 8
Limited time

Temperature check on
storage vessel, daily.

Temperature control

Temperature checks
recorded.

Wash programme pH7

( neutral)

Operator to complete
cleaning record
start/end time. +ve
release on cleaning
procedure
Certificate of
conformity each del.

5.2

6.0

Bread Improver

7.0

Potassium Sorbate

8.0

Sorbate solution

5.3

Taints from poor tank

cleaning

Tank cleaned weekly, by

member of QADept.

6.1

Foreign bodies in final

product. Survival of
micro-organisms
Foreign bodies in final
product.
Survival of microorganisms
Incorrect solution
strength.

Purchase from approved,

audited supplier.
Sieve specification met
Purchase from approved,
audited supplier

Monitored on plant

11

8.1

Compliance with
specification

Sieve integrity
Compliance with
specification
Compliance with
specification

Bread 1800g/10 litres

water

Certificate of
conformity each del.

Weights taken.
1/4ly verification for
legislation

Pest
controller/Hygiene

Water authority,
production, CRISIS
MGT team

Q.A. Stores ,
production

QA/Stores Personnel

- QA/Stores
Production

HACCP Example - Courtesy of Fletchers Bakery, Sheffield

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (2-4) STAYFRESH BREAD September 2004
Process Step

Hazard

Control Measures

CCP

Critical Limits

Foreign bodies in
final product.
Survival of microorganisms
Foreign bodies in
final product.
Survival of microorganisms
Micro growth on
machine
Infestation

Sieved at stage 17.

Purchased from approved,
audited supplier

Sieve integrity
Compliance with
specification

Purchased from approved,

audited supplier

Compliance with
specification

Cleaning and water

Good storage

No evidence of
growth
No evidence of
infestation

9.0

Bag Flour

9.1

10.0

Vinegar

10.1

11.0

Ice Making Machine

12.0

Ambient Storage

13.0

Bulk Storage

13.1

Infestation in silos

See Step 1.2

14.0

Chilled Storage

14.1

Ingredient
deterioration

Maintain temp <4 C

Temperature control
>8 C Action

15.0

Chilled Bulk Storage

15.1

See step 5.2

16.0

Packaging Store

16.1

Ingredient
deterioration
Foreign body hazards
( wood/ infestation)

17.0

Sieve dry ingredients

17.1

18.0

Weigh Station

18.1

19.0

Purchased packaging from

approved, audited supplier,
shroud it and store
appropriately.
Sieve checks, metal
detection step
Document codes and
follow recipe

See Step 1.2

Monitoring
Procedure
Certificate of
conformity each del.
Random challenge
tests for micro
Certificate of
conformity each del.
Random challenge
tests for micro
Routine testing on
water schedule
Regular
housekeeping
checks and control
of spillages
See Step 1.2

Stores/QA
Production

reclean

Plant and
Hygiene DeptStores

Clean and report if

evidence found

Check ingredient
temp. reject out of
spec. ingredients.

Stores Q.A.
Personnel

See step 5.2

Temperatures
checked daily and
on 24hour alarmed
system
See step 5.2

See step 5.2

See step 5.2

All food contact

items covered. No
findings of foreign
matter
Sieve mesh size &
integrity step
Correct codes and
recipe

Regular
housekeeping
checks and control
of packagingSieve checked
before & after use
QA Audit, Foreman
checks ( hourly)

Clean and report if

evidence found

Dough temps checked.

Calibrated probe

20.0

Divider

No perceived hazard

Dough weights checked

Calibrated scale

21.0

First mould rounder

Fibres on belts

Intermediate proof

No perceived hazard

No fibres near food

contact area.
-

Daily checks

22.0

Regular checks on
integrity
-

23.0

Final Mould

Fibres on belts

Baking Tin Storage

Dirt from incorrect

storage

- No fibres near
food contact area.
Free from dirt

Daily checks

24.0

Regular checks on
integrity
Proper storage- off floor,
upside down/covered

Reject out of spec.

deliveries. Inform
Qa and supplier

Hygiene / Pest
control Co

Mixer

Reject out of spec.

deliveries. Inform
Qa and supplier

Responsible
Personnel
Stores/QA
Production

See Step 1.2

Foreign bodies in
final product.
Wrong recipe
amounts, lack of
ingredient trace codes
No perceived hazard

12

Corrective Action

routine use

Replace sieve
Hold incorrect
product
-

Stores

Production
Engineering/QA
Prodn/QA

Prodn/QA
Prodn/QA

Remove fibres or
replace belt
-

- Production
Engineering
-

Remove fibres or
replace belt
clean tins/ ensure
blower is working

- Production
Engineering
Prodn/
engineering

HACCP Example - Courtesy of Fletchers Bakery, Sheffield

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (3-4) STAYFRESH BREAD September 2004
Process Step

Hazard

Control Measures

25.0

Dough into tins

Foreign bodies in final

product.

Check tin blower is on

and working

Prodn

26.0

Prover

Product debris from

structure

Tins air-jet blown to remove

any foreign bodies, online
vacuum system.
Regular cleaning of structure

Weekly clean

Hygiene

27.0

Addition of lids.

No perceived hazard

28.0

Lid storage

No perceived hazard

29.0

Baking

Under baking - survival

of pathogenic organisms.

30.0

Removal of lids.

No perceived hazard

Product temp check 2

hourly with cal. Temp
probe.
-

31.0

Remove bread from tins.

No perceived hazard

32.0

Potassium Sorbate
Sprayer
Cooler controlled
condition

Microbial spoilage

5g of 15.2% solution

11

Microbial spoilage

Correct temperature at
packing

33.0

Correct heating process

34.0

Metal detection

34.1

Metal in final product.

100% effective

35.0

Slicer

35.1

Metal in final product

Blade break detector on slicers

36.0

Bag Machine

37.0

Thurne tag BBE code

38.0

Metal Detection

38.1

39.0

Finished Prod. Wt.

Control

18.1

40.0

Basket

CCP

Critical Limits

Ex-oven temp > 94C

Min 4g
Max 6 g
Ex cooler temp
<34 C

Detection 3.5mm Fe,

4.5mm Non Fe.
6.35mm SS
Broken blade detectors
operational

Monitoring
Procedure

QA 3 x daily
+ hr production
Internal temp. taken 2
hourly. Every product
type. Process , cooler
on.
Inspect sensitivity 1
per hr. during
production
Detectors challenged
hourly.

No perceived hazard

Lack of traceability

Thurne tag checks for codingstart and end of run

12

Correct code

Daily and changeover

checks

Metal in final product

100% effective

Detection 3.00mm Fe /
4.00mm Nfe
6.35mm SS

Non compliance to
average weight
procedure

15 minute average weight

checks

13

Target 800g, T1 and

T2 procedure
inoperation

Bread Average
weight procedure

Dirty baskets

Operator Inspection

Inspect sensitivity 1
per hr. during
production

Corrective Action

Reject under baked

product.

Responsible
Personnel

Production
Q.A.

Hand spray Adjust

sprayer
Report fault to Engs.
Document quantity,
temp & date code.

Production
QA, Engrs.
Production
Engineers

Quarantine
unscreeded prd return
through detector
Stop using machine
Check blades entact,
if broken blade is
found isolate &
destroy bread back to
last good check. Call
engineer to rectify
fault.
-

Production
Q.A.

Recall product
incorrectly coded,
amend code
Quarantine
unscreeded prd return
through detector

Remedial action
procedure
Inform - Supplier

Production
Engineers
Q.A.

Prodn/ QA

Production
Q.A.

Prodn/QA

Logistics
Production Q.A.

HACCP Example - Courtesy of Fletchers Bakery, Sheffield

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (4-4)

STAYFRESH BREAD September 2004

Process Step

Hazard

41.0

Stack

No perceived hazard

42.0

Ambient storage

No perceived hazard

43.0

Load onto ambient

vehicle
Deliver customer
ambient

Dirty vehicles

Vehicle check prior to

loading
-

Free from foreign

matter, taints
-

Despatch trailer
check
-

Do not load/ clean

trailor
-

Despatch

Monitoring
Procedure

Corrective Action

Responsible
Personnel
Engineers/
Production.

44.0

No perceived hazard.

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (4-4)

Control Measures

CCP

Critical Limits

Monitoring
Procedure

Corrective Action

Responsible
Personnel

FROZEN BREAD September 2004

Process Step

Hazard

Control Measures

40.0

Freezer

Temperature out of spec,

product defrosts

Freezer checks, 24 hour

surveillance on freezer

41.0

BOX

No perceived hazard

42.0

Seal and code

43.0
44.0

CCP

Critical Limits

-8 Deg C

24 hour freezer alarm,

QA Hold product and

check for quality

Lack of traceability

Box code checks hourly

12

No perceived hazard

Temperature out of
spec

Do not load/ clean

trailor
-

Despatch

Frozen storage

Vehicle check prior to

loading
-

Hourly checks and

QA audit
Despatch trailer
check
-

Stop

Palletise

Correct BB and
julienne code
Free from foreign
matter, taints
-

Doc Title: Food Safety HACCP Stayfresh bread

Originated by:
Doc Ref: QA/haccp/bread/full haccp/stayfresh (and frozen)
bread

Authorised by:

Date :Sept 2004

Revision : 3
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