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SINCERE SALAD DRESSING COMPANY HACCP PROGRAM

COMPANY INFORMATION
Company Name: Company Address: Sincere Salad Dressing Company 123 Salad Shooter Way Groveland, Kansas

Contact Person Name, Title: Contact Phone Number: Contact Fax Number: Contact Email: Brief Company History:

Renee Kerr, Quality Manager 555-555-5555 x000 550-550-5500 rkerr@sinceresalad.com The Sincere Salad Dressing Company evolved from a country vegetable market founded in 1927 in Medora, KS. A signature salad dressing spice packet sold by Polk Farms grew in popularity steadily becoming what is now a modern food processor. The company principles for providing high quality products at a fair price are practiced to this very day.

Types of Products Produced/ Type of Manufacturing: Quality Policy:

Salad Dressing/ Food Products It is the quality policy of the Sincere Salad Company to provide goods and services that consistently meet or exceed our customer’s expectation. Our mission is to create distinctive value. We will succeed in business only by creating value for our customers, our suppliers, employees, shareholders, and neighbors. We will build stronger customer relations and create solutions: Explore, Discover, Create, Deliver!

Mission Statement:

Vision Statement:

At Sincere Salad Dressing, we believe our most valuable assets are our associates and our customers. Our goal is to create an innovative, entrepreneurial environment that empowers great ideas. We want our associates to have the creativity to see, the freedom to develop, and the freedom to act. We will act with integrity and responsiveness in all facets of our business.

Sincere Salad Dressing Organizational Chart
General Manager Plant Manager Operations Manager Hourly Employees (3) Shift Supervisors Plant Controller Human Resource Manager Purchasing Manager

Sales Manager

Quality Manager AIB Coordinator

Accounting Clerk

Executive Account Manager Executive Account Manager

(3) Customer Service Representatives

Quality Technician

Cost Accountant

Account Manager

Hourly Employees Purchasing Supervisor Lead Maintenance Tech

Account Manager

(3) Maintenance Technicians Planning & Scheduling

Manager
Shipping Coordinator (2) Shipping Clerks

R&D department Graphics Manager Graphic Arts Specialist

HACCP Team
Name Coordinator: Other Team Members: Renee Kerr Guermo Tank Jeffrey Caine Eric Hale Jack Curtain Tom Coltrane Corey Weathers Michael Bland Tim Scoffield Position Quality Manager Plant Manager Maintenance Supervisor HR Manager Shipping / Receiving Supervisor Operations Manager Quality Technician Purchasing Manager Line Operator

HACCP Training Coordinator(s) :

Renee Kerr / Guermo Tank- certified by AIB International (HACCP on Demand). – September 10, 2009.

which covers processing equipment. and grounds. . and chemical concentration checks. Ensure sanitation activities do not pose a risk to product. Program Description: Goal: Maintain a sanitary environment. or if there is a program failure. mixing. and verification activities. Training is provided by the QA dept and records are maintained in Human Resources. A Master Cleaning schedule has been created for all processing and storage areas. All areas. building structure.Program Title: Person Responsible: Where Located: Master Cleaning Schedule/ SSOPs Renee Kerr / Quality Manager Quality Department Guermo Tank/ Plant Manager Revision Approval Authority: Revision Timing: Reviews occur annually and if there are any significant changes in equipment. support areas. procedures. The CIP systems for cleaning the bulk storage tanks. The cleaning of product contact surfaces will be verified as effective by visual start-up inspections. cleaning chemicals or methods. Scope: Content: Training: Scope is outlined in plant work instructions and controlled inspection forms. including processing. and pasteurization of product will have documented cleaning frequencies. ATP testing. and utensils. necessary for the production of safe and legal products. product storage areas.

support areas. and grounds. infestation. SSD CHEMICAL CONTROL PROGRAM Program Title: . The contracted service will maintain a pesticide usage chart. record of pest activity. – Licensing and insurance are reviewed on annual basis. schematics. including processing.Program Title: Person Responsible: Where Located: SSD Pest Control Program Michael Bland / Purchasing Manager Purchasing Department Guermo Tank/ Plant Manager Revision Approval Authority: Revision Timing: Reviews occur annually and if there are any significant changes in control methods or if there is a program failure. and the corrective action taken to prevent reoccurrence. All areas. All pesticide operators servicing the plant will be certified pesticide operators with a valid license and insurance certificate. The entire plant grounds will be maintained to prevent pest harborage. Pest monitoring devices will be identified and checked by the plant PCO who has the overall responsibility for evaluating the effectiveness of the pest control program. MSDS file. and potential product contamination. Training records are maintained in HR. and Rodenticide Act (FIFRA). Training: Associates are trained during annual review or at new hire. product storage areas. Program Description: Goal: Scope: Content: Manage pest population to minimize its potential for product adulteration and/or contamination. All pesticides will be used according to the label and all activities will be in compliance with the Federal Insecticide. rodent trap checks. pesticide sample labels. Fungicide.

and pest control chemicals. All chemicals purchased at the plant are reviewed by the purchasing department to insure that they are appropriate for use in a food plant. and wear safety equipment. The plant maintains a control program for cleaning compounds. Program Description: Goal: Scope: Content: Protect the product and process environment from possible chemical contamination. application. maintenance. such as sanitation. All personnel using chemicals will be trained for proper usage. All chemicals. The usage of cleaning compounds and sanitizer for hand cleaning of equipment will be maintained by using test strips to insure that the proper concentration was used. production. Chemical inventory is audited on annual basis or if a chemical is added or removed. Program Title: Allergen Control Program . Training: All associates are trained as new hire and on annual basis. CIP records to clean and sanitize product zone areas will be maintained and reviewed by the QA department as evidence of effective cleaning. A running inventory of chemical usage is maintained by the appropriate department head to note any unusual usage. The control of chemicals in raw materials and packaging materials will be addressed separately by our supplier certification program and ingredient hazard analysis. where appropriate. and laboratory.Person Responsible: Where Located: Michael Bland/ Purchasing Manager First Aid Room Guermo Tank / Plant Manager Revision Approval Authority: Revision Timing: Reviews occur annually and if there are any significant changes in chemical usage or if there is a program failure. maintenance chemicals.

the program will be modified and reconfirmed by residue testing Scope: Content: Training: All associates are trained on an annual basis for FDA. scaling. Training records are maintained in HR ofc. USDA. Program Description: Goal: Is to ensure that the company meets and maintains all local. The QA department will perform scheduled testing for protein residue on product zones and finished to confirm that the current programs are effective. rework usage. state and federal requirements for this production facility. When deficiencies are noted. processing. All EPA. The production department with the cooperation of the sales department will minimize the amount of changeovers from allergen to non-allergen product due to the potential for cross contamination. and other regulatory requirements. and mixing to insure that formulae and usage are accurate.Person Responsible: Where Located: Guermo Tank/ Plant Manger Plant Manager’s / Environmental Coordinator’s Ofc. N/A Revision Approval Authority: Revision Timing: Reviews occur annually and if there are any changes to government guidelines and regulations. The product label will clearly and accurately list all ingredients. OSHA. the cleaning procedures and inspection will be documented on the pre-op and operational inspections. and packaging equipment. and Department of Natural Resources. or if there is a program failure. . The production department will maintain an approved rework usage matrix and record usage on the scaling reports. The product development and QA department will review and identify allergens in new raw materials and existing products produced at the plant. any change in allergen usage. The QA department will audit the recipes. The R & D department with the assistance of the purchasing department will review existing and new raw materials for allergen potential. Where there is a potential for cross contamination in scaling.

Program Title: SSD GOOD MANUFACTURING PRACTICES Eric Hale/ HR Manager Person Responsible: .

Visitors are trained at start of visit. All transport vehicles will be inspected for cleanliness prior to shipping and the temperature of product will be controlled through the distribution chain. GMP forms are maintained by HR. or if there is a program failure. and the lines have been set up to prevent any potentials for cross contamination. All personnel working at the plant will receive documented GMP training for their given area of responsibility for food safety and regulatory compliance. Sanitation. air-handling systems will be filtered. which could affect the integrity of the product. Transportation & Storage. Glass Policy. Personnel Practices. All lights will be protected. Personnel will wear clean outer uniforms and a policy for handling injuries or cuts will be in effect. personnel. Plant Maintenance. Content: Training: Annual and new hire training. Program Title: Person Responsible: SSD SUPPLIER CONTROL PROGRAM Michael Bland/ Purchasing Manager . The building exterior and grounds will be maintained to prevent pest problems and environmental issues. Employees have been trained in proper hygienic practices and adequate hand washing facilities have been provided. Program Description: Goal: Scope: Maintain an environment and encourage practices that minimize the potential for product adulteration. The water quality and sanitary facilities will be checked for compliance. Body Fluids Program. The equipment installation and building design will be of sanitary design and a preventive maintenance program will be in effect to ensure food safety and ongoing process capability.Where Located: Human Resource Office Guermo Tank/ Plant Manager Revision Approval Authority: Revision Timing: Reviews occur annually and if there are any significant changes in equipment.

soy. etc. COA’s Specification. adherence to specifications. dried vegetables etc. Ingredients that do not affect quality or present food safety risk will be evaluated every two years. Critical ingredient suppliers must have an annual AIB audit with a score of 800 and submit a copy of their HACCP plan. or if there is a program failure. any change in point of allergen addition. The purchasing department will maintain a list of approved suppliers and only buy from approved vendors. food safety requirements. including packaging material. Shipping and Receiving. spices. A weighted average for the above criteria will be used to score the suppliers. coming to the plant. Program Description: Goal: Control of incoming materials through Contract Agreement. Suppliers of critical ingredients affecting quality or food safety will be evaluated yearly. performance defects. Guermo Tank/ Plant Manager Revision Approval Authority: Revision Timing: Reviews occur annually and if there is any removal or addition of allergens to the program. and service. Letter of Continuing Guarantee. All raw materials. Scope: Content: Training: Training is accomplished through ISO work instructions for purchasing.Where Located: Purchasing Dept.. Program Title: FOOD SAFETY CONSUMER COMPLAINTS . will be required to submit certificates of guarantee and/or certificates of analysis. egg products. Suppliers of critical ingredients such as milk products. The supplier evaluation program will be done by the material review team and consist of evaluating price. gelatin.

Associates are informed through food safety alerts posted at the work stations and employee information boards. All complaints from customers and consumers. The company will keep a separate file for food safety complaints. The HACCP and prerequisite programs will be reevaluated when food safety concerns are noted in the market place. and food safety issues. The customer service department will respond back to the consumer. including quality.Person Responsible: Where Located: Corey Weathers/ Quality Technician Quality Department Guermo Tank/ Plant Manager Revision Approval Authority: Revision Timing: Reviews occur annually and if there is a program failure. The Quality Department will require documented investigations by the department responsible for that activity with corrective action taken to prevent reoccurrence. service. Program Description: Goal: Scope: Content: Identification and resolution of complaints. The Quality Department will track the number and type of food safety complaints per units produced with performance goals established to document continuous improvement. Training: Program Title: RECALL and TRACEABLITY PROGRAM .

Traceability records for packaging material. the procedures will be revised and personnel will receive further training. packaging codes. When deficiencies are noted in the program. raw material usage. and distribution records will be kept to for two years. from the market in a timely and effective manner. All raw material. Scope: Content: Training: Training is accomplished semi-annually with the primary and alternate Recall team. rework and finished product that may pose suspect to consumers. processing aides. that is in violation of a regulatory requirement. The recall team will test this program every six months and report on the effectiveness of the program to management. The proper coding of the manufactured product on a day to day basis will be the responsibility of the production department and verified by the QA department. or if there is a program failure. rework usage.Person Responsible: Where Located: Renee Kerr/ Quality Manager Quality Department Guermo Tank/ Plant Manager Revision Approval Authority: Revision Timing: Reviews occur semi-annually (recall drills) and if there are any significant changes to items. The plant has documented policies and procedures to recall product produced at the plant and distributed to the customers. Program Description: Goal: Removal of suspect product. packaging material. . work in progress.

SINCERE SALAD DRESSING PROCESSING FLOWCHART BULK RECEIVING AND STORAGE X ray unit PALLETIZED INGREDIENT AND PACKAGING MATERIAL RECEIVING DRY STORAGE REFRIGERTED STORAGE DRY STORAGE REFRIGERATED STORAGE DUMP STATION BULK SCALING AND MINOR INGREDIENT ADDITION/ SIFTERS GLASS STORAGE GLASS INTRODUCTION STATION OAKS MIXER GLASS INVERSION STATION PASTEURIZER (1) REWORK GLASS WASHING STATION COOLING GLASS INSPECTION X-Ray Unit (2) GLASS HOT FILL Metal Detector LABELLING AND BOXING Capper (3) REFRIGERATED STORAGE REFRIGERATED SHIPPING .

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and single service foil packets.HACCP FINISHED PRODUCT PROFILE General Product Information: Description of Product(s): Intended Use and Consumer/ Customer: Salad Dressing Ready to eat/ General Public 45 degrees Fahrenheit at the retail level/ 40 degrees Fahrenheit. GMPs (Glass policy. biological(people) Allergen control program.5-7. supplier control program. boxed pouches. 2009 .0 glass jars. Allergens. Personnel practices). metal detection. plastic.5 5. refrigerated truck 12 months unopened/ 6 months opened refrigerated FD&C Yellow #5 (food coloring) 9. controlling or eliminating each food safety issue identified above: Signature of Company Official: Title: Plant Manager Guermo Tank Date: Sept. 10. product or process parameters essential to preventing. glass x ray unit. sifters Method of Storage and Distribution: Shelf-life/ Traceability information: Technical Product Information: Preservative(s): Water activity (aw): pH/ titratable acidity: Packaging requirements: Food Safety Information: Potential for consumer/ customer misuse: Describe the potential food safety issues associated with this product/ process (be specific): List any support programs or ingredient. sanitation. Bacteria cross contamination if left unrefrigerated. glass.

glass B None C tartrazine (Allergen) P None B None C None P pieces/ shards Liquid. metal. glass B None C Allergen P large lumps. metal. salts P foreign material. . C = Chemical. metal. rocks B Salmonella C Allergen P None B None C Pesticides P large lumps. L/L and/ or M/L (likelihood/ severity) in all three hazard risk assessments. Any item identified as “Critical” must be brought forward to Receiving on the Process Hazard Analysis form for further analysis. L = Low. must be considered critical. pasteurized eggs sugar vinegar salt Dried milk powder Yellow #5 food color Glass jars Hazards: B = Biological. nitrates. glass B None C None P None B None C None P large lumps. N = Negligible (1) Critical Raw Material: Any raw material. P = Physical Risk Assessment: H = High. with the exception of those having negligible.RAW MATERIAL HAZARD ANALYSIS Product or Process Name: Salad Dressing Risk Assessment Likelihood M L-M L L-M H N N M M-H N N N N N M-H N H M-H N M-H N N N M-H Severity M L L M H N N L-M M N N N N N M N H M N M N N N M Is this a Critical Raw Material (1) (Yes/No)? Y Y N Y Y N N Y Y N N N N N Y N Y Y N Y N N N Y List all raw materials used in the plant Well water Identify known hazards B Bacteria – fecal coliform C MTBE. M = Medium.

If YES. If you are at that process step. list the hazard eliminated in Column 2. process. this is not a CCP: enter NO. product. Go to the next hazard or process step. identify the last process step where it will be eliminated. Pasteurizer Yes. write “none” and continue to the next hazard or process step. go to the next hazard or process step. modify the step. List every process step. if not.PROCESS HAZARD ANALYSIS (1) List every Critical Ingredient identified in the Raw Material Hazard Analysis. Damage to above ground or underground tanks. Go to Column 2. this step must be considered a CCP: identify the CCP number. write “none. Note: If this is a last process step identified in Column 4. (4) Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process step? If NO. from Receiving to Shipping.” Go to column 4. write “none. proceed to Column 5. (3) Is this hazard(s) CONTROLLED to the best of the plant’s ability by Support Programs? If YES. and tanker spills into soil. If NO. or Support Programs.) If no hazard is identified.) (5) Can a viable product still be produced if the process step listed in Column 4 fails? If YES. (Be as specific as possible when listing the hazard and its source. If NO. shown on the simplified Process Flow Diagram. None Supplier control program Supplier control program None Pasteurizer No Liquid Pasteurized eggs B Salmonella C Allergen P None None None Supplier control program None None No Sugar B None C pesticides . you must stop. Well water B Bacteria C MTBE P None Supplier control program -Nanofiltration Supplier control program -Quarterly testing at state certified laboratory. (2) Does this raw material or process step INTRODUCE or INTENSIFY a potential food safety hazard? If YES identify hazard(s). list all of the Support Programs that will control the introduction or intensification of the hazard(s) identified in Column 2. (Note: If no control or elimination is identified in Column 3 or 4 and these are necessary for food safety.” Go to column 3.

metal.PROCESS HAZARD ANALYSIS P large lumps. metal. glass None Supplier Control Program Glass Policy None No Metal Detector/ Glass Xray Unit . glass Glass Policy Metal Detector/ Glass Xray Unit Salt B None C Allergen P large lumps.

proceed to Column 5. If NO. (Note: If no control or elimination is identified in Column 3 or 4 and these are necessary for food safety. (Be as specific as possible when listing the hazard and its source. If you are at that process step. if not. this step must be considered a CCP: identify the CCP number. product. list all of the Support Programs that will control the introduction or intensification of the hazard(s) identified in Column 2. modify the step.) (5) Can a viable product still be produced if the process step listed in Column 4 fails? If YES.” Go to column 3. write “none. If YES. you must stop. List every process step. go to the next hazard or process step. (4) Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process step? If NO. (2) Does this raw material or process step INTRODUCE or INTENSIFY a potential food safety hazard? If YES identify hazard(s). list the hazard eliminated in Column 2. write “none. Dried milk powder B None C Allergen P large lumps. (3) Is this hazard(s) CONTROLLED to the best of the plant’s ability by Support Programs? If YES.PROCESS HAZARD ANALYSIS (1) List every Critical Ingredient identified in the Raw Material Hazard Analysis. Go to Column 2. metal. Go to the next hazard or process step. Note: If this is a last process step identified in Column 4. identify the last process step where it will be eliminated. If NO.” Go to column 4. shown on the simplified Process Flow Diagram. from Receiving to Shipping.) If no hazard is identified. or Support Programs. this is not a CCP: enter NO. process. write “none” and continue to the next hazard or process step. glass None Supplier control program Glass Policy None None Metal Detector/ Glass Xray Unit Yellow #5 food color B None C Tartrazine (Allergen) P None None Supplier Control Program None None None None None Glass policy None None None Glass Xray Unit Glass jar B None C None P pieces / shards B .

PROCESS HAZARD ANALYSIS C P .

sticks Supplier control program/ COA Supplier control program/ COA Supplier control program/ COA Pasteurizer None. (2) Does this raw material or process step INTRODUCE or INTENSIFY a potential food safety hazard? If YES identify hazard(s). If you are at that process step. rocks. (Note: If no control or elimination is identified in Column 3 or 4 and these are necessary for food safety.” Go to column 4. list the hazard eliminated in Column 2. identify the last process step where it will be eliminated. If YES. if not. List every process step. If NO. write “none” and continue to the next hazard or process step. modify the step. write “none. process. product. go to the next hazard or process step. (3) Is this hazard(s) CONTROLLED to the best of the plant’s ability by Support Programs? If YES. write “none. Go to the next hazard or process step. glass. (4) Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process step? If NO. Go to Column 2. from Receiving to Shipping. list all of the Support Programs that will control the introduction or intensification of the hazard(s) identified in Column 2.) If no hazard is identified.) (5) Can a viable product still be produced if the process step listed in Column 4 fails? If YES. or Support Programs. bones.PROCESS HAZARD ANALYSIS (1) List every Critical Ingredient identified in the Raw Material Hazard Analysis. you must stop. Note: If this is a last process step identified in Column 4. Metal Detector/ Glass Xray Unit Dry storage (Bulk) B None C None P None Refrigerated storage (Bulk) B None C None P None B None . Bulk receiving and storage (X ray unit) B Bacteria C Allergens P metals. proceed to Column 5. this step must be considered a CCP: identify the CCP number. If NO. this is not a CCP: enter NO. shown on the simplified Process Flow Diagram. (Be as specific as possible when listing the hazard and its source.” Go to column 3.

PROCESS HAZARD ANALYSIS Palletized ingredient & packaging material receiving C Allergens P None Supplier control program/ COA None .

(Note: If no control or elimination is identified in Column 3 or 4 and these are necessary for food safety.) (5) Can a viable product still be produced if the process step listed in Column 4 fails? If YES. this is not a CCP: enter NO. go to the next hazard or process step. if not. modify the step. List every process step. process. (4) Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process step? If NO. product.” Go to column 3. list the hazard eliminated in Column 2. Go to Column 2. If NO. (3) Is this hazard(s) CONTROLLED to the best of the plant’s ability by Support Programs? If YES.) If no hazard is identified. shown on the simplified Process Flow Diagram. If YES. (2) Does this raw material or process step INTRODUCE or INTENSIFY a potential food safety hazard? If YES identify hazard(s). Dump station (palletized) B None C None P None B Bacteria/ viruses from employees GMPs. Dry storage (Palletized) B None C None P None Refrigerated storage (Palletized) B None C None P None . you must stop.Personnel practices Pasteurizer . this step must be considered a CCP: identify the CCP number. (Be as specific as possible when listing the hazard and its source. list all of the Support Programs that will control the introduction or intensification of the hazard(s) identified in Column 2. proceed to Column 5. write “none” and continue to the next hazard or process step.PROCESS HAZARD ANALYSIS (1) List every Critical Ingredient identified in the Raw Material Hazard Analysis.” Go to column 4. Go to the next hazard or process step. write “none. write “none. from Receiving to Shipping. or Support Programs. If you are at that process step. Note: If this is a last process step identified in Column 4. If NO. identify the last process step where it will be eliminated.

sanitizers P Lumps.PROCESS HAZARD ANALYSIS Bulk scaling & minor ingredient addition/ Sifters C cleaners. metal Chemical control policy GMPs. Glass Policy None Metal Detector/ Glass Xray Unit .Personnel practices. glass.

(3) Is this hazard(s) CONTROLLED to the best of the plant’s ability by Support Programs? If YES. process.) If no hazard is identified. 1 Chemical control policy GMPs. write “none. proceed to Column 5. Glass Policy GMPs. Oaks mixer B Bacteria C cleaners. metal GMPs. (Note: If no control or elimination is identified in Column 3 or 4 and these are necessary for food safety. write “none” and continue to the next hazard or process step.Personnel practices Chemical control policy GMPs. list the hazard eliminated in Column 2. (Be as specific as possible when listing the hazard and its source. If YES.Personnel practices. write “none. or Support Programs. Glass Policy Metal Detector/ Glass Xray Unit Cooling B None . If NO. Go to the next hazard or process step.Personnel practices.” Go to column 4. list all of the Support Programs that will control the introduction or intensification of the hazard(s) identified in Column 2.Personnel practices Pasteurizer None Metal Detector/ Glass Xray Unit Pasteurizer B Bacteria/ Salmonella C cleaners. sanitizers P Lumps. identify the last process step where it will be eliminated. glass. metal Product must be brought to 190 degrees fahrenheit in order to destroy possible bacteria/viruses introduced from suppliers or SS employees. this step must be considered a CCP: identify the CCP number. modify the step. If NO. List every process step. If you are at that process step. glass. Go to Column 2. go to the next hazard or process step. sanitizers P Lumps. (2) Does this raw material or process step INTRODUCE or INTENSIFY a potential food safety hazard? If YES identify hazard(s). if not. Note: If this is a last process step identified in Column 4. this is not a CCP: enter NO.” Go to column 3. you must stop. (4) Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process step? If NO.) (5) Can a viable product still be produced if the process step listed in Column 4 fails? If YES. from Receiving to Shipping. product. shown on the simplified Process Flow Diagram.PROCESS HAZARD ANALYSIS (1) List every Critical Ingredient identified in the Raw Material Hazard Analysis.

PROCESS HAZARD ANALYSIS C None P None B None Glass storage C None P pieces / shards Glass Xray Unit .

Go to Column 2. (2) Does this raw material or process step INTRODUCE or INTENSIFY a potential food safety hazard? If YES identify hazard(s). you must stop. shown on the simplified Process Flow Diagram. (3) Is this hazard(s) CONTROLLED to the best of the plant’s ability by Support Programs? If YES. proceed to Column 5. (Be as specific as possible when listing the hazard and its source.) (5) Can a viable product still be produced if the process step listed in Column 4 fails? If YES. Note: If this is a last process step identified in Column 4. If you are at that process step. If NO. from Receiving to Shipping. List every process step. Go to the next hazard or process step. write “none” and continue to the next hazard or process step. write “none. (Note: If no control or elimination is identified in Column 3 or 4 and these are necessary for food safety.” Go to column 4. go to the next hazard or process step. identify the last process step where it will be eliminated. list all of the Support Programs that will control the introduction or intensification of the hazard(s) identified in Column 2. (4) Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process step? If NO. write “none. if not. or Support Programs.(1) List every Critical Ingredient identified in the Raw Material Hazard Analysis. this is not a CCP: enter NO. modify the step. this step must be considered a CCP: identify the CCP number.) If no hazard is identified. If YES. process. product. list the hazard eliminated in Column 2. If NO.” Go to column 3. Glass introduction station B None C None P contamination/ pieces Glass policy/ Personnel Practices Glass Xray Unit Glass inversion station B None C None P contamination/ pieces Glass policy Glass Xray Unit Glass washing station B None C None P contamination/ pieces Glass policy Glass Xray Unit B None .

Glass inspection xray unit C None P contamination/ pieces. write “none” and continue to the next hazard or process step. or glass introduction stage 2 List every Critical Ingredient identified in the Raw Material Hazard Analysis. product. write “none. Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process step? If NO.” Go to column 3. glass. you must stop. list the hazard eliminated in Column 2. write “none. If NO. Does this raw material or process step INTRODUCE or INTENSIFY a potential food safety hazard? If YES identify hazard(s). Go to the next hazard or process step. If you are at that process step. Note: If this is a last process step identified in Column 4. bulk scaling. (Be as specific as possible when listing the hazard and its source. from Receiving to Shipping. shown on the simplified Process Flow Diagram. identify the last process step where it will be eliminated.Personnel practices. metal Supplier Control Program. Personnel Practices Allergen control program. this step must be considered a CCP: identify the CCP number. list all of the Support Programs that will control the introduction or intensification of the hazard(s) identified in Column 2. Glass Policy Pasteurizer None Metal Detector/ Glass Xray Unit) Glass Hot fill B None . If YES. Go to Column 2. go to the next hazard or process step. if not. proceed to Column 5. or Support Programs. chemical control policy GMPs. modify the step. (Note: If no control or elimination is identified in Column 3 or 4 and these are necessary for food safety. this is not a CCP: enter NO. List every process step.” Go to column 4. Is this hazard(s) CONTROLLED to the best of the plant’s ability by Support Programs? If YES. Rework B Bacteria C Allergen/sanitizers P Lumps.) Can a viable product still be produced if the process step listed in Column 4 fails? If YES. If NO.) If no hazard is identified. fragments Glass policy Foreign material from Oakes mixer. process.

this is not a CCP: enter NO. 3 (1) List every Critical Ingredient identified in the Raw Material Hazard Analysis. write “none. If NO. if not. list all of the Support Programs that will control the introduction or intensification of the hazard(s) identified in Column 2. or Support Programs. . you must stop.) If no hazard is identified. identify the last process step where it will be eliminated.” Go to column 4.) (5) Can a viable product still be produced if the process step listed in Column 4 fails? If YES. If you are at that process step. modify the step.C None P None Metal detector Labeling & boxing Capper. write “none” and continue to the next hazard or process step. Note: If this is a last process step identified in Column 4. Refrigerated Storage B None C None P metal fragments B None C Nome P None No. this step must be considered a CCP: identify the CCP number. process. Go to Column 2. (3) Is this hazard(s) CONTROLLED to the best of the plant’s ability by Support Programs? If YES. proceed to Column 5. Metal pieces from equipment or tooling. write “none. product. List every process step. (4) Is this hazard ELIMINATED (reduced to an acceptable level) at this or a later process step? If NO. list the hazard eliminated in (2) Does this raw material or process step INTRODUCE or INTENSIFY a potential food safety hazard? If YES identify hazard(s). If YES. go to the next hazard or process step. (Be as specific as possible when listing the hazard and its source. from Receiving to Shipping. If NO. Go to the next hazard or process step. shown on the simplified Process Flow Diagram.” Go to column 3. (Note: If no control or elimination is identified in Column 3 or 4 and these are necessary for food safety.

Column 2. Refrigerated shipping B None C None P None B C P B C P B C P .

HACCP MASTER PLAN (1) CCP (2) Significant Hazard (3) Critical Limits (4) Monitoring (5) Corrective Action(s) (6) Verification (7) Records .

How: : Temperature readings are taken every 2 hours with a calibrated thermometer. All product since the last good check will be placed on hold for re pasteurization . Repaired/ replaced unit shall be inspected and verified by qualified maintenance personnel and QA before being placed into service. Monitoring must be observed and verified at least four times a shift by the supervisor and at least twice a shift by QA. Pasteurizer temperature monitor log.1 Biological Bacteria/ viruses >190 degrees degrees for a minimum of 5 minutes. What: Product temperature must be at >190 degrees Fahrenheit. Every 2 hours during the shift . monitor log must be signed at each check by a qualified production associate. Unit will be repaired or replaced with a known working unit. A sample is obtained from the pasteurizer and the temperature is verified and recorded. Temperature must be monitored every 2 hours. Frequency: At the beginning of each shift and at the end of each shift.

Who: Shift Supervisor. Monitoring will be observed and verified by QA. Signature of Company Official: Guermo Tank Title: Plant manager Date: 9/10/2009 HACCP MASTER PLAN .

Monitoring must be observed and verified at least four times a shift by the supervisor and at least twice a shift by QA.5mm or greater A working Reject mechanismProduct will be kicked out of the process.(1) CCP 2 (2) Significant Hazard Glass inclusion (3) Critical Limits 0. (7) Records Glass X ray unit monitor log How: Unit will be checked using verified test samples to ensure unit is working properly. Repaired/ replaced unit shall be inspected and verified by qualified maintenance personnel and QA before being placed into service (6) Verification Unit must be monitored every 2 hours. . Unit will be repaired or replaced with a known working unit. (4) Monitoring What: Glass X ray unit (5) Corrective Action(s) All product since the last good check will be placed on hold for re inspection through a known good unit or destroyed. monitor log must be signed at each check by a qualified production associate.

Frequency: At the beginning of each shift and at the end of each shift. Every 2 hours during production. and after line changes. Signature of Company Official: Guermo Tank Title: Plant manager Date: 9/10/2009 . Who: Qualified Production associate and shift supervisor. Monitoring will be observed and verified by QA. after maintenance.

A working Reject mechanismProduct will be kicked out of the process. (4) Monitoring What: Metal detector (5) Corrective Action(s) All product since the last good check will be placed on hold for re inspection through a known good unit or destroyed.5 mm (non ferrous metals) 4.5 mm (ferrous metals) 2. Repaired/ replaced unit shall be inspected and verified by qualified maintenance personnel and QA before being placed into service (6) Verification Unit must be monitored every 2 hours. Unit will be repaired or replaced with a known working unit. (7) Records Metal detector monitor log .0mm stainless steel. monitor log must be signed at each check by a qualified production associate.HACCP MASTER PLAN (1) CCP 3 (2) Significant Hazard Metal (3) Critical Limits 2. Monitoring must be observed and verified at least four times a shift by the supervisor and at least twice a shift by QA.

and after line changes. Signature of Company Official: Guermo Tank Title: Plant manager Date: 9/10/2009 . Every 2 hours during production. after maintenance. Who: Qualified Production associate and shift supervisor.How: Unit will be checked using verified test samples to ensure unit is working properly. Frequency: At the beginning of each shift and at the end of each shift. Monitoring will be observed and verified by QA.

HACCP DEVIATION REPORT Date:____________________ Critical Control Point:___________________ Location:________________ Equipment:____________________________ Specified Range:__________ Actual Reading:_________________________ Past History:________________________________________________________ __________________________________________________________________ __________________________________________________________________ Current Corrective Action:_____________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ Future Corrective Action Needed:_______________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ Production Disposition:_______________________________________________ __________________________________________________________________ __________________________________________________________________ __________________________________________________________________ .

Attach a copy of all records of the critical control point deviation. Date:___________________________ Supplier:________________________ Product:_________________________ Product Lot Identifier:_____________________ DESCRIPTION OF UNUSUAL OCCURRENCE: . HACCP CORRECTIVE ACTION REQUEST o Major o Minor Problem Noted: Temporary Action Taken: Long-Term Corrective Action: Assigned To/Due Date: Prepared by:_________________________ Date: ________ Reviewed by:________________________ Date:_________ Was the corrective action effective?_______________________________ Remarks: Corrective Action o Open o Closed NOTICE OF UNUSUAL OCCURRENCE AND CORRECTIVE ACTION (NUOCA) This NUOCA contains trade secret/business confidential information and is exempt from disclosure pursuant to applicable law.

DESCRIPTION OF CRITICAL LIMITS EXCEEDED (if any): (Identify by CCP Number) PREDETERMINED CORRECTIVE ACTION PURSUANT TO HACCP PROGRAM: ◊ Product Segregation and Hold ◊ Product to be Destroyed ◊ Further Hazard Analysis (Describe below) ◊ Reconditioning /Alternative Use (Describe below) ACTION TAKEN UPON FURTHER HAZARD ANALYSIS PURSUANT TO GENERIC CORRECTIVE ACTION PLAN: (Describe in detail) RECOMMENDED ACTION FOR REEVALUATION OR MODIFICATION OF HACCP PROGRAM: (Describe in detail) ________________________________________ Signature REVIEWED BY: ________________________________________ Signature of HACCP Coordinator Date:_____________ .