Organization

:

SPRINTECH

Doc. Title:

HACCP Plan Procedure

Document Code:

Rev#: 00

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

Organization:

SPRINTECH

Doc. Title:

HACCP Plan Procedure

Document Code:

STP/ISP-0

Rev#: 00

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

stored and transported is also considered together with facts Page 3 of 25 . 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.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. 2.2 Describing a product A full description of the product with relevant safety information is prepared as given in Appendix II.Organization: SPRINTECH Doc. A team leader to convene the group and to direct the work of the team ensuring that the HACCP concept is properly applied. Also information regarding how the product is to be packaged. each with an understanding of particular food safety hazards and associated risks. 4. Members with major role in production of the food packaging material. Procedure 4. 4. 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. 2. The team includes: 1. Title: Document Code: HACCP Plan Procedure STP/ISP-0 Rev#: 00 1.

3 Describing a product’s 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. processing . 4. Labelling information is also included. see Appendix II. 4. This information is recorded on the same form of product description. packaging . After the flow diagram has been made. 4.Organization: SPRINTECH Doc. Any observed deviation will result in an amendment of the original flow diagram to make it accurate. Page 4 of 25 .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. This information will assist the HACCP team to identify 'real' hazards associated with the process. Title: Document Code: HACCP Plan Procedure STP/ISP-0 Rev#: 00 regarding it's shelf life and recommended storage temperatures. storage and distribution is presented in a detailed flow diagram.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. a multidisciplinary team will confirm it on-site during operating hours.

Title: HACCP Plan Procedure Document Code: Rev#: 00 STP/ISP-0 Food safety hazards for HACCP plan have been classified into three types of hazards: 1.6 Identification of Critical Control Points (CCPs) The identification of a critical point for the control of a hazard is done by the HACCP team . chemical or physical nature of raw materials. chemicals or physical agents or allergens e. survival or multiplication of pathogenic micro-organisms and unacceptable generation of chemicals in intermediate products. eliminated. Once a food safety hazard has been identified. 4. final products. the following should be considered: a. the qualitative and/or quantitative evaluation of the presence of hazards c. the likely occurrence of hazards and severity of their adverse health effects b. and if so whether control measures exist. parasites). production line or line environment d. then appropriate control measures are taken into consideration. or reduced to an acceptable level. If the hazard can be controlled adequately. Page 5 of 25 .Organization: SPRINTECH Doc. The team will determine whether the hazard can occur at this step. Each process step identified in the flow diagram is considered in sequence. These are any action or activity that can be used to control the identified hazard. production or persistence in foods of toxins or other undesirable products of microbial metabolism. such that it is prevented. Physical In conducting the hazard analysis. contamination (or recontamination) of a biological (micro-organisms. Biological 2. intermediate products or final products. according to their judgment . experience and knowledge of the process. Chemical 3.

and is essential for food safety. Critical limits correspond to the extreme values acceptable with regard to product safety. A frequency of observations or measurements which provides reliable information is established. when monitoring and checking is performed. The procedure describes the methods. Ensure that appropriate control measures are effectively designed and implemented. then this step is a CCP for the specified hazard. Title: Document Code: HACCP Plan Procedure STP/ISP-0 Rev#: 00 and is not best controlled at another step. Production should cease until control measures are available and a CCP is introduced. The identification of critical control points has two consequences for the HACCP team which should then: 1. 4. 2. It should be based on substantiated evidence that the chosen values will result in process control. how monitoring and checking is performed.Organization: SPRINTECH Doc. Establish and implement a monitoring system at each critical point.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. who is to perform monitoring and checking. the frequency of observations or measurements and the recording procedure and identify each critical point: a.8 Monitoring Procedures at Critical Control Points Monitoring is the mechanism for confirming that critical limits at each CCP are being met. They separate acceptability from unacceptability. c. Page 6 of 25 . b. 4. They are set for observable or measurable parameters which can demonstrate that the critical point is under control.

• Description of means and action required to correct the observed deviation. Monitoring will indicate that preventive measures (checking equipment. so that they can be taken without hesitation when monitoring indicates a deviation from the critical limit. • Action to be taken with regard to products that have been manufactured during the period when the process was out of control. time. etc.10 Verification Procedures The HACCP team should specify the methods and procedures to be used for Page 7 of 25 . 4. 4. Such corrective action will include: • Identification of the person(s) responsible for the implementation of the corrective action.) should have to be taken if corrective actions for the same procedure have to be taken repeatedly. checking the person handling the food packaging material.Organization: SPRINTECH Doc. actor and subsequent verification check).9 Corrective Actions For each critical control point corrective actions is planned in advance by the HACCP team. Title: HACCP Plan Procedure Document Code: STP/ISP-0 Rev#: 00 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. checking the efficacy of previous corrective measures. type of action. • Written record of measures taken indicating all relevant information (for example: date.

• Inspection of operations. Methods for verification may include in particular random sampling and analysis. The frequency of verification should be sufficient to confirm that HACCP plan is working effectively. the monitoring frequency. storage and/or transport activities • Physical check on the process being monitored Page 8 of 25 . Verification procedures include: • Audits of HACCP and its records.Organization: SPRINTECH Doc. Title: HACCP Plan Procedure Document Code: STP/ISP-0 Rev#: 00 determining if the HACCP plan is working correctly. The frequency of verification shall depend on the characteristics of the business . the accuracies of the employees. 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. • Validation of critical limits. • Review of deviations and product dispositions. Verification shall comprise all of the following elements. corrective actions taken with regard to the product. the number of deviations detected over time and the hazards involved. intensified analysis of intermediate or final products. 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. • Confirmation that CCPs are kept under control. reinforced analysis or tests at selected critical points. surveys on actual condition during storage.

process equipment. storage or distribution conditions. such a review must result in the amendment of the procedures laid down. Where necessary. In case of change. Documents and records should be kept for a sufficient time to allow the competent authority to audit the HACCP system. The changes should be fully incorporated into the documentation and recordkeeping system in order to ensure that accurate up-to-date information is available. to ensure that it is or will be still valid. Title: Document Code: HACCP Plan Procedure STP/ISP-0 Rev#: 00 • Calibration of instruments used for monitoring. validation activities should include actions to confirm the efficacy of all elements of the HACCP plan. Documents should be signed by Management Representative of the company. Documentation examples are: Page 9 of 25 .Organization: SPRINTECH Doc.11 Documentation and Record Keeping HACCP procedures should be documented. Where possible. 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. processing conditions (factory layout and environment. 4. • change in packaging. Examples of change include: • change in raw material or in product. cleaning and disinfection program). • receipt of any information on a new hazard associated with the product. it is necessary to review the system. • change in consumer use. Verification is carried out by Management Representative someone other than the person who is responsible for performing the monitoring and corrective actions.

the critical points in the production. • Critical limit determination.Organization: SPRINTECH Doc. storage. • Verification activities.1 Related Documents    HACCP Master Plan HACCP Plan Validation/Reassessment Checklist Corrective & Preventive Action Form Page 10 of 25 . 4. the preventive measures and documentation procedures applicable in the operations of the company. transport and/or distribution process and the corrective measures. 4. Title: HACCP Plan Procedure Document Code: STP/ISP-0 Rev#: 00 • Hazard analysis. • Deviations and associated corrective actions.12 Training The Management representative and food safety team leader shall make sure that all personnel are aware of the hazards identified (if any). • Modifications to the HACCP system. Record examples are: • CCP monitoring activities. • CCP determination.

Title: Document Code: HACCP Plan Procedure STP/ISP-0 Page 11 of 25 Rev#: 00 .Organization: SPRINTECH Doc.

CCP Decision Tree.Organization: SPRINTECH Doc.Flow Diagram Page 12 of 25 Rev#: 00 . Title: Document Code: HACCP Plan Procedure STP/ISP-0 Figure 1.

Title: Document Code: HACCP Plan Procedure STP/ISP-0 Figure 2.Organization: SPRINTECH Doc. Manufacturing Process Flow Diagram Appendix I: Establishing a HACCP Team Page 13 of 25 Rev#: 00 .

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 . 2014 Team Member Position HACCP Team Role Syed Mujtaba Ali Production Member/Advisor Waqas Hassan Management Representative Advisor Usman Shaukat A. Title: HACCP Plan Procedure Document Code: Rev#: 00 STP/ISP-0 HACCP Team Facility Name : Sprintech Packaging Date : September 23 .Organization: SPRINTECH Doc.

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 . The HACCP Team will evaluate raw materials and processes to determine Critical Control Points. Facility management will provide adequate resources for the implementation and maintenance of the HACCP Program. Title: HACCP Plan Procedure Document Code: Rev#: 00 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. Sign-off and Approval Position Name Production Syed Mujtaba Ali Management Representative Waqas Hassan A. The facility HACCP Plan will be re . The team will provide documented training for the facility.Organization: SPRINTECH Doc. Critical Control Points will be monitored as will other points and processes.assessed at least annually.

Chemical and Physical Characteristics Intended Shelf Life & Storage Conditions Packaging Requirements Labeling Requirements Method of Distribution Intended Use Page 16 of 25 Rev#: 00 .Organization: SPRINTECH Doc. Title: Document Code: HACCP Plan Procedure STP/ISP-0 Appendix II: Product Description Format Product Description & Intended Use Section: Date: Product Category Name Product description: Biological.

. production volume increased О О 2. including computer and their softwares. e. О Annual Validation (Reassessment ) of the HACCP Plan including Hazard Analysis Topic YES NO If “YES” Describe Food Safety Implication? 1. Title: HACCP Plan Procedure Document Code: Rev#: 00 STP/ISP-0 Appendix III: HACCP Validation/Reassessment Checklist HACCP Validation/Reassessment Checklist Plant Name : Product Date Conducted : Conducted by : Validation Type О Initial Validation ( within 12 months of implementation) О Validation (Reassessment) due to changes in the raw materials or source of raw materials .g. processing method or system . packaging . e. product formulation .Organization: SPRINTECH Doc.Evaluate product and process Product description changed.g. intended use.. consumer? О О Formula changed? О О Ingredients / Packaging changed? О О Any new product consumption or storage methods? О О Any new suppliers? О О Process flow changed? О О Equipment / software changed? О О Finished product distribution changed? О О Other . finished product distribution systems or the intended use or the intended consumers of the finished product or type of consumer complaints. Evaluate product / process history Repeat CCP deviations? О О Any recent industry recalls of similar product since last annual О О Page 17 of 25 Are modifications to the HACCP system required? .

Organization: SPRINTECH Doc. corrective action. Review current CCP Documentation Do the CCPs control the hazards? О О Are the CPP critical limits adequate? О О О О О О О О Do monitoring methods and frequency demonstrate control? Do corrective actions properly address affected product? Does validation include review of consumer complaints? Page 18 of 25 . monitoring. critical limits.. О О guidance Any confirmed food safety consumer О О complaints 3. Evaluate adequacy of CCP’s. CCP verification. Title: HACCP Plan Procedure Document Code: New or emerging hazards О STP/ISP-0 Rev#: 00 О Regulatory Agency recommendation e. and record keeping procedures.g.

Title: HACCP Plan Procedure Document Code: STP/ISP-0 Rev#: 00 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. 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 . or Deletions were needed. Also attached is information used to support modification(s) of this plan. Additions.Organization: SPRINTECH Doc. the person(s) responsible listed above has/have determined that Changes. Those changes are documented below.

do not complete Columns 46 and go to next process step. HTL . If NO.Infestation C Yes – Plant Chemical P No B No C No P Yes – Foreign Material B Yes . LDPE . go to column 4. lamination) Ink and chemicals Paper . Title: HACCP Plan Procedure Document Code: Rev#: 00 STP/ISP-0 Raw Material Hazard Analysis Facility Name : Sprintech Packaging 1 List each raw material/ ingredient in the process 2 3 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 .Moulds C No P B No Yes – Foreign Materials & 4 If YES. 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. indentify the program or process. HDPE. 2014 C No P Yes – Foreign Material B No C No Yes – Foreign Material P B Yes . (otherwise leave blank) . 6 Assign a CCP # when the answer in Column #4 is NO. Bleach Board (various types and grades) Packing Materials Date : September 23 . resins . Is this hazard ELIMINATED by a subsequent process step? If YES. NYLON PE ) Adhesives (hot melt. this step is NOT a CCP. BOPP. If the hazard is eliminated at this step. CPP. If a pre-requisite program or process is identified. enter NO and go to column 6 and assign CCP #. Indentify the subsequent process step in Column 5 and proceed to the next process step.OPP.Organization: SPRINTECH Doc. PVC .

Identify the last process step that will eliminate the potential hazard. 2014 Yes – Design checklist No No No Line Clearance CCP-1 Page 21 of 25 Line Clearance CCP-2 . enter NO and go to column 6 and assign CCP #. 6 Assign a CCP # when the answer in Column #4 is NO. Indentify the subsequent process step in Column 5 and proceed to the next process step. If the hazard is eliminated at this step. If YES.Infestation C No Yes – Foreign Material P 4 Is this hazard CONTROLLED by a Pre-requisite Program or process step? If YES. If a pre-requisite program or process is identified.Infestation P B No C Yes No P No Yes – Contamination / infestation Yes – Personal Hygiene & Housekeeping programs B Is this hazard ELIMINATED by a subsequent process step? 5 Yes – Receiving Inspections Yes – Receiving Inspections Yes – Incorrect Design Yes – Line Clearance No C Lamination Solventless 3 No Yes – Foreign Material B B Printing Date : September 23 . this step is NOT a CCP. If NO. do not complete Columns 46 and go to next process step. go to column 4.Organization: SPRINTECH Doc. (otherwise leave blank) Yes – Receiving Inspections Yes – Receiving Inspections Yes . Title: HACCP Plan Procedure Document Code: Rev#: 00 STP/ISP-0 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 C Receiving Inspections Warehousing P Yes . indentify the program or process.

Title: HACCP Plan Procedure Document Code: Lamination Solvent Base Slitting Bag Making C Yes P No B Yes – Contamination / infestation C No P No B No C No P 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 .Organization: SPRINTECH Doc.

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. Monitoring What How Printing procedure Operator removes all materials from previous order before new job starts up. No materials from other jobs allowed in area. Lamination procedure Operator removes all materials from previous order before new job starts up. Operator Operator removes materials per critical limits and reinspects line. Verified by operator or other coworker Production Records Operator . Verified by operator or other coworker Production Records Operator Operator removes materials per critical limits and reinspects line. Incorrect unitizing or palletizing due to inadvertent mixing of bags results in allergen risk due to mixed product types No mixing of bags. Laminated materials from previous jobs have not been fully cleared. Verified by operator or other coworker Production Records Operator removes materials per critical limits. Lamination procedure Operator removes all materials from previous order before new job starts up.Organization: SPRINTECH Doc. Laminated materials from previous jobs have not been fully cleared. No materials from other jobs allowed in area. 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. No materials from other jobs allowed in area. Title: HACCP Plan Procedure Document Code: Rev#: 00 STP/ISP-0 HACCP Master Plan Facility Name : Sprintech Packaging Date : September 23 .

Title: Document Code: CCP-5 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. Verified by operator or other coworker Production Records .Organization: SPRINTECH Doc. HACCP Plan Procedure Rev#: 00 STP/ISP-0 Work instructions for operators/ helpers Page 24 of 25 Every pallet Operator Segregate affected pallets.

Organization: SPRINTECH Doc. Title: Document Code: HACCP Plan Procedure STP/ISP-0 Page 25 of 25 Rev#: 00 .