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SC/FSMS/H/004
Page 2
FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
APPROVED BY: FST
REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

DISTRIBUTION LIST NO OF COPIES

1. GENERAL MANAGER 1

2. COFFEE MILL OPERATIONS MANAGER 1

3. ESTATE MANAGERS 8

4. QUALITY CONTROL MANAGER 1

5. PRODUCTION SUPERVISOR 1

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
APPROVED BY: FST
REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

. DISTIBUTION LIST ......................................................................................................................................... 2

1. ABBREVIATIONS..................................................................................................................................... 3

1. INTRODUCTION/PURPOSE................................................................................................................... 5

2. TERMS AND DEFINITIONS..................................................................................................................... 6

3. PRODUCT DESCRIPTION....................................................................................................................... 6
3.1RAW MATERIAL CHARACTERISTICS………………………………………………………………………..6

3.2 FINAL PRODUCT CHARACERISTICS………………………………………………………………………..7

3.2.1 GREEN COFFEE ……………………………………………………………………………………………..7

COFFEE GRADES AND SIZES ………………………………….………...……………………………….8

OTHER GRADES …………………………………………………………………………………………..9

CHEMICAL CHARACTERISTICS ………………………………………………………………..…………9

3.2.2 INSTANT COFFEE ……………………………………………………………….…………………………10

MICROBIOLOGICAL LIMITS ………………….……………………..…………….……………………….11

3.2.3 ROASTED GROUND COFFEE/ ROASTED COFFEE BEANS ………………….………………….....12

MYTOXIN …………………………………………………………………………………….………………13

3.2.6 PACKAGING AND LABELLING …………………………………………………………….……………..13

4. FLOW DIAGRAMS .................................................................................................................................. 15

4.1 PARCHMENT COFFEE PRODUCTION .............................................................................................. 15

4.2.GREEN COFFEE PRODUCTION FLOW CHART ............................................................................... 16

4.3. ROASTING & PACKAGING OF COFFEE …………………………………………………………….......17

5. DESCRIPTION OF PROCESS STEPS AND CONTROL MEASURES …..……………………... 18

5.2 EXISTING CONTROL MEASURES…………..……………………………………………...……………...18

6. OPERATIONAL PRE-REQUISITE PROGRAM (OPRP) …………………..………………………..20

7. HAZARD IDENTIFICATION AND DETERMINATION OF ACCEPTABLE LEVELS...................................21

7.1 HAZARD ASSESSMENT.......................................................................................................................23

7.2 CRITICAL LIMITS..……………………………………………..………………………………………..……27

7.3 CRITICAL CONTROL POINTS PLAN ..................................................................................................29

7.4 VERIFICATION PLANNING...................................................................................................................30

7.5 TRACEABILTY ...................………………………………………...………………………………………..33

7.6 PRODUCT LOT IDENTIFICATION ………………………………..……………………………………….. 36

7.7 CONTROL OF NON-CONFORMITY.....................................................................................................37

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
APPROVED BY: FST
REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3
1 ABBREVIATIONS

CCP Critical Control Point


CL Critical Limit
OPRP Operation Pre-requisite Program
HACCP Hazard Analysis Critical Control Point
PRP Pre-requisite Program
KEBS Kenya Bureau of Standards
OTA Ochratoxin A
NEMA National Environmental Management Authority
MSDS Material Safety Data Sheet
PCPB Pesticides Control Product Board
GAP Good Agricultural Practice
CRF Coffee Research Foundation
Company Sasini Ltd
FST Food Safety Team
FSMS Food Safety Management System
PPE Personal Protection Equipment
EMCA Environment Management Control Act
P1,2,3 Parchment Coffee Grade
PL Parchment Light
MH Mbuni Heavy Coffee
ML Mbuni Light Coffee
UG Under Grade Coffee
FIFO First In First Out
UVI Ultra Violet Sheet
MC Moisture Content
MD Managing Director
GM General Manager
PHI Pre Harvest Interval
SAS Sasini Limited
PH Acidity or Alkalinity
Doc No Document Number
Rev No Revision Number
CR Cleaning Records
L.P.O Local purchase order

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
APPROVED BY: FST
REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

1. Introduction/Purpose
This document is developed using the guidelines of ISO 22000;2005 clause 7 and 8
with respect to hazard identification, evaluation, control and monitoring. This document
presents a detailed HACCP study for the Sasini products and processes and it contains:
a) Food safety hazard(s) to be controlled at the CCP.
b) Control measure(s).

c) Critical limit(s).
d) Monitoring procedure(s).

e) Correction and corrective action(s) to be taken if critical limits are exceeded.


f) Responsibilities and authorities.
g) Record(s) of monitoring.

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
APPROVED BY: FST
REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

2. Terms and Definitions


For the purposes of this document, the terms and definitions given in ISO 22000;2005
shall apply:

3. PRODUCT DESCRIPTION
The final products involved in the process are;

1) Green beans
2) Instant coffee
3) Roasted ground coffee

3.1 Raw Material Characteristics.


The raw materials in processing of final products.

3.1.1 Red ripe Cherry.

Biological
The red ripe cherry is raw material for green coffee production.
It is sourced from Arabica coffee variety of SL28, 34, K7, and Ruiru11.

The coffee cherry is made of;

Exocarp Outer skin

Mesocarp
Endosperm
Silver skin

Chemical
Composition includes among others, Chlorogenic acid, caffeic acid, Ferulic acid,
Quibic acid, sterols, tocopherols Kahweol, polyphenols and kauranic derivatives.

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

Physical
Red ripe mature berry

(a) No additives or processing aids are involved.


(b) Coffee berry is produced in a large plantations of Sasini limited and from out
growers.

Plantations includes; Kamundu, Kakindu, Ting’ang’a, Doondu, Gulmarg,


Ruiru mills, Mweiga and Wahenya Estates
a) Coffee cherry is packed in nylon bags and delivered from the field to the

processing factory using trailers.


b) Coffee cherry is processed within 6 hours after picking.
c) Hand- sorting to remove sticks, under ripes and mouldy beans is done

prior to processing on clean mats or clean concrete floors.


d) Coffee cherry should be free of mouldy beans, sticks, and stone. Kept on
clean surfaces on raised table or concrete floors to avoid contaminants.

3.2 Final product characteristics

3.2.1 Green coffee

The green coffee under KS 593:2011 specification is raw material for ground
roasted coffee in the value addition.

a) Biological, chemical and physical characteristics.


3.2.1.1 Physical characteristic
8 Shall be practicably free from extraneous and foreign matter
8 Shall be free of contaminants
8 Shall be free from foreign odor
8 Shall be free from live infestation by pests, rodents and derivatives
8 Shall be free of fungal infestation
8 Shall be free from adulterants
8 Color grayish green , brownish green or bluish green

b) Moisture content
8 Shall not exceed 12% when tested according to ISO 1446.

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

Coffee Grades and Sizes


SI No Grade General description Screen appeture KS 174

i. E Elephant-(Retained on 21) two beans joined Size diameter 8.3mm

together, it is a genetic defect. And includes very

large(bold) AA

ii. AA Flat beans- (through screen 21 retained in 18) Size diameter 7.2mm

iii. AB Flat beans-(through screen17,retained on 17) Size diameter 6.35mm

iv. PB Pea berries-(through screen 17,Retain on 12

One ovule develops instead of the usual two Size diameter 4.76mm

v. C Smaller beans- (through screen 16 retained on Size diameter3.96mm

10)

vi. TT Light density beans, from AA,AB and E grades Not applicable

by air extraction

vii. T Smallest, consists of broken and small C(through Size diameter 2.9mm

screen 7)
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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

Other Grades
SI No Grade General Description

I. MH Mbuni heavy

II. ML Mbuni light

III. UG Ungraded

IV. SB Sorted beans

V. HE Hulled ears

Packaging
-Average net weight of each package
-bean grade

-coffee year
-outturn number

Chemical characteristics
a) Heavy metal contamination
SI No Contaminants Max Limits(mg/kg)
i. Lead 1.0

ii. Tin 250

iii. Arsenic 0.5

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

b) Pesticide residues
8 Only pesticides approved by relevant government body (PCPB) and

CRF shall be used.


8 Levels of pesticides shall NOT exceed recommended levels by Codex

Alimentarius commission for coffee

3.2.2 Instant coffee

The raw material for preparation of instant coffee is spray dried Robusta coffee.

The material must meet Kenya standard specification for instant coffee KS
175:2011.
a) Biological, chemical and physical characteristics

Physical characteristics

8 Shall free from extraneous and foreign matter

8 Shall be free from foreign odor

8 Shall be free from fungal infestation

8 Shall be free from adulterants

8 Shall be free from contaminants

8 The coffee shall not contain chicory

8 Shall have characteristic of coffee flavor


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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

Chemical

SI Parameter Requirements Test method

i. Moisture, % by mass, max. 4 KS 1039

ii. Total ash (on dry matter basis),by 1.5 KS 1039


mass, max

iii. Acid insoluble ash,% mass, max 1.0 KS1039

iv. Caffeine content(on dry basis),% by 2.8 KS ISO 4052


mass, min

v. Solubility in water Dissolves readily in 30 KS 1039


s with moderate
stirring

vi. Solubility in cold water at 16° C ± 2° Soluble with KS1039


C moderate stirring in
3min

For granulated coffee the maximum moisture content will be 5% by mass

Microbiological limits

The coffee shall comply with the microbiological limits tested through KS 220 method.

Characteristic Limits Test Method

Coliforms/10g Not detectable

Salmonella/30g Not detectable KS 220

S.aureus/10g Not detectable

Yeast and moulds/g Less than 100cells


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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
APPROVED BY: FST
REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

(a) Packaging – instant coffee shall be packaged in food grade containers that
guarantee quality and safety of the product throughout the shelf life.
(b) Labeling- shall comply with KS 40 the following information shall be legibly and
indelibly marked on the package:-
-name of the product as instant/soluble coffee

-brand/trade name
-name, location, contact details and physical address

-country of origin
-date of manufacture
-expiry date
-storage instruction
-net weight in metric units
-batch/lot number

3.2.3 Roasted Ground Coffee/Roasted Coffee Beans


The roasted ground /beans coffee characteristic shall be guided by KS
1052:2011 Standard.
3.2.3.1 Physical Characteristics
- Shall be free from any extraneous and foreign matter
- shall be free from foreign odour
- shall be free from infestation by pests and their derivatives.
- shall be free from fungal infestation
-Shall be free from adulterants

-shall be free from contaminants.

3.2.3.2 Biological Characteristics


Microbiological limits
Roasted ground coffee and roasted coffee beans shall comply with the
microbiological limits indicated below.

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

Characteristic Limits Test Method

Coliforms/10g Not detected

KS 220
Salmonella/30g Not detected

S.aureus/10g Not detected

Yeasts and moulds/g Less than 100cells

Mycotoxin
Roasted ground coffee and roasted coffee beans shall comply with the mycotoxin
limits of maximum of 5 ppb.

SI No. Parameter Maximum limit(ppb) Test method

1 Ochratoxin A 5 ISO 15141 part 1/2

3.2.6 Packaging and labelling


3.2.6.1 Packaging
-The coffee shall be packaged in food grade containers that ensure the quality and
safety of the product throughout the shelf life.
-The weight of container shall be ascertained with calibrated scales.

3.2.6.2 Labelling

The following information shall be included


8 Name of the product
8 Brand name
8 Name, location and physical address of the manufacturer
8 Country of origin

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

8 Date of manufacture
8 Expiry date
8 Storage instruction
8 Net weight
8 Batch/lot number

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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
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4. FLOW DIAGRAMS

4.1 PARCHMENT COFFEE PRODUCTION

GOOD FIELD AGRICULRAL PRACTICES

Washed cherry Mbuni coffee


Water from
rivers, dams PULPING DRY PROCESS.

Cherry reception/sorting
Water to recycling
pulp to Pre-grading channel

decomposing

Skin dry
Fermentation tanks
Rubbish to waste

Lights to re- pass


Sun drying
pulpier
Washing

Grading channel heavies


Water to waste
and lights separately

Skin drying- remove all


Water to waste
free/ excess water

Sun and /or mechanical


drying

STORAGE

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

4.2 GREEN COFFEE PRODUCTION FLOW CHART

PARCHMENT MILLING
PROCESS
Rubbish/stones etc to waste Pre cleaning/destoning Rubbish/stones etc to waste

Milling/hulling
Parchment shells Husk
Grading by bean size
Dust to waste-shells/ears to bagging off Dust to waste shells/ears to bagging off
(screening)

Grading by bean density


(gravity table)

Manual sorting
Remove rejects and foreign matter Remove rejects/and foreign matter

Quality evaluation and


classification

GREEN COFFEE
Bagging off shipment in bags

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

4.3 ROASTING & PACKAGING OF COFFEE


Green coffee from Mill
RECEPTION OF GRADED
GREEN COFFEE BEANS

Removal of damaged diseased


INSPECTION/ANALYSIS
Assessment mouldy beans and beans, foreign matter
foreign matter

SORTING

ROASTING

TEMP 100 155


DEGREES
TIME 20
MINUTE
QUAN 60KGS
TITY
ROASTING
COOLING

Time 20 minutes

Temp 115 to 200


degrees

GRINDING
FINE MEDIUM COURSE

FINE, MEDIUM OR COURSE ROASTED


COFFEE

PACKAGING TINS

SATCHETS
STORAGE
POUCHES

PACKING
Pouches Sachets/Tins

Temporary storage

At room temperature

On rows and bays


On Wooden pallets

Distribution

Covered clean van

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
APPROVED BY: FST
REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

5. Description of Process Steps and Control Measures

5.2 Existing Control Measures


a) GAP (Good Agricultural Practices)
Chemicals residuals-PHI (Pre harvest intervals) is maintained to ensure that
chemicals on trees are completely dissipated before picking can be done.
Tree hygiene to remove mouldy and diseased berries.

b) Ground collection
Cherry fallen on the ground contains moulds which can introduce afflatoxin
collection from the ground shall be prohibited or ground covers are laid during
picking.

c) Sorting
After cherry is picked sorting shall be done to eliminate contaminants.

d) Clean vessels (Harvesting vessels).


Harvesting vessels, bags etc and trailers shall be kept clean before picking
commences to ensure no contaminants are introduced to the coffee.
e) Pulping
Pulping machine can damage the coffee bean and introduce moulds during the
drying process.
Proper setting shall be done to ensure no damage occurs on the beans.
Machines moving parts shall be oiled and greased routinely to ensure no metal
fillings are introduced into the parchment. The type of the grease used to oil the
machine should be food grade, which does not increase hazard in the chain.

f) Fermentation
The monitoring of fermentation process shall be followed to ensure No moulds
formation takes place between the periods before complete drying takes place.

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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

g) Drying

Drying on the table to reduce moisture content from 65% to 11% shall be made
such that the coffee does not acquire moulds due to prolonged wetting.
Monitoring of the moisture levels shall be conducted frequently.

Minimum of 14 days between the times the coffee was placed on the tables
should not be exceeded.
In the event that the weather does not allow for sun drying taking place,
mechanical driers or UVI tents shall be used.
Any coffee that gets into contacts with soil during this process shall be discarded.

h) Storage
Mould formation during storage should be eliminated by ensuring that coffee is
kept 30cm from the wall on raised wooden pallets.
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
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6.0 OPERATIONAL PREREQUISITE PROGRAMS (OPRPs).


PROCESS HAZARD CONTROL MONITORING CORRECTION VERIFICATION AUTHORITY RECORDS OF
STEP MEASURES PROGRAM AND RESPONSIBILITY MONITORING
CORRECTIVE
ACTION

1 Picking and Ochratoxin Inspection of Factory Sorting and External Test Estate Manager Supervisors
reception of A incoming raw Supervisor to discarding Analysis from pulping record
coffee cherries materials. check the mouldy beans KEBs book
sorting and extraneous
matter.

Isolate and
handle as per
the procedure for
handling
potentially
unsafe products

2 Pulping Stones Ensure there Check sieves Isolate and Check the Factory machine Annual
is adequate for intactness handle as per presence of operator maintenance
water in before and the procedure for stones in the records
reservoir after handling wet parchment
operations potentially on tables
unsafe products
Presence of
Ensures the water in the
Check disc are set Aagard pre- Annnual Pulper, Service
pulper discs properly to maintenance of Estate Manager records book
grader
avoid nipping the disc during the
of beans that assembly picking season
Use the
can lead to
development standard
of moulds gauge device
to set the gap

3 Drying Ochratoxin Dry to Moisture Factory Use calibrated Factory Supervisor Moisture test
A required analysis done supervisor to re- moisture records
moisture on every dry if moisture is meters
content batch after high, increase
between every 5 days drying time, seek
10% and authority to use
11% m.c. mechanical
driers

4 Milling stones regulate Check for Increase air flow Manufacturer’s Mill Operator Records, for
vibration, air stones in the by adjusting the manual on inspection of
flow and product by lever, change trouble final product
slope of the sampling the the slope of the shooting.
deck clean coffee deck and Maintenance
after every run increase the records
vibration
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
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7.0 HAZARD IDENTIFICATION AND DETERMINATION OF ACCEPTABLE LEVELS


PROCESS STEP HAZARD ACCEPTABLE JUSTIFICATION STATUTORY&
LEVELS REGULATORY
REQUIREMENT
PRACTICE AND
PRODUCTS

1. Agronomy Chemical residuals of Heavy metals, lead, Fungicides and Acceptable levels as
fungicides and pesticides. tin , arsenic and pesticides are per Codex
other residuals shall used for pest and commission on coffee
be within acceptable disease control
limits may persist if GAP KS 593:2011
is not observed.

2. Processing Mouldy beans may contain Max limit Moulds contain KS 1052:2011,
Ochratoxin A Ochratoxin A that
<5 ppb may cause Liver Max limit <5ppb of
cirrhosis Ochratoxin A
ISO 15141 PART
1/2

3. Pulping E-coli, salmonella River water contains E coli is a disease No E. coli, salmonella,
= causing bacteria yeast or moulds shall
that can result to be found in the final
2400 CFU of E coli ill health and death product.

KS 220

4. Drying Moulds may contain ISO 15141 PART Growth due to Moisture content shall
1/2 moist conditions, not exceed 12%
Ochratoxin A poor handling
Maximum limit ,resulting from KS 1446
damage on
<5 ppb parchment

5. Storage Moulds may contain ISO 15141 PART Growth due to No E. coli, salmonella,
Ochratoxin A 1/2 moist conditions, yeast or moulds shall
roof leakage. NOT be found in the
Other contaminants Maximum limit floods final product.

<5 ppb KS 220

6. Milling Stones Within acceptable Stones may cause Green coffee shall
limits ill health to comply with the limits
consumers, it is provided in KS Codex
also a source of stan 193
contamination
Moulds may contain None in the final
product Growth due to
Ochratoxin A
moist conditions,
poor handling and
cross –
contamination
Human Handling of during hulling Maintain GMP as
Salmonella ,yeast and E-coli the product during guided in KS 1500
processing Employees poor
hygiene & health
can contaminate
the final product

7. Storage and Other contaminants, such as Green coffee shall Green coffee shall Codex commission on
dispatch foreign odour, adulterants, be free of be free of coffee
foreign matter etc contaminants extraneous
contaminants KS 593:2011
Hydrocarbons during transport
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ISSUE NO: 3

8. Sorting/Inspection Salmonella and E. coli None in the final May be KS 1500


,contamination while physically product introduced by
handling coffee poor hygiene,
during hand
sorting ,lack of
proper PPE

9. Roasting Hydrocarbons through use of Roasted coffee shall May cause ill Roasted coffee shall
fossil fuel(diesel) in the roaster be free of health meet KS 1053:2011
machine contaminants and requirements
adulterants & foreign
Salmonella and E. coli through odour.
handling of the coffee after
roasting No Bacteria shall be
found in final Proper roasting
products temperatures shall No coli forms or
eliminate any salmonella in final
biological hazard products when KS
220 testing is done

10. Cooling Contamination adulterants Roasted coffee shall Contaminants Roasted coffee shall
,foreign odour and other be free of could be a source meet KS 1053:2011
extraneous matter contaminants of ill health requirements

11. Grinding Metal contaminants Within acceptable Metal Within acceptable


limits KS 1052:2011 contaminants limits KS 1052:2011
either from wear
and tear of
processing
machine or
introduction from
any other source

12. Packaging Salmonella and E-coli Within acceptable May be introduced No bacteria should be
introduction during manual limits KS 1052:2011 during manual detected in final
handling/packaging handling and poor product
hygiene

13. Distribution Cross contamination during Final products shall Unhygienic Final products shall be
transport can lead to be free of all sort of dispatching of final processed, packaged,
contamination like contaminants products may stored and distributed
hydrocarbons, foreign odour, introduce under hygienic
pests, adulterations or having contaminants conditions in
unhygienic mode of transport accordance with
Public Health Act, cap
242,KS 1500 Standard

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

7.1 HAZARD ASSESSMENT


1. Methodology,

In our production chain as described in clause 7.0 the main hazards identified are,

8 Pesticide residual from the field.

8 Microbiological contamination during pulping, milling and packaging process


through physical handling.

8 Ochratoxin A contamination during the process of pulping, drying and storage.

8 Stones and extraneous contamination during hulling.

8 Metal contamination before and after grinding of roasted coffee.

8 Cross-contamination during dispatch due to unhygienic conditions.

2. Risk Assessment

Risk levels are determined through the severity and likelihood of occurrence of each
hazard. The severity and occurrence are weighted to give the magnitude of each risk level
on human health.

Severity Occurrence Risk level

1- least 1- least low

2- severe 2- likely medium

3- very severe 3-very likely high

The highest risks on human health shall call for stringent measures to reduce or eliminate the
hazard. The point at which the risk shall be eliminated will form the CRITICAL CONTROL
POINT and the point at which risk occurrence shall be minimized shall require an OPRP.

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

PROCESS STEP HAZARD SEVERITY OCCURANCES RISK CONTROL


LEVELS 1-least likely LEVELS MEASURES
1-least severe 2-likely
2-severe 3-very likely
3-very severe
1. Agronomy Presence of Very Severe Very likely High (9) PRP (GAP) use
Chemical approved chemicals
residuals of Accumulation Residual levels observe
fungicides and of chemical shall be within
pesticides
residual levels acceptable limits. PHI, and application
persistent after
spray,
may cause rates.
adverse health
conditions CCP 1-No process
overtime step is capable of
reducing or
elimination the
hazard hence
considered CCP.

2. Processing/sorting lapse in sorting Very Severe Least Likely Medium(6) PRP- raw materials
may lead to receipt procedure,
presence of May cause verification results
mouldy beans
severe health of mycotoxin OPRP handling of
which may contain
problems. No presence are within potentially unsafe
Ochratoxin A
control acceptable limits Products
measure exists
to eliminate if
present

3. Pulping E-coli from raw Very Severe Likely Medium (6) Proper roasting at
pulping water recommended
Product is not roasting
consumed in temperatures shall
its raw form eliminate all bacteria

4. Drying Growth of moulds Very Severe Very Likely High (9) OPRP temperature
due to poor time regimes
handling or Ochratoxin A With low drying the
adverse weather
may cause prolonged wet CCP- 2 ,for
conditions
severe health condition may Ochratoxin A
problems. encourage mould
growth. OPRP Emergency
preparedness
program

5. Storage Growth of moulds Very Severe Likely Medium (6) PRP storage
due to high
humidity or water Ochratoxin A Storage facility built Facility maintenance
contamination may cause according to to prevent leakage,
may lead to requirement to allow
death or water entry
growth of moulds proper ventilation.
hence produce
Ochratoxin A FIFO for stocks control.

Other
contaminants

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

PROCESS STEP HAZARD SEVERITY OCCURANCES RISK CONTROL


LEVELS 1-least likely LEVELS MEASURES
1-least severe 2-likely
2-severe 3-very likely
3-very severe
6. Milling Severe Likely Medium (6) PRP –increase of
vibration and air flow,
Contamination by May cause Destoner setting may OPRP -inspection and
Stones during the further cause some product maintenance .OPRP
drying process. contamination of to get contaminated cleaning of sieves and
product air ducts will reduce
Salmonella and E- Human activity passable metal and
coli , from physical though physical stones parts.
handling handling
Inspection and
maintenance of screens

PRP Good
maintenance practices
9 scheduled
maintenance

PRP Good
manufacturing practices
use of portable water
for cleaning and

PRP Good Hygiene


practices for personnel

7. Storage and Growth of moulds Very Severe Likely Medium (6) PRP storage
dispatch due to poor
temperature Ochratoxin A Storage facility built Facility maintenance
regimes or water may cause according to
to prevent leakage,
invasion may lead requirement to allow
death or water entry
to growth of proper ventilation,
moulds hence
produce FIFO for stocks control.
Ochratoxin A

8. Inspection /sorting Sorting may Very Severe Likely Medium (6) Personnel hygiene to
introduce be maintained and
Salmonella and E- PRP personnel provision of proper
coli due physical PPE.
handling Hygiene is observed.
Provision of
At this stage the antibacterial soap for
water activity is very hand washing.
low not conducive for
further microbial
growth

9. Roasting Roasting Least Severe Likely Low (1) Proper maintenance


machine uses and cleaning
diesel which may May not lead to
lead to adverse heath GMP
Hydrocarbons effect on
contamination consumers

10. Cooling Cross Least Severe Least Likely Low (1) GMP, hygiene and
contamination by machine maintenance.
extraneous matter Hydrocarbons Hydrocarbon
may cause ill contamination could
health. result to long term
health problems.

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

PROCESS STEP HAZARD SEVERITY OCCURANCES RISK CONTROL


LEVELS 1-least likely LEVELS MEASURES
1-least severe 2-likely
2-severe 3-very likely
3-very severe
11. Grinding Metal fillings Very Severe Very Likely High (9) Good manufacturing
practices ,
Metal Machine parts are
contamination at subject to wear and PRP installation of
this point is likely tear during grinding magnets
and can cause this is a constant
adverse health operation the OPRP magnet
problem to likelihood is high. inspection
consumers
and cleaning

CCP-3 beyond this


point metals
contamination cannot
be controlled

12. Packaging Through physical Severe Likely Medium (4) PRP-Sickness


handling and reporting. Proper
packing,
Salmonella and Salmonella is Packaging is packaging
disease causing hermetical and no
E-coli likelihood of and may lead to contact with PRP personnel hygiene
introduction is adverse health personnel.
very high. effects

13. Distribution Cross Least Severe Least Likely Low (1) GMP, hygiene
contamination by transporting vessels.
extraneous matter Hydrocarbons Hydrocarbon
may cause ill contamination could
health. result to long term
health problems.

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

7.2 CRITICAL LIMITS

Rationale for choosing Critical limits.

a) Chemical Residual.

Pesticides and fungicides are used in the field and residual chemicals
contamination could find their way into the final products.

The MRL (maximum residual levels) of the chemical shall be determined by


referring to MSDS or other regulatory bodies, and by allowing at least the
absolute pre- harvest interval (PHI) recommended for each chemical used.

b) Moisture level

Coffee shall be dried from a moisture level of 65% to 11%.

This shall be to reduce the level of mould formation that leads to development of
Ochratoxin A; the mould causes liver cirrhosis with continued use and may lead
cancer and death.

Monitoring shall be done using visual and feeling method and verified through
use of moisture meters.

c) Roasting and Grinding

Metals in the grinding of the roasted beans may end up in the final products.

Removal of these metals shall require the use of a magnet before roasting and
grinding. A strong magnet shall be placed in the hopper before grinding and
roasting.

Two samples from sachets of bamba coffee from a 12x250gm carton shall be
assessed for presence of metal fillings in 50 Kgs.

100gm from every 50kgs of roasted coffee beans shall be assessed for presence
of metal fillings.

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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

After assessment, if the sample shall have metal fillings the coffee shall be
reprocessed by passing it through the magnet.

Verification analysis shall be carried out twice a year for presence of metal
through an external Laboratory.

Monitoring the presence of metals using a strong magnet shall determine the
effectiveness of the control measure.

All metals corrected by the magnet shall be kept in a bag for weighing and
recording and for future reference for a period of six months.

Roasting

Roasting temperatures shall be monitored in order to eliminate any bacteria


present in the coffee.

Ground Coffee (AA, AB, or PB) Temperature Time

Medium roast 100°C- 12O °C 20 Mins

Medium Dark 100°C- 120°C 25 Mins


Kahawa bamba 100°C -110°C 10mins
Medium Dark

Medium 100-110°C 15 mins

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FSMS – HACCP PLAN MANUAL AUTHORIZED BY: GM
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

7.3 CRITICAL CONTROL POINTS PLAN

FOOD CONTROL CRITICAL MONITORING CORRECTION RESPONSIBILITIES MONITORING

SAFETY MEASURES LIMITS PROCEDURES AND AND AUTHORITIES RECORDS


CORRECTIVE
HAZARD
ACTION
(CCP)

1. 1. Chemical Use of approved Maximum

Residuals and residual


Observe the pre-
recommended levels as
harvest interval.
chemicals. per the
Isolate take Estate Manager Picking and
Observation of international
Amount of samples for spray records
the PHI requirement
chemical verification for
guide and
recommended maximum
National
rates, spray residual levels
regulatory
intervals. of chemical.
body

(KEPHIS)

2. Ochratoxin No ground Below 11% Visual inspection Re-dry or

A(moulds) collection m.c. and hand feeling, recondition to


Factory supervisors Moisture
verification using 11% MC.
Proper drying of content records
Moisture testing
coffee (GMP)
meters
.

Segregate, sort
Daily moisture
and discard
testing after the
Mouldy.
10th day until dry

to 11% mc

3. Metal Use magnet to Zero Sample the packed Re-pass the Production supervisor metal filling
remove all the coffee and test for coffee through monitoring
fillings
metals after metal fillings using the magnet. sheet
(production grinding the a magnet.
roasted coffee
Unit)
before Every batch of
packaging. 50kgs

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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

7.4 VERIFICATION PLANNING


Purpose

To confirm that PRP(s) OPR(s) and elements within HACCP plan input hazards
analysis is continually updated, and are within identified acceptable level of other
procedures required by the organization are implemented effectively.
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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

7.4.1 Verification Planning

DATE PRP, ASPECT METHOD OF FREQUENCY RESPONSIBILITY CORRECTIVE


VERIFICATION ACTION
OPRP

G.A.P Chemical Chemical residues Seasonally Estate managers and Recall and
residues, testing from Quality control discard.
external analysis Manager.
results

Drying Ochratoxin A External testing Twice a year Quality Manager Discard


maximum limits
KS 220

Metals metals External analysis Twice a year Quality Manager Recall and
reprocess

Food Storage Use of Daily Warehouse Destroy affected


Storage humidity and thermometer and supervisor lot.
temperature hygrometer
for conditions
of mould
growth

Premises Microbiological, Personnel medical 6 monthly Estate manager and Sort and
and utility cross tests Maintenance segregate and
contamination, Before supervisor quarantine
foreign matter Hygiene production and personnel.
inspections at random

Premise
inspection

Distribution Vehicle 1. Proper Before every Estate manager Sort, discard


and condition for maintenance of dispatch /operations and reprocess.
transport transport vessel, supervisors

2.Cleaning and
proper hygiene
before loading and
for delivery
vehicles

Equipment Missing parts, Final magnet Bi annually Machine operator Proper


broken parts inspection maintenance.
grease loose Routine
parts Complaints
equipment
hygiene

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ISSUE NO: 3

Waste Salmonella, - Effluent water Routine Section managers Water treatment


handling E.coli, foreign use- open lagoons
matter, - Pulps as organic
chemical manure.
hazard
Husks-use as
organic manure.

Packaging
materials dispose
as appropriate.
Water Salmonella, Water testing and Routine Section manager Analyze and act
supply heavy metals, purification as per
suspended recommendation
particles .

Personal Salmonella, Medical exam. Routine Section supervisors As per public


hygiene E.coli, foreign Report, health act cap
matters and 242 and
chemical Issuance records occupational
hazards health and
- Personnel safety act 2008.
inspection Spot/random
checks
- Proper hygiene

Education Mycotoxins, - Routine personal Periodic as Estate manager As per


and salmonella, E- hygiene checks, necessary regulations
training Coli
- Proper pest and
vermin’s control

-Training
attendance.

- Certificates of
competence

Withdraw Contaminated Batch sampling or annually Quality Assurance Recall and


procedure products. act as per Manager reprocess or
customer discard.
complaints.

Traceability Forward and Document annually Process owners Introduce


backward sampling relevant
documents and
steps.

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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

7.5 TRACEABILITY SYSTEM

The traceability process in our production system shall be guided by the


following;

(a) All incoming goods (raw materials) shall have.


▪ Delivery notes and Goods return notes. (GRN).
▪ For purchased items the delivery notes shall be accompanied by invoices.
▪ Before purchase an LPO shall be raised.
▪ All the purchased items shall be recorded in a purchase register.

(b) Raw materials coming from various units shall have the following;

▪ Delivery notes indicating;

8 Number of bags
8 Registration of the vessels
8 Type
8 Time of delivery
8 Destination
8 Level of compliance for parchment coffee moisture contents of 11%
8 Name of the dispatching personnel

(b) Outgoing finished products shall have the following documents for

traceability purposes

(i)Dispatch book/ Delivery Note

- GRN number

- Indicating destination

- Batch number

- Frippery date

- KEBS sticker

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ISSUE NO: 3

- Vehicle delivery

- Destination

- Customers LPO
- Loading sheet number

(ii) Traceability records

- Wet processing

- Picking books

- Delivery Note books

- Field supervisor books

- Factory Dispatch book

(iii) Dry processing

- Weigh bridge ticket

- Parchment storage

- Milling statement

- Sample test records

- Delivery notes

- Outgoing statement

- Delivery notes

(iv) Value Addition

- Delivery Note

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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

- Processing records

- Dispatch records

- Invoices

- Loading sheets

- LPO registers
- Sales invoices

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ISSUE NO: 3

7.6 PRODUCT LOT IDENTIFICATION

Purpose

To enable identification of product lots and their relations to batches of raw materials,
processing and delivery records.

Product Lot Identification

Date Raw Supplier Processing Product Product lot Delivery Customers Recommendation
materials
batches
method lot sample No.

Cherry Farm/field Wet method As per

number outturn no.

Parchment Grower’s Dry method


coffee
Green Coffee mill Dry method

coffee

7.7 CONTROL OF NON-CONFORMITY

Purpose

To ensure that when critical limits of CCP(s) are exceeded or there is a loss of control of
OPRP(s), the products affected are identified and controlled with regard to their use and release.

Control of Non-conformity

As CP/OPRP Critical limit Affected end Assessment Control Handling Corrections Review
product of end recommended recommended
product

Field Maximum Green and As per Use Good agriculture Sort. Isolate or As
operations residue Roasted standards recommended practices discard the necessary
levels,(KEPHI ground coffee on chemical chemicals ( affected lot
S), residues GAP)
International
recommendati Observe PHI
ons

Primary Moisture Parchment, M.C tests Adequate G. A. P ’s Re drying, As


processing content of Green coffees using drying, testing Reconditioning necessary
between 10- moisture of moisture to attain
(WET) 11% meter on a levels acceptable m.c,
lot sample. use mechanical
driers

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REVISION NUMBER: 03 SERIAL NO: SC/FSMS/H/004 DATE OF ISSUE: APRIL 2013
ISSUE NO: 3

Stones Rate of Green coffee Free from Proper use of Proper pre Re-pass the As
vibration/ stones pre-cleaner cleaning and coffee through necessary
oscillation, and de-stoner. servicing of the de- the de-stoner.
Volume of stoner
parchment
being cleaned. Check the flow
Air flow control rate of coffee
entering the pre
cleaner.

Metal Zero. Ground coffee Free from Proper use of GMP Re call for Routine
and instant metal fillings magnet reprocessing to
coffee re-correct
exceeded limits.
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