HACCP Example - Courtesy of Fletchers Bakery, Sheffield

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

Process Step Hazard Control Measures CCP Critical Limits Monitoring Corrective Responsible
Procedure Action Personnel
1.0 Flour intake 1.1 Foreign bodies in final Approved supplier & 1 Sieve integrity Certificate of Reject out of Q.A. Stores
product compliance with Sieve contact no analysis with every specification Personnel.
specification sieve damage delivery. deliveries. Engineers
line,4&6mm mesh Daily check of Follow sieve
integrity procedure Engs.
1.2 Infestation in silos Pest Control Contract & Activity in traps, other Annual clean and Pest control to Pest
hygiene schedule evidence eg, monthly inspections. advise controller/Hygiene
droppings, beetles
1.3 Survival of micro- Purchase from approved, 8 Compliance with Certificate of Reject out of QA, production,
organisms audited supplier specification analysis, random specification stores
challenge testing. deliveries. Inform
QA and supplier.
2.0 Water intake 2.1 Routine microbiological 8 Compliance with Certificate of Water board inform Water authority,
Survival of micro- checks, Water authority. specification analysis, random of contamination, production, CRISIS
organisms, chlorine (water haccp referenced) challenge testing. stop use of suspect MGT team
overdose, foreign matter water. Recall suspect
product
3.0 Salt 3.1 Foreign bodies in final Approved supplier & 8 Sieve integrity Certificate of Reject out of Q.A. Stores ,
product. compliance with Compliance with analysis with every specification production
Survival of micro- specification sieve in line, specification delivery. deliveries. Inform
organisms 4mm mesh. random challenge QA and supplier.
testing.
4.0 Vegetable Fat 4.1 Foreign bodies in final Approved supplier & 8 Compliance with Certificate of Reject out of Q.A. Stores ,
product. compliance with specification analysis with every specification production
Survival of micro- specification. delivery. Random deliveries. Inform
organisms, rancidity challenge testing. QA and supplier.
Stock rotation.
5.0 Yeast Intake 5.1 Microbiological, Approved supplier 8 Maintain temperature Certificate of Reject out of Q.A. Stores
compliance with spec. Temp. below 4C Max 8 conformity each specification Personnel
check on delivery. Limited time delivery. deliveries. Inform
QA and supplier.
5.2 Temperature check on 2 Temperature control Temperature checks Q.A. to advise on QA/Stores Personnel
storage vessel, daily. recorded. required action

5.3 Taints from poor tank Tank cleaned weekly, by Wash programme pH7 Operator to complete Repeat wash cycle. QA Technologist
cleaning member of QADept. ( neutral) cleaning record
start/end time. +ve
release on cleaning
procedure
6.0 Bread Improver 6.1 Foreign bodies in final Purchase from approved, 8 Sieve integrity Certificate of Reject out of spec. QA/Stores
product. Survival of audited supplier. Compliance with conformity each del. deliveries. Inform Production
micro-organisms Sieve specification met specification QA and supplier.
7.0 Potassium Sorbate Foreign bodies in final Purchase from approved, 8 Compliance with Certificate of Reject out of spec. - QA/Stores
product. audited supplier specification conformity each del. deliveries. Inform Production
Survival of micro- QA and supplier.
organisms
8.0 Sorbate solution 8.1 Incorrect solution Monitored on plant 11 Bread 1800g/10 litres Weights taken. Do not use re weigh Production
strength. water 1/4ly verification for adjust weight
legislation accordingly
 HACCP Example - Courtesy of Fletchers Bakery, Sheffield
HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (2-4) STAYFRESH BREAD September 2004

Process Step Hazard Control Measures CCP Critical Limits Monitoring Corrective Action Responsible
Procedure Personnel
9.0 Bag Flour 9.1 Foreign bodies in Sieved at stage 17. 8 Sieve integrity Certificate of Reject out of spec. Stores/QA
final product. Purchased from approved, Compliance with conformity each del. deliveries. Inform Production
Survival of micro- audited supplier specification Random challenge Qa and supplier
organisms tests for micro
10.0 Vinegar 10.1 Foreign bodies in Purchased from approved, 8 Compliance with Certificate of Reject out of spec. Stores/QA
final product. audited supplier specification conformity each del. deliveries. Inform Production
Survival of micro- Random challenge Qa and supplier
organisms tests for micro
11.0 Ice Making Machine Micro growth on Cleaning and water - No evidence of Routine testing on reclean Plant and
machine growth water schedule Hygiene Dept-
12.0 Ambient Storage Infestation Good storage - No evidence of Regular Clean and report if Stores
infestation housekeeping evidence found
checks and control
of spillages
13.0 Bulk Storage 13.1 Infestation in silos See Step 1.2 See Step 1.2 See Step 1.2 See Step 1.2 Hygiene / Pest
control Co

14.0 Chilled Storage 14.1 Ingredient Maintain temp <4 C 2 Temperature control Temperatures Check ingredient Stores Q.A.
deterioration >8 C Action checked daily and temp. reject out of Personnel
on 24hour alarmed spec. ingredients.
system
15.0 Chilled Bulk Storage 15.1 Ingredient See step 5.2 2 See step 5.2 See step 5.2 See step 5.2 See step 5.2
deterioration
16.0 Packaging Store 16.1 Foreign body hazards Purchased packaging from - All food contact Regular Clean and report if Stores
( wood/ infestation) approved, audited supplier, items covered. No housekeeping evidence found
shroud it and store findings of foreign checks and control
appropriately. matter of packaging-
17.0 Sieve dry ingredients 17.1 Foreign bodies in Sieve checks, metal 1 Sieve mesh size & Sieve checked Replace sieve Production
final product. detection step integrity step before & after use Engineering/QA
18.0 Weigh Station 18.1 Wrong recipe Document codes and 12 Correct codes and QA Audit, Foreman Hold incorrect Prodn/QA
amounts, lack of follow recipe recipe checks ( hourly) product
ingredient trace codes
19.0 Mixer No perceived hazard Dough temps checked. - - Calibrated probe - Prodn/QA

20.0 Divider No perceived hazard Dough weights checked - - Calibrated scale Prodn/QA

21.0 First mould rounder Fibres on belts Regular checks on - No fibres near food Daily checks Remove fibres or - Production
integrity contact area. replace belt Engineering
22.0 Intermediate proof No perceived hazard - - - - - -

23.0 Final Mould Fibres on belts Regular checks on - - No fibres near Daily checks Remove fibres or - Production
integrity food contact area. replace belt Engineering
24.0 Baking Tin Storage Dirt from incorrect Proper storage- off floor, - Free from dirt routine use clean tins/ ensure Prodn/
storage upside down/covered blower is working engineering
 HACCP Example - Courtesy of Fletchers Bakery, Sheffield

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

Process Step Hazard Control Measures CCP Critical Limits Monitoring Corrective Action Responsible
Procedure Personnel

25.0 Dough into tins Foreign bodies in final Tins air-jet blown to remove - - Check tin blower is on - Prodn
product. any foreign bodies, online and working
vacuum system.
26.0 Prover Product debris from Regular cleaning of structure - - Weekly clean - Hygiene
structure

27.0 Addition of lids. No perceived hazard - - - - - -

28.0 Lid storage No perceived hazard - - - - - -

29.0 Baking Under baking - survival Correct heating process 3 Ex-oven temp > 94C Product temp check 2 Reject under baked Production
of pathogenic organisms. hourly with cal. Temp product. Q.A.
probe.
30.0 Removal of lids. No perceived hazard - - - - - -

31.0 Remove bread from tins. No perceived hazard - - - - - -

32.0 Potassium Sorbate Microbial spoilage 5g of 15.2% solution 11 Min 4g QA 3 x daily Hand spray Adjust Production
Sprayer Max 6 g + ½ hr production sprayer QA, Engrs.
33.0 Cooler controlled Microbial spoilage Correct temperature at 4 Ex cooler temp Internal temp. taken 2 Report fault to Engs. Production
condition packing <34 C hourly. Every product Document quantity, Engineers
type. Process , cooler temp & date code.
on.
34.0 Metal detection 34.1 Metal in final product. 100% effective 6 Detection 3.5mm Fe, Inspect sensitivity 1 Quarantine Production
4.5mm Non Fe. per hr. during unscreeded prd return Q.A.
6.35mm SS production through detector
35.0 Slicer 35.1 Metal in final product Blade break detector on slicers Broken blade detectors Detectors challenged Stop using machine Production
operational hourly. Check blades entact,
if broken blade is Engineers
found isolate &
destroy bread back to Q.A.
last good check. Call
engineer to rectify
fault.
36.0 Bag Machine - No perceived hazard - - - - - -

37.0 Thurne tag BBE code Lack of traceability Thurne tag checks for coding- 12 Correct code Daily and changeover Recall product Prodn/ QA
start and end of run checks incorrectly coded,
amend code

38.0 Metal Detection 38.1 Metal in final product 100% effective 6 Detection 3.00mm Fe / Inspect sensitivity 1 Quarantine Production
4.00mm Nfe per hr. during unscreeded prd return Q.A.
6.35mm SS production through detector
39.0 Finished Prod. Wt. 18.1 Non compliance to 15 minute average weight 13 Target 800g, T1 and Bread Average Remedial action Prodn/QA
Control average weight checks T2 procedure weight procedure procedure
procedure inoperation
40.0 Basket Dirty baskets Operator Inspection - - - Inform - Supplier Logistics
Production Q.A.
 HACCP Example - Courtesy of Fletchers Bakery, Sheffield

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

Process Step Hazard Control Measures CCP Critical Limits Monitoring Corrective Action Responsible
Procedure Personnel

41.0 Stack No perceived hazard - - - - - -

42.0 Ambient storage No perceived hazard - - - - - -

43.0 Load onto ambient Dirty vehicles Vehicle check prior to - Free from foreign Despatch trailer Do not load/ clean Despatch
vehicle loading matter, taints check trailor
44.0 Deliver customer No perceived hazard. - - - - - -
ambient

HACCP ANALYSIS FOOD SAFETY BREAD PLANT: (4-4) FROZEN BREAD September 2004

Process Step Hazard Control Measures CCP Critical Limits Monitoring Corrective Action Responsible
Procedure Personnel

40.0 Freezer Temperature out of spec, Freezer checks, 24 hour 5 -8 Deg C 24 hour freezer alarm, QA Hold product and Engineers/
product defrosts surveillance on freezer check for quality Production.
41.0 BOX No perceived hazard - - - - - -

42.0 Seal and code Lack of traceability Box code checks hourly 12 Correct BB and Hourly checks and Stop -
julienne code QA audit
43.0 Palletise No perceived hazard Vehicle check prior to - Free from foreign Despatch trailer Do not load/ clean Despatch
loading matter, taints check trailor
44.0 Frozen storage Temperature out of - - - - - -
spec

Doc Title: Food Safety HACCP – Stayfresh bread Authorised by: Date :Sept 2004
Originated by: Revision : 3
Doc Ref: QA/haccp/bread/full haccp/stayfresh (and frozen) Page 4 of 4
bread